vvEPA
United Stales Industrial Environmental Research EPA-600 7 79 •
Environmental Protection Labora1 February 1979
AgtM • '711
EPA Industrial Boiler
FGD Survey:
Fourth Quarter 1978
Interagency
Energy/Environment
R&D Program Report
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports m 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.
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EPA-600/7-79-067a
February 1979
EPA Industrial Boiler
FGD Survey:
Fourth Quarter 1978
by
J. Tuttle, A. Patkar, D. Welch, M. Hessling, and M. Eckstein
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-2603
Task No. 45
Program Element No. EHE624
EPA Project Officer: R. Michael McAdams
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
-------
NOTICE
This report (prepared by PEDCo Environmental, Inc.,
Cincinnati, Ohio under EPA Contract No. 68-02-2603, Task No.
45) is provided as an information transfer document. Data
in this report are supplied voluntarily by industrial
representatives; flue gas desulfurization (FGD) system
designers, vendors, and suppliers; regulatory personnel; and
others. Neither EPA nor the designated contractor warrants
the accuracy or completeness of information contained in
this report.
Initial distribution of the report is limited to organi-
zation 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
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TABLE OF CONTENTS
SECTION p»r,f
NOTICE 11
TABLE OF CONTENTS 1U
EXECUTIVE SUMMARY lv
INTRODUCTION \
STATUS OF INDUSTRIAL BOILERS hITH FGO SYSTEMS 3!
A SUMMARY OF ALL INSTALLATIONS BY NAME, LOCATION, START-UP flATt,
CURRENT STATUS, AND PAGE LOCATION FOR ADDITIONAL DATA.
SUMMARY OF FGQ SYSTEMS ON INDUSTRIAL BOILERS b
A BRIEF SUMMARY OF THE SOURCE CHARACTERISTICS, THE CONTROL PROCESS AC:n
CONTROL SYSTEM SUPPLIER, AND INFORMATION ON RFCENT SYSTEM
a SUMMARY BY VENDOR OF F6D SYSTEMS ON INDUSTRIAL BOILERS lh
A LIST OF THE CONTROL SYSTEMS SUPPLIED BY EACH SYSTFM VENDOR OR MANUFACTURER.
5 OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS 19
6 UNDER CONSTRUCTION F6D SYSTEMS ON INDUSTRIAL BOILERS 22
7 PLANNED F60 SYSTEMS ON INDUSTRIAL BOILERS ?3
8 SUMMARY OF DISPOSAL PRACTICES FOR FGD SYSTEMS ON INDUSTRIAL BOILFKS ?U
9 PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS ?8
AN IN-DEPTH DATA PRESENTATION FOR THE OPERATIONAL CONTROL SYSTEMS.
THIS SECTION PRESENTS BACKGROUND INFORMATION, OPERATING EXPFHIFNCE,
DESIGN DATA, DISPOSAL PRACTICES, AND ANY OTHER RELEVANT INFORMATION
AVAILABLE CONCERNING THE FGD SYSTEMS AT THE VARIOUS INSTALLATIONS.
10 DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BOILPKS 116
SAME AS SECTION 9, FOR CONTROL SYSTEMS UNDER CONSTRUCTION.
II DESIGN INFORMATION FOR PLANNED FGD SYSTEMS ON INDUSTRIAL BOIIERS Ub
SAME AS SECTION 9, FOR PLANNED CONTROL SYSTEMS.
12 DESCRIPTION OF INDUSTRIAL BOILER FGO SYSTEMS NOT OPERATING 1«9
SAME AS SECTION 9, FOR CONTROL SYSTEMS HHFRE Fll« SOME RFASU*. THF SYSTfcM
IS NOT OPERATING.
13 INDUSTRIAL BOILER FGD COSTS 157
14 PROCESS DIAGRAMS FOR INDUSTRIAL BOILER FGO SYSTEMS 17"
111
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F XFCUT IVE S
THF FIPST Fill L-SCALE UNITED STATES APPLICATION liF FLHF GAS OESULFIIR I 7 AT ION (FGO) IFCHNOLORY TO
INOIISTRTAI BOUFRS WAS AT THE r,ENFRAL MOTORS PI ANT IN ST. LOUIS, MISSOURI HHF«E TWO FGD SYSTEMS WFKF
INSTALLFO ON Twfl rOAL-FIWFl) UOU.FRS IN 1"»7?. IN THIS 4TH UUARTFH 197ft REPORT, 13? OPERATIONAL FGD
SYSTEMS ARh DFSCRT8FD. tHFSE SYSTF*S ARF, CONTKOLL TNG SO? H.MJSS10NS FROM ?<)«, BOILFHS, LOCATFD AT 39
PLANT SITFS ACROSS THF UNITED STATES. FRPI SYSTEMS AT 2? PLANTS ARE KNOrtN TO BE IINOEH CONSTRUCTION
OR IN SOMF STAGE OF PLANNING. IN ADDITION THERF AWF 7 INSTALLATIONS TNCLUDFO IN THE REPORT WHERE
FGD OPERATIONS HAVE FITHfcR BEEN TERMINATED, INDEFINITELY SHUT DOwN, OS NEVER STARTED-UP. THF TOTAL
COVERAGE OF THIS REPORT IS THEREFORE f>8 INSTALLATIONS. TABLE 1 SUMMARIZES THF NUMBER AND SCF»» OF
THOSE SYSTEMS OPERATING, UNDER CONSTRUCTION, OR IN SOME PLANNING PHASE.
TABLE I
NUMBER AND SCFM OF INDUSTRIAL BOILER FGD SYSTEMS
STATUS
OPERATIONAL
IINOFR CONSTRUCTION
PLANNING*
CONTRACT AWARDED
LETTFR OF INTFN1
REOUFSTING/FVALUATING BIDS
CONSIDERING USING FGD
TOTAL 61 9,109,030 172 312
•NOTE: THFHF. ARE PROBABLY SFVERAL FGH SYSTEMS BEING PLANNED WHICH HAVE NOT BEFN LOCATED BY THIS
SURVEY AND THEREFORE ARE NOT COVERED IN THIS REPORT.
TABLE 2 SUMMARIZES THE PLANTS ACCORDING TO THE YEAR OF FGD STARTUP, AND THE SCFM CAPACITY.
HIGHLIGHTS FROM THF. CURRENT INDUSTRIAL BOILER SURVEY ARE GIVEN BELOW:
CATERPILLAR TRACTOR CO. REPORTED THE FOLLOWING ITEMS:
EAST PEORIA - THE BOILER CAN OBTAIN NO MORE THAN 80* LOAD BECAUSE FAN CAPACITY IS NOT GREAT
ENOUGH TO OVERCOME AN ABNORMALLY HIGH PRESSURE OROP IN THE SCRUBBERS. FAN AND DRAFT TESTS ARE
BFING RUN Tfl PINPOINT THE PROBLEM AREA.
MAPLETON - CONSTRUCTION HAS BEEN COMPLETED ON 1HREF BOILERS AND THE FMC DOUBLE ALKALI FGD SVS-
TF.MS ANO START-HP IS FxPECTFO IN LAT£ DECEMBER OR IrARLY JANUARY 19/q. INSTALLATION HAS JUST
BEGUN ON TWO ADDITIONAL BOILERS SCHEDULED FOR START-UP IN 1980.
NO. OF
INSTALLA1IONS
39
11
4
0
2
5
CAPACITY
SCFM
5 , 486 , 530
1 ,235,500
177,000
0
?86,000
1,924,000
NO. OF SEPERATE
FGD SYSTEMS
132
27
5
0
4
fl
NO. OF BOILERS
CONTROLLED
206
69
7
0
14
16
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CATERPILLAR TRACTOR CO. (CtlNIINUEn)
MORTON - ACCEPTANCE TESTING WAS COMPLFTFD THIS QUARTER ANO AN APPLICATION H»S REE* SUH'-IT TTRn
TO THE STATE FOR A STATE PFRMTT TO OPFRATF.. PLANT PERSONNHL FFFL THEY KILL KFCFIVE THE FIRST
SUCH A PERMIT IN ILLINOIS TO BURN HIGH SULFUR COAL IN AN INDUSTRIAL HOILE".
TABLE ?-
STARTUP YEAR AND SCFM OF INDUSTRIAL BOILER FGD SYSTEMS
YEAR UMTS SCFM
1972
1973
197U
1975
1976
1977
1978
1979
I960
1988
19«4
19»7
YEAR NOT YFT
DETERMINED
TOTAL
1
a
5
12
t>
4
7
13
3
2
1
1
2
61
64,000
MS, 300
431 ,400
1 , 480 , 300
1,024,530
?46,000
1,505,000
1,187,500
371,000
460,000
1 ,200,000
?80,000
124,000
9, 109,030
CHEVRON U.S.A., INC. REPORTED SYSTEM AVAILABILITY INDEX FOR THE QUARTER WAS 100X.
GENERAL MOTORS REPORTFD THAT MODIFICATIONS WERE MADF TO TWO GM FGD SYSTEMS:
PARMA - NFW FRP STACKS WERE INSTALLFD ATOP THE SCRUBBER MODULES, AND THF TOPS OF THE MODULES
WERE RECONSTRUCTED TO REDUCE THE GAS VELOCITY. THE ORIGINAL STAINLESS STEEL STACKS WE«< SADLY
CORRODED.
DAYTON - THE FNTOLETER "VANE CA6F" SCRUBBERS WERE RECONSTRUCTED DURING THE REPORT PERIOD. THE
INTERMEDIATE SECTIONS *FRE REMOVED, AND NEW HASTELLOY-G 2-STASE RADIAL VANE MIST ELIMINATORS
WERE INSTALLED.
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GETTY OIL HAS BEGUN OPERATING FIVE OUT OF A TOTAL OF NINF. IN-HOIISF DESIGN FfiD SYSTEMS. At
GETTY'S ENHANCED OIL RECOVERY OPERATION NFAH RAKERSF1F. LD, CALIFOHNIA. OF THF. FOUR KEMAtMnlG I'MTS
TO BE STARTED UP, TWO ARE SCHEDULED TO SIAkT IN MIO-JAiMIIAWY AND Trtll IN MI11-FF.BHIJAHY 1979.
ONE SYSTEM IS USING SODIUM HYDROXIDE SCRUBBING IN AN ATTEMPT TO EVALUATE THE PERFORMANCE OF
CAUSTIC COMPARED TO SODA ASH AS THE ALKALI.
THE U.S. AIR FORCE HAS AWARDED TO AIRPOL INDUSTRIES THE FGD SYSTEM CONTRACT FOR THE HFAT PLANT AT
GRISSOM AIR FORCE BASE IN HUNKER HILL, INflJAMA. THF SYSTFM WILL CONTROL 32,000 SCFM, FOR COAL WITH
A SULFUR CONTENT RANGING FROM 0.9 TO 1.6*, AT A DESIGN RATE OF 1.? LHS OF SH2/MM BUI HEAT INPUT.
ITT RAYONIER, INC. REPORTED THAT THE BOILER ANn THE AIRPOL FGD SYSTEMS OPERATED APPROXIMATELY 95X OF
THE PERIOD. THE ONLY OUTAGE DURING THE PFRIOD WAS A 3-DAY DOWNTIME THAT WAS BOILER-RFLATEI1.
KERR-MCGEF SODA ASH PLANT, UTILIZING A COMBUSTION EQUIPMENT ASSOCIATES RESIGN FOR S03 REWlVAL. RE-
PORTED THAT BOTH SCRUBBERS DEMONSTRATED IOOX RELIABILITY FUR THIS QUARTER.
MEAD PAPERBOARl) CO. REPORTED AN AVAILABILITY INDEX VALUE OF 1001 FOR THIS AIRPOL FGD SYSTEM FOR THE
QUARTER.
PHILIP MORRIS, INC. is INSTALLING A FLAKT INC. SODIUM CARBONATE FGD SYSTEM AT THEIR TOBACCO
REPROCESSING PLANT IN CHESTERFIELD, VIRGINIA. THE SYSTFM WILL INCLUDE A 6 RPM IJUENCHFR, A 3-STAGE
FRP SPRAY TOWER, A POLYPROPYLENE CHEVRON MIST ELIMINATOR, A SODA ASH STORAGE TANK AND AN OXIDATION
TOMER. THE SCRUBBER IS DESIGNED TO HANDLE 39,000 SCFM, OR 2/3 OF THE FLUE GAS FROM A NEW 500,000
L8/HR PULVERIZED COAL-FIRED BOILER. THF REMAINING 1/3 OF THE GAS WILL BE USED FOR REHEAT.
START-UP IS SCHEDULED FOR JUNE 1979.
RICKENBACKER AIR FORCF BASE REPORTED THFIR RESfARCH-COTTRF.LL/BAHCO SCRUBBER TO HAVE AN FED SYSTEM
AVAILABILITY INDEX OF APPROXIMATELY 98X FOR THE QUARTER.
AT THE ST. JOE ZINC CO. FGD SYSTEM CONSTRUCTION IS NEAHING COMHLETETION; THE BUREAU OF MINF.S CITRATE
PROCESS SYSTEM IS NOW SCHEDULED TO START-UP IN MARCH 1979.
AT THE WESTERN CORRECTIONAL INSTITUTION IN PITTSBUPG, THE SCORE (SULF-X CONCURRENT OXIDFS REMOVAL)
PROCESS* DEVELOPED BY PITTSBURG ENVIRONMENTAL AND ENERGY SYSTEMS, INC. IS BFING INSTALLED.
SIMULTANEOUS REMOVAL OF S02 (90X) AND NOX (hOX) WILL BE ACHIFVJ-0. EMISSIONS CONTROL IS SCHFDULEn TO
BEGIN IN MAY 1979 AND THE REGENERATION LOOP (ELEMENTAL SULFUR BY-PRODUCT) IS SLATED 10 BEGIN IN THE
LATE FALL OF 1979.
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OF THE MORF THAN )TO ACTIVE (OPERATING, UNUER CONSTRUCTION, MR PLANMFH) FRO UNITS alinkFSSFn J,-i
THIS REPORT, MORE THAN HALF AHF BFING USEn Ort SCHEDULED TO BF. USED IN ENHANCED OIL RECOVERY (Ef)H)
SITES IN CALIFORNIA. BECAUSE OF THf FACT THFSt- UNITS PREOOMINATfc IN THIS RFPORT, A BRIFF DISCUSSION
OF THE EOR INDUSTRY FOLLOWS.
IN 1976, THF SAN JOAQIIJN VALLFY AIR BASIN PRODUCED ABOUT 0-3% OF CALIFORNIA'S CRUDE Oil OUTPUT.
EOR OPERATIONS ACCOUNTED FOR AHODT SOX (IF THAT PRODUCTION. ADDITIONALLY, EOR OPERATIONS IN !H£
BASIN ACCOUNTED FOR APPROXIMATELY BOX OF CALIFORNIA'S TOTAL EOR OPERATIONS.
THE MOST COMMON MEANS OF PRODUCING CRUDE OIL R£LIFS ON NATURAL UNDERGROUND PRESSURE TO PUSH THE
OIL TO THE SURFACE OF A KȣLL. IF NATURAL PRESSURE IS LACKING, PUMPS ARE USFD TO PULL THE OIL OUT OF
AN OIL RESERVOIR. THESE METHODS OF PRODUCING CRUDE OIL ARE TEHMED PRIMARY RECOVERY. IF WATER IS
PUMPED INTO AN OIL RESERVOIR (SECONDARY RECOVERY), TMUDE RECOVtRY CAM HE INCREASED OR "FNHANCFO".
WHEN THE CAPABILITIES OF THP PRIMARY AND THE SECONDARY METHODS ARE EXHAUSTED, ADDITIONAL FNHANCFK
RECOVERY (TERTIARY RECOVERY) METHODS ARF CONSIDERED. TERTIARY Oil. RECOVERY EMPLOYS THERMAL VEANS TO
MAKE HEAVY, VISCOUS CRUDE OILS MOVE THROUGH SAKO AND ROCK STRATA MORE EASILY.
TYPICALLY STEAM IS INJECTED CONTINUOUSLY TO FLOOD THE UNDERGROUND OIL RESERVOIR KITH STEAM At-0
HOT WATER. THERE ARE CURRENTLY ABOUT 800 STEAM GENERATORS (TYPICAL STEAM QUALITY IS 80 PERCENT) IN
THE SAN JOAOUIN BASIN AND MOST OF THESE UNITS HAVE CAPACITIES IN THE RANGE OF 15 MM BTU/HR TO
65 MM BTU/HR. STEAM GENERATORS IN THIS SIZE RANGE VARY FROM ABOUT 5,000 TO 30,000 ACFC i APPROX-
IMATELY 600 F.
THE CALIFORNIA AIR RESOURCES BOARD (CARS) HAS PROPOSED REGULATIONS WHICH MOULD REQUIRE THF
FOLLOWING FOR OIL-FIRED STEAM GENERATORS:
SOURCE SOe EMISSION LIMIT NOX EMISSION LIMIT
NFW GENERATORS 60 PPM 100 PPM
EXISTING GENERATORS ^00 PPM 150 PPM
THIS REPORT ADDRESSES IN DETAIL FGD OPERATIONS FOR THOSE EOR PRODUCTION COMPANIES WHO HAVF
GIVEN PERMISSION. THOSE COMPANIES ARE AS FOLLOWS:
BELRIDSE OIL COMPANY
CHANSLOR WESTERN OIL AND DEVELOPMENT COMPANY
CHEVRON U.S.A., INC.
GETTY OIL COMPANY
MOBIL OIL COMPANY
SHELL OIL COMPANY
SUN PRODUCTION COMPANY
TENNECO OIL COMAPNY
TFXACO, INC.
IN SECTION 3 OF THIS REPORT (BEGINNING ON PAGE 3) THE READER CAN FIND A DETAILED INDEX
TO INFORMATION ON THE ABOVE INSTALLATIONS.
vil
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SFfTIflN 1
INTRODUCTION
THIS REPORT ADDRESSES THE APPLICATION (jF Ft HE GAS DFMILFUP J ZA T1 ON (FGn) TECHNOLOGY TO INDUSTRIAL
BOILERS. AN INDUSTRIAL BOILER WILL BE OEMNEO AS A BOILER OH SIMM KFMFWATOH WHICH IS (IHFHATINK OK
SCHEDULED FOR OPERATION AT AN INOUSTHIAL SITfr. THIS IS IN CONTRAST TO A UTILITY BOILFR KHF.KFIN THf
PRIME FUNCTION IS STFAM GENERATION AND SUBSEQUENT CONVERSION To fcLECIHICAl POWER FOR SALE 10 THE
PUBLIC. THE NEED FOR SUCH A DOCUMEM HAS ARISEN AS A RESULT OF MOWF STRINGENT EMISSION KFGULATTliNS
DESIGNED TO REDUCE SULFUR DIOXIDE (SO?) EMISSIONS. IN VIEft OF THE DEVELOPMENTAL STATUS OF FSO TFCH-
NOLOGY, EPA'S INDUSTRIAL ENVIRONMFNTAL RESEARCH LAflORATOkY IN RESEARCH TRIANGLE PARK, NORTH CARO-
LINA, HAS ESTABLISHED THIS PERIODICALLY UPDATED ENGINEERING APPLICATION/TNFOHPATION TRANSFER
PROGRAM FOR INDUSTRIAL USE OF SOS CONTROL TECHNOLOGY.
FIRST ISSUED IN DFCEMHF.R 1977 AS A COMPREHENSIVE 900-PAGE REPORT ON S02 CONTROL SYSTEMS ON ALL
NON-UTILITY COMBUSTION AND PROCESS SOURCES, THf CURRENT SERIES, IM THE INTEREST OF ECONOMIZING OPER-
ATIONS. ADDRESSES ONLY INOUSJRIAL BOILER APPLICATIONS OF F60 TECHNOLOGY. THE FIRST ISSUE OF THIS
SERIES. ENTITLED "EPA INDUSTRIAL BOILErt FGD SURVEY: FIRST QUARTER 1978," PRESENTED DETAILED TECH-
NICAL INFORMATION ON INDUSTRIAL BOILER FGD INSTALLATIONS. THE INFORMATION WAS OBTAINED BY A
SURVEY OF PLANT PERSONNEL, CONTROL SYSTEM VENDORS, REGULATORY AGENCIES, AND ENGINEERING FIRMS.
THE CURRENT REPORT REPRESENTS AN EXPANSION OVER THE THIRD UUARTEH 1978 ISSUE WITH RESPECT TO
BOTH THF NUMBER OF INSTALLATIONS, AND THE INFORMATION PRESENTED FOR EACH INSTALLATION. THE DATA
ARE GIVEN IN TWO TYPES OF TABLES: ONE GIVES SUMMARY INFORMATION; THE OTHER DETAILED INFORMATION.
SUMMARY TABLES PRESENT INFORMATION AS FUNCTIONS OF TYPE OF CONTROL PROCESS, CONTROL SYSTEM VENDOR,
DISPOSAL TECHNIQUES AND OPERATIONAL STATUS (OPERATIONAL, UNDER CONSTRUCTION, PLANNED, OR NOT OPERAT-
ING). NUMBERS, OPERATIONAL STATUS, AND OVERALL CAPACITY OF THE FGD SYSTEMS ARE SUMMARIZED IN THE
EXECUTIVE SUMMARY. DETAILED INFORMATION INCLUDES! CONTROL SYSTEM DESIGN PARAMETERS, OPERATING EX-
PERIENCE, ECONOMICS, PROBLEMS AND SOLUTIONS, WASTE DISPOSAL TECHNIQUES, AND MAINTENANCE PRACTICES.
THE INFORMATION IN THIS REPORT WILL BE PERIODICALLY UPDATE!) AND EXPANDED BY MEANS OF TELEPHONE
AND MAIL SURVEYS, AND PUBLISHED EACH QUARTER. IN FUTURE ISSUES, THE DATA BASE ON SELECTED PLANTS
WILL BE EXPANDED BY ON-SITE SURVEYS.
CERTAIN ENGINEERING SYMBOLS AND TERMS ARE USED VERY FREOUFNTLY IN THE FIELD OF FGO TECHNOLOGY.
TABULATED BFLOW ARE THE DEFINITIONS OF PERTINENT SYMBOLS AND TERMS USED IN THIS REPORT.
SYMBOL/TERM DEFINITION
ACF ACTUAL CUBIC FEET, UNIT OF GAS VOLUME MEASURED AT ITS ACTUAL TEMPERATURE AND
PRESSURE.
ACFM ACTUAL CUBIC FEET PER MINUTE, UNIT OF GAS FlOw HATE MEASURED AT ITS ACTUAL
TEMPERATURE AND PRESSURE
AVAILABILITY HOUHS THE FGD SYSTEM HAS AVAILABLE (WHETHER OPERATED OR NOT) DIVIDED BY HOURS IN
PERIOD, EXPRESSED AS PERCENTAGE
CS CARBON STEEL
F DEGREES FARENHEIT, UNIT OF TEMPERATURE
-------
DEFINITIONS (CONTINUED)
SYMBOL/TERM
DEFINITION
P.O.
FRP
GAL
6PM
I.R.
L/6
MM
MS
MW(EQUIVALENT)
OPERABILITV
PSIG
RELIABILITY
9CFM
SS
T
M.6.
FORCED DRAFT
FIBERGLASS-REINFORCED POLYESTER (OR PLASTIC)
GALLONS
GALLONS PER MINUTE
\
INDUCED DRAFT
LIOUID-TO-GAS RATIO, RECIRCULATING LIQUID FLOW DIVIDED BY THE ACTUAL GAS FLOW,
GAL/1000 ACF
MILLION (DOLLARS, GALLONS, BTU, ETC.)
MILD STEEL
2000 SCFM/MW IS THF CONVERSION FACTOR USED FOR THIS REPORT. ALTHOUGH THERE AHF
SEVERAL METHODS IN USE FOR ARRIVING AT EQUIVALENT MM, SUCH AS LB/HR OF STEAM,
MM 8TU/HR OF HEAT INPUT, THF FACTOR MOST INFLUENTIAL IN AFFECTING EQUIPMENT
SIZING IS FLON RATE. THIS CONVERSION ALLOWS FOR EASY COMPARISON BETWEEN THESF
INDUSTRIAL FGD SYSTEMS AND THE UTILITY FGD SYSTEMS.
HOURS THE FGD SYSTEM OPERATED DIVIDED BY BOILER OPERATING HOURS IN PERIOD,
EXPRESSED AS PERCENTAGE
POUNDS PER SQUARE INCH, UNIT OF PRESSURE, AS COMPARED TO ATMOSPHERIC PRESSURE
OF 14.7 PSI.
HOURS THE FGO SYSTEM WAS OPERATED DIVIDED BY HOURS IT MAS CALLED UPON TO OPERATE,
EXPRESSED AS PERCENTAGE
STANDARD CUBIC FEET PER MINUTE, UNIT OF GAS FLOW RATE MEASURED AT 70 F AND 1 ATM.
PRESSURE
IF THE PRESSURE IS ASSUMED TO BE ONE ATMOSPHERE, THEN THE FOLLOWING RELATION
EXISTS: SCFM = ACFMCObO * 70)/(4feO + ACTUAL TEMP)
STAINLESS STEEL
TEMPERATURE
WATER GAUGE, PRESSURE DROP EXPRESSED AS INCHES OF WATER (ATMOSPHERIC = 407 IN.)
0/XX
0/0
SYMBOL USED WHEN THE MONTH OF A STARTUP DATE IS NOT AVAILABLE
SYMBOL USED WHEN NEITHER THE MONTH NOR THE YEAR OF A STARTUP DATE IS AVAILABLE
THE ENGLISH SYSTEM IS USED IN THIS REPORT. SOME OF THE CONVERSION FIGURES BETWEEN THE ENGLISH
AND METRIC SYSTEMS AND ABBREVIATIONS ARE SHOWN BELOW:
1 F (FOOT) = 0.3048 M£T£R
1 T (SHORT TON) = 0.91 METRIC TON
1 LB (POUND) = 0.45 KILOGRAM
1 GAL (GALLON) = 3.79 LITER
1 BBL (BARREL) = 0.16 KILOLITER
I SCFM = 1.58 NORMAL CUBIC METERS PER HOUR
1 GALLON/1000 ACF = 0.135 LITEHS/NOhMAL CUBIC METER
i BTU = o.as KCAL
ANYONE DESIRING TO RECEIVE THE QUAHTFRLV UPDATED VERSIONS OF THIS REPORT FREE OF COST, MAY
REQUEST ADDITION OF HIS/HER NAME TO THE MAILING LIST BY CONTACTING IHE EPA PROJECT OFFICER 0« PEDCO.
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STATUS TO JANUARY 1979
SECTION 2
STATUS OF INDUSTRIAL BOILERS WITH FGD SYSTEMS
INSTALLATION NAME
ALYESKA PIPELINE SERVICE CO.
AMERICAN THREAD CO.
ARCO/PflLYMERS, INC.
ARMCO STEEL
BELRIDGE OIL CO.
BELRIDGE OIL CO.
BELRIDGE OIL CO.
8UNGE, INC.
C.A.M.(CARBIDE-AMOCO-MONSANTO)
CANTON TEXTILES
CARBORUNDUM ABRASIVES
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CHANSLOR WESTERN OIL * OEV. CO
CHEVRON U.S.A. INC.
CHEVRON U.S.A. INC.
OUPONT, INC.
OUPONT, INC.
FIRESTONE TIRE AND RUBBER CO.
FMC (SODA ASH PLANT)
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
LOCATION
VALDEZ, ALASKA
MARION, NORTH CAROLINA
MONACA, PENNSYLVANIA
MIODLETOWN, OHIO
MCKlTTRICK, CALIFORNIA
MCKITTRICK, CALIFORNIA
MCKlTTRICK, CALIFORNIA
CAIRO, ILLINOIS
HOUSTON, TEXAS
CANTON, GEORGIA
BUFFALO, NEW YORK
EAST PEORIA, ILLINOIS
JOLIET, ILLINOIS
MAPLETON, ILLINOIS
MAPLETON, ILLINOIS
MORTON, ILLINOIS
MOSSVILLE, ILLINOIS
BAKERSFIELD, CALIFORNIA
BAKERSFIELD, CALIFORNIA
BAKERSFIELO, CALIFORNIA
GEORGIA
TEXAS
POTTSTOWN, PENNSYLVANIA
GREEN RIVER, WYOMING
DAYTON, OHIO
PARMA, OHIO
PONTIAC, MICHIGAN
ST. LOUIS, MISSOURI
START-UP
DATE STATUS*
PAGE UUMREW+
6-77
0-73
6-8U
0-75
1-79
h-78
7-78
9-77
0-84
6-74
0-80
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1-78
10-75
3-79
7-78
4-79
0-87
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8,
e.
8,
9,
9,
9,
9,
9,
9,
9,
16,
18,
16,
18,
16,
17,
18,
16,
18,
16,
16,
17,
18,
17,
19
19
22
19
22
19
19
0
23
19
23
19
19
22
17,23
18,
17,
17,
18,
18,
18,
18,
17,
17,
16,
17,
17,
19
19
22
19
23
23
,27,
,25,
,24,
,25,
, 0,
,27,
,27,
,24,
,27,
,25,
,27,
,24,
,24,
.24,
,24,
,24,
,24,
,24,
,26,
,27,
,24,
23,24,
19
19
20
20
20
,24,
,25,
,25,
,24,
,24,
16,20,25,
IS7)
157)
157)
157)
157)
15B)
158)
158)
0)
158)
0)
159)
159)
159)
b)
159)
159)
16U)
16U)
0)
U)
0)
160)
160)
161)
161)
161)
161)
* STATUS COOES
0 - STATUS NOT DEFINED 5 - PLANNED-SEOUESTING/EVALUATING BIOS
1 - OPERATIONAL 6 - PLANNED-CONSIDERING S02 CONTROLS
2 - CONSTRUCTIONAL 7 - TERMINATED
3 - PLANNED-CONTRACT AWARDED 8 - INDEFINITELY SfcUT DQ*N
4 - PLANNED-LETTER OF INTFNT SIGNED 9 - NEVER STARTEO-UP
* FOR COMPLETE INFORMATION ON IHf INDICA1ED FGD SYSTEM REFER TO FIRSI PAGF LISTEP.
THE INSTALLATION APPEARS IN OTHER SUMMARY SECTIONS ON THE PAGES IN PARENTHESES.
A ZERO INDICATES THAT INFORMATION IS NOT AVAILABLE FOR AN INSTALLATION IN A
PARTICULAR SECTION SEARCHED HY THE COMPUTER SYSTEM. SECTION 14 PROVIDES PHOCFSS
DIAGRAMS FOR SEVERAL INSTALLATIONS: AN INDEX TO THE FIGURES IS IN SECURd. 14.
-------
STATUS TO JANUARY 1979
SECTION 2
STATUS OF INDUSTRIAL TOILERS WITH FGO SYSTEMS
INSTALLATION NAME
GENERAL MOTORS CORPORATION
GEORGIA-PACIFIC PAPER CO.
GETTY OIL COMPANY
GETTY OIL COMPANY
GETTY OIL COMPANY
GREAT SOUTHERN PAPER CO.
GREAT WESTF.RN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GREAT WESTFRN SUGAR
GREAT WESTFHN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GRISSOM AIR FORCE BASE
HARRIS MINING CO.
ITT RAYONIER. INC.
KERR-MCGEE CHEMICAL CORP.
HEAD PAPFRBIIARn CO.
MINN-DAK FARMER'S CO-OPERATIVE
MOBIL OIL COMPANY
MOBIL nit COMPANY
NEKOOSA PAPERS, INC.
NORTHERN OHIO SUGAR COMPANY
NORTHERN OHIO SUGAR COMPANY
PHILLIP MORRIS, INC.
RICKENRACKER AIR FORCE BASF.
SHELL OIL COMPANY
SHELL OIL COMPANY
LOCATION
STAHT-UP
DATE STATUS*
TUNOWANDA, NEr. YORK
CROSSETT. ARKANSAS
8AKERSFIELH, CALIFORNIA
BAKERSFIELO, CALIFORNIA
BAKERSFIELO, CALIFORNIA
CEDAR SPRINGS, GFORGTA
HILLINGS, MONTANA
FORT MORGAN, COLORADO
GERING, NEBRASKA
GREELEY, COLORADO
I.ONGMONT, COLORADO
LOVELANO, COLORADO
SCOTTS 8LUFF, NEBRASKA
BUNKER HILL, INDIANA
SPRUCE PINE, NORTH CAROLINA
FERNANOINA BEACH, FLORIDA
TRONA, CALIFORNIA
STEVENSON, ALABAMA
WAHPETON, NORTH DAKOTA
BUTTONWILLOM, CALIFORNIA
SAN ARDO, CALIFORNIA
ASHDOWN, ARKANSAS
FINDLAY, OHIO
FRFEMONT, OHIO
CHESTERFIELD, VIRGINIA
COLUM8US, OHIO
RAKERSFIEL", CALIFORNIA
TAFT, CALIFORNIA
6-7S
7-75
6-77
12-7«
1-79
0-7->
10-77
10-76
10-75
10-75
10-73
10-73
10-75
9-79
0-73
0-75
6-78
0-75
6-77
2-79
0-74
2-76
10-74
10-75
6-79
0- 0
0- 0
1*
1 »
1
1
2
1 •
1 fr
1*
1*
1"
-*—
l»
f
<**
8«
^J-
1 »
1
!•
2
1
1»
->—
1 9
2*
6
6
PAGE NUMBER*
73(10,17,20,30,161)
75(10,16,20,35,162)
77(10,17,20,25,162)
AQ(10,la,20,26,162)
124(10,18,22,26,162)
62(10,16,20,26,163)
&4(11,17,20,26,163)
85(11,17,20,26,163)
86(11,17,20,26,163)
87(11,17,20,26,163)
150(11,17,.0,26,164)-
88(11,17,21,26,164)
89(11,17,21,26,164)
143(12,16,23,24, 0)
151(12,18, 0,27,164)
90(12,16,21,26,164)
92(12,16,21,25,165)
95(12,16,21,24,165)
98(12,13,21,27,165)
125(12,17,22,?5,166)
100(13,18,21,25,166)
102(13,16,21,24,166)
152(13,17, 0,26,166)
105(13,17,21,26.167)
127(13,16,22, 0,167)
106(13,18,21,25,167)
145(13,18,23,27, tt)
146(14,18,27,27, 0)
* STATUS COOES
0 - STATUS NOT DEFINED 5 - PLANNED-REOUESTING/EVALUATING BIDS
I - OPERATIONAL 6 - PLANNED-CONSIDERING S02 CONTROLS
2 - CONSTRUCTIONAL . 7 - TERMINATED
3 - PLANNED-CONTRACT AnARDED 8 - INDF.FINITELY SHUT DOWN
4 - PLANNED-LETTER OF INTENT SIGNED 9 - NEVER STARTED-UP
* FOB COMPLETE INFORMATION on THE INDICATED FGD SYSTEM REFER TO FIRST PAGE LISTED.
THE INSTALLATION APPEARS IK OTHER SUMMARY SECTIONS ON THE PAGES IN PARENTHESES.
A ZERO INDICATES THAT INFORMATION IS NOT AVAILABLE FOR AN INSTALLATION IN A
PARTICULAR SECTION SEARCHED BY THE COMPUTE* SYSTEM. SECTION 14 PROVIDES PROCESS
DIAGRAMS FOR SEVERAL INSTALLATIONS: AN INDEX TO THE FIGURES is IN SECTION ia.
-------
STATUS rn JAMIAKIT IO?Q
SFCTION 2 (CONTINUED)
STATUS r»F INOUSTR1AL HOILERS WITH FUO SYSTEMS
INSTALLATION NAMF
SHELLER GL08JF CORP.
ST. JOE ZINC co.
ST. REGIS PAPER CO.
SUN PRODUCTION COMPANY
SUN PRODUCTION COMPANY
TENNECO OIL CO.
TEXACO INCORPORATED
TEXACO INCORPORATED
TEXASGULF
TRANSCO TEXTILES. INC.
U.S. GYPSUM CORP.
WESTERN CORRECTIONAL INST,
LOCATION
NORFOLK, VIRGINIA
MONACA, PENNSYLVANIA
CANTONMENT. FLORIDA
FELLOWS* CALIFORNIA
OILDALE, CALIFORNIA
GREEN RIVER, WYOMING
SAN AROO, CALIFORNIA
SAN AROO, CALIFORNIA
GRANGER, WYOMING
AUGUSTA, GEORGIA
OAKMONT, PENNSYLVANIA
PITTSBURG, PENNSYLVANIA
START-UP
HATE STATUS*
PAGE NUMBFH+
0-75 •*«» I53(ia,1rt, 0,27,167)
3-79 ?• 129(14,16,22,25,168)
0-73 1 110(14,16,21,27,168)
4-79 2 132(14,16,22,25,168)
4-79 2 133(10,16,22,25,168)
1-82 5» 147(10,18,23,25, 0)
11-73 1 112(15,16,21,27,169)
3-79 2 134(15,16,22,27,169)
9-76 !• 114(15,18,21.27,169)
3-75 8 155(15,17, 0,26,169)
0- 0 •*>• 156(15,16, 0,24,169)
11-79 3« 148(15,18,23, 0, 0)
* STATUS COOES
0 - STATUS NOT DEFINED
1 - OPERATIONAL
2 - CONSTRUCTIONAL
3 - PLANNED-CONTRACT AWARDED
5 - PLANNED-REQUESTING/EVALUATING BIOS
6 - PLANNED-CONSIDERING 302 CONTROLS
7 - TERMINATED.
8 - INDEFINITELY SHUT DOHN
a - PLANNED-LETTER OF INTENT SIGNED « - NEVER STARTED-UP
+ FOR COMPLETE INFORMATION ON THE INDICATED FGD SYSTEM REFER TO FIRST PAGE LISTED.
THE INSTALLATION APPEARS IN OTHER SUMMARY SECTIONS ON THE PAGES IN PARENTHESES.
A IF HO INDICATES THAT INFORMATION IS NOT AVAILABLE FOR AN INSTALLATION IN A
PARTICULAR SECTION SEARCHED BY THE COMPUTER SYSTEM. SECTION 1« PROVIDES PROCESS
DIAGRAMS FOR SEVERAL INSTALLATIONS: AN INDEX TO THE FIGURES IS IN SECTION 14.
-------
STATUS TO JANUARY 197«»
SECTION ?
SUMMARY OF FGD SYSTEMS ON INDUSTWIAl BUTLERS
COMPANY INFORMATION
BACKGKOUNI) AND SUMMARY OF RF.CF.NT OPEHATIONS
ALYESKA PIPELINE SERVICE CO.
VALDEZ, ALASKA
FMC ENVIRONMENTAL EOIIIPMFNT
OIL CO.031 - O.U SULFUR)
SO,000 SCFM (DESIGN MAXIMUM)
START-UP 6/77
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
*HK&0« THF ALEYSKA FGO SYSTEM IS UNimiF IN THAT IT
WAS NOT INSTALLED PRIMARILY FOR CONTKOL »F FMIS-
StONS, HUT TO TKEAT GAS HSFO IN THF OIL STORAGE
TANKS.
*OTH QTR 7«: FRD OPERATIONS FOR THIS REPORT PERIOD
WERE PKUBLF.M FREE. C*CLOHEXYLAMINE IS NO* HEING
SPRAYED INTO THE FLUF GAS EXITING THF SCRUBBER.
THIS HAIStS THE PH (IF THE CARRY-OVFK BETWEEN h ANO
7 ANO HAS APPARENTLY STOPPED THE CORROSION INSIDE
THF MILD STEEL OIL STORAGE TANKS.
AMERICAN THREAD CO.
MARION, NORTH CAROLINA
N.W. SLY MANUFACTURING CO.
COAL (1 - 1.5* SULFUR)
18,500 SCFM (TOTAL - 2 BOILERS)
START-UP 0/73
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
*BKGD! AMERICAN THREAD IN MAftlON, NO*1H CANdLINA
IISFS A CAUSTIC SCRUBBING APPROACH TO CONTROL
PARTICIPATE AND S02 EMISSIONS FKO^ two COAL-FIRED
BOILERS.
• «TH OTR 7«: THE PLANT KFPORTEO NO IIPEKATING
PROBLEMS CONCERNING THE *ECIRCULAIION TANKS OH
PUMPS. PATCH-UP WORK ON IHE FAN ROTOR LINING AND
REPLACEMENT OF a SPRAY NOZZLFS CAUSED TWO OAYS OF
DOWNTIME.
J
ARCO/POLYMERS. INC.
HONACA, PENNSYLVANIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.OX SULFUR)
236,000 SCFM (TOTAL - 3 BOILERS)
START-UP 6/80
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
•BKGD: AKCO/PULYMEWS HAS AWARDED A CONTRACT TO FMC
ENVIRONMENTAL EQUIPMENT DIVISION FOR A IJOUBLF
ALKALI FGO SYSTEM. THF SYSTEM WILL CONSIST OF A
SEPARATE SCRUBBER TRAIN FOR EACH OF THF THREF
IDENTICAL BOILEWS. EACH ABSORBER MODULE WILL
HAVE FOUR DISC-AND-OONUT TRAYS AND BF FOLLOWED
BY A CHEVRON MIST ELIMINATOR.
*OTH OTH 78: CONSTRUCTION OF THF FGD SYSTEM BEGAN
IN SEPTEMBER 1"»78.
4
ARMCO STEEL
MIDDLETONN, OHIO
KOCH ENGINEERING
COAL CO.8* SULFUR)
84,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/75
LIME SCRUBBING
STATUS - OPERATIONAL
•BKGO: THIS CONTROL SYSTEM SERVES T*0 MULTI-RETORT
UNDERFEED STOKER, COAL-FIRED BOILERS EACH WITH
A CAPACITY OF 100,000 LBS/HR STEAM.
»«TH OTR 78: ABRASION IS A CONTINUING PROBLEM.
FIBERGLASS PIPING HAS BEFN INSTALLED IN SOME
LOCATIONS. NO OTHER INFORMATION HAS BEEN MADF
AVAILABLE DUE TO THE POSSIBILITY OF LITIGATION
NEW EMISSION STANDARDS.
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
HEATER TECHNOLOGY
OIL (1.11 SULFUR)
12,000 SCFM (1 BOILER)
START-UP 6/78
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
«HKGO: BELRIOGE IS UTILIZING A HEATER TECHNOLOGY
FGO SYSTEM TO CONTROL 802 EMISSIONS FROM A SMALL
OIL-FIRED H.IX SULFUR) STEAM GENERATOR AT AN FN-
HANCFO OIL RECOVERY SITE.
•«TH QTH 78: AN AVAILABILITY OF 89X WAS
DEMONSTRATED THIS (JUARTER. SEVFRF VIBRATIONS IN
THE RECIRCULATION PUMP CAUSED THE RECIHCULATION
PIPING TO FAIL. CAUSTIC LINE LEAKS WERE REPAIRED.
BELMIDGE OTL CO.
MCKITTRICK, CALIFORNIA
THEHMOTICS INC.
CRUDE OIL (1.1X SULFUR)
12,000 SCFM
START-UP 7/78
SODIUM HYDROXIDE SCRUBBING
STATUS - OPF.HATIONAL
*BKGO: BELRIDGE IS UTILIZING A IHERMOIICS, INC.
FGD SYSTFN TO CONTROL 802 EMISSIONS FROM A SMALL
OIL-FIRED ci.ix SULFUH) STEAM GENERATOR AT THE
MCKITTRICK ENHANCED OIL RECOVERY SITF.
*«TH UTR 78: DURING THIS QUARTER, THF SCRUBBER
EXHIBITED AN AVAILABILITY INDEX OF 9H.
FLECTHICAL MALFUNCTIONS AND A LEAK IN THF CAUSTIC
FEFO LINE WERE MAJOR PROBLEMS. A SEAL ON THE
RECI»CMLATION PUMP RFQUIRFD REPLACEMENT.
BELRIDGE OTL CO.
MCKITTRICK, CALIFORNIA
C-E NATCO
CRUDE OIL (1.1X SULFUR)
12,000 SCFM
START-UP 1/79
SODIUM HYDROXIDE SCRUBBING
STATUS - CONSTRUCTION
*«TH UTR 78: CONSTRUCT 10* OF A C-E NATCO FKD
SYSTEM INSTALLED ON A SMALl !>IL-FI»ED STFAM BFN£R-
ATOR, IS NFA31NG COMPLETION. THF ORIGINAL START-
UP DATE OF NOVEMBER 1
-------
STATUS TO JANUARY I979
SECTION ? (CONTINUED)
SUMMARY OF FGD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
BUN6E, INC.
CAIRO, ILLINOIS
DRAVO CORP./NAT'L LIME ASS'N
COAL (3X SULFUR)
44,000 SCFM (TOTAL - 2 BOILERS)
START-UP .9/77
LIME SCRUBBING
STATUS - INDEFINITELY SHUT DOWN
*BKGf>: HUNGE PURCHASED THIS LIME SYSTEM FOR TEST-
ING PURPOSES. THE PLANT RFPOHTS THAT THE LFWIS
SCRUBBER, A HORIZONTAL ROTARY SCRUBBP* *I1H
INTERNAL CHAINS, PERFORMED WELL OURII»C THF TEST,
EFFECTING 94Z 802 CONTROL.
*4TH (1TK 7fl: BUNGE IS STILL FIRING LOW SULFUR
(0.9X) COAL ANO HAS NO PLANS TO HEIl'SF THF SYSTEM.
C.A.M.(CARBIDE-AMOCO-MONSANTO)
HOUSTON, TEXAS
VENDOR NOT YET SELECTED
FUEL NOT YET SELECTED
1,200,000 SCFM (1 BOILER)
START-UP 0/84
PROCESS NOT YET SELECTED
STATUS - PLANNED-CONSIDERING S02 CONTROL
*BKGD: UNION CARBIDE, AMOCO, AND MONSANTO HAVE
ENTERED INTO A JOINT VENTURE (C.A.C.) WHICH WILL
PRODUCE 3,000,000 LB/HH STEAM FOR PROCESS USE AMD
100 MW ELECTRICITY TO THE LOCAL UTILITY GRID.
«4TH UTH 78: AFTER THE SELECTION OF A CONTROL
SYSTEM IN EARLY 1979, CONSTRUCTION WILL START
EARLY IN 1980 WITH SCHEDULED COMPLETION IN 1980.
CANTON TEXTILES
CANTON, GEORGIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (O.BX SULFUR)
25,000 SCFM (1 BOILER)
START-UP 6/74
CAUSTIC HASTE STREAM
STATUS - OPERATIONAL
•BKGO: AT CANTON TEXTILES THE CONTROL SYSTFM CON-
SISTS OF AN FMC MEDIUM ENERGY VENTURl SCRUHBER AND
UTILIZES A CAUSTIC WASTE STREAM FOR SOS REMOVAL.
THE UNIT HAS BEEN IN OPERATION SINCE JUNE 1974.
*4TH OTR 78: THE PLANT REPORTED THAT COAL FIRING
RESUMED IN MID-OCTOBER 1978. THE BUILD-UP (IF FLY-
ASH IN THE SCRUBBER CAUSED 10 HOURS DOWNTIME. THE
SCRUBBER OPERATED AT A 99+X RELIABILITY INDEX.
CARBORUNDUM ABRASIVES
BUFFALO, NEW YORK
CARBORUNDUM ENVIR. SYS. LTD.
COAL (2.2X SULFUR)
30,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/80
LIME SCRUBBING
STATUS - PLANNED-CONTRACT AWARDED
*BKGD: THE CARBORUNDUM FGD SYSTEM CONSISTS OF A
VENTURl FOR PARTICULATE CONTROL FOLLOWED BY A SIX-
STAGE SPRAY TOWER. IN 1975 THE VENTURl WAS PUT
INTO SERVICE USING WATER ONLY. THF HIGH CHLORIDFS
CONTENT OF THE FLUE GAS CAUSED SERIOUS CORROSION
PROBLEMS, AND BOTH THE VENTURl AND THE SPRAY TOWER
WILL BE REPLACED BEFORE START-UP OF THE COMPLETE
LIME SCRUBBING SYSTEM IN 1980. THE NEW VENTURl
AND SPRAY TOWER WILL BE MADE OF HASTELLOY-C
AND FRP, RESPECTIVELY.
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.21 SULFUR)
210,000 SCFM.(TOTAL - 4 BOILERS)
START-UP 4/78
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
•BKGO: START-UP OCCURRED IN APRIL i9?s. FGD
OPERATIONS PROCEEDED FOR 30 DAYS BEFORE BOILER
PLANT SHUTDOWN FOR THE SUMMER. AN ABNORMALLY HIGH
PRESSURE DROP THROUGH THE SCRUBBERS IS RESTRICTING
THE BOILERS TO ABOUT 80X OF THEIR CAPACITY.
*4TH UTtJ 78: FAN AND DRAFT TESTS WERE RUN IN DE-
CEMBER TO PINPOINT THE LOCATION OF THE HIGH PRES-
SURE DROP. THIS FURTHER DELAYED EMISSION TESTS.
CATERPILLAR TRACTOR co.
JOLIET, ILLINOIS
ZURN INDUSTRIES
COAL (3.2X SULFUR)
67,000 SCFM (TOTAL - 2 BOILERS)
START-UP 9/74
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
*OKGD: THt FGD SYSTEH CONSISTS OF AN INDEPENDENT
SCRUBBING TRAIN ON EACH OF TWO COAL-FIRFD BUILERS.
•4TH OTR 7ft: FILTER CLOTH WEAR CONTINUES TO BE A +
PROBLEM. THE HASTELLOY-C S02 PROBES REQUIRE CON- V
TINUING MAINTENANCE. FLYASH ACCUMULATION IN THE
BOTTOMS OF THE GUILLOTINE DAMPERS IS STILL A
PROBLEM.
CATERPILLAR TRACTOR CU.
MAPLETON, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.2X SULFUR)
131,000 SCFM (TOTAL - 3 BOILERS)
START-UP 1/79
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
•BKGO: AT THE CATERPILLAR MAPLETON PLANT, FMC CON-
CENTRATED MODE DUAL ALKALI TECHNOLOGY WILL BE
UTILIZED TO CONTROL 802 EMISSIONS.
•4TH QTR 78: THREE SCRUBBERS ARE SLATED FOR START-
UP IN JANUARY 1979. DELAY OF THE START-UP DATE
FROM OCTOBER 1978 WAS A RESULT OF CONSTRUCTION
ACTIVITY AND NOT THE INSTALLATION OF SPECIAL
DESIGN MODIFICATIONS.
-------
STATUS 10 JANUARY 1979
SECTION ? (CONTINUED)
SUMMARY OF FGI) SYSTEMS ON INDUSTRIAL «OTLFRS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
FMC ENVIRONMENTAL EUUIPMENT
COAL (3.21 SULFUR)
105,000 SCFM (TOTAL - 2 BOILFRS)
START-UP I/BO
DOUBLE ALKALI (CONCENTRATED)
STATUS - PLANNED-CONTRACT AWARDED
*«TH QTH ye: AT THE MAPLETON PLANT, AN ADDITIONAL
? NEW BOILERS ARE PLANNED FOR START-UP IN THE
EARLY 1980'S. INSTALLATION FOR THESF TwO ARE
JUST NOW BEGINNING. THEY KILL EACH HE EOUIPPED
WITH FMC DOUBLE ALKALAI FGO SYSTEMS. THEY WILL
SHARE REGENERATION AND SLUDGE HANDLING FACILITIES
WITH THE OTHER THREE FRD SYSTEMS AT THIS SITE.
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
ZURN INDUSTRIES
COAL (3.21 SULFUR)
38,000 SCFM (TOTAL - f BOILERS)
START-UP 1/78
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
*BKGD: THE CATERPILLAR MORTON PLANT UTILIZES ZURN
INDUSTRIES' DILUTE MODE DOUBLE ALKALI TECHNOLOGY
TO CONTROL EMISSIONS FRO* THE STEAM PLANT.
««TH QTK 78: THE PUFFING PROBLEM HAS BEEN SOLVED
BY MODIFYING THE INTERNALS OF THE SCRUBBERS. I>H
IS SAMPLED HOURLY WITH MULTIBAND LITMUS PAPER.
ACCEPTANCE TESTING HAS BEEN COMPLETED AND AN
APPLICATION HAS BEEN SUBMITTED TO THE STATE FOR A
PERMIT TO OPERATE.
CATERPILLAR TRACTOR CO.
MOSSVILLF, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.22 SULFUR)
140,000 SCFM (TOTAL - « BOILERS)
START-UP 10/75
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
*BKGDS THt CATERPILLAR MOSSVILLE PLANT HAS UTIL-
IZED FMC CONCENTRATED MODE FGO SYSTEM EACH HEATING
SEASON SINCE OCTOBER 1975. THERE ARE FOUR COAL-
FIRED BOILERS, EACH POSSESSING A SEPARATE SCRUB-
BING TRAIN.
*4TH OTR 7fl: EROSION OF VALVES, FITTINGS, LININGS,
PUMPS, FANS AND SCRUBBER NOZZLES IS A SIGNIFICANT
PROBLEM. AN EMISSIONS TEST IS SCHEDULED FOR LATE
JANUARY OR EARLY FEBRUARY.
CHANSLOR WFSTERN OIL * OEV. CO
BAKERSFIELO, CALIFORNIA
FMC ENVIRONMENTAL EQUIPMENT
OIL (1.51 SULFUR)
70,000 SCFM (TOTAL - 8 BOILERS)
START-UP 3/79
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
*BKGD: CHANSLOR WESTERN HAS PURCHASED A DOUBLE
ALKALI FGO SYSTEM FROM FMC.
*4TH RTK 78: CONSTRUCTION IS HEARING COMPLETION,
BUT THE ORIGINAL START-UP SCHEDULED FOR DECEMBER
1978 HAS BEEN EXTENDED TO MARCH 1979 DUE TO
ADDITIONAL ELECTRICAL WORK AND EQUIPMENT INSTAL-
LATION.
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
KOCH ENGINEERING
OIL (1.1* SULFUR)
248,000 SCFM (TOTAL - 18 BOILERS)
START-UP 7/78
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
•BKGDS CHEVRON U.S.A. UTILIZES THREE KOCH ENGINE-
ERING ABSORBERS TO REMOVE S02 FROM THE FLUE GAS OF
EIGHTEEN BOILERS. THE SYSTEMS ARE DESIGNED TO
REDUCE 302 EMISSIONS TO LESS THAN 70 PPM.
*4TH OTR 78: THE FGO SYSTEM OPERATED PROBLEM-FREE
DURING THE QUARTER DEMONSTRATING AN AVAILABILITY
INDEX OF 100X.
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
KOCH ENGINEERING
OIL (1.1* SULFUR)
146,000 SCFM (TOTAL - 12 BOILERS)
START-UP 4/79
SODIUM CARBONATE SCRUBBING
STATUS - PLANNEO-REOUESTING/FVALUATING BIDS
««TH OTR 78: CHEVRON U.S.A. IS PLANNING TO INSTALL
TWO MORE FGO SYSTEMS AT THE BAKERSFIELD OIL SITE.
THESE WILL BE ONCE-THROUGH, SODIUM CARBONATE
SCRUBBING SYSTEMS AND ARE SCHEDULED TO GO ON-
STREAM BY APRIL 1979. A CONTRACT HAS BEEN AWARDED
TO KOCH ENGINEERING FOR THE DESIGN AND INSTALLA-
TION OF THE TWO SYSTEMS. CONSTRUCTION IS SCHED-
ULED TO BEGIN IN JANUARY 1979.
OUPONT, INC.
GEORGIA
VENDOR NOT YET SELECTED
COAL <1.5* SULFUR)
280,000 SCFM (TOTAL - ? BOILERS)
START-UP 0/8*7
DOUBLE ALKALI
STATUS - PLANNED-CONSIDERING 502 CONTROL
*3KD UTK 78: DUPONT ANNOUNCED PLANS TO ERECT A
COAL-FIRED BOILER AT AN AS YET UNSPECIFIED SITE TN
GEORGIA. THE COMPANY HAS DECIDED UPON A.DOUBLE
ALKALI FGD STRATEGY TO CONTROL S02 EMISSIONS FROM
3 COAL-FIRED BOILERS. START-UP IS SLATED FOR
1987.
-------
SFCTIOM 3 (CONTINUED)
SUMMARY OF FRD SYSTEMS OK INDUSTRIAL BORERS
STATUS TH JiK'ilARV 197°
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
DUPONT. INC.
TEXAS
VENDOR NOT YFT SELFCTE1
COAL (0.5X SULFUR)
320,000 SCFM (TOTAL - 2 80ILFRS)
STAHT-IIP 0/82
LIHESTONF SCRUBBING
STATUS - PLANNED-CONSIDERING S02 CONTROL
• 3RD (JTH 7fi: DUPONf ANNOUNCED PLANS TO ERECT A
COAL-FIRED BOILER AT AN AS YET UNSPECIFIED SITF IN
TEXAS. THE COMPANY HAS DECIDED UPON A LIMESTONE
FGO STRATEGY TO CONTROL SO? EMISSIONS FROf ? rOAl.-
FIRED BOILERS. START-UP is SLATED FOR 1982.
FIRESTONE TIRE ANO RUBBER CO.
POTTSTOWN, PENNSYLVANIA
FMC ENVIRONMFNTAL EQUIPMENT
COAL (2.5 - 3.OX SULFUR)
8070 SCFM (13,000 ACFM d 300 F)
START-UP 1/75
OOUBLt ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
*BKGD: THE FGD SYSTEM AT FIRESTONE-POTTSTOWN
CONSISTS OF AN FMC OOUHLf ALKALI DUAL THROAT
VENTURI SC*U8BFR. THIS CONTROL SYSTEM «AS BUILT
AS A DEMONSTRATION PROJECT FUNDED BY FIRESTONE.
*OTH UTR 78: THE SYSTEM OPERATED *ITH A RELIABIL-
ITY INDEX VALUE OF 93.7X DURING THE PERIOD.
A BROKEN BELT ON THE RECIRCULATION PUMP CAUSED
20 HOURS DOWNTIME.
FMC (SODA ASH PLANT)
GREEN RIVER, WYOMING
FMC ENVIRONMENTAL EQUIPMENT
COAL (IX SULFUR)
446,000 SCFM (TOTAL - 2 BOILERS)
START-UP 5/76
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
*BKGO: THE FGO SYSTEM CONSISTS OF TwO FMC SODIUM
SCRUBBING UNITS TO REMOVE SULFUR DIOXIDE ANO PART-
ICULATE MATTER FROM THE FLUE GAS OF TWO BOILERS.
*4TH OTR 78: THE PLANT REPORTED NO MAJOR OPERATING
PROBLEMS. DURING THIS REPORT PERIOD THE INDEX t
VALUF OF THE FGD SYSTEM WAS REPORTED TO BE V
CLOSF TO 100X.
GENERAL MOTORS CORPORATION
DAYTON, OHIO
ENTOLETER, INC.
COAL(0.7X - 2.OX SULFUR)
36,000 SCFM (TOTAL - 2 BOILERS)
START-UP 9/74
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGO: THE FGD SYSTEM CONSISTS OF TWO ENTOLETER
SODIUM HYDROXIDE SCRUBBING UNITS TO CONTROL EMIS-
SIONS FROM TWO 60,000 LB/HR COAL-FIRED BOILERS. /
*4TH OTR 78: NEw HASTELLOY-G MIST ELIMINATORS V
HAVE BEEN INSTALLED, REPLACING THE BADLY CORRODED
STAINLESS UNITS. THE PHENOL LINING HAS FLAKED OFF
AND WILL NOT BE REPLACED. WORK IS SCHEDULED TO
BEGIN ON A NEW PH MONITORING SYSTEM IN JANUARY.
GENERAL MOTORS CORPORATION
PARMA, OHIO
GM ENVIRONMENTAL
COAL (2.5X SULFUR)
128,400 SCFM (TOTAL - 4 BOILERS)
START-UP 3/74
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
*BKGD: THE FGD SYSTEM CONSISTS OF 4 CM-DESIGNED
DUAL ALKALI SCRUBBERS OPERATING ON 4 BOILERS. THE
SCRUBBERS HANDLE A TOTAL 240,000 ACFM OF FLUE GAS.
*4TH OTR 78: AN OPERABTLITY OF 23.9X WAS REPORTED •
FOR THE PERIOD. THE CORRODED STAINLESS STEEL y
STACKS WERE REPLACED WITH CORTEN STEELr AND THE
TOPS OF THE ABSORBERS WERE MODIFIED TO REDUCE FLUE
GAS VELOCITY ENTERING THE STACKS.
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
GM ENVIRONMENTAL
COAL (0.84X SULFUR)
107,300 SCFM (TOTAL - 2 BOILERS)
START-UP 4/76
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
*BKGD: THE SCRUBBER SYSTEM CONSISTS OF TWO G.M.
SODIUM UNITS FOR THE REMOVAL OF FLYASH AND SULFUR
DIOXIDE FROM THE FLUE GAS OF TWO COAL-FIRED
BOILERS.
•4TH OTR 78: PRESSURE FILTERS HAVE BEEN INSTALLED
IN THE RECIRCULATION LINES TO PREVENT FURTHER
ABRASION PROBLEMS IN PUMPS ANO PIPING DUE TO
FLYASH. TO DATE, THIS MODIFICATION HAS BEEN
SUCCESSFUL.
7
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
A.O. LITTLF
COAL (3.2X SULFUR)
64,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/72
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
*BKGD: THIS 502 CONTROL SYSTEM CONSISTS OF TWO GM
DESIGNED SODIUM SCRUBBING UNITS OPERABLE ON TWO
OF THE FOUR COAL-FIRED BOILERS. THE SYSTEM IS
EQUIPPED WITH 60 F REHEAT ANO HAS THE CAPABILITY /
FOR FGD SYSTEM BYPASS. V
«4TH OTR 78: THE DUCTWORK DOWNSTREAM OF THE FGD
SYSTEM «AS RECONSTRUCTED TO PREVENT STAGNATION OF
THF EXHAUST GASES. CORROSION OF THE STEEL LINER
REMAINS A PROBLEM.
-------
STATUS TO JANUARY 1979
SECTION 3 (CONTINUED)
SUMMARY OF FGO SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
GENERAL MOTORS CORPORATION
TONONANDA, NEW YORK
FMC ENVIRONMENTAL EQUIPMENT
COAL (1.2X SULFUR)
92,000 SCFM fTOTAL - 0 BOILERS)
START-UP 6/75
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
*8KGO: THE F6D SYSTEM CONSISTS OF FOUR 6* SODIUM
SCRUBBING UNITS FOR THE REMOVAL OF PAKTICULATES
AND SULFUR DIOXIDE FROM FOUR COAL-FIRED BOILERS.
*flTH QTR 78: THE FOUR STAINLESS STEEL STUB STACKS
HAVE CORRODED DUE TO ACID CARRY-OVER AND PLANS ARE
BEING MADE TO EITHER RELINE OR REPLACE THEM.
ALSO, CHEVRON MIST ELIMINATORS KILL BE INSTALLED
TO REDUCE THE ENTRAINED LIQUID IN THE FLUE GAS.
GEORGIA-PACIFIC PAPER co.
CROSSETT, ARKANSAS
AIRPOL INDUSTRIES
BARK,COAL/OIL (1.5X - a.OX SULFUR)
220,000 SCFM (1 BOILER)
START-UP 7/75
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
•BKGD: THE FGO SYSTEM CONSISTS OF AN AIRPOL
CAUSTIC SCRUBBING UNIT TO REMOVE SULFUR DIOXIOF
AND PARTICULATE MATTER FROM THE FLUE GAS OF A
COAL/BARK OR OIL/BARK POWER BOILER. THE SYSTEM IS
PRECEDED BY CYCLONES FOR PAHTICULATE REMOVAL.
oflTH QTR 78: THE PLANT REPORTED NO OPERATING
PROBLEMS DURING THIS PERIOD.
SETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
FMC ENVIRONMENTAL EQUIPMENT
OIL (1.1X SULFUR)
72,000 SCFM (TOTAL - 6 BOILERS)
START-UP fe/77
SODIUM CARBONATE SCRUBBING
STATUS - OBERATIONAL
*«TH QTR 7«: THE SODIUM CARBONATE SCRUBBING FGD
SYSTEM SUPPLIED BY FMC IN JUNE 1977, HAS PERFORMED
HELL DURING THE QUARTER. THE POSITIVE DISPLACE-
MENT MOYNO PUMP EXPERIENCED ABRASION ON THE ROTOR.
ALLOYS SUCH AS CHROME-ALLOY AND NI-HARD ARE BEING
REVIEWED AS REPLACEMENT MATERIAL.
BETTY OIL COMPANY
BAKERSFIELO, CALIFORNIA
IN-HOUSE DESIGN
OIL (1.1X SULFUR)
495,000 SCFM CTOTAL-45 BOILERS)
START-UP 12/78
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
*BKGO: GETTY OIL COMPANY HAS DEVELOPED AN IN-
HOUSE FGO PROCESS DESIGN AND PLANS TO UTILIZE THIS
PROCESS TO CONTROL EMISSIONS FROM 81 STEAM GENER-
ATORS, AT THE BAKERSFIELO EOR SITE. THERE WILL BE
9 FGD SYSTEMS, EACH CONTROLLING FL»E GAS GENERATED
BY 9 STEAM GENERATORS. EACH SYSTEM WILL INCLUDE
AN ABSORBER MODULE (PURCHASED FROM KOCH ENGINEER-
ING) CONTAINING THREE FLEXIMESH TRAYS AND ONE
FLEXIMESH MIST ELIMINATOR. THIS ENTRY ADDRESSES
THE 5 FGD SYSTEMS WHICH HAVE STARTED.
«4TH QTR 78: THE 5 SYSTEMS WHICH HAVE BEGUN OPERA-
TING HAVE EXPERIENCED PROBLEMS WITH FANS, MIST
ELIMINATORS, AND SCALING.
6ETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
IN-HOUSE DESIGN
OIL (1.11 SULFUR)
396,000 SCFM (TOTAL-36 BOILERS)
START-UP J/79
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
*BKGO: GETTY OIL HAS DEVELOPED AN IN-HOUSE FGD
PROCESS DESIGN AND PLANS TO UTILIZE THIS PROCESS
TO CONTROL EMISSIONS FROM 81 STEAM GENERATORS, AT
THE BAKERSFIELD EOR SITE. THERE WILL BE 9 FGD
SYSTEMS, EACH CONTROLLING FLUE GAS GENERATED BY 9
STEAM GENERATORS. THIS ENTRY ADDRESSES THE « FGD
SYSTEMS NOT YET STARTED.
*«TH QTR 78: OF THE « UNITS YET TO BEGIN OPERA-
TING, 2 ARE SCHEDULED TO START IN MID-JANUARY
AND 2 IN MID-FEBRUARY.
6REAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
AIRPOL INDUSTRIES
BARK,COAL/OIL (l.OZ - 2.OX SULFUR)
420,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/75
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
*BKGn: THE FGD SYSTEM CONSISTS OF TWO AIRPOL
CAUSTIC SCRUBBERS TO CONTROL PARTICULATE AND
SULFUR DIOXIDE FROf TWO POWER BOlLErtS. THE
PRIMARY FUEL IS BARK/COAL (BARK/OIL IS FIRED
OCCASIONALLY).
*QTH QTR 7*: FAILURE OF SEALS AND PACKINGS TN
PUMPS CONTINUED TO BE A PROBLEM. NEW SEALS WILL
BE INSTALLED. RUBBER-LINED PIPING IS GRADUALLY
BEING REPLACED WITH STAINLESS STEEL. PLANS ARE
BEING MADE TO REDUCE THE SOLIDS CONTENT IN THE
LIQUOR BY INCREASING THE BLEED-OFF.
10
-------
STATUS TO JANUARY 1979
SECTION t (CONTINUED)
SUMMARY OF FGD SYSTEMS ON INDUSTRIAL BOtLFRS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
GREAT WESTERN SUGAR
BILLINGS* MONTANA
GREAT WESTERN SUGAR
COAL (0.7X SULFUR)
60,000 SCFM (.TOTAL - 3 BOILERS)
START-UP 10/7T
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL-
•BKGO: GREAT WESTERN SUGAR USES CONDENSATE PROCFSS
WATER PRIMARILY FOR PARTICULATE CONTROL. TMF
WATER HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOfc
SO? REMOVAL BECAUSE THE MTfcR IS INTROnuCFD
THROUGH PIPES RATHER THAN SPR*Y NOZZLES.
y
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
GREAT WESTERN SUGAR
COAL (1.2X SULFUR, AVERAGE)
65,230 SCFM CTOTAL - 2 BOILERS)
START-UP I0/7fe
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
•BKGO: THE VENTURI SCRUBBER WAS DESIGNED FOR PAR-
TICULATE CONTROL AND STARTED IN OCT. 7ft. THE CON-
OENSATE PKOCESS WATER USED HAS A HIGH PH (8.7)
WHICH REMOVES SOME S02. THE PAHTICUL4TE AN11 SO?
CONTROL EFFICIENCIES ARE 961 ANO «8X RESPECTIVELY.
y
GREAT WESTERN SUGAR
GERING, NEBRASKA
GREAT WESTERN SUGAR
COAL (1.2X SULFUR, AVERAGE)
110,000 SCFM (TOTAL - 2 BOILERS)
START-UP 10/75
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
*BK&0: GREAT WESTERN SUGAH USES CONDENSATF PROCESS
WATER PRIMARILY FOR PARTICULATE CONTROL. THE
WATER HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOW
S02 REMOVAL. THE VENTURI SCRUBBERS WERE INSTALLED
IN OCT. 75, THE PLANT OPERATES ONLY DURING THE
FALL QUARTER.
y
6REAT WESTERN SUGAR
6REELEY, COLORADO
GREAT WESTERN SUGAR
COAL (0.6X SULFUR)
25*000 SCFM (1 BOILER)
START-UP 10/75
AMMONIA-LADEN PROCESS MATER
STATUS - OPERATIONAL
•BKGO: GREAT WESTERN SUGAR USES CONDENSATE PROCESS
WATER PRIMARILY FOR PARTICULATE CONTROL. THE
WATER HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOft
80S REMOVAL BECAUSE THE WATER IS INTRODUCED
THROUGH PIPES RATHER THAN SPRAY NOZZLES.
GREAT WESTERN SUGAR
LONGMONT, COLORADO
GREAT WESTERN SUGAR
COAL C0.7X SULFUR)
3CFM-N/A
START-UP 10/73
AMMONIA-LADEN PROCESS WATER
STATUS - TERMINATED
SUGAR PRODUCTION AND ALL PLANT OPERATIONS
HAVE BEEN TERMINATED AT THF LONGMONT PLANT.
GREAT WESTERN SUGAR
LOVELANO, COLORADO
GREAT WESTERN SUGAR
COAL U.2X SULFUR, AVERAGE)
121,800 SCFM CTOTAL - 3 BOILERS)
START-UP 10/73
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
•BKGD: GREAT WESTERN SUGAR USES CONDENSATE PROCESS
WATER PRIMARILY FOR PARTICULATE CONTROL. THE
WATER HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LO* y
SO? REMOVAL. THE SCRUBBERS W£R£ 1NSTALLFD IN OC- J
TOBER 1973. THE PLANT OPERATES ONLY DURING THE
FALL QUARTER.
GREAT WESTERN SUGAR
SCOTTS BLUFF, NEBRASKA
GREAT WESTERN SUGAR
COAL (1.2X SULFUR, AVERAGE)
65*230 SCFM (TOTAL - Z BOILERS)
START-UP 10/75
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
*BKGD: THE PLANT OPERATES ONLY OURINP THE FALL
QUARTER OF EACH YEAR. THE VENTURI SCRUBBER WAS
DESIGNED FOR PARTICULATE CONTROL AND «AS STARTED
IN OCT. 75. THE PARTICULATE AND S02 REMOVAL
EFFICIENCIES ARE
-------
STATUS TO JANUARY 1979
SECTION ^ (CONT IH'UEO)
SUMMARY ()F FGD SYSTEMS Ofu INDUSTRIAL ROILFRS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
GRISSOM AIR FORCE RASE
BUNKER HILL, INDIANA
AIRPOL INDUSTRIES
COAL (0.9X - 4.6X SULFUR)
32,000 SCFM (TOTAL - 3 BOILERS)
START-UP 9/79
DOUBLE ALKALI (CONCENTRATED)
STATUS - PLANNED-CONTRACT AWARDED
*aTH (JTW 78: THE AIM FORCE HAS AWARDED A CONTRACT
TO ATHPOL INDUSTRIES FOH A CONCENTRATED DOUBLE-
ALKALI FGO SYSTEM TO CONTROL EMISSIONS FROM ONE
NEW AND TrtO EXISTING COAL-FIRED BOILERS. START-UP
IS SCHEDULED FOR AUGUST 30, 1979. ATRPOL HAS
GUARANTEED THAT EMISSIONS FROM THE SYSTEM HILL NOT
EXCEED 1.2 LB/MM BTU SOS OR 0.171 LB/MM BTU FOR
PARTICIPATE.
HARRIS MINING CO.
SPRUCE PINE, NORTH CAROLINA
W.W. SLY MANUFACTURING CO.
COAL (0.8X SULFUR)
a,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/73
WATER SCRUBBING (NA,NH? OPTN.)
STATUS - INDEFINITELY SHUT DOWN
•BKGO: THE FGO SYSTEM CONSISTS OF A W.W. SLY IM-
PINJET SCRUBBER CURRENTLY BEING USED STRICTLY AS A
PARTICIPATE CONTROL DEVICE. THE SYSTEM HAS THE
CAPABILITY OF SCRUBBING WITH AMMONIA OR CAUSTIC
IF S02 CONTROL IS NECESSARY. HOWEVER, AS LONG AS
CURRENT LOW-SULFUR COAL SUPPLIES LAST, THERE IS NO
NEED FOR soa CONTROLS.
ITT RAYONTER, INC.
FERNANOINA BEACH, FLORIDA
AIRPOL INDUSTRIES
BARK,OIL (2.01 - 2.51 SULFUR)
176,000 SCFM (TOTAL - 4 BOILERS)
START-UP 0/75
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGD: AT FERNANDINA BEACH, ITT RAYONIER FIRES
BAHK AND OIL IN TWO OF TH£ FOUR PROCESS STEAM
BOILERS. PARTICULATE AND 802 EMISSIONS ARE CON-
TROLLED IN TWO AIRPOL SCRUBBING TRAINS.
• 4TH QTR 78: MODULE A WAS DOWN FOR TEN DAYS
TO REPAIR THE CRACKED FOUNDATION OF THE FAN.
AT THIS TIME THE PRECEDING DUST COLLECTOR
WAS ALSO REPAIRED. NEW OUST COLLECTORS ARE
SCHEDULED TO BE INSTALLED IN APRIL WHICH WILL
HEIP REDUCE EROSION PROBLEMS.
v/
KERR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
COMBUSTION EQUIPMENT ASSOC.
COKE/COAL/OIL (0.5* - 5.01 SULFUR)
090,000 SCFM (TOTAL - 2 BOILERS)
START-UP 6/78
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
*BKGD! THE FSO SYSTEM CONSISTS OF A COMBUSTION
EQUIPMENT (CEA) SODA ASH SCRUBBING SYSTEM WHICH
REMOVES FLYASH AND SULFUR DIOXIDE FROM THE FLUE
GAS OF THE TWO COAL-FIRED BOILERS.
• 4TM QTR 78: THE 317L S3 SIEVE TRAYS ARE WORKING
WELL. FUEL USED, WAS A MIXTURE OF O.SX SULFUR
COAL AND 3.51 SULFUR COKE. BOTH SCRUBBERS
DEMONSTRATED 100X RELIABILITY DURING THIS PERIOD.
HEAD PAPERBOARD CO.
STEVENSON, ALABAMA
AIRPOU INDUSTRIES
OIL (1.5Z - 3X SULFUR)
100,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/75
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
•BKGD: AIRPOL INDUSTRIES HAS SUPPLIED A PARTICUL-
ATE AND S02 CONTROL SYSTEM FOR THE TWO OIL-FIRED
BOILERS AT THIS MEAD PULP MILL.
•4TH QTR 78: THE SCRUBBER DEMONSTRATED 100X RELI-
ABILITY DURING THE REPORT PERIOD. IN NOVEMBER
ONE BOILER MAS DOWN FOR 24 HOURS AND THE OTHER
FOR 4» HOURS TO REPLACE SEALS AND PREHEATERS.
THE BOILERS OPERATED AT APPROXIMATELY 80* LOAD.
MINN-DAK FARMER'S CO-OPERATIVE
WAHPETON, NORTH DAKOTA
KOCH ENGINEERING
LIGNITE (l.OZ SULFUR)
164,000 SCFM (TOTAL - 2 BOILERS)
START-UP 6/77
AMMONIA SCRUBBING
STATUS - OPERATIONAL
•BKGD: KOCH ENGINEERING HAS SUPPLIED TWO AMMONIA-
BASED 302 CONTROL SYSTFMS FOR THESE COAL-FIRED
BOILERS. EACH YEAR THE PLANT ONLY PRODUCES SUGAR
DURING THE SEPTEMBER-FEBRUARY PfRIOO.
*4TH QTR 78: PLANS ARE BEING MADE TO ENCLOSE
MORE OF THE WASTE TREATMENT FACILITIES SINCE
EXCESSIVE HEAT LOSS IN THE DIGESTERS WAS A CON-
CERN. THE FGD SYSTEM OPERATED PROBLEM FREE DURING
THE REPORT PERIOD.
MOBIL OIL COMPANY
BUTTONWILLOW, CALIFORNIA
HEATER TECHNOLOGY
OIL (1.1Z SULFUR)
80,500 SCFM (TOTAL - 7 BOILERS)
START-UP 2/79
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
•BKGD: MOBIL OIL HAS PURCHASED SEVEN EOUCTOR-TYPE
SCRUBBERS FROM HEATER TECHNOLOGY FOR THE CONTROL
OF EMISSIONS FROM 7 STEAM GENERATORS (25 MM BTU/
HR). EACH SYSTEM CONSISTS OF A VENTURI SECTION, A
RECYCLE TANK, AND AN OUTLET DUCT WITH A-MIST
ELIMINATOR.
•4TH QTR 78: START-UP DATE HAS BEEN EXTENDED TO
FEBRUARY 1979 DUE TO DELAYS IN AWARDING SUB-
CONTRACTS FOR PIPING AND OTHER WORK.
12
-------
STATUS TO JANUARY 1979
SPCTION 5 (CONTINUED)
SUMMARY OF FGO SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RF.CF.NT OPERATIONS
MOBIL OIL COMPANY
SAN ARDOr CALIFORNIA
IN-HOUSE DESIGN
OIL (2.OX - ?.25X SUIFUR)
175,000 SCFM (TOTAL - 28 BOILERS)
START-UP 0/74
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•RKOG: MOBIL HAS DESIGNED THE FGO SYSTEM BY IN-
HOUSE ENGINEERING BASED ON A PATENTED SODIUM HYDR-
OXIDE SCRUBBING PROCESS. THE I.I). FANS ARE LINED
WITH EPUXY RESIN TO REDUCE CORROSION.
•aTH QTR 78: BECKMAN PH CONTROLLERS ARE WORKING
WELL AND ADDITIONAL UNITS HAVE BEEN INSTALLED.
AN AVAILABILITY OF ABOUT 951 WAS DEMONSTRATED
BY THE FGD SYSTEM DURING THE REPORT PERIOD.
NEKOOSA PAPERS, INC.
ASHOOWN, ARKANSAS
AIRPOL INDUSTRIES
COAL (IX - 1.5X StILFIIK)
211,000 SCFM ITOTAL - 1 BOILER)
START-UP 2/76
CAUSTIC SCRUBBING
STATUS - OPERATIONAL
*BKGD: THE FGO SYSTEM CONSISTS OF TWO AIRPOL
CAUSTIC SCRUBBERS CONTROLLING FLYASH AND SULFUP
DIOXIDE.
*4TH QTH 78: NEKOOSA IS CURRENTLY USING PURCHASED
CAUSTIC INSTEAD OF THEIR NORMAL ON-SITE CAUSTIC
WASTE STREAM BECAUSE OF A PUMP FAILURE. ONE
SCRUBBER MODULE WAS SHUTDOWN TO PATCH THE SEPARA-
TOR LINING ANO REPAIR CORROSION LEAKS. THE BOILER
REMAINED OPERABLE BECAUSE THE ENTIRE GAS FLOW WAS
HANDLED BY THE OTHER SCRUBBER.
NORTHERN OHIO SUGAR COMPANY
FINOLAY, OHIO
GREAT WESTERN SUGAR
COAL (l.?X SULFUR, AVERAGE)
65,230 SCFM (TOTAL - 2 BOILERS)
START-UP 10/74
SODIUM CARBONATE SCRUBBING
STATUS - TERMINATED
»BKGD: THE VENTURI TOWER WAS MAINLY DESIGNED FOR
PARTICULATE CONTROL, AND WAS STARTED UP IN OCTOBER
'74. PARTICULATE AND S02 REMOVAL EFFICIENCIES
WERE 90x AND 7&x RESPECTIVELY. THE 302 CONTROL
WAS EFFECTED BY THE PROCESS CONDENSATE USED FOR
SCRUBBING (PH=8.7).
*4TH QTR 78: THIS PLANT HAS TERMINATED ALL SUGAR
PRODUCTION OPERATIONS. THE SCRUBBER OPERATED FROM
OCTOBER 1974 THROUGH THE *77-'78 SEASON BEFORE THE
SHUTDOWN OCCURRED.
NORTHERN OHIO SUGAR COMPANY
FREEMONT, OHIO
GREAT WESTERN SUGAR
COAL (IX SULFUR)
40,000 SCFM (TOTAL - 2 BOILERS)
START-UP 10/75
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
PHILLIP MORRIS, INC.
CHESTERFIELD, VIRGINIA
FLAKT, INC.
COAL
39,000 SCFM (TOTAL - J BOILER)
START-UP 6/79
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
•BKGD: PARTICULATE AND soz EMISSIONS ARE BEING
CONTROLLED BY A SCRUBBER/ABSORBER MODULE OF PRO-
PRIETARY DESIGN. THE FLUE GAS IS GENERATED BY TWO
UNION BOILERS, EACH RATED a 70,000 LB/HR STEAM.
*4TH QTR 78: CONSTRUCTION IS HEARING COMPLETION ON
A NON-REGENERABLE SODIUM CARBONATE FGO SYSTEM
(SUPPLIED BY FLAKT, INC.) WHICH WILL CONTROL
EMISSIONS FROM A NEW PULVERIZED COAL-FIRED BOILER
GENERATING FLUE GAS EQUIVALENT TO 30 MW. THE
FLAKT SYSTEM WILL REMOVE A MINIMUM OF 90X OF THE
S02 FROM 2/3 OF THE FLUE GASl THE REMAINDER OF THE
GAS WILL BE USED FOR REHEAT.
RICKENBACKER AIR FORct BASE
COLUMBUS, OHIO
RESEARCH-COTTRELL/BAHCO
COAL (3.6X SULFUR)
55,000 SCFM (TOTAL - 7 BOILERS)
START-UP 3/76
LIMESTONE SCRUBBING
STATUS - OPERATIONAL
•BKGD: THIS RESEARCH-COTTRELL/BACHO LIME FGD UNIT
WAS FIRST PLACED IN SERVICE MARCH 11, 1976.
THE SYSTEM WAS SWITCHED OVER TO LIMESTONE IN APRIL
1977, AND HAS REMAINED IN THAT OPERATING MODE TO
DATE.
*4TH OTR 78: A TOTAL OF 36 HOURS DOWNTIME WERE
REPORTED FOR THIS PERIOD, YIELDING AN AVAILABILITY
OF 9S.4X. THE NUCLEAR DENSITY CONTROL VALVE ON
THE THICKENER UNDERFLOW WAS REPAIRED ANO CAUSED NO
DOWNTIME.
SHELL OIL COMPANY
BAKERSFIELD, CALIFORNIA
VENDOR NOT YFT SELECTED
OIL U.1X SULFUR)
99,000 SCFM (TOTAL - 6 BOILERS)
START-UP O/ 0
PROCESS NOT YET SELECTED
STATUS - PLANNED-CONSIDERING 802 CONTROL
•BKGO: SHELL OIL IS CONSIDERING IMPLEMENTING FGD
TECHNOLOGY TO CONTROL EMISSIONS FROM e SMALL OIL-
FIRED (1.1X SULFUR) STEAM GENERATORS. NO PROCESS
OR START-UP DATE HAVE AS YET BEEN SPECIFIED. AN
302 REMOVAL EFFICIENCY OF 94X WILL BE REQUIRED.
13
-------
SECTION J (CONTINUED)
SUMMARY OF FGO SYSTEMS ON INDUSTRIAL BOILFRS
STATUS TO JANUARY 1979
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
SHELL OIL COMPANY
TAFT, CALIFORNIA
VENDOR NOT YET SELECTED
OIL (1.1* SULFUR)
55,000 SCFM (TOTAL - 2 BOILERS)
START-UP O/ 0
PROCESS NOT YET SELECTED
STATUS - PLANNED-CONSIDERING SOS CONTROL
*BK6D: SHELL OIL IS CONSIDERING IMPLEMENTING FGD
TECHNOLOGY TO CONTROL EMISSIONS FROM 2 SMALL OIL-
FIRED (1.1X SULFUR) STEAM GENERATORS. NO PROCESS
OR START-UP DATE HAVE AS YET BEEN SPECIFIED. AN
SOS REMOVAL EFFICIENCY OF 94* WILL BE REQUIRED.
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
H.N. SLY MANUFACTURING CO.
COAL (< I. OX SULFUR)
8,000 SCFM (TOTAL - 1 BOILER)
START-UP 0/75
SODIUM HYDROXIDE SCRUBBING
STATUS - INDEFINITELY SHUT DOWN
*BKGO: AFTER SYSTEM RESTART IN OCTOBER 1977,
THERF HAVE BEEN NO PROBLEMS RESULTING FROM EITHER
BOILER OR SCRUBBER OPERATIONS. THE PLANT UNDER-
WENT A VIRGINIA EPA INSPECTION AND WAS FOUNn TO HE
IN COMPLIANCE WITH THE PARTICULAR EMISSION
REGULATIONS.
•QTH QTR 78: NO SCRUBBER RELATED PROBLEMS HAVE
OCCURRED DURING THIS REPORT PERIOD. AT PRESENT
THE USE OF NAOH HAS BEEN DISCONTINUED, SO THIS
SYSTEM HAS BEEN MOVED TO OUR "INDEFINITELY
SHUTDOWN" STATUS.
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
BUREAU OF MINES
COAL (2.51 - 4.5Z SULFUR)
142,000 SCFM (TOTAL - I BOILER)
START-UP 3/79
CITRATE PROCESS
STATUS - CONSTRUCTION
*BKGD: CONSTRUCTION CONTINUES ON THE CITRATE
PROCESS SCRUBBING SYSTEM WHICH WILL CONTROL SOS
EMISSIONS FROM A 60-MM (NOMINAL PEAK CAPACITY)
COAL-FIRED POWER GENERATING UNIT. STARTUP IS
SCHEDULED FOR MARCH 1979. THIS SYSTEM WILL ALSO
BE REPORTED IN THE EPA/PEDCO UTILITY FGD SURVEY,
SINCE THE SYSTEM WILL BE OPERATED WITH A UTILITY-
TYPE LOAD PROFILE, DURING THE ONE-YEAR DEMONSTRA-
TION PERIOD.
ST. REGIS PAPER CO.
CANTONMENT, FLORIDA
AIRPOL INDUSTRIES
BARK,OIL/GAS (< l.OZ SULFUR)
115,000 SCFM (1 BOILER)
START-UP 0/73
CAUSTIC SCRUBBING
STATUS - OPERATIONAL
•BKGD: AIRPOL HAS SUPPLIED THE CAUSTIC SCRUBBING
SYSTEM TO REMOVE PARTICULATE AND SULFUR DIOXIDE
FROM THE FLUE GAS OF A BARK BOILER, WHICH CAN
ALSO FIRE NATURAL GAS AND OIL.
*4TH OTR 7B: PLANT HAS CHANGED THE FEEDWATER
SOURCE FROM SCREEN ROOM BLACK WATER TO EVAPORATOR
CONDENSATE WATER, TO ALLEVIATE PLUGGING PROBLEMS
IN THE MIST ELIMINATOR AND PIPING.
SUN PRODUCTION COMPANY
FELLOWS, CALIFORNIA
C-E NATCO
OIL (1.4Z SULFUR)
6,000 SCFM (IS,000 ACFM 3 570 F)
START-UP 4/79
SODIUM HYDROXIDE SCRUBBING
STATUS - CONSTRUCTION
*BKGD: SUN OIL HAS FOUR ss MM BTU/HR AND TWO so MM
BTU/HR STEAM GENERATORS AT THIS OIL SITE. T.HE
CRUDE OIL HAS 1.4 PERCENT SULFUR.
*4TH (JTR 7«: C-E NATCO IS CONSTRUCTING THE SYSTEM.
STARTUP DATE IS APRIL 1979.
SUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
C-E NATCO
OIL (1.21 SULFUR)
6,000 SCFM (IS,000 ACFM S 570 F)
START-UP 4/79
SODIUM HYDROXIDE SCRUBBING
STATUS - CONSTRUCTION
*BKGD: SUN OIL HAS TWO 25 MM BTU/HR STEAM GENERA-
TORS AT THIS OIL SITE. THE CRUDE OIL HAS 1.2
PERCENT SULFUR.
•4TH OTR 78: THE SYSTEM, SUPPLIED BY C-E NATCO, IS
UNDER CONSTRUCTION. STARTUP IS EXPECTED TO OCCUR
BY APRIL 1979.
TENNECO OIL CO.
GREEN RIVER, WYOMING
VENDOR NOT YET SELECTED
COAL U.5X SULFUR, MAXIMUM)
140,000 SCFM (TOTAL - ? BOILERS)
START-UP 1/H2
SODIUM CARBONATE SCRUBBING
STATUS - PLANNED-REQUEST ING/EVALUATING BIDS
•BKGD: TENNECO OIL HAS RETAINED BROWN AND HOOT
FOR THE DESIGN OF A SODA ASH PLANT AND THE
CONCOMMITTANT POLLUTION CONTROL EQUIPMENT.
THF PLANT WILL BE LOCATED IN GREEN KIVER, WYOMING
AND WILL HAVE TWO BOTLFRS BURNING WYOMING COAL.
*4TH OTH 78: TENNECO AND B*H ARE EVALUATING BIDS
FOR THE SODIUM CARBONATE SCRUBBING SYSTEMS WHICH
WILL CONTROL SOS EMISSIONS FROM THF BOILERS.
-------
STATUS TO JANUARY 1979
SECTION 3 (CONTINUED)
SUMMARY OF F6D SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
CEILCOTE
OIL (1.71 SULFUR)
300,000 SCFM .(TOTAL - 32 BOILERS)
START-UP 11/73
SODIUM HYDROXIDE SCRUBBING
STATUS " OPERATIONAL
«BKGf>: FGO SYSTEM CONSISTS OF A HORIZONTAL. PACK-
ED-BEO SCKUBBER FOR FACH OF THE OIL-FIRED BOILERS.
*4TH QTR 7A: CORROSION IN THE QUENCHER AND ABRA-
SION/PLUGGING IN THE ABSORBER CONTINUE TO BE PROB-
LEM AREAS. DURING THIS QUARTER EACH SCRUBBER MAS
SHUTDOWN FOR MAINTENANCE AN AVERAGE OF 100 HOURS.
TEXACO is PLANNING TO PHASE OUT THIS GROUP OF
SCRUBBERS BY LATE 1979.
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
OUCON COMPANY
OIL U.7X SULFUR)
117,000 SCFM (TOTAL - 9 BOILERS)
START-UP 3/79
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
TEXACO IS PLANNING TO PHASE OUT THE
EXISTING FGO SYSTEMS AT THEIR SAN ARDO, CALIFORNIA
SITE. AS THE FIRST STEP OF THE PROGRAM, 9 OF THE
PRESENT 31 SCRUBBERS ON 50 MM BTU/HR STEAM GENER-
ATORS ARE BEING REPLACED BY A NEW SYSTEM, SUPPLIED
BY OUCON COMPANY. THE NEW FGD SYSTEM WILL CON-
SIST OF THREE TRAINS OF A VENTURI SCRUBBER/SPRAY
ABSORBER COMBINATION.
*
-------
STATUS TO JANUARY 1979
SlIMMAKY BY VFNIH1R OF FRl> SYSTEMS ON INDUSTRIAL BOIIEPS
VFNOOR
INSTALLATION NAME / LOCATION
CONTROL SYSTEM PROCFSS
A.O. LITTLE
AIRPOL INDUSTRIES
BUREAU OF MINFS
C-E N*TCO
CARBORUNDUM ENVIR. SYS. LTD.
CEILCOTF
COMBUSTION EQUIPMENT ASSOC.
DRAVO CORP./NAT'L LIME ASS'N
DUCON COMPANY
ENTOLETER, INC.
FLAKT, INC.
FMC ENVIRONMENTAL EQUIPMENT
GENFWAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
GEORGIA-PACIFIC PAPER CO.
CROSSFTT, ARKANSAS
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
GRISSOM AIR FORCE BASE
8UNKER HILL, INDIANA
ITT RAYONTER, INC.
FERNANOINA BEACH, FLORIDA
MEAD PAPFRBOARO CO.
STEVENSON, ALABAMA
NEKOOSA PAPERS, INC.
ASHOOWN, ARKANSAS
ST. HFGIS PAPFh CO.
CANTONMENT, FLORIDA
U.S. GYPSUM CORP.
OAKMONT, PENNSYLVANIA
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
BELRIDGE OIL CO.
MCKITTHICK, CALIFORNIA
SUN PRODUCTION COMPANY
FFLLOWS, CALIFORNIA
SUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
CARBORUNDUM ABRASIVES
BUFFALO. NEW YORK
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
KERR-MCGtF CHFMICAL CORP.
TRONA, CALIFORNIA
BUNGE, INC.
CAIRO, ILLINOIS
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
GENERAL MOTORS CORPORATION
DAYTON, OHIO
PHILLIP MORRIS, INC.
CHESTERFIELD, VIRGINIA
AIYFSKA PIPELINE SERVTCF co.
VALDF7, ALASKA
ARCO/POl YMF.RS, INC.
MONACA, PENNSYLVANIA
CANTON TfXTTLFS
CANTON, GEORGIA
SODIUM HYDROXIDE SCRUBBING
CAUSTIC WASTE STREAM
CAUSTIC WASTE STRFAM
DOUBLE ALKALI (CONCENTRATED)
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
CAUSTIC SCRUBBING
CAUSTIC SCRUBBING
DOUBLE ALKALI (DILUTE)
CITRATE PROCESS
SODIUM HYDROXIDE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
LIME SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
LIME SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
DOUBLE ALKALI (CONCFNTRATEO)
CAUSTIC WASTE STREAM
-------
STATUS TO JANUARY 1979
SECTION q (CONTINUED)
SUMMARY BY VENDOR OF FGD SYSTEMS ON INDUSTRIAL BOILERS
VENDOR
FMC ENVIRONMENTAL EQUIPMENT
GM ENVIRONMENTAL
GREAT WESTERN SUGAR
HEATER TECHNOLOGY
INSTALLATION NAME / LOCATION
CATERPILLAR TRACTOk CO.
FAST PEOKIA, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLE, ILLINOIS
CHANSLOR WESTERN OIL * DEV. CO
BAKERSFIELD, CALIFORNIA
FIRESTONE TIRE AND RUBBER CO.
POTTSTOWN, PENNSYLVANIA
FMC (SODA ASH PLANT)
GREEN RIVER, WYOMING
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
GENERAL MOTORS CORPORATION
PARMA, OHIO
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
GREAT WESTERN SUGAR
HILLINGS, MONTANA
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
GREAT WESTERN SUGAR
GERING, NEBRASKA
GREAT WESTERN SUGAR
GREELEY, COLORADO
GREAT WESTERN SUGAR
LONGMONT, COLORADO
GREAT WESTERN SUGAR
LOVELANO, COLORADO
GREAT WESTERN SUGAR
SCOTTS BLUFF, NEBRASKA
NORTHERN OHIO SUGAR COMPANY
FINDLAY, OHIO
NORTHERN OHIO SUGAR COMPANY
FREEMONT, OHIO
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
MOBIL OIL COMPANY
BIITTONMILLOW, CALIFORNIA
CONTROL SYSTEM PROCESS
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM CARBONATE SCRUBBING
DOUBLE ALKALI (DILUTE)
SODIUM HYDROXIDE SCRUBBING
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PffOCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
-------
STATUS TO JANUARY 1<»7P
SECTION a (CONTINUED)
SUMMARY BY VENDOR OF FGI) SYSTEMS ON INDUSTRIAL BOILERS
VENDOR
INSTALLATION NAME / LOCATION
CONTROL SYSTFM PROCESS
IN-HOUSE DESIGN
KOCH ENGINEERING
PITTSBURG ENV. * ENGY. SYSTEMS
RESEARCH-COTTRELL/8AHCO
SHEMCO INC.
THERMOTICS INC.
VENDOR NOT YET SELECTED
M.H. SLY MANUFACTURING CO.
ZURN INDUSTRIES
SETTY OIL COMPANY
flAKERSFIELO, CALIFORNIA
GETTY OIL COMPANY
8AKFRSFIELO, CALIFORNIA
MOBIL OIL COMPANY
SAN ARDO, CALIFORNIA
ARMCO STEEL
MIDDLETOtvN, OHIO
CHEVRON U.S.A. INC.
BAKERSFTELD, CALIFORNIA
CHEVRON U.S.A. INC.
8AKERSFIELD, CALIFORNIA
MINN-DAK FARMER'S CO-OPERATIVE
WAHP6TON, NORTH DAKOTA
WESTERN CORRECTIONAL INST.
PITTSBURG, PENNSYLVANIA
RICKENBACKER AIR FORCE BASE
COLUMBUS, OHIO
TEXASGULF
GRANGER* WYOMING
BELRIDGE OIL CO.
MCKITTHICK, CALIFORNIA
C.A.t*.(CARBTDF-AMOCO-KONSANTO)
HOUSTON, TEXAS
DUPONT, INC.
GEORGIA
DUPONT, INC.
TEXAS
SHELL OIL COMPANY
BAKERSFIELO, CALIFORNIA
SHELL Oil COMPANY
TAFT, CALIFORNIA
TENNECO OIL CO.
GREEN RIVEK, WYOMING
AMERICAN THREAD CO.
MARION, NORTH CAROLINA
HARRIS MINING co.
SPRUCE PINE, NORTH CAROLINA
SHFLLER GLOBE CORP.
NORFOLK, VIRGINIA
CATFKPILLAR TRACTOR CO.
JOLICT, ILLINOIS
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
SODIUM CARBONATE SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
LTME SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM CARBONATE SCRUBBING
AMMONIA SCRUBBING
SULF-X SCORE
LIMESTONE SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
PROCESS NOT YET SELECTED
DOUBLE ALKALI
LIMESTONE SCRUBBING
PROCESS NOT YET SELECTED
PROCESS NOT YET SELECTED
SODIUM CARBONATE SCRUBBING
CAUSTIC WASTE STREAM
KAIEK SCRUBBING (NA.NH3 OPTN.)
SODIUM HYDROXIDE SCRUBBING
DOUBLE ALKALI (DILUTE)
DOUBLE ALKALI (DILUTE)
-------
STATUS TO JANUARY 197')
SECTION 5
OPERATIONAL f&O SYSTEMS ON INDUSTRIAL HOfLERS
COMPANY/LOCATION/FUEL
NEW/
RETROFIT
UNIT SI7E
(SCFM)
PROCESS/VFNDOR
START-UP
NO/YH
ALYESKA PIPELINE SERVICE CO.
VALDEZ, ALASXA
Oil (0.03X - 0.1% SULFUR)
NEW
50,000 SODIUM HYDROXIDE SCRUBBING fe/77
FMC ENVIRONMENTAL EQUIPMENT
AMERICAN THREAD CO.
MARION, NORTH CAROLINA
COAL (1 " 1.5* SULFUR)
RETROFIT
IB,500
CAUSTIC WASTE STREAM
W.A. SLY MANUFACTURING co.
0/73
ARMCO STEEL
MIDDLETOHN, OHIO
COAL (0.81 SULFUR)
RETROFIT
64,000
LIME SCRUBBING
KOCH ENGINEERING
0/75
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
OIL (l.lt SULFUR)
NEW
13,000
SODIUM HYDROXIDE SCRUBBING
HEATER TECHNOLOGY
6/78
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
CRUDE OIL fl.lX SULFUR)
NEW
I?,000
SODIUM HYDROXIDE SCRUBBING
THERMOTICS INC.
7/78
CANTON TEXTILES
CANTON, GEORGIA
COAL (0.81 SULFUR)
INTERRUPTIBLE NATURAL GAS
RETROFIT
25,000 CAUSTIC WASTE STREAM fe/74
FMC ENVIRONMENTAL EOUIPMENT
CATERPILLAR TRACTOR CO. .
EAST PEORIA, ILLINOIS
COAL (3.2X SULFUR)
NEW, 2 RETRO 210,000 DOUBLE ALKALI (CONCENTRATED) a/78 r
FMC ENVIRONMENTAL EQUIPMENT
CATERPILLAR TRACTOR CO.
MOS3VILLE, ILLINOIS
COAL (3.as SULFUR)
2 NEW 2 RETRO 140,000 DOUBLE ALKALI (CONCENTRATED) 10/75 '
FMC ENVIRONMENTAL EQUIPMENT
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
COAL (3.2X SULFUR)
RETROFIT
67,000
DOUBLE ALKALI (DILUTE)
ZURN INDUSTRIES
9/74
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
COAL (3.2X SULFUR)
RETROFIT
39,000
DOUBLE ALKALI (DILUTE)
ZURN INDUSTRIES
1/78
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
OIL (1.1X SULFUR)
RETROFIT
248,000 SODIUM CARBONATE SCRUBBING
KOCH ENGINEERING
7/78
FIRESTONE TIRE AND RUBBER CO.
POTTSTOHN, PENNSYLVANIA
COAL (2.5 - 3.OX SULFUR)
RETROFIT
8070
DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
1/75 ,.
(SODA ASH PLANT)
6REEN RIVER, WYOMING
COAL (IX SULFUR)
NE*
446,000 SODIUM CARBONATE SCRUBBING
FMC ENVIRONMENTAL
S/76
-------
STATUS TO JANUARY 1979
SECTION 5 (rOMTTNUFlO
OPERATIONAL FED SYS1FMS ON IMQUSTKfAI. ROILFWS
COMPANY/LOCATION/FtlfcL
NfcW/
RETROFIT
UNIT M7F.
(SCFM)
PROCFSS/VFNOOR
START-UP
MO/YR
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
COAL (3.2X SULFUR)
RETROFIT 60,000 SODIUM HYOROXIOF SCRUBBING
A.O. LITTLF
0/72
GENERAL MOTORS CORPORATION
DAYTON, OHIO
COALC0.7X - 2.OX SIR FUR)
RETROFIT Jh.OOO SODIUM HYDROXIDE SCRUBBING
ENTOLETFR, INC.
9/7a
GENERAL MOTORS CORPORATION
TONOWANOA, NFW YORK
COAL U.2X SULFUR)
RETROFIT
9?,000 SODIUM HYDROXIDE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
6/75
GENERAL MOTORS CORPORATION
PARMA, OHIO
COAL (2.5X SULFUR)
RETROFIT
128,400 DOUBLE ALKALI (DILUTE)
GM ENVIRONMENTAL
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
COAL (0.84X SULFUR)
ALSO HOOD, PAPER, AND CARDBOARD.
NEh
107,300 SODIUM HYDROXIDE SCRUBBING
GM ENVIRONMENTAL
0/76
GEORGIA-PACIFIC PAPER CO. NEW
CROSSETT, ARKANSAS
BARK,COAL/OIL C1.5X - a.OX SULFUR)
230,000 CAUSTIC WASTE STREAM
AIRPOL INDUSTRIES
7/75
6ETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
OIL (J.1X SULFUR)
RETROFIT
7?,000 SODIUM CARBONATE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
6/77
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
OIL (1.1X SULFUR)
RETROFIT
495,000 SODIUM CARBONATE SCRUBBING
IN-HOUSE DESIGN
12/78
GREAT SOUTHERN PAPFR CO. RETROFIT
CEDAR SPRINGS, GEORGIA
BARK,COAL/OIL (t.OX - 2.OX SULFUR)
«20,000 CAUSTIC WASTE STRFAK
AIRPOL INDUSTRIES
0/75
GREAT WESTERN SUGAR
BILLINGS, MONIANA
COAL (0.7X SULFUR)
RETROFIT
60,000 AMMONIA-LADEN PROCESS WATER
GREAT WESTERN SUGAR
10/77
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
COAL (1.2X SULFUR, AVERAGE)
RETROFIT 65,230 AMMONIA-LADEN PROCESS WATF.R
GRfcAT WESTERN SUGAR
10/76
GREAT WESTERN SUGAR
GERING, NEBRASKA
COAL (1.2X SULFUR, AVERAGE)
RETROFIT 110,000 AMMONIA-LADEN PROCESS WATER
GREAT WESTERN SUGAR
10/75
GREAT WESTFRN SUGAR
GREELEY, COLORADO
COAL (0.6X SULFUR)
RETROFIT
25,000 AMMONIA-LADEN PROCESS WATER
GREAT WESTERN SUGAR
10/75
20
-------
STATUS Til .[ANIIAWY 1079
SECTION 5 (CONTINUFO)
OPFHATTONAl FGD SYSTEMS ON INDUSTRIAL 80TLERS
COMPANY/LOCATION/FUEL
NEW/
RETROFIT
UNIT SIZE
(SCFM)
PROCESS/VENDOR
START-UP
MO/YR
GREAT WESTERN SUGAR
LOVELAND, COLORADO
CO»L (1.2Z SULFUR, AVERAGE)
RETROFIT
121,800 AMMONTA-LADEN PROCESS HATER
GREAT WESTERN SUGAR
10/73
GREAT WESTERN SUGAR
8COTTS BLUFF, NEBRASKA
COAL (1.2Z SULFUR, AVERAGE)
RETROFIT
65,230 AMMONIA-LADEN PROCESS MATER
GREAT WESTERN SUGAR
10/75
ITT RAYONIER, INC.
FERNANDINA BEACH, FLORIDA
BARK,OIL (3.OS - 2.5X SULFUR)
RETROFIT
176,000 SODIUM HYDROXIDE SCRUBBING
AIRPOL INDUSTRIES
0/75
KERR-MCGEE CHEMICAL CORP. NFW
TRONA, CALIFORNIA
COKE/COAL/OIL CO.51 - 5.OX SULFUR)
090,000 SODIUM CARBONATE SCRUBBING
COMBUSTION EQUIPMENT ASSOC.
6/78
HEAD PAPERBOARD CO.
STEVENSON, ALABAMA
OIL (1.5X - 3X SULFUR)
NEW
100,000 SODIUM CARBONATE SCRUBBING
AIRPOL INDUSTRIES
0/75
MINN-DAK FARMER'S CO-OPERATIVE RETROFIT
MAHPETON, NORTH DAKOTA
LIGNITE (l.OX SULFUR)
164,000 AMMONIA SCRUBBING
KOCH ENGINEERING
6/77
MOBIL OIL COMPANY
SAN AROO, CALIFORNIA
OIL (2.OX - 2.25X SULFUR)
RETROFIT
175,000 SODIUM HYDROXIDE SCRUBBING
IN-HOUSE DESIGN
0/74
NEKOOSA PAPERS, INC.
ASHDOWN, ARKANSAS
COAL (IX - 1.51 SULFUR)
NFW
211,000 CAUSTIC SCRUBBING
AIRPOL INDUSTRIES
2/76
NORTHERN OHIO SUGAR COMPANY
FREEMONT, OHIO
COAL (IX SULFUR)
RETROFIT
40,000 SODIUM HYDROXIDF SCRUBBING
GREAT WESTERN SUGAR
10/75
RICKENBACKER AIR FORCE BASE
COLUMBUS, OHIO
COAL (3.6X SULFUR)
RETROFIT
55,000 LIMESTONE SCRUBBING
RESF. ARCH-COT TRELL/BAHCO
3/76
ST. REGIS PAPER CO.
CANTONMENT, FLORIDA
BARK,OIL/GAS (< I.OX SULFUR)
RETROFIT
115,000 CAUSTIC SCRUBBING
AIHPOL INDUSTRIES
0/73
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
OIL (1.7X SULFUR)
RETROFIT
3HO,000 SODIUM HYDROXIDE SCRUBBING
CEILCOTE
11/73
TEXASGULF
GRANGER, WYOMING
COAL (0.75X SULFUR)
NEW
140,000 SODIUM CARBONATE SCRUBBING
SWEMCO INC.
"»/76
21
-------
ST*TUS TO JANUARY 1979
SECTION 6
UNDFH CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL ROILFRS
COMPANY/LOCATION/FUEL
NEW/
RETROFIT
UNIT SIZE
(SCFM)
PROCESS/VENDOR
START-UP
MO/Yh
ARCO/POLYMERS, INC.
MONACA, PENNSYLVANIA
COAL (.3.01 SULFUR)
RETROFIT ?36,000 DOUBLE ALKALI (CONCENTRATED) 6/SO
FMC ENVIRONMENTAL EQUIPMENT
8ELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
CRUDE OIL Cl.ll SULFUR)
RETROFIT
13,000 SODIUM HYDROXIDE SCRUBBING
C-F NATCO
1/79
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
COAL (3.2* SULFUR)
NEW
131,000 DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
1/79
CHANSLOR WESTERN OIL K OEV. CO
BAKERSFIELD, CALIFORNIA
OIL C1.5X SULFUR)
NEh
70,000 DOUBLE ALKALI (CONCENTRATED)
• FMC ENVIRONMENTAL EQUIPMENT
3/79
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
OIL Cl.ll SULFUR)
RETROFIT
396,000 SODIUM CARBONATE SCRUBBING
IN-HOUSE DESIGN
1/79
MOBIL on. COMPANY
BUTTONHILLOW, CALIFORNIA
OIL Cl.lt SULFUR)
RETROFIT
80,500
SODIUM CARBONATE SCRUBBING
HFATER TECHNOLOGY
?/79
PHILLIP MORRIS, INC.
CHESTERFIELD, VIRGINIA
COAL
NEW
39.000
SODIUM CARBONATE SCRUBBING
FLAKT, INC.
6/79
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
COAL (2.5Z - a.51 SULFUR)
RETROFIT
142,000 CITRATE PROCESS
BUREAU OF MINES
3/79
SUN PRODUCTION COMPANY
FELLONS, CALIFORNIA
OIL C1.4Z SULFUR)
RETROFIT
6,000
SODIUM HYDROXIDE SCRUBBING
C-E NATCO
1/79
SUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
OIL C1.2X SULFUR)
RETROFIT
6,000
SODIUM HYDROXIDE SCRUBBING
C-t NATCO
fl/79
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
OIL (1.7Z SULFUR)
RETROFIT 117,000 SODIUM CARBONATE SCRUBBING
DIICON COMPANY
3/79
-------
STATUS 10 .lAMiiAMY
SECTION 7
PLANNED FGD SYSTEMS ON INDUSTRIAL BOTLEMS
COHPANY/LOCATION/FUFL
NE*/
RETROFIT
UNIT SIZE
CSCFM)
PROCESS/VENDOR
START-UP
MO/YR
CARBORUNDUM ABRASIVES
BUFFALO, NEH YORK
COAL (3.2* SULFUR)
RETROFIT
50,000
LIKE SCRUBBING
CAKHORUNDIIM ENVTR. SYS. LTD.
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
COAL C3.2X SULFUR)
NEh
105,000
DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
1/ftO
6RISSOM AIR FORCE" BASE
BUNKER HILL, INDIANA
COAL (0.« -
-------
STATUS TO JANUARY 1979
Sf-CUOM ft
SUMMARY OF DISPOSAL PRACTICES 1-OH FRO SYSTEMS ON INDUSTRIAL BORERS
INSTALLATION NAME / LOCATION
STATUS/COMMFNTS
ALKALINE SULFITE/8ISULFITF RECYCLED TO PULP PROCESS
MEAD PAPERBOARO CO.
STEVENSON, ALABAMA
NFKOOSA PAPERS, INC.
ASHOOKN, ARKANSAS
OPERATIONAL
KECOVFRFti SOLUTION USED AS MAKE-UP TO COOKING LIQUOR IN PULP
MILL.
OPERATIONAL
SO? RFCOVFREO FRO" SODIUM SULFITE/SULFATE LIQUOR AND RE-
CYCLED TO PULPING PROCESS.
DEWATERED SLURRY TO L»NDFILL
ARCO/POLYMFRS, INC.
MONACA. PENNSYLVANIA
BUNGE, INC.
CAIRO, ILLINOIS
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLE, ILLINOIS
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CHANSLOR WESTERN OIL * OEV. CO
BAKERSFIELD, CALIFORNIA
DUPONT, INC.
GEORGIA
CONSTRUCTION
FLYASH ADDITION TO DEWATEREO CAS03/CASO« FILTER CAKF.,
THEN TO LANDFILL.
INDEFINITELY SHUT DOWN
OPERATIONAL
60+* SOLIDS (CASOfl) SLUDGE DIRECTLY TO LANDFILL
OPERATIONAL
60+X SOLIDS (CAS04) SLUDGE DIRECTLY TO LANDFILL
OPERATIONAL
OPERATIONAL
CONSTRUCTION
60+t SOLIDS (CASOfl) SLUDGE DIRECTLY TO LANDFILL
PLANNED-CONTRACT AWARDED
60+X SOLIDS (CAS04) SLUDGE DIRECTLY TO LANDFILL.
CONSTRUCTION
SALTS IS THEREBY PREVENTED.
PLANNED-CONSIDERING S02 CONTROL
DUPONT, INC.
TEXAS
FIRESTONE TIRE AND RUBBER CO.
POTTSTOWN, PENNSYLVANIA
GENERAL MOTORS CORPORATION
TONOMANDA, NEW YORK
GENERAL MOTORS CORPORATION
PARMA, OHIO
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
GRISSOM AIR FORCE BASE
BUNKER HILL, INDIANA
U.S. GYPSUM CORP.
OAKMQNT, PENNSYLVANIA
PLANNED-CONSIDERING S02 CONTROL
OPERATIONAL
OPERATIONAL
FLY ASH AND NAaS03/SO« HASTE LIQUOR OEWATERED AND THEN TO
SAN]TARY LANDFILL
OPERATIONAL
50*Z SOLIDS (CAS03/S04) SLUDGE TO DRYING POND AND LANDFILL
OPERATIONAL
5X SOLIDS SLURRY DEWATERED AND TO LANDFILL
PLANNED-CONTRACT AWARDED
NEVER STAWTED-UP
SLUDGE TO POND FOR DRYING. THEN TO LANDFILL.
-------
STATUS TM JANUARY
SECTION 8 (CONTINUED)
SUMMARY OF DISPOSAL PRACTTCFS FOW FRO SYSTEMS ON INDUSTRIAL HfltlFRS
INSTALLATION NAME / LOCATION
STATllS/COMMFNTS
HOLDING POND FOR EVAPOKAITOnl
AMERICAN THREAD co.
MARION, NORTH CAROLINA
Off NATIONAL
THt SODIUM StILFTTE/SULFATE rtASTE LIQUOR IS PUMfFD TO
A RED CLAY LINED ASH BASIN. LEACHING UF THE SOLUBLE SODIUM
SALTS is THEREBY PREVENTED.
ARMCO STEEL
MTDDLFTOWN, OHIO
FMC (SODA ASH PLANT)
GREEN RIVER, WYOMING
SETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
KERR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
OPFR4TIONAL
OPERATIONAL
NA5S03/S04 LIOUOR DISPOSED TO COLLECTION PONO - NO PRIOR
AERATION. LANPFHL IN THE FUTURE
OPERATIONAL
6 GPM BLtEOOFF TO A SLOWDOWN TANK. THE BLOWOOHN IS THEN
SENT TO A DISPOSAL PON!) ONCE A KEEK.
OPERATIONAL
SCRUBBER EFFLUENT IS CLARIFIED AND THEN PUT INTO A MINERAL
DEPOSIT.
MOBIL OIL COMPANY
SAN ARDO, CALIFORNIA
MOBIL OIL COMPANY
BUTTONWTLLOW, CALIFORNIA
SUN PRODUHTION COMPANY
FELLOWS* CALIFORNIA
SUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
TENNECO OIL CO.
GREEN RIVER, WYOMING
OPERATIONAL
CONSTRUCTION
INTERMITTENT BLOWDOWN TO vKASTE DISPOSAL SITE.
CONSTRUCTION'
1 GPM BLEEOOFF TO DISPOSAL POND
CONSTRUCTION
1 GPM BLEEOOFF TO DISPOSAL POND
PLANNED-REQUEST ING/EVALUATING BIDS
NON-FIXATED SLURRY TO LINED POND
CANTON TEXTILES
CANTON, GEORGIA
RICKEN8ACKER AIR FORCE RASE
COLUMBUS, OHIO
OPERATIONAL
NA S03/S04 LIOUOR DISPOSED TO LINED HOLDING PONDS
OPERATIONAL
UNSTABIL1ZED CASOS/SOfl SLUDGE TO LINED POND
REGENERABLE - ELEMENTAL SULFUR PRODUCT
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
CONSTRUCTION
WASTEWATFR TREATMENT AND DISCHARGE TO CITY SEWFR
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
GENERAL MOTORS CORPORATION
DAYTON, OHIO
GEORGIA-PACIFIC PAPER CO.
CROSSETT, ARKANSAS
OPERATIONAL
NAJS03 OXIDIZED TO NA3SO«, PH NEUTRALIZED AND DISCHARGED TO
CITY SEWFB SYSTEM
OPERATIONAL
NAaSOVSOl LIOUOR AT 35 GPM TO ON-SITF CLARIFICATION AND
OEKMFKING FACILITY
OPERATIONAL
25
-------
STATUS TO JANUARY 1979
8 (CONTINUFOJ
SUMMARY OF DISPOSAL PRACTICES FOK FRO SYSTEMS ON INDUSTRIAL BfllLF.HS
INSTALLATION NAME / LOCATION
STATUS/COMMENTS
WASTEWATER TREATMENT AND DISCHARGE TO CITY SErfER
NORTHERN OHIO SUGAR COMPANY
FREEMONT, OHIO
NORTHERN OHIO SUGAR COMPANY
FINDLAY, OHIO
OPERATIONAL
TERMINATED
BLEED-OFF STREAM TO HOLDING TANK
NASTEHATER TREATMENT AND DISCHARGE TO RIVER
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
GREAT WESTERN SUGAR
BILLINGS, MONTANA
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
GREAT WESTERN SUGAR
BERING, NEBRASKA
OPERATIONAL
CLARIFICATION FOLLOWED BY PONDING AND DISCHARGE TO RIVER
OPERATIONAL
OPERATIONAL
OPERATIONAL
EFFLUENT TO HOLDING POND
GREAT WESTERN SUGAR
GREELEY, COLORADO
GREAT WESTERN SUGAR
LOVELANO, COLORADO
GREAT WESTERN SUGAR
SCOTTS BLUFF, NEBRASKA
GREAT WESTERN SUGAR
LONSHONT, COLORADO
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
OPERATIONAL
OPERATIONAL
EFFLUENT STREAM TO HOLDING POND
OPERATIONAL
EFFLUENT STREAM TO HOLDING POND.
TERMINATED
INDF.FINI1ELY SHUT OOwN
NA2SOVSUO LllJUfW DISCHARGED TO A HOLDING POND
WASTEMATER TREATMENT AND DISCHARGE TO TAILINGS POND
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
ITT RAYONIER, INC.
FEHNANDINA BEACH, FLORIDA
OPERATIONAL
OPERATIONAL
HOLDING POND FOR EVAPORATION.
9 GPH BLEEOOFF TO A BLOWDOWN TANK.
INTO A DISPOSAL POND ONCE A WEEK.
CONSTRUCTION
MOLDING POND FOR EVAPORATION.
9 GPM 8LEEDOFF TO A SLOWDOWN TANK.
INTO A DISPOSAL POND ONCE A WEEK.
OPERATIONAL
THE BLOWDOWN IS EMPTIED
THE SLOWDOWN IS EMPTIED
-------
STATUS TO JANUARY
SECTION « (CONTINUED)
SUMMARY OF DISPOSAL PRACTICES FOR f-KD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME / LOCATION
STATUS/COMMENTS
WASTEWATER TREATMENT
ALYESKA PIPELINE SERVICE CO.
VALDEZ, ALASKA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
CARBORUNDUM ABRASIVES
BUFFALO, NEW YORK
CHEVRON U.S.A. INC.
BAKEBSFIELD, CALIFORNIA
MINN-OAK FARMER'S CO-OPERATIVE
HAHPETON, NORTH DAKOTA
8T. REGIS PAPER CO.
CANTONMENT, FLORIDA
TEXACO INCORPORATED
SAN AROO, CALIFORNIA
TEXAS6ULF
GRANGER, WYOMING
OPERATIONAL
NAaS03/HS03 AERATFO TO NA?Sfia AND TRAKSFF.RRED TO *AS TEhA TfcN
TREATMENT PLANT AT A RATE OF 10 6PM. IT IS KIX60 «ITH ABOUT
10,000 GPM OF BALLAST WATER FROM TANKERS IN PORT VALDF.7.
CLEANED fcATFR IS THFN ijISCHARGED INTO PDHT VALOfZ.
OPERATIONAL
OPERATIONAL
PLANNED-CONTRACT AMHOEH
PLANNED-REQUEST ING/EVALUATING BTDS
OPERATIONAL
BLEED STREAM GOES TO AN ACTIVATED SLUDGF SYSTEM 3 160 GPM
ANAEROBIC DIGESTION, FOLLOWED BY AN OPEN POND, FOLLOWED BY
AEROBIC DIGESTION.
OPERATIONAL
EFFLUENT IS TREATFD IN AN ON-STTE SFWAGF TREATMENT PLAMT
OPERATIONAL
HALF OF THE SCRUBBER UNDERFLOW IS TREATED AND RECYCLED AS
BOILER FEEDWATER; THE OTHER HALF GOES TO WASTEWATER
DISPOSAL WELLS.
OPERATIONAL
OVERFLOW TO SEWER/SLUOGE TO LANDFILL
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
INDEFINITELY SHUT DOWN
DISPOSAL TECHNIQUE NUT KNOWN
C.A.M.(CARBIDE-AMOCO-MONSANTO)
HOUSTON. TEXAS
HARRIS MINING co.
SPRUCE PINE, NORTH CAROLINA
SHELL OIL COMPANY
BAKERSFIELD, CALIFORNIA
SHELL OIL COMPANY
TAFT, CALIFORNIA
PLANNED-CONSIDERING SOa CONTROL
INDEFINITELY SHUT OOwN
PLANNED-CONSIDERING SO? CONTROL
PLANNED-CONSIDERING S02 CONTROL
SCRUBBER EFFLUENT DISPOSED OF IN WASTE WEILS
CONSTRUCTION
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
-------
STATUS tO JANIIAHY 1979
nESCHlPIIIlN HIP tlPfkAItuNAl FGD SYSTEMS ON IMDUSTKIAL BOILEK5
INSTALLATION NAHF
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FG1 UNITS
NUMBER OF B1ILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEH / RETROFIT
START-UP 0*TE
CONTROL SYSTFf STATUS
802 REMOVAL EFFICIENCY
P»RTICUL*TE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ALYESKA PIPFLINF SERVICE ro.
VALOfZ, ALASKA
OIL (0.051 - 0.1X SULFUR)
SO,000 SCFC (OFSIGN MAXIMUM)
25 MM (FOIJIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, aOOO SCFP = 1 EQUIVALENT
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZIN6
FMC ENVIRONMENTAL EQUIPMENT
SODIUM HYDROXIDE SCRUBBING
NEW
JUNE, 1977
OPERATIONAL
96+X (150-160 PPM 9 INLET)
PARTICULATE EMISSIONS MEET NSP3.
2 GPM - OPEN LOOP
HASTFHATER TREATMENT
NA2S03/HS03 AERATED TO NA2S04 AND TRANSFERRED TO NASTEMATER
TREATMENT PLANT AT A RATE OF 10 GPM. IT IS MIXED KITH ABOUT
10,000 GPM OF BALLAST MATER FROM TANKERS IN PORT VALOEZ.
CLEANED WATER IS THEN DISCHARGED INTO PORT VALDEZ.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE VALDEZ TERMINAL UF THE ALASKAN OIL PIPELINE, ALYESKA PIPELINE SERVICE COMPANY OPERATES
THE OIL STORAGE AND TRANSFER FACILITY. OIL FLOWING IN FROM THE PIPELINE IS TEMPORARILY STORED IN
SEVERAL HUGE TANKS, THEN TRANSFERRED FROM THE TANKS TO OIL TANKER SHIPS IN NEARBY PORT VAIDE?.
ALYESKA NEEDED NEUTRAL BLANKET AIR FOR THE OIL STORAGE TANKS. A LOW OXYGEN CONTENT BEING PARTICULAR-
LY DESIRABLF. IT HAS DETERMINED THAT ON-SITE BOILER FLUE GAS HOULD HAVE THE REQUIRED LOW OXYGEN
CONTENT. CORROSION PREVENIION JN THE OIL STORAGE TANKS DICTATED THE NEED FOR S02 CONTROLS.
THAT IS, THE DEVICE HAS NOT INSTALLED TO MEET AN EMISSIONS REGULATION. NEVERTHELESS, THE
"INERT GAS" SYSTEM IS BASICALLY A SODIUM HYDROXIDE FGD SYSTEM AND HAS DESIGNED AND INSTALLED BY
FMC ENVIRONMENTAL EQUIPMENT DIVISION.
THE BOILERS 00 NOT OPERATE AT STEADY STATt CONDITIONS. THIS IS DUE TO THE FACT THAT *HE* OIL
IS REMOVED FROM THE TANKS AT A FASTER fcATF THAN rT IS BFING FFD BY THE PIPELINE, AN ADDITIONAL INERT
AIR BLANKET IS NEFDFD. THIS REOUIRFS INCREASING THF BOILER LOAD FROM THE NORMAL LEVEL OF PLANT
POHER PRODUCTION TO HUN THf COMPRESSORS AND PRODUCE ADDITIONAL GAS FOR BLANKET PRODUCTION.
-------
STATUS in JAC'HAPY
SECTION
-------
STATUS TO JANUAHY 1
-------
STATUS T" JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR
FGD SYSTEMS on INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATIN6
NUMBER OF SEPARATE F.GO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
AMERICAN THHF.AO CO.
MARTliN, NORTH CAROLINA
COAL (1 - I.5X SULFUR)
18,500 SCFM (TOTAL - Z ROTLERS)
2
2
9 MW (EQUIVALENT); TOTAL 3 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MX.
THIS IS BECAUSE GAS FLOW KATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
W.W. SLY MANUFACTURING CO.
CAUSTIC WASTE STREAM
RETROFIT
1973
OPERATIONAL
70X (500 PPM a INLET)
971 ,
HOLDING PONO FOR EVAPORATION
THE SODIUM SULFITE/SULFATE HASTE LIOUOR IS PUMPED TO
A RED CLAY LINED ASH BASIN. LEACHING OF THE SOLUBLE SODIUM
SALTS IS THEREBY PREVENTED.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AMERICAN THREAD COMPANY, LOCATED IN MARION, NORTH CAROLINA OPERATES TWO COAL-FIRED BOILERS, EACH
I
HITH A DESIGN CAPACITY OF 30,000 ACFM 3 100 F. DURING THE WINTER MONTHS ONF BOILER IS OPERATED
7 DAYS/NEEK AT 75Z LOAD AND THE OTHER OPERATED 5 OAYS/WFEK ALSO AT 75X LOAD. BOTH BOILERS
OPERATE 5 DAYS/MEEK AT 50Z LOAD DURING THE SUMMER MONTHS.
THE SCRUBBERS HERE SUPPLIED BY W.M. SLY MANUFACTURING CO. AND WERE ORIGINALLY INSTALLED TO CON-
TROL PARTICULATE. EACH IS CONSTRUCTED OF 30« SS AND 316 SS HITH SPRAY NOZZLES OF 30<1 SS. FACH
SCRUBBER IS 10 FEET IN OIAMFTES AND 12 FEFT HIGH WITH TWO SPHAY LEVELS AND HAS A PRESSURE DROP OF
& IN. K.C. AT FULL LOAD. THE FLUE GAS ENTERS EACH SCRUBBER AT A RATE OF 30,000 ACFM 9 350 F AND
LEAVES AT 160 F.
THE SCRUBBING LIQUOR IS A 7X CAUSTIC WASTF STREAM FROM A MERCFRIZINK STFP IN WHICH THREAD IS CLEANFO
»ND SHRUNK. THE CONTROL PH IS 8.5 IN THE RtCIHCIILATION TANK. SPENT LtOUOR ENTERING THE TANK IS AT
* PH OF 2.5. THE SCRUH9F.RS HAVE BEEN EXHIBITING 901 RFLI ABILITY. RECIRCULATTUIM AND Si MORF HAND-
LING PUMPS ARF MADE OF RIJBBFR-LINED CAST TRflN.
A 35-flOX BLEED STREAM FROM THE RFCIRCULAT TON TANK REMOVFS WASTF. SOLIDS Til AN ASH PONO FOB SET-
TLING.
31
-------
STATUS TO JANUARY 1979
SECTIOM 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERAT tONAl. FGH SYSTFMS ON INDUSTRIAL BOILF.KS
AMERICAN THRFAD CO.; MARION, NORTH CAROLINA (CONTINUED)
REFER TO FIGURE \9-? IN SECTION 11 FOR A Df-TAILFO PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
2ND OIIARTER-197« PLANT RFPORTS THAT IT IS STILL EXPERIENCING SCRUBBER I.D. FAN PROBLEMS DUE TO
VIBRATION AND CORROSION. TO OVERCOME THIS PROBLEM, PLANS ARE BEINC MADE TO ELIMINATE THE I.D. FANS
ON THE SCRUBBER AND UPGRADE BOILER I.D. FANS.
OTHER PROBLEMS HAVE BEEN AS FOLLOWS:
1. VIBRATION CRACKS IN PVC PIPINS.
2. FAILURE OF PUMP RUBBER LINING.
3. THF NEFO TO DRAIN THE HECIRCULATION TANK AND PAINT IT WITH EPOXY PAINT TO ALLEVIATE
CORROSION PROBLEMS.
3RD QUAHTER-1978 THE VIBRATION CRACKS IN THE PVC PIPING ARE LOCATED AT THE ENTRANCE TO THE SCRU-
BBER AND MERE CAUSED BY AN UNBALANCED FAN. THE FAN BECAME UNBALANCED WHEN ITS FIBERGLASS COATING
WAS ERODED AWAY. TWO WEEKS WERE REQUIRED TO PATCH THE COATING. THE CRACKED PIPE SECTIONS WERE RE-
PLACED. PLANS ARE BEING MADE TO REMOVE THE SCRUBBER 1.0. FAN COMPLETELY FROM THE SYSTEM AND TO
UPGRADE THE EXISTING BOILER 1.0. FAN SO THAT IT HAS THE CAPACITY TO OVERCOME THE SCRUBBER SYSTEM
PRESSURE DROP.
THE REPLACEMENT OF A PUMP LINING CAUSED THREE DAYS DOWNTIME.
EPOXY PAINT USED ON THE RECIRCULATION TANK MAS INEFFECTIVE. ONE-HALF INCH PLATES MERE WEL-
DED TO THE TANK TO PATCH HOLES CAUSED BY THE CORROSIVE LIQUOR. THE SCRUBBER WAS DOWN FOR A WEEK.
CORROSION OF PRESSURE GAUGES AND COPPER LINFS HAS ALSO BEEN A PROBLEM AREA.
4TH QUARTER-I978 DURING THE REPORT PERIOD THE BOILERS OPERATED 5 DAYS/MEEK, 24 HOURS A DAY. THE
PATCH-UP WORK ON FIBERGLASS COATING OF ID FAN ROTORS CAUSED TWO DAYS OF SCRUBBER DOWNTIME. FOUR OF
THE LOWER LEVEL SPRAY NOZZLES (304 SS) EXPERIENCED EROSION DUE TO THE ABRASIVE FLYASH AND WERE
REPLACED. RECIRCULATION TANKS AND PUMPS HAD NO OPERATING PROBLEMS. THE RELIABILITY INDEX OF
SCRUBBERS IMPROVED TO A VALUE OF ABOUT 96X.
32
-------
STATUS TO JANUARY 1979
SFCT1HM 9 (CONTTNUFDl
PERFORMANCE DESCRIPTION FOR flPtHAITnNAI FGH SYSTEMS ON TNDIISTRIAI HdlLFRS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
303 REMOVAL EFFICIENCY
SLUDGE OR BY-PROOUCT DISPOSAL
CONTROL SYSTEM COST
AR«CD STfFL
MIOniF.TOnN, OMin
COAL (O.aZ SULFUR)
HO.OOO SCFM (TOTAL - 2 HOILERS)
SOO.dOO LB/HH STEAM (TOTAL)
1
2
02 M* (EQUIVALENT): TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 3000 SCFK = 1 EQUIVALENT Mh.
THIS IS BECAUSE GAS FLOM RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
KOCH ENGINEERING
LIME SCRUBBING
RETROFIT
1975
OPERATIONAL
NOT AVAILABLE
HOLDING POND FOR EVAPORATION
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
ARMCO STEEL. MIDDLE TOWN OPERATES TWO MULTI-RETORT, UNDERFEED STOKER. COAL-FIRED BOILERS, EACH
WITH A CAPACITY OF 100,000 LBS/HH STEAM. THE COAL BURNED IS TYPICALLY 0.7J TO 0.9X SULFUR AND
8% TO 10X ASH. INITIALLY THE BOILERS HERE OPERATED IN THE WINTER MONTHS ONLY, HOWEVER BEGINNING
IN 1976, OPERATIONS WERE YEAR-ROUND WITH REDUCED CAPACITY DURING THE SUMMER.
THE CONTROL SYSTEM CONSISTS OF A VARIABLE-THROAT VENTURI SCRUBBER WITH A PRESSURE DROP-CONTROL-
LED, ADJUSTABLE PLUG. IMMEDIATELY DOWNSTREAM FROM THE VENTURI IS AN ABSORBER MODULE 17 FEET IN
DIAMETER WITH THREE GAS SCRUBBING TRAYS, *N S-TYPE CHEVRON MIST ELIMINATOR AND A 106-INCH DIAMETER
STUB STACK. THE SYSTEM IS DESIGNED TO HANDLE 110,000 ACFM AT 425 F AND IS INCHES WG WITH AN
OUTLET LOADING OF 0.02 GR PFR SCFD. FRESH WATER IS SUPPLIED FROM CLARIFIED RIVER WATFf* AT THE
RATE OF 1600 GPM TO THE TOP TRAY AND VENTURI THROAT. A LIME SLURRY IS ADDED IN A 10,000 GALLON
RECYCLE TANK WHICH HOLDS EFFLUENT FROM THE ABSORBER MODULE. THE DESIGN L/G RATIO IS 11.fl GALLONS
PER 1000 ACF.
A PH OF APPROXIMATELY 7 IS MAINTAINED IN THE RFCYCLE TANK. IF PH VABTES "ORE THAN TWO-TENTHS
OF A PH UNIT (6.0-7.2), A LIGHT/BU7ZER ALERTS THE OPERATORS WHO ADJUST THF PH BY OPFNING OR
CLOSING A VALVE LEADING FROM THF LIMfr SLURRY HOLDING TANK TO THE RECYCLE TANK.
THE LARGEST PROBLEM AFFECTING SCRUBBER PERFORMANCE HAS BEEN CONTROL OF EXCESS AIR IN THE BPILFRS.
WITHOUT CONTROL, EXCESS AIR RESULTS IN 1.5 TO 3 TIMES THE SCRUBBER DESIGN FLOW RATE. THESF HIGH
EXCESS AIR HftTFS ALSO PFSULt IN THt PRESENCE OF UNHIWNEO CARbON WHICH COULD NOT HE SCRUBBED AND
33
-------
STATUS TO JANUARY 1<»7<>
SFCTION
-------
STATUS TO JANIIAKY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILEHS
ARMCO STEFLJ MIODLETOWN, OHIO (CONTINUED)
* THE EXCESS AIR PROBLEM HAS BEEN REDUCED TO ABOUT flOX BY PATCHING LEAKS FOUND ON THE BORER AMt>
REDUCING THE COMBUSTION AIR TO THE BOILER. HOWEVER, DUE TO THE AGE AND CONDITION OF THE BOILER
IT IS NOT LIKELY THAT THE EXCESS AIR WILL BE REDUCED FURTHER. THF BOILER IS OPERATED AN ESTIMATED
10 MO/YR. THE SCRUBBED NORMALLY OPERATES APPROXIMATELY 2 TO 3 MONTHS BEFORF IT HAS TO BE SHUT DOWN
FOR REPAIRS. THE PLANNED PROPORTIONAL LIME SLAKER WAS NEVER INSTALLED.
4TH QUARTER-1978 ABRASION CONTINUES TO BE A MAJOR PROBLEM. NO OTHER INFORMATION MAS MADE AVAIL-
ABLE AT THIS TIME DUE TO POSSIBLE LITIGATION CONCERNING NEWLY PROPOSED EMISSION STANDARDS. THE NEW
STANDARDS ARE BEING SET ON A STACK-BY-STACK BASIS.
3"5
-------
STATUS TO JANUARY 1979
S^CTI.JN 0 (CflNTINUFO)
PEHFORM.NCE DESCRIPTION FO* OPERA! TONAL FGf) SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
BfLRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
OIL U.I* SULFUR)
12,000 SCFH (1 BOILER)
20,000 ACFM d 570 F
1
1
6 MM (EQUIVALENT)
50 MM BTU/HR
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 2000 SCFM = 1 EQUIVALENT K
THIS IS BECAUSE 6AS FLOM RATE IS THE PRIMARY FACTOR IN MODULE SIZING.
HEATER TECHNOLOGY
SODIUM HYDROXIDE SCRUBBING
NEH
JUNE, 1978
OPERATIONAL
90* (500 PPM 802 AT INLET)
15 GPM
MASTEHATER TREATMENT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BELRIOSE OIL COMPANY HAS AN ENHANCED OIL RECOVERY SITE IN MCKITTRICK, CALIFORNIA. THERE ARE
SEVERAL SMALL STEAM GENERATORS, EACH RATED AT 50 MM BTU/HR, WHICH BURN. A PART OF THE OIL PRODUCED
BY THE RECOVERY OPERATIONS. THE CRUDE OIL HAS 1.1 PERCENT SULFUR.
THE F6D SYSTEM, WHICH MAS SUPPLIED NEH BY HEATER TECHNOLOGY IM JULY 1978, TREATS A FLUE GAS
FLOM OF 24,000 ACFM AT 570 F. THE SYSTEM CONSISTS OF AN EDUCTOR-TYPE VENTURI MOUNTED ON ONE SIDE
OF A RECYCLE TANK, AND A STUB STACK MOUNTED ON THE OTHER. THE VENTUHI HAS AN ADJUSTABLE DISK, WHICH
FORMS THE CONTACT STAGE FOR THE GAS AND RECIRCULATIN6 LIQUOR. THE GAS THEN FLOWS THROUGH THE MIST
ELIMINATOR HOUSED INSIDE THE STUB STACK. THE LIQUOR. DISENGAGED FROM THE GAS, IS RECIRCULATEO WITH
A CONSTANT BLEED-OFF OF 10 6PM. THE DESIGN L/G RATIO IS «0 GAL/1000 ACF. THE PROCESS USED IS
SODIUM HYDROXIDE SCRUBBING AND FRESH CAUSTIC MAKEUP IS ADDED TO THE RECYCLE TANK. THE VENTURI
SECTION, CONTACTING DISC, RECIRCULATING PIPING AND THE RECIRCULATING PUMP ARE MADE OF 3»6L SS. THE
RECYCLE TANK IS CARBON STEEL MITH EPOXY TAR COATING AND THE MIST ELIMINATOR IS FRP. THE PRESSURE
DROP ACROSS THE ENTIRE SYSTEM IS LESS THAN THE VACUUM CREATED BY THE EOUCTOR, ABOUT 1 IN. *.G.
THE BLEED-OFF STREAM IS TAKEN TO WASTEWATER TREATMENT. IN ADDITION, IT IS NECESSARY TO BLOW
DOMN FROM THF RECYCLE TANK INTERMITTENTLY.
-------
STATUS Tft JANUARY |
-------
ST»TUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F6D UNITS
NUMBER OF BOILERS SEINE CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NED / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
N»TEH MAKE-UP
8LUO6E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
CRUDE OIL (1.1* SULFUR)
13,000 SCFM
24,000 ACFM a 570 F
1
1
5000 LB/HR STEAM
6 MM (EQUIVALENT)
50 Ml* BTU/HR; 50,000 LB/HR STEAM
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 2000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
THERMOTICS INC.
SODIUM HYDROXIDE SCRUBBING
NEM
JULY, 1978
OPERATIONAL
90Z (500 PPM S02 3 INLET)
15 GPM
WASTEWATER TREATMENT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BELRIDGE OIL COMPANY HAS AN ENHANCED OIL RECOVERY SITE IN MCKITTRICK, CALIFORNIA. THERE ARE
SEVERAL SMALL STEAM GENERATORS, EACH RATED AT 50 MM BTU/HR, WHICH BURN A PART OF THE OIL PRODUCED
BY THE RECOVERY OPERATIONS. THE CRUDE OIL HAS 1.1 PERCENT SULFUR.
TH§ FGD SYSTEM, WHICH WAS SUPPLIED NE* BY THERMOTICS INC. IN JULY 1978, TREATS A FLUE GAS
FLO* OF 2«,000 ACFM AT 570 F. THE SYSTEM CONSISTS OF AN EOUCTOR-TYPE VENTURI MOUNTED ON ONE SIDE
OF A RECYCLE TANK, AND A STUB STACK MOUNTED ON THE OTHER. THE VENTURI HAS AN ADJUSTABLE DISK, WHICH
FORMS THE CONTACT STAGE FOR THE GAS AND RECIRCULATING LIUUOR. THE GAS THEN FLOWS THROUGH THE MIST
ELIMINATOR HOUSED INSIDE THE STUB STACK. THE LIQUOR, DISENGAGED FROM THE SAS, IS RECIRCULATED WITH
A CONSTANT BLEED-OFF OF 10 6PM. THE DESIGN L/G RATIO IS «0 GAL/1000 ACF. THE PROCESS USED IS
SODIUM HYDROXIDE SCRUBBING AND FRESH CAUSTIC MAKEUP IS ADDED TO THE RECYCLE TANK. THE VENTURI
SECTION, CONTACTING DISC, RECIRCULATING PIPING AND THE RECIRCULATING PUMP ARE MADE OF J16L SS. THE
RECYCLE TANK IS CARBON STEEL WITH EPOXY TAR COATING AND THE MIST ELIMINATOR IS FRP. THE PrtESSUR*
DROP ACROSS THE ENTIRE SYSTEM IS LESS THAN THE VACUUM CREATED BY THE EDUCTOR, ABOUT 1 IN n.G.
THE BLEED-OFF STREAM IS TAKEN TO WASTEHATER TREATMENT. IN ADDITION, IT IS NECESSARY TO BLOW
DOWN THE RECYCLE TANK INTERMITTENTLY.
-------
STATUS Tf> JANUARY 1979
SECTION 9 (CONTINUED!
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS DN INDUSTRIAL HOILFRS
8ELRI06E OIL CO.? MCKITTRICK, CALIFORNIA (CONTINUED)
THE F6D SYSTEM HAS THE ADVANTAGES OF SIMPLE DESIGN AND NO REQUIREMENT OF A FAN. ON THE (1THFK
_HANO, THE COCURRENTf SINGLE-STAGE CONTACT NECESSITATES HIGH PH (AflOUT 8.0) IN THE RECIRULATING LOOP
IF THE SO? REMOVAL IS TO EXCEED 90 PERCENT. THIS LEADS TO HIGHER CONSUMPTION OF THE ALKALI. THE
INTERMITTENT" SLOWDOWN OF THE RECYCLE TANK RESULTS IN CORRESPONDING GENERATOR DOWNTIME.
OPERATING HISTORY
3RD aUARTER-l<»78 SINCE FGD SYSTEM START-UP ON JULY 6, 197B THF SCRUBBER HAS EXPERIENCED
APPROXIMATELY 1 1/2 WEEKS OF DOWNTIME. MAJOR PROBLEMS HAVE BEEN FAULTY RELAYS IN THE INSTRUMENTA-
TION, AND PUMP FAILURE. THE RECIRCULATION PUMP WAS REPLACED.
«TH OUARTER-1978 THE SCRUBBER OPERATED 96 DAYS OUT OF 105 DAYS OF GENERATOR OPERATIONS. THIS
CORRESPONDS TO AN AVAILABILITY OF 93 PERCENT. F.LECTRICAL CONNECTION MALFUNCTIONS AND LEAKS IN
CAUSTIC FEED LINE WERE THE MAJOR PROBLEMS. THE RECIRCULATION PUMP SEAL REQUIRED REPLACEMENT.
-------
STATUS TO JANUARY 1979
SF'.jOM 9 (COK'TIMIFD)
PFRFOSMAMCE DESCRIPTION FOP OPE&A1IONAL fGn SYSTEMS ON INDUSTRTAl BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE BATING
NUMBER IF SFPARATE FGO UNITS
NUMBER OF HHILFRS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CANTON TtHTTLES
CANTON, GEORGIA
COAL (O.flT SULFUR)
}NTERRUPTIBLE NAtUKAL GAS
35,000 SCFM (1 BOILER)
1
1
13 Mh (E8UIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
CAUSTIC WASTE STREAM
RETROFIT
JUNE. 1971
OPERATIONAL
70X (500 PPM 9 INLET)
80X - SOX (5.92 LB/MM BTU AT INLET)
OPEN LOOP
NON-FIXATED SLURRY TO LINED PONO
NA S03/S01 LIOUOK DISPOSED TO LINED HOLDING PONDS
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
CANTON TEXTILE MILLS IN CANTON, GEORGIA HAS A 13 HW (EQUIVALENT) STEAM BOILER WHICH FIRES COAL
FROM OCTOBER TO MAY AND INTERRUPT ISLE NATURAL 6AS THE REMAINDER OF THE YEAR. THE BOILER IS A COM-
BUSTION ENGINEERING (C-E) VERTICAL UNIT EQUIPPED «ITH A CYCLONIC DUST COLLECTOR. THE OUST COLLECTOR
CAPTURES APPROXIMATELY 75 TO 100 POUNDS OF FLY ASH PER HOUR. THE TYPICAL COAL BURNED HAS A SULFER
CONTENT OF 0.8 PERCENT AND AN AS-RECEIVED HEAT VALUF OF 13,600 BTU PER POUND OF COAL. SULFER DIOXIDE
CONCENTRATION IN THE FLUE GAS IS 500 PPM WITH A PARTICULATE LOADING OF 5.93 LB/MM BTU.
THE FBO SYSTEM, UFSIGNEO BY R.S. NOONAN, INC., CONSISTS OF AN FMC MEDIUM ENERGY, VENTORI-TYPE
SCRUBBER MADE OF 31&L SS AND A SEPARATOR (8 FT OIA X 12 FT HIGH) OF FRP. THE FLUE GAS ENTERS THE
VENT1IRI (PRESSURE DROP-6 TO 12 IN W.G.) AT A RATE OF 02,000 ACFM 9 «30 F THROUGH A 30 HP. BUFFALO
FORCE FD FAN. THE DUCTING LEADING TO AND FROM THE SCRUBBER IS HADE OF I/a IN. 316L SS, AND FRP
RESPECTIVELY. THE FLUE GAS LEAVES THE SYSTEM THROUGH AN FRP STACK. DYEING WASTE WATER CONTAINING
SODIUM SULFATE WITH A PH W APPROXIMATELY 10.5 10 12 IS THE SCRUBBING LIQUOR. THE SCRUBBING LIQUOR
IS INJECTED IWTO THF. FLUE GAS STREAM THROUGH 1 IN. DIA. 316L SS SPRAY NOZZELS AHEAD OF THE VENTURI
THROAT. THF WASTEwATFR IS COLLECTED IN AN EQUALIZATION BASIN. DEPENDING ON THE DESIRED DEGREE OF
NEUTRALIZATION. THE BASTEWATER IS THEN RtCYClEU TO THF SCRUBBER OR PUMPED TO THF WASTEWATFR TREAT-
40
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCR1PIIUN FOR OHtRAIIONAL FGf> SYSTFMS ON INDUSTRIAL BOILEkS
CANTON TEXTILES; CANTON, GEORGIA (CONTINUED)
MENT FACILITY. A PH LEVEL OF 8.0 IS OBTAINED IN TMF FRP RECIRCULATTON TANK. THE ALI IS CHALMERS RE-
CIRCULATIDN PUMP IS MADE OF RUBBER LINED CAST IRON WHILE DYE RETENTION TANK IS OF CONCRETE.
OPERATING HISTORY
SEVERAL OPERATIONAL PROBLEMS WERE ENCOUNTERED UPON INITIAL STARTUP. A SEVERE PLUGGING PROBLEM
WAS ENCOUNTERED IN SEVERAL PUMPS DUE TO THE PRESENCE OF COTTON FIBERS IN THE KASTEwATER. A SCREEN
BASKET AROUND THE INITIAL SCRUBBER SYSTEM INTAKE PIPE IN THE OYE COLLECTION MANHOLE HAS BEING USED
TEMPORARILY UNTIL FURTHER INVESTIGATION IS COMPLETED. SURFACE-ACTIVE AGENTS IN THE DYEING WASIE-
WATERS WHICH PRODUCE FOAMING IN THE SCRUBBER PUMP WERE DETECTED AND A OEFOAMER ADDITIVE IS NOW
INJECTED INTO THE SCRUBBER FEED FROM THE DYE RETENTION BASIN. FOULING OF THE PH PROBES AND MIST
CARRYOVER ARE OTHER PROBLEM AREAS THAT HAVE BEEN INVESTIGATED.
REFER TO FIGURE 14-5 IN SECTION 1« FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1977 NO OPERATIONAL PROBLEMS WERE REPORTED DURING THIS SURVEY PERIOD. THE PLANT
REPORTED THE SYSTEM WAS rfOKKJNG SATISFACTORILY. THE PLANT WAS BURNING NATURAL GAS BUT EXPECTED
TO RETURN TO COAL DURING THE HEATING SEASON (DECEMBER-MAY).
1TH QUARTFR-1977 THE PLANT STARTED BURNING COAL AND OPERATING THE SCRUBBER 100 PERCENT OF THE
TIME IN MID-OCTOBER. NO OPERATIONAL PROBLEMS KERF ENCOUNTERED DURING THIS PERIOD.
1ST QUARTER-1978 THE SCRUBBER DEMONSTRATED AN OPERA8ILITY OF 100X.
2ND OUARTER-1978 THE SCRUBBER WAS SHUTDOWN IN MID-MAY WHEN GAS FIRING RESUMED FOR SUMMER. COAL-
FIRING WILL RESUME IN MID-OCTOBER. DURING COAL-FIRED OPERATIONS IN 1977 AND 1978, THE SCRUBBER RAN
AT A 100X OPERABILITY.
3RD QUARTER-197B NO UPDATE INFORMATION WAS AVAILABLE FOR THIS REPORT PERIOD.
«TH QUARTER-1978 COAL FIRING RESUMED IN MID-OCTOBER, AND WILL CONTINUE FOR THE REST OF WINTER
MONTHS. DURING THIS SURVEY PERIOD (6 DAYS PER WEEK), THE SCRUBBERS OPERATED AT 99X RELIABILITY.
THE DOWNTIME OF 10 HOURS WAS CAUSED BY BUILD-UP OF ABRASIVE FLYASH IN THE SCRUBBER. THE INTERIOR OF
THE SCRUBBER WAS THEN CLEANED. THE 316L SS DUCTWORK ENTERING THE SCRUBBER IS AFFECTED BY FLYASH
EROSION AND *ILL BE REPLACED WITHIN A YEAR. NO OTHER OPERATING PROBLEMS WERE REPORTED.
-------
STATUS TO JANUARY 1179
SECTION <» (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTFMS ON INOUSTRIAI BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FED UNITS
NUMBER OF BOILERS BFIN6 CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP OATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUD6E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
COAL (3.21 SULFUR)
210,000 SCFM (TOTAL - 1 BOILERS)
80,000 ACFM a 350 F, FOR EACH OF « FGO SYSTEMS
a
a
105 MW (EQUIVALENT)S TOTAL - « BOILFRS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
Z NEW, 3 RETRO
APRIL, 1978
OPERATIONAL
901 (2,000 PPM 3 INLET)
DEWATERED SLURRY TO LANDFILL
f>0+* SOLIDS (CAS04) SLUDGE DIRECTLY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE CATERPILLAR TRACTOR COMPANY PLANT LOCATED IN EAST PEORIA, ILLINOIS HAS FOUR COAL-FIRED
BOILERS. Tun OF THE BOILERS ARE RATED AT 200,000 POUNDS OF STEAM PER HOUR AND THE REMAINING TnQ ARE
RATED AT 810,000 POUNDS OF STEAM PER HOUR. THE COAL BURNED IS ILLINOIS COAL WITH A HEATING VALUE
OF 10,500 BTU/LB AND AN AVERAGE SULFUR CONTENT OF 3.21. THE TOTAL BOILER CAPACITY IS ABOUT 100 MW
(EQUIVALENT). MECHANICAL COLLECTORS ARE USED FOR PRIM»RY PARTICIPATE CONTROL. GASES EXHAUST
THROUGH A L'INEO STACK WHICH IS APPROXIMATELY 175 FT TO 180 FT HIGH. THE STACK CONSISTS OF TWO
KIDNEY SHAPFf) FLUES EMBODIED WITHIN ONF OUTER SHELL.
THE AIR QUALITY CONTROL SYSTEMS HAVE BEEN SUPPLIED BY FMC ENVIRONMENTAL EQUIPMENT DIVISION.
THERE IS ONE SCRUBBER TRAIN FOR EACH OF THE FOUR BOILERS, WHICH CONTROLS BOTH PAHTICULATE AND 802
EMISSIONS FROM ABOUT 90,000 ACFM q «2S F. THE FOUR FGO SYSTEMS SHARE COMMON REGENERATION
FACILITIES, VACUUM FILTERS, AND SLUDGE DISPOSAL.
REFER TO FIGURE lfl-7 IN SECTION Id FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH QUARTER-1977 START-UP WAS SCHEDULED FOR M»RCH 1978 AND CONSTRUCTION WAS PROGRESSING SMOOTHLY.
1ST nUARTFR-l"78 CONSTRUCTION flF THE FOUR F&O SYSTEMS WAS COMPLETED. START-UP HAS DELAYED DUE
-------
STATUS TO .lAN'UAKY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL ?GD SYSTEMS ON INDUSTRIAL BOILEHS
CATERPILLAR TRACTOR CO.? EAST PEORIA, ILLINOIS (CONTINUED)
fO THE COAL SHORTA6E.
END 9IIARTER-1978 DURING THIS REPORT PERIOD START-UP OCCURRED. BECAUSE THE flOILCR PLANT WAS NEAR
THE. END OF THE HEATING SEASON, THE BOILER LOADS WERE IN THE 70,000-100,000 L8/HR STEAM RANGE.
DURING COLO WEATHER OPERATIONS, THE BOILER LOADS ABE APPROXIMATELY 800,000 LB/HR. THE SYSTEM MS
BUILDING GOOD FILTER CAKE DURING THE START-UP PHASE OF OPERATIONS. FINAL STEADY STATE OPERATIONS
NERE NOT ACHIEVED BEFORE SUMMER SHUTDOWN.
fRD OUARTER-1978 THE FGD SYSTEM HAD JUST STARTED UP AGAIN AFTER SUMMER SHUTDOWN.
NO MAJOR START-UP PROBLEMS NERE REPORTED.
4TH OUAHTER-1978 PLANT PERSONNEL REPORT THAT AN ABNORMALLY HIGH PRESSURE DROP THROUGH THE
^SCRUBBERS IS RESTRICTING THE BOILERS TO ABOUT BOX OF THEIR CAPACITY. FAN ANO DRAFT TESTS MERE
|bEIN6 RUN IN DECEMBER TO PINPOINT THE PROBLEM AREA. THE FAN AND DRAFT TESTS FURTHER DELAYED
^SCHEDULED EMISSION TESTING. SINCE START-UP IN SEPTEMBER SCRUBBER OPERATIONS HAVE NOT BEEN SUFFICI-
ENTLY CONSISTENT TO COMPLETE ANY EMISSION TESTS.
A TEN-INCH PLASTIC RECIRCULATION LINE BROKE ON ONE SCRUBBER AND HAD TO BE REPLACED.
-------
STATUS 10 JANUARY I«>79
PERFORMANCE OHSc«iPTn>!i FOK MHFWAI IDNAL FGD SYSTEMS on iNousiimi HHILEHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTFRISTTCS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER <1F BOILFRS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RFTROFIT
START-UP OATE
CONTROL SYSTEM STATUS
803 REHOVAL EFFICIENCY
PARTICUIATE REMOVAL EFFICIENCY
MATER MAKF-IIP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATFRPILLAK TKACTOH CO.
JDLIET, ILLINOIS
COAL (3.it SULFUR)
67,000 SCFM (TOTAL - 2 BOILERS)
a
e
30 M* (EOUIVAIENT); TOTAL - Z BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 3000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
ZURN INDUSTRIES
DOUBLE ALKALI (DILUTE)
RETROFIT
SEPTEMBER, 1970
OPERATIONAL
90+x (aooo PPM a INLET)
NOT AVAILABLE
CLOStO LOOP: 0.5 GPM
DEHATF.RED SLURRY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE JOLTFT PLANT OPERATES TWO COAL-FIRED BOILERS RATED AT 100,000 AND so.ooo POUNDS OF STEAM
PER HOUR. TMFSE BOTLFRS ARE ON-LTNE ONLY DURING WINTER MONTHS, ONE OF WHICH OPERATES 20 HR/OAY
AND THE OTHER ONLY WHEN A GREATER STEAM RATE IS REQUIRED DUE TO COLD WEATHER. THE COAL HAS A
HEATING VALUF OF 10,500 BTU/LB AND IS FIRED AT A RATE OF v.65 TONS/HR. TOTAL 302 EMISSIONS FROM
THE BOLER IS 6.7« LHS/MM 8TU.
THE FGD SYSTEM ON EACH BOILER IS A 7URN DOUBLE ALKALI SCRUBBER CONSTRUCTED OF 316L STAIN-
LESS STFEL. FACH SCBOHReR EXHAUSTS THROUGH A CARBON STEEL STACK. THE TOTAL FLUE GAS FLOW RATE
IS 103,500 ACFM a> 350 F. THE SCRUBBER UNI1S APE PRECEDED BY MECHANICAL COLLECTORS FOR PARTICULATE
REMOVAL. THF 7HRN SCRUHBER UTILIZES A DUSTRAX10R MODULE FOR BOTH PARTICULATE AND 803 CONTROL.
SPENT SCRUBBING LIUUOR IS PUMPED TO THE REGENERATION »HEA WHERE LIME IS ADDED TO PRODUCE CALCIUM
SULFITE./SHLFATE IN CLARIFIERS. CLARIFIFR UNDERFLOW, WHICH IS 15-aOX SOLIDS BY WEIGHT, IS
DEMATEREO BY VACUUM FILTERS 10 APPROXIMATELY 651 SOLIDS BY WEIGHT. THE TH1XOTROPIC SLUDGE
PRODUCED IS READY FOR DISPOSAL AT A LANDFILL. CLARIFIER OVERFLOW IS RETURNED TO THE SCRUBBER AS
REGENERATED SCRUBBING LIUUOR. SODA ASH IS ALSO ADOEO TO THE REGENERATED LIQUOR TO REPLENISH
SODIUM LOST IN THE SLUDGE. LIME AND SODA ASH ARE STORED IN OUTSIDE SILOS AND PNEUMATICALLY CONVEYED
TO USE POINTS. A CHEMICAL TREATMENT BUILDING (.AS ERECTFD TO HOUSE REGENERATION AND SLUDGE HANDLING
EQUIPMENT.
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STATUS IP JANUAkY 11»79
SFCTION O fCf)NTINUPD)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FRD SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.? JOLIET, ILLINOIS (CONTINUED)
REFER TO FIGURE 11-23 OF SECTION 1/1 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1977 PROBLEMS OCCURRED NHEN A TANK RAN DRY AND DAMAGED A PUMP. SOME PIPE PLUGGING
PROBLEMS ALSO OCCURRED AS A RESULT OF THE PUMP FAILURE. A MAJOR PROBLEM AREA WAS THE HEAVY
HEAR OF THE FILTER CLOTHS ON THE VACUUM FILTERS. THE FILTER CLOTH LASTS ONLY 2 TO 3 WFEKS.
NO SOLUTIONS HAD BEEN FOUND BUT FILTER DESIGN MODIFICATIONS WERE BEING CONSIDERED.
THE UNITS NERE ULTRASONICALLY TESTED AND RESULTS SHOW THAT THE SYSTEMS ARE ON THE HIGH
SIDE OF TOLERANCE LEVELS. A MINOR LEAK WAS DETECTED AS A RESULT OF A FAULTY MELD.
4TH QUARTER-1977 FGD SYSTEM RESTART OCCURRED AT THE BEGINNING OF THE HEATING SEASON.
PLANT HAD INITIATED A PROCESS OF DETAILED RECORD KEEPING BUT MAS STILL WORKING
ON THE INTERNAL INFORMATION TRANSFER PROCESS. PLANT HAS INDICATED THAT A SUMMARY OF THESE
RECORDS WILL BE AVAILABLE TO THIS REPORT IN THE FUTURE.
1ST QUARTER-1978 FILTER CLOTH PROBLEMS CONTINUED WITH REPLACEMENT BEING REQUIRED EVERY 2-3 WEEKS.
THE SYSTEMS WERE DOWN IN MARCH BECAUSE OF PLUGGED PIPELINES.
2ND OUARTER-1978 UNRELIABLE 802 MONITORS HERE A PROBLEM DURING THIS PERIOD. HEAVY ATTRITION OF
FILTER CLOTHS CONTINUED.
3RD OUARTER-1978 DUE TO SHORT FILTER FABRIC LIFE AND SLUDGE FREEZE UP PROBLEMS, FILTER DESIGN
MODIFICATIONS MERE STILL BEING CONSIDERED, BUT HAD NOT YET BEEN MADE.
302 MONITORS ARE STILL A PROBLEM EXHIBITING PLUGGING, CORROSION, AND UNRELIABLE PERFORMANCE.
PROBES OF 304 SS, 316L S3 AND TEFLON COATING HAVE ALL BEEN TRIED WITHOUT SUCCESS. HASTELLOY-C
PROBES HAVE BEEN INSTALLED, BUT THE PLANT HAS NOT HAD TIME TO EVALUATE THEIR PERFORMANCE. REHEAT
EQUIPMENT WAS SCHEDULED TO BE INSTALLED BUT HAS NOT BEEN AS OF THIS UP-DATE. GUILLOTINE-TYPE
DAMPERS REPLACED THE LOUVER-TYPE ISOLATION DAMPERS ORIGINALLY INSTALLED. HOWEVER, THE GUILLOTINE-
TYPE CANNOT BE CLOSED TIGHTLY BECAUSE FLY ASH COLLECTS IN THE BOTTOM OF THE GUILLOTINE SHEATH.
t
1TH OUARTER-1978 THE BOILERS STARTED OPERATIONS IN THE LAST MEEK OF OCTOBER. FILTER CLOTH HEAR
CONTINUES TO BE A PROBLEM. THE HASTELLOY-C 802 PROBES REQUIRE EXCESSIVE MAINTENANCE FOR PROPER
FUNCTIONING. CORROSION AND EROSION OF THE PROBES IS NOT YET EVIDENT. FLYASH ACCUMULATION IN THE
BOTTOM OF THE GUILLOTINE DAMPERS IS STILL A PROBLEM. I
ALTHOUGH PIPE PLUGGING IS NOT NORMALLY A PROBLEM (THE ENTIRE SYSTEM IS FLUSHED AND CLEANED
DURING THE SUMMER OFF SEASON), SLIGHT BUILDUPS IN THE PIPING HAVE OCCURRED.
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
COAL (3.2Z SULFUR)
3S.OOO SCFM (TOTAL - 2 HOtLERS)
2
2
19 Hh (EQUIVALENT); TOTAL 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 200U SCFM = 1 FOUIVALfNT Mw.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
ZURN INDUSTRIES
DOUBLE ALKALI (DILUTE)
RETROFIT
JANUARY, 1976
OPERATIONAL
90Z (2000 PPM 3 INLET)
OEWATERED SLURRY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE MORTON PLANT, A PARTS DISTRIBUTION CENTER, CATERPILLAR TRACTOR OPEKATFS A TWO-BOILER STEAM
PLANT WHICH GENERATES A TOTAL OF 66,000 ACFM AT «50 F AT MAXIMUM LOAD. THE STOKER COAL-FIRED
BOILERS ARE MANUFACTURED BY KICKS AND ARE RATED FOR 60,000 LB/HR SIEAM EACH AT 150 PSIG. AN OIL-
FIRED BOILER RATED AT 120,000 LB/HR STEAM IS AVAILABLE AS BACK-UP. HEAT INPUT IS 70.7 MM 8TU/HH.
THE HEATING VALUE OF THE COAL IS 10,400 BTU/LB.
EMISSIONS ARE CONTROLLED BY A ZURN INDUSTRIES AIR OUALITY CONTROL SYSTFM CONSISTING OF A 1)118-
TRAXTOR SCRUBBER IN WHICH PART1CULATE AND S02 REMOVAL OCCUR SIMULTANEOUSLY. SULFUR DIOXIDE REMOVAL
IS BROUGHT ABOUT BY THE USE OF ZURN DILUTE MODf DOUBLE ALKALI FGO TECHNOLOGY. THE ThO BOILERS AND
THE TWO SCRUBBING TRAINS AND MOST ANCILLARY EQUIPMENT ARE WITHIN THE BOILFR HOUSE.
THE SYSTEM AT MORTON IS VERY SIMILAR TO THAT AT THE CATERPILLAR JOLIET PI ANT, WHICH HAS BEFN
OPERATING EACH HEATING SEASON SINCE OCTOBER 197q. WHENEVER POSSIBLE, PROBLEM AREAS AND
SOLUTIONS IDENTIFIED IN JOLIET OPERATIONS HAVE HEFN IMPLEMENTED TO IMPROVE THE SYSTEM DESIGN
AT MORTON. SPECIFIC AREAS IN WHICH MODIFICATIONS TO DESIGN HAVE BEEN MADF AWE HATEH BAI ANCE
PUMPS, PM MONITORING, PIPING, LIME STORAGE, AND COLO WEATHER PROTECTION.
REFER TO FIGURE 14-9 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM UF THIS SYSTEM.
OPERATING HISTORY
1ST OUARTFH-197B SYSTEM START-UP OCCURRED AT THF BEGINNINU OF JANUARY. INITIAL OPERATIONS »ERF
PROBLEM-FBEF. THROUGH JANIIAHf AND PART f.F FEBRUARY, ZURN PEHSUNNEL Wf«F TRAILING THE KfiUfR PL»NT
46
-------
STATUS TO JANUARY !<»? THE CAUSE OF WHICH nAS NOT KNOWN.
3RD OUAHTER-I978 ACCEPTANCE TESTING WAS DELAYED DUE TO THE PUFFING PROBLEM. THE TESTING
•ILL BE ATTEMPTED LATE THIS FALL. EVEN THOUGH PUFFING REMAINS A PROBLEM, PLANT PERSONNEL FEEL THEY
ABE CLOSER TO RESOLVING IT DUE TO NEH DESIGN MODIFICATIONS TO THE SCRUBBER.
«TH QUARTER-1978 DURIN6 THIS QUARTER, THE PUFFING PROBLEM HAS CORRECTED. THE PUFFING PROBLEM
HAS A RESULT OF SEVERE PRESSURE PULSATIONS INSIDE THE ABSORBER DURING OPERATIONS. INSTANTANEOUS
PRESSURE DROPS OF 10 INCHES W.G. ACROSS THE SCRUBBER OCCURRED SEVERAL TIMES. ZURN INDUSTRIES PER-
SONNEL TRIED TO SOLVE THE PROBLEM BY INSTALLING TURNING ELBOWS IN THE STACK, HUT THIS FAILED TO
SOLVE THE PROBLEM. FINALLY PLANT PERSONNEL INSTALLED WINDOWS IN THE ABSORBER AND THROUGH THE USE
OF SPOTLIGHTS OBSERVED THE ACTION OF BLOWING COLO AIR THROUGH THE ABSORBER. IT WAS NOTICED THAT A
HAVE BEGAN TO PROPAGATE BACK AND FORTH ACROSS THE ABSORBER CAUSING THE WATER LEVEL AT THE BOTTOM
OF THE DOHNCOMER CHANNELS TO DROP BELOW THE BOTTOM OF THE CHANNELS. GAS WAS THEN ALLOWED TO PASS
UP THE DOWNCOMER CHANNELS (ONE ON EACH SIDE OF THE ABSORBER) INSTEAD OF THE NORMAL SCRUBBING TUBES
AND PREVENTED THE SCRUBBING LIQUOR TO RETURN TO THE BOTTOM POOL. AS A RESULT, PULSATIONS OCCURRFO
ALONG THE DOWNCOMER. THE PROBLEM MAS SOLVED BY SEALING THE OOWNCOMER WITH WELDED PLATES EXCEPT FOM
THREE TUBES. THESE TUBES WERE LONGER THAN THE ORIGINAL DOWNCOMER CHANNEL TO ENSURE THE TU8E BOTTOMS
REMAINED CONTINUOUSLY SUBMERGED.
SINCE THE PH PROBES CONTINUOUSLY BECAME PLUGGED AND GAVE FALSE READINGS, PH IS MEASURED HOURLY
WITH A MULTI-BAND LITMUS PAPER.
AN INITIAL WATER BALANCE PROBLEM WAS CAUSED BY TOO MUCH WATER ENTERING THE FGO SYSTEC AS PUMP
SEAL MATER. IT WAS CORRECTED BY INSTALLING ROTAMETFRS ON SEAL WATER LINES TO REGUL*TF FLO*.
ACCEPTANCE TESTING HAS BEEN COMPLETED AND AN APPLICATION HAS BEEN SUBMITTED TO THE STATE FOR
A STATE PERMIT TO OPERATE. THE PLANT BELIEVES THEY WILL RECEIVE THE FIRST SUCH PERMIT IN ILLINOIS
TO BURN HIGH SULFUR COAL IN AN INDUSTRIAL BOILER.
-------
STATUS TIJ JANIJAKY 1979
SFCTJON 0 (CONTINUED)
PE»FORMA*CF DESCRIPTION FOK OPERATIONAL Ff,r> SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCF CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PRClCtSS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOa REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATFfcPILLAH TRACTON CO.
MOSSVILLE, ILLINOIS
COAL (3.?X SULFUR)
130,000 SCFM (TOTAL - 1 BOILERS)
0
a
70 MW (EQUIVALENT); TOTAL - 9 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 3000 SCFM = 1 EQUIVALENT^
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZINi
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
p NE* 3 RETRO
OCTOBER, 1975
OPERATIONAL
90+X (2000 PPM 3 INLET)
DENATERED SLURRY TO LANDFILL
60+X SOLIDS (CAS01) SLUDGE DIRECTLY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THF MOSSVILLE PLANT, CATERPILLAR TRACTOR OPERATES A FOUR-BOTLER STEAM PLANT. TWO OF THE
BOILERS ARE RATED AT 150,000 LBS/HR STEAM AND THO ARE RATED AT 80,000 LBS/HR STEAM. THE ENTIRE
q-UNIT PLANT TS ROUGHLY EQUIVALENT TO 70 MM OF ELECTRICAL GENERATING POWER. THE COAL FIRED IS
HIGH-SULFUR (3.ZX-1.0X) ILLINOIS COAL. THE FOURTH BOILER, AT 150.000 LBS/HR, BEGAN OPERATIONS
IN 4UNE 1977 AND ITS FGD SYSTEM WAS BYPASSED UNTIL OCTOBER 1977. THE TWO MOST RECENTLY INSTALLED
BOILERS HAVF MFCHANICAL COLLECTORS PRECEEOING THE SCRUBBERS.
FMC ENVIRONMENTAL EQUIPMENT DIVISION HAS SUPPLIED AN AIR QUALITY CONTROL SYSTEM CONSISTING OF A
VENTURI SCRUBBER FOR PARTICIPATE CONTROL AND AN ABSORBER MODULE FOR 802 CONTROL. FMC CONCENTRATED
MODE, OOUBLF ALKALI FGD TECHNOLOGY IS BEING USED IN THE ABSORBER MODULES. THE TWO 150,000
LB/HR BOILERS HAVE MECHANICAL COLLECTORS REMOVING ABOUT 90X OF THE INLET FLYASH. THE SCRUBBING
TRAINS ON THE TWO SMALLER BOILERS HAVE NO PRECEDING MECHANICAL COLLECTORS. THE POSITION OF THE
VENTURI CAN 8F CONTROLLED AUTOMATICALLY BY STEAM FLOW, BUT CURRENTLY IS NOT IN OPERATION.
WHILE THE FLYASH IN THE FINAL FILTER CAKE PROVIDES ADDED MECHANICAL STABILITY, THE HIGH ASH
CONTENT IN THE RECIRCULATING SLURRY CAUSED SEVERE EROSION/ABRASION PROBLEMS IN EARL* OPERATIONS.
THE ORIGINALLY INSTALLED ȣIR-TYPE CONTROL VALVES HAVF BEEN REPLACED HITH SPOOL PIECES AND A
CONSTANT VOLUME PUMPING SYSTEM. THERE WAS ALSO SIGNIFICANT WEAR IN THE VENTURI SCRUBBER BOTTOMS,
WHICH HAS SOLVED BY THF. INSTALLATION OF WEAR PLATES.
SEVERAL PROBLEM AREAS WERE IDENTIFIED AND DEALT WITH DURING THE TWO HEATING SEASONS PRIOR TO.
as
-------
STATUS TO JANUARY
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPFKATTONAl FGD SYSTEMS ON TNOHSTRTAt BOTLERS
CATERPILLAR TRACTOR CO.? MOSSVILLE, ILLINOIS (CONTINUED)
THE 1977-78 SEASON. THESE ARE LISTED BELOW.
PUMPS - THE RUBBER-LINED SLURRY PUMPS WERE OVERSIZED WHICH CAUSED HIGH PIPE VELOCITIES AND
ACCELERATED WEAR ON THE PUMP LININGS. THESE PUMPS WERE REVISED TO LOWER THEIR OUTPUT. LOW SEAL
WATER PRESSURE ALLOWED PROCESS LIQUOR TO GET INTO THE PUMP AND PACKING. ALL SEAL WATER
IS NOW ONCE-THROUGH AND SYSTEM PRESSURES HAVE BEEN ADJUSTED TO MAINTAIN SEAL WATER PRESSURE
ABOVE PROCESS LIQUID PRESSURES.
SLUDGE HANDLING - SLUDGE IS TRANSPORTED FROM THE VACUUM FILTERS TO THE LOADING AREA ON A BELT
CONVEYOR. SEVERAL STRATEGIES. ALL INVOLVING SCRAPING OR PLOWING THE DEWATERED SLUDGE OFF THE BELT,
RESULTED IN EXCESSIVE WEAR OF EITHER THE BELTS OR THE PLOWS. THE PRESENT APPROACH SIMPLY DUMPS
THE MATERIAL OFF THF FND OF THE BELT INTO BINS. THE POSITION OF THE BELT IS CHANGEABLE SO THAT
EIGHT BINS CAN BE FILLED BEFORE THEY MUST BE EMPTIED. A FURTHER MODIFICATION HAS A DUAL POSITION
CHUTE UNDER EACH BELT END POSITION, SO THAT A TOTAL OF 16 BINS CAN BE WORKED AT A TIME.
SLUDGE BINS ARE THEN LOADED HYDRAULICALLY INTO TRUCKS AND HAULED TO THE SANITARY LANDFILL AREA.
ANOTHER PROBLEM, COLD WEATHER ICING ON THE SLUDGE LOADING AREA, HAS SOLVED BY ENCLOSING THE AREA.
INSTRUMENTATION - ORIGINAL DESIGN PLANS CALLED FOR CONTROL BY THE MONITORING OF THE sos/soa
RATIO AND SODIUM ION CONCENTRATION. THE CONTROL RANGE MAS FOUND TO BE TOO SMALL AND THE PRESENT
APPROACH IS PH CONTROL (6.5) AND CLEANING OF THE PROBES EVERY OTHER OAT.
ORIGINAL DESIGN DID NOT MONITOR 302 CONCENTRATION BUT A COMPLETE MONITOR SYSTEM WAS INSTALLED
PRIOR TO THE 1977-78 SEASON.
PIPING - MODIFICATIONS HAVE BEEN MADE WHICH FACILITATE CLEANING OR SCHEDULED REPLACEMENT.
REFER TO FIGURE lfl-10 IN SECTION Ifl FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
«TH QIJARTER-1977 CATERPILLAR BEGAN A PROCEDURE OF DETAILED RECORD KEEPING, BUT THE INFORMATION
HAS NOT YET AVAILABLE TO THIS REPORT.
2ND QUARTFR-1978 NUMEROUS BOILER-RELATED PROBLEMS HAVE COMPOUNDED FGD SYSTEM PROBLEMS. MAJOR
FGD PROBLEM AREAS WERE AS FOLLOWS:
EROSION OF SCRUBHEK LINER MATERIAL.
EXCESSIVE WEAR OF PIPING, PUMPS, AND CONTROL VALVES.
SLUOGF FRFEZE-UP ON THE CONVEYOR BELT PLUGGED SLUDGE CHUTES.
3RD OUARTER-1978 PERFORMANCE OF THE VENTURI SPRAY NOZZLES HAS NOT BEEN SATISFACTORY. NQZZELS OF
316L S3 WFRF. ORIGINALLY INSTALLED AND LASTED ABOUT FOUR MONTHS. CERAMIC NOZZLES WERE THEN TRIED BUT
BROKE WHEN BEING REMOVED. THE PLANT RETURNED TO USING 316L SS SINCE THE STEEL NOZZLES WERE CHEAPER
THAN THE CERAMIC NOZZLES. PLANS ARF BEING MADE TO MODIFY THE NOZZLE CONFIGURATION. THE VENTURI
IS BETN6 OPERATED MANUALLY SINCE PLANT PERSONNfL HAVE NOT HAD TIME TO DEBUG THE AUTOMATIC CONTROL.
49
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BflTLtKS
CATERPILLAR TRACTOR CO.; MOSSVILLE, ILLINOIS (CONTINUED)
END-DISCHARGING DISH CONVEYORS FOR THE SLUDGE CONVEYOR SYSTEM HAVE NOT YCT BEEN INSTALLED
BECAUSE THE ENTIRE SLUDGE HANDLING FACILITY IS CURRENTLY BEING REEVALUATED. THIS REEVALUATJCIN IS
A RESULT OF THE MANY PROBLEMS CATERPILLAR HAS HAD WITH THEIR SLUDGE HANDLING SYSTEM.
MODIFICATIONS TO PIPING IN ORDER TO FACILITATE PIPE CLEANING AND SCHEDULED REPLACEMENTS HAVE MOT
BEEN SIGNIFICANT. THE GUILLOTINE DAMPERS AT THIS PLANT ARE EXPERIENCING THF SAME PROBLEMS AS THE
DAMPERS AT THE JOLIET PLANT* FLYASH COLLECTING IN THE BOTTOM OF THE DAMPER PREVENTS THE HAMPER FKOV
BEING CLOSED TIGHTLY. WEAR PLATES HERE INSTALLED IN THE BOTTOM OF THE VENTURI SCRUBBERS TO PREVENT
ABRASIVE WEAR AND ARE MORKING HELL. PLANT PERSONNEL FEEL THEY ARE STILL IN A DEBUGGING PHASE.
«TH OUARTER-1978 PLANT PERSONNEL DESCRIBED THE FGD SYSTEM OPERATION AS SPORADIC AND FLUCTUATING.
PROBLEMS ARE ENCOUNTERED, CONTINUOUSLY CAUSING SYSTEM SHUTDOWN. EROSION CONTINUES TO BE A SIG-
NIFICANT PROBLEM. VALVES, FITTINGS, LININGS, PUMPS, FANS, AND SCRUBBER NOZZLES ARE ALL ERODING.
THE WEAR PLATE INSTALLED IN THE BOTTOM OF THE SCRUBBER HAS SLOWED THE EROSION THERE.
THE VENTURI NOZZLE CONFIGURATION WAS NOT CHANGED AND THE VENTURI IS STILL OPERATED MANUALLY.
THE SLUDGE HANDLING FACILITIES HAVE NOT BEEN REEVALUATED OR CHANGED YET. FILTER FABRIC WEAK AND
SLUDGE FREEZE-UP CONTINUE TO BE A PROBLEM.
A MAINTENANCE PROGRAM TO CLEAN THE GUILLOTINE DAMPER OF FLYASH HAS NOT VET BEEN DEVELOPED.
AN EMISSIONS TEST IS SCHEDULED FOR LATE JANUARY OH EARLY FEBRUARY 1979.
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
- PERFORMANCE DESCRIPTION FOR OPERATIONAL Fcr> SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FED UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
WATER MAKE-OP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CHEVRON U.S.A. INC.
BAKERSFIEID, CALIFORNIA
OIL (1.1* SULFUR)
248,000 SCFM (TOTAL - IB BOILERS)
150,000 ACFM 3 500F, FOR EACH OF 3 FGD SYSTEMS.
3
18
125 MW (EQUIVALENT): TOTAL - 18 BOILERS
900 MM BTU/HR (TOTAL - 18 BOILERS: 6 BOILERS/FGO SYSTEM)
(FOR THIS REPORT, UNLESS STATED OTHEHKISE. 2000 SCFM = 1 EQUIVALENT M*.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
KOCH ENGINEERING
SODIUM CARBONATE SCRUBBING
RETROFIT
JULY, 1978
OPERATIONAL
90Z (70 PPM 9 OUTLET)
ia - 13 GPM
MASTENATER TREATMENT AND DISCHARGE TO TAILINGS POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
CHEVRON U.S.A. HAS AN OIL SITE AT BAKERSFIELD, CALIFORNIA. THERE ARE ABOUT SO STEAM GENERATORS
MHfCM BURN 1.1* SULFUR CRUDE OIL. EACH GENERATOR IS RATED AT 50 MM BTU/HR. THE STEAM IS USED FOR
(ENHANCED OIL RECOVERY FROM THE OIL NELLS.
KOCH ENGINEERING COMMISSIONED THREE FGD SYSTEMS IN JUNE/JULY 1978. THE SODIUM CARBONATE
SCRUBBING PROCESS IS USED. EACH SCRUBBER TREATS FLUE GASES FROM 6 GENERATORS «ITH A TOTAL
FLOW RATE OF 150,000 ACFM AT 500 F. THE GAS IS QUENCHED IN THE BOTTOM PORTION OF THE ABSORBER BY
120 6PM OF THE RECIRCULATIN6 LIQUOR. THERE ARE 3 KOCH FLEXITRAYS AND A KOCH FLEXIMESH MIST
ELIMINATOR IN EACH SCRUBBER. THE SPENT LIQUOR IS MIXED WITH FRESH SODIUM CARBONATE SOLUTION IN THE
BOTTOM OF THE SCRUBBER. A CONTINUOUS BLEED-OFF STREAM (1-2 GPM) IS TAKEN TO A DISPOSAL POND,
HMEREAS THE REST OF THE LIQUOR IS RECIHCULATEO AT A TOTAL RATE OF 900 GPM (15 wTX DISSOLVED SOLIDS).
A PH OF 6.5 IS MAINTAINED AT THE TOP TRAY AND AN L/G RATIO OF 8 GAL/1000 ACF IS USED. THERE IS
«0 REHEAT FACILITY BUT THE SCRUBBER CAN BE BYPASSED. THE BOILER t.O. FANS WERE UPGRADED
FROM 50 HP TO 75 HP TO OFFSET THE PRESSURE DROP OF 9 IN. KG. ACROSS THE ABSORBER. THF. SCRUBBERS AWE
DESIGNED TO REMOVE L ss AND THF
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
E DESCRIPTION FliR OPFRA1IONAI FGP SYSTEMS ON INDUSTRIAL BOILERS
CHEVRON U.S.A. INC.; rIAKERSF IELD, CALIFORNIA (CONTINUED)
FLEXIMESH is iwcninr rt*s. THE STACK is M*OF. OF 316 ss AND THE PIPING is FOP.
T(» FTGMRF lfl-l? IN SECTION 1« FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QIIARTFH-197« BECAUSE OF LOW STEAM DEMAND ONLY T«0 OF THE EXISTING THREE SCRUBBERS ARE OPERA-
TIONAL (OUT OF THF 1» STEAM GENERATORS 13 ARE OPERATIONAL). ONE SCRUBBER CONTROLS 7 GENER-
ATORS WHILE THE OTHER CONTROLS 5 GENERATORS. THE RFMAINING 6 STEAM GENERATORS AND THE CORRESPOND-
ING SCRUBBER HILL BF BROUGHT ON-LTNE AS STEAM DEMAND INCREASES (POSSIBLY IN DECEMBER OR JANUARY).
NO MAJOR PROBLEMS HAVE OCCURRED SINCE START-UP IN JUNE-JULY 1978. HOWEVER, SOME CLOGGING OF
THE SOOA ASM FEFO CHUTE FROM THE STORAGE SJLO DOES OCCUR. THIS CLOGGING IS EASILY CORRECTED WITH NO
DOWNTIME NECESSARY. SYSTEM OPERABILITY FOR THE PERIOD HAS 95X.
GOOD OPERATION IS ATTRIBUTED TO REGULAR MAINTENANCE PRACTICE WITH EMPHASIS ON DAILY CLEANING OF
THE PH PRfWFS.
flTH OUARTFH-197B SYSTEM AVAILABILITY OF 1 OOJC WAS REPORTED FOR THIS PERIOD. THERE WERE NO
SCALING OR PLUGGING PROBLEMS. ROTATING EQUIPMENT (FANS. PUMPS) MAVF OPERATED WITHOUT TROUBLE. THE
MIST ELIMINATOR HASH FREQUENCY IS TWICE A DAY, ABOUT iO MINUTES AT A TIKE, APPROXIMATELY 50 GPM
FLOW OF FRESH WATER.
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOB OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
803 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
FIRESTONE TIRE AND RUBBER CO.
POTTSTOWN, PENNSYLVANIA
COAL (2.5 - 3,0t SULFUR)
6070 SCFM (13,000 ACFM 3 300 F)
1
1
fl MW (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 2000 SCFM = 1 EQUIVALENT MW
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
RETROFIT
JANUARY, 1975
OPERATIONAL
90.5X (1000 PPM 3 INLET)
97.ax (5 LB/MM BTU 3 INLET TO MECHANICAL COLLECTOR.)
DEWATEREO SLURRY TO LANDFILL
SEE SECTION 13 FOB DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FIRESTONE TIRE AND RUBBER CO. LOCATED IN POTTSTOHN, PENNSYLVANIA HAS BEEN OPERATING AN FGD
SYSTEM SINCE JANUARY 1975 AS A DEMONSTRATION-SIZE PLANT, DESIGNED TO TEST THE FEASIBILITY OF FGP
ON INDUSTRIAL BOILERS. THE UNIT IS DEMONSTRATING 90 PERCENT 802 REMOVAL EFFICIENCY AND TREATS
A FLUE GAS CAPACITY OF 13,000 ACFM OR 3 MW (EQUIVALENT). THIS FLOW REPRESENTS APPROXIMATELY
1/3 OF THE TOTAL OUTPUT OF ONE 120,000 LB/HR STEAM BOILER. THE SULFUR DIOXIDE EMISSION REGULATION
FOR THE PLANT IS 0.86 LOS/MILLION BTU OF HEAT INPUT.
THE PLANT IS USING THE CONCENTRATED DOUBLE ALKALI PROCESS PATENTED BY FMC CORPORATION. THE LOAD
CAPACITY OF THE BOILER ON WHICH THE SCRUBBER IS OPERATING IS APPROXIMATELY 15 MW. IN OCTOBER 1976,
THE BOILER MAS CONVERTED FROM BURNING RESIDUAL FUEL OIL (2.8* S) TO COAL (2.5-3.OS S).
THE VENTURI SCRUBBER IS SPRAYED WITH ALKALINE LIQUOR WHERE THE FLUE GAS ENTERS. THE FAN AND
DAMPER UPSTREAM OF THE VENTURI CONTROL THE FLUE 6AS FEED. SCRUBBING LIQUOR FLOWS FROM THE VENTURI
TO THE BOTTOM OF THE CYCLONE DEMISTER AND THEN INTO THE RECIRCULATION TANK. DROPLETS OF SCRUBBING
LIQUOR ARE SPUN OUT IN THE CYCLONE AND RUN BACK DOWN INTO THE RECIRCULATION TANK. THE SCRUBBING
LIQUOR IS PARTLY RECIRCULATED TO THE VENTURI THUS COMPLETING THE SCRUBBING CYCLE. ACCUMULATION OF
SOLUBLE SODIUM BISULFITE IS PREVENTED BY CONTINUOUSLY DRAWING OFF A SMALL STREAM OF SCRUBBER SOLU-
TION TO THE LIME REACTOR TANK WHERE THE SODIUM SULFITE REACTS WITH LIME TO FORM CALCIUM SULFITE AND
SODIUM HYDROXIDE WHICH IS RECYCLED TO THE ABSORBER. CALCIUM SULFITE SLURRY IS TRANSFERRED TO THE
ROTARY FILTER. THE FILTER CAKE FORMED (180 LBS/HR, 55X SOLIDS) IS HAULED TO THE LANDFILL. THE
53
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGP SYSTEMS ON INDUSTRIAL BOILERS
FIRESTONE TIRE AND RUBBER CO. ; POTTSTQWN. PENNSYLVANIA (CONTINUED)
WATER BALANCE IS MAINTAINED BY MAKING UP FOR THE LOSSES BY EVAPORATION AND In THE FtLtt-M CAKE.
THE VENTURI SCRUBBER HAS A VARIABLE THROAT ((, IN. TO IS IN.) AND IS MAOF OF 316L SS. THE OPFR-
ATING VELOCITY THROUGH THE VENTURI THROAT IS 200 FT/SEC 3 130 f. THE OPERATING L/G IS 10 GAL/
1000 ACF. THE SPRAY NOZZLES ARE ALSO MADE OF 316L SS. IHE CYCLONIC OEMISTER (1.67 FT OIA X 7.17
FT HIGH) OPERATES WITH A PRESSURE DROP OF 2" WG. GAS VELOCITY THROUGH THE OEHISTEH IS 100 FT/SEC
3 130 F. THE DEMISTER, RECIRCULATION TANK, AGITATOR. RECIRCULATION PIPING, ANO THE FILTER ARF HADE
OF 316L SS. THE INLET DUCTWORK, P.O. FAN, THICKENER, AND LIME REACTOR TANK ARE OF CAHBOM STEEL.
THE RECIRCULATION PUMP IS CAST IRON KITH RUB8EH LINING AND THE STACK IS FRP.
REFER TO FIGURE 10-13 IN SECTION ia FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
1ST QUARTER-1975 THE SYSTEM WENT ONSTREAM BURNING 2.2X SULFUR OIL. THE FGD SYSTEM OPERATED 687
HOURS AND WAS CALLED UPON TO OPERATE 819 HOURS, YIELDING A RELIABILITY OF 84.SZ. DOWNTIME WAS DUE
PRIMARILY TO FAILURES OF COMPONENTS SUCH AS PUMP PACKING.
2ND OUARTER-1975 THE SYSTEM OPERATED 1450 HOURS AND WAS CALLED UPON TO OPERATE 1509 HOURS,
YIELDING A RELIABILITY INDEX VALUE OF 96.4JC.
3RD OUARTER-1975 SYSTEM OPERATED 1436 HOURS, HAS CALLED UPON TO OPERATE 1503 HOURS, YIELDING
A RELIABILITY INDEX VALUE OF 95.5Z.
4TH OUARTER-1975 SYSTEM OPERATED 1320 HOURS, WAS REQUIRED TO OPERATE 1493 HOURS, YIELDING A RELI-
ABILITY INDEX VALUE OF 88.4t. LIME FEEDER MALFUNCTIONING AND THICKENER PLUGGING HERE PROBLEMS.
1ST QUARTER-1976 SYSTEM OPERATED 1961 HOURS, WAS CALLED ON TO OPERATE 2035 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 96.IX.
2ND OUARTER-1976 SYSTEM OPERATED 1280 HOURS, WAS CALLED UPON TO OPERATE 1335 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 9S.9Z.
3RD OUARTER-1976 SYSTEM OPERATED 1157 HOURS, WAS CALLED UPON TO OPERATE 1166 HOURS, THUS DEMON-
STRATING ITS HIGHEST RELIABILITY INDEX VALUE, 99.21.
«TH QUARTER-1976 IN OCTOBER, THE SYSTEM OPERATED AT A RtLIABILITY INDEX (IF 100Z, UNTIL THt UNIT
MAS CONVERTED TO COAL FIRING (2.5 - 3.0* SULFUK). THE SYSTEM OPERATED FOR AN ADDITIONAL 511 HOURS,
OF THE 526 REOUIREO, DEMONSTRATING A RELIABILITY INDEX VALUF OF 97.21. IN NOVEMBER ANp DECEMBER,
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGn SYSTEMS ON INDUSTRIAL HOILENS
FIRESTONE TIRE AND RUBBER CO. f POTTSTOHN. PENNSYLVANIA (CONTINUED)
THE SYSTEM OPERATED FOR 1172 HOURS AGAINST THF REQUIREMENT OF I2U HOURS. THEREFORE. THE AVERAGE
RELIABILITY INDEX FOR THE TWO MONTHS HAS 96.7X.
1ST OUARTER-1977 SYSTEM OPERATED 1193 HOURS, MAS REQUIRED TO OPERATE FOR 1159 HOURS, YIELDING *
RELIABILITY INDEX VALUE OF 81.71. SYSTEM HAS DESIGNED FOR A MUCH LOWER PARTICULATE LOADING THAN
THAT ACTUALLY ENCOUNTERED ON COAL FIRING. THE HIGH GRAIN LOADING CAUSED ABNORMAL WEAR AND DOWNTIME
OF THE F.O. FAN.
2ND OUARTER-1977 SYSTEM OPERATED 1598 HOURS, HAS REQUIRED TO OPERATE 1690 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 83.71. THE MAJOR CAUSES OF DOWNTIME HERE F.D. FAN EROSION AND PUMP
COMPONENT FAILURES.
3RD OUARTER-19T7 SYSTEM OPERATED 1131 HOURS, WAS REQUIRED TO OPERATE 1197 MuiwS, YIELDING A
RELIABILITY FIGURE OF 99.SX. THE TOTAL REQUIRED HOURS WERE LOW IN JULY DUE TO BOILER HOUSE
SHUTDOWN AND SUBSEQUENT START-UP.
«TH OUARTER-1977 IN OCTOBER, THE SYSTEM OPERATED 432 HOURS OUT OF THE 511 REQUIRED AS THE BOILER
HAS FIRING COAL. THE RELIABILITY VALUE HAS THEREFORE 64.6S. DOWNTIME HAS CAUSED BY PROBLEMS HITH
THE LIME CONVEYOR. WHEN OIL HAS BEING FIRED THE SYSTEM OPERATED 95 OF THE 102 HOURS REQUIRED,
DEMONSTRATING A RELIABILITY VALUE OF 9S.6S. IN NOVEMBER AND DECEMBER, THE SYSTEM OPERATED 792 HOURS
OF THE REQUIRED «54, WHILE BURNING COAL, YIELDING A RELIABILITY OF 86.71. DOWNTIME MAS CAUSED BY
FAN PROBLEMS AND LIME FEEDER PROBLEMS.
1ST QUARTEH-1978 THE SPRAY NOZZLES, ORIGINALLY 316 STAINLESS STEEL, HERE REPLACED BY 316L SS.
THE SPRAY BARS HERE METALLIZED HITH 316 SS.
2ND QUARTER-J978 THE FAN HAS REPLACED BY A NEW FAN CONSTRUCTED OF AN ABRASION RESISTANT CARRON
STEEL. THE FAN HOUSING HAS METALLIZED HITH 316 SS. LEAKS IN THE VENTUHI SECTION AND DOWNSTREAM
DUCTHORK HERE REPAIRED. THE FGD SYSTEM EXHIBITED AN AVAILABILITY OF 69.SX FOR THIS REPORT PERIOD.
3RD OUARTER-1978 NO UNUSUAL PROBLEMS WERE ENCOUNTERED DURING THIS PERIOD. DOWNTIME "AS DUE
TO NORMAL MAINTENANCE. PRELIMINARY ENGINEERING FOR THE FULL SCALE-UP SYSTEM IS COMPLETE. FINAL
DESIGN HILL BE DELAYED UNTIL THE ENERGY BILL CURRENTLY BEFORE CONGRESS IS FINALIZED. PLANT
PERSONNEL ATTRIBUTE THEIR SUCCESSFUL OPERATION OF THE FGD SYSTEM TO A GOOD UNDERSTANDING AND
IN-DEPTH KNOWLEDGE OF PROCESSES AND CONTROLS.
55
-------
STATUS TO JANUARY 1979
SFCTION 9 (COHTINUFIJ)
PERFORMANCE DESCRIPTION FOB OPERATIONAL Fen SYSTEMS ON INDUSTRIAL HUILERS
FIRFSTONE TTHF AND OURBER CO. ; POTTSTOWN, PENNSYLVANIA (CONTINUED)
1TH OIIABTFR-197R IN OCTOBER, THE BOILER WAS DOWN FOR MAINTENANCE, HENCE THF SCRUBBER DID NOT OP-
ERATE. OMRINR NOVEMBER AND DECFHBER, THF SYS1FM OPERATED 311 HOURS OF A RF.OUIRED 312
HOURS, WHTLF BURNINK COAL, YIELDING A RELIABILITY OF 93.71. DOWNTIME OF 20 HOURS HAS
CAUSED BY BREAKAGE OF BELT ON RECTRCULATION PUMP HHICH WAS THEN REPLACED. SCHEDULED MAINTENANCE
RF.QUIREO AN ADDITIONAL HOUR OF DOWNTIME.
S6
-------
STATUS TO JANUARY 1979
SECTION 0 (CnNTIMJFD)
PERFORMANCE DESCRIPTION FOR OPFRMTONAL FGO SYSTFMS ON INDUSTRIAL
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
MEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
FMC (SODA ASH PLANT)
GREFr- MIVFk, WYOMING
COAl fix SULFUR)
446,000 SCFM (TOTAL - 2 BOILERS)
2
2
223 MM (EQUIVALENT)? TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM s 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
NEW
MAY, 1976
OPERATIONAL
95X (BOO PPM AT INLET)
REMOVED BY PRECEDING ESP (99.5X)
OPEN LOOP: L/G = 15-20 GAL/1000 ACF
HOLDING POND FOR EVAPORATION
NA2S03/S04 LIQUOR DISPOSED TO COLLECTION POND - NO PRIOR
AERATION. LANDFILL IN THE FUTURE
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
FMC CHEMICAL CORP. HAS A SODA ASH PLANT IN GREEN RIVER, WYOMING. THE PLANT HAS TNO COAL-FIRED
POWER BOILERS WHICH BURN 1.0 PERCENT SULFUR COAL. THE FLUE GAS FROM EACH BOILER (330,000 ACFM AT
320 F) IS TREATED BY A HOTSIOE ESP WITH 208 PLATES AND A PARTICULATE REMOVAL EFFICIENCY OF 99.5 *.
THE FLUE GASES ARE SCRUBBED BY THE PLANT END-LIQUOR IN TWO SCRUBBERS, EACH WITH THREE PAIRS OF
OISC-AND-OONUT TRAYS. THE SCRUBBERS AND THE DISCS ARE LINED WITH CEILCOTE 103 WHEREAS THE DONUT
PARTS OF THE TRAYS ARE MADE FROM INCONEL 825. THE 3CRUBBFR LIQUOR IS MAINTAINED AT A PH OF 6.5 AND
IS RECIRCIILATED AT A RATE OF 15 - 20 GALLONS/1000 ACF OF FLUE GAS. A PART OF THE RECIRCULATING
LIQUOR IS CONTINUOUSLY PURGED TO REMOVE SULFITES AND SULFATES FORMED BY THE REACTION OF 302 WITH
SODA ASH. THE RECIRCULATING PUMPS AND THE RELATED PIPING IS RUBBER LINED. A MESH-TYPE OEMISTER IS
USED IN EACH SCRUBBER. THE GASES ARE REHEATED BY DIRECT FIRING OF NATURAL GAS AT THE EXIT OF THE
SCRUBBERS. THE REHEATED FLUE GAS IS MIXED NITH BYPASSED GAS BEFORE GOING TO THE STACK AT ABOUT
»80 F. DAMPERS WITH REMOTE CONTROLS REGULATE THE FLOW OF OFFGAS THROUGH AND AROUND THE SCRUBBERS.
*PPROXIMATELY SOX OF THE TOTAL FLUE GAS IS RUN THROUGH THE SCRUBBERS.
AUTOMATIC CONTROLS MAINTAIN SOLUTION LEVEL IN THE SCRUBBER BASIN. THE PRIMARY SOURCE OF WATER
HAKE-HP IS PROCESS WASTEWATFR WHICH IS CHANNELED TO A MAKE-UP TANK. IF MORE MAKE-UP IS REQUIRED,
57
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
FMC (SODA ASH PLANT): GREEN RIVER, WYOMING (CONTINUED)
RIVER HATER IS TAPPFD. THE SCRUBBER BLEED STRMM IS DISCHARGED TO A WASTF POND AT A HATE OF ?00-2-j«
GPM AT THE SITE.
REFER TO FIGURE 14-11 IN SECTION Ifl FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1977 SOME PROBLEMS OCCURRED WITH THE SCRUBBER LINING AS A RESULT OF FAULTY
INSTALLATION. THE POSSIBILITY OF RUNNING THE SYSTEM WITH NO REHEAT WAS BEING INVESTIGATED.
4TH OUARTER-1977 THE SCRUBBERS CORRODED AS A RESULT OF FAULTY INSTALLATION OF THE LINING.
THE IMPURITIES IN THE SCRUBBING LTQIIOR CAUSE FOAMING AND SEDIMENTATION ON THE TRAYS.
1ST OUARTER-1978 PIPELINE FHEEZUPS, AND LEAKS FROM THE VANE DAMPERS WERE THE MAIN PROBLEM AREAS.
2ND OUARTER-1978 THE DEMISTER WAS PLUGGED. AND THE RFCTRCULATION PUMP WAS DOWN FOR SOME PERIOD.
PH CONTROL IS NOT VERY EFFECTIVE, CAUSING PH EXCURSIONS TO ABOUT ?.0. THIS HAS CAUSED SCALING IN
THE PIPELINES AND IN THE TOWER. FMC TESTS HAVE MEASURED 302 REMOVAL EFFICIENCY IN THE RANGE OF 87X-
94X> DEPENDING ON L/G AND PH.
3RD OUARTER-1978 TWO ANNUAL SCHEDULED OUTAGES OCCURRED DURING THIS PERIOD. ONE LASTED Z WEEKS
IN AUGUST WHILE THE OTHER LASTED I WEEK IN SEPTEMBER. MAINTENANCE OH THE FBI) SYSTEM DURING THESE
OUTAGES INCLUDED CLEANING OF THE SYSTEM AND FREEING OF THE OAHPFR. THE DAMPERS HAD A PROBLEM
OPERATING PROPERLY DURING COLD WEATHER. IT WAS DETERMINED THAT THE PUMP OUTAGE DURING THE 2ND
QUARTER WAS CAUSED BY A BROKEN SHAFT. THE SHAFT WAS REPLACED.
«TH OUARTER-1978 DURING THE REPORT PERIOD, NO MAJOR OPERATING PROBLEMS OCCURRED. ORIGINAL LINING
WAS REINSTALLED ON THE UECIRCULATTON PUMP WHILE USING A SPARE HUMP. THE BEARINGS OF THE SHAFT ON
THE LOUVER DAMPER WERE ADJUSTED FOR FREE OPERATION OF THE DAMPERS. NO SCALING PROBLEMS HAVE BEEN
REPORTED. THF RELIABILITY VALUE OF THE FGD SYSTEM HAS CLOSE TO 1001.
-------
STATUS TO JANUARY
SECTION 9 CCflNTtNUFn)
PERFORMANCE DESCRIPTION FOB OPFfcAIIONAI Fun SYSTEMS i)M INnUSTKTAL
INSTALLATION NAME
INSTALLATION IDCATION
SOURCE CHARACTERISTICS
SOURCF RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
808 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUD6E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOTORS TORPORAT IIlN
fiAYTfiw, ilHJfl
COAL(0.7T - 2.01 SULFUR)
3f>,000 SCF* (TOTAL - ? BOILERS)
54,000 ACFM ,1) 500F, FUR EACH OF TWO
1?<|,000 Lfl/HR STEAM (TliTAL)
18 Ml» (ElJIIIVALtNT) ; TOTAL - 2 BflTI E»S
(FOR THIS REPORT, UNLESS STATED OTHERWISE, ?«00 SCFM = 1 FQIIIVALFNT Mw.
THIS IS BFCAUSE GAS FLOW RATE rS THF PRIMARY FACTOR IN MOnilLF. SIZING.)
ENTOLETER, INC.
SODIUM HYDROXIDE SCRUBBING
RETROFIT
SEPTEMBER, 1974
OPERATIONAL
661 C1.«3 LB/MM BTU H INLET)
97.51 (0.107 LB/MM BTU 9 OUTLET)
50 6PM
WASTEHATER TREATMENT AND DISCHARGE TU CITY S£*ER
NAasns/sna i IQIIOR AT 35 GPM TO PN-SITE CIABTFICATION AND
DEMATERING FACILITY
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN DAYTON, OHIO, GENERAL MOTORS OPERATES A FACTORY WHICH MANUFACTURES BRAKES A*0 OTHER PARTS
FOR THEIR AUTOMOBILES. THE PLANT HAS TWO STOKER-FEED, COAL-FIRED BOILERS WHICH WERF INSTALLED IN
1954 BY BABCOCK AND WILCOX. EACH BOILER IS RATED AT 60,000 LB/HR STEAM, AND BURNS A MAXIMUM OF 3
TONS OF COAL PER HOUR. THE BOILERS ARE EOIIIPPED WITH INTERNAL MULTICLONES FUR PRIMARY PARTICULATF
CONTROL. THE STEAM GENERATED BY THESE BOILERS IS USED FOR BUILDING HEAT ANn PROCESS NEEDS. ONE
BOILER tS OPERATED CONTINUOUSLY THROUGHOUT THF YEAR AND THE OTHER IS OPERATED APPROXIMATELY 6 MONTHS
PER YEAR. THE MAJORITY OF THE TIME (8 - 10 MONTHS/YR) ONLY ONE BOILER IS IN SERVICE.
THE EMISSION CONTROL SYSTEM WAS DESIGNED TO CONTROL BOTH FLYASH AND 803, AMD WAS SUPPLIED AS A
RETROFIT APPLICATION BY ENTOLFTER, INC. IN SEPTEMBER 1970. tACH BOILER IS FOLLOWED BY A BOILER 1.0.
FAN, A PLENUM, AND A SCRUBBER P.O. FAN. THF PIFNUM CAN FUNCTION IN ONE HF THREF WAYS: IT CAM FEED
FLUE GASES TO THE SCRUBBER MODULE: IT CAN BYPASS THE GASES TO THt ATHOSPHFRF IN CASE HF A SCRUBBER
•»*LFUNCTIONJ OR IT CAN MIX AMBIENT AIR WITH W FLUE CASES IN CASE OF LOW L«UO IN ORDFH TO MAINTAIN
CONSTANT AIR FLOW TO THE SCRUBBFR FAN.
59
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STATUS TO JANUARY 1979
SECTION 9 (CINTINUFn)
t>FRFO»M«NCF DESCRIPTION FOR OPFKATIONAI. FRf> SYSTEMS ON INDUSTRIAL BUILEHS
GENERAL MOTORS CORPORATION; DAYTON, OHIO (CONTINUED)
THE SCRUBBER CONSISTS OF THF ENTOLtTtR "VANE-CARE" (5 FT. DIA. X 5 FT. HIGH) WHICH IS HOUSED IN
A CONICAL BOTTOM SFCIION (« FT. OIA. X 5 FT. HIGH), AN INTERMEDIATE SECTION (*. FT. DIA. X
5 FT. HIGH), Ann A DISENGAGEMENT 70NE (10 FT. DIA. X IS FT. HIGH). THE FLUE GAS (31,000 ACFM
9 SOOF) ENTERS THE BOTTOM SFCTION TANGENT!ALLY. RECIRCULATING LIWJOR IS SPRAYED FROM THE TOP OF
THE VANE CARE SECTION, WHICH CAN BE MOVED VERTICALLY TO VARY THE PRESSURE DROP ACROSS THE SCRUBBER.
A PRIMARY OEMTSTER IS LOCATED ABOVE THE PREVIOUSLY MENTIONED INTERMEDIATE SECTION AND A SECONDARY
DEMISTER IS LOCATED ATOP THE DISENGAGEMENT 70NE . THE GAS THEN PASSES THROUGH A STUB STACK TO THE
ATMOSPHFRF. SCRUBBtNR LIOIIOR IMPINGES ON THE BOTTOM OF THE VANE CAGE AND A SPRAY CHAMBER EFFECT
PROVIDES THF so? RFMOVAL. SCRUBBER UNDERFLOW, CONTAINING PARTICULATE AND A NA2so3/soa SOLUTION is
SENT TO THE RECYCLE TANK, WHERE MAKEUP WATER AT A RATE OF 50 GPM IS ADOF.O. RECYCLE PUMPS TAKE
LIQUOR FROM THE RECYCLE TANK TOP, ALONG NITH THE CAUSTIC STREAM ADDED AT A RATE OF 14 GALLONS
PER HOUR TO THE FEED LINE, AND RECIRCULATE IT TO THF TOP OF THE VANE CAGE AT A RATE OF 200 GPM.
THE L/6 RATIO IS 6 GAL/1000 ACF, AND A TYPICAL PRESSURE DROP ACROSS THE SCRUBBER IS 7 IN. NG. A
BLEED OFF FROM THE REC1RCULATION LINE (50 GPM) IS PURGED TO A WASTEWATER TREATMENT FACILITY, WHICH
CLARIFIES ALL THF PLANT WASTE STREAMS, ADJUSTS THE PH (7-0), AND DISCHARGES TO CITY SENERS.
ABSORBER MODULES, DEMISTERS, STACKS, AND THE RECYCLE TANK ARE CONSTRUCTED OF 316L STAINLESS
STEEL. THE SCRUBBER i-.D. FANS, PLENUMS, CAUSTIC TANK, CAUSTIC PUMP, AND INLET DUCTWORK ARE ALL
CARBON STEEL. THF RECIRCULATION PUMPS AND PIPING ARE RUBBER-LINED.
THE TOTAL INSTAI.LFD COST OF THE SYSTEM WAS (666,000 IN 1974 DOLLARS. THE AVERAGE OUTLET 803
CONCENTRATION IS 0.31 LB/MM BTU, WELL UNDER THE REGULATION OF 1.0 L8/MM BTU. THE OUTLET PARTICULATE
LOADING IS 0.107 LB/M" BTU AND THE REGULATION IS 0.177 L8/MM BTU.
PFFER TO FIRURE l«-!5 IN SECTION in FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH OIIARTFR-1974 UPON START-UP, SEVERAL PROBLEMS WERE ENCOUNTERED. PARTICULATE BUILDUP CAUSED
PLUGGING OF THE RECYCLE TANK DRAIN AND WASTE STREAM SUMP PUMPS. MR PURGE STREAMS WERE INSTALLED TO
ALLFVTATE THESE PROBLEMS.
1ST QUARTEH-1975 THE DAMPERS AND DAMPER CONTROL SYSTEMS HERE MAJOR PROBLEMS. THREE SETS OF
EXPANSION JOINTS HAD TO BE INSTALLED BEFORE ACHIEVING PROPER FLOW CONTROL.
ZHD OIIAHTER-1975 A FAN BEARING HAD TO BE REPLACED THREE TIMES.
JRD OUARTFR-1975 INSTRUMENTATION AND CONTROL PROBLEMS PROMPTED WIRING REVISIONS.
4TH OIIARTF»-1<»7«> THf FGO SYSTEM DEMONSTRATED AN AVAILABILITY OF 93 PERCENT
60
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STATUS in JANUARY
SFCUON 9 (CONTINUED)
E INSCRIPTION FOP OPFRAIIONAI pen SYSIFMS ON iNniisrwtii HHTI.FWS
GENERAL MOTORS CORPORATION; DAYTON, OHIO (CONTINUED)
1ST QUARTEK-1377 T*hR£ «FRE MECHANICAL PROBLEMS MTH THE v»t,E CAGK URIVt. THI- ACCESS IJOOK
DEVELOPED LFAKS AND THfc LIQUOR CORROOFO THE OUTER SURFACE OF THE INLET DUCT AROUND THE ACCESS DOOR.
aTM nUARfER-1977 CORROSION AM) PLUGGING PRflHLEMS CONTINUED TO HAMPER SCWUBftER OPERATIONS.
HOWEVER. USUALLY WHEN A SCRUBBER IS DOWN, THE OTHER BOILER IS FIRED UP WHILE REPAIRS AWE MADE TO THE
OOWNEO UNIT.
1ST IJIIARTFH-197H THE PRIMARY OFMISTER WAS SEVERELY CORRODED DUE TO ACID DROPPING DOWN ONTO IT
FROM THE UPPER PEMISTFK.
HMD QUARTFR-197« THE FOLLOWING SYSTEM MODIFICATIONS WERE BEING PLANNED: THF INTERMEDIATE SECTION
WILL BE REMOVED, THE PRIMARY OEMISTER WILL BE REPLACED BY A SIMILAR VANE-TYPE HASTELLOY-G OEMISTEH,
THE SECONDARY OEMISTES WILL BE REPLACED BY A RADIAL VANE HASTELLOY-G DEMISTER, AND A CONVEX
IMPINGEMENT BAFFLE PLATE OF HASTELLOY-G WILL BE INSTALLED ABOVE THE PRIMARY I1EMJSTER TO ASSIST IN
RAPID DRAINAGE OF THE ACID DROPLETS.
3RD QUARTFR-197* THE MODIFICATIONS DESCRIBED IN THE ?ND OUARTER 1978 ARE STILL IN THE DESIGN PRO-
CESS. WORK INCORPORATING THE MODIFICATIONS SHOULD BEGIN ABOUT THE END OF OCTOBER.
THE SCRUBBER LINING OF COAL TAR EPOXY WAS A8RADEO IIFF AND A CARP.OLENE LINER WAS INSTALLED.
THIS LINING HAS BFE1 FLAKING OFF TN PLACES.
THE PH PROBES AND PH MONITORING SYSTEM ARF BEING REDESIGNED SINCE THE SYSTEM CURRENTLY IN USE
SEEMS TO BF CONTINUALLY OUT OF CALIBRATION. AN ULTRASONIC CLEANER WAS INSTALLED BUT IS NOT WORKING
WELL. THE PH MONITORING SYSTEM IS A DUAL PROBE SYSTEM WHICH ALLOWS A PROBE TO RE IN USE WHILE THE
OTHER IS CLEANED.
«TH QIIARTFR-197* 01IRING THE REPORT PERJUO THE SCRUBBERS WERE RECONSTRUCTED. NE« HASTELLOY-6 MIST
ELIMINATORS *FRE INSTALLED, AS DESCRIBED IN ?ND OUARTER-i<»7«. WORK IS SCHEDULED TO BEGIN ON
INSTRUMENTATION MODIFICATIONS ABOUT MID-JANUARY. THESE INCLUDE REMOVAL OF THE FLUE GAS FLOW SENSORS
AND INSTALLATION OF A NE* PH MONITORING SYSTEM. *ORK WILL 8E DONE ON ONE MODULE AT A TIME, AND
ONLY IB HOURS OF MUTUAl DOWNTIME ARE EXPECTED FOR HOOK-UP. THE PHENOL SCRUBBER LINING SUPPLIED BY
CARBOLINE HAS FLAKED OFF. NO PLANS CURRENTLY EXIST TO RELINE THE SCRUBBERS.
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STATUS TO JANUARY 1979
SECTION <» (CONTINUED)
PERFORMANCE OESCRIPTTON FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW t RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
803 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
PARMA, OHIO
COAL C2.5X SULFUR)
las.aoo SCFM (TOTAL - « BOILERS?
3?0,000 LB/HR STEAM (TOTAL)
1
4
6S M»s (EQUIVALENT); TOTAL - « BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 3CFM = \ EQUIVALENT
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZINE
GM ENVIRONMENTAL
DOUBLE ALKALI (DILUTE)
RETROFIT
MARCH, 1970
OPERATIONAL
90% (800-1300 PPM 3 INLET)
e« (AT INLET: UNITS i«? - 1.75 LB/CIN; UNITS s*« - i.es
LB/MJN)
CLOSED LOOP
OEWATERED SLURRY TO LANDFILL
50*1 SOLIDS (CAS03/SO*)) SLUDGE TO DRYING POND AND LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE CHEVROLET PARMA PLANT OF GENERAL MOTORS IS LOCATED NEAR CLEVELAND, OHIO. THE PLANT HAS FOUR
SPREADER-STOKER BOILERS FIRED BY TRAVELING GRATES, CAPABLE OF PRODUCING A TOTAL OF 320,000 LB/HR OF
STEAM AND GENERATING 138,
-------
STATUS TO JANIJAWT 1970
SECTION Q (CONTINUED)
PERFORMANCE DESCRIPTION FOP OPFWM T'INAI FRO SYSTEMS DM INDUSTRIAI wnn FVS
GENERAL MOTORS CORPORATION; PARMA, OHIO (CONTINUED)
FROM 136-?«?0 PPM FOR THF SCRUHMERS.
THE SULFUR DIOXIDE CONTAINED IN THE HfllLEH FLUE r,AS IS ABSORBED BT A REGENERATED CAUSTIC
SOLUTION fO.l MOLAR NAOH), FORMING A SOLUTION OF SOLUBLE SODIUM SALTS. THE SPENT CAUSTIC IS THEN
REGENERATED fl* REACTING" THE SODIUM SALT SOLUTION WITH SLAKED LIME, RESULTING l'-t THF FORMATION OF
CALCIUM SULFITE'SIII.FATE SOLIDS, WHICH ARE SEPARATED OUT OF THF SOLUTION. NEXT, SODA »SH !S
ADDED TO THE SOLUTION IN ORDER To MAKE UP FOR SODIUM LOSSES AND MINIMIZE THE SCALE POTENTIAL FROM
THE CALCIUM WHICH REMAINS IN SOLUTION. THE REGENERATED CAUSTIC FORMF.n IS THEN RECYCLED HACK TO THE
SCRUBBER POR ADDITIONAL SULFUR DIOXIDE »E»OVAl. THF CALCIUM SALT AND FLY ASH SLUDGE VsHtC* RESULTS
IS DEWATEREO AND HAULED AWAY BY TRUCK TO AN OFF-SITE LANDFILL.
EQUIPMENT SPECIFICATIONS
SCRUBBERS. EACH OF THE 4 SCRUBBERS IS 10.S FT OIA X ?2.S FT HIGH X It GAUGE THICK AND CONTAINS 3
BUBBLE-CAP TRAYS. ALL THE SCRUBBERS AND TRAYS AHE MADE OF JlbL SS. THE SCRUBBERS HAVE A TIISNDOwN
RATIO OF 3 AND ALSO HAVE A BYPASS DUCT. THE DFSIGN L/G RATIO IS ?.0 GALLONS/ACF HUT THIS
MAY BE VARIED DURING OPERATION. THE PRESSURE DROP ACROSS THE SCRUBBER RANGFS BETWEEN 8-9 IN. «G.
OEMISTERS. ORIGINAL 316 SS MIST ELIMINATORS Wt RE CORRflOFD DUE TO CONOENSA T III* AND WERE «KPLACpn BY
FLEXIMESH-TYPE POLYPROPYLENE MIST ELIMINATORS.
RECYCLE TANKS/PUMPS. ALL THE a RECYCLE TANKS ARE MILD STEEL WITH TAR TYPF RESIN COATING. THE PUMPS
(6 TOTAL. 2 SPARE) ARE CENTRIFUGALS WITH MILD STEEL CASING ANO HAVF RUHKER I(MINGS. THF PUMP MOTORS
ARE aO HP.
CHEMICAL MIX TANKS * AGITATORS. BOTH THE MIX TANKS ARE MILD STEEL *ITH 500(1 GALLONS CAPACITr. THE
DESIGN RESIDENCE TIME IS 7 MINUTES. NEW AGITATORS ARE PROPELLER TYPE. THESE ARE SPECIALLY DESIGNFO
TO BIVE HIGHER FLOW RATE THROUGH THE BLADES. THE DRIVE RATINGS ARE 5 HP AND 05 WPM.
CLARIFIERS. BOTH THE CLARIFIERS (60 FT DIA X 10 FT LIQUID DEPTH) HAVE A CONICAL ROTTOM ANO 300,000
GALLONS CAPACITY. THE DESIGN RETENTION TIME IS ABOUT a HOURS AT A FLOW RATF OF 1?00 GPM.
VACUUM FILTERS. BOTH THE VACUUM FILTERS HAVE 500 SO. FT. OF SURFACE AREA KtTH A 10 FT DRUM DIA-
METER. THE DRUM DRIVE SPEED IS u.5 RPM MAXIMUM.
FILTRATE TANK/PUMPS. THE TANK (9 FT DIA X 7 FT HIGH) IS MRO STEEL AND HOLDS 6ftO GALLONS OF
FILTRATE. THE PUMPS ARE MILD STEEL, CENTRIFUGAL AND HAVE A CAPACITY OF 300 RPM »T 15 FI. OF HEAD.
EARLY PROBLEMS AND SOLUTIONS
THE SYSTEM WAS STARTED UP ON FEBRUARY ?fl, !<»7a ANO BY APRIL Tl, IT MAO OPERATED FOR 36« HOURS.
THERE WFRF TWO SCHEDULED SHUTDOWNS DURING THIS PERIOD FOR EQUIPMENT INSPECTION:. THE SFCOND SHUTDOWN
-------
STATUS TO JANUARY 1971
SFCT10M <* (CnivTINUFO)
PERFORMANCE DESCRIPTION FOB flPITHAT ItJNAl FRO SYSTEMS ON INDUSTRIAL BOILERS
GENERAL HOinRS CORPORATION; PARMA, OHIO (CONTINUED)
REVFALED THAT SOLIDS «*FRE NOT BEING DISCHARGFO FROM THE PRIMARY CLARIFtER RAPIDLY ENOUGH.
AS * RESULT, THE CLARIf-IER RAKE JAMMED. A PIPING CHANGE HAS MADE TO BLEND THE CAUSTIC FEED
IN KITH THE RFCYCLE LIOUOR. THIS IMPROVED PFRFORMANCF BUT DID NOT COMPLETELY ELIMINATE
THE PROBLFH. PREMATURE CAKE CRACKING IN THE VACUUM FILTERS REQUIRED THE PRESENCE OF AN OPERATOR
DURING OPERATION. CAKE WASHING TO REDUCE LOSSES HAS NOT INITIALLY SUCCESSFUL BECAUSE THE SPRAY
HATER TENDFD TO KNOCK THE CAKE OFF THE DRUM. ALTERATIONS IN SPRAY PATTERN AND OTHER MEASURES
APPARENTLY SOLVFO THIS PROBLEM. THERE HAS NO EVIDENCE OF CORROSION OR ABRASION IN THE PUMPS
OR PIPING.
THE SYSTEM HAS SHUT DOHN FROM MAY 1 TO MAY SB, 1970, BECAUSE OF UNEXPECTED BUILDUP OF SOLIDS IN
THE CLARIFIER, HITH SUBSEOUENT OVERFLOW INTO THE SCRUBBER. THE PROBLEM HAS SOLVED BY H USING
A POLYMERIC FLOCCULATION AGENT TO ATTAIN BETTER SETTLING AND 2; WITHDRAWING SLUDGE FROM THE
CLARIFIER AT MORE FHEOUENT INTERVALS. SYSTEM AVAILABILITY TO THE BOILER HAS 87 PERCENT IN APRIL
1974. LESS THAN 10 PERCENT IN MAY, AND 100 PERCENT IN JUNE, JULY, AND AUGUST AFTER THE SYSTEM HAS
RESTARTED. PLUGGING BY GYPSUM DEPOSITS IN THE OVERFLOW LINE BETWEEN THE CLARIFIERS AND IN THE
LINE FROM CLARIFIER NO. 2 TO THE MIX TANKS HAS CORRECTED BY RELOCATIN6 A CHEMICAL FEED LINE AND
REPLACING SOME PIPING. THE SYSTEM HAS DOHN THROUGH JULY AND AUG. 1975 FOR REPLACEMENT OF GRAVITY
FLOH LINES HITH AN OPEN FLUME THAT CAN BE EASILY CLEANED. THE OPERABILITV INDEX FOR THE FGD SYSTEM
INCREASED SIGNIFICANTLY THROUGHOUT THE COURSE OF 1976.
REFER TO FIGURE 11-16 IN SECTION 14 FOP A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
OPERATION HOURS
MONTH BOILER FGD SYSTEM OPERABILITY (X)
MAY-JUN. 75
THE SYSTEM HAS RESTARTED AND PARTICULATE TESTS HERE CONDUCTED IN MAY. THE SYSTEM HAS SHUT DOWN DUE
TO PLUGGED CHFMICAL FEED LINE TO THE CLARIFIER AFTER RESTART. AROUND JUNE 10, THE SYSTEM WAS
SHUTDOWN BECAUSE OF SIMILAR PLUGGING IN ANOTHER PART OT THE LINE. THE UNIT RAN FOR ABOUT TWO HEEKS
IN JUNE.
JUL.-AU6. 75
THE FGD SYSTM HAS OOHN IN JULY AND AUGUST FOR REPLACEMENT OF GRAVITY FLOH LINE WITH AN OPEN FLUME.
OCT. 75 2331 184« 79
THE FGD SYSTEM RESTARTED ON SEPTEMBER B, AND OPERATED DURING THIS PERIOD AT AN AVAILABILITY FACTOR
OF »0 PERCENT. THE FIGURES GIVEN FOR OCTOBER REPRESENT THE OPERATION HOURS FROM SEPTEMBER 8 TO "
NOVEMBER 9.
DEC. 75 2135 1250 59
HOLIDAY SHUTDOWN FROM 12/?3 TO 1/4. DUE TO PROBLEMS WITH SOLIDS AND SOLIDS CARRY-OVER. G.M. CON-
-------
STATUS 10 JAMtAHY
SECTION 9 rcflNriMIJF.01
PERFORMANCE DESCRIPTION FOR OPFKAITONAI rr,n SYSTF^S ON INOI.-STHIAI HOTLFHS
GENERAL MOTOKS CORPORATION; PARMA, OHIO (CONTINUED)
OPERATION HOUPS
MONTH BOILER FRP SYSTEM OPERARILITY (Z)
OIICTEn STPFAM TFSTS DURING DECEMBER TO DETERMINE HHFTHER THE CARRY-OVER OF SOLIDS WAS OIIE TO A HIGH
SOLIDS RFCIRCULATION PATE. IMF FRO SYSTEM *SS DOWN MOST OF DECEMBER BECAUSE OF THESF TFSTS, WHICH
CAUSED THE I OW flPF.RABILITY FACTOR.
FEB. 76 B997 H9b «0
G.M. HAS FiJHi'l) SOLIDS CONCENTRATION IN THE HLARTFIfcR TOO HIGH FOR EFFICIENT SYSTEM OPERATION. 4.0.
LITTLF WAS SCHEDULED TO CONDUCT TESTS ON THE SYSTEM IN APRIL AS PART OF AH' FPA EVALUATION PROGRAM.
MAR. 76 IS79 SDH J
APR. 76 10HO 807 78
THE IOW OPERARILITY INDEX DURING THE MONTH OF MARCH RESULTED FROM EXTENSIVE MODIFICATIONS PERFORMED
ON THE SYSTEM BY G.M. DURING THIS PERIOD THE SCRUB8FR SLOWDOWN AND SCRUBBER FLO* INDICATION SYSTEM
WAS REVISED. FROM APRIL 19 TO THE END OF THE MONTH THE SYSTEM KAS OPERABLE 1001. DURING THIS
PERIOD ALL SYSTEM MODIFICATIONS WERE COMPLETED AND ALL MAJOR PROBLEM AREAS CORRECTED.
MAY 76 Jl«9 J042 91
JUN. 76 <*?* 8Jft 88
ONE SYSTEM UPSET OCCURRED DURING THE PERIOD DUE TO AN OPERATOR ERROR. BOILER HOURS HERE LOM IN JUNE
BECAUSE OF LOU PROCESS DEMAND. THE SCRUBBING SYSTEM CHARACTERIZATION STUDY WAS CONCLUDED ON MAY Ifl.
JUL. 76 S99 509 100
AUG. 76 715 715 100
THE BOILER LOAD DEMAND WAS VERY LIGHT DURING THE REPORT MONTHS, REOU1RING ONLY ONE BOILER BEING
CONTINUOUSLY ON L1NF. THE SYSTEM WAS DOWN FOR A ONF-WFFK PF.KTQO BECAUSE OF THE ANNUAL PLANT
INVENTORY. MODIFICATIONS TO THE OPERATION OF THE OF THE GAS SCRUBBING SYSTEM HAVE INCLUDED:
ELIMINATION OF POLYMERIC ADDITION.
ELIMINATION OF SLUDGE BLANKET FOR FILTRATION.
HIGH PFHCF.NT SULF»TE CONCENTRATION IN THE FILTER CAKE.
INCORPORATION OF PH CONTROLLER IN THE CHEMICAL Mix TANK REGULATING THE LIME FEED INTO SYSTEM.
PH CONTROL SHOIJI ft REDUCE THE STOICHIOMFTRIC REQUIREMENTS FROM THE l.?5-1.50 RANGE DOWN TO
1.10-1.20.
SEP. 76 H09 ggi HO
OCT. 76 1171 714 63
TWO BOILERS AND THEIR CORRESPONDINK SCRUBBER MODULES WERE IN SERVICE DURING THE MONTH. OPERATION
TIME WAS LOORFD PRIMARILY IN THE INITIAL PART OF THE MONTH. A NUMBER OF PROBLEMS WERE ENCOUNTERED,
FORCING A SHUTDOWN THROUGHOUT THE REMAINDER OF THE MONTH. THESE INCLUDED:
SOLIOS OPPOSITION AND PLU8GING OF THF CHEMICAL TANKS AND REACTORS, HEOIIIRING SHUTDOWN/CLFANOUT.
-------
STATUS TO JANUAkY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL ROlLfHS
GENERAL MOTORS CORPORATION; PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER FGO SYSTEM OPERABILITY (X)
REPLACEMENT OF OEMISTER PADS.
AGITATOR PROBLEMS.
THE SYSTEM MAS RETURNED TO SERVICE THE SECOND KEEK IN OCTOBER. TWO BOILERS AND THEIR CORRESPONDING
SCRUBBERS WERE PUT BACK IN THE GAS STREAM. PROBLEMS ENCOUNTERED STEMMED PRIMARILY FROM A MECHANICAL
COLLECTOR MALFUNCTIONING RESULTING IN EXCESSIVE PARTICULATE LOADING IN THE MODULES AND EVENTUALLY
CAUSING WIDESPREAD PLUGGING OF THE LOWER BUBBLE-CAP TRAYS. SHUTDOWN AND CLEANOUT OF MODULES PLUS
REPAIRS TO THE MECHANICAL COLLECTOR MERE REQUIRED. SYSTEM RESTART OCCURRED NOVEMBER 8.
MAJOR MODIFICATIONS PERFORMED TO THE DOUBLE ALKALI SYSTEM DURING THE PERIOD INCLUDED THE INSTAL-
LATION OF A GREAT LAKES PH MONITOR AND CONTROL UNIT FOR THE REGULATION OF LIME FEED TO THE REGEN-
ERATION REACTOR-CLARIFIES UNIT. THIS UNIT EMPLOYS A DIGITAL READOUT AND WAS SCHEDULED FOR OPERATION
SOMETIME IN (NOVEMBER. SUPERIOR CRYSTAL GROWTH OF THE CALCIUM SULFITE/SULFATE SALTS RESULTED PY
RUNNING A SEEDING LINE BACK TO THE REACTOR-CLARIFIER UNIT.
NOV. 76 1321 787 60
DEC. 76 1559 349 22
DURING THE L*TTER P«RT OF NOVEMBER AND EARLY DECEMBER, THE SCRUBBERS WERE TAKEN OUT OF THE FLUE GAS
PATH BECAUSE OF CONTINUED SOLIDS BUILDUP IN THE MIX TANK. IN ADDITION, SOME PIPING ARRANGEMENTS
MERE MODIFIED AND THE GEAR REDUCER IN THE MIX TANK HAD TO BE REPLACED. THE FGD FIGURES REPORTED FOR
THE MONTH OF DECEMBER ARE NOT FULLY REPRESENTATIVE BECAUSE IT IS PART OF THF LOCAL HAW CONTRACT THAT
ONLY UAH PERSONNEL CAN OPERATE THE FGD SYSTEM AND THEREFORE THE SCRUBBERS COULD NOT BE OPERATED.
JAN. 77 J852 608 33
FEB. 77 1462 892 61
THERE WAS A FAILURE OF THE AGITATORS AT THE MIX TANKS. THEY WERE LATER REPLACED WITH NEW ONES.
THE PLANT MAS SHUTDOWN FOR SOME PERIOD DUE TO CUTBACK OF NATURAL GAS SUPPLY AND REUUEST TO CURTAIL
ELECTRICAL CONSUMPTION.
APR. 77 1300 1158 89
MAY 77 1222 1118 92
BOILER HOURS MERE LOW DUE TO REDUCED SUMMER REQUIREMENTS.
JUN. 77 1180 1103 94
JUL. 77 702 276 39
THE FGD SYSTEM GAVE A VERY HIGH OPERABILITY FOR JUNE. THE FGD SYSTEM MAS DOWN FOR A CONSIOERA8LF
PORTION OF JULY. THE CHEMICAL MIX TANK BLEED OFF LINES AND OTHER PIPING HAD TO BE CLEANED OF
SEDIMENTED SOLIDS.
AUG. 77 755 678 90
SEP. 77 7*4 480 71
-------
STATUS TO JANUARY 1<179
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FDR OPERATTONAI. FGD SYSTFMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER FSO SYSTEM OPERABILITY (X)
DURING THIS LOW-LOAD PERIOD THE LIME FEED PUMP AND LIME FEED LINES WERE CLEANED. GENERALLY, EVERY
SUMMER AN ANNIIHL FGD OVERHAUL IS CARRIED OUT.
OCT. 77 1277 398 '31
NOV. 77 1380 980 67
DEC. 77 1790 968 5«
THE CHEMICAL MIX TANK AGITATORS WERE TOTALLY REDESIGNED AND REPLACED BY HIGH-CARSON STEEL. PROPELLER
TTPES. THE BLADES WERE SPECIFICALLY DESIGNED TO INCREASE THE FLO* THROUGH THE PROPELLERS, THUS
INCREASING THE INTENSITY OF MIXING. DUE TO THANKSGIVING HOLIDAYS IN NOVEMBER AND CHRISTMAS AND NEW
YEAR HOLIDAYS IN DECEMBER. THE FGO SYSTEM HAD LOWER OPERATION HOURS. SOME OF THE BOILERS HAD TO BE
RUN FOR BUILDING MAINTENANCE.
1ST OUAHTER-1978 THE BOILERS OPERATED FOR 3370 HOURS WHEREAS THE FGD OPERATED FOR 70 HOURS.
THE OPERABILITY INDEX WAS THEREFORE 1.25X. THE RAKE SHAFT IN THE THICKENER WAS BROKEN IN EARLY
JANUARY. THERE WAS A CONSIDERABLE DELAY IN RECEIVING REPLACEMENT PARTS. IN ADDITION, SEVERE WINTER
(BLIZZARD* HEAVY SNOW) MADE IT IMPOSSIBLE TO PERFORM ANY REPAIRS.
ZHD OU»RTER-t978 THE F6D SYSTEM OPERATED FOR 3669 HOURS, AND THE BOILERS OPERATED FOR 3an HOURS.
THE OVERALL OPERABILITY WAS 78.8 PERCENT. IN APRIL, THE PIPELINES WERE FLUSHED AND CHEMICAL TANKS
HERE CLEANED ALONG WITH SCRUBBER INTERNALS, STACKS AND MIST ELIMINATORS. IN JUNE, THE AVAILABILITY
HAS 100 PERCENT. DURING THE SUMMER QUARTER, USUALLY A LOW-LOAD PERIOD, SEVERAL MODIFICATIONS MERE
SCHEDULED. NEW VACUUM PUMPS AND FILTERS WILL BE INSTALLED, AND THE LIME SLURRY FEED PUMPS
HILL BE REPLACED BY DIAPHRAGM PUMPS TO AVOID PLUGGING OF CONTROL VALVES. THE NEW FILTER CLOTH, MADE
OF POLYPROPYLENE, HAS GIVEN MUCH LONGER FILTERING LIFE (ABOUT 3 MONTHS) THAN THE OLD ONE, MADE OF
NYLON. THIS IS DUE TO THE POOR FILTERING CHARACTERISTICS OF THE NYLON (PLUGGING).
SRO OUARTER-1978 ?QH THIS PERIOD THERE HAS BEEN NO DOWNTIME DUE TO EQUIPMENT OR PROCESS FAILURE.
WARREN-RUPP DIAPHRAGM PUMPS WERE INSTALLED TO REPLACE THE EXISTING LIME SLURRY FEED PUMPS. THE
PLANT REPORTED loos OPERABILITY.
«TH OUARTER-1978 DURING OCTOBER AND NOVEMBER THE BORERS OPERATED 3815 HOURS AND THE FGO SYSTEM
OPERATED 670 HOURS FOR AN OPERABILITY OF S3.81. NEW FRP STACKS (9.5 FT. OIA. X 38 FT. HIGH) WERF
MOUNTED ON TOP OF THE ABSORBERS, REPLACING THE OLD STAINLESS STEEL-LINFD ONES WHICH WERE BADLY
CORRODED. MODIFICATIONS WERE MADE TO THE TOP OF THF SCRUBBERS. THESE INCLUDED ENLARGING THE
OPENING TO THE STACK TO RFOUCE THE GAS VELOCITY, AND REPLACING THE FLEXTMFSH MIST ELIMINATOR WITH A
POLYPROPYLENE CHEVRON DEMISTER. DURING THE RECONSTRUCTION, WATERLINES WERE TESTED IN PREPARATION
67
-------
STATUS Til JANUARY 1979
o (CONTIMUFI)J
DESCRIPTION FO» OPFKAIIOMI. F&f) SYSTEMS ON TNDIISTKTAI BOILERS
GENERAL MOTORS CORPORA! riJMs PARMA, OHIO (CONT TNMEO)
FOR HINTER AND THF NFW VACUUM FILTER PUMPS WKf^ t«»STAlLfO. PFAK BOILER LOAPS FOR THIS WINTER ARE
EXPFCTED TO BE ABOUT 175,000 LBS/HOIJR MjTM 3 BOILFHS OPERATING SIMULTANEOUSLY.
6fi
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOB (IPf WAT IdNAL FED SYSTEMS ON INDUSTRIAL RnlLFkS
INSTALLATION NAME
INSTALLATION LOCATinN
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SVSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
PONTIAC. MJCMTGAN
COAL (O.SaX SULFUR)
ALSO MOOD, PAPER, AND CARDBOARD.
107,300 SCFM (TOTAL - 2 80UERS)
350,000 LB/HR STEAM (TOTAL - S BOILERS)
2
?
53 M* (EQUIVALENT)» TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE* 2000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THF PRIMARY FACTOR IN MODULE SIZING.)
GM ENVIRONMENTAL
SODIUM HYDROXIDE SCRUBBING
NEW
APRIL, 1976
SYSTEM OPERATED TWO MONTHS IN EARLY 19T3.
OPERATIONAL
NOT DETERMINED
851
OPEN LOOP; 50 GPM
DEWATERED SLURRY TO LANDFILL
5X SOLIDS SLURRY DEWATERFD AND TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GENERAL MOTORS TRUCKS AND COACH PLANT LOCATED AT PONTIAC, MICHIGAN OPERATES SEVERAL BOILERS
TO GENERATE STEAM FOR BUILDING HEAT AND PROCESS REQUIREMENTS. TWO OF THESE BOILERS, NOS. 6 AND 8,
ARE SPREADER STOKERS AND FIRE A MIXTURE OF COAL (O.BOX SULFUR) AND SOLID REFUSE (PAPER AND CARD-
BOARD). BOILER NO. 6, INSTALLED IN 197? BY ERIE CITY, IS HATED AT 188 MM BTII/HR OR ISO,000 LBS/HR
OF STEAM. BOILER NO. fl, INSTALLED IN 197? BY RILEY, IS RATED AT 250 MM BTU/HR OR 200,000 LBS/HR
OF STEAM. THE PARTICULATE EMISSIONS ARF CONTROLLED BY MECHANICAL COLLECTORS SUPPLIED BY ZURN
INDUSTRIES, DESIGNED TO OPERATE AT 93X EFFICIENCY, WITH A PRESSURE DROP OF ABOUT 3 IN. N6.
PEABODY ENGINEERING SUPPLIED 2 WET SCRUBBERS IN APRIL 1976, PRIMARILY FOR ADDITIONAL PARTICULATE
CONTROL. EACH SCRUBBFRU2 FEET DIA X 21.5 FEET HIGH) CONTAINS 5 IMPINGEMENT TRAYS AND OPERATFS
«1TM AN L/G OF 5 GAL/1000 ACF. THE SCRUBBER EFFLUENT IS MIXED WITH CAUSTIC AND MAKEUP WATER IN A
HOLD TANK, AND PUMPED TO A CLARIFIER. THF OVERFLOW IS RECYCLED TO THE SCRUBBER, THUS SIGNIFICANT
302 CONTROL IS ACHIEVED. THE UNDERFLOW IS SENT TO A WASTE TREATMENT PLANT, WHERE THE FLYASH IS RE-
MOVED AND LANDFILLEO. THE EFFLUENT DISCHARGF FROM THE WASTE TREATMENT PLANT TS 10 - 25 6PM.
-------
STATUS TO JANUARY 1979
SFCTIOta 0 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPFKATTONAI FRO SYSTFMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PONTIAC. MICHIGAN (CONTINIIEO)
THE SCRUBBERS, TRAYS, AND MIST ELIMINATORS (RADIAL VANE TYPE) ARE ALL MADF OF 516L SS.
REFER TO FIGURE 18-17 IN SECTION la FOR A DETAILED PROCESS FLOW DIAGKAM OF THIS SYSTEM.
OPERATING HISTORY
3ND GUARTER-1976 UNSTABLE PH CONTROL AND WEAR OF MECHANICAL EQUIPMENT HANDLING THE FLYASH SLURKY
HERE MAJOR STARTUP PROBLEMS.
3RD OUARTER-1'm AN AVAILABILITY OF 100 PERCENT HAD BFEN REPORTED WHEN BURNING A MIXTURE OF COAL
AND REFUSE. THE SCRUBBER DISCHARGE SLURRY CAUSED NEAR DUE TO ITS FLYASH CONTENT.
4TH QUARTfR-1977 FLYASH ABRASION IN THE PUMPS AND PIPING CONTINUED TO BE THE PROBLEM.
1ST OU*RTFH-1<>78 FLYASH CAUSED SERIOUS EROSION OF LIOUIO HANDLING EQUIPMENT.
3ND OUARTER-1978 IT MAS DECIDED TO INSTALL PRESSURE FILTERS IN THE SCRUBBER EFFLUENT LINES TO
REMOVE FLYASH.
3BD OUARTER-1178 THE PRESSURE FILTERS WERE INSTALLED AND ARE WORKING WELL. NO OTHER
PROBLFMS OCCURRED DURING THE REPORT PERIOD.
«TM OU*RTER-1<»78 NO NEW OPERATING PROBLEMS DEVELOPED DURING THIS RFPORT PERIOD. THE PRESSURE
FILTERS HERE INSTALLED IN THE RECIRCULATION PIPING BETWEEN THE RECYCLE PUMP AND THE INLET TO THF
ABSORBER. THEIR PERFORMANCE THUS FAR HAS BEEN RATED AS EXCELLENT.
70
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STATUS 10 JANUARY
SFCTJON 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FED SYSTEMS ON INDUSTRIAL ROILFXS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
*
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
803 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
COAL C5.ST SULFUR)
64,000 SCFM (TOTAL - 2 BOILERS)
2
P
3S MB (TOTAL - a BOILERS)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM s J EQUIVALENT Ml*.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
A.O. LITTLE
SODIUM HYDROXIDE SCRUBBING
RETROFIT
197?
OPERATIONAL
90+1 (2000 PPM 3 INLET)
REMOVED BY PRECEDING CYCLONE AND FSP
OPEN LOOP
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
NA8S03 OXIDIZED TO NA3S04, PH NEUTRALIZED AND DISCHARGED TO
CITY SEWER SYSTEM
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GENERAL MOTORS CORPORATION PLANT LOCATED IN ST. LOUIS, MISSOURI OPERATES a COAL-FIRED BOIL-
ERS. THO OF THESE BOILERS, ONE PULVERIZED COAL-FIRF.D ANO THE OTHER A SPREADER STOKER, ARf RATED AT
A TOTAL OF 250,000 LB/HH STEAM ANO GENERATE ABOUT 60,000 SCFM OF FLUE GAS. COAL COMPOSITION IS
TYPICALLY 3.HI SULFUR AND 10X ASH. THE ST. LOUIS SOa EMISSION REGULATION OF l.a LBS/MM BTU APPLIES
ONLY FROM OCTOBER THROUGH MARCH, ANO THE SCRUBBERS OPERATE ONLY DURING THIS PERIOD. FLUE GAS FROM
ALL FOUR BOILERS EXITS THROUGH A COMMON STACK ANO SUFFICIENT FLUE GAS FROM THE TWO CONTROLLABLE
BOILERS IS SCRUBBED TO MAINTAIN THE REGULATION AT THE STACK OUTLET. THE REMAINING FLUE GAS BYPASSES
THE SCRUBBERS, AND A COMPLEX DAMPER SYSTEM ALLOWS PLANT PERSONNEL TO VARY THE SCRUBBER/BYPASS RATIO.
BOTH BOILERS ARE EUUIPPEO WITH CYCLONES FOR PAkTICULATE REMOVAL, AND THE PULVERIZED COAL UNTT ALSO
UTILIZES AN ESP.
THE SCRUBBER CONSISTS OF A THREE-STARE IMPINGEMENT TOWER WITH A CHEVRON MIST ELIMINATOR. THE
SYSTEM IS EQUIPPED WITH DIRECT STEAM COIL REHEAT. THE THAY TOwER AND MIST ELIMINATOR ARE CONSTRUC-
TED OF 316L STAINLESS STEEL.
71
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STATUS TO JANUARY 1479
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; ST. LOUIS. MISSOURI (CONTINUED)
OPERATING HISTORY
3RD QUARTER-1977 «N OPERABILITY OF IQOX HAS REPORTED DURING THE MAY-AUGUST PERIOD.
4TH QUAHTER-1977 IN SPITE OF A CHEVRON DEMISTER AND 60 f REHEAT, THE STACK LINER WAS CORRODED.
1ST QUARTER-lire THE OUCTMORK DOWNSTREAM OF THE SCRUBBERS DEVELOPED SOME LEAKS.
2ND QUARTER-I978 A HORIZONTAL PORTION OF THE DOWNSTREAM DUCTWORK,ABOUT 15-20 FEET IN LENGTH, HILL
BE REDESIGNED TO AVOID STAGNATION OF EXHAUST GASES
3RD OUARTER-1978 THE DOWNSTREAM OUCTMORK MAS RECONSTRUCTED DURING THE REPORT PERIOD.
4TH OUARTFR-1978 NO NEM FGD-RELATEO PROBLEMS HAVE DEVELOPED DURING THE REPORT PERIOD, HOWEVER.
THE PLANT HAS REPORTED THAT PLUME OPACITY HAS BECOME A PROBLEM.
72
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR fJPERAT JIJNAI. FED SYSTEMS ON INDUSTKJAl
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
HATF.R MAKF.-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOTORS CORPORATION
TONOPANDA, NEW YORK
COAL ft.HI SULFUR)
9?,000 SCFM (TOTAL - 1 BOILERS)
36(000 ACFM d 406 F, F0» EACH OF 3 FGD SYSTEMS
39,600 ACFM d 350 F, FOR 1 FGD SYSTFM
300,000 LB/HR STEAM (TOTAL - 9 BOILERS)
a
4
06 MW (EQUIVALENT)? TOTAL - 4 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM HYDROXIDE SCRUBBING
RETROFIT
JUNE, 1<)75
OPERATIONAL
90Z-95X (1,000 PPM 3 INLET)
90X (1.0 LB/MM BTU AT INLET)
OPEN LOOP
OEWATEREO SLURRY TO LANDFILL
FLY ASH AND NA2S03/S04 WASTE LIQUOR DEwATERED AND THEN TO
SANITARY LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE CHEVROLET DIVISION OF GENERAL MOTORS HAS A MOTOR PRODUCTION PLANT AT TONOWANDA, NEK YORK.
THERE ARE 4 COAL-FIRED BOILERS AT THE FACILITY WHICH BURN 1.16 PERCENT SULFUR COAL WITH A HEATING
VAtUE OF 12,650 BTU/LB. THE TOTAL COAL FEED RATE IS 17 TONS/HR WHICH IS FOUIVALENT TO 412 MM BTU/HR
WHICH IS EQUIVALENT TO 46 MW OF ELECTRICAL GENERATION.
ONE SCRUBBER HANDLES 39,000 ACFM AT 350 F WHEREAS EACH OF THE OTHER THREE 36,000 ACFM AT 406 F.
THERE IS A CYCLONF. BEFORE AND AFTER SCRUBBER FOR OUST COLLECTION AND MIST REMOVAL PURPOSES, RESPEC-
TIVELY. THE VARIABLE THROAT VENTURI SCRUBBERS WERE SUPPLIED BY FMC CORP. THE PH OF RECYCLE
SCRUBBER LtniJOR IS CONTROLLED AT 7.0 AND A L/6 RATIO OF 20 GALLONS/1000 ACF IS USED. PRESSURE DROP
ACROSS EACH SCRUBBER IS 10 IN. WG. CAUSTIC SODA IS AODFD TO THE SPENT LIQUOR IN A SEPARATE RECYCLE
T*NK. THE BLEED OFF RATE FROM THE RECYCLF TANK VARIES FROM 25 - 100 6PM. THE DISCHARGE CONTAINS
FLYASH AND SOOIUM SULFATE. THE FLYASH IS CONTROLLED AT LESS THAN It SUSPENDEn SOLIDS. THE EFFLUENT
IS OISCHARBFO TO THE WASTE TREATMENT PLANT AFTER AERATION. THE AVERAGE INLFT CONCENTRATIONS ARE
73
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOB OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION TONOMANOA, NEN YORK (CONTINUED)
8.«S LB/N« BTU OF SOZ AND i LB/NN BTU OF PARTICULATE. THE EFFICIENCY OF S02 REMOVAL IS 90* HHEREAS
TM«T Of PARTICIPATE REMOVAL IS 80«~9SS.
E*CN SCRUBBER AND THE CYCLONIC OEMISTER IS MADE OF 3I6L SS. PLUME REHEAT IS NOT INCORPO ATED
WTO TMf SYSTEM. THE ENER6Y REQUIREMENTS FOR THE SYSTEM ARE ABOUT S - 51 OF THE FUEL BURNED.
0CPCR TO FIGURE IB-IB IN SECTION !• FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
•D KHUTOR-1977 AVERAH OPERABILITT DURING THIS PERIOD MAS REPORTED TO BE 1001.
*TN OU*»fBNI*77 MAJOR PROBLEMS HAVE BEEN PH CONTROL AND RECYCLE PIPE EROSION. CONTROL
LATINS MIIER VALVE REPLACED FOR PH CONTROL AND CAST IRON PIPE MAS USED TO
8* RCCYCLE PIPING. DURING MOV - DEC CONDENSATION FOLLOWING THE OEMISTER
c
COmODEO THE STACK LINING. A DECISION HAS BEEN MADE TO RELINE THE STACK.
Mt OBMnt*-t«TS THE STACK MAS NOT RfLINED.
ONE MORE CYCLONE NIU. BE RETROFITTED AFTER EACH BOILER IN ORDER TO REDUCE THE
tttOIM TO THE SCHUBBERS.
MO OIM*TER-t*78 * MIST ELIMINATOR MILL BE INSTALLED TO PREVENT FURTHER CORROSION OF THE STACK
LtNtR. THE LINER HILL EITHER BE REPLACED OR COATED MTTH AN ACID-RESISTANT MATERIAL.
«T* OOMTER-1978 NO DEFINITE PLANS HAVE BEEN MADE REGARDING THE STACKS. THE ORIGINAL STACKS
(•MUTED ATOP THE ABSORBERS) ARE STAINLESS STEEL. THEY ARE CORRODED, BUT NOT BETOND USE. THE MIST
ELIMINATORS TO BE INSTALLED MILL BE CHEVRON-TYPE. THE MATERIAL HAS NOT BEEN SELECTED. BUT SOME SORT
or PLASTIC is CONSIDERED LIKELY. THERE ARE NO PLANS TO ADD CTCLONES FOLLONINC THE BOILERS, A FACT
rOUSLY REPORTED DUOINC THE 2ND QUARTER.
74
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STATUS tn .IANUAHY i<*7«
SFCTION 3 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPt-WAl lONAI. FGD SYSTF!,S UN INDUS1RTAI Hl
INSTALLATION NAMF
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
.START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTKULATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GEORGIA-PACIFIC PAPER CO.
CROSSFTT, ARKANS4S
BARK,COAL/OIL (1.5X - ?..OX SULFUR)
220,000 SCFM (I BOILHRI
1
\
110 MW (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHFHWISF, 2000 SCFM s \ EHUIVALENT Wrt.
TH]S IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
A1RPOL INDUSTRIES
CAUSTIC WASTE STHFAM
NEW
JULY, ms
OPERATIONAL
BOX »500 PPM 3 INLET)
90X (0.5 GH/SCF AT INLET)
OPfN LOOP; SCRUBBED WITH 2,100 6PM "BLACK WATER" FROM PULP
MILL.
WASTFWATER TREATMENT ANO DISCHARGE TO CITY SEHER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGD SYSTEM AT GEORGIA-PACIFIC PAPER CO., CROSSETT, ARKANSAS UTILIZES A CAUSTIC PULP MILL
WASTEWATER STREAM (BLACK HATER) TO REMOVf PARTICULATF ANO S02 FROM FLUE GAS GENERATED HY A BARK/OIL
OR BARK/COAL BOILER. THE BOILER IS AN ERIE CITY POWER BOILER RATED AT 600,000 LB/HOUR STFAM, ANO
SENERATES 220,000 SCFM OF FLUE GAS, HHICH IS EUUIVALENT TO HO MW OF ELECTRICAL CAPACITY. THE
NORMAL OPERATING RANGE IS BETWEEN aOO,000 ANO 500,000 LBS STFAM/HOUR WITH AN OPERATING SCHEDULE t'F
2« HOURS/DAY, 359 DAYS/YEAH. IT IS ONE OF ELEVFN HOILERS THAT TllBN 5 TURBINES AND SENEHATf; a1) Ml».
THE FLUE GAS IS DUCTED TO A SINGLE SCRUBBER AT THF RATE OF S20.0UO ACFM 4 JtO F HY MF.A-JS OF A
BUFFALO FORBF 1.0. FAN WHICH IS DRIVEN BY A aOOO HP WFSTINGHOIISE TURBINE. THE SCRUBBER ITSELF IS
MADE OF 30fl SS ANO CONSISTS OF AN UNLINED VENTURI THROAT (
-------
STATUS T
-------
STATUS 10 JANUARY 197O
SFCT10N 9 fCONTINUED)
DESCRIPTION FOW CiPEKAUllNAl Fr.n SYSTFMS ON INOHSTMTAL H.ITLFHS
INSTALLATION NAMF
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF HDILFRS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP OATF
CONTROL SYSTEM STATUS
303 REMOVAL EFFICIENCY
SLUOGF OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GETTY OIL COMPANY
RAKF&SFmO, TALIFORNIA
OTL tl.lX SULFUR)
72,f>00 SCFM (TOTAL - 6 BOILERS)
1
f>
36 Mh (EQUIVALENT)? 6 BOILERS, EACH j> 50 MM BTU/HR
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE SAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZTNB.)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
RETROFIT
JUNE, 1977
OPERATIONAL
90*1 (600 PPM 9 INLET)
HOLDING POND FOR EVAPORATION
6 GPM BLEEDOFF TO A SLOWDOWN TANK. THE SLOWDOWN IS THEN
SENT TO A DISPOSAL POND ONCE A WEEK.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
GETTY OTL COMPANY HAS AN OIL FIELD NEAR BAKERSFIELO, CALIFORNIA WHICH OCCUPIES ABOUT IS SQUARE
MILES. THERE ARE 136 STEAM GENERATORS; 100 WITH A HEAT RATE OF SO MM BTU/HR AND 36 WITH A HEAT
RATE OF SO MM BTU/HR. THE FUEL USED IS CRUDE OIL WITH 1.11 SULFUR AND A HEATING VALUE OF 6.4 MM
BTU/BBL. STEAM IS DISTRIBUTED THROUGHOUT THE OIL FIELD BY INSULATED PIPELINES AND INJECTED INTO
THE OIL WELLS. CONDENSATION OF THE STEAK REDUCES THE VISCOSITY OF THE OIL. WHICH FLOWS FREELY TO
THE SURFACE ALONG WITH THE WATER. THE OIL IS SEPARATED FROM WATER BY DECANTATION IN SETTLING TANKS,
AND PURIFIED BY DISTILLATION IF REQUIRED.
THE FLIIF GASES (130,000 ACFH 3 500 F) FROM SIX BOILFKS C50 MM BTU/HR EACH) ARE MANIFOLDED
INTO A TRAY ABSORBER (13.5 FEET DIA X 35 FEET HIGH) WHICH WAS RETROFITTED IN JUNE 1<»77 BY FMC
ENVIRONMENTAL EQUIPMENT DIVISION. THE PROCESS IS SODIUM CARBONATE SCRUBBING. THE RECIRCULATION
LIQUOR IS MAINTAINED AT A PH (IF b.«, WITH AN L/G RATIO OF 8.1 GAL/1000 ACF. THE RECIRCULATION FLOW
IS 1000 GPM. A BLEED STREAM OF b GPM IS CONTINUALLY SENT TO THE SLOWDOWN TANK WHICH IS EITHER
EMPTIED INTO A DISPOSAL POND OR INJECTED INTO DEEP WELLS EVERY WEEK. THE INLET S02 CONCENTRATION IS
600 PPM. THE OUTLET IS 60 PPM. THE ABSORBER, THERFFOKF, HAS 901 SOi REMOVAL EFFICIENCY.
THE ORIGINAL ABSORBER CONTAINED THREE DISK-AND-DONUT TRAYS AND AN INCONFL WIRE MESH MIST ELIMI-
NATOR. THE ABSORBER MOOULE AND THE STACK ARE MADE OF 316L SS. WHERFAS THE DOWNSTREAM DUCTWORK
»ND THE RECIRCIII.ATION PIPING *(*F MILD STEF.L. THE RFC tRCIJLATION PUMP IS RUBBER LINFD.
77
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
GETTY OIL COMPANY! BAKERSFIELO, CALIFORNIA (CONTINUED)
SOME IMPORTANT MAINTENANCE PRACTICES ARF:
1. DAILY CHECK AND CALIBRATION OF PH CONTROLLERS.
2. FRFOUENT CHECKS -ON FLOW WATERS (MAKEUP WATER. SODA ASH, RECIRCULATTON LIQUOR. AND SLOWDOWN)
AND FLUID LEVELS (BLOWDOWN TANK, SODA ASH TANK, AND SCRUBBER).
t--
3. MEEKLY FILLING OF SODA ASH TANK AND DISPOSAL OF BLOMOOMN.
4. SCHEDULED LUBRICATION OF PUMPS AND FAN, SEAL REPLACEMENT.
REFER TO FIGURE 11-Sl IN SECTION J« FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1977 THE RECTRCULATION PUMP LINFR WAS CHANGED FROM BUNA-N TO NATURAL RUBBER, DUE TO
THE SMELLING OF THE FORMER LINER. THE RUBBER PINCH VALVE ON THE HECTRCULATION PUMP HAS REPLACED BY
A SS GLOBE VALVE. THERE WERE SOME MINOR PROBLEMS WITH THE PH AND LEVEL CONTROLLERS.
4TH OUARTER-1977 THF FAN ROTOR MAS STRENGTHENED AND ClEANED OF THF SCALING. THE FAN BEARING
BURNED UP. IT MAS REPLACED AND THE FAN WAS REALIGNED.
1ST OUARTER-197B HIGH STACK DISCHARGE VELOCITY (60 FPS) CAUSED BY SMALL STACK DIAMETER AND POOR
LOCATION OF MIST ELIMINATOR (TOO CLOSE TO STACK TRANSITION SECTION) RESULTED IN HIGH ENTRAPMENT OF
DROPLETS. THE STACK AND TOP SECTION OF THE SCRUBBER WERE REDESIGNED.
3ND QUABTER-1978 THE MFSH nEMISTER MAS REPLACED BY A MUNTE&S CHEVRON TYPF M|ST ELIMINATOR.
A KOCH FLEXTTRAY MAS INSTALLED ABOVE THE 3RD TRAY IN ORDER TO IMPROVE so? REMOVAL EFFICIENCY,
PARTICULARLY DURING TURNDOMN CONDITIONS. THE PH PROBES ARE FOULED FREQUENTLY. SEVERAL
TYPES OF CONTROLLERS ARE PRESENTLY BEING TESTED FOR HIGH RELIABILITY. THE MILD STEEL RECIRCULATION
LINES MERF ERODED, AND MILL BE REPLACED BY 316L SS. THE AIR BUBBLER IN THE SODA ASH TANK LEVEL
CONTROLLER IS OFTEN PLUGGED. IT MILL BE REPLACED BY A DIAPHRAGM-TYPE LEVEL CONTROL DEVICF. THE
SLOWDOWN TANK OUTLET LINE HAS DEVELOPED SCALING. A POSITIVE DISPLACEMENT PUMP WAS TO BE INSIALLFO
IN THIS LINE, AND A SCALING INHIBITOR MAS POSSIBLY TO BE ADDED IN THE TANK LIQUOR.
3RD OUARTFH-1978 THE SLOWDOWN TANK OUTLET LINE WAS REPLACED WITH A ONE-INCH LINE TO INCREASE
VELOCITY AND THUS SOLVE THE SCALING PROBLEM. NFw J16L SS RFCIRCUI.ATION LINES HAVE HEFN INSTAL-
LED. AS HAS THE DIAPHRAGM-TYPE LF.VEL CONTROL IHVICE IN THE SODA ASH TANK. PM CONTROLLERS ARE STILL
BEING TESTED. A SCREW-TYPF POSITIVE DISPLACEMENT PUMP WAS INSTALLED, REPLACING AN EARLIFR PUMP
MHICH ERODED DUE TO HIGH RPM. A SILICON OISPERSANT IS NOW BEING ADDED TO THE LIQUOR TO ASSIST IN
ALLEVIATING THE SCALING PROBLEM, RUT THFBF HAS NOT BEEN SUFFICIENT TIMF TO FVALUATE ITS
EFFECTIVENESS. SINCE AUGUST 7 THE SYSTF" HAS EXPERIENCED ONLY ? HAYS DOwNTTHF OIIF TO REPLACEMENT
OF FAN BEARINGS.
flTH (JHARTFR-197* THF PIISITIVF DISPl ACf MFf< t (M)YNO) PUMP, WHICH HA* A NATIWAl R1IRBEH STATOR AND
78
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOP OPERATIONAL F6n SYSTEMS ON INDUSTRIAL BOILERS
6ETTY OIL COMPANY I BAKERSFJELD, CALIFORNIA (CONTINUED)
316L ROTOR HAS EXPERIENCED ABRASION ON THE ROTOR. EROSION IS CAUSED BY THE ASH COLLECTED IN THE
SCRUBBER AND SCALING. SEVERAL OTHER MATERIALS SUCH AS CHROME-ALLOY AND NI-HARD ARE BEING
REVIENED AS REPLACEMENTS. THE BLEED-OFF STREAM FLOW IS CONTROLLED MANUALLY AS A FUNCTION OF ITS
SPECIFIC GRAVITY (SET Pflal.15).
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STATUS TO JANUARY 1979
SECTION a (CONUNUFI))
PERFORMANCE nf-SCRIPTTHN FOR OPERATIONAL FGrt SYSTFMS ON INTHSTRIAL BOILF.RS
INSTALLATION NAMF
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCF RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SO? REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
RFTTY OIL COMPANY
RAKF.PSFIELO. CALIFORNIA
OIL (1.IX SULFUR)
«95,000 SCFM (TPTAL-15 BOILERS)
5 FGD SYSTEMS, EACH TREATING 300,000 ACFM a 500 F
5
85
215 *W (EODIVALENT)! 2250 MM BTU/HR (TOTAL-IS BOILERS)
EACH BOILEH RATED AT 02,000 LBS/HR STEAM
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM s I EQUIVALENT MN,
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
IN-HOUSE DESIGN
SODIUM CARBONATE SCRUBBING
RETROFIT
DECEMBER, 1978
OPERATIONAL
96Z (600 PPM S02 3 INLET)
SOX (55 LH/HR ASH a INLET)
NASTEMATER TREATMENT AND DISCHARGE TO TAILINGS POND
HOLDING POND FOR EVAPORATION.
9 GPM BLEF.OOFF TO A SLOWDOWN TANK. THE SLOWDOWN IS EMPTIED
INTO A DISPOSAL POND ONCE A WEEK.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
GETTY OIL, COMPANY HAS AN OIL FIELD NEAR BAKERSFIELO, CALFORNIA, HHICH OCCUPIES ABOUT 15 SQUARE
MILES. THFRF ARE 136 STEAM GENERATORS; 100 WITH A HEAT RATE OF 50 MM BTU/HR AND 36 tilTH A HEAT
RATE OF 20 MM BTU/HR. THE FUEL USED IS CRUDE OIL WITH 1.1X SULFUR AND A HEATING VALUE OF 6.0 MM
8TU/BBL. STEAM IS DISTRIBUTED THROUGHOUT THE OIL FIELD BY INSULATED PIPELINES AND INJECTED INTO
THE OIL WELLS. CONDENSATION OF THE STEAM REDUCES THE VISCOSITY OF THE OIL, WHICH FLOWS FREELY TO
THE SURFACE ALONG WITH THE WATER. THE OIL IS SEPARATED FROM WATER BY DECANTATION IN SETTLING TANKS,
AND P.URIFIED QY DISTILLATION IF REQUIRED.
THE FLUE GASES (200,000 ACFM AT 500 F) FROM NINE BOILERS (50 MM BTU/HR EACH) ARE MANIFOLDED
INTO ONE ABSORBER (18 FT OIA X 33 FT HIGH). EACH ABSORBER HAS 3 FLEXITRAYS AND ONE FLEXICHEVRON
OEMISTER SUPPLIED BY KOCH ENGINEERING. THE OVFRAI.L DESIGN OF THE FGD SYSTEMS, HOWFVER, IS PERFORM-
ED INH01ISE BY GETTY OIL ENGINEERS. THE PROCESS USED IS SODIUM CARBONATE SCRUBBING. THE FLUE GASES
ARE QUENCHED IN THf BOTTOM PART OF THE ABSORBER. THE RFCIRCULATION LIQUOR PH IS MAINTAINED BETWEEN
6.5-6.8 AND HAS IT PERCENT DISSOLVFD ROLTDS RY WEIGHT. THE DFSTGN L/G RATIO TS 9 GM./1000 ACF *NO
80
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FSO SYSTEMS ON INDUSTRIAL HUILPHS
SETTT OIL COMPANYl 8AKERSFIELO, CALIFORNIA (CONTINUED)
THE FLOW TO THE TOP TRAY IS ABOUT 1300 fiPM. A BLEED-OFF STREAM OF 9 GP« IS CONTINUOUSLY SENT TD A
SLOWDOWN TANK, WHICH IS EMPTIED INTO A DISPOSAL PONtl ONCE A WEEK. THF ABSORBER IS DESIGNED TO
REMOVE 96X OF 302 (600 PPM AT INLET) ANO ABOUT 50 PERCENT OF THE ASH (35 LB/HR *T INLET).
REFER TO FIGURE 14-20 IN SECTION 14 FOR A DETAILED PROCESS FLO* DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1978 OF THE 9 FGD SYSTEMS UNDER CONSTRUCTION, ONE MAS STARTED UP ON SEPT. 18. 1978
AND ANOTHER IS SCHEDULED FOR START-UP THE FIRST MEEK IN OCTOBER. THE LAST OF THE SYSTEMS IS
SCHEDULED FOR START-UP 8Y MID FEBRUARY.
1TH OUARTER-1978 A TOTAL OF FIVE FGD SYSTEMS HAVE STARTED UP. THE MAIN STARTUP PROBLEMS ANO THEIU
SOLUTIONS ARE:
I. SCALING—THE STEAM CONOENSATE IS FILTERED, SOFTENED AND RECYCLED TO THE GENERATORS AND THE F60
SYSTEMS. STILL, SOME OF THE DISSOLVED SPECIES SEEM TO CAUSE SCALING IN THE ABSORBERS NHEN
SUBJECTED TO A PH CHANGE. SILICON OISPERSANTS HAVE BEEN USED TO REDUCE THE SCALING.
2. FANS—MISALIGNMENT OF BEARINGS HAS BEEN A FREQUENT SOURCE OF HIGH VIBRATIONS. ALL THE FANS ARE
FORWARD-CURVED-BLADE CENTIFU6AL TYPE, NITH A DESIGN RATING OF tt IN KG. AT 560 HP. SOME OF THE
FANS, HOWEVER, HAVE NOT BEEN ABLE TO GENERATE THE SPECIFIED POSITIVE PRESSURE. PROPER VENDOR
SELECTION MAY BE THE SOLUTION.
3. MIST ELIMINATOR—IN ONE ABSORBER, THE FLEXI-CHEVRON MIST ELIMINATOR HAS ACHIEVED LO* DROPLET
REMOVAL. THIS MAY BE DUE TO CHANNELING IN THE ABSORBER, ANO THE PROBLEM IS UNDER INVESTIGATION.
SOME OTHER CHEVRON MIST ELIMINATORS MAY BE EVALUATED. OUT OF THE « REMAINING UNITS, 2 ARE SCHEDULED
TO START IN MID-JANUARY ANO 2 IN MID-FEBRUARY 1979.
ONE FGO SYSTEM STARTEO-UP IN DECEMBER 1978 IS USING SODIUM HYDROXIDE SCRUBBING IN AN ATTEMPT TO
EVALUATE THE PERFORMANCE OF CAUSTIC AGAINST SODA ASH AS THE ALKALI. THE SODA ASH CONSUMPTION HAS
BEEN VERY HIGH (2-2.2 L8/LB 302 REMOVED) COMPARED TO THE STOICHIOMETRIC REQUIREMENT (1.7 LB/LB 302
REMOVED, MAX.).
81
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STATUS TO JANUARY
SECTION S (CONTINUFO)
PERFORMANCE DESCRIPTION FOB OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILFRS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE ?GD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKF-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT SOUTHERN PAPER CO.
CFDAR SPRTNCS, GEORRIA
BARK,COAL/OIL Cl.OX - a.OX SULFUR)
020,000 SCFM (TOTAL - 2 BOILERS)
2
2
210 MH (EQUIVALENT)s TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERVlISE, ?000 SCFM = 1 EQUIVALENT MW.
THIS IS HFCAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN "OOULE SIZING.)
AIRPOL INDUSTRIES
CAUSTIC WASTE STREAM
RETROFIT
1<»75
OPERATIONAL
85X-90X (1,000 PPM AT INLET)
ti.i% (DFSIGN: «.s GR/SCF AT INLET)
OPEN LOOP; 150 - 100 GPM PER ABSORBER
WASTEWATER TREATMENT AND DISCHARGE TO RTVER
CLARIFICATION FOLLOWED 3Y PONDING AND DISCHARGE TO RIVER
SEF SECTION 1J FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN CEDAR SPRINGS, GEORGIA, THE GREAT SOUTHERN PAPER COMPANY OPERATES TWO 500,000 LR/HB BOILERS
GENERATING A TOTAL OF 700,000 ACFM AT 425 F. THE BOILERS NORMALLY RUN AT NEARLY PEAK CAPACITY AND
FIRE BARK AND COAL (1.5X SULFUR). A FUEL OIL BACK-UP SYSTEM IS ALSO AVAILABLE.
EMISSIONS FROM THE TWO BOILERS ARE HANDLED BY TWO AIRPOL VENTURI SCRUBBERS, EACH FOLLOWED BY A
RADIAL VANE SFPARATOR AND A STUB STACK. PRESSURE DROP ACROSS THE SCRUBBER IS ABOUT ft INCHES W.G.,
AND THE DESIGN S02 REMOVAL EFFICIENCY IS BS-90*. IHfc SCKUBBhRS OPERATE WITH AN L/G RATIO OF ABOUT 5
GAL/1000 ACF. THE INLFT S02 CONCENTRATION OF THE FLUE GAS IS TYPICALLY 1000-1200 PPM AND THE
PARTICULATE LOADING IS «.5 GR/SCFD.
SCRUBBER UNDERFLOW, CONTAINING FLYASH AND SODIUM SULFATE, GOES TO A COMMON STAINLESS STEEL
RECIRCULATION TANK. SOLIDS CONTENT IN THE TANK IS 3-5X AND PH IS MAINTAINED AT 3.5-5 USING A 5X
CAUSTIC WASTE STREAM FROM AN ONSITE OEMINFRALIZF.R. A BLEFO STREAM OF ABOUT 600 GPM IS PUMPFD TO AN
ASH SETTLING POND.
THE SCRUBBERS, SEPARATORS AND STUB STACKS ARF ALL STAINLESS STFEL. THF PIPING, HEC1RCULATION
PUMPS (3 AT 2300 6PM), AND ASH PUMPS (2 AT 500 GPM) ARE RUBBER LINED.
RFFFH TO FTRU»E >a-?2 IN SFCTION la FflH A DETAILED PROCESS FLOH DIAGRAM OF THIS SYSTFM.
82
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STATUS TO JANUARY 1979
SFCTION 1 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPFRATIONAL FGD SYSTEMS ON INDUSTRIAL RUTLfHS
6RE*T SOUTHERN PAPER CO.S CEDAR SPRINGS, GEORGIA (CONTINUED)
OPERATING HISTORY
OTH OUARTER-1977 THE EXPANSION JOINT BETWEEN THE EXISTING STACK AND SCRUBBER HAD TO HE REPLACED
IN SEPTEMBER. SOME INTERNAL WEAR WAS DETECTED ON THE PUMPS DUE TO ASH CONTENT. EROSION AND PLUG-
GING PROBLEMS WITH THE PM PROBES HAVE BEEN ENCOUNTERED. THE PLANT WAS IN PROCESS OF CHANGING THE
CONTROL PH AND MOVING TM£ PROBES. TANKS AND NECESSARY EQUIPMENT TO CONTROL THE PROPER PH ARE
EXPECTED TO BE COMPLETED IN A COUPLE OF MONTHS. OME EROSION HAS DETECTED IN THE RECTRCULATION
LINES Of THE POWER BOILER SCRUBBER. THF LINES AND SOME OF THE VALVES HAD TO BE REPLACED.
1ST. 2ND, 3RD QUARTER-197B GREATER PH CONTROL WAS ACHIEVED BY INSTALLING A CAUSTIC HOLD TANK AND
REGULATING THE FLOW FROM THAT TANK TO MAINTAIN A CONSTANT PH IN THE RECIRCUlATION TANK. THE RUBBER-
LINED PIPING HAS ERODED AND IS GRADUALLY BEING REPLACED WITH STAINLESS STEEL. THE VENTURI SCRUBBFR
AND SEPARATOR MERE INSPECTED FOR CORROSION AND FOUND TO BE IN GOOD CONDITION.
4TH QUARTER-1978 PROBLEMS HAVE BEEN EXPERIENCED WITH PACKINGS TN ALL THE PUMPS. A MECHANICAL
SEAL WAS TRIED AND LASTED 3 WEEKS. NEW SFALS WILL BE INSTALLED. AND SINCE THERE ARE BACK-UPS FOR
ALL THE POMPS IN THE SYSTEM, THIS SHOULD NOT CAUSE ANY DOWNTIME. PLANS FOR 1979 INCLUDE UPGRADING
THE ASH HANDLING SYSTEM AND POSSIBLY INSTALLING A MIST ELIMINATOR IN THE TOP OF THE SEPARATOR.
THE SOLIDS CONTENT IB THE RECIRCULATEO LIBUOR WILL BE REDUCED BY INCREASING THE MAKE-UP WATER
INPUT AND THE BLEED-OFF RAT.E AT THE RECIHCUl ATION TANK. ALSO, THE PRESENT BLFEO LINE AND ASH PUMPS
HILL BE REPLACED WITH A GRAVITY LINE.
-------
STATUS TO JANUARY 1979
SECTION' 9 (CONTINUED)
PERFORMANCE DtSCRlPriON F0« OPERATIONAL FRH SYSTEMS ON INDUSTRIAL ROtLEKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE SATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BFING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
$m REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN
HILLINGS, MONTANA
COAL C0.7X SULFUR)
60.000 SCFM (TOTAL - S BOILERS)
3
3
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS HATER
RETROFIT
OCTOBER, 1977
OPERATIONAL
35Z (300-400 PPM a INLET)
HASTEWATER TREATMENT ANO DISCHARGE TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGO SYSTEM AT GREAT WESTERN SUGAR, BILLINGS, MONTANA PLANT HAS BEEN PRIMARILY DESIGNED
FOR PARTICULATE CONTROL. HOWEVER, THE SCRUBBING LIQUOR CONTAINS ENOUGH NH3 (PH=«.7) TO OBTAIN
A REMOVAL EFFICIENCY OF 35* FOR Sfii. THE CONCENTRATION OF 302 AT THE INLET IS 300-400 PPW.
THE SYSTEM CONSISTS OF A VARIABLE THROAT VENTURI SCRUBBER AND A SINGLE STAGE, THREE PASS CHEVRON
DEMISTER. THE SCRUBBER WAS INSTALLED IN OCTOBER, i977 AND HAS BEEN OPERATING SATISFACTORILY.
THE SCRUBBER EFFLUENT IS 8LEO OFF TO A POND WHERE IT IS BLENDED ANO COOLED KITH OTHER PROCESS
WASTE STREAMS AND THEN PUMPED TO A RIVER.
3RD QUARTER-1978
OPERATING HISTORY
NO INFORMATION WAS REPORTED FOR THIS UPDATE PERIOD.
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGfi SYSTFMS ON INDUSTRIAL ROILEWS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FRO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BV-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
COAL (1.21 SULFUR, AVERAGE)
65,230 SCFM (TOTAL - 2 BOILERS)
100,000 ACFM FACH 3 aOO F (TOTAL - ? BOILERS)
350,000 LBS/MR STEAM (TOTAL - 2 BOILERS)
326 MM BTU/HR, 32 MW (EQUIVALENT) » TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHFRWISE. 2000 SCFM = 1 EQUIVALENT M«.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE STZING.)
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS MATER
RETROFIT
OCTOBER, 1976
OPERATIONAL
OSX (300-«00 PPM 3 INLET)
95X (730 LBS/HR a INLET)
HASTENATER TREATMENT AND DISCHARGE TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GREAT WESTERN SUGAK COMPANY HAS TWO COAL FIRED BOILERS AT THEIR FORT MORGAN, COLORADO PLANT.
EACH BOILER is RATED AT 125,000 LBS/HR OF STEAHJ AND BURNS COAL WITH o.si PERCENT AVERAGE SULFUR,
8.7 PERCENT AVERAGE ASH, AND AN AVERAGE HEATING VALUE OF 10,176 BTU/LB. THE SUGAR FACTORY IS OPER-
ATIONAL ONLY 3 MONTHS OF EVERY YEAR, DURING THE FALL QUARTER.
THE FGO SYSTEM HAS RETROFITTED IN OCTOBER i"J76 AS A PROPRIETARY DESIGN PRIMARILY FOR PARTICULATE
CONTROL. THF FLUE GASES FROM EACH BOILER (100,000 ACFM a flOO F) PASS THROUGH MULTICLONES, AND THEN
ARE SENT THROUGH A VENTURI SCRUBBERi WHICH OPERATES WITH A PRESSURE DROP OF 6 IN. *.G. AND L/G
VALUE OF 8 RAL/1000 ACF. THE SCRUBBERS ARE FOLLOWED BY A COMMON VESSEL WHICH CONTAINS A SINGLE-
STAGE, THREF.-PASS CHEVRON MIST ELIMINATOR (M-E). WASH WATER FLOW TO THE M-E IS 120 6PM, WITH A
FREQUENCY OF 15 MINUTES EVERY 8 HOURS. THE PRESSURE DROP ACROSS THE M-E IS 0.5 IN. n.G. A CONSTANT
BLEEO-OFF STREAM OF 800 GPM FROM EACH SCRUBBER IS SF.NT TO A POND, WHICH OVERFLOWS INTO ANOTHER
HOLDING POND.
THE VENTURI SCRUBBER, THE PLUG, M-E VESSEL, AND THE M-E ARE ALL MADF OF 316L SS.
REFER TO FIRURE i«-as IN SECTION ia FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
85
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPFRAHONAI FGO SYSTEMS ON INDUSTRIAL ROILFHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
502 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT ttESTERN SUGAR
GERING, NFBRASKA
COAL (1.2% SULFUR, AVERAGE)
110,000 SCFM (TOTAL - 2 BOILERS)
97,000 ACFM EACH 9 «50 F (TOTAL - i BOILERS)
205,000 LBS/HR STEAM (TOTAL - 2 BOILERS)
21 Mh (EQUIVALENT) j TOTAL - 2 BOILERS
218 MM BTU/HR (TOTAL)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EWIIVALtNT Mil,
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER, 1975
OPERATIONAL
701 (600 PPM a INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
EFFLUENT TO HOLDING POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GREAT WESTERN SUGAR COMPANY HAS TWO COAL-FIREO BOILERS AT THEIR GERING, NEBRASKA PLANT.
BOILER *1 IS RATED AT 150,000 LBS/HR OF STEAM AND WAS SUPPLIED BY ERIF CITY IN 1965. BOILER
»2 IS HATED AT 55,000 Lfl/HR OF STEAM AND HAS SUPPLIED BY ERIE CITY TN 195«. THE COAL HAS 0.73
PERCENT AVERAGE SULFUR, 8.5 PERCENT AVERAGE ASH, AND AN AVERAGE HEATING VALUE OF 10,180 BTU/LB.
THE SUGAR FACTORY IS OPERATIONAL ONLY 3 MONTHS OF EVERY YEAR, DURING THE FALL OUARTFR.
THE FGO SYSTEM WAS RETROFITTED IN OCTOBER 1975 AS A PROPRIETARY DESIGN PRIMARILY FOR PARTICIPATE
CONTROL. THE FLUE GASES FROM TWO BOILERS (105,000 ACFM 3 310 F) PASS THROUGH CYCLONES, ARE MIXED IN
A COMMON DUCT, AND THEN SENT THROUGH TWO VENTURT SCRUBBERS (EACH HEATING 97,000 ACFM 3 4SO F),
WHICH OPERATF WITH A PRESSURE DROP OF 6 IN. rt.G. AND L/G VALUE OF 6.2 GAL/ACF. THE OPERATING GAS
VELOCITY AT THE VENTURI INLET IS «3 FPS. THE SCRUBBERS ARE FOLLOWED BY A MIST ELIMINATOR (M-E)
VESSEL WHICH CONTAINS A SINGLE-STAGE, THREE-PASS CHEVRON M-E. WASH WATER FLOW TO THE M-E IS ISO
GPM, WITH A FREOUENCY OF 15 MINUTES FVERY B HOURS. THF PRESSURE DROP ACROSS THE M-E IS 0.5 IN. W.G.
THE SCRUBBER EFFLUENT, 700 GPM FROM EACH SCRUBBER, IS SENT TO A POND.
THE VENTURI SCRUBBERS, VARIABLE DIAMETER PIU6S, M-E VFSSFL, AND M-E ARE ALL MADE (IF 30«L S3.
HEFFR TO FIGURE l«-*7 FOR A flFTAII.EO PRnrFSS FLU* DIAGRAM OF THIS SYSTEM.
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SY3TFMS ON INDUSTRIAL ROILFRS
INSTALLATION NAME
INSTALLATION LOCATION
"SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F61 UNITS
NUMBER OF BOILERS BEIN6 CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NED / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUD6E OB BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN- SUGAR
GREFLEY, COLORADO
COAL (0.61 SULFUR)
25,000 SCFM CI BOILER)
1
1
12 MW (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 2000 SCFM = I EQUIVALENT MW,
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTflH tN MODULE SIZING.)
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER, 1975
OPERATIONAL
35* (300-flOO PPM 9 INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE GREELY, COLORADO PLANT, GREAT WESTERN SUGAR HAS IN OPERATION 6 COAL FIRED BOILERS
MANUFACTURED BY STERING AND PLACED IN SERVICE IN 1920. THE BOILERS OPERATE 2796 HOURS PER YEAR
DURIN6 THE FALL AND EARLY WINTER MONTHS. EACH BOILER POSSESSES THE FOLLOWING CHARACTERISTICS:
AN OPERATING HEAT INPUT OF 29.7 MM BTU/HR, A DESIGN STEAM CAPACITY OF 12,225 LB/HR AND A DESIGN
FLUE GAS FLOW RATE OF 26,333 ACFM 3 550 f. THE COAL USED AS FUEL HAS AN AVERAGE HEATING VALUE
OF 9208 8TU/LB, AN AVERAGE SULFUR CONTENT OF 0.66X AND AN AVERAGE ASH CONTENT OF 5.39X.
THE SCRUBBER SYSTEM IS A WET VENTURI FOLLOWED BY A CHEVRON TYPE, ONE PASS MIST ELIHINATOK.
THE MIST ELIMINATOR is CONSTRUCTED OF s/16" 316 STAINLESS STEEL AND THE SCRUBBER is CONSTRUCTED
OF 10 6A. 316L S3. OcMISTER WASH FLOW PATE IS 120 GPM. DESIGN FLUE GAS FLOW RATE IS lfea.000
ACFM 3 550 F AND THE L/G RATIO IS 5.5 GAL/1000 CFM. THE FLOW OF SCRUBBING LIQUOR TO THE VENTURI
IS 550 GPM. THE PRESSURE DROP ACROSS THE SCRUBBER IS 7" WG.
THE WASTE WATER FROM THE SCRUBBER IS AN ASH/WATER SLURRY WHICH IS CONTINUOUSLY DISCHARGED
TO A POND AT 1100 GPM.
REFER TO FIGURE l«-28 IN SECTION la FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QUARTER-197B NO INFORMATION WAS REPORTED FOR THIS REPORT PERIOD.
-------
STATUS TO JANUAWY 1<)70 LRS/HR OF STEAM AND BURNS COAL WITH O.S? PERCENT AVERAGE SULFUR.
9.4 PERCENT AVERAGE ASM. AND AN AVERAGE HEATING VALUE OF 10.305 8TIJ/LB. THE 3UGAR FACTORY IS OPER-
ATIONAL ONLY J MONTHS OF EVERY YEAR. DURING THE FALL BUARTER.
THE FGD SYSTEM IKAS RETROFITTFn IN OCTOBER 19,71 AS .A PROPRIETARY DESIGN PRIMARILY FOR PARTICULATE
CBNT«r»u. TKE FLUE GASES FROM EACH BOILER (100^000, ACFM i mo F) PASS FMROUGH C»CLONES AND AHE MIKED
IN A COMMON DUCT, ANO THEN SENT THROUGH TWO VENTURI SCRUBBERS, WHICH OPERATE WITH A PRESSURE DROP
OF 7 IN. w.fi. AND L/G VALUE OF 7.5 GAL/1000 ACF. THE OPERATING GAS VELpCI.T.t AT- THE VENTURI INLET
IS 45 FPS. THE SCRUBBERS ARE FOLLOWED flf * "1ST ELItMNftTGK (M-E) VESSEL WHICH CONTAINS A ONE-PASS,
THREE-STAGE CHEVRON M-E. WASH MATER FLOfe TO THE M-E IS 120 GPM, KITH A FREQUENCY OF IS MINUTES
EVERT 5 HOURS. THE PRESSURE 0«OP ACROSS THE M-E IS 0.5 IN. W.G. THE EFFLUENT STREAM FROM EACH
SCRUBBER. 750 GPM. IS SENT TO A POND, WHICH OVERFLOWS INTO ANOTHER HOLDING PONn.
THE VENTURI SCRUBBERS. VARIABLE DIAMETER PLUGS. M-E VESSEL. AMD THE M-E ARE .ALL MADE
OF 316L SS.
RF.FFR TO flfillRF \Q-?1 IN SECTION la f fif t. OETAILEP PWC1CFSS FL1H ItTAGfl*** OF THIS SYSTF.M. -
-------
STATUS TO JANUARY
SECTION «> (CONTINUED)
PERFORMANCE ntSCRIPTTON FOP OPERATIONAL FCr SYSTFMS 0* INMl'STWl M HIlTLFWS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOa REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUD6E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTfRN SUGAR
SCOTTS (HUFF, NEBRASKA
COAL (1.2* SULFUR, AVERAGE)
65»230 SCFM (TOTAL - Z BOILERS)
130,000 ACFV EACH 9 «00 F (TOTAL - I BOILERS)
300,000 LBS/HR STEAM (TOTAL - Z BOILERS)
32 MW (EQUIVALENT); TOTAL Z - BOILERS
315 MM RTU/HR (TOTAL)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EOUIVALENT MW.
THIS IS BECAUSE GAS FLOM RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
GREAT WESTERN SUGAR
AMMONIA-LAOEN PROCESS WATER
RETROFIT
OCTOBER, 1975
OPERATIONAL
35* (400 PPM a INLET)
<>5%
MASTEMATER TREATMENT AND DISCHARGE TO RIVER
EFFLUENT STREAM TO HOLDING POND.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GREAT WESTERN SUGAR COMPANY HAS TWO COAL-FIRED BOILERS AT THEIR SCOTTS BLUFF, NEBRASKA
PLANT. EACH BOILER IS RATED AT ISO,000 LBS/HR OF STEAM AND BURNS COAL WITH 0.61 PERCENT AVERAGE
SULFUR, 5.2 PERCENT AVERAGE ASH, AND AN AVERAGE HEATING VALUE OF v,300 BTU/LB. THE SUGAR FACTORY IS
OPERATIONAL ONLY 3 MONTHS OF EVERY YEAR, DURING THE FALL QUARTER.
THE F60 SYSTEM WAS RETROFITTED IN OCTOBER 1<»75 AS A PROPRIETARY DESIGN PRIMARILY FOR PARTICULATE
CONTROL. THE FLUE GASES FROM TWO BOILERS C130.000 ACFM EACH 3 «00 F) PASS THROUGH CYCLONES AND ARE
MIXED, AND THEN SENT THROUGH THO VENTURI SCRUBBERS, WHICH OPERATE WITH A PRESSURE DROP OF 6 IN.
W.G. AND L/G VALUE OF 6.5 GAL/1000 ACF. THE OPERATING GAS VELOCITY AT THE VENTURI INLET IS 56 FPS.
THE SCRUBBERS ARE FOLLOWED BY A DEMISTER VESSEL WHICH CONTAINS A SINGLE-STAGE, THREE-PASS CHEVRON
"1ST ELIMINATOR (M-E). WASH WATER FLOW TO THE M-E IS 150 6PM, WITH A FREQUENCY OF 10 MINUTES EVERY
« HOURS. THE PRESSURE DROP ACROSS THE M-E IS 0.5 IN. n.G. THE SCRUBBER FFFLUENT, flaS GPM FROw EACH
SCRUBBER, IS SENT TO A POND.
THE VENTURI SCRUBBERSt VARIABLE DIAMETER PLUGS, M-E VESSEL, AND THE M-E ARE ALL MADE OF 316L S3.
REFER TO FIGURE l«-30 IN SECTION 14 FOR A DETAILED PROCESS FLOW OF THIS SYSTEM.
-------
STATUS TO JANUARY 1971
SECTION 1 (CONTJNUFn)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTFMS ON INOMSTRIAt BOILEHS
INSTALLATTON NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
803 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ITT RAYONIF.R, INC.
FERNANOINA BEACH, FLORIDA
BARK,OIL (2.OX - 2.5X SULFUR)
176,000 SCFM (TOTAL - fl BOILERS)
2
a
88 MW (EQUIVALENT); TOTAL - 0 BOILERS
(FOR THIS REPORT, UNLFSS STATED OTHERWISE, ?000 SCFM s 1 FQIUVALENT M*.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN HOOULE SIZING.)
AIRPOL INDUSTRIES
SODIUM HYDROXIDE SCRUBBING
RETROFIT
1975
OPERATIONAL
BOX - 85* (1,200 PPM AT INLET)
971 (1.7 GR/SCF AT INLET)
OPEN LOOP
WASTEWATER TREATMENT AND DISCHARGE TO TAILINGS POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
ITT RAYONTEP OPERATES AN AMMONIA-BASED SULFITE PULP MILL IN FERNANDINA BEACH, FLORIDA. THERF
ARE FOUR PROCESS STEAM BOILERS TYPICALLY OPERATING AT APPROXIMATELY 80 TO SOX LOAD. TWO ARF. RATED
AT 125,000 LB/HR STEAM, ONE AT 100,000 LB/HR STEAM AND ONF AT 150,000 LB/HR STEAM. ALL ARE RATED AT
600 PSI6. THE FOUR BOILERS OPERATE IN THF FOLLOWING MANNER:
NO. 1 - 100,000 LB/HR STEAM - FIRES FUEL OIL (NO. 6)
NO. 2 - 125,000 LB/HR STEAM - FIRES A COMBINATION OF BARK AND NO. 6 FUEL OIL
NO. 3 - SAME AS NO. 2
NO. fl - 150,000 LB/HR STEAM - HRES FUEL OIL (NO. 6)
FLUE GASES LEAVING THE NUMBER TWO AND THREf BOILFRS ENTER INTO SEPARATE MECHANICAL COLLECTORS
(BUELL CYCLONE COLLECTORS) FOR PARTICULATF HfMOVAl OF ABOUT 97% (1.7 GR/SCF a) INLET). Two IDENTICAL
FGO SYSTEMS ARE USED TO REMOVE 80 TO 85 PERCENT OF THE SO? FROM THE GAS FROM ALL FOUR BOILERS.
BOILERS ONE AND TWO ARF MANIFOLDED INTO ONE SCRUBBER SYSTFM DESIGNED FOR 165,000 ACFM AT 060 F WHILE
GASES FROM THREF AND FOUR ARE MANIFOLDED INTO THE SFCOND SCRUBHER SYSTEM DESIGNED FOR 140,000 ACFM
»T 160 F. EACH SYSTEM USFS A VARIABLE-THROAT VF.NTUHI SCRIIBBEW FOR 802 REMOVAL WHICH IS PRECEEOED BY
AN I.D. FAN. THE PRESSURE DROP ACROSS THF VENTURI VARIES BETWEEN 15 AND gg INCHES WG. A 10X CAUS-
TIC SOLUTION IS INJFCTfD AT TH(= THROAT OF THE VF.NTUR1 BY A 75 HP PIIMPCFULL LOAD). THF CAUSTIC IS
EITHER 08TATNFI) FRO" THF "!OOI> STARt HF THFIR PII|,H HLFACHING OPERATION OR PUPtHASfD. USUALLY PIlB-
90
-------
STATUS TO JAMIAWt 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPFKAIIflNAL Fl,l> STSTFnS nN IMtilSTRTAI ROTl FRS
ITT RAYONIER, INC.» FERNANDtNA BEACH, FLORIDA (CONTINUED)
CHASED CAUSTIC IS USED AND THE CAUSTIC FROM THE BLF»CH|NU OPERATION IS SOI D TO KRAFT MILLS.
CONTROL PH IS IN THF RANGE OF 5.5 TO 6.0. THE LIOUIO-SAS MIXTURE ENTERS 4 SEPARATOR (J8 FT HIGH X
16.5 FT DIA.) WHICH INCORPORATES SPIN VANFS FOR LIQUID SEPARATION. THE LTOHtD DROPS TO THE BOTTOM
OF THE SEPARATOR INTO THE RECIRCULATION TANK. THE RASES LEAVE THF TOP OF THE SEPARATOR AND LFAD
DIRECTLY TO THE STACK, EXITING AT A TEMPERATURE OF APPROXIMATELY t35 F.
THE VENTURIS, SEPARATORS (INCLUDING SPIN VANES), SPENT LIQUOR PIPING AND HOLD TANKS »R£ ALL
CONSTRUCTED OF 316L SS.
REFER TO FIGURE i«-3i IN SECTION i« FDR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH OUARTER-1<»77 PLANT REPORTED THAT BOILERS NO. Z AND 3 HERE OPERATING AT REDUCED LOADS,
EACH IN THE RANGE OF 75,000 - 90,000 LBS/HR STEAM. THE SPENT CAUSTIC WAS NOT BEING
USED FOR SCRUBBING LIQUOR. ITT WAS SELLING THE SPENT CAUSTIC TO KRAFT MILLS WHO USE IT
FOR THEIR SODA BASE. CONDENSATE STEAM WAS BEING RECYCLED AND USED FOR SCRUBBING PURPOSES.
SOME EROSION HAS BEEN NOTED AT THE VENTURI THROAT.
ZH6 OUARTER-1«J78 THE PLANT WAS STILL UTILIZING CONOENSATE nATER FOR SCRUBBER LIOUOK. APPROX-
IMATELY 3 TONS PER DAY OF SODIUM HYDROXIDE WAS BEING USED TO MAINTAIN PH. THE ORIGINAL HOT WASTE
STREAM CAUSTIC WAS NOT USED FOR SCRUBBER PURPOSES, DUE Tj) PROCESS-RELATED PROBLFMS THAT OCCURRED.
SCRUBBER EFFLUENT WAS STILL BEING SOLO TO KRAFT MILLS. THE SYSTEM HAS TWO SCRUBBERS, 'A' AMD '8'.
A-MODULE HAS DOWN « WEEKS IN JUNE AND JULY BECAUSE OF AN F.n. FAN FAILURE, BELIEVED TO BE A RESULT
OF POORLY OPERATED MECHANICAL COLLECTORS. NEW MECHANICALS WERF BEING INSTALLED TO PRFVFNT FURTHER
ABRASION. THE PLANT REPORTF.O THAT SINCE JANUARY, SCRUBBER OPERABILITY HAD BEEN APPROXIMATELY 95*.
3RD OUARTER-1978 THE BOILER AND FGO SYSTEM OPERATED APPROXIMATELY 95* OF THE PERIOtt. THE
ONLY OUTAGE DURING THE PERIOD "AS BOlLER-RELATf0 AND LASTED THREE DAYS. THF BEARINRS IN THE 1.0.
FAN HAD TO BE REPLACED.
«TH OUARTER-1978 THE FGO SYSTEM DEMONSTRATED AN FSTIMATED <»St RELIABILI1Y. A CRACKED FiN FOUNDA-
TION ON MODULE A CAUSED THAT MODULE TO BE NON-OPERARLE FOR 10 DAYS. I-BEAM? WERE PLACFD UNDER THF
FOUNDATION TO RESTORE SUPPORT. AT THE SAME tiff, NEH SFALS WFHE PLACED IN THF OUST COLLECTOR TO
SLOW DOWN THE SEVERE EROSION PROBLEMS ON THF FAN. THE FAN SHROUD HAS BEEN REBUILT SEVERAL TIMES;
THIS IS THE SECOND FAN. THE PLANT PLANS TO INSTALl NEW DUST COLLECTORS SOMFTIMF IN APRIL. UNTIL
THEN, INTERMITTENT DOWNTIME IS FXPfrCTEO.
91
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STATUS TO JANUARY 1979
SFCTint. 9 (cni"T IMUFD)
OESCR1PUHN FOR fiHEKAlIolVAI. Ffin SYSTFfS ON INDUSTP1AI HOILFWS
INSTALLATION NAMF
INSTALLATION LOCATION
SOURCF CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATF FGO UMTS
NUMBER OF BOILERS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTFH STATUS
308 REMOVAL EFFICIENCY
PAHTICULATE REMOVAL EFFICIENCY
MATER MAKF-tlP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
rHF'TCAL CORP.
IRliNA, CALIFORNIA
COKF/CIIAL/OTL 10. 5X - 5.0* SULFUR)
a90,000 Sr.FM (TOTAL - ? BOILERS)
7?«i,ooo APFM 3 S20 F (TOTAL - 2 BOILERS)
2
f
235 I»M (bfl MA ELECTRIC POWER. ANO THE BALANCE IS PROCESS
STfAK) TflTAL - 3 BOILERS
(FOR THIS RFPORT, UNLESS STATED OTHERWISE, 2000 SCFH = I EQUIVALENT M».
THIS IS HFCAUSE GAS FLON RATE IS THE PRIMARY FACTOR IN MOOilLE SIZING.)
COMBUSTION EQUIPMENT ASSOC.
SODIUM CARBONATE SCRUBBING
NEW
JUNE, 197R
OPERATIONAL
98*1 (AT MAXIMUM LOADING)
98. 5X (COLLECTED BY PRECEDING ESP'S)
OPEN LOOP: 125 GPM BURKITE SCRUBBING LIQUOR (a7t NA2C03 AND
HOLDING POND FOR EVAPORATION
SCRUBBER FFFLUENT IS CLARIFIED AND THEN PUT INTO A MINERAL
DEPOSIT.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
KERR-MCGEE CHEMICAL CORP. HAS A NEW 1.3 MM TON/YR SODA ASH PLANT AT TRONA, CALIFORNIA. THE
PLANT, LOCATED ALONB THF SHORE OF SEARLFS LAKE, IS THF LARGFST YET BUILT TO YIELD SODA ASH BY DIRECT
CARBONATION OF BRINF ANO WAS COMMISSIONED IN JUNE 1<)78. THF PROCESSING INNOVATIONS, WHICH
HAVE IMPROVFD THE PLANT EFFICIENCY, INCLUDE CARBONATION UNDER 13.5 PSI PRESSURE, USE OF A COAL-
FIRED POWFR PLANT, AND RECOVERY OF CO? FHOM THF FLUF GASES.
THE PLANT HAS TWO BOILERS, tACH PRODUCING 600,000 LB/HR STEAM AT 1500 PSI. THE STEAM IS INITIAL-
LY USED TO DRIVE TWO 32 MW NON-CONDENSING STEAM TURBINES FOR ELECTRIC POWER, THEN IS USED AS PROCESS
STEAM. THE TOTAL MW EOIIIVALENT IS ABOUT ?«5 Mh. EACH BOILER BURNS A MIXTURE OF WESTERN COAL
(0.7 PERCENT SULFUR) AND PETROLEUM tfmE (5.5 PFRCENT SULFUh). THE HIGH SULFUR COKE IS MIXED WITH
THE COAL IN ORDER TO IMPROVE THF PARTIAL IONI7ATION ANO THEREFORE IMPROVE FLY-ASH COLLECTION IN THE
ESP WHICH OPFRATES ON THf COLO SIDE OF THE PRFHEATER AT 9H.5 PERCENT EFFICIFNCY AND 300 F. THE FLUE
GAS FLOW PATl- FROM FACH BOILER IS 3**,00t. ACFM Al ?2u F AND MAY CONTAIN SOZ BFThEFN 335 TO 59B5 PPM
92
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR (IPFWftllUfcAl FRU RrSTFr-iS nN INniiSTwtAl RtllLFHS
KERR-MCGEE CHEMICAL CORP.; TRONA, CALIFORNIA (CONTINUED)
DEPENDING UPON THE FUEL. THE AIH POLLUTION REGULATIONS DICTATE THAT EACH BOILER "AY RELEASE NOT
MORE TH*N 10 LBS/HH PAHTICULATE, 200 LH3/HR OF SO? AND 1
-------
STATUS TO JANIllfRY 1979
SECTION 9 (CONTINUFD)
PERFORMANCE DESCRIPTION FOR OPERATIONAL Pen SYSTFMS ON JNOUSTRIAI HOILEHS
KERR-MC6EE CHFMICAL CORP.; TRONA, CALIFORNFA (CONTINUED)
LIQUID AS REPORTED IN THE 2ND QUARTER 1978, BUT JNSTfAO rtAS A PROBLEM WITH TRAY TIEDOhN.
THE HOLFS PUNCHED IN THE TRAYS WERE IINDERSI7EO AND THE PUNCHING HAS NOT CLEAN CUT; RAGCEO LOliSF
FIBERS WERE LEFT AROUND IHE PERIMFTER OF THF HOLE. THIS QUARTER, THE BOILERS BIWNEO * "IXTI'BF OF
COAL *ND COKE. THE COAL "AS RATED AT 10,000 BTU/LB AND 0.5* SULFUR, THE COKE MAS KATFO AT 13,1110
BTU/LB AND 3.5% SULFUR. A NET SULFUR CONTENT OF 1.5* IS DESIRfcD. ONE BOILFR WAS !>OwN FOR 30 DA*S,
BUT HAS NOT A RESULT OF SCRUBBER PROBIEMS. ROTH SCRUBBFRS DEMONSTRATED 1001 RELIABILITY.
9fl
-------
STATUS Tf JANUARY 1979
SFCTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOB OPERATIONAL FGP SYSTEMS If! INDUSTRIAL RDTLFHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEIN6 CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
HEAD PAPERBOARO CO.
STEVENSON, ALAHAMA
OTL (1.5X - 31 SULFUK)
100,000 SCFM (TOTAL 2 BOILERS)
1
i
50 MW (EQUIVALENT); TOTAL - 2 BOILERS
(FOR THIS RFPORT, UNLESS STATED OTHERWISE, 3000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THF PRIMARY FACTOR IW MODULE SIZINB.)
AIRPOL INDUSTRIES
SODIUM CARBONATE SCRUBBING
NEW
1975
OPERATIONAL
95X (1,500 PPM 9 INLET)
90%
ALKALINE SIILFITF/BISULFTTE RECYCLED TO PULP PROCESS
RECOVERED SOLUTION USED AS MAKE-UP TO COOKING LI3UOR IN PULP
MILL.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE MEAD PAPERBOARD COMPANY IN STEVENSON, ALABAMA, IS A NEUTRAL SULFTTE PULP MILL MTH A 500
TON/DAY PULP PRODUCTION RATE. THE MILL HAS A CHEMICAL RECOVERY SYSTEM THAT ABSORBS S02 FROM THE
BILLERUD REACTOR. EFFLUENT FROM THE RECOVERY SYSTEM FLOWS BACK TO THE PULPING OPERATION.
ELSEWHERE ON-SITE, AN AIRPOL INDUSTRIES ABSORBER TOWER CONTROLS PARTtCULATF AND S02 EMISSIONS
FROM TNO OIL-FIRED (1.5X - 3.OX SULFUR) COMBUSTION-ENGINEERING PACKAGE BOILERS EACH PRODUCING
175,000 LB/HR STEAM AT 600 PSI. THE BOILERS ARE TYPICALLY OPERATED AT ROX OF MAXIMUM LOAD. FLUE
SAS VOLUME INTO THE SCRUBBER IS 173,000 ACFM a 050 F. HOT GASES PASS THROUGH A STAINLESS STEEL
VENTURI/OUENCH SECTION FOR COOLING AND TMTTAI S02 REMOVAL. THF FLUE GAS THEN ENTERS THE BOTTOM OF
THE ARSOR8ER SECTION AND PASSES UP THROUGH THREE BURBLE-CAP TRAYS. A SODIUM CARBONATE SOLUTION IS
INTRODUCED THROUGH A BANK OF FIGHT, 1.5-INCH NOZZLES CONSTRUCTED OF 316L SS AND SPIN VANES. THE
SOLUTION IS ADDED TO THE RECIRCULATION I!«E ON THE SUCTION SIDE OF THE RECTRCULATTON PUMP AT A RATE
OF 20-25 GPM. SCRUBBER EFFLUENT, MOSTLY SOOIUH SULF1TE, TS SENT TO THE MILLS PULPING OPERATIONS BY
A CONTINUOUS BLEED-OFF LINF AT 30-35 GPM FQR EVENTUAL USE IN THE DIGESTERS.
MILL MATER IS ADDED TO THE RECIRCULATION TANKS t»HEN NFEOFD TO COVER EVAPORATION LOSSES. IT IS
NOT A CONTINUOUS FLOW. EVAPORATION LOSSFS AWE ESTIMATED TO BE APPROXIMATELY 1UO GPM. THF WECTRCUL-
ATION RATF TO THE VENTIIRI IS APPROXIMATFLY ?00(. RPM AND THE HFCIRCULAT ION RATF Til THE ABSORRFH FS
-------
STATUS TO .IANUAWY 1979
5Fcnnw 9 fcniMTiNUFii)
PFHFORM4NCF nfSCTPtTUM FdC OPFKAITONAI FliO SYSTFMS ON INDUSTRIAL HOILFHS
MEAD PAPERBOAfJD CO.; STFvFNSON, ALABAMA (CUNT IMJEO)
ABOUT 1200 GPM. THE RAS FXIIS 1HHUIIGH A FIBERGLASS STACK AT APPROXIMATELY 140 F.
THE PH MONITORING SYSTEM CONSISTS OF A FIBFRGLASS BOK MOUNTED ON THE REC IRCHLATTON TANK. OVER-
FLOW FROM THE TANK TO THE BOX INSURFS COKT1NUOUS FLOW.
OPERATING HISTORY
EARLY OPFRATIONS
THE SO? SCRUBBING SYSTEM WAS DOWN FROM MARCH THROUGH JULY 1976 DUE TO ABRASION PROBLEMS. THE
ABRASION WAS CAUSFO PARTIALLY BY HIGH STRF.AM VELOCITY THROUGH THE EXISTENT VENTIIRI PARTICIPATE
SCRUBBER INTO THE SO? SCRUBBER. SODIUM CARBONATE AND CARBON PARTICLES THAT HAD NOT GONE INTO SOLU-
TION ALSO WERF VERY ABRASIVE TO THE S02 SCRUBBER LINING. IN ADDITION, THE ORIGINAL GLASS-FLAKE"
LINER (5 MM THICK) WAS EXPERIENCING STRESS CRACKING.
THE HIGH VELOCITIES INTRODUCED BY THE VENTIIRI WFRE ELIMINATED BY REMOVING THE P»STICUL*TE
VENTIIRI SECTION OF THF SYSTEM. THE GLASS-FLAKED LINING WAS PATCHED WITH $60,000 WORTH OF CARPENTER
20 LINER. THESE CORRECTIVE ACTIONS HELPED FOR A WHILE, BUT AS IT TURNED OUT, THE CARPENTER 20 WAS
NOT INSTALLED PROPERLY AND SOLUTION WAS GETTING BETWEEN IT AND THE MRD STEEL SHELL. IT MAS FINALLY
DECIDED TO INSTALL NEW RUBBER LINING 1NSIOF THF ENTIRE SCRUBBER, INCLUDING THF SPIN VANES, AT A COST
OF 1150,000. TO PREVENT ANY HEAT PROBLEMS, ADDITIONAL NOZZLES WERE INSTALLED. TO DATE, NO MAJOR
PROBLEMS HAVE OCCURRED WITH THE RUBBER LINING.
SCRUBBER MAINTENANCE is PERFORMED WHENEVER MILL OPERATIONS CEASE FOR ROUTINE PLANT MAINTENANCE
WHICH OCCURS SEVERAL TIMES PFS YEAH. THE PH CONTROL SYSTEM RECEIVES CONTINUING MAINTENANCE AND THE
PH PROBES ARE CLEANED ONCF PER WFEK.
RFFER TO FIGURE 10-3S IN SECTION 14 FOR A DETAIIF.D PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH OUARTER-1977 MINOR FMflRITtI.EMENT, DUE TO LOCALIZED HIGH TEMPERATURE, HAS BEEN DETECTED ON THE
LINING SURFACE. SOMF MFTAL, NOZZLES, AND RUBBER HVAVE BEEN REPLACED.
2ND OUARTER-197A THt PLANT MAS DOWN 12 OATS IN JUNE FOR A MAJOR PAPER MACHINE UPDATE, AND THE
BOILERS WERE DOWN 9 DAYS DURING THAT PERIOD. DURING BOILER DOWNTIME, THE RUBBER LINERS IN THE
ABSORBER MODULE WERE RfcPAIRED AND MODIFICATIONS *£RF MADE AT THE INLET TO THE ABSORBER, REDIRECTING
AIR FLOW Tn MINIMIZE FURTHER FLYASH ABRASION OF THE LINERS. THE PLANT REPORTED AN OPERABILITY OF
JOOX FOR THE FGO SYSTEM.
3RD QUARTER-197B »N AVAILABILITY OF 1001 MAS SFPOKTEO FOR THF FGO SYSTEM DURING THIS PERIOD.
4TH OIIARTFR-197S THF. RUBBER LINER IN THE ABSORBFP AND THE DEFLECTOR SHIELD AT THE INLET OF THE
96
-------
STATUS TO JAUIIAHT I"»79
SECTION 0 (tOKTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGn SYSTEMS ON 1NDUSTKIAL BIIILFRS
HEAD PAPERBOARO CO.J STEVENSON, ALABAMA (CONTINUED)
ABSORBER ARF HOLOINK *ELL. THE PLANT HAS REPORTED 1001 RELIABILITY FOR THE SCRUBBER. ONE OF THE
BOILERS MAS DONN FOR Z4 HOURS AND THE OTHER MAS DOMN FOR 48 HOURS IN NOVEMBER FOR THE REPLACEMENT
OF SEALS AND PREHEATERS. THE SCRUBBER MAS CHECKED AT THIS TIME. NORMALLY THE SCRUBBER IS INSPECTED
NO MORE THAN TMICE A YEAR AND THESE INSPECTIONS AR€ DURING SCHEDULER MILL SHUTDOMNS. FOUR NOZZLES
IN THE ABSORBER MERE REPLACED ON DECEMBER 1ST, WITHOUT ANY DOWNTIME.
THF. PLANT is CONSIDERING CHANGING THE PH CONTROLLED MAKE-UP LIQUOR FEED TO A FLO* CONTROLLED
FEED BECAUSE THE PH PROBES ARE HARD TO KEFP CALIBRATED AND ARE UNRELIABLE.
97
-------
STATUS TO JANUARY 197<»
SECTION <> (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPFWATIONAL FPO SYSTEMS ON INDUSTKIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEH / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MINN-DAK FARMER'S CO-OPERATIVE
WAHPETON, NORTH DAKOTA
LIGNITE (1.05! SULFUR)
1M.OOO SCFM (TOTAL - 2 BOILERS)
2
2
82 M* (EQUIVALENT)} TOTAL - 2 BOILERS
TWO BOILERS, EACH a 275,000 LBS/HR STEAM ^50 PSIG - 055 F)
(FOR THIS REPORT* UNLESS STATFD OTHERWISE, 2000 SCFM = 1 EQUIVALENT Mh.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MOOULE SIZING.)
KOCH ENGINEERING
AMMONIA SCRUBBING
RETROFIT
JIINF, 1977
OPERATIONAL
TESTS INCONCLUSIVE.
200 CPM AMMONIACAL WASTE STREAM
WASTEWATER TREATMENT
BLEED STREAM GOES TO AN ACTIVATED SLUDGE SYSTEM a 160 GPM
ANAEROBIC OIGFSTION, FOLLOWED BY AN OPEN POND, FOLLOWED BY
AEROBIC DIGESTION.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
MTNN-DAK FARMER'S CO-OP. HAS A SUGAR FACTORY AT WAHPETON, NORTH DAKOTA. THERE ARE TwO BOILERS,
EACH WITH A CAPACITY OF 275,000 LBS STEAP/HR AT 250 PSIG AND «55 F. EACH BOILER GENERATES 125,000
ACFM OF FLUE GAS AT 350 F. THE FUEL BURNED IS IX SULFUR LIGNITE. SULFUR DIOXIDE REMOVAL IS EFFECT-
ED BY AN AMMONIA WASTE STREAM FROM AN ON-SITE PROCESS ADDEu TO THE RECIRCULATING SCRUBBER LIOUOR.
KOCH ENGINEERING HAS SUPPLIED TWO VARIABLE THROAT VFNTURI SCRUBBERS WITH OPEN ENDED PIPE INLETS*
FOR SCRUBBING LIOUOR. THE SYSTEM WAS PRIMARILY DESIGNED FOR PARTICULATE CONTROL. INLET CONCENTRA-
TIONS OF SO? AND PARTTC'ILATF ARE Tb-l<»3 LB/HB AND .3-.4 GR/SCF RESPECTIVELY. OUTLET CONCENTRATIONS
OF S02 ANO PARTICULATE ARE 10-J7 LH/NR AND .027-.05» ftk/SCF kESPECTIVELY. THE GAS FROM EACH VENTURI
IS ROUTED THROUGH A CHEVRON-TYPE MIST ELIMINATOR AND ONF 7 FOOT X 130 FOOT STACK. THE PRESSURE DROP
ACROSS FACH SCRUBBER IS 11 INCHES n.6. THf SCRUBBER IIOUQH IS RECIRCULATED AT A RATE OF 2000 GPM
FROM A CONCRETE TAH-LINFO HECIKCIIL ATION PIT APPHOX JM4TEI » 10 FT X 10 FT X 10 FT. THE HECIRCllL AT ION
PUMP IS HATFO AT 75 HP AND 3000 GPM. ANOTHER PUMP IS KFPT ON STANDBY. SCRUBBER SLOWDOWN IS a«h GPM
TO AN AEROBIC DIGESTER. AFTER THF DIGESTER 1HE WASTF STREAM GOES TO AN 0<»Eh POND, THEN AN AEROBIC
DIGESTER, THfW AGAIN TU A POND.
-------
STATUS in JANUARY 1
SECTION <» (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL pen SYSTFMS ON INDUSTRIAL BHHMS
MINN-DAK FARMER'S CO-OPERATIVE; WAHPETON, NORTH DAKOTA (CONTINUED)
THERE ARE A TOTAL OF FIVE PONOS ON SITE, FOUR KASTEWATER AND ONE MAIN RFSEWVOIH. THE FOUR
WASTEWATF.R PONDS ARE USED INTERCHANGEABLY FOR MAKE-UP AN'O .tASTf DISPOSAL. MAKE-UP 10 THE PEClKCtlL-
ATION TANK IS 500 SPM WHERE PH IS MAINTAINED AT APPROXIMATELY 5.a. WHEN ADfMTIONAL MAKE-UP IS
REQUIRED, IT IS OBTAINED FROM THE BAROMETRIC CONOENSORS. THE BAROMETRIC CONDENSER *ATE» IS THE
MAKE-UP WATER THAT CONTAINS THE "AMMONIACAL WASTE hASTE WHICH REMOVES SO?. THTS MAKE-UP IS NOT A
CONTINUOUS FLOW.
DEMISTER WASH WATER IS ALSO BAROMETRIC CONOENSOR WATER AND IS A 250 6PM SPRAY EVERY 8 HOURS.
THE PUMPS USED FOR PUMPING MAKF-UP FROM THF PONOS AND SCRUBBER RLflWDOWN ARE LOCATFn TN A CENTRAL
PUMPHOUSE. THERE ARE SEVERAL PUMPS WHJCH ARE USED INTERCHANGEABLY. 80 GPM HATER LOSS TO THE
ATMOSPHERE THROUGH THE STACK HAS BEEN CALCULATED, BUT NFVFR MEASURED.
THE SCRUBBERS AND THE LIQUOR INLET PIPES ARE MADE OF 316L SS, THE DECISTER AND STACK ARE II *> SS,
AND THE RECIRCULATING PIPING IS FIBERGLASS. THE TOTAL PURCHASE COST OF THE EfHIIPMENT WAS *300,000
IN 1ST? DOLLARS. INITIALLY THE SYSTEM WAS DESIGNED TO USE A LI"E SLURRY OF PH 10.0 AS THF SCRUBBING
LIQUOR. HOWEVER, DURING THE FIRST SIX WEFKS OF OPERATION, NUMEROUS PLUGGING AND SCALING PROBLEMS
OCCURRED. HENCE. PLANT PERSONNEL BEGAN USING THE AMMONIA-RICH WASTE STREAM FROM ANOTHER ON-SITE
PROCESS IN EARLY 1978.
EACH YEAR, THE PLANT ONLY OPERATES FROM SEPTEMBER - FEBRUARY. THIS IS THE BEET SUGAR PRODUCTION
PERIOD. DURING THE REMAINDER OF THE YEAR, PRODUCTION DISTRIBUTION IS THE MAIN PLANT ACTIVITY.
REFER TO FIGURE ia-J« IN SECTION 11 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QUARTER-1976 THE FGD SYSTEM BEGAN OPERATIONS FOR THE 117B-1979 SEASON ON SEPTEMBER 12. NO
F60-RELATED PROBLEMS OCCURRED. THE WASTE TREATMENT HAS BEEN MODIFIED TO INCLUDE AN ANAEROBIC
OI6ESTER FOLLOWED BY AN OPEN POND ANO AN AEROBIC D1GESTFR.
«TH OUARTER-1978 EXCESSIVE HEAT LOSS WAS A PROBLEM FOR THE DIGESTERS. THEY ARF CURRFNTLY ONLY
PARTIALLY ENCLOSED. PLANS ARE BEING MAOt TO ENCLOSF MORE OF THE WASTE TREATMENT FACILITIES. OTHER-
WISE, THE FGD SYSTEM PERFORMED WELL FOR IHE OUARTEK. PLANT PERSONNEL FEEL MOST OF THEIR INITIAL
PROBLEMS HAVE BEEN SOLVED.
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOB OPERATIONAL FGO SYSTEMS ON INOOSTRTAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOBIL OIL COMPANY
SAN ARDH, CALIFORNIA
OIL (2.OX - 2.251 SULFUR)
175,000 SCFM (TOTAL - 2» BOILERS)
?B
28
9! MM (EQUIVALENT); BOO MM BTU/HR! TOTAL - 28 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 2000 SCFM = 1 EQUIVALENT Ni
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SHINS.)
IN-HOUSE DESIGN
SODIUM HYDROXIDE SCRUBBING
RETROFIT
1970
OPERATIONAL
901 (1500 PPM 3 INLET)
HOLDING POND FOR EVAPORATION
SEE SECTION 11 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE MOBIL OIL COMPANY HAS AN OIL SITE IN SAN ARDO, CALIFORNIA WHERE 20 STEAM 6ENERATORS ARE
USED TO FORCE OIL OUT OF WELLS BY A DEEP WELL STEAM INJECTION PROCESS. THE FUEL USED IS CRUDE OIL
WITH 2 - 2.5Z SULFUR. EACH STEAM GENERATOR IS FOLLOWED BY AN INDIVIDUAL FGD SYSTEM DESIGNED BY
IN-HOUSE ENGINEERING. THE UNITS EXPERIENCED STARTUP IN THE PERIOD FROM 1973 THROUGH 1974.
THERE ARE TWO SIZES OF STEAM GENERATORS; 22MM BTU/HR (20 UNITS) AND 50MM BTU/HR (8 UNITS).
THE SMALL UNITS GENERATE 8,000 ACFM, AND THE LARGE UNITS 18,000 ACFM. THE GASES ARE
SCRUBBED BY A LIHUOR CONSISTING OF NAOH AND ALKALINE OIL FIELD WASTEWATER
-------
STATUS TO JANUARY 1979
SfCTTOW O (CONTINUED)
PERFORMANCE DESCRIPTION FOH (IHFWAI IONM FRf) SYSTEMS (IN TNOIISTHlAi BOILERS
MOBIL OIL COMPANY; SAN AROO, CALIFORNIA (CONTINUED)
CANNOT HE HYPASSETI. THE MISI ELIMINATORS, ORIGINALLY 316L ss, HAVE BEEN LINEO WITH PHI-NOLTC EPOXY
RESTN TO COMBAT CORROSION.
REFF.R TO FIGURF 11-36 IN SECTION 10 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
INADEQUATE MIST REMOVAL HAS RESULTED IN CORROSION OF THE 1.0. FAN IMPELLER. BLADES, AND HUBS,
WHICH NEED REPLACEMENT F.VERY YEAR. THE HIGH CLORIOF CONIFNT IN THE WASTFWATER IS THE PRIMARY CAUSE
OF PITTING OF S3 MATERIAL.
3RD OUARTFR-1978 FOR THIS PERIOD, THERE WAS NO MAJPR DOWNTIME REPDRTF.D AS A RESULT OF EQUIP-
MENT OR PROCESS FAILURE. RELIABILITY WAS ESTIMATED AT ABOUT 901. A BECKKAN PH CONTROL UNIT WAS
INSTALLED ON A SCRUBBING UNIT WITH PLANS TO ADD MORE CONTROLLERS.
«TH OUABTER-197D THE I.D. FANS ARE ALSO LINED WITH EPOXY RESIN TO REDUCE CORROSION. THE BFCK-
MAN PH CONTROLLER HAS PERFORMED WELL AND SEVERAL MORF OF THESF DEVICES HAVE BEEN INSTALLED. THE
AVERAGE AVAILABILITY OF AN FGD SYSTEM WAS ABOUT 95 PERCENT.
101
-------
STATUS TO JANU»R* 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INOUSTRTAt BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SWEN STATUS
802 REMOVAL EFFICIENCY
PARTICULARS REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDBE Off BY-PRODUCT DISPOSAL
CONTROL 9YSTEM COST
NFKOOSA PAPERS, INC.
ASHDOMN, ARKANSAS
COAL (IS - 1.5X SULFUR)
ill,000 SCFM (TOTAL - 1 BOILER)
2
1
105 Ml* (EQUIVALENT)? DESIGN - 500,000 LB/HR STEAM
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = t EQUIVALENT MW.
THIS IS BECAUSE CAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
AIRPOL INDUSTRIES
CAUSTIC SCRUBBING
NEW
FEBRUARY, 1976
OPERATIONAL
90+X (600 PPM a INLET)
9BZ - 991 (l.«2 GR/SCF AT INLET)
OPEN LOOP
ALKALINE SULFITE/BISULFITE RECYCLED TO PULP PROCESS
302 RECOVERED FROM SODIUM 9ULFITE/SULFATE LIQUOR AND RE-
CYCLED TO PULPING PROCESS.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
TME NEKOOSA-EDMARDS PAPER PULP MILL IN ASMDOMN. ARKANSAS OPERATES A SINGLE 105 MM EQUIVALENT
STEAM BOILER FIRED MITH COAL OR FUEL OIL. THE BOILER IS DESIGNED FOR 500,000 LB/HR STEAM AT 850
PSI. TME COAL HAS 1-1.SX SULFUR AND A HEATING VALUE OF 12,000 BTU/LB. IT IS BURNED AT A RATE OF 27
TONS/HR. TME BOILER IS OPERATED CONTINUOUSLY AT (24 HRS/DAY) 40* TO 60S LOAD.
THO AIRPOL VARIABLE THROAT VENTURI SCRUBBEKS ARE DESIGNED TO REMOVE BOTH SULFUR DIOXIDE AND
PARTICULATE AT AN AVERAGE PRESSURE DROP OF 14-16 INCHES n.G. THE INTENT OF NEKOOSA-EDMARDS MAS TO
MAKE, FROM TME SCRUBBER EFFLUENT, 3ALTCAKE MHICH MOULD BE USED AT THE MILL. EACH VENTURI IS FOLLOW-
ED BY A CYCLONIC SEPARATOR. THE SEPARATORS ARE MILD STEEL WITH FLAKEGLASS LININGS. EACH SCRUBBER
HANDLES HALF OF THE INCOMING FLUE GAS, THE TOTAL AMOUNT OF GAS BEING 325,000 ACFM AT 355 F. THE
INLET S02 CONCENTRATION IS TYPICALLY 600 PPM WITH A PARTICULATE LOADING OF 1.42 GAL/SCFM. SCRUBBING
LIQUOR IS RECIRCULATED AT A RATE OF 2,000 GPM THROUGH PUMPS RATED AT 2,200 GPP.
THE TMfl RFCTRCIILATION TANKS ARf MRf! STFFL »Nfl ARE LINED. TMFRF SIZE IS ESTIMATED TO «F 15 FEET
HIGH X 10 FEET IN DIAMETER. BLOMOOMN FROM THE RECIRCULATION TANKS IS 300 GPM THROUGH PUMPS RATED AT
300 GPM. FROM THE RECIRCULATION TANKS, THE BLOKDOWN GOFS TO AN ASH PONO, THEN A STABILIZATION POND
AND FTNALLT TMF »TVFR. SCRIIBBFR MNHERFl n* CONStSTS OF FLYASH AND * SOLUTION flp NA2S01/S01.
102
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STATUS t(l JANUARY 1979
SFCT10N 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR HPFRA1TONAL FED SYSTEMS ON INOIISTWTAI HIITLFRS
NEKOOSA PAPERS. INC.I ASHOOWN, ARKANSAS (CONTINUED)
CAUSTIC IS USUALLY OBTAINED AS A nASTF STHtAM AFTER THE PULP BLEACHING STAGE. IT IS USED AT A
RATE Of 500-600 GPM, OR 12 LB/MIN OF SODIUM HYDROXIDE AND IS ADDED TO THE RECIRCULATION TANK.
PURCHASED CAUSTIC IS OCCASIONALLY USED. IT IS USED AS A 50X SOLUTION, EXACTLY THE HAY IT IS PUR-
CHASED. THE USAGE RATE IS 1 TO 4 SPM AND IT IS INJECTED ON THE SUCTION SIDE OF THE RECIHCULATION
PUMP. THE PH OF THE .ENTERING CAUSTIC IS 10.5 TO 11. THE PH IN THE RECTRCULATION TANK IS 5.5 TO
6.0. PH PROBES ARE LOCATED IN THE FIBERGLASS LINE BETWEEN THE SEPARATOR AND RECIRCULATION TANK.
GASES ARE EXHAUSTED THROUGH A FLAKEGLASS LINED STACK APPROXIMATELY 12 FEET IN DIAMETER AND 200+
FEET IN HEIBHT. THF OUTLET TEMPFRATURF is 125 F. THFRE is NO RFHFAT.
THE PREDOMINANT DIFFICULTIES WITH THE FSO SYSTEM HAVE BEEN TWO-FOLD. FIRST, THE PLANT HAS HEF.N
UNABLE TO DEVELOP AN ADEQUATE PH CONTROL MECHANISM. THF PH CONTROL SYSTEM MONITORS THE AMOUNT OF
CAUSTIC A6ENT» I.E., SODIUM HYDROXIDE. WHICH GOES INTO THE RECYCLE TANK, KEEPING THE PH OF THE
SCRUBBER SOLUTION AT A NONCORROSIVE LEVEL. THE PLANT HAS BEEN PLAGUED WITH PROBLEMS IN
OPERATING THE PH CONTROL SYSTEM AND HAS SUFFERED A GREAT DEAL OF CORROSION. THE SECOND PROBLEM
CONCERNS THE CHEMICAL REGENERATION PORTION OF THE SYSTEM. THE INTENT OF THF PLANT WAS TO SEPARATE
THE Fit *8H FROM THE 3CRUB8ER LIQUID AND TAKE THE SCRUBBER LIQUID THROUGH A SERIES OF EVAPORATORS
WHERE SODIUM SULFATE, I.E.. SALTCAKE, WOULD BE GENERATED. THE PLANT HAS BEEN UNABLE TO OPERATE THE
FLY ASH SEPARATION SYSTEM PROPERLY, AND THERE IS NOT ENOUGH EVAPORATION CAPACITY FOR THE PLANT TO
PROCESS THE SCRUBBER EFFLUENT AT FULL OPERATIONAL CAPACITY.
IN SPITE OF THE OPERATIONAL PROBLEMS, THE SULFUR DIOXIDE AND PARTICIPATE REMOVAL EFFICIENCIES
OF THE F6D SYSTEM ARE 90 AND 99 PERCENT, RESPECTIVELY, ACCORDING TO THE PLANT ENGINEER. THF WASTE
PRODUCT FROM THE SCRUBBER IS NOT RECYCLED, AT PRESENT, AND IS PUMPED TO THE wASTEWATER TREATMENT
PLANT.
UPON STARTUP, PROBLEMS OCCURRED WITH THE PIPING AND VALVES WHICH WERE CONSTRUCTED OF CARBON
STEEL. THE CARBON STEEL StSTEM WAS REMOVED AND REPLACED WITH STAINLESS STEEL VALVES AND PIPING.
SOME PIPING LEAKS OCCURRED AND WERE REwELDEO. SOME CORROSION OF DUCT DAMPERS OCCURRED AND WFRE RE-
LIEVED BY ADJUSTING THE PH OF THE SCRUBBING LIQUOR.
REFER TO FIGURE 19-37 IN SECTION la FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1977 NO MAJOR PROBLEMS WERE REPORTED. CORROSION PROBLEMS STILL EXIST AND PH CONTROL
IS STILL A PROBLEM. FLOW METERS ARF BEING INSTALLED TO MONITOR SCRUBBER "ATER.
«TH OUARTER-1977 TWO IN LINE FLOW METERS WERE INSTALLED ON EACH SCRUBBER, ONF AT THE THROAT INLET
OF THE VENTURI AND ONE AT THE THROAT. THE PLANT REPORTFO THAT PH CONTROL WAS STILL A PROBLEM.
SOME PROBLEMS WERE BEING ENCOUNTERED WITH THE PH PROBES DUE TO THE CONSTANT FLOW OF LAHGE
AMOUNTS OF SOLIDS, AND SOLIDS DEPOSITS ON THE PROBES.
-------
STATUS TO JANUARY 1979
9 (CDNTIMif-h)
rtFSCRlPTK" r MK npFRATIONAl FGD SYSTFMS ON INDUSTRIAL BtULERS
NEKOOSA PAPFRS, INC.; ASHODHN, ARKANSAS (CONTINUED)
3NO QUARTEH-1<»7« NO MAJOR PROBLEMS OCCIIRREn DURING THE RFpnRT PERIOD. IN JUNF A PARTICIPATE
COMPLIANCE TEST HAS RUN'. PARTICIPATE EMISSIONS HFRF 0.05 LH/MM HTII AGAINST THE 0.1 LB/MM BTU
REGULATION. CAUSTIC SCRUBBING SOIHT10N IS CYCLEO TO THF SCRIIRHFR FROM THE PULP BLEACH PLANT
AT «oo 6PM. THF ROTLFR OPERATED 2153 HOURS AT aoz TO &oz CAPACITY. DURING THAT PERIOD THE SCRUBBER
DEMONSTRATED 1 OOt OPF.RABIL ITY.
3RD QUARTER-197H DURING THIS RFPOPT PERIOD THF ONLY PROBLEM THAT WAS REPORTED WAS A RECYCLE
PUMP FAILURE CAUSING ONE SCRU88FR TO BE DOWN FOR APPROXIMATELY 1.5 DAYS. HOHEVERt OUF TO THE
PARALLEL ARRANGEMENT OF THE SCRUBBING TRAINS AND LOW OPERATING LEVEL OF THE BOILER (40 - 60S), THE
TOTAL FLUE GAS Finn MAS ROUTED THROUGH THF REMAINING SCRUBBER TRAIN. THE BOILER HAS REPORTED
TO OPERATE 24 HOURS PFR DAY DURING THIS PERIOD.
OTH OUARTF.R-1978 DUE TO THE PARALLEL ARRANGEMENT OF THE SCRUBBER MODULES AND LOW BOILER LOADS,
SCRUBBER-RELATED BOILER DOWNTIME IS RARE. THE ENTIRE VOLUME OF FLUE GAS CAN BE ROUTED TO ONE OF THE
SCRUBBERS WHEN THF OT«f.R NEEDS MAINTENANCE WORK. HOMFVER> THE PLANT IS CURRENTLY UNDERGOING EXPAN-
SION WHICH HILL REQUIRE BOILER LOADS OF 80Z TO 90Z. THIS HILL MEAN THAT THE ENTIRE VOLUME OF GAS
HILL NOT BE »BLF TO BE ROUTED THROUGH ONE MODULE AND PLANT PERSONNEL REPORT THAT THEY EXPECT MORE
BOILER DOWNTIME DUE TO FGD PROBLEMS OR AT LEAST REDUCED OPERATING LOADS.
DURING THIS QUARTER, THF LINING OF ONE OF THF SEPARATORS HAS PATCHED. THE LINING HAD SEEN
CHIPPING OFF CAUSING THE MILD STEFL SHELL TO CORRODF. CORROSION LEAKS IN THE SEPARATOR WERE ALSO
REPAIRED. THE BOILER HAS NOT SHUT DOWN. PLANS HAVF BEEN MADE TO RELINE THF SEPARATORS HITH AN AS
YET UNDETERMINED LINING MATERIAL IN THE SPRING.
PURCHASED CAUSTIC (S700-SBOO/DAY) HAS USED 5 TO 4 WEEKS THIS QUARTER SINCE THE PUMP THAT
DELIVERS THE ON-SITE CAUSTIC FROM THF PULP BLEACHING OPERATION BROKE DOHN DUE TO A MECHANICAL
FAILURE. NO SCRUBBER DOWNTIME RESULTED.
PH PROBFS ARE CLEANED THICE HEEKLY. AN AVAILABILITY OF 100Z HAS DEMONSTRATED BY THE F60 SYSTEM.
101
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STATUS TO JANUARY 1979
SECTION 1 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPFRAT TllNftL FGD SYS1FMS ON INOIISTKIAL 80IUFRS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
808 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
NORTHFRN OHIO SUGAR COMPANY
FREFCflNT, OHIO
COAL (IX SULFUR)
80,000 SCFM (TOTAL - 2 BOILERS)
110,000 LB/HR STEAM (TOTAL - 2 BOILERS)
I
?
GREAT WESTERN SUGAR
SODIUM HYDROXIDE SCRUBBING
RETROFIT
OCTOBER, 1975
OPERATIONAL
MASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGD SYSTEM CURRENTLY OPERATING AT THE FREEMONT, OHIO PLANT OF GREAT WESTERN SUGAR
HAS BEEN DESISNFO FOR BOTH SOZ ANf> PARTICIPATE CONTROL. THE SYSTEM CONSISTS OF A VARIABLE THROAT
VENTURI SCRUBBER MITH A SINGLE PASS, THREE STAGE CHEVRON DEMISTER.
A BLEED-OFF STREAM OF SCRUBBER EFFLUENT IS CONTINUOUSLY DISCHARGED TO A HOLDING POND FOR
TREATMENT.
REFF.R TO FIGURE 11-26 IN SECTION 1« FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
10-5
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE RESCRIPT TON FOH OPFRATIONAL FGO SYSTEMS ON INDUSTRIAL BOTLEKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOB REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUOSE OR RY-PROOUCT DISPOSAL
CONTROL SYSTEM COST
RICKENHACKER AIR FORCE
COLUMBUS, OHIO
COAL (3.6% SULFUR)
55,000 SCFM (TOTAL - 7 fiOTLERS)
277,000 L8/HR STEAM
1
7
27 M* (EQUIVALENT)? TOTAL - 7 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EUUIVALENT MK-.
THIS IS HFCAUSE GAS FLOW RATE IS THF PRIMARY FACTOR IN MOOULf SI/ING.)
RESEARCH-HUTTRFLL/BAHCO
LIMESTONE SCRUBBING
RETROFIT
MARCH, 1976
OPERATIONAL
90X* (OFSI6N)
ACTUAL REMOVAL IS NOW LOWER DUE TO EASING UF REGULATIONS.
981
OPEN LOOP - 2.5 GPM/MW (MAX)
NON-FIXATFO SLURRY TO LINED POND
UNSTABILI7F.H TASOS/SOO SLUDGE TO LINED POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
ON MARCH 11, 1976 THE FIRST U.S. INSTALLATION OF THF SWEDISH BAHCO SULFUR OIOXIDF. REMOVAL SYSTF.M
HAS PLACED IN SERVICE AT RICKENBACKER AIR FORCfc BASE IN COLUMBUS, OHIO. THF SYSTEM, MANUFACTURED
BY A.B. BAHCO VENTILATION OF ENKOPING, SwFOEN, DISTRIBUTED EXCLUSIVELY IN THE UNITED STATES BY
RESEARCH/COTTRELL, WAS ORIGINALLY INSTALLED AT RICKENBACKER TO HANDLE THE FLUE GAS FROM SEVEN
31 MM BTU/HR STOKER-TYPE COAL FIRED BOILERS INSTALLED BFTWEFN 1951 AND 1956. IN JUNE 1977, A NFh
60 MM BTU/HR BOILER CAME INTO SERVICE. THIS UNIT SFPLACEO Z OF THE OLDER BOILERS, AND A THIRD WAS
PLACED ON STAND-BY. THE BOILERS ALL FIRE A HIGH SUIFIIR (3.6Z) COAL.
THE RICKENBACKER EMISSION CONTROL SYSTEM CONSISTS ESSENTIALLY OF A MECHANICAL COLLECTOR, 2-STAGF.
BACHO SCRUBBER TOWER, LIMESTONE STORAGE AND HANDLING SYSTEM, CLARIFIER, BOOSTER FAN AND ASSOCTATfO
DUCT-WORK, PUMPS, CONTROLS, AND A SLUDGE DISPOSAL POND.
SOLID PARTICULATE AND SULFUR OIOXIDE-LADFN FLUE GAS TAKEN FROM FACH OF THF EXISTING SIX
STACKS IS FED THROUGH A COMMON HEADER AND INTO A MECHANICAL COLLECTOR WHERE PRIMARY PARTICULATE
REMOVAL TAKES PLACE. THE MECHANICAL COLLECTOR HAS A DESIGN REMOVAL EFFICIENCY OF 70 PERCENT AND
WAS INSTALLED PMIMAHILY III REOMCfc FAN .HEAR. THF PARTIALLY CLEANtO GAS THFN FLOWS INTO THF BACHO
106
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STATUS TO JANUARY 19T9
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERA! Tf)*»l FGD SYSTEMS ON INDUSTRIAL BOILERS
RICKENBACKER AIR FORCE BASE} COLUMBUS, OHIO (CONTINUED)
TOWER WHERE ADDITIONAL PARTICULATE AND PRIMARY SULFUR DIOXIDE REMOVAL TAKES PLACE.
THE BACHO SCRUBBING VESSEL IS A VERTICAL TOWER CONSISTING OF TWO SCRUBBING STAGES. GAS FLOWS
*
THROUGH THE TOWER WHERE IT IS CONTACTED KITH A LIMESTONE SLURRY. AFTER PASSING THROUGH THE
FIRST SCRUBBIN8 STA6E, ENTRAINED MOISTURE IS REMOVED BY A CYCLONIC TYPE MIST ELIMINATOR. THE
GAS THEN PASSES THROUGH A SECOND SCRUBBING STAGE AND A SECOND CYCLONIC MIST ELIMINATOR. THE
CLEANED GAS IS DISCHARGED TO THE ATMOSPHERE THROUGH A STUB STACK ATOP THE ABSORBER TONER.
FINE MESH LIMESTONE IS EMPLOYED AS THE REAGENT IN THE SCRUBBING SYSTEM. THE SCRUBBING SLURRY IS
PUMPED TO THE ABSORBER WHERE IT TS CONTACTED WITH THE FLUE GAS IN A COUNTERCURRENT FASHION.
THE SPENT SCRUBBING SOLUTION IS DISCHARGED TO THE THICKENER WHERE THE WASTE SOLIDS SETTLE OUT.
THICKENER OVERFLOW IS RETURNED TO THE MIX/HOLD TANK. THICKENER UNDERFLOW IS DISCHARGED TO A 5-
*CR€ HVfNU.OH-t.INEn DISPOSAL POND. THIS POND IS LOCATED APPROXIMATELY 000 FEET FROM THE ABSORBER
TOMER* CLEAR WATER FROM THE POND IS RETURNED TO THE PROCESS AS MAKE-UP WATER IN THE SLURRY TANK.
REFER TO FIGURE 10-39 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
MM* 76 THROUGH OCT. 76 THE INITIAL OPERATION PROCEEDED IN AN OPEN-WATER-LOOP MODE BECAUSE THE
THICKENER MAS NOT VET COMPLETELY INSTALLED. SULFUR DIOXIDE INLET CONCENTRATIONS WERE IN THE 1SOO TO
2000 PPM RANGE. HIGH OXYGEN CONCENTRATIONS ALSO EXISTED IN THE FLUE GAS BECAUSE THESE OLDER, IN-
EFFICIENT BOILERS OPERATE AT 150 TO 160 PERCENT EXCESS AIR RATES. SULFER DIOXIDE REMOVAL EFFICIFNCY
HAS IN THE LOW <>0 PERCENT PLUS RANGE. EARLY PROBLEMS HERE PRIMARILY OF A MECHANICAL NATURE USUALLY
ASSOCIATED WITH START-UP. THE MAJOR START-UP PROBLEMS HERE AS FOLLOWS:
IIP PROBLEMS WERE AS FOLLOWS!
1. ELECTRICAL CIRCUITS AND SYSTEM CONTROL PANEL.
2. PUMP MALFUNCTION-SPARE PARTS SHIPMENT DELAY.
3. SEDIMENTATION BUILDUP IN THE SCRUBBER VESSEL (THIS WAS DUE PRIMARILY TO OPERATION AT
HIGHER THAN DESIGN SOLIDS CONCENTRATION IN THE SCRUBBING SOLUTION BECAUSE THE THICKENFR
WAS NOT TET IN SERVICE PLUS GRIT GETTING THROUGH THE LIME SLAKER GRIT REMOVAL STEP).
4. FAMILIARIZATION OF THE OPERATING S1AFF WITH THE MECHANICS OF THE PROCESS.
5. 1.0. BOOSTER FAN PROBLEMS. ADDITIONAL BRACING, AND EPOXY GROUTING "AS REQUIRED TO STOP
THE ELEVATED FAN CONCRETE SUPPORT FROM VIBRATING WHILE THE FAN WAS OPERATING.
NOV. 76 THROUGH JUN. 77 DOWNTIME WAS LESS THAN 5X. OPERATING PROBLEMS WERF MECHANICAL- AND
CONTROL- RATHER THAN PROCESS-RELATED. FAN-RELATED PROBLEMS ACCOUNTED FOH OVER 75* OF THE ACTUAL
DOWN-TIME. THIS RESULTED FROM EXCESSIVE FAN VIBRATIONS CAUSED BY BEARING, SUPPORT, AND INSTRUMENT-
ATION DIFFICULTIES. IN APRIL 1977. THE FAN WHEEL DEVELOPED A CRACK IN THE RIM ATTRIBUTED TO
FATIGUE FROM RESONANT VIBRATION. THE FAN NAS SENT BACK TO THE MANUFACTURER, AMFRICAN STANDARD, »HO
107
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STATUS 10 JANUARY lilt
SETT inn. 9 (rn;»TiwiFo)
DESCRIPTION FOP HPFWA1TONAL FB5 SYSTEMS (IN fNIHISTHIAL BOILERS
RICKENBACKFR AIR FORCE RASEj COLUMBUS, OHIO (CONTINUED)
MADE THE REIIItBEn MODIFICATIONS. THE ORIGINAL FAN WSS RADIAL BLADE WITH RIMS, AND A MAJOR MODIFI-
CATION HAS CHOPPING THE RIMS OFF, THFREBY REDUCING THE DIAMETER. THE FAN w»s RETURNED IN EARLY MAY
AND THE VIBRATION PROBLEM WAS SOLVED. OTHER OPERATIONS flERE RELATIVELY PROBLEM-FREE. THERE WERE
NO CORROSION, EROSION, SCALING, OR PLUGGING PROBLEMS. THE SYSTEM BEGAN RUNNING ON LIMESTONE IN
APRIL, AS PART OF THE EPA TEST PROGRAM. LIMESTONE PERFORMED WELL, YIELDING AOEOUATE REMOVAL.
ON JUNE 3RD, THE STFAM PLANT WAS SHUTDOWN FOR THE TTE-IN OF THE NEW NO. 8 BOILER. TIE IN WAS COM-
PLETED IN JIJN€.
AUG. 77 THE ARMS BROKE OFF IN THE 35-FOOT DIAMETER THICKENER TANK, CAUSING A 30 DAY DOWNTIME.
SEP. 77 A HAKF-UP KATF.R BOOSTER PUMP HAD TO HF REPLACED.
OCT. 77 THE MOTOR DRIVE ON THE SLAKER BELT HAD TO BF REPAIRED. ALTHOUGH THE SLAKER IS NO LONGER
USED HITH THE LIMESTONE REAGENT, THE BELT IS USED TO CONVEY THE LIMESTONE TO THE DISSOLVING TANK.
1ST QUARTER-1<)7 8 IT WAS DISCOVERED THAT WITH A STOICHIOMF.TRIC RATIO OF 0.75 THE REQUIRED DEGREE
OF 302 REMOVAL CAN BE ACHIEVED. THE CURRENT REGULATION LIMITS EMISSIONS TO 2.2 LBS/MK BTU HEAT
INPUT. DURING THE JANUARY BLIZZARD, SOME FREEZE-UP PROBLEMS WERE ENCOUNTERED.
DURING JANUARY THE BOILERS OPERATED 744 HOURS AND THE FGU SYSTEM OPERATED 546 HOURS YIELDING OPER-
ABILITY AND AVAILABILITY INDEX VALUES OF 801. ALL DOWNTIME WAS ATTRIBUTABLE TO FREEZE-UPS DURING
BLI7ZARD CONDITIONS. DURING FEBRUARY, THF BOILERS OPERATED b?a HOURS AND THE CONTROL SYSTEM OPERA-
TED 168 HOURS. HOWEVER THE FGO SYSTEM WAS AVAILABLE 55! HOURS. THEREFORE THE OPERABILITY INDEX WAS
351 WHILE THF AVAILABILITY WAS 82*. THE ABSORBER LINES WERE THAWED OUT FEBRUARY 6, BUT DURING
FEBRUARY, THE GOVERNOR OF OHIO TEMPORARILY SHELVED POLLUTION CONTROL REGULATIONS. THEREFORE THE
F6D SYSTEM WAS NOT OPERATED ALTHOUGH IT WAS AVAILABLE FOR OPERATION. THE SYSTEM WAS SHUTDOWN ON
FEBRUARY 13 AND DIO NOT OPERATE DURING MARCH.
2ND OIIAHTER-l^TB SYSTEM WAS RESTARTED APRIL 10 AND WAS REPORTED TO HAVE RUN WITH A 100* OPERA-
BILITY INDEX VALUF FOR THE REMAINING PERIOD. PLANT REPORTED THAT ALL PREVIOUS PROBLEMS HAVE
BEEN CORRECTED. DURING THE LAST PORTION OF THE 2ND QUARTER THE BOILER LOAD DROPPED TO ITS SUMMER
LEVEL, ABOUT SO MM BTH/HR, AS OPPOSED TO THE MAXIMUM COLO SEASON LOAD OF 150 MM BTU/HR.
3RD QIIARTFR-1978 THE SYSTEM OPERATED hITH AN AVAILABILITY INDEX OF OVER 99.51 FOR THE
PERIOD. THE SCRUBBER WAS CLEANED AND INSPECTED DURING A 5-OAY BOILER MAINTENANCE OUTAGE AND
FOUND TO «E RFLATIVFLY FRFE OF CORROSION AND SCALING. THF SYSTEM WAS OBTAINING ABOUT 75% 802
REMOVAL, WHTCH WAS SUFFICIENT TO MEET THE REGULATION. WHILE THE BOILER IS OPERATING AT ITS REDUCED
SUMMER LOAD, FRESH MAKE-UP AIR IS BEING MIXED WITH THE FLUE GAS ENTERING THE F.D. FAN TO MAINTAIN
FULL CAS P»FSSU»E AMD VELOCITY THROUGH THF ABSORBER.
108
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STATUS TO JANUARY 1
-------
STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR flPFRATIONAl FGD StSTFMS ON INDUSTRIAL BUUERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F6D UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOE REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ST. REGIS PAPEK CO.
CANTONMENT. FLORIDA
BARK,01L/GAS (< i.OX SULFUR)
115.000 SCFM (I BOILER)
1
1
57 MW (EQUIVALENT)? DESIGN - 100,000 LR/HR STEAM
(FOR THIS REPORT, UNLESS STATED OTHERWISE^ 3000 SCFH = I EQUIVALENT Mh.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACIOR IN MODULE SIZING.)
AIRPOL INDUSTRIES
CAUSTIC SCRUBBING
RETROFIT
1973
OPERATIONAL
801 - 90X
90.5X (100 LB/HR AT INLET)
OPEN LOOP; 200 GPM-250 GPM SCRUBBING LIQUOR FEED
WASTfcWATFR TREATMENT
EFFLUENT IS TREATED IN AN ON-SITE SEWAGE TREATMENT PLANT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE BOILER AT ST. REGIS PAPER LOCATED IN CANTONMENT, FLORIDA IS RATED AT 57 MW EQUIVALENT AND
PRODUCES 300,000 LBS/HR STEAM. THE TYPICAL SULFUR CONTENT OF THE FUEL (OIL OR BARK, NATURAL GAS) IS
LESS THAN IX. THE HEATING VALUES OF THE FUELS ARF AS FOLLOWS; BARK d SOX HOIS URE IS 4030 BTU/LR,
THE OIL IS 6,000,000 RTII/BARREL AND THE GAS IS IflOO BTU PER CUBIC FOOT.
THE SCRUBBER SYSTEM WAS RETROFITTED BY AIRPOL IN 1973. THE UNIT IS CONSTRUCTED OF 31f>L STAIN-
LESS STEEL AND HANDLES 8 TOTAL FLUE RAS VOLHMF OF 175,000 ACFM. PARTICULATFS »RE CONTROLLED BY
CYCLONES PRECEDING THE SCRUBBER. SCRUBBER PRESSURE D«OP IS APPROXIMATELY 10 IN. W.G. WITH RD-90X
SULFUR DIOXIDE REMOVAL EFFICIENCY. THE SCRUBBER TS FOLLOWED BY A CHEVRON-TYPE MIST ELIMINATOR.
SCRUBBER UNDERFLOW CONSISTS UF ASH AND A SODIUM SULFITE/SULFATE SOLUTION. BLOWDOWN FROM THE
SCRUBBER OCCURS EVERY FEW MINUTES. TO MAINTAIN THE RECIHCULATION TANK AT A CONSTANT VOLUME, A SOL-
ENOID IS USED WHICH AUTOMATICALLY OPENS A VALVE AND INTRODUCES MAKE-UP WATER WHEN THE LEVEL OF THE
LIQUOR DROPS TO A CERTAIN POINT. THE TANK HAS A CAPACITY OF 9000-5000 GALLONS AND IS MADE OF 30«
STAINLESS STEFL. A BLEED-OFF SIHEAM FROM THE RfcClRCHLATION TANK IS SENT TO AN ON-SITE SFWAGE TREAT-
MENT PLANT WHFRE IT HFCEIVES PRIMARY CLARIFICATION AND AERATION/STABILIZATION STABILIZATION FOR RED-
UCTION OF BTOI OR1CAL (IXYGEN DEMAND (BOD).
RFFFR TO FIRIlRF 1O-0? IN Sf-CTIUN la Fflfc A f.FIAHEn PrtncFSS FLOW OIARRAM (IF THIS SYSTEM.
HO
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STATUS TO JAWIAHY
SECTION <» (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPFkAT IllfcAl FGO SYSTFf.S ON rNDUSTRTAI ROTLF.RS
ST. RE6J3 PAPER CO.? CANTONMENT, FLORIDA (CONTINUED)
OPERATING HISTORY
3RD QUARTER-1977 WOOD FIBERS FROM BARK HERE CLOGGING SEPARATORS AND CONTROL VALVES. INSPECTION
HAS HADE AND SOLUTION TO PROBLEM WAS BEING INVESTIGATED.
ATM QUARTER-1977 AFTER INVESTIGATION OF THE CLOGGING PROBLEM IT WAS DECIDED To CHANGE THF h-AKF-IIP
HATER SOURCE. WATER IS NOW OBTAINED FROM A CLEANER PORTION OF THE PROCESS LOOP. PLANT REPORTS
SATISFACTORY OPERATIONS *»ITH NO OTHER MAJOR PROBLEMS.
2ND QUARTER-1
-------
STATUS TO JANUARY t<»79
N 9 (CONTINUED)
PK»FORM»NCF DESCRIPTION POM OPtH AT TOtfAL FGf> SYSTFMS ON INDUSTRIAL BOILERS
INSTALLATIMN NAMF
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER HF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
TFXACO INri)RPn»»TEI>
SAN •RPO, CALIFORNIA
OIL (1.7X SULFUR)
3ftO,UQO SCFM (TOTAL - 32 BOILERS)
24,000 ACFM a 600 F, FOR EACH OF 25 F6D SYSTFMS
70,000 ACFM a 600 F, FOR EACH OF 2 FGD SYSTEMS
10,000 ACFM a hOO F, FOR EACH OF 5 SYSTEMS
3?
32
!00 MW (F.QUIVALENT) ; 710 MM BTU/HRS TOTAL- 12 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE* 2000 SCFM = 1 EQUIVALENT HK.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
CEILCOTE
SODIUM HYDROXIDE SCRUBBING
RETROFIT
NOVEMBER, 1973
OPERATIONAL
731 (1000 PPM a INLET)
WASTEMATER TREATMENT
HALF OF THE SCRUBBER UNDERFLOW IS TREATED AND RECYCLED AS
BOILER FEFDWATER; THE OTHER HALF GOES TO WASTEWATER
DISPOSAL WELLS.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
TEXACO IISFS SEVERAL OTL-FIRF0 BOILERS AT THE SAN ARnfl, CALIFORNIA SITE. THE STEAM IS INJECTED
INTO OIL WELLS TO FACILITATE OIL FLOW. TH£RF ARE THREE DIFFERENT SIZES OF THE BOILERS: 2 a 180 MM
BTU/HR, AND 25 a 50 MM BTU/HR, AND 5 3 30 MM BTU/HR. THE FUEL OIL HAS A TYPICAL SULFER CONTENT OF
1.7X.
THE FLUE GASES (70,000 ACFM FROM THE LARGE, 34,000 ACFM FROM THE INTERMEDIATE* AND 10,000 ACFM
FROM THE SMALL GENERATORS it 60O F) ARE SCRUBBED BY FGD SYSTEMS SUPPLIED BY CEILtOTE COMPANY IN
NOVEMBER 1973. EACH BOILER IS FOLLOWED BY A OUENCHTNG CHAMBER AND A SCRUBBFR. THE SCRUBBERS, WHICH
ARE HORIZONTAL TOWERS PACKED WITH 2 IN. TELLERITE PACKINGS, ARE OF SIZES: 15 FT X 20 FT (2 UNITS),
7 FT X 8 FT X 12 FT C?5 UNITS), AND THF GAS FLOWS ACROSS THE HORIZONTAL SCRUBBER WHEREAS
THE LIQUID TS SPRAYED PRIMARILY IN A CROSS-CURRENT MOOE. THE ABSORBER SECTION IS FOLLOWED BY A
SHORTER PACKEO DEPTH WHICH SERVES AS A MIST ELIMINATOR (M-E). THE SCRUBBING LIQUOR IS A MIXTURE
OF NATURAL WATER AND Sill NAOH SOLUTION. THE TYPICAL LIQUID MASS FLUX VALUES ARE 2000 - 3000
LBS/HR FT?. A I/G RATIO flF 14 fJAI/1000 SCF IS I1SFO AND PH AT THE INLET IS 8.0. THE FLUE GASES
11?
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STATUS TO JAMIAttY l°7<»
SFCTTO'j Q (rniiTINUFO)
NI F Of SCRIPT M.'I HIP r>HFW41Tl)NA| FGI» SYSfFiS nu T.OilSTKIii
TEXACO INCORPORATED: SAN mnit, r»i IFORNIA
ENTFH THE QUENCHERS AT MjO F H\ln 1000 PPM SO? AiJI) Lf.AVF TMF M-F'S AT IhO F -1ITH ?70 PPM SO?. THE
SPFNT LIOUOR IS SPLIT INTO Two STREAMS, ONE RFCYCLF.D AS BOILER FEFO HATER AFTER KEMOVIIxR FLYASH AND
'SOFTENING, THE OTHER ts OTSPUSF.D OF IN WASTE-WATER OISPOSAL WELLS.
THE ARSOHBEB MODULES, I>0*»PSTKFAM DUCTWORK, STACK AND THE T.O. FAN ARE MADF OF F»P, &HFREAS THE
PACKING IS POLYPROPYLENE. THE QUFNCHFU SECTION IS 31* SS, WHFRFAS THE SPFNT LtOllOR PIP1NC, CAUSTIC
TANKS, *NO THE CAUSTIC FEED LINES ARE HJLD STEEL.
RFFFR TO FimiRE 19-aa IN SECTION 10 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
THE MAJOR OPERATIONAL PROBLEM AREAS ARE:
1. THE UUENCHER SECTION HAS SUFFERED SEVERE CORKOSION DUE TO ACIO ATTACK.
S. FRP LTNF.R DETERIORATES DUE TO MECHANICAL ABRASION DURING CLE ING OPERATIONS. IT NEEDS
OCCASIONAL RESURFACING.
J. THE PACKED BpDS ARE FREQUENTLY PLUGGED BY FLYASH. THE OIL IN THE NATURAL LIQUOR HAS CAUSED
FOULING OF THE PACKED BEDS.
a. OCCASIONAL OVERINIECTTON OF CAUSTIC HAS RESULTED IN PLUGGING OF SPRAY NOZZLES BY SCALE.
1ST QUAHTEH-197H DUE m THE LOrt S02 REMOVAL AND HIGH MAINTENANCE COST OF THE ABOVE DESIGN, TEXACO
HAS UNDERTAKEN A TEST PROGRAM WHICH, IF SUCCESFUL, WILL PHASE UIIT THE PRESENT SCRUBBERS BY THE END
OF 1979. FOR MORE INFORMATION ON THE PROGRAM SEE THE OTHER TEXACO, SAN ARDO BACKGROUND INFORMATION
ENTRY IN SECTION 10 OF THIS REPORT.
3ND QUARTER- 147 A THE AVAILABILITY OF EACH F6D SYSTEM WAS APPROXIMATELY 9«X. ON AN AVERAGE, ONE
SYSTEM HAS SHUTDOWN TWO OATS A MONTH FOR MAINTENANCE.
3RD 01IARTFR-1978 THERE MAS NO MAJOR DOWNTIME DUE TO EQUIPMENT OR PROCESS FAILURE. THE SCRUBBERS
XERE DOWN FOR SCHEDULED MAINTENANCE FOR ABOUT 8 HOURS P=R MONTH REOUIRING ABOUT 24-MAN-HOURS PER
UNIT. GENERALLY DURING THIS REGULAR MAINTENANCE PFRIOO THE PACKING IS REPLACED AND THE INTERNALS
INSPECTED AW CLEANED. TFXACO IS CONSIDERING CONVERTING FROM NAOH TO NA2C03 AS THE REAGENT. NO
TIMETABLE MAS BEEN ESTABLISHED FOR SUCH A TRANSITION.
«TH QIIARTER-197S OPERATIONAL PROBLEMS OF CORROSION IN THE OUENCHER, AND ABRASION AND PLUGGING IN
*BSORBER CONTINUED. THE ABSORBERS ARE MOUNTED ATOP THE GENERATORS WITH ONLY i OR z FT CLEARANCE.
HENCE, THF HEAI LOSSES FROM THE RADIATION SECTION WEAKfN THF FHP SHELL OF THE ABSORBERS. IN THIS
ER, EACH SCRUBBER WAS SHUT DOWN FOR MAINTENANCE FOR AN AVERAGE TIME OF 100 HOUBS.
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ST47US TO JANIIAHY IP7<)
SfCTION 9 (CONTINUED!
pfQFMRMiNCF DESCRIPTION FOR OPERATIONAL FOn SYSTEMS ON fNOUSTHTAI BOTLFHS
INSTALLATION NAME
INSTALLAtlON LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F60 UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
TEXASGllLF
GRANGER, WYOMING
COAL (0.751 SULFUR)
140,000 SCFM (TOTAL - 2 BOILERS)
600,000 LB/HR STEAM (TOTAL)
70 M* (EQUIVALENT); TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = J EQUIVALENT M*.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
SWEMCO INC.
SODIUM CARBONATE SCRUBBING
NEW
SEPTEMBER. 1976
OPERATIONAL
90S (860 PPM 9 INLET)
99.31 (HOT-SIDE ESP W/PRECEDING MECHANICAL COLLECTOR)
WASTEHATER TREATMENT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
TEXASGULF INC. HAS 1EEN OPERATING A NEW SODA ASH PLANT (1 MM TONS/YR) AT GRANGER, WYOMING, SINCE
SEPTEMBER 1976. THO BUTLERS GENERATE A TOTAL OF 600,000 LBS/HR SATURATED STEAM a 300 PSIG.
UNIT EFFICIENCY IS 85X WHEN BURNING WYOMING SUB-BITUMINOUS COAL, WHICH MAS 13.97X MOISTURE, 6.43X
ASH, 0.751 SULFUR, ANO A HEATING VALUE OF IS 10,424 BTU/LP ON AN AS-RECEIVED BASIS. F.ACH BOILER
BURNS APPROXIMATELY a5,000 LB/HR OF THE COAL.
AFTER FLUE GASES LEAVE EACH BOILER, (196,150 ACFM a 350 F) THEY PASS THROUGH A MECHANICAL
COLLECTOR, FSP, FFI1NOMIZFR, AND WFT SCRUBBER. fTHF FCONOMJ7FR TS LOCATED AFTFR THE PRFCIPITATER
BECAUSE THE ASH FROM WESTERN CUAL IS COLLECTED M|)MF EFFICIENTLY MHEN THE GAS IS HOT). THE CYCLONE
ANO ESP TOGETHER HAVE A PARTICULATE REMOVAL EFFICIENCY OF 99.3X. THE SCRUBBING UNITS, INSTALLED AT
DOWNSTREAM OF THE ECONO^i/tR, WERE SUPPLIED HY SflEMCO IN SEPTEMBER 1976. THE SYSTEM CONSISTS OF
A QUENCHER, A SIEVE TRAY AHSORBFH (15 FT OIA X 20.5 FT HIGH) AND A BYPASS. THE ENGINEERING "ORK
WAS DONE BY «.G. MCKEF * CO. FLUE GAS IS SPRAY-COOLED FKOM 350 F TO 125 F AS IT ENTERS THE
QUENCHER «!TH 19 PVC NOZZLES ON FIBERGLASS HEADERS AND IS DIRECTED INTO THE CIRCULATING LIOIIOR
IN THF RES*Wvni». tHfi G»8 nilHULFS UP THROUGH IHg LII1UIIR, ENTERS THE ADJACENT AHSOHBER, TRAVELS
UP THBO'IGH T»0 MFVE TK»»S,, AND A MESH TYPf MIST ELIMINATOR OF TEFLON AT THF TOP. SCRUBBING
uioiioR (700 PPM to IMF ARSMBHFR, *oo GPM TO THF CJIIENCHER) is •JECIRCIH.ATFO FPO« THE SCRUBBER PUMP
TANK WHICH RFTf-lVfS l>'t SC*iMBf.H FFFLUFNT (1P?3 f,P"). CM V»LOE tS MAINTAINED AT h.3. A
1 14
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STATUS TO JANUARY 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPFRATIONAI FGn SYSTEMS ON INDUSTRIAL HOTLFWS
TEXASGULFj GRANGER, WYOMING (CONTINUED)
BLEED-OFF (850 TO «87 LB/MIN) CONTAINING «X OF SODIUM SALTS IS PURGED TO A MOLDING PONfl FOK EVAPORA-
TION. THE CLARIFIED MAKEUP HATER (60 TO 93 GPM) IS USED FOR M-E WASHING (15 GPM) AND QUENCHER SPRAY
(45 TO 66 6PM). MAKEUP SODA ASH 301 BY HEIGHT, ISFEO FROM A LIQUOR HEAD TANK TO THE SCHUB9FR PUMP
TANK AT A MINIMUM RATE OF 56 LB/MIN AND MAX. RATE OF 119 LB/MIN.
EACH ABSORBER IS OIV-IOEf) VERTICALLY INTO TWO SECTIONS, ONE OF WHICH HAS A DAMPER AT THE TOP.
THIS PERMITS CURTAILMENT OF GAS FLO* THROUGH HALF OF THE UNITS AT LOH LOADS. THE ABSORBER,
THEREFORE. CAN OPERATE AT THE DESIGN EFFICIENCY WHEN THE BOILER PRODUCES FROM 25)t TO 1001 OF ITS
RATED OUTPUT. THE ABSORBER BYPASS ALLOWS UP TO 351 OF THF INCOMING HOT FLUE GAS TO BE DIVERTED.
TTP1CALL»» TEXASGULF USES THE BYPASS TO KEEP THE FLUE GAS IN THE STACK 10 F WARMER THAN THAT AT THE
SCRUBBER OUTLET. THE ABSORBERS ARE MADE OF CARBON STEEL WITH FLAKED GLASS LINING AND THE TRAYS ARE
OF INCONEL 6ZS. THE RECIRCULATION TANKS ARE MADE OF FRP AND THE STACK (7.5 FT 10 X 150 FT HEIGHT)
18 DOUBLE*ALLEO, INSULATED STEEL TYPE WITH FLAKED GLASS COATING BY CEILCOTE COMPANY.
REFER TO FIGURE i«-as IN SECTION in FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
THE THROAT IN ONE OF THE QUENCHERS WAS REPLACED BY THAT OF INCONEL 625 BECAUSE OF CORROSION
PROBLEMS.
1ST OUARTER-1978 THE OUTLET DUCTWORK, WHICH WAS CORRODED DUE TO THE ACID CONDENSATE, WAS TO BE
REPLACED. THE SYSTEM OPERATED WITHOUT ANY MAJOR PROBLEMS.
2*0 OUARTER-19T8 DURING A MAJOR ELECTRICAL TURNAROUND, THE SCRUBBER MODULES WFRE CLEANED AND
REPAIRED, SLUDGE FROM THE TRAYS WAS REMOVED AND THE OUTLET DUCTWORK WAS REPLACED BY 30a SS. THE S03
MEASURING INSTRUMENTS MERE BEING UPGRADED BY LEAR SIEGLER, THE SUPPLIER.
3RD OUAHTER-1978 DURING THE REPORT PERIOD, THE BOILER AND F6D SYSTEM WERE DOWN TWICE FOR
SCHEDULED INSPECTION OUTAGES. DOWNTIME HAS « DAYS FOR ONE MODULE AND Z DAYS FOR THE OTHER. SOME
MINOR PLUGGING WAS OBSERVED DURING THE INSPECTION PERIODS.
«TH QUARTER-1978 DURING THIS PERIOD, OUTAGE OCCURRED ON NO. 3 BOILER FOR A DAY IN OCTOBER. IN
NOVEMBER, THE NO. 2 BOILER WAS DOWN FOR SCHEDULED INSPECTION FOR 3.5 DAYS. DURING THIS TIME, THE
TRAYS AND INTERIOR OF THE SCRUBBER WERE CLEANED. SOME OF THE PIPING LEADING TO TRAYS WAS REPLACED.
SOHE OF THE PLUGGED NOZZLES IN THE QUENCHER HERE EITHFR CLEANED OR REPLACED. THE RELIABILITY IMDF.X
VALUE FOR BOTH SCRUBBERS WAS ABOUT IOOX.
115
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STAtl'S TO JANUARY 1979
SECTION 10
(tFSTGN INFORMATION FOR UNDER CONSTRUCTION FC-0 SYSTEMS ON TNOUSrRIAL BOILERS
INSTALLATION NAMF
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILFBS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ARCO/POLYMFRS, INC.
MONACA, PENNSYLVANIA
COAL (3. OX SULFUR)
236,000 SCF« (TOTAL - 3 BOILERS)
900, 000 LR/HR STEAM a 700 PSIG AND 700 F.
118 MW (EQUIVALENT); TOTAL - 3 BOILF.RS
(FOR THIS REPORT, UNLESS STATED OTHERWISE' 2000 SCFM = t EQUIVALENT MH.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
RETROFIT
JUNE, 1980
CONSTRUCTION
901 (1,800 PPM 3 INLET)
99.51
DEWATERED SLURRY TO LANDFILL
FLYASH ADDITION TO OEWATERED CAS03/CASO« FILTER CAKE,
THEN TO LANDFILL.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
ARCO/POLYMERS, RFAVER VALLEY PLANT LOCATED NEAR MONACA, PENNSYLVANIA, AWARDED A CONTRACT
IN JUNE 197R TO FMC TO INSTALL THREE FOUR-STAGE DISC CONTACTOR SCRUBBERS. THE SYSTEM
WILL UTILI7F THE FMC DOUBLE ALKALI PROCESS WITH THE SCRUBBERS SHARING A COMMON REGENERATION UNIT.
THREE BOILERS GENERATE PROCESS STEAM USED TO OPERATE A TURBINE WHICH GENERATES 18 TO SO
KVA (CAPACITY 35 KVA). tHfc STEAM RATE FUR EACH BOILER IS 300,000 LB/HR a 700 PSIG AND 700 F.
TOTAL HEAT INPUT IS 1100 MM BTU/HR. PULVERIZED COAL (3.OX SULFUR) IS THE FUEL USED WITH AN ASH
CONTENT OF 151. IT HAS A HEAT VALUE OF 12,000 BTU/LB 3 4-bX MUISTUKE CONTENT. THE COST FOR THE
COAL IS S8.84/TON.
KDPPERS ESP'S PRECLF.AN THE FLUE GAS BEFORE IT ENTERS THE SCRUBB^S AT A RATE OF. 165,000 ACFM
(EACH) 3 400 F. THE INLET CONCENTRATION OF PARTICULATES TO THE ESP S IS 5 GR/SCF. GAS ENTERING THE
SCRUBBERS WTLL HAVE AN SO? CUNCFNTRATION OF APPROXIMATELY 1800 PPM. THE SCRUBBERS 117 FT D1A X 62
FT HEIGHT) WTTM 0 DISCS AND flflNUTS (FACH) WILL HI- CONSTRUCTED OF C RBON STFEL WITH CEILCOTE LININGS
(FLAKED GLASS LINING) AND THE MIST ELIMINATORS (1 FOR EACH SCRUBBER' ARE SINGLE STAGE CHEVRON PAD
TYPF CONSTRHCTFH flF PVC PIASTIC WITH PROVISIONS FOR A SFCONO STAGE. EACH StRUBRFR WILL EXHAUST
TO INDIVIDUAL I1SOLMFO STACKS I INED WtTh FHP. ASSOCIATED *ITH £AC STACK IS A REHEATF.R USING
116
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STATUS TO JANUARf 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CUNSTKIICT ION FGO SYSTEMS ON INDUSTRIAL HHILERS
ARCO/POLYMERS, INC.; MONACA, PENNSYLVANIA (CONTINIJEn)
STEAM HEATEO AMBIENT AIR. THE SCRUBBERS KILL HANOLF 100* OF THE FLUE GASES WITH BY-PASS ONLY
AVAILABLE FOR EMERGENCIES. THE L/6 RATIO FOR THE SCRUBBERS IS APPROXIMATELY JO. THF HFSTINGHOUSE
F.O. FANS WILL BE OF CARSON STEEL AND PUMPS OF RUBBFR-LTNEO CARBON STEEL. THE DUCTING LEADING TO
AND FROM THE SCRUBBFRS i*ILL BE OF FIBERGLASS LINED (CEILCOTE) CARBON STEEL AND FRP, RESPECTIVELY.
CALCIUM SUtFATE HASTE WILL BE HAULED BY TRUCK TO A DISPOSAL SITE.
REFER TO FIGURE 14-3 IN SECTION la FOR A DETAILED PROCESS FLOM DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD SUARTER-19T8 CONSTRUCTION IS TO BEGIN IN SEPTEMBER 1978.
4TH 8UABTER-197B CONSTRUCTION OF THE PLANNED FGD SYSTEM STARTED IN SEPTEMBER 1976.
117
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STATUS TO JANUARY 1979
SECTION 10 (CONTINUED!
DESIGN INFORMATION FOR UNDER CONSTRUCTION FC.U SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNTTS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
MATER MAKE-UP
CONTROL SYSTEM COST
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
CRUDE OIL (I.IX SULFUR)
12,000 SCFM
20,000 ACFM H 570 F
1
1
5 MM (EOUIVALFNT)
SO MM BTU/HR
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MH,
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
C-E NATCO
SODIUM HYDROXIDE SCRUB ING
RETROFIT
JANUARY, 1979
CONSTRUCTION
90* (500 PPM 802 9 I LET)
15 GPM
SEE SECTION It FOR '•' TAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BELRI06E OIL COMPANY HAS AN ENHANCED OIL RECOVERY SITE IN MCKITTRICK, CALIFORNIA. THE SITE IS
LOCATED IN HESTERN KERN COUNTY AND HAS SEVERAL SMALL STEAM GENERATORS RATED AT SO AND 25 MH BTU/HR.
THE CRUDE OIL HAS 1.1 PERCENT SULFUR CONTENT.
IN VIEW OF THE NEW REGULATIONS OF THF CALIFORNIA AIR REi URCE BOARD (CARB), BELRIDGE HAS UNDER-
TAKEN A PROGRAM TO EVALUATE THE COMMERCIALLY AVAILABLE FGD TfHNOLOGY FOR APPLICATIONS TO A SMALL
(TYPICALLY 50 MM BTU/HR) STEAM GENERATOR. THEY HAVE ALREADY INSTALLED TWO FGO SYSTEMS SUPPLIED BY
HEATER TECHNOLOGY AND THERMOTICS. (SEE SECTION 9 OF THIS REPORT FOR DESCRIPTIONS OF THESE SYSTEMS).
A THIRD SYSTEM, BEING SUPPLIED BY C-E NATCO, IS UNDER CONSTRUCTION. C-E NATCO, A SUBSIDIARY OF
COMBUSTION ENGINEERING, IS THE PRINCIPAL SUPPLIER OF THE STEAM GENERATORS TO THE OIL FIELDS. THE
FGD SYSTEM IS SCHEDULED TO GO ONSTREAM BY EARLY JANUARY 19/ .
THE FLUE GAS (29,000 ACFM AT 570 F) IS QUENCHED RY A •-T OF SPRAYS IN THE BOTTOM PART OF THE
ABSORBER (7 FEET OIA X J5 FEET HIGH). THE QUENCHER SECTIO , HAS A SEPARATE RECIRCULATION PUMP
(300 GPM) HHICH ALSO BLEEDS OFF A PURGE STREAM (10 GPM). THE PH IN THIS STAGE IS RANGFS FROM 6-6.5.
THE COOLED GAS PASSES THROUGH A 'CHIMNEY-TRAY" (TRAY WITH ft CENTRAL OOWNCOMFH) AND IS FURTHER CON-
TACTED WITH LIQUOR SPRAYS (PH BETWEEN 7.5-8.0). THF ABSORPTION STAGE HAS A SEPARATE
RECIRC1ILATION PUMP MOU GPM) WHICH ALSO RECEIVES A CONTINUOUS STREAM OF FRESH SODIUM CARflONATF
SOLUTION (l"> GPM). IHh FLIIF GAS PASSES THHOllRH A CHEVRON MIS! FLIMINAT, ANf) A STUB SIAC* AT THE
118.
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STATUS TO JANUARY 1979
SFCTION 1ft (C 'NTWIFnl
DESIGN INFORMATION FUR UMDt* CONSTRUCT? N FGD SYSTH4S (IN INIHiS TRIAL HlltlFBS
BELRIDGE OIL C0.» MCKITTRICK, CALIFORNIA (CONTINUFO
TOP OF THE ABSORBER.
THE ABSORBER, TRAY, RECIRCULATION PUMPS, PIPING, *ND STACK ARE MADE OF 316L ss. THE
SODA ASH MIX TANK, FEED. PUMP AND PIPJNS ARE CAK80N ST F.L, AND THE MIST ELIMTNATOH IS FRP.
OPERATING HISTORY
«TH aUARTER-l<»78 THE SYSTEM IS UNDER CONSTRUCTION ANO THE STARTUP DATE IS DELAYED TO EARLY
JANUARY 1979 FROM NOVEMBER 1978.
119
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STATUS TO JANUARY 1979
10 (rnNTJMIFU)
DFSTG*! INFIiHMATION FUH UNDER CONSTRUCT I ON FRO SYSItMS ON INDUSTRIAL HOILEPS
INSTALLATION
INSTALLATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLU06E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATFWPILLAR TRACTOR CO.
MAPLfTi)N, ILLINOIS
COAL (3.2Z SULFUR)
111,000 SCFM (TOTAL - 3 BOILERS)
80,000 ACFM a 350 F, FOR EACH OF 2 FGD SYSTEMS
40,000 ACFM St 350 F, FOR 1 FGO SYSTEM
600.000 LB/HR STEAM {TOTAL - 3 BOILERS)
65 Mh (EQUIVALENT); TOTAL - 3 BOILERS
(FQR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM r 1 EQUIVALENT HH.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EOUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEW
JANUARY, 1979
CONSTRUCTION
90X (2000 PPM 9 INLET)
OEMATERED SLURRY TO LANDFILL
60+X SOLIDS (CAS04) SLUDGE DIRECTLY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE MAPLETON, ILLINOIS PLANT, CATERPILLAR TRACTOR IS INSTALLING FIVE NEH BOILERS, THREE OF
WHICH ARE SLATED TO BFGTN OPERATIONS DURING JANUARY 1979. THE OTHER TWO WILL BEGIN OPERATIONS IN
THE EARLY I980'S. BECAUSE CONSTRUCTION HAS NOT YET BEGUN ON THESE TMO FGD SYSTEMS THEY ARE REPORTED
IN SECTION 11 OF THIS REPORT. TMO BOILERS STARTING IN JANUARY 1979 ARE RATED AT 250,000 LB/HR STEAM
EACH, THE OTHER IS RATED AT 100,000 LB/HR STEAM. BOTH BOILERS STARTING IN THE EARLY 1980*3 HILL BE
1,100,000 LB/HR.
CATERPILLAR HAS AWARDED A CONTRACT TO FMC ENVIRONMENTAL EOUIPMENT TO PROVIDE CONCENTRATED MODE
DUAL ALKALI FGD SYSTEMS FOR ALL FIVE BOILERS. EACH BOILER HILL HAVF.A SEPARATE'FGD SYSTEM. EACH
SY.STEM WILL INCLUDE A VENTURI SCRUBBER FOLLOWED BY A CYCLONIC MIST ELIMINATOR.
FACILITIES FOR REGENERATION, SLUDGE HANDLING AND DISPOSAL WILL BE SHARED BY ALL FIVE BOILERS.
*
THE SAME FACILITIES HAVF BEFN DESIGNED TO HANDLE A TOTAL OF EIGHT BOILERS. THE ADDITIONAL CAPACITY
FOR THRFE BOILERS WAS PLANNED FOR PROBABLE PLANT EXPANSION IN THE FUTURE. THFRE IS NO PLANNED
START-UP DATE FOR THESE THREE BOILERS.
120
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STATUS f() JANIIAWY
SECTION in (CONTINUED)
OFSIC.N T"HHn;»T!(V'l F(i» IC'IIFW ri'VSThilCT l')l( l-Cli SYMf .«S 'I" IMlliSIKI At. HUlLf*
CATERPILLAR TUACTOH CO.! MAPLETON, ILLINOIS (CON flNIIEn)
OPFKATING HISTOHY
3RD QIIARTEH-1977 SYSTEM MAS UNDER CONSTRUCTION. START-UP WAS EXPF.CTFI) LATF IN THE FALL OF 1977.
4TH OUARTFH-1977 CHNSTBllCTIdN DELAYS ON THE STFAH GENERATION SIDE PUSHFO PLANT ST*RT-UP BACK TO
THE FALL flF 197B.
2ND OIURTER-1<»7» START-UP HAS STILL PLANNED FOR THE 1978-197<» HEATING SEASON. THHEE BOlLfRS AND
THEIM INDIVIDUAL FHC FGO SYSTEMS WILL CtlMF ON-LINF AT THAT TIME.
3RD QUARTER-! 97R CONSTRUCTION HAS NF.ARING COHPLFTION. SPECIAL MOD IF ICATIONS WF.RE BEING MADE
HHICH WERE BELAYING STA»T-UP. EXPERIENCE GAINED AT MflSSVILLF. IS BEING APPLIED TO MAPLETON SINCE THE
SYSTEMS ABE SIMILAR.
«TH QIIARTER-107H DELAYS OF THP START-UP DATE FOR THF THREE 80ILEHS AND THEIR RELATED FGD SYSTEMS
ACTIVITIES AND NOT THE INSTALLATION OF SPFCTAL MODIFICATIONS. CONSTRUCTION OF THESE THREE BOILERS
HAS BEEN COMPLETED? START-UP IS EXPECTED AT THE END OF DECEMBER OR BEGINNING OF JANUARY. INSTALLA-
TION HAS JUST HEGUN ON THE OTHER TWO a-50,000 LB/HR BOILERS. START-UP FOR THESE TWO BOILERS WILL BE
IN THE EARLY 19flO*S.
121
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STATUS TO JANUARY
SECTION 10 (tONTtNUFOl
DESIGN INFORMATION FDR UNDER fONSTKUCTION FRO SYSTEMS UN INDUSTRIAL BOILfKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F60 UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
MATCH WAKE-UP
SLUOCC OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CHANSLOR WESTER* OIL * OEV. CO
BAKEkSFtELO. CALIFORNIA
OIL (1.5Z SULFUR)
70,000 SCFM (TOTAL - « BOILERS)
310 MM BTU/HR (TOTAL - 8 BOILERS)
133,400 ACFM 3 550 F (TOTAL - 8 BOILERS)
1
a
35 MK (EQUIVALENT); TOTAL - 8 STEAM GENERATORS
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 8000 SCFM = I EQUIVALENT MI,
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEM
MARCH, 1979
CONSTRUCTION
9M (710 PPM a INLET)
71 6PM
OENATERFD SLURRY TO LANDFILL
SALTS IS THEREBY PREVENTED.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
OPERATING HISTORY
CHANSLOR WESTERN OIL COMPANY HAS AN ENHANCED OIL RECOVERY SITE NEAR BAKER3FIELD, CALIFORNIA.
THE OIL PRODUCTION INVOLVES INJECTION OF STFAM IN THE OIL NELLS. OECANTATION OF OIL FROM OIL-MATER
MIXTURE, AND PURIFICATION OF OIL IF NECESSARY. THE CRUDE OIL PRODUCED BY THIS PROCESS HAS APPROX-
IMATELY 1.51 SULFUR. A PART OF THE OIL PRODUCED IS USED AS A FUEL FOR THE BOILERS NHICH 6ENERATF
THE NECESSARY PROCESS STEAM. THERF ARE SFVERAl BOILERS ON THE SITE, MANY OF NHICH ARE RATED AT 50
MM BTU/MR. THE BOILERS ARE CLASSIFIED AS "STEAM GENERATORS' BECAUSE OF THEIR SHE, PORTABLE NATURE,
AMD LOWER QUALITY OF STEAM (BOX) PRODUCFD.
EISHT OF THE STFAM GENERATORS, MITH A TOTAL HEAT OUTPUT OF 310 MM BTU/HR, ARE BEING CONSTRUCTED
ALONG MITH A NEN, FMC DOUBLE-ALKALI (CONCENTRATED) FGD SYSTEM. THE FLUE GASES FROM THE EIGHT STEAM
GENERATORS ARE MANIFOLDED TOGETHER U33.SOO ACFM 3 550 F), AND PASS THROUGH A PRE8ATURATOR AND AN
ABSORBER (IS* DIAMETER BY «' HIGH) MITH 4 OISC-AND-DONUT TRAYS. THE RECIRCULATION LIOUOR PM IS
MAINTAINED AT b.S, AND A L/G RATIO IS USED. THE FLUE GASES PASS THROUGH A CHEVRON MIST ELIMINATOR
TO .A STACK. A CONSTANT BLEED-OFF STMEAM (60 6PM) IS TAKEN TO THE REACTION TANK WHERE IT REACTS HITH
LIMF SLURRY TO REGENERATE snoitw HYDROXIDE. THE CALCIUM SULFTTE/SULFATE SLURRY is SENT TO THF
THTCKENFK, VACUUM FILTFR AMD -I ANOF U L.
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STATUS TO JANUARY 1<»79
SFCTION 10 (CONTINUED)
DFSIGN INFORMATION FOR 11NOE& CONSTRUCTION FBO SYSTF.MS ON TNOMSTPIAL KOILEHS
CHANSLOR WESTERN OIL * OEV. COS HAKERSFIELD, CALIFORNIA (CONTINUED)
REFER TO FI6UBF 10-11 IN SECTION JO FOR A DETAILED PROCESS FLOW IHA6RAM OF THIS SYSTEM.
OPERATING HISTORY
JRO OU»RTER-l478 THE PLANT IS NEAHING COMPLETION OF CONSTRUCTION. THE COMMtSIONINR ACTIVITIES
HILL BE UNDERWAY SOON.
«TH QUARTER-1<»78 CONSTRUCTION WORK HAS BEEN HELD UP PHIMAKILY DUE TO DELAYS IN SHIPKFNT OF
ELECTRIC CONNECTIONS AND EQUIPMENT.
tas
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STATUS TO JANUARY 1979
Si-rilDN 10 (CONT INUFI))
INFORMATION ""OB UNDER CONSTRUCTION FRO SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMRER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BFIN6 CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP OATE
CONTROL SYSTEM STATUS
SO? REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GFTTY OIL COMPANY
BAKERSFIELO, CALIFORNIA
OIL (1.1X SULFUR)
39h,000 SCFM (TOTAL-36 BOILERS)
0 FGO SYSTEMS, EACH TREATING 300,000 ACFM a 500 F
a
36
200 KW (EQUIVALENT)S 1800 MM BTU/HR (TOTAL-36 BOILERS)
EACH BOILER RATEO AT 42,000 LBS/HR STEAM
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 3000 SCFM = 1 EQUIVALENT MM,
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
IN-HOUSE DESIGN
SODIUM CARBONATE SCRUBBING
RETROFIT
JANUARY, 1979
CONSTRUCTION
96Z (600 PPM S02 9 INLET)
50Z 135 LB/HR ASH 3 INLET)
WASTEHATER TREATMENT AND DISCHARGE TO TAILINGS POND
HOLDING POND FOR EVAPORATION.
9 GPH BLEEDOFF TO A SLOWDOWN TANK. THE SLOWDOWN IS EMPTIED
INTO A DISPOSAL POND ONCE A WEEK.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
120
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DFSIGN TNFllBMAttUN FUM
STATUS TO JANUARY t<*79
SFCTION 10 (CONTINUED)
Cl'f»STklirT TPM FRO SYbUMS UN TNOuSTMAL
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
MATER MAKE-HP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOBTI OTL COMPANY
RIITTONwHLO*, C
OIL <1.U SULFUR)
BO,500 SCFM (TOTAL - 7 BOILERS)
7 FGD SYSTEMS, FACH TREATING 23,000 ACFM 3 550F.
7
7
aO Ml* (EQUIVALENT); 350 MM 8TU/HR (TOTAL - 7 BOILERS)
(FOR THIS REPORT, UNLESS STATED OTHERWISE* 3000 SCFM = ! EQUIVALENT l>
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.
HFATER TFCHNOLORY
SODIUM CARBONATE SCRUBBING
RETROFIT
FFBRUARY, 1979
CONSTRUCTION
851 (500 PPM 3 INLET)
15 GPMj OIL FIELD WASTE WATER
HOLDING POND FOR EVAPORATION
INTERMITTENT SLOWDOWN TO WASTE DISPOSAL SITE.
SFE SECTION IS FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
MOBIL OTL COMPANY HAS AN ENHANCED OIL RECOVERY SITE AT RUTTONWILLOW, CALIFORNIA. THE
OPERATION REQUIRES PROCESS STEAM WHICH IS SUPPLIED BY SEVERAL STEAM GENERATIONS RATED AT 50 MM
BTU/HR. MOBIL HAS BEEN OPERATING SEVERAL FGD SYSTEMS AT THE SAN ARDO OIL SITE SINCE 197«. (SEE
SECTION 9 OF THIS REPORT FOR DETAILS ON THESE SYSTEMS).
HEATER TECHNOLOGY HAS RETROFITTED 7 FGD SYSTEMS AT BUTTONWILLOW IN OCTOBER, t978. EACH SYSTEM
TREATS FLUF GAS FROM ONE GENERATOR (23,000 ACFM 3 550 F). THE PROCESS USED IS SODIUM CARBONATE
SCRUBBING. THE SYSTFM INCLUDES AN EDUCTOR-ABSORBER, A RECYCLE TANK, A WJST El IMINATOR. AND A STUB
STACK. THE EOUCTOR HAS AN ADJUSTABLE DISK WHICH FORMS THE CONTACT STAGE FOR THE GAS AND RECIRCULAT-
IN6 LIQUOR. THE RECIRCULATION PH IS SET AT ABOUT 8.0 AND A L/G RATIO OF 40 GAL/1000 ACF IS USED.
FRESH SODIUM CARBONATE SOLUTION IS ADDED TO THE RECYCLE TANK (15 RPM), AND A BLEED-OFF STEAM IS
TAKFN TO HOLDING POND (10 6PM).
THE PDUCTOR, CONTACTING DISC, HFCICULATTON PIPING AND THE PUMP ARE MADE OF 316 SS. THE RECYCLE
TANK IS CARBON STEFL WITH EPOXY TAR COATING AND THE CHEVRON-TYPE MIST ELIMINATOR IS FRP.
REFER TO FIGURE 11-35 IN SECTION i« FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
125
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STATUS TO JANUARY 1979
SFCTION 10 (CONTINUFO)
DESISN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BOILHKS
MOBIL OIL COMPtNY: BUTTONHILLOW, CALIFORNIA (CONTINUED)
OPERATING HISTORY
*TH OUARTeR-l«»T8 THE START-UP DATE HAS BFEN FXTENDF.D TO FEBRUARY OF 1979, OUE TO OELAVS IN
AWARDING SEPARATE CONTRACTS FOR PIPING AND OTHER WORK.
126
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STATUS TO JANUARY 1979
SFCTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FRO SYSTEMS ON INDUSTRIAL BOREHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
MEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
308 REMOVAL EFFICIENCY
CONTROL SYSTEM COST
PHILLIP MORRIS,. INC.
CHESTERFIELD, VIRGINIA
COAL
39,000 SCFM (TOTAL - 1 BOILER)
55,000 ACFM a 350F, 300,000 L8/HR STEAM
I
1
30 M* (EQUIVALENT); 337 MM BTU/MR
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = \ EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FLAKT, INC.
SODIUM CARBONATE SCRUBBING
NEW
JUNE, 1979
CONSTRUCTION
90S (DESIGN MINIMUM)
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
PHILIP MORRIS, INC. IS CURRENTLY EXPANDING THEIR TOBACCO REPROCESSING PLANT AT CHESTERFIELD,
VIRGINIA. THE PLANT EXPANSION, WHICH IS BEING HANDLED BY AUSTIN PROCESSES, INC., INCLUDES THE
ADDITION OF A 337 MM RTU/HR BABCOCK AND WILCOX PULVERIZED COAL-FIRED BOILER AND AN EMISSIONS CONTROL
SYSTEM FROM FLAKT, INC. THE BOILER FLUE GAS (88,900 ACFM 9 350 F) WILL FIRST PASS THROUGH A COLO-
SIDE ESP WITH A GUARANTEED MINIMUM COLLECTION EFFICIENCY OF 99.6*. THE FGD SYSTEM IS DESIGNED TO
HANDLE THO-TMIROS OF THE GAS DISCHARGED FROM THE PRECIPITATOR WITH A MINIMUM soa REMOVAL EFFICIENCY
OF 90t. THE REMAINING ONE-THIRD OF THE GAS WILL BE USED FOR REHEAT.
FLUE GASES ENTERING THE SCRUBBER ARE FIRST COOLED AND SATURATED IN A PREOUENCHER BY A 6 6PM
SPRAY OF FRESH HATER. THE ABSORBER ITSELF IS A 3-STAGE SPRAY TOWER (9 FT. DIA. X 35 FT. HIGH)
UTILIZING SODIUM CARBONATE SCRUBBING AND OPERATING AT 130 F WITH AN L/G RATIO OF 18 GAL/ACF. THE
DESIGN IN'.ET PH IS 7.5. PRESSURE DROP ACROSS THE SCRUBBER IS EXPECTED TO BE ABOUT 3.5 IN. B.C.
FOLLOWING THE ABSORBER THE FLUE GASES FLOW THROUGH A 3-PASS CHEVRON MIST ELIMINATOR BEFORE JOINING
WITH THE REHEAT GAS IN A MIX CHAMBER. THE STACK IS DUAL-WALL CORTEN STEEL-LINED, 5.5 FT.
IN DIAMETER X IBS FT. HIGH. A BLEED STREAM OF 5 - H GPM IS TAKEN FROM THE RECIRCULATION LINE JUST
DOWNSTREAM OF THE PUMP. THIS STREAM, WITH A PH OF ABOUT 6.5, GOES TO AN AERATION TANK WHERE ANY
SULFITE IS CONVERTED TO SULFATE. FINAL DISPOSAL OF THE SODIUM SULFATE SLUDGE HAS NOT BEEN DETER-
MINED, AS PHILIP MORRIS PLANS TO EXPERIMENT WITH VARIOUS METHODS. MAKE-UP SODIUM CARBONATE SOLUTION
IS ADDED IN THE RECTRCULATION LTNF JUST DOWNSTREAM OF THE HLEEDOFF. THE MAKE-UP SOLUTION IS
STORED IN A CARBON STEEL SODA ASH MIX TANK, 13 Fl. IN OIAMfTER X 33 FT. HIGH. THF SPRAY TOWER IS
137
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STATUS TO JAfcUAKY 1979
SECTION 10 (CONTINUFD!
DFStGN INFORWTION FOR IINnEU CONSTRUCTION FBI) SYSTEMS ON INDUSTRIAL BOILF.R5
PHtLLIP MORRIS, INC.; CHESTERFlFLfl, VIRGINIA (CONT INUF.O)
MADE OF FRP AND THE NOZ7LF.S (b PER STAGE) ARE 316 STAINLESS STEEL.. ALL PUMPS ARE RUBBER-LINED.
RECIRCULATION LINFS ARE 316 SS ANfl THE MIST ELIMINATOR IS POLYPROPYLENE.
REFER TO FIGURE l«-38 IN SECTION iq FOR A DETAILED PROCESS FLOW OTA6RAM OF THIS SYSTEM.
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STATUS TO JANUARY 1<»7<)
SECTION 10 (CONTINUED)
OFSI6N INFORMATION FOR UNOfR CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME ST. JOE ZINC CO.
INSTALLATION LOCATION MONAC&, PENNSYLVANIA
SOURCE CHARACTERISTICS COAL (2.51 - *.5l SULFUR)
SOURCE RATING 182,000 SCFM (TOTAL - I BOILER)
NUMBER OF SEPARATE FGO UNITS 1
NUMBER OF BOILERS BEING CONTROLLED 1
SOURCE CAPACITY 60 Mw (ELF.CTRIC POWER: NOMINAL PEAK CAPACITY)
(FOR THIS RF.PORT, UNLESS STATED OTHERWISE. 2000 SCFM = 1 EQUIVALENT M»
THIS IS BECAUSE GAS FLOW RATE IS THF PRIMARY FACTOR IN MODULE SIZING.)
CONTROL SYSTEM VENDOR BUREAU OF MINES
CONTROL PROCESS CITRATE PROCESS
NEW / RETROFIT RETROFIT
START-UP DATE MARCH, 1979
CONTROL SYSTEM STATUS CONSTRUCTION
802 REMOVAL EFFICIENCY 90»X
SLUDGE OR BY-PRODUCT DISPOSAL REGENERABLE - ELEMENTAL SULFUR PRODUCT
CONTROL SYSTEM COST SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN THE SUMMER OF 1977, CONSTRUCTION BEGAN AT MONACA, PA. ON A CITRATE PROCESS (BUREAU OF MINES)
FGD SYSTEM FOR ONE OF THE TNO 60-MH (NOMINAL PEAK CAPACITY) BOILERS OF THE GEORGE F. HEATON POWER
PLANT USED BY ST. JOE ZINC CO. TO GENERATE ELECTRICITY FOR A ZINC SMELTER. ST. JOE HAS A RECIPROCAL
AGREEMENT WITH THE LOCAL UTILITY COMPANY, DUQUESNE LIGHT, WHEREBY ST. JOE CAN SELL UP TO 25-MW Of
ITS TOTAL 120-MW CAPACITY TO DUQUESNE. IN RETURN, ST. JOE CAN BUY SUFFICIENT POWER TO MAINTAIN
ELECTRO-SMELTING OPERATIONS IN THE EVENT OF AN EMERGENCY. THIS FGD SYSTEM IS THE FIRST SMALL COM-
MERCIAL SIZE EXPERIMENTAL CITRATE CONTROL SYSTEM BEING BUILT FOR REMOVING SULFUR DIOXIDE FROM
COAL-FIRED POWER PLANT STACK GAS.
UNDER A S1Z.7 MILLION COST-SHARING AGREEMENT BETWEEN THE BUREAU AND ST. JOE, COSTS FOR TESTING
THE CITRATE PROCESS FOR A FULL YEAR ARE BFIN6 SHARED ABOUT SO-50. THE CITRATE PROCESS WAS DEVELOPED
BY THE BUREAU IN THE I960's TO HELP CURB SULFUR DIOXIDE EMISSIONS FROM BASE METAL SMELTERS.
THE CITRATE PROCESS DERIVES ITS NAME FROM THE WATER SOLUTION OF SODIUM CITRATE AND CITRIC ACID
USED AS A BUFFERING AGENT DURING SOS ABSORPTION FROM THE FLUE GAS. THE CITRATE PROCESS IS DESIGNED
TO TREAT 230,000 ACFM it 300 F FLUE GAS GENERATED BY FIRING PULVERIZED COAL POSSESSING 2.5-0.5X
SULFUR, 151 ASH AND AN HHV OF APPROXIMATELY 12,500 BTU/LB. THE PLANT WILL MEET THE PENNSYLVANIA AIR
QUALITY REGULATION OF 0.695 LBS OF 302 PER MILLION BTU HEAT INPUT TO THE BOILER.
THE DEMONSTRATION PLANT, DESIGNED WITH A 60S TURNDOWN RATIO, UTILIZES A SINGLE PROCESS TRAIN
CONSISTINR OF GAS COOLING AND 802 ABSORPTION, SULFUR PRECIPITATION, SULFUR RECOVERY, SODIUM SULFATE
REMOVAL, AND H2S GENERATION UNIT OPERATIONS. FLUE GAS FROM AN EXISTING PRECIPITATOR ENTERS AN
129
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STATUS TO JANUARY 1<>79
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FRO SYSTEMS ON INDUSTRIAL BOILERS
3T. JOE ZINC CO.; MONACA, PENNSYLVANIA (CONTINUED)
EOUCTOR TYPE VENTURI SCRUBBER, THROUGH AN P.O. FAN WHERE IT IS COOLED FROM 300 F TO 130 F BY BOTH
HUNIDIFICATION AND SENSIBLE COOLING. A BLEED STREAK IS TAKEN FROM THE VENTURI RECYCLE STREAM TO
PREVENT BUILD-UP OF ASH AND ACIDS. THIS STREAM FLOWS THROUGH A PACKED COLUMN COUNTERCURRENT TO A
STREAK OF AIR WHERE 802 IS STRIPPED FROM THE LIQUID AND RECYCLED TO THE SCRUBBER. THE STRIPPED
LIQUID IS DISCHARGED TO AN AGITATOR TANK WHERE IT IS NEUTRALIZED WITH LIME. FROM THERE- IT IS PUMP-
ED TO THE EXISTING ASH POND.
THE COOLED, CLEANED FLUE GAS THEN ENTERS A PACKED ABSORBER (26 FT OIA X 85 FT HIGH) MADE OF
FLAKE-GLASS LINED, CARBON STEEL, WHERE IT FLOWS UPWARD COUNTERCURRENT TO THE DESCENDING CITRATE
SOLUTION. MORE THAN <»0t OF THE 802 IS REMOVED FROM THE FLUE GAS, MAINLY AS SULFUROUS ACID, IN THE
PRESENCE OF THE CITRATE BUFFER SOLUTION. CITRATE SOLUTION LEAVING THE ABSORBER FLOWS IN SERIES
THROUGH TWO TANOEM REACTORS IN THE SULFUR RECOVERY SECTION. THE CITRATE RECYCLE STREAM FROM THE
REGENERATION SECTION IS COOLED FROM 131 F TO 123 F BY HEAT EXCHANGE WITH RIVER WATER BEFORE ENTFRING
THE ABSORBER.
SULFUR 15 FORMED BY CONTACTING THE SOS-RICH SOLUTION WITH AN H2S-C02 GAS FROM THE HYDROGEN
SULFIDE GENERATING UNIT. OFF-GAS WHICH IS MAINLY C02 WITH SMALL QUALITIES OF H23, CS2, AND COS FROM
THE REACTOR SYSTEM IS SENT TO THE BOILER FIREBOX FOR INCINERATION VIA A SURGE DRUM. CRYSTALLINE
SULFUR IS FORMED IN THE REACTORS AND SULFUR SLURRY FLOWS TO A DIGESTER WHERE A SMALL STREAM OF
S02-RICH SOLUTION FROM THE ABSORBER IS REACTED WITH ANY DISSOLVED OR ENTRAINED H2S IN THE SLURRY
ENTERING THE DIGESTER. FROM THE DIGESTER, T.HE SLURRY FLOWS TO THE SULFUR FLOTATION TANK. SEPARA-
TION OF THE SULFUR FROM THE BULK OF THE SOLUTION IS ACCOMPLISHED BY FLOTATION WITH AIR. SULFUR
FROTH, CONCENTRATED TO ABOUT 10X SOLIDS, IS SEPARATED FROM THE TOP OF THE SOLUTION AND FLOWS TO THE
SULFUR SLURRY TANK.
REGENERATED CITRATE SOLUTION IS DRAWN FROM THE BOTTOM OF THE FLOTATION TANK AND RETURNED TO THE
ABSORBER. SULFUR IS SEPARATED FROM THE REMAINING SOLUTION RY HEATING THE SLURRY TO ABOUT 260 F MTH
STEAM IN A SHELL-AND-TUBE EXCHANGER. THE MOLTEN SULFUR AND THE CITRATE SOLUTION ARE SEPARATED BY
GRAVITY IN A PRESSURIZED, STEAM-JACKETED DECANTER VESSEL. THE MOLTEN SULFUR IS DISCHARGED
CONTINUOUSLY FROM THE BOTTOM RY INTERFACE LEVEL CONTROL AND FLOWS TO A HEATED STORAGE TANK. THE
CITRATE SOLUTION LEAVES THE TOP OF THE DECANTER AND RETURNS TO THE FIRST REACTOR.
SODIUM SULFATE OECAHYORATE, PRODUCED BY THE NEUTRALIZATION OF CAUSTIC WITH A SMALL AMOUNT OF
GENERATED SULFURIC ACID, IS REMOVED FROM CITKA1E SOLUTION BY VACUUM CRYSTALLIZATION.
GENERATION OF H2S GAS IS ACCOMPLISHED USING RECOVERED ELEMENTAL SULFUR, A GASEOUS REOUCTANT
(METHANE) AND TURBINE EXTRACTION STEAM AS CONSUMPTIVE FEED STOCKS IN A FIXED-BED CATALYTIC REACTOR.
REFER TO FIGURE 14-11 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD 0IIARTFR-1«)7» ALL MAJOR EQUIPMENT HAS BEEN INSTALLED; INSTALLATION OF PIPING AND WIRING IS IN
130
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STATUS TD JANUARY 197<»
SECTION JO (CONTINUFin
DF.SIGN INFORMATION FOR UNDER CONSTRUCT ION Ff-f) SYSTEMS 0*J INDUSTRIAL HUILEKS
ST. JOE ZINC CO.; MONACA, PENNSYLVANIA (CONTINUF.O)
PROGRESS.
flTH OUARTFR-I97B THE PLANT REPORTED THAT INSTALLATION OF PIPING AND WIRING IS STILL IN PROGRESS.
START-UP HAS-BEEN RESCHEDULED FOR MARCH J9T9.
151
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STATUS TO JANUARY 1979
SFCTTIllM 10 (CnuTlNUED) * 5
OFSIGN INFORMATION FOR IINOFH CONSTKUCTinN FBI! SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCF. RATING
NUMBER OF SFPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
SUN PRODUCTION COMPANY
FELLOWS, CALIFORNIA
OIL (1.4X SULFUR)
6,000 SCFM US,000 ACFM H 570 F)
1
1
C-E NATCO
SODIUM HYDROXIDE SCRUBBING
RETROFIT
APRIL, 1979
CONSTRUCTION
851 (000 PPM 9 INLET)
4 GPM
HOLDING POND FOR EVAPORATION
1 GPM BLEEDOFF TO DISPOSAL POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
SUN PRODUCTION COMPANY HAS AN ENHANCED OIL RECOVERY SITE NEAR FELLOWS, CALIFORNIA. SEVERAL
STEAM GENERATORS ARE USED TO PRODUCE THE PROCESS STEAM REQUIRED FOR THE OPERATION. A PART OF OIL,
NHICH HAS A t.4 PERCENT SULFUR, IS USED AS FUEL.
C-E NATCO HAS BEEN AWARDED A CONTRACT TO INSTALL AN F6D SYSTEM ON ONE 25 MM BTU/HOUR STEAM GENE-
RATOR. NO F6D SYSTEM TREATS 12,000 ACFM FLUE GAS AT 570 F. THE FLUE GAS IS CONTACTED WITH ONE SET
OF SPRAYS (150 GPM) IN THE BOTTOM OF THE ABSORBER (4.5' DIAMETER X 35 FT HIGH). PH OF 6.5 IS MAIN-
TAINED IN THE FIRST STAGE. THE GAS WHICH PASSES UP A TRAY WITH A CENTRAL DOWNCOMER, IS FURTHER
CONTACTED WITH A SECOND SET OF SPRAVS (150 GPM). A CHEVRON HIST ELIMINATOR (INCOLOT 825) LEADS INTO
A STUB STACK. THE EXCESS LIQUOR FROM THE TRAY OVERFLOWS TO THt FIRST STAGE. PH IS MAINTAINED AT
7.5 IN THF SECOND STAGE. MAKEUP SODIUM HYDROXIDE SOLUTION (0.05 GPM) IS ADDED TO THE SECOND STAGE
BY A POSITIVE DISPLACEMENT PUMP WHILE FRESH MAKEUP WATER (4 GPM) IS ADDED TO THE FIRST STAGE. A
BLEEDOFF (1 BPM) STREAM IS TAKEN TO WASTF DISPOSAL FROM THE FIRST STAGE RECIRCULATION LINE.
THE ABSORBER, MIST ELIMINATOR, RECIRCUlAT ION PUMPS AND PIPING, AND THE SPRAY HEADERS ARE 316L
SS. THE CAUSTIC FEED PUMP AND THE PIPING AND THE INLFT DUCTWORK IS C.S.
4TH OUARTEH-1978
OPERATING HISTOHY
THE SYSTEM IS UNDER CONSTRUCTION. THE STAKTIIP IS EXPECTED BY APRIL 1979.
132
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STATUS TO JANUARY 1979
SFCTION 10 (CONTTMIFD)
DFSIRN INFIIPMATION FOR IINDFH CONSTHIC T lflrt FGI> SYSThMS (IN TNOHSTPML l
INSTALLATION NAME
INSTALLATTON LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SFPARATF FGD UMTS
NUMBER OF BOILERS BFIN6 CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PROOUCT DISPOSAL
CONTROL SYSTEM COST
SUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
OIL U.2X SULFUR)
6,000 SCFM (l?,non ACFM ol 570 F)
I
C-E NATCO
SODIUM HYDROXIDE SCRUBBING
RETROFIT
APRIL. 1979
CONSTRUCTION
85% (700 PPM 3 INLET)
4 GPM
HOLDING POND FOR EVAPORATION
1 GPM BLEEDOFF TO DISPOSAL POND
SEE SECTION 11 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
SUN PRODUCTION CO. HAS AN ENHANCED OIL RECOVERY SITE NEAR OILDALE, CALIFORNIA. SEVERAL SMALL
GENERATORS ARE USED TO PRODUCE THF PROCESS STEAM REQUIRED FOR THE OPERATION. A PART OF THE OIL.
WHICH HAS 1.2 PERCENT SULFUR. IS USED AS FUEL.
C-E NATCO HAS BEEN AWARDED A CONTRACT TO INSTALL AN FGD SYSTEM ON ONE 25 MM BTU/HOUR STEAM GEN-
ERATOR. NO FGO SYSTEM TREATS 12,000 ACFM FLUE GAS AT 570 F. THE FLUE GAS IS CONTACTED WITH ONE
SET OF SPRAYS (ISO GPM) IN THE BOTTOM OF THE ABSORBER (4.5 FT DIAMETER X 35 FT HIGH). PH OF 6.5 IS
MAINTAINED IN THE FIRST STAGE. THE GAS. WHICH PASSES UP A TRAY WITH A CENTRAL OOWNCOM£R. IS FURTHER
CONTACTED WITH A SECOND SET OF SPRAYS (150 GPM). THE GAS PASSES UP A CHEVRON MIST ELIMINATOR INTO A
STUB STACK. THE EXCESS LIOUOR FROM THE TRAV OVERFLOWS TO THE FIRST STAGE. A PH OF 7.5 IS MAINTAIN-
ED IN THE SECOND STAGE. MAKEUP SODIUM HYDROXIDE SOLUTION (0.05 GPM) IS ADDED TO THE SECOND STAGE BY
A POSITIVE DISPLACEMENT PUMP WHILE FRESH MAKEUP WATER (« GPM) IS ADDED TO THE FIRST STAGE. A BLEED
OFF (1 GPM) STREAM IS TAKEN TO WASTE DISPOSAL FROM THE FIRST STAGE RECIRCULAT10N LINE.
THE ABSORBER, MIST ELIMINATOR, RECIRCULATION PUMPS AND PIPING, AND SPRAY HEADERS ARE 316L S3.
THE CAUSTIC FEED PUMP AND THE PIPING AND THE INLET DUCTWORK ARE C.S.
133
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STATUS TO JANUARY 1979
SFCTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F60 UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
TEXACO INCORPORATED
SAN ARDOr CALIFORNIA
OIL (1.7X SULFUR)
117,000 SCFM (TOTAL - 9 BOILERS)
26>000 ACFM a 600 F, FOR EACH OF 9 BOILERS.
5
9
58 MM (EQUIVALENT); 50 MM BTU/HR/BOILER
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 3000 SCFM = 1 EQUIVALENT MN,
THIS IS BECAUSE GAS FLON RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
DUCON COMPANY
SODIUM CARBONATE SCRUBBING
RETROFIT
MARCH, 1979
CONSTRUCTION
951 (1000 PPM 3 INLET)
SCRUBBER EFFLUENT DISPOSED OF IN WASTE WELLS
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
TEXACO HAS CHOSEN TO PHASE OUT THE EXISTING CEILCOTE SCRUBBER SYSTEMS AT SAN ARDO OIL FIELDS DUE
TO LOU 302 REMOVAL AND HIGH MAINTAINENCE COST. A MAJOR PROBLEM OF THE PRESENT DESIGN HAS BEEN
SCRUBBER FOULING BECAUSE OF HIGH ASH CONTENT IN THE FLUE GAS. AS THE FIRST STEP OF THE PHASE-OUT
PROGRAM, 9 OF THE PRESENT CEILCOTE SCRUBBERS ON THE 50 MM BTU/HR STEAM GENERATORS WILL BE REPLACED
BY 3 DUCON CO. SCRUBBERS HEAOERED IN PARALLEL. START-UP OF THE NEW EQUIPMENT IS SCHEDULED FOR MARCH
1979. THE NEXT STEP OF THE PHASE-OUT PROGRAM IS DEPENDENT ON THE PERFORMANCE OF THE OUCON SYSTFM.
(FOR INFORMATION ON THE CEILCOTE DESIGN SEE THE TEXACO, SAN ARDO ENTRY IN SECTION 9 OF THIS REPORT).
EACH DUCON SCRUBBING UNIT WILL CONSIST OF A VENTURI FOR PARTICULATE REMOVAL FOLLOWED BY A HORIZ-
ONTAL 3-STAGE SPRAY ABSORBER (2 IN USE, 1 STAND-BY). IT IS HOPED THAT THE VENTURI DESIGN «ILL
ALLEVIATE THE FOULING PROBLEM. ANOTHER DESIGN FEATURE OF THE DUCON SYSTEM IS SEPARATE RECYCLE TANKS
FOR VENTURI AND ABSORBER. FRESH SCRUBBING LIQUOR IS INTRODUCED AT THE ABSORBER, ENTERS THE ABSORBER
RECYCLE TANK AND PARTIALLY OVERFLOWS TO THE VENTURI WHERE IT IS RECYCLED AND FINALLY DISPOSED OF IN
ON-SITE WASTE WELLS. IN A COMPLETE CYCLE, THE SCRUBBER LIQUOR IS RECYCLED 1 TIMES BEFORE DISPOSAL.
A VOLUME OF 78,000 ACFM a 600 F WILL BE HANDLED BY EACH SCRUBBER. FURTHERMORE, EACH TRAIN CAN
TREAT 501 OF THE LOAD AND CAN »E ISOLATED FROM THF FLUE GAS FLOW. IT IS HOPED THAT THIS SYS1FM DF-
SIGN WILL YIELD SIGNIFICANTLY HIGHER AVAILABILITIES THAN THE DESIGN CURRENTLY IN USE.
THE DUCON ABSORBFR MODULE IS CONSTRUCTED OF FIBERGLASS. THE VENTURI IS MADE OF 316L SS. THE
OVERALL DIMENSIONS OF THF SYSTEM ARE 12 FFE1 X 23 FFFT * 25 FEtT. THF. SrrfAY MIZZLES WILL BE NYLON
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STATUS TO JANUARY 1179
SFCTTON 10 (CONTTWUFin
OFSIKN INFORMATION FOR HM)fR CONSTHIICTTrtN FRI) SYSTEMS ON TunilST P T. AL HOfLFKS
TEXACO INCORPORATED; SAN AROO. CALIFORNIA (CONTINUED)
OR STAINLFSS STEEL. ROTH THE ABSORBER AND VF.NTIIRI RECYCLF PUMPS ARF "AMiFar fURFO BY GAl.LTRFH. THEY
•ARE RUBBER-LINED AND SIZED BOO AND 1200 6PM RESPECTIVELY AT aO HP. THERE ARE i GARDEN CITY FANS PER
UNIT RATED AT 100 HP EACH. OUCON HAS GUARANTEED i S02 REMOVAL EFFICIENCY.
REFER TO FIGURE I«-«3 IN SECTION Jfl FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1978 TEXACO HAS TAKEN DELIVERY ON ONF DUCON SYSTEM. DELIVERY ON THE OTHER UMTS IS
EXPECTED SOON. THE UNITS ARE SCHEDULED TO START-UP WITH A NAOH SYSTEM. CONSIDERATION IS t»EING
6IVEN TO FUTURE CONVERSION TO NA2C03.
4TN OUARTER-1978 CONSTRUCTION IS PROGRESSING AS SCHEDULED AND THE SYSTEMS WILL BE SODIUM
CARBONATE SCRUBBING. THE THREE FGO SYSTEMS ARE ON THE PLANT SITE. THE SYSTEMS ARE SCHEDULED TO 8E
ONSTREAM IN MARCH 1974.
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STATUS TO JANUARY 197"?
SECTION II
OEST6N IfcFflRMAT HIM FOR PLANNtl) FCtl SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FRO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP OATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLU06E OR BY-PRODUCT DISPOSAL
C.A.r.(CAHBtOF-AMOCO-MONSANTO)
HOUSTON, TEXAS
FUtL NOT YF.T SELECTED
1,200,000 SCFM (1 BOILER)
1
I
600 I'M (EQUIVALENT); 1 BOILER
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT HI
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
VENDOR NOT YET SELECTED
PROCESS NOT YET SELECTED
NEW
1964
PLANNED-CONSIDERING S02 CONTROL
NOT DETERMINED
DISPOSAL TECHNIQUE NOT KNOWN
BACKGROUND INFORMATION
UNION CARBinE. AMOCO AND MONSANTO HAVE ENTERED TN A JOINT VENTURE (C.A.H.) TO ERECT A C06ENERA-
TION FACILITY NEAR HOUSTON, TEXAS. THE CAM PLANT WILL RE DESIGNED TO PROVIDE 3 MILLION LBS/HOUR
STEAM FOR PROCESS USF BY THE TEXAS CITY PLANTS OF THE THREE COMPANIES. AS A COGENERATION PLANT, CAM
MILL ALSO PROVIDE STEAM FOR COMMUNITY PUBLIC SERVICE COMPANY TU GENERATE ABOUT 100-MH OF ELECTRICITY
FOR THE AREA. CAM WILL ALSO SAVE ENERGY BY OPERATING AT A 75* FUEL EFFICIENCY COMPARED TO THE 35*
FOR THE CONVENTIONAL ELECTRIC UTILITY PLANTS.
THE TYPF OF COAL OR LIGNITE TO 8E USED IS NOT FINALIZED. HOWEVER. IT IS CERTAIN THAT AN FGO
SYSTEM WILL BE REQUIRED. STARTUP FOR THE FACILITY IS SCHEDULED FOR 1984.
OPERATING HISTORY
3RD OUARTER-1978 THE SYSTEM IS STILL IN THE VERY EARLY STAGES OF DEVELOPMENT. STEARNS-ROGERS
HAS BEEN CONTRACTED TO 00 PRIMARY ENGINEERING AND AID IN THE CHOICE OF AN FGD SYSTEM AND VENDOR.
AS OF THIS REPORT PFRIOD, COAL TYPE HAS NOT BEEN CHOSEN AND A CONTROL SYSTEM OR- SYSTEM VENDOR HAS
NOT BEEN SELECTED.
4TH OUARTER-I970 THE SYSTEM IS NOW UNDERGOING DETAILED DESIGN ENGINEERING AND PLANNING AND IS
SCHEDULED FOR FINAL REVIEW BY THE THREE COMPANIES. IF APPROVED BY ALL THREE PARTNER COMPANIES,
CONSTRUCTION WILL START IN EARLY I960 WITH COMPLETION OF THE PROJECT SCHEDULED FOR 1984. THE
SELECTION OF CONTROL SYSTEM IS EXPECTED BY THE END OF THE NFXT QUARTER.
136
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STATUS TO JANUARY 1979
SECTION II (CONTINUED)
I1FSTGM INFORMATION FOR Pl.ANNK) Fr,n SYSTFMS fir, (MnilSIKIAl niilLFHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP OATE
CONTROL SYSTEM STATUS
803 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CARBORUNDUM ABRASIVES
BIIFFALII, Nfift YORK
COAL C2.2X SULFUR)
30,000 SCFM (TOTAL - 2 BOILERS)
160,000 LBS/HR STFAM (TOTAL - 2 BOILERS)
1
2
15 MK (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING
CARBORUNDUM ENVIR. SYS. LTD.
LIME SCRUBBING
RETROFIT
1980
PLANNED-CONTRACT AWARDED
95X
WASTEWATER TREATMENT
BACKGROUND INFORMATION
AT THE CARBORUNDUM ABRASIVES PLANT IN BUFFALO, NEW YORK THERE ARE 4 COAL-FIRED BOILERS BURNING
2.2X SULFUR COAL WITH AN AVERAGE HEAT VALUE OF 13,000 8TIJ/L8. TWO OF THESE BOILERS ARE IDENTICAL
AND HAVE A TOTAL STF.AM GENERATING CAPACITY OF 160,000 LB/HR.
THE FLUF. GASES FROM THF. TWO BOILERS MLL BE CONTROLLED BY A VENTURI SCRUBBER (a FT INLET, 13 IN
THROAT, 13 FT HIGH) FOLLOWED BY A b-STAGE SPRAY TOWER (8.5 FT DIA X 38 FT HIGH). THE FGD SYSTEM WAS
DESIGNED BY CARBORUNDUM ENVIRONMENTAL SYSTEMS LTD., AND WILL HANDLE 90,000 ACFM,' OR 1001 OF THE FLUE
GAS FROM BOTH BOILERS. LTMF WILL BE USED AS THE SCRUBBING MEDIUM AND THE DESIGN S02 REMOVAL
EFFICIENCY IS 95X. THE SPRAY TOWER IS DESIGNED TO OPERATE AT 125 F WITH AN L/G RATIO OF
80 GAL/1000 ACF. THE MAXIMUM LIQUID FLOW RATE IS 3000 GPM. MAKE-UP WATER WILL PF FED TO THE TOP
OF THE ABSORBER AT A RATE OF « GPM, WHILE A 30 GPM BLEED STREAM WILL FLOW FROM THE HECIRCULATION
TANK DIRECTLY TO AN EXISTING TERTIARY WASTE TREATMENT FACILITY.
REFER TO FIGURE 11-6 IN SECTION 1« FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
PARTICULATE REMOVAL OPERATING HISTORY
THE VENTURI AND ABSORBER MODULE WERE INSTALLED IN 1<»75. THE VENTURI WAS PUT INTO SERVICE FOR
PARTICULATE REMOVAL AT THAT TIME USING WATER AS THE SCRUBBING MEDIUM. THE HIGH CHLORIDE CONTENT OF
THE FLUE GAS HAS CAUSED SERIOUS CORROSION PROBLEMS. EFFLUENT FROM THE VENTURI HAS A PH OF 2.8.
THE 316L SS VFNTURI WILL BF REPLACED WITH A HASTELLOY-C UNJT BEFORE START-UP FOR S02 REMOVAL. THE
ABSORBER, ALSO OF 316L SS IS BEING USED AS A SEPARATOR AND IS ALSO BADLY CORRODED. AN FRP UNIT WILL
137
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STATUS TO JANUARY 1979
SECTION 11 (CONTINUED)
DESIGN INFORMATION FOR PLANNED FED SYSTEMS (IN INDUSTRIAL BOILERS
CARBORUNDUM ABRASIVES: BUFFALO, NEW YORK (CONTINUED)
BE INSTALLED TO REPLACE IT AND WILL INCLUDE A 3-PASS CHEVRON MIST ELIMINATOR, ALSO MADE OF FHP. AN
ACID-RESISTANT COATING WAS RECENTLY APPLIED TO THE STACK LINER. COMPLETION OF THESE MODIFICATTONSi
AND START-UP FOR SOa REMOVAL ARE SCHEDULED FOR !980.
138
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STATUS TO JANUARY t<»79
SECTION II (CONT1MIEI))
DESIGN INFORMATION FO" PLANNFD Fr;n SYSTFl-'S C1N INDUSTRIAL RuTLF.MS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CATERPILLAR TRACTOR CO.
MAPLFTON, ILLINOIS
COAL (3.2* SULFUR)
105.000 SCFM (TOTAL - 2 BOILERS)
80,000 ACFh a 3SO f, FOR E4CH OF 2 FGO SYSTEMS,
500,000 L8/HR STEAM (TOTAL - 2 BOILERS)
2
2
52 M* (EQUIVALENT)J TOTAL - 2 BOILERS.
(FOR THIS REPORT, UNLESS STATF.O OTHERWISE, 2000 SCFM a 1 EQUIVALENT
THIS IS BECAUSE GAS FLOW RATE IS THF PRIMARY FACTOR IN MOOULE
FMC ENVIRONMENTAL EOUtPMENT
DOUBLE ALKALI (CONCENTRATED)
NEW
JANUARY, 1
-------
STATUS TO JANUARY 1979
SFCTION n (cnNTiwuF.D)
DFSIGW INFORMATION FUK PLANNER FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAMF
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
803 REMOVAL EFFICIENCY
MATER MAKE-UP
SLU06E OR BY-PRODUCT DISPOSAL
CHEVWON U.S.A. INC.
BAKEHSFIELO, CALIFORNIA
OIL (1.1* SULFUR)
136.000 SCFM fTOTAL - 12 BOILERS)
150,000 ACFM 3 500 F, FOR EACH OF 2 FGO SYSTEMS
2
IS
73 Mw (EQUIVALENT)? TOTAL - 12 BOILERS
600 MM BTU/HR (TOTAL - 12 BOILERS; 6 BOILERS/FGD SYSTEM)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
KOCH ENGINEERING
SODIUM CARBONATE SCRUBBING
RETROFIT
APRIL. 1979
PLANNED-REQUEST ING/EVALUATING BIOS
90X (680 PPM 3 INLET)
12-13 GPM
MASTENATER TREATMENT
BACKGROUND INFORMATION
CHEVRON U.S.A. HAS AN OIL SITE AT BAKF.RSF tELO, CALIFORNIA. THERE ARE ABOUT SO STEAM GENERATORS
KHICH BURN 1.11 CRUDE OIL. EACH GENERATOR IS RATED AT 50 MM BTU/HR. THE STEAM IS USED FOR ENHANCED
OIL RECOVERY FROM THE OIL WELLS.
A CONTRACT MAS AWARDED TO KOCH ENGINEERING TO CONSTUCT THO MORE FGD SYSTEMS. THE DESIGN HILL BE
SIMILAR TO EXISTING NA2C03 SCRUBBING UNITS. REFER TO SECTION 9 OF THIS REPORT FOR DETAILS ON THESE
FED SYSTEMS.
OPERATING HISTORY
«TH ouARTER-me. THE FGD SYSTEMS ARE UNDER DESIGN. THE CONSTRUCTION MILL START IN JANUARY
1979. THE START-UP IS STILL EXPECTED TO BE APRIL, 1979.
140
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STATUS TO JANUAHY 1179
SECTION 11 (CONTINUED!
OFSTGI INFORMATION FIIH P14NNE" FRO SYSTF.MS 01. IMnilSTtf tAl
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS REINS CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
STAHT-U" DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OIIPOHiT, INC.
RFORGtA
COAL (1.5% SULFUR)
280,000 SCFM (TOTAL - 3 BOILERS)
1,?00,000 L«/HR STEAM (TOTAL - 3 HOILFRS)
1
^
110 MM (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
VENDOR NOT YET SELECTED
DOUBLE ALKALI
NEW
1<>BT
PLANNED-CONSIDERING S02 CONTROL
90X
DEWATERED SLURRY TO LANDFILL
111
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STATUS TO JANUARY 1979
SFCTION 11 (CONTINUED)
DESIGN INFORMATION FOB PLANNED FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FED UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OIIPONT, INC.
TEXAS
COAL C0.5X SULFUR)
330,000 SCFM (TOTAL - i BOILERS)
1,600,000 L«/HR STEAM (TOTAL - 3 BOILERS)
1
Z
160 MW (EQUIVALENT); TOTAL - Z BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT Mh.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
VENDOR NOT VET SELECTED
LIMESTONE SCRUBBING
NEW
1988
PLANNED-CONSIDERING SOZ CONTROL
SOX
DEKATEREO SLURRY TO LANDFILL
IDS
-------
STATUS TO JANUARY 1979
SECTION H (CONTINUED)
DESIGN INFORMATION FOR PUNNED FRO SYSTFMS ON INOUSTHUL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUD6E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GRISSOM AIR FORCE BASE
BUNKER HILL, INDIANA
COAL (0.9X - 4.6X SULFUR)
33,000 SCFM (TOTAL - 3 BOILERS)
I
S
16 M* (EQUIVALENT); TOTAL - 3 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 3000 SCFM s t EHUIVALF^T Ha.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
AIRPOL INDUSTRIES
DOUBLE ALKALI (CONCENTRATED)
I NEW Z RETRO
SEPTEMBER, 1979
PLANNED-CONTRACT AWARDED
DEWATERED SLURRY TO LANDFILL
CAPITAL! SI,600,000 - S3,000.000 (1978). THIS IS THF
PROJECTED TOTAL INSTALLED COST.
BACKGROUND INFORMATION
AT 6RISSOM AIR FORCE BASE NEAR BUNKER HILL, INDIANA, THE AIR FORCE HAS INITIATED A PROJECT ftMlCH
INCLUDES THE ERECTION OF A NEH 65,000 LB/HR COAL-FIRED BOILER AND AN FGD SYSTEM FOR THE NEn UNIT AND
T»0 EXISTING 40,000 LB/HR COAL-FIRED UNITS. THE NAVY IS THE MILITARY CONSTRUCTION AGENT FOR THE
PROJECT AND ARNOLD M. DIAMOND HAS THE OVERALL CONSTRUCTION CONTRACT. COAL FOR THE BOILERS MAY
RANGE FROM 0.« - 4.6X SULFUR AND WILL HAVE AN AVERAGE HEATING VALUE OF 11,500 BTU/LB. THE BOILERS
FIRE APPROXIMATELY WITH 40X EXCESS AIR.
AIR POLLUTION INDUSTRIES, INC. (AIRPOL) HAS BEEN AWARDED A CONTRACT TO SUPPLY A CONCENTRATED
DOUBLE ALKALI FGD SYSTEM. THE SYSTEM WILL HAVE A GUARANTEED MAXIMUM SOS DUTLET CONCENTRATION OF
I.Z LB/MILLION BTU AND A MAXIMUM PARTICIPATE CONCENTRATION OF 0.171 LB/MILLION flTU. FLUE GAS FMOM
EACH BOILER WILL PASS THROUGH A MECHANICAL COLLECTOR. THE GAS FROM ALL THRFE BOILERS ftILL THEN BE
MANIFOLDED TOGETHER AND PASS THROUGH TWO PARALLEL ABSORBER TRAINS, EACH CAPABLE OF HANDLING 5UX
OF THE FLUE GAS. THE MAXIMUM FLOW RATE IS B0,«73 APFM a «63 F.
THE AIRPOL SYSTEM CONSISTS OF Z PARALLEL 316 S3 VENTURI SCRUBBERS, EACH FOLLOWED BY A
CYCLONIC SEPARATOR AND STUB STACK. THFRF IS A COMMON RECIRCULATTON TANK MADF OF 316 STAINLESS
STEEL AND TWO 600 GPM RUBBER-LINED RFCIHCULATION PUMPS. THf L/G RATIO IS IS GALl ONS/1OOO ACF,
"1TM A SLURRY INLET TEMPERATURE OF 155 F AND A PH OF BETWEEN 5 AND 7. RFCtRCULATION PIPES WTLL
*E MADE OF FRP.
A 100-200 GPM BLEED STREAM FROM THE RECIRCIIl ATTCIN TANK GOES TO A 316 SS LIMf REAC1ICIK
143
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STATUS TO JANUARY 1979
SFCTION 11 tCONTIK'UFII)
DFSTBM INFORMATION FOR PLAMJi-D FGfl SYS1FHS Oh INDUSTRIAL BOILERS
6RIS80M ATM FORCE BASF; BUNKER HILL, INDIANA (CONTINUED)
WHERE THE SnnillM SULFIIE/SUIFATF IS HF.AC1ED nITH SLAKFO LIME PRODUCING CALCIUM SULFATE AND
RF6FNFRATTNG THF. SODIUM HYDROXIDE. FROM THE REACTION TANK THE MIXED SLURRY FLOWS TO A THICKENER/
CLARIFIES, WHERE INSOLUBLE CALCIUM COMPOUNDS ARE SEPARATED FROM THE CLEAR OVERFLOW CONTAINING THE
REGENERATED NAOH. THE CL*HIFIF.R OVERFLOW IS RETURNED TO THE ABSORBER* hHlLF. THE UNDERFLOW IS
REACTED ONCE AGAIN WITH LIHF IN A PIPELINE MIXER TO PRECIPITATE ANY RESIDUAL SULFITE AS SULFATE.
THE SLURRY IS THEN FILTERED IN A ROTARY FILTER* AND THE FILTRATE IS RETURNED TO THE REACTION TANK.
THE FILTER CAKE WILL BE LANOFILLfcD. THE TANKS WILL BE MADE OF 316 SS AND THE PIPING OF FHP. THE
LIME STORAGE TANK AND SLAKER WILL BE CARBON STFEL.
100
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STATUS TO JANUARY 1979
SECTION II (CONTINUED)
OFSTRN INFORMATION FOR PLANNFO FKH SYSTEMS ON INOIISTIHAI
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATF
CONTROL SYSTEM STATUS
SOB REMOVAL EFFICIENCY
SLUD6E OR BY-PRODUCT DISPOSAL
SHELL OIL COMPANY
BAKERSFItLO, CALIFORNIA
OIL tl.lZ SULFUR)
99,000 SCFM (TOTAL - » BOILERS)
400 MM BTII/HR, (50 MM 8TII PER BOILER)
1
A
SO MN (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = | EQUIVALENT MM.
THIS IS BECAUSE GAS FLON RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
VENDOR NOT YET SELECTED
PROCESS NOT YET SELECTED
NEW
PLANNED-CONSIDERING 803 CONTROL
9«X (575 PPM 303 3 INLET)
DISPOSAL TECHNIQUE NOT KNOWN
BACKGROUND INFORMATION
SHELL OIL IS CONSIDERING IMPLEMENTING FGO TECHNOLOGY TO CONTROL EMISSIONS FROM 8 SMALL OIL-
FIRED (1.IX SULFUR) STEAM GENERATORS. NO PROCESS OR START-UP OATF. HAVE AS YET BEEN SPECIFIED. AN
SOS REMOVAL EFFICIENCY OF 9«X MILL BE KF.OUIRED.
145
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STATUS TO JANUARY 1979
SECTION 11 (CONTINUED)
DESIGN INFORMATION FOR PLANNFD FGD SYSTFMS ON INDUSTRIAL BOILFHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNTTS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
3LUD6E OR BY-PRODUCT DISPOSAL
SHELL OIL COMPANY
TAFT, CALIFORNIA
OIL (t.lZ SULFUR)
a5,000 SCFM (TOTAL - 2 BOILERS)
0
a
12 M* (EUUIVALENT); 100 MM BTU/HHf TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
VENDOR NOT YET SELECTED
PROCESS NOT YET SELECTED
NEM
PLANNED-CONSIDERING S02 CONTROL
9« (575 PPM 802 3 INLET)
DISPOSAL TECHNIQUE NOT KNOWN
BACKGROUND INFORMATION
SHELL OIL IS CONSIDERING IMPLEMENTING FGO TECHNOLOGY TO CONTROL EMISSIONS FROM 2 SMALL OIL-
FIRED (1.11 SULFUR) STEAM GENERATORS. NO PROCESS OR START-UP DATE HAVE AS YET BEEN SPECIFIED. AN
S02 REMOVAL EFFICIENCY OF 9
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STATUS 10 JAMIAWY 1
-------
STATUS TO JAMJAtfY 1979
IifCTION 11 (COMIMIFIO
DFSH-N INFORfHTTON FOP PLANNED FGO SYSTFMS ON INOUSTR1AI BOILERS
INSTALLATION NA*F
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATINfi
NUMBER OF SEPARATE F6H UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
CORRECTIONAL INST.
KITTSBURG, PENNSYLVANIA
COAL (5.51 SIILFIIK)
10,000 SCFM (TOTAL - 1 BOILER)
20, Con ACFM o> bOOF
30,000 LB/HR STEAM
5 MW (EQUIVALENT), 38 MM BTU/HR
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = I EQUIVALENT HH.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
PITTS8URG ENV. * ENGY. SYSTEMS
SULF-X SCORE
RETROFIT
NOVEMBER, 1979
PLANNED-CONTRACT AWARDED
90X (3000 PPM 3 INLET)
60X NOX REMOVAL (200 PPM a INLET)
BACKGROUND INFORMATION
THE WESTERN CORRECTIONAL INSTITUTION IN PITTSBURGH, PA. HAS TWO IDENTICAL COAL-FIRED BOILERS,
EACH RATED AT 30,000 LB/HR STEAM. ONE BOILER IS ALWAYS ON STAND-BY AND THE OPERATING BOILER BURNS
HIGH SULFUR C3.5X S) PENNSYLVANIA BITUMINOUS CflAL.
THE FGO SYSTEM, SULF-X SCORE PROCESS, WILL BE RETROFITTED BY PITTSBURGH ENVIRONMENTAL AND
ENERGY SYSTEMS, INC. THE PROCESS HAS DEMONSTRATED 802 AND NOX REMOVAL CAPABILITIES ON A i-MH BOILER
AT THE U.S. ARMY POWER PLANT AT FORT BENJAMIN, HARRISON, PA. IRON SULFIDE (FES) SLURRY IS USED AS
THE ABSORBENT WHICH RFAC1S WITH S02 AND NO TO FORM IRON OXIDE (FED), IRON BISULFIDE (FES?) AND
NITROGEN. THE BLEfD-OFP STREAM IS SENT THROUGH A THICKENER, VACUUM FILTER AND A CALCINER WHERE THE
IRON COMPOUNDS ARE REDUCED BY COAL TO FES AND S. FES IS RECYCLED WHILE S IS RECOVERED *S A BY-
PRODUCT. THE ABSORBER (5 FT, DIA. X 30 FT. HIGH) HILL HAVE a KOCH ENGINEERING FLEXITRAYS AND A
FLEXIMESH DEMISTER. THE FLUE GAS (20,000 ACFM S 600 F) WILL CONTAIN 2000 PPM S02-AND 200 PPM NO
WHICH WILL BE REDUCED TO 200 PPM AND «0 PPM RESPECTIVELY. THE ABSORBER WILL BE MADE OF 316L SS,
BUT THE REGENERATION SECTION WILL BE PRIMARILY OF CARBON STEEL.
OPERATING HISTMKY
4TH OUARTER-197B THE SYSTEM IS IN THE OFSIGN PHASE. THE AHSOR8ER SECTION ONLY OF THE FGD SYSTEM
WILL BE STARTF.D UP IN MAY 1979 AND TESTED FOR A SHORT DURATION. THE REGENERATION LOOP WILL BE
COMPLETED BY LATE FALL OF 1979.
I UK
-------
STATUS TO JANUARY
SFCTION J?
INSCRIPTION OF INnilSTPtAl BnTLFk FPD SYSTEMS NOT OPF.RAT1NC,
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SnURCF RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOS REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
BIlNGf, INC.
CAIRO. ILLINOIS
COAL ill SULFUK)
IflfOCO SCFH (TOTAL - Z BOILERS)
81,000 ACFM ,1 520 F
1
?.
2? Mw (EOUIVALENT); TOTAL - i BOILERS
1«0,000 LQS/HR STEAM (TOTAL)
(FOR THIS REPORT, UNLESS STATED OTHFRKISE, ?OOU SCFM = 1 FOIIIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
DRAVO CORP./NAT'L LIME ASS'N
LIME SCRUBBING
RETROFIT
SEPTEMBER, 1977
INDEFINITELY SHUT DOWN
9« (3700 PPM INLET)
OENATERED SLURRY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BUNSE PURCHASED THIS LIME SCRUBBING SYSTEM FOR TESTING PURPOSES. THE LF*IS SCRUBBER, HHICH IS
*
* HORIZONTAL ROTARY VESSEL WITH INTERNAL CHAINS, PERFORMED VERY WELL DURING THE TEST (9« PERCENT 803
REMOVAL). PRESENTLY, BUNSE 19 USING LOW SULFUR COAL (0.9 PERCENT) AND HAS NO PLANS- TO RESTART
F6D OPERATIONS.
149
-------
STATUS TO JANUARY 1<»7
-------
STATUS TO JANUARY 1979
SFCTION 12 (CONTINUED)
DESCRIPTION OF INDUSTRIAL BUILFR FGU SYSTh«S NOT OPEHATINR
INSTALLATION NAME
INSTALLATION LOCATION
40URCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
^ARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
HARRIS MINING -en.
SPRUCE PINE, NORTH CAROLINA
COAL (O.SZ SULFUR)
0,000 SCFM (TOTAL - 2 BOILERS)
2
2
2 MW (EQUIVALENT); TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MH.
THIS is BECAUSE GAS FLOW RATF. rs THF PRIMARY FACTOR IN MODULE SIZING.)
H.W. SLY MANUFACTURING CO.
WATER SCRUBBING (NA.NH3 OPTN.)
RETROFIT
1973
INDEFINITELY SHUT OOhN
96X
DISPOSAL TECHNIQUE NOT KNOWN
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE F6D SYSTEM AT THE HARRIS MINING COMPANY LOCATED AT SPRUCE PINE, NOKTH CAROLINA REMOVES FlY-
*SH AND SULFUR DIOXIDE FROM THE FLUE GAS OF A COAL FIRED BOILER. THE SCRUBBER IS A *.W. SLY
IHPINGENT TYPE SCRUBBER CONSTRUCTED OF 30« STAINLESS STEEL. THE BOILER IS BATED 1.9 MM
(EQUIVALENT 200 BOILER HORSEPOWER). COAL COMPOSITION IS TYPICALLY 0.8X SULFUR AND 5X ASH. PRIMARY
INTEREST IN FLUE 6AS SCRUBBING IS IN FLYASH REMOVAL AND NO TESTS FOR SULFUR DIOXIDE REMOVAL EFFI-
CIENCY HAVE BEEN MADE.
OPERATING HISTORY
2ND QUARTER-1977 NO OPERATIONAL PROBLEMS HAVE BEEN HEPOKTtD.
>ST OUARTER-1978 THIS PLANT HAS BEEN MOVED TO THE INACTIVE SYSTEMS FILF UNTIL SUCH TIME AS ACTUAL
F6D OPERATIONS BEGIN. THE SCRUBBER IS EQUIPPFD WITH ALKALI ADDITION CAPABILITY, BUT WITH
*HE LOW SULFUR COAL CURRENTLY BEING FIHFP, NO ALKALI ADDITION UR PH CONTROL IS OCCURRING.
2ND BUARTER-1978 PLANT REPORTED NO CHANGE.
J"D QHARTER-197H PLANT REPORTED NO CHANGE.
151
-------
STATUS TO JANUARY !<>79
SFCTJflN \? (CflwTINUFn)
TON nF INDIISTKtAL BOILFR FGO SYSTEMS NOT OPERATING
INSTALLATION
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS HFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
NDRTHFAN OHIO SUGAR COMPANY
FIWHAY, OHIO
COAL (1.2X SULFUR, AVERAGE)
h5,230 SCFM (TOTAL - 2 80TLERS)
100,000 LKS/HR STEAM (TOTAL - 2 BOILERS)
2
2
33 MW (EQUIVALENT), TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT Hi
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING,;
GREAT MFSTERN SUGAR
SODIUM CARBONATE SCRUBBING
RETROFIT
OCTOBER, 197«
TERMINATED
76Z (600 PPM a INLET)
901
MASTEWATER TREATMENT AND DISCHARGE TO CITY SEMER
BLEED-OFF STREAM TO HOLDING TANK
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE NORTHERN OHIO SUGAR COMPANY HAS TERMINATED ALL SUGAR PRODUCTION OPERATIONS AT FINDLAY OHIO.
THE PLANT IS NOW OPEN ONLY AS A SHIPPING AND RECEIVING STATION. THE SCRUBBER OPERATED DURING THE
1975, 1976, AND 1977 SUGAR PRODUCTION SEASONS BEFORE THE SHUTDOWN OCCURRED.
152
-------
STATUS TO JANUARY 1979
SECTION 12 (CONTINUED!
DESCRIPTION OF INDUSTRIAL ROUFk FRD SYSTms NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE BATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS 8EIM6 CONTROLLED
SOURCF. CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
SMELLER GLOBE CORP.
NORFOLK, VIRGINIA
COAL (« l.OZ SULFUH)
8,000 SCFM (TOTAL - 1 BOILER)
1
1
9 MW (EQUIVALENT); TOTAL - I BOILER
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = l EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THF PRIMARY FACTOR IN MODULE SIZING.)
n.h. SLY MANUFACTURING CO.
SODIUM HYDROXIDE SCRUBBING
RETROFIT
1975
INDEFINITELY SHUT DOWN
NOT DETERMINED
NOT DETERMINED
OVERFLOW TO SEWER/SLUDGE TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN NORFOLK, VIRGINIA, SHELLER GLOBE CORPORATION OPERATES THE MITCHELL SMITH DIVISION PLANT,
MHERE THE PRIMARY PRODUCT IS CORK RUBBER GASKET MATERIAL. PROCESS (AUTOCLAVE) AND HEATING STEAM
ARE SUPPLIED BY A BOILER RATED AT 350 BOILER HP (ABOUT 3.5 Mw EQUIVALENT). STEAM CONDITIONS ARE
125 PSI AT 325 F. THE BOILER WAS ORIGINALLY ERECTED IN 193«», BUT UNDERWENT A COMPLETE OVERHAUL IN
1977. BOILER TUBES, REFRACTORY BRICK, GRATE, AND SOOT BLOWERS WERE REPLACED DURING THE OVERHAUL.
THE BOILER FIRES COAL SUPPLIED BY GENERAL COAL - NOMINAL SIZE IS 1.25 X 0.25 INCHES. COAL
CHARACTERISTICS ARE AS FOLLOWS: HHV=13,200 8TU/LB, ASHS6X, AND SULFUR IS LESS THAN IX.
THE EMISSIONS CONTROL SYSTEM AT SHELLER GLOBE CONSISTS OF A W.W. SLY SINGLE-STAGE IMPINJET
SCRUBBER (*I70) WHICH REMOVES PAHTICULATE AND 502 FROM THE FLUE GAS. THE SYSTEM USES A NAOH MAKE-UP
PRIMARILY FOR CORROSION CONTROL BUT S02 CONTROL IS AN ADDITIONAL BENEFIT. RECYCLE TANK SUPERNATANT
IS PH NEUTRALIZED AND IS DISCHARGED TO CITY SEWERS WHILE FLT ASH AND SEDIMENT ARE SETTLED, SCRAPED
OUT AND HAULED TO A SANITARY LANDFILL.
THE SCRUBBER MODULE IS CONSTRUCTED OF 316L S3 (10 FT DIA X 15 FT HIGH). THE FLUE GAS RATE ENTE-
RING THE SCRUBBER IS 19,200 CFM d 150 F. THE OUCTINS ENTERING AND EXITING THE SCRUBBER IS MADE OF
»'•• C.S. AND CORTEN STEEL RESPECTIVELY. THE ».«. SLY FAN (BOILER ID) IS MADE OF CARBON STEEL.
THE RECYCLF TANK IS CONSTRUCTED OF UNLINEO STEEL (20 FT X 10 FT X 8 FT) AND THE PIPING IS OF PVC.
CHEMICALS ARE PURCHASED FROM THE CHEMICAL TREATMENT CO. WHO ALSO OPERATE THE SCRUBBING SYSTEM.
REFER TO FIGURE 11-10 IN SECTION la FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
153
-------
STATUS TO JANllSUY 1979
SECTION 12 (CONTINUED)
INSCRIPTION OF INDUSTRIAL ROILEK FGO SYSTEMS NOT OPERATING
SHELLER GLOBE CORP.! NORFOLK, VIRGINIA (CONTINUED)
OPERATING HISTORY
UPON INITIAL STARTUP NO CAUSTIC WAS INTRODUCED TO THE SYSTEM AND WITHIN A FEW MONTHS THF INTER-
NALS OF THE MODULE AND THE STEEL PIPING SYSTEM WERE CORRODED BEYOND USE. THIS NECESSITATED REPLACE-
MENT OF THE INTERNALS, SUBSTITUTION OF STFEL PIPE WITH PVC, AND ADDITION OF NAOH TO THE SCRUBBING
LIQUOR.
2ND OUARTER-1978 DURING THE REPORT PERIOD THE UNIT UNDERWENT A VIRGINIA EPA CERTIFICATION
INSPECTION, AND HAS FOUND TO BE IN COMPLIANCE. NO SCRUBBER-RELATED PROBLEMS HAVE OCCURRED.
3RD OUARTER-1978 BOILER OPERATION WAS ESTIMATED TO BE AT 60Z CAPACITY 39 MRS PER DAY, b DAYS PER
WEEK. HO SCRUBBER-RELATED PROBLEMS HAVE BEEN REPORTED. PLANT PERSONNEL ARE CONSIDERING REPLACEMENT
OF THE PRESENT SYSTEM DUE TO WEAR ON THE EQUIPMENT.
«TH OUARTER-1978 NO SCRUBBER RELATED PROBLEMS HERE REPORTED DURING THIS PERIOD. AT PRESENT, THE
USE OF FRESH NAOH HAS BEEN DISCONTINUED.
151
-------
STATUS TO JANUARY 1979
SECTION 13 (CONTINUFO)
DESCRIPTION OF INDUSTRIAL BOHFK FfiO SYSTtMS NOT OPERATIC,
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILFRS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOZ REMOVAL EFFICIENCY
HATER MAKE-UP
SLUD6E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
TRANSCO TEXTILES, INC.
AUGUSTA, r.f-OHHIA
FUEL OIL (21 MAX. SULFUR)
50,000 ACFM
1
1
SO MK (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, ZOOO SCFM = 1 FOUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
NEW
MARCH, t<»75
INOEFINITFLY SHUT DOWN
BOX-85Z (610 LB/HR S INLET)
48 GPM; OPEN LOOP
WASTEHATER TREATMENT AND DISCHARGE TO RIVER
NA2S03/S04 LIQUOR DISCHARGED TO A HOLDING POND
SEE SECTION J3 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGD OPERATIONS HAVE BEEN TERMINATED FOR AN INDEFINITE PERIOD. THE PLANT BURNS NUMBER 6
FUEL OIL AND THE SULFUR DIOXIDE EMISSIONS ARE 501 OF THE EXISITING REGULATIONS. THF BOILFR IS
RATED AT 20 MH (EQUIVALENT) AND PRODUCES 150,000 LBS/HR STEAM. WHEN OPERATIONAL, THE SCRUBBER
SYSTEM MAD A FLUE GAS VOLUME OF 50,000 ACFM AT 140 DEGREES F. SYSTEM START-UP OCCURRED IN MARCH
1975 AND SCRUBBER OPERATIONS WERE TERMINATED LATER IN THE SAME YEAR. THERE ARE CURRENTLY NO PLANS
TO INITIATE OPERATIONS.
155
-------
STATUS TO JANUARY I97«J
N 1? CCOfvTlNUFl))
neSCRIPT !'"'< OF INDUSTRIAL BOILEH FGU SYSTEMS NOT OPERATING
INSTALLATION NAMI-
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS 8EIN6 CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
U.S. GYPSUM CORP.
OAKMONT, PENNSYLVANIA
COAL
J<»,BOO SCFM (TOTAL - 1 BOILERS)
1
a
10 HVs (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT HH,
THIS TS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
AIRPOL INDUSTRIES
DOUBLE ALKALI (DILUTE)
NEM
NEVER STARTED-UP
SUFFICIENT TO MEET REGULATION
MEETS CODE
10 6PM (CLOSED LOOP)
DEMATERED SLURRY TO LANDFILL
SLUDGE TO POND FOR DRYING. THEN TO LANDFILL.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AN AIRPOL DOUBLE ALKALI SCRUBBING SYSTEM IS ON-SITE, INSTALLED, AND READY FOR OPERATIONS.
HOWEVER, IIS GYPSUM DECIDED NOT TO INITIATE PRODUCTION AT THIS FACILITY FOR ECONOMIC REASONS. A
CHECK DURING THE «TH QUARTER 1<978 REPORT PERIOD REVEALED THAT THERE ARE STILL NO PLANS TO USE THIS
FACILITY.
156
-------
STATUS TO JANUARY 1979
SECTION 13
INDUSTRIAL ROILFk FRO COSTS
COMPANY PROCESS COST
LOCATION STATUS _.
CAPACITY (RCFM) START-UP DATE CAPITAL OPERATING
ALYESKA PIPELINE SERVICE CO. SODIUM HYDROXIDE SCRUBBING
VALDEZ, ALASKA OPERATIONAL
50»000 6/77
PLANT PERSONNEL HAVE NOT SEPARATED OUT FGO SYSTEM
COSTS FROM OVERALL PROJECT COSTS NOR 00 THEY KEEP
OPERATING COSTS FOR THE FED SYSTEM.
AMERICAN THREAD CO. CAUSTIC WASTE STREAM $138,000. St6>300.
MARION, NORTH CAROLINA OPERATIONAL
18,500 1973
THE CAPITAL COST REPRESENTS TOTAL INSTALLED COST
IN 1972 DOLLARS. THE OPERATING COST INCLUDES NEW
FIBERGLASS LININGS IN DUCTWORK AND ON FANS AND
OPERATING LABOR AND MATERIALS FOR 1977.
ARCO/PRLYMERS, INC. DOUBLE ALKALI (CONCENTRATED} $6,000,000. 121,000,000.
MONACA, PENNSYLVANIA CONSTRUCTION
236,000 6/80
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
COST INCLUDING EQUIPMENT, INSTALLATION, DUCTWORK,
STACK, PIPING, ENGINEERING, START-UP, TESTING,
INSTRUMENTATION, ENGINEERING, AND OVERHEADS IN
1978 DOLLARS. THE PROJECTED OPERATING COST IS
S8/TON OF COAL.
ARMCO STEEL LIME SCRUBBING $70,000.
MIDOLETOHN, OHIO OPERATIONAL
84,000 1975
THIS IS THE REPORTED CAPITAL COST IN 1975 DOLLARS.
BELRID6E OIL CO. SODIUM HYDROXIDE SCRUBBING $125,000.
MCKITTRICK, CALIFORNIA CONSTRUCTION
12,000 1/79
THIS IS THE REPORTED CAPITAL COST IN 1978 DOLLARS.
(57
-------
STATUS TO JANUARY 197<»
SECTION U (CONTINUFn)
INDUSTRIAL BOILFR FCO COSTS
COMPANY
LOCATION
CAPACITY (SCFM)
PROCESS
STATUS
START-UP DATE
COST
CAPTTAL OPERATING
8ELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
ia,ooo
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
b/78
THE CAPITAL COST INCLUDES THE SCRUBBFR, RECYCLE
TANK, STACK, OEMISTER. PIPING, DUCTWORK, AND
INSTRUMENTATION IN 1<»78 DOLLARS.
$100,000.
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
12,000
SODIUM HYDROXIDE SCRUBBING $100,000.
OPERATIONAL
7/78
THIS IS THE REPORTED CAPITAL COST IN 1978 DOLLARS.
BUNGE, INC.
CAIRO, ILLINOIS
44,000
LIME SCRUBBING
INDEFINITELY SHUT DOWN
9/77
11,000,000.
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
COST OF THE FGD SYSTEM, ENGINEERING, START-UP, AND
TESTING IN 1977 DOLLARS.
CANTON TEXTILES
CANTON. GEORGIA
as,ooo
CAUSTIC WASTE STREAM 1138,000.
OPERATIONAL
fa/70
THE CAPITAL COST REPRESENTS THE TOTAL COST FOR THE
INSTALLED SYSTEM, IN 1970 DOLLARS.
J30.000.
158
-------
STATUS TO JANUARY 1979
SECTION I* (CONTINUED)
INDUSTRIAL HIIILFM FRO COSTS
COMPANY PROCESS rr.cT
LOCATION STATUS _„..
START-.IP PATE CAPTTAl OPFHAT TKT.
CATERPILLAR TRACTOR CO. ROUBLE ALKALI (CONCENTRATED)
EAST PEORIA, ILLINOIS OPERATIONAL
310,000 • «/7»
.NO ECONOMIC" INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGf> SYSTEMS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (OTLUTE)
JOLIET, ILLINOIS OPERATIONAL
67,000 9/74
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGD SYSTEMS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (CONCENTRATED)
MAPLETON, ILLINOIS CONSTRUCTION
131,000 1/79
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR F60 SYSTEMS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (OTLUTE)
MORTON, ILLINOIS OPERATIONAL
38,000 1/78
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FSO SYSTEMS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (CONCENTRATED)
HOSSVILLE. ILLINOIS OPERATIONAL
140,000 10/75
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGD SYSTEMS.
159
-------
STATUS TO JANUARY 1979
SECTION 11 (CONTINUFlO
INDUSTRIAL BUILFH FRO COSTS
COMPANY
LOCATION
CAPACITY CSCFM)
PROCESS
STATUS
START-UP PATE
COST
CAPITAL
OPERATING
CHANSLOR WESTERN OIL K OEV. CO DOUBLE ALKALI
BAKERSFIELO, CALIFORNIA CONSTRUCTION
70,000 3/79
tCONCENTRATEO)
11,500,000.
THE CAPITAL COST INCLUDES THE SCRUBBER, LIOUOR
REGENERATION EQUIPMENT, ANO DUCTWORK IN 1978
OOLLARS.
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
248,000
SODIUM CARBONATE SCRUBBING
OPERATIONAL
7/78
12,600,000.
1930,000.
THE CAPITAL COST IS IN J978 DOLLARS. THIS REPRE-
SENTS THE TOTAL INSTALLED COST OF THE FGO SYSTEM
INCLUDING SITE PREPERATION. THE OPERATING COST
INCLUDES ELECTRICITY, SODA ASH, AND MAINTENANCE
(LABOR AND MATERIALS). THIS CORRESPONDS TO A 340
DAY YEAR AND APPROXIMATELY SOOO/DAY PER SCRUBBER
IN 1978.
FIRESTONE TIRE AND RUBBER co.
POTTSTOWN, PENNSYLVANIA
8070
DOUBLE ALKALI (CONCENTRATED)
OPERATIONAL
1/75
•163,000.
$60,000.
THE CAPITAL COST INCLUDES EQUIPMENT, ENGINEERING
ANO STARTUP. THE COST DOES NOT INCLUDE LABOR AND
MATERIALS FOR ELFCTRTCAL SYSTEM, PIPING, OR STRUC-
TURAL AND FOUNDATIONS ERECTION IN 1974 DOLLARS.
THE OPERATING COST INCLUDES CHEMICALS, LABOR,
ELECTRICITY, DISPOSAL, MATERIALS, AND LAB WORK FOR
1977.
FHC (SODA ASH PLANT)
GREEN RIVER, WYOMING
446,000
SODIUM CARBONATE SCRUBBING S10,000,000.
OPERATIONAL
5/76
THIS TOTAL CAPITAL COST, IN 1975 DOLLARS,
INCLUDES ESP ANO FGD PURCHASE AND INSTALLATION
COSTS.
160
-------
STATUS TO JANHAkY 1979
COMPANY
tOCATION
CAPACITY (SCFM)
GENERAL MOTORS CORPORATION
DAYTON, OHIO
36.000
SECTION I? (CONTINUED)
INDHSTklAL HOllF* KGO COSTS
PROCFSS
STATUS
ST4M-IIH DA1E
COST
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
9/7 fl
CAPITAL
1668,000.
OPEHATING
THE CAPITAL COST IS THF TOTAL INSTALLED COST FOR
THE T*0 FRO SYSTEMS, IN 197a DOLI ARS.
GENERAL MOTORS CORPORATION
PARMA, OHIO
128,400
DOUBLE ALKALI
OPERATIONAL
1/70
(DILUTE)
S3,ZOO,000.
S6ia,000.
THE OPERATING COST REPRESENTS SH.70/TON COAL.
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
107,300
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
4/76
1600,000.
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
COST IN 1972 DOLLARS.
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
64,000
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
1978
1773,000.
S17S,000.
THE CAPITAL COST IS IN 1973 DOLLARS. THE OPERAT-
ING COST INCLUDES MAINTENANCE MATERIALS, LABOR AND
ELECTRICITY IN 1976.
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
9Z,000
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
6/75
,200,000.
THE CAPITAL COST IS IN 1974 DOLLARS.
161
-------
STATUS TO JANUARY 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FRO COSTS
COMPANY PROCESS COST
LOCATION STATUS .„.._._.—.——.———
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
GEORGIA-PACIFIC PAPER CO.. CAUSTIC HASTE STREAM $275,000.
CROSSETT, ARKANSAS OPERATIONAL
320,000 7/75
THE CAPITAL COST REPRESENTS THE ABSORBER COST ONLY
AND IS IN 1974 DOLLARS.
BETTY OIL COMPANY SODIUM CARBONATE SCRUBBING $400,000. $390,000.
BAKERSFIELD, CALIFORNIA OPERATIONAL
72,000 b/77
THE CAPITAL COST INCLUDES THE ABSORBER MODULE,
SODA ASH TANK, PUMPS, AND PIPING IN 1977 DOLLARS.
IT DOES NOT INCLUDE THE STACK, DUCTING, ENGINEER-
ING, OR OVERHEADS. THE OPERATING COST IS EQUIV-
ALENT TO S0.16/MM BTtI, INCLUDES THE COST FOR
SODA ASH, ELECTRICITY, AND SCRUBBER MAINTENANCE,
AND REPRESENTS A 340-DAY YEAR.
BETTY OIL COMPANY SODIUM CARBONATE SCRUBBING $2,500,000. 12,900,000.
BAKERSFIELO, CALIFORNIA OPERATIONAL
•95,000 12/78
THE CAPITAL COST INCUDES COST OF SCRUBBER, SODA
ASH TANK, PIPING, AND PUMPS TN 197B HOLLARS FOR
5 SCRUBBER SYSTEMS. THE OPERATING COST INCLUDES
ELECTRICITY, SCRUBBER MAINTENANCE, AND SODA ASH,
IS BASED ON A 340-DAY YEAR, AND REPRESENTS
S0.16/MM BTU FOR 5 SCRUBBING UNITS.
BETTY OIL COMPANY SODIUM CARBONATE SCRUBBING 12,000,000. S2,S20,OOU.
BAKERSFIELD, CALIFORNIA CONSTRUCTION
396,000 1/79
THE CAPITAL COST INCLUDES COST OF SCRUBBER, SODA
ASH TANK, PIPING, AND PUMPS IN 1978 DOLLARS FOR
4 SCRUBBER SYSTEMS. THE OPERATING COST INCLUDES
ELECRICITY, SCRUBBFR MAINTENANCE, AND SODA ASH,
IS BASER ON A 340-DAY YEAR, AND REPRESENTS
S0.16/MM BTU FOR 4 SCRUBBING UNITS.
163
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STATUS 10 JANUARY 1979
SECTION 1? (CONTINUED)
INDUSTRIAL BUTLFB Ffil) COSTS
COMPANY PROCESS rniT
LOCATION STATUS . .
CAPACITY (SCFH) START-UP DATE CAPITAL OPFkATTNG
GREAT SOUTHERN PAPER CO. CAUSTIC WASTE STREAM $600,000.
CEDAR SPRINGS, GEORGIA OPERATIONAL
420,000 . • 1975
.THE CAPITAL" COST is THE EQUIPMENT COST FOR THE TWO
SCRUBBEK MODULES IN 1970 DOLLARS.
6REAT WESTERN SUGAR AMMONIA-LADEN PROCESS WATER
BILLINGS, MONTANA OPERATIONAL
60>000 10/77
NO COST INFORMATION HAS BEEN SUPPLIED FOR THE
BILLINGS FGD SYSTEM.
GREAT WESTERN SUGAR AMMONIA-LADEN PROCESS HATER 3707,000. $88,200.
FORT MORGAN, COLORADO OPERATIONAL
65,a30 10/76
THE CAPITAL COST IS THE TOTAL INSTALLED COST OF
THE FGO SYSTEM IN 1976 DOLLARS. THE OPERATING
COST INCLUDES ELECTRICITY, STEAM, MAINTENANCE,
LAABOR, AND MATERIALS.
6REAT WESTERN SUGAR AMMONIA-LADEN PROCESS WATER $693,000. $3U,60u.
BERING, NEBRASKA OPERATIONAL
110,000 tO/75
THE CAPITAL COST IS THE TOTAL INSTALLED COST OF
THE F60 SYSTEM IN 1975 DOLLARS. THE OPERATING
COST INCLUDES ELECTRICITY, MAINTANENCE, LABOR, ANO
MATERIALS.
GREAT WESTERN SUGAR AMMONIA-LADEN PROCESS WATER
6REELEY, COLORADO OPERATIONAL
25,000 10/75
NO COST INFORMATION HAS BEEN SUPPLIED FOR THF
GREELEY FGD SYSTEM.
161
-------
STATUS TO JANHAHY
SECTION 1? (CniJTfMUFD)
INDUSTRIAL flUTLF" FGD COSTS
COMPANY PKOCFSS COST
LOCATION STATUS »———
CAPACITY (SCFM) START-UP PATE CAPITAL OPERATING
GREAT WESTERN SUGAR AMMONIA-LADEN PROCESS WATER
LON6MONT, COLORADO TERMINATED
SCFM-N/A 10/73
NO COST INFORMATION HAS BEEN SUPPLIED FOR THE
LONGMONT F6D SYSTEM.
GREAT WESTERN SUGAR AMMONIA-LADEN PROCESS HATER §431,000. s8Q,aoo.
LOVELAND, COLORADO OPERATIONAL
lai.eoo 10/73
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
COST FOR TWO SCRUBBERS, I.D. FANS, NEW BREECHING,
AND WATER SYSTEM IN 1973 DOLLARS. THE OPERATING
COST INCLUDES ELECTRICITY, STEAM, MAINTANENCE,
LABOR, AND MATERIALS.
GREAT WESTERN SUGAR AMMONIA-LADEN PROCESS WATER $523,000. $30,200.
SCOTTS BLUFF, NEBRASKA OPERATIONAL
65,230 10/75
THE CAPITAL COST IS THE TOTAL INSTALLED COST OF
THE FGO SYSTFM IN 1975 DOLLARS. THE OPERATING
COST INCLUDES ELECTRICITY, STEAM, MAINTANENCE,
LABOR, AND MATERIALS.
HARRIS MINING CO. HATER SCRUBBING (NA,NH3 OPTN.) $31,000.
SPRUCE PTNF, NORTH CAROLINA INDEFINITELY SHUT DOWN
1,000 1973
THE CAPITAL COST tS THE TOTAL INSTALLED COST IN
1973 DOLLARS.
ITT RAVONIFR, INC. SODIUM HYDROXIDE SCRUBBING 5500,000.
FERNANDINA BEACH, FLORIDA OPERATIONAL
176,000 1975
THE CAPITAL COST IS FOR Z SCRUBBERS, DUCTWORK,
AND STACKS IN 1975 DOLLARS.
164
-------
STATUS TO JANUARY 1979
SECTION 13 (CONTINUED)
RIUI.FH FSII
COMPANY
LOCATION
CAPACITY (SCFM)
PROCESS
STATUS
START-HP DATF
COST
CAPITAL OPERATING
KERR-MCGFF CHFMICAL CORP.
TRONA, CALIFORNIA
490,000
SODIUM CAKBONA-TE SCRUBBING
OPERATIONAL
b/7B
,00(1,0(1 (I.
KERR-MCGFE SPENT $1.5 MM IN A PILOT PLANT FUR
SEVERAL YEARS BEFORE AND DURING CONSTRUCTION OF
THE NEW FACILITY. OUT OF THE SSOO MM PROJECT
COST, Sib MM OF THAT IS FOR POWER PLANT AND $6 MM
TS FOR THE BOILER'S RfLATEO POLLUTION CONTROL
COSTS.
MEAD PAPEHROARO CO.
STEVENSON, ALABAMA
100,000
SODIUM CARBONATE SCRUBBING S173,000.
OPERATIONAL
t<»75
THE CAPITAL COST REPRESENTS THE ORIGINAL EQUIPMENT
AND INSTALLATION COST IN 1974. SINCE THEN, EXTEN-
SIVE MODIFICATIONS HAVE BEEN REQUIRED. ANOTHER
S173,000 MAS SPENT FOR REPAIRS AND UPGRADING IN
1976. OVER THE SCRUBBER PLANT LIFE, AN ADDITIONAL
1136,000 HAS BEEN SPENT, INCLUDING:* 35,000 (RUB-
BER LINERS), 154,000 (STAINLESS STFFL LINERS), AND
S07.000 (GENERAL REPAIRS).
THE OPERATING COST INCLUDES S4D,000/YR FOR
OPERATING LABOR, S40,000/YR FOR MAINTENANCE
LABOR, AND $760,000/YR FOR REAGENT (B526 TONS).
1800,000.
MINN-DAK FARMER'S CO-OPERATIVE
WAHPETON, NORTH DAKOTA
164,000
AMMONIA SCRUBBING
OPERATIONAL
6/77
5300,000.
THE CAPITAL COST REPRESENTS THE TOTAL EQUIPMENT
COST IN 1977 DOLLARS.
IbS
-------
STATUS TO JANUARY 1979
SECTION n (CONTINUFin
INDUSTRIAL BOILER FRO COSTS
COMPANY PROCESS COST
LOCATION STATUS
CAPACITY CSCFM) START-UP DATE CAPITAL OPERATING
MOBIL OIL COMPANY SODIUM CARBONATE SCRUBBING $500,000.
BUTTONHILLOW, CALIFORNIA CONSTRUCTION
80,500 2/11
THE CAPITAL COST INCLUDES ABSORBER MODULES, RE-
CYCLE TANKS, STACK, OEMISTERS, PUMPS, ANO PIPING
IN 1978 DOLLARS. IT DOES NOT INCLUDE CAUSTIC
TANK, FEED PUMPS, OR FEED PIPES.
MOBIL OIL COMPANY SODIUM HYDROXIDE SCRUBBING 13,900,000. $1,290,000.
SAN AROO, CALIFORNIA OPERATIONAL
175,000 1970
THE CAPITAL COST REPRESENTS EQUIPMENT, INSTAL-
LATION, PIPING, DUCTWORK, STACK, MATER TREATMENT
FACILITY, AND INSTRUMENTATION IN 1978 DOLLARS.
THE OPERATING COST INCLUDES ELECTRICITY, CAUSTIC,
LAOOR, AND MAINTENANCE. IT DOES NOT INCLUDE IN-
DIRECT (FIXED) COSTS. THE AVERAGE OPERATING COST
FOR THE ?a SMALLER SYSTEMS IS $35,000/YR EACH, AND
FOR THE « LARGER SYSTEMS IS S65.000/YR EACH.
NEKOOSA PAPERS, INC. CAUSTIC SCRUBBING $850,000.
ASHDOHN, ARKANSAS OPERATIONAL
211,000 3/76
THE CAPITAL COST REPRESENTS THE EQUIPMENT COST IN
1975 DOLLARS.
NORTHERN OHIO SUGAR COMPANY SODIUM CARBONATE SCRUBBING $523,000. $30,200.
FINDLAY, OHIO TERMINATED
65,230 10/74
THE CAPITAL COST IS THE TOTAL INSTALLED COST OF
THE FGD SYSTEM IN 1974 DOLLARS. THE OPERATING
COST INCLUDES ELECTRICITY, MAINTENANCE, LABOR, ANO
MATERIALS.
166
-------
STATUS TO JANUAKY 1973
COMPANY
LOCATION
CAPACITY CSCFM)
NORTHERN OHIO SUGAR COMPANY
FREEMONT, OHIO
40,000
SFCTION J? (CONTINUED)
INDUSTkTAL HtHLFK FGU COSTS
PROCESS
STATUS
START-UP DATF
COST
CAPITAL
SODIUM HYDROXIDE SCRUBBING
OPERATION*!
10/75
NO COST INFORMATION HAS BEEN SUPPLIER FOR THE
FHEEMONT FGO SYSTEM.
PHILLIP MORRIS, INC.
CHESTERFIELD, VIRGINIA
39,000
SODIUM CARBONATE SCRUBBING
CONSTRUCTION
h/79
NO COST INFORMATION IS AS YET AVAILABLE.
RICKENBACKER AIR FORCE BASE
COLUMBUS, OHIO
55,000
LIMESTONE SCRUBBING
OPERATIONAL
3/76
12,200,000.
1207,000.
THE CAPITAL COST INCLUDES ADJACENT ELECTRICAL SUB-
STATION, SLUDGE DISPOSAL, EXTERNAL FLUES-, AND
OTHER ATYPICAL EOUIPMENT IN 1975 DOLLARS. THE OP-
ERATING COST REPRESENTS THE OVERALL 1977 COST FOR
15,000 TONS OF COAL. DURING THE 1977 U.S.E.P.A.
DEMONSTRATION TESI, OPERATING COSTS WERE S5.6I/TON
OF COAL. THESE COSTS INCLUDE OPERATING AND MAIN-
TENANCE, LABOR, POWER, MATER, MAINTENANCE PARTS,
AND SLUDGE DISPOSAL, BUT DOES NOT INCLUDE DEPRE-
CIATION.
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
8,000
SODIUM HYDROXIDE SCRUBBING ISO,000.
INDEFINITELY SHUT POWN
1975
THE CAPITAL COST IS THE ESTIMATED REPLACEMENT COST
IN 197B. AN ESTIMATED MAINTENANCE COST OF S160/NO
HAS REPORTED
-------
STATUS TO JANUARY 1979
SFCT1MN I 3 (rnNTINUeo)
INDUSTRIAL RlllLFK FRO COSTS
COMPANY PROCESS COST
LOCATION StAIHS —
CAPACITY (SCFM) START-HP OAtE CAPITAL OPERATING
ST. JOF. 7INC CO. CITRATE PROCESS $13,700,000.
MONACA, PENNSYLVANIA CONSTRUCTION
143,000 3/71
THE CAPITAL COST IS IN 1977 DOLLARS AND IS BEING
JOINTLY FUNDED BY ST. JOE ZINC, THE US EPA, AND
THE U.S. BUREAU OF MINES.
ST. REGIS PAPER CO. CAUSTIC SCRUBBING $100,000.
CANTONMENT, FLORIDA OPERATIONAL
115.000 1973
THE CAPITAL COST IS FOR THE ABSORBER ONLY AND IS
IN 1973 DOLLARS.
SUN PRODUCTION COMPANY SODIUM HYDROXIDE SCRUBBING $100,000. $35,000.
FELLOHS, CALIFORNIA CONSTRUCTION
6,000 4/79
THE CAPITAL COST IS THE TOTAL INSTALLED COST
OF THE FGO SYSTEM IN 1979 DOLLARS. THE ESTIMATED
OPERATING COST INCLUDES ONLY DIRECT COSTS OF RAW
MATERIALS (SO LB/HR OF SO X CAUSTIC, 4 GPM MAKEUP
MATER), AND ELECTRICITY t\f> HP).
SUN PRODUCTION COMPANY SODIUM HYDROXIDE SCRUBBING $100,000. $35,000.
OILDALE, CALIFORNIA CONSTRUCTION
6,000 4/79
THE CAPITAL COST IS THE TOTAL INSTALLED COST
OF THE F6D SYSTEM IN 197<» DOLLARS. THE ESTIMATED
OPERATING COST INCLUDES ONLY DIRECT COSTS OF RAW
MATERIALS (50 L8/HR OF 501 CAUSTIC, 4 GPM MAKEUP
AND ELECTRICITY u& HP).
I6H
-------
STATUS TO JANUARY 197<»
SECTION H (CONTINUED)
INOUSTMAL BOILFH FP-II COSTS
COMPANY PROCESS rf,sr
LOCATION STATUS '.
CAPACITY (SCFM) START-HP 0»TF CAPITAL OPERATING
TEXACO INCORPORATE!! SODIUM HYDROXIDE SCKIJHBING
SAN ARDO. CALIFORNIA OPERATIONAL
380,000 U/7S
NO ECONOMIC INFORMATION HAS AS YFI HEEN PROVIDED
BY TEXACO.
TEXACO INCORPORATED SOOIIIM CARBONATE SCRUBBING
SAN AROO, CALIFORNIA CONSTRUCTION
117,000 J/79
NO ECONOMIC INFORMATION HAS AS YET BEEN PROVIDED
BY TEXACO.
TEXASGULF SODIUM CARBONATE SCRUBBING
GRANGER, WYOMING OPERATIONAL
140,000 4/76
THE CAPITAL COST IS FOR TMO SCRUBBING UNITS ONLY
AND IS IN 1976 DOLLARS.
TRANSCO TEXTILES. INC. SODIUM CARBONATE SCRUBBING
AUGUSTA, SEORSIA INDEFINITELY SHUT DOWN
50,000 J/75
NO ECONOMIC INFORMATION MAS MADE AVAILABLE,
U.S. GYPSUM CORP. DOUBLE ALKALI (DILUTE)
OAKMONT, PENNSYLVANIA NEVER STARTEO-IJP
19,300
NO ECONOMIC INFORMATION WAS MADE AVAILABLE.
169
-------
LIST OF FIGURES
PAGE
14-1 ALYESKA PIPELINE SERVICE CO. 174
14-2 AMERICAN THREAD CO. 175
14-3 ARCO/POLYMERS , INC. 176
14-4 ARMCO STEEL 177
14-5 CANTON TEXTILES 178
14-6 CARBORUNDUM ABRASIVES 179
14-7 CATERPILLAR TRACTOR CO., EAST PEORIA 180
14-8 CATERPILLAR TRACTOR C0.f JOLIET 182
14-9 CATERPILLAR TRACTOR CO., MORTON 184
14-10 CATERPILLAR TRACTOR CO., MOSSVILLE 186
14-11 CHANSLOR WESTERN OIL & DEV. CO. 187
14-12 CHEVRON U.S.A. INC. 188
14-13 FIRESTONE TIRE AND RUBBER CO. 189
14-14 FMC (SODA ASH PLANT) 190
14-15 GENERAL MOTORS CORPORATION, DAYTON 191
14-16 GENERAL MOTORS CORPORATION, PARMA 192
14-17 GENERAL MOTORS CORPORATION, PONTIAC 193
14-18 GENERAL MOTORS CORPORATION, TONOWANDA 194
14-19 GEORGIA-PACIFIC PAPER CO. 195
171
-------
LIST OF FIGURES (continued)
NO. PAGE
14-20 GETTY OIL COMPANY 196
14-21 GETTY OIL COMPANY 197
14-22 GREAT SOUTHERN PAPER CO. 198
14-23 GREAT WESTERN SUGAR, BILLINGS 199
14-24 GREAT WESTERN SUGAR, FINDLEY 200
14-25 GREAT WESTERN SUGAR, FORT MORGAN 201
14-26 GREAT WESTERN SUGAR, FREEMONT 202
14-27 GREAT WESTERN SUGAR, GERING 203
14-28 GREAT WESTERN SUGAR, GREELEY 204
14-29 GREAT WESTERN SUGAR, LOVELAND 205
14-30 GREAT WESTERN SUGAR, SCOTTS BLUFF 206
14-31 ITT RAYONIER, INC. 207
14-32 KERR-MCGEE CHEMICAL CORP. 208
14-33 MEAD PAPERBOARD CO. 209
14-34 MINN-DAK FARMER'S COOP. 210
14-35 MOBIL OIL COMPANY, BUTTONWILLOW 211
14-36 MOBIL OIL CORP., SAN ARDO 212
14-37 NEKOOSA PAPERS, INC. 213
14-38 PHILLIP MORRIS, INC. 214 ,
14-39 RICKENBACKER AIR FORCE BASE 215
41-40 SHELLER GLOBE CORP. 216
14-41 ST. JOE ZINC CO. 217
172
-------
LIST OF FIGURES (continued)
NO. PAGE
14-42 ST. REGIS PAPER CO. 219
14-43 TEXACO, INC., SAN ARDO 220
14-44 TEXACO, INC., SAN ARDO 221
14-45 TEXASGULF 222
173
-------
FlUt Utt III
Y PI PL-m —
bL^ ^nJJS-^^-*
I>UMT
Figure 14-1. Alyeska Pipeline Service Co.
EQUIPMENT LIST
EQ NO.
Al
M
Mtl
PI
fi
n
Tl
it
T3
T4
HAW
ABSORBER
l.D. FAN
HIST ELIMINATOR
REC1RCULATIOH
PUMP
BUED-OFF
PUHP
HAKE -UP
PUHP
RECIRCULATION
TANK
MAKE-UP TANK
AERATOR
NEUTRALIZATION
TANK
SIZE, FEET
MATERIAL
NO.
2
2
2
2
1
1
1
1
1
1
GAS STREAH NO.
RATE. Ib/hr i 1000
icf* x 1000
PARTICULATES. Ib/hr
SOj, tb/hr
TEMPERATURE. *F
HJO, Ib/hr
02. i
NO,, Ib/hr
VELOCTTT, ft/Sic
CD
(?)
(?)
(£) LIQUID STREAM NO.
RATE. Ib/hr « 100
9(«
TOTAL SOI IDS, S
pH
TEMPERATURE, *F
HjO, Ib/hr
SULFITE, ag/l
SULFATE, «9/l
' CHLORIDE. mg/\
SPECIFIC GRAVITY
®
$
600
8.0
(7)
Ca)
2.0
fl.O
(?)
10
^
-------
H
-J
Ul
Figure 14-2. American Thread Co.
EQUIPMENT LIST
£0 NO.
A1
F1
FZ
PI
P2
T1
NAME
ABSORBER
F.O. FAN
1.0. FAN
RECIRCULATION
PUMP
WASTE PUM>
RECIRCULATION
TANK
SIZE, FEET
10 DIA. x 1Z HIGH
60 HP
60 HP
12 I IZ * 1 HIGH
MATERIAL
304SS, 316SS
3/i" C.S.
«.
Z
Z
z
MS STRCM*.
MTE. Ib/hr « 1000
•eta • 1000
MKTICUtAUS. Ib/hr
Stfe. Ih/Hr
IDVEMTUMEt f
HfO. Ib/Mr
Ot, I
Mfc, Ib/hr
mOCITT, ft/MC
(D
CO
400
(f)
41.2
1)0
qj
(D LIQUID STREW NO.
MTE, Ib/hr x 100
90"
TOTAL SOLIDS, *
(*
TENPCMTWE, *F
H&. Ib/hr
SULFITE, "9/1
SULFAtE. ng/1
CM.OHIDE, «9/l
SPECIFIC GMVITT
C^
2.5
(?)
8.5
0
(D
cf
(^
o
®
O
(9
O
id
6
-------
H
-J
a\
TO SH«
ruti*
Figure 14-3. Areo/Polymers, Inc.
tQUimiMT LIST
EO HO.
A1
Fl
HI
PI
P2
RF1
SSI
Tl
T2
T3
T«
T5
NAME
ABSORBER
F.D. FAN
MIST ELIMINATOR
RECIRCULAT10N
PUMP
LINE REACTOR
PUMP
ROTARY VACUUM
FILTER
SODA ASH
STORAGE
RECIRCULATION
TANK
LINE REACTOR
THICKENER
SURGE TANK
LINE SLAKER
SIZE. FEET
MATERIAL
NO.
3
3
3
3
3
1
3
3
1
GAS STREAM NO.
RATE, Ik/hr ii 1000
•eta i 1000
MRTICUUHS. Ib/hr
SO?. Ib/hr
TEMPERATURE. *f
H20, Ib/hr
0?, i
NO,. Ib/hr
mociiT. rt/tic
(1)
^
(3)
© LIQUID STREAM NO.
RATE. Ib/hr » 100
9P» '
torn SOLIDS, i
PM
TEMPERATURE. *F
HjO. Ib/br
SULFITE. «g/1
SULFATE, ag/1
CHlORIOEt«j/l
SPECIFIC 6MVITV
(|)
$
•(p
$
(J)
^
9
®
0
ft
^
^
4
-------
w r3^"""
Figure 14-4. Armco Steel.
EQUIHCMT LIST
EQ NO.
A1
F1
PI
Tl
TZ
VI
NAME
ABSORBER
F.D. FAN
RECIRCULATION
PUMP
RECIRCULATION
TANK
LIME SLURRY
HOLD TANK
VENTURI
SUE, FEET
17 DIA.
10,000 GAL.
MATERIAL
C.S., FIBERGLASS
LINED TRAYS. 3161 SS
RUBBER-LINED C.S.
RUBBER-LINED C.S.
316L SS
NO.
1
1
1
1
1
1
CAS STREAM HO.
RATE, Ib/hr « 1000
•eta x 1000
PARTICVLATES, Ib/hr
SO?. 1b/hr
TWERATUtt, *t
H20. Ib/hr
02, S
MV, Ib/hr
VELOCITT, ft/sec
(tj
140
42S
(|)
• 3
33
<3)
(J) LIQUID STREAM NO.
RATE. Ib/hr x 100
90"
TOTAL SOLIDS, S
pH
TEMPERATURE, *F
MjO. Ib/hr
SULFITE. iij/1
SULFATE. nj/1
CHLORIDE, *g/l
SPECIFIC GRAVITY
©
1600
@
©
®
3200
(^
<5»
1600
7.0
($>
100
(gl
1600
®
^
®
(^
$>
-------
-0
00
RMT
Figure 14-5. Canton Textiles.
EQAIIPNENT LIST
EO NO.
Fl
PI
n
n
N
n
si
STl
ti
TZ
TJ
NAME
I.D. FAN
HAKE-OP PUMP
HAKE -UP PUMP
MAKE-UP PUMP
REC1RCUIAT10N
PUMP
BLEED-OFF
PUMP
SEPARATOR
• STACK
RECIRCULATION
TANK
DYE RETENTION
BASIN
DTE COLLECTION
MANHOLE
SUE, FEET
14.979 GAL.
MATERIAL
%
FIBERGLASS
FIBERGLASS
NO.
1
1
1
1
1
1
1
1
1
1
1
GAS STREAM NO.
RATE. Ib/hr x 1000
tcta i 1000
WWTICUUTES. Ib/hr
S0|. Ib/hr
TEMPERATURE. *F
MjO, Ib/hr
02. 1
MX. Ib/hr
VELOCITY, ft/tec
„.-. "?' ." --'
Q)
42
295.2
124.2
410
(J)
24. S
37.3
OP
(4) LIQUID STREAM HO.
RATE, Ib/hr x 100
9P»
TOTAL SOLIDS, t
PH
TEMPERATURE. *F
HjO, Ib/hr
SULFITE. ag/1
SULFATE. ag/l
CHLORIDE, ag/l
SPECIFIC GMKITY
^
(£)
7.5
^
1-291
10.4-
12. t
IS)
201
($)
0-2<»1
152
V
(\S
^
^
1-201
1.0
ft
-------
IftUB
FlUI MS »
Figure 14-6. Carborundum Abrasives,
EQUIPMENT LIST
CO NO.
Al
F)
F2
PI
P2
P3
H
Tl
TZ
VI
HAKE
ABSORBER
F.O. FAN
1,0. FAN
ABSORBER
RECYCLE PUMPS
VENTURI
RECYCLE PUMPS
BLEED-OFF
PUNP
HAKE-UP PUMP
RECIRCULATION
TANK
HAKE-UP TANK
VENTURI
SIZE, FEET
B.S 01A. X 38 HIGH
4 INLET s 13 NIGH
13 IN. THROAT
MATERIAL
316L SS
11H. SS. HASTAUOY M
LININC
NO.
I
1
I
2
1
1
J
1
1
1
CAS STRLAH NO.
RATE, 1b/hr a 1000
Kim i 1000
PART1CULAIES. Ib/hr
SO;, Ib/hr
TEMPERATURE , *F
H20. Ib/hr
02. *
no,, ib/nr
VELOCITY, fl/itc
$
45.8
535.6
3SO
(?)
33.1
26. 6
125
(?)
® LIQUID STREAM NO.
RATE. Ib/hr a 100
9P*
TOTAL SOLIDS. %
pH
TEMPERATURE. *F
HjO. Ib/hr
SULFITE. -9/1
SULFATE, B9/1
CHLORIDE, im/l
SPECIFIC GRAVITY
CD
2.8
©
(?)
(8)
3000
0^)
30
11
Q>
45
0
O
*d
Id
O
|0>
-------
CO
o
"DQ®
i
-------
H
00
MS STREAM HO.
KATE, Ib/hr > 1000
•eta x 1000
PARTICULATES. Ib/hr
SO?, Ib/hr
TEMPERATURE , *F
HjO, Ib/hr
Of, *
HO,. Ib/hr
VELOCITY, ft/tec
ty
80
1040
isn
(?)
104
Cp
0 LIQUID STREAM NO.
RATE. Ib/hr x 100
90"
TOTAL SOLIDS, X
pH
TEMPERATURE. *F
HjO, Ib/hr
SULFITE. 09/1
SULFATE. M9/1
CHLORIDE. Bj/1
SPECIFIC GRAVITY
©
®
2.1
CD
®
gp
(^
28. 5
fy
@
fy
fy
<&
<&
nil
LIQUID STREAM NO.
lATE. Ib/hr k 100
«?•
TOTAL SOLIDS, I
PM
TEMPERATURE, *F
HjO. Ib/hr
SULFIU, «9/l
SULFATE. «9/l
CHLORIDE, •}/)
SPECIFIC GRAVITY
©
<9
&
171.2
eo
0
§
O
6
®
^
©
®
(8
®
(Dt
<&
id
S
@
^
<&
Figure 14-7. (continued)
-------
EQUIPMENT USt
FLUE CAS II
00
(0
FLUE GAS IN
'^J*^
« %>J
^-iffhTT^Tf ^
» I t« |
,Fj>=, -.
I^l
P7
^—I
nw
WATER
VR?
L.
LANOMU
LSrJ
V^
Figure 14-8. Caterpillar Tractor Co., Joliet.
(continued)
EO NO.
Al
F)
LSI
PI
n
t3
P4
n
P6
P7
PB
SSI
T1
T2
T3
T4
T5
T6
YM
VF2
VR1
VR2
NAHt
ABSORBER
F.D. FAN
UME STORAGE
TANK
BLEED-OFF PUMPS
LIME NIX TANK
PUMPS
SODA ASH MIX
TANK PUKPS
FEED HATER PUMPS
. SlUDGC PUMP
SLUDGE PUMP
FILTRATE PUMPS
VACUUM PUMPS
SODA ASH STORAGE
TANK
PRIMARY LIME
MIX TANK
SECONDARY LIME
MIX TANK
SODA ASH
MIX TANK
SURGE TANK
THICKENER
CLARIFIER
VACUUM FILTER
VACUUM FILTER
SPARE
VACUUM RECEIVER
VACUUM RECEIVER
SPARE
SIH, FEET
50,000 GAL
MATERIAL
316 S.S.
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.
MET SURFACES
304 SS
MET SURFACES
304 SS
C.S.
C.S.
NO.
2
2
1
4
2
2
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
-------
CO
OJ
GAS STREAM M.
KATE. Ib/hr i 1000
tflm i 1000
PART1CUUTCS. Ib/hr
SOz, Ib/hr
TEMPERATURE, *f
HjO. Ib/hr
02. 1
NO*. Ib/hr
VELOCITY, ft/tec
©
57.5
34S.I
ISO
(|)
41.0
22.9
32. 8
130
LIQUID STREAK HO.
RATE. Ib/hr n 100
W"
TOTAL SOLIDS. S
pH
TEMPERATURE. *F
Htf. Ib/hr
SULFITE, Bg/1
SULFATE. ag/1
CHLORIDE. •»/!
SrtCIFIC GRAVITT
Kl
o
52.0
65
(5)
4C.O
241.1
350
^
0 LIQUID STREAN NO.
RATE. Ib/hr x 100
13.2 9P"
15.0 TOTAL SOLIDS, t
23.5 pM
125 TEMPERATURE, ^F
HjO. Ib/hr
SULFITE. ng/1
SULFATE, ag/1
CHLORIDE, ag/l
SPECIFIC GRAVITY
®
.6
^
12.0
<&
12.0
^
12.0
tt)
©
9
(5)
©
@
12.0
@
12.0
@>
O
IS
V
10.4
^
2.9
(|P
^
(^
@
0
<9
ft
d
«
12.0
^
4
15-20
-------
EquimoiT LIST
nuc US
H
00
auc MS
•UWOFIU
Figure 14-9. Caterpillar Tractor Co., Morton,
(continued)
EOHO.
A1
Fl
LSI
PI
P2
PJ
P4
PS
PC
P7
n
SSI
Tl
TZ
T3
T4
T5
T6
T7
VF1
VFZ
VR1
VR2
NAME
ABSORBER
F.O. FAN
LINE STORAGE
TANK
CITY WATER PUMP
LINE NIX TAHK
PUHPS
FILTER MSH PUMP
FEED HATER PUMPS
SLUDGE PUMP
SLUDGE PUMP
FILTRATE PUMPS
VACUUM PUMPS
SODA ASH STORAGE
TANK
PRIMARY LIME
NIX TANK
SECONDARY LIME
MIX TANK
SOFTENING TANK
SURGE TANK
THICKENER
CLARIFIER
MIX TANK
VACUUM FILTER
VACUUM FILTER
SPARE
VACUUM RECEIVER
VACUUM RECEIVER
SPARE
SUE, FEET
MATERIAL
316 S.S.
C.S.
c.s.
C.S.
c.s.
c.s.
c.s.
C.S. _j-
c.s.
WET SURFACES
30* SS
WET SURFACES
304 SS
C.S.
C.S.
NO.
2
2
I
1
2
1
2
2
2
2
2
1
1
I
1
1
1
I
1
1
1
1
1
-------
00
in
US STREAM HO.
•AH. Ib/hr « 1000
•cto * 1000
PARTICIPATES. Ib/kr
SOj, Ib/hr
TEMPERATURE, *F
M|0. Ih/kr
0». *
Wk. 1k/kr
VUOCITV. fl/MC
LIQUID STREAM NO.
RATE. Ib/kr k 100
«P
TOTAL SOLIDS. 1
pH
TEMPERATURE. *F
HjO, Ib/hr
SULT1TE. »9/l
SULFATE, «g/l
CHLORIDE. BQ/J
SPECIFIC UAVITV
©
•9.3
33.0
IflJ^i
379
410
3900
®
100.4
22. S
l«-3
21
134
1500C
t.5
77.7
(J)
19.3
33.0
JjQiJ
379
410
3900
0 LIQUID STREAM NO.
100.4 MTE< lb/hr * "*
22. S «l"
14 j TOTAL SOLIDS. 1
21 PH
114 TEMPERATURE, "f
tsooo HzO. »b/lir
(.S SULFITE. "S/l
SULFATE. «g/l
77.7 CHLORIDE, ag/l
SPECIFIC GRAVITY
(|)
US
2
6.0
134
1500
99140
1.01
Cjp
us
2
6.0
134
1500
99840
1.01
(7)
230
2
C.O
134
1500
99140
__>OJ
(8)
5.17
70
(9)
1.43
70
®
• 0
It
IS
1.0
6*00
1.09
0
6t
13.2
7.5
6*00
1.00
^
24
3.4
SO
1.0
1200
1.31
t
560
912QC
1.00
&
633
125
12.0
7«
560
91200
1.00
®
633
12S
12.0
?Q
560
9120C
1.00
®
10
2.0
12.0
70
1000
1.00
S
O
^
-------
CO
a\
n »u-« _ Ml L1W SIMMt
auc
MS -
IK
<8
SL.
-i
—,&
K
fun
j
H
3
u
J£
M!-a—
i
F
lr
Ji
<5)
-1
^s^
UATE
O
r
It
Lii
12
* -j
R 43
J
MO
1
^
& rap UK sow sorruw
f*
VL .
VI
V«
^if^ ®
!_® _
'3 » n
1^___J t__l_J
£
to
¥
4M^
1
"* |r«i
gure 14-10. Caterpillar tractor Co
^•cwi"™
DISMSM.
ja,_iaaL«
PS
. , Mossville.
lOUIPWHT LIST
EQNO.
F1
FR1
Pt
PZ
P4
PS
P6
RF1
SI
T1
TZ
Tl
T4
VI
NAME
F.O. FAN
FILTRATE
RECEIVER
RECIRCULATION
PUMP
BLEED-OFF
PUMP
CAUSTIC PUMP
FILTRATE PUMP
EXHAUST PUMP
UNDERFLOW PUMP
ROTARY FILTER
SEPARATOR
RECIRCULATION
TANK
LIME MIX TANK
THICKENER
SURGE TANK
VARIAILE THROAT
VENTURI
SUE, FEET
MATERIAL
NO.
1
1
1
4
4
4
Steam flow characteristics for Boiler No. 2 are from a final report on particulate and
SO2 emissions, January 21, 1977.
MS STREW HO.
RATE. Ib/hr R 1000
•eta x 1000
^ARTICULATES, Ib/hr
SOj, Ib/hr
TEWERATURE, *F
NjO, Ib/hr
02, t
N0«. Ib/hr
TELOCITT, ft/tec
0)
40
604. i
440.1
413
©
21.4
10. 5
21.4
159
OP
® LIQUID STREAM MO.
RATE, Ib/hr x 100
gp«
TOTAL SOLIDS, f
pH
TEMPERATURE, *F
HjO, Ib/hr
SULFITE. 119/1
SULFATE, Hg/1
CHLORIDE, ng/1
SPECIFIC GRAVITY
(5)
$
14 S
6.48
130
24.2
86.9
1.1)1
(2)
2.9
(8)
K.4R
130
74.2
B6.9
1.131
c^
«*
.2
(^
8.3
^
^
8.4
120
13.7
70.8
1.108
<9
130
(^
130
<&
^
0
di
23.5
60*
$
-------
CO
®p™*
Figure 14-11. Chanslor Western Oil & Dev. Co.
CQUIMENT LIST
CO NO.
Al
r\
PI
ft
n
P4
PS
P6
P7
PS
RF1
T1
TZ
TJ
T4
NAME
ABSORBER
F.O. FAN
RECIRCULATION PUMP
BLEED-OFF PUMP
MAKE-UP LIQUOR
PUMP
SODA ASH MAKE-UP
PUMP
LIME REACTOR PUMP
CLARIFIED EFFLUENT
PUMP
HAKE-UP HATER PUHP
HAKE-UP HATER PUHP
ROTARY FILTER
SODA ASH HAKE-UP
RECIRCULATION TANK
LIME REACTOR
THICKENER
SHE. FlfT
MATERIAL
M.
1
8
1
1
1
'
1
GAS STREAM NO.
RATE. Ib/hr « 1000
Kim i 1000
PARTICUUTES. Ib/hr
SO;, Ib/hr
TEMPERATURE, *F
HtO, Ib/hr
02. t
NOx. Ib/hr
VELOCITY, ft/JK
(Jj
113.4
491. S
sso
(£)
19.7
^
(4) LIQUID STREAM NO.
RATE. Ib/hr « 100
9P"
TOTAL SOLIDS. 1
PH
TEMPERATURE, 'F
HjO, Ib/hr
SULFITE, «9/l
SULFATE, ng/1
CHLORIDE, m)/\
SPECIFIC GRAVITY
CD
®
CD
^
71
03
tp
^
0
(£
-------
H
00
00
nut s«s 1*
IT n *m»n«M
rut
to ATWSWWC uHMisyo AM»ME*E
S>
H3"
PI
-£*-
DISPOSAL I
Figure 14-12. Chevron U.S.A. Inc.
IQUIWMT LIST
EO NO.
Al
ri
PI '
PZ
P3
ST1
Tl
NAME
ABSORBER
F.D. FAN
RECIHCULATION
PUHP
HAKE -UP LIQUOR
PUMP
MAKE-UP WATER
PUHP
STACK
MAKE-UP TANK
SUE. FEET
16.S DIA.
MATERIAL
31 6L 55
3)6 SS
NO.
3
18
3
3
1
CAS STREAM NO.
HATE. Ib/hr x 1000
icf> i 1000
PAATICULATES, Ib/hr
SO}. Ib/hr
TEMPERATURE. *f
HjO. Ib/hr
oz, ••
NO,. Ib/hr
KEIOCITY, ft/**?
(|)
ISO
575.6
SOO
®
57.6
(|)
@ LIQUID STREAM NO.
RATE, Ib/hr x 100
9P»
TOTAL SOLIDS, S
B»
tlillRATURE.^F
HjO, Ib/hr
SULFITE, «9/I
SUIFATE, ag/l
CHLORIDE, ag/1
SPECIFIC CRAVITT
Cp
750
i. Ow
«.5
c&
CD
$
®
d^
9
®
QI
^
6
d^
6
-------
00
vo
.TO STAC*
W ri
M
1
P
CD
'J^
P—
. s>
a —
1
P
r^
SI
^T3
a?
WAT!
II
SSI
HE
II
i
-i
®
9
Tf.
Of UK
n
T2
I i
* ' -»
M
©
I 1 I
L'
?igure 14-13. Firestone Tire
n
^£2
ft
1
1*
\
>—.,
\
£ mm
1 CAK
and Rubber Co.
EQUIPMENT LIST
EQ NO.
Fl
LSI
PI
P2
RF1
SI
SSI
Tl
T2
T3
T4
VI
NAME
F.D. FAN
LIME STORAGE
TANK
RECIRCULATION
PUHP
LIME REACTOR
PUMP
ROTARY FILTER
SEPARATOR
SODA ASH
STORAGE
RECIRCULATION
TANK
LIME REACTOR
THICKENER
SURGE TANK
DUAL THROAT
VENTURI
SIZE, FEET
4.67 OIA x 7.17 HIGH
.5-1.25 THROAT LENGTH
MATERIAL
RUBBER-LINED
f*e*r fcnu
I*n3 1 I nun
CAST IRON
3)6L S.S.
3161 S.S.
316L S.S.
C.S.
C.S.
C.S.
3141 S.S.
NO.
1
1
1
1
1
1
J
1
1
1
1
GAS STREAM NO.
RATE. Ib/hr x 1000
tclm * 1000
PARTICULATES. Ib/hr
SOj. Ib/hr
TEMPERATURE, "F
H?0, Ib/hr
02. i
H0». Ib/hr
mOCm. ft/stc
0P
1)
4SO
360
300
(|)
10
11. 7
14.2
130
(1)
0 LIQUID STREAM NO.
RATE, Ib/hr > 100
9P»
TOTAL SOLIDS, t
pH
TEHPLRATURE, "f
HjO, Ib/hr
SULFITE. «9/l
SULFATE, Bg/I
CHlOBIDf, B9/I
SPECIFIC GRAVITY
CD
C
^
^
(9
o
l.B
55
ft
^
-------
n STAC it
Maim Munn>Ta
run
ua.
Q
£
!_,
t
Ellkkki
X~><
NT^
xr~>J
IAt
_•]
amsm HUN Mm
, ®
»r»
~ ".' *
:.^i
.114
* <'
& ***,,.
-f
riii
& i
erw n
{
\
" f
•4
a>
K
«_-^
f
&
TO nun pj"
-------
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VO
Figure 14-1§. General Motors Corporation, Dayton.
EQUIPMENT LIST
CO NO.
Al
n
PI
n
n
T1
T2
T3
NAME
ABSORBER
P.O. FAN
RECIRCUIATION
PUMP
CAUSTIC PUMP
BLEED-OFF
PUMP
RECIRCULATION
TANK
CAUSTIC TANK
BLEED-OFF
TANK
SIZE, FEET
6 D1A. x 10 HIGH
35,000 SCFH,
9 IN. U.G.
200 6PM. 25 HEAD
BO 6PM
SO 6PH
7.5 DIA. i 12 HIGH
9 OIA. x 18 HIGH
6 DIA. 1 t.S HIGH
MATERIAL
31 6L SS
C.S.
RUBBER-LINED C.S.
C.S.
RUBBER-LINED C.S.
3161 SS
C.S.
31 M. SS
NO.
2
2
3
1
2
1
1
J
GAS STRUM NO.
RA1C, Ib/hr > 1000
tdm * 1000
PARTICULATCS, Ib/hr
SO?. Ib/hr
TEMPERATURE, •{
H20, Ib/hr
02. »
NO,, Ib/hr
VELOCITY, ft/SIC
(i)
45
55.3
lll.S
400
-------
to Figure 14-16. General Motors Corporation, Parma.
tquimiNt LIST
EQ NO.
A1
F1
i
HI
"
Pt
PI
N
PS
Rfl
111
«1
Tl
Tf
Tl
T4
Tl
Tl
NAME
ABSORBER
F.D. FAN
RIHEATER
REC{RCULATION
PUMP
PUMP
UNDERFLOH PUMP
UNDERFLOW PUMP
' FILTRATE PUMP
ROTARY VACUUM
FILTER
LIME STORAGE
SODA ASH
STORAGE
CHEMICAL MIX
TANK
CHEMICAL NIX
TANK
CLARIFIES 11
CLARintR It
FILTRATE TMK
•tCIKCULAtlM
TANK
SUE, FEET
10.S OIA. « ZZ.S HIGH
200 HP. 1? IN. W.G.
?-7M GPM
?-550 GPM
700 GPM
100 6PM
K 6PM
100 GPM
SOO SQ. FT. AREA
90 TON
IS TON
SOOO GAL
5000 GAL
60 DIA. • 14 HIGH
60 DIA. i 14 HIGH
4 MA. » 7 H1W
f-HNML
t-MOOML
MATERIAL
3161 SS
C.S.
C.S..
RIMER-LINED
I
RUBIER-LINED
RMBER-LINEO
RUBBER-LINED
RUBIER-LINED
C.S.. POLYPROPYLENE
CLOTH
C.S.
C.S.
C.S.
C.S.
C.S.
C.I.. TAt
COATING
NO.
4
4
4
4
1
I
I
t '
t
t
,
1
t
1
1
1
4
GAS STREAM NO.
RATE. Ih/iir « 1000
«cta « 1000
PARTICULATES. Ib/hr
SO?. 1fc/hr
TEMPERATURE. *F
HjO, Ib/hr
02, 1
"0», l*/hr
VELOCITY, ft/sec
(ft
Sl.i
71.2
1*7
sso
(i)
1S.S
60.8
41. S
152
(3)
© LIQUID STREAK M.
RATE. U/hr « 100
«P"
TOTAL SOLIDS, I
PH
TEMPERATURE. 'F
H|0. Ib/hr .
SULFITE. Bg/1
SULFAIE. ai/1
CHLORIDE. Bf/1
SPECIFIC GRAVITr
dp)
c«)
Cjp
(•)
$
^
^
0
1200
ft
ft
15-21
4
4
4
19
0
&
so
(?) '
-------
VO
u>
Figure 14-17. General Motors Corporation, Pontiac,
nnrmm HIT
tO NO.
A)
Ft
PI
ft
PS
M
PS
P6
T1
Tf •
MME
ABSORBER
1.0. FAN
RECIRCULATIM
PUMP
WOERFLCM
POMP
RECIRCULATION
PUMP
RECIRCULATION
PUMP
MAKE-UP PIMP
MAKE-UP PUMP
MHOIM TAJ*
CLARIFim
SIZE. FEET
12 OIA. i 21. S HIGH
WTERIAl
3161 SS
M.
I
I
MS STREAM MO.
RATf . It/hr » 1000
•cte« 1000
PARTIOMTCS. 16/hr
SOj, U/hr
1CMKRATURE, *F
MjO, Ik/Or
02, *
NO,. Ift/hr
ULOCITV. ft/iK
^
91
85.5
360
(*)
75
2B.2
360
(3)
© LIQUID STMAM M.
RATE. Ib/hr « 100
4P"
TOTAL SOLIDS. I
PH
TEMPERATURE, *F
HjO, Ib/hr
SULFITE. «9/l
SULFATE. «9/l
OaORIOE. •»/!
SPECIFIC 6AAVITY
(|)
$
(J)
qp
^
10-20
S.O
4
4 OS
4>
32S
4
so
4
so
4
4
4
9
-------
VO
to mwimm tempt to «nmnni "5*8.« *n»swnt HHMISJJO «nasnc«
J? J? f
JL A A_
Figure 14-18. General Motors Corporation, Tonowanda
LIST
CO NO.
n
PI
n
n
P4
PS
P«
P7
SI
STI
Tl
TZ
T3
T4
ts
t«
VI
HAHt
i.o. FAN
REC1RCVLATION
PUMPS
OVERFLOW PUMP
CHEMICAL FttD
PUMPS
SCRUMER M.OM-
DOUN PUMPS
HASTE TREATMENT
TRANSFER PUMPS
CAUSTIC FEED
PUMPS
MAKE-UP PUNP
SEPARATOR
STACK
RECYCLE TANK
OVERFLW TANK
OCNICAL FEED
TANK
AERATION MIHR
MOLDING TANK
CAUSTIC STORAGE
TANK
VARUVU TMOKT
VERTURI
S1ZC, FEET
WTERIAl
1161 SS
S.S.
im n
NO.
4
t
1
1
I
2
1
1
4
4
4
1
1
1
1
1
«
8AS STREAM «.
•AH, Ik/kr « 1000
•Cffel 1000
PMTICOUTES. 11/kr
•ft. IMir
fBVOMTUK. *F
MfO. lk/hr
ft. »
NO,. lW*r .
mocm, ft/Mt
(J)
3».«
130.0
2S7.3
3SO
(J)
3C.O
104.0
210.1
4 OS
®
11.0
25.7
»
<$) nquio SIMM n.
RATE, Ib/hr • 100
P*
to. 4 TOTAL SOLIDS, t
21. t |M
TEMPCMTURE. *F
HlO. Ik/hr
SULFin. •!/!
SW.FATE. B9/1
CHLORIDE. «|/1
SPECIFIC CRAY ITT
(S)
6.0
(jp
fi.O
^
7.0
t|)
792
7.0
<$
720
7.0
<$
y
^
'1.0
^
<1.0
^
<1.0
^
25-101
$
6
-------
10 STACK
V0
Ul
NWE-W tutcx mm
PU.P mn nuctu
n cm sows
Figure 14-19. Georgia-Pacific Paper Co,
iquincm LIST
EO NO.
ri
PI
SI
Tl
»1
NAME
F.D. FAN
RECIRCULATION
PIMP
SEPARATOR
RECIRCULATION
TMK
VENTUR1
SIZE. FEET
5000 6PM
24 * SS HIGH
I.S HIM i 10 MISH
MAURIAL
304SS (WB8ER-LIHEO
304SS. FIBER6U5S
LINED
JMSS
30455
NO.
1
1
1
1
1
SAS STREAM NO.
RATE. lb/hr i 1000
•eta • 1000
MRTICUUTES. IWhr
S0». Ik/hr
TOVCMTURE. *F
NjO, Ik/hr
01. t
Mh. lk/kr
HLOCITT. ft/we
Q)
320
765
1094
110
@
SO
164
OP
© Liquid STREAM NO.
RATE, Ib/hr « 100
«•
TOTAL SOLIDS. I
P«
TEMPERAIUtE. *F
HjO, Ib/hr
SULflTE. ag/1
SW.FATI. kg/I
CHLORIDE. -9/1
SPECIFIC GRAVITY
®
$
sooo
C^J
2100
(|i)
2000
7.5
^
40
V
®
^
^
^
K^
«^
-------
VO
OS
OH
MS
II
CD
or
©
ssa
Figure 14-20. Getty Oil Company.
EQUIPMENT LIST
FQ NO.
Al
F1
PI
Tl
T2
NAME
AI&ORBER
F.D. FAN
RECIRCULATION
PUMP
DISPOSAL TANK
SODA ASH
HI I TANK
SUE, FEET
13.5 OIA. > 35 HIGH
42.000 GAL
MATERIAL
31 U SS
l/«" C.S.
NO.
1
1
1
1
1
6AS STREAM NO.
RATE. Ib/hr x 1000
•eta • 1000
PAKTICUUTES. Ib/hr
M». Ih/hr
1BPIM1WE. *T
HlO. Ib/hr
02. *
NOi. Ib/Hr
KIOCITT, ft/MC
(I1)
110
500
0)
I2.fi
150
t
dp
® LIQUID STREAK NO.
RATE. Ib/hr x 100
»•
TOTAL SOLIDS. S
PH
TEMPERATURE. *F
H;0. Ib/hr
SULFITE. ng/1
SULFATE. •?/!
CHLORIDE, •»/)
SPECIFIC GRAVITT
(p
to
$
1000
e.i
(?)
(•)
OP
ty
fy
fy
0
^
-------
vo
-J
BISMML
Figure 14-21. Getty Oil Company.
tquiPMEKT LIST
{QUO.
At
F1
PI
n
n
T2
MNE
ABSORBER
r.D. FAN
RKIRCUUTION
PUMP
BLEED-OFF PUMP
DISPOSAL TANK
SODA ASH
Nil TANK
SIZE. FEET
18 DIA. X 33 HIGH
500 HP, 11 IN. US
40 HP. 1000 6PM
40 HP, T-2 SHt
20 OIA. X 20 HIGH
41.000 tAL.
MATERIAL
31. Ib/hr
mocnr. rt/itc
(T)
zoo
too
d)
127
ISO
CD
© LIQUID STREAM NO.
RATE. Ib/hr i 100
«•
TOTAL SOLIDS. S
»H
TEMPERATURE, *F
H}0. Ib/hr
SULFITE. -J/1
SULFATE. -9/1
CHLORIDE. «j/l
SPECIFIC GRAVITY
-------
00
Q ,n,i
Figure 14-22. Great Southern Paper Co,
fQUIPNENT ilST
CQ NO.
PI
ft
SI
n
TZ
VI
IMNC
REClRCttATtflM
PUMP
ASH PIMP
SEPARATOR
KCIRCUUTIOM
TANK
MOID TANK
VtNTUII
SIZE, FttT
?<00 9P"
*»9«»
MATERIAL
RUMER-
IINEO
RUUER-
UNfO
ss
ss
ss
NO.
3
?
I
\
\
Z
CAS STREAN NO.
RATE. It/kr • 1000
tcf* « 1000
PARTICULARS. Ife/hr
SOf. m/hr
TENPUATURf . *f
H|0. Ib/hr
Oz. t
NO,. Ifc/fcr
VELOCITt. (1/tK
(1)
ISO
tioo
2SOO
4IS
Of)
211
•S
ISO
110
0)
(?) LIQUID STREJM NO.
RATE. Ib/hr * IUO
«•
TOTAL SOLIDS. 1
P«
TEMPERATURE. *F
HjO. Ib/hr
SW.FITE. ^/l
SW.FATE. mt/\
CHLORIDE. •!/!
SPECIFIC GRAVITY
(J)
$
"8iO
Q>
CO
1200
I-?
(•)
I COO
1-^i
^
1COO
J-S
^
coo
t-l
0
^
^
4
^
Q>
-------
vo
Figure 14-23. Great Western Sugar, Billings,
LIST
EQM.
Fl
NEt
PI
n
M
sn
T1
VI
NANE
F.O. FAH
HIST ELIMINATOR
RECIRCULATUM
MAKE-UP w»
HASTEHATEt W»
STACK
RECIRCUUmOR
TANK
VARIABLE THROAT
vfMTMi
SIIE, FEET
MATERIAL
NO.
1
1
1
1
'
MS STKJHM.
•MI. Ib/Kr • 1000
•Cta i 1000
MMTIOIUnS. Ih/ftr
SOf. IWfcr
TOKMTVK. «r
N|0. Ih/hr
Of. B
•0,. Ik/kr
mocm. rt/ttc
d?
4
gf)
® iimn sfiRM w.
MTt, lb/hr * 1*00
fP"
TOTM. SOLIDS. S
l«
TortMTuw, OF
HfO. Ib/hr
SUUUTE. «|/l
SW.FMTE. *nn
CHLORIDE, ••/!
SPECIFIC CMVITT
(D
$
^
(S)
^
1*
^
9
^
^
$
OP
-------
IM
TO NUMB
n
o
o
Figure 14-24. Great Western Sugar, Findley.
couimiin LIST
!Q NO.
n
MIt
PI
n
n
ST1
T1
VI
KAMI
F.O. FAN
HIST ELIMINATOR
RtCIRCULATION
PUMP
MAKE -UP PUMP
MASTEHATC* PUMP
STACK
KICUCUIATION
TANK
VMIMlt TMMMT
VfNTimt
SUE. FEET
7.S D1A
MATERIAL
SHUL-316L SS
im n
M>.
t
1
1
1
GAS STIUM NO.
MTE, Ib/hr i lUOtf
Htm i 1000
PARTItULATES. lu/hr
SO?. Ib/hr
TEHPEMIUU. *F
N20. Ib/hr
03, .
kOk, lo/hr
»HOCIT», ft/itc
CO
I2Q
261.)
SIS
®
61.1
1UO
9P"
TOTAL SOLIDS, %
P"
TEMPERATURE. *'f
H;0. Ib/hr
suirin, ng/i
SULFATE. ng/l •
CHLORIOC. «9/l
SPECIFIC GMVITf
ty
(6)
soo
(?)
300
($
300
($
r!20
<$
fy
&
®>
(ft
$
$
6
-------
10
o
EBttlST
I •" TO
gj ATNosranc
TO mum
Figure 14-25. Great Western Sugar, Fort Morgan.
E9UIPMOIT LIST
EQ NO.
F1
Mil
PI
P2
P3
ST1
Tl
VI
KAMI
F.D. FAN
MIST ELIMINATOR
RECIRCULATION
HASTEHATER PUMP
MAKE-UP PUMP
STACK
RECIRCULATION
TANK
VARIABLE THROAT
VENTURI
SIH. FEET
9.5 DIA. x 60 HIGH
MATERIAL
SHELL -304L SS
316L SS
NO.
2
1
t
6AS STREAM NO.
RATE. Ib/hr > 1000
•eta i 1000
PART1CULATES. Ib/hr
SO}. Ib/hr
TEMPERATURE. *F
NjO. Ib/hr
0?. J
N0|. Ib/hr
VELOCITY, ft/we
®
100
728
26fi
400
(5)
6S.1
34.7
267
100
(5)
0 LIOUID STROM NO.
RATE, Ib/hr « 100
9P>
TOTAL SOLIDS. I
PH
TEMPERATURE, 'f
HjO. Ib/hr
SULFITE. •)/!
SULFATE. «9/l
CHLORIDE. If/I
SPECIFIC CRAVm
(s)
1600*
(¥1
800
(b
icoo
(D
1600
tt)
120
-------
N>
O
10
IDWUSt
TO
n
fin
i
1
rt
|
(!)
I q
(T)
V
I
i
AA
W '
<*)
$tl
A/
w
Kl
1
tl
NA
V
(Tl
(3) oonm
*™
®
_T1 wa-w
n
M "*
Figure 14-26. Great Western Sugar, Freemont,
LIST
10 NO.
Ft
«1
PI
M
PS
STl
Tl
VI
NANf
F.D. rut
HIST ELIMINATOR
RECIRCULATION
PUMP
MAKE-UP PUMP
MASTEMATER PUMP
STACK
RECIRCUIAT10N
TANK
VAHIAM.E THROAT
VENTURI
SUE. FEET
HATCRIAL
NO,
?
J
1
1
1
MS STtCANM.
•ATE. Jfc/fcr • 1000
•Cta • 1000
MUTICIIUTES. Ih/kr
SOj. U/hr
TEMKtA.VRf. *r
N}0. Ib/hr
02. »
•OB, Ib/kr
niOCITY. ft/MC
(I)
^
())
© LIQUIt S1RIAN HO.
RATE, Ik/kr • 100
•»•
TOTAL SOLIDS. I
PH
TEMTERATWE, 'f
MjO. Ib/hr
SULFITE. ••/!
SULFATE. «i/1
CM.ORIK. «|/I
SPECIFIC CRAVITT
^
$
QJ
$
$
V
V
<$
0
^
d>
4
4
-------
to
O
U)
n MUM
Figure 14-27. Great Western Sugar, Gering,
EQUIMEHT LIST
EQ NO.
n
ME1
PI
n
P3
STl
Tl
VI
MM
F.D. FAH
HIST ELIMINATOR
RECIRCUIAT10N
PUMP
MAKE-UP PUMP
HASTEUATER PUMP
STACK
RECIRCULATION
TANK
VMIAM.E THROAT
VENTURI
SIZE. rEET
9 OIA.
MATERIAL
SHELL 3041 SS
J04L SS
NO.
2
\
^
\
t
CM STREAM M.
•ATE. Ib/hr • 1000 •
•eta i 1000
PMTICUUTES. Ib/hr
SO;. It/hr
TEMPERATURE, *f
HfO, Ib/hr
01. »
NO*. Ib/hr
VaOCITIT. ft/stc
(t)
97
336.6
450
(?)
101. 0
(i)
0 LIQUID STREAM HO.
MTE. Ib/hr « 100
DP"
TOTAL SOLIDS, t
PH
TEMPERATURE. *f
H|0. Ib/hr
' SULFITE. m/|
SULFATE. ng/t
CHLORIDE. ag/I
SPECIFIC CHAVITT
(?)
(p
600
(J)
1400
$
$
ISO
Q>
4
^
^
-------
£ ®_
IBWIIT
TO
5T1
•{ML
A
1 1
|Q
(?) 1 __
Tl
_f^v WHI^fl*
M
® g_
n
TO«IOI*
Figure 14-28. Great Western Sugar, Greeley.
LIST
10 NO.
M
Wl
PI
n
P3
ST!
Tl
¥1
NAMf
r.o. FAN
NUT ELIMINATOR
RECIRCULATION
PUHP
NAKE-UP PIWP
MASTEMATER PUMP
STACK
RECIRCULATION
TANK
VMIAIIC TMKMT
VCNTUK1
SUC, FECT
-t
MATERIAL
316 SS
• •
J1U SS
NO.
6
1
1
1
1
MS STUEAN NO.
Mil. Ib/hr « 1000
•eta « 1000
rWIICULATtS. Ib/hr
SO?, U/hr
TEWEMTUIE, *F
HjO. Ib/hr
02, »
NOt, Ib/hr
mOCITY. ft/ltc
CO
164.6
141.1
450
C')
221. 0
OP
(4) LIQUID STKEAN M.
HATE. )b/hr • 100
9P"
TOTAL SOLIDS, S
l«
IEHPEMTWE. *F
HjO, Ib/hr
SULFITC, ng/I
SULFATE, «9/l
CHLORIDE. •»/!
SPECIFIC GHAVITT
Cp
550»
$
1100
(p
sso
OP
1100
($
120
(^
V
®
^
^
O
ft
4
-------
to
o
Ul
Figure 14-29. Great Western Sugar, Loveland.
EQUIP*IT LIST
EQ NO.
Fl
MCI
PI
n
n
ST1
Tl
VI
NAME
F.D. FAN
HIST ELIMINATOR
RECIRCULATION
PUMP
MAKE-UP PUMP
HASTEHATER PUMP
STACK
RECtRCULATION
TANK
VARIABLE THROAT
VENTURi
SHE, FEET
65 HIGH > 10.2 DiA.
MATERIAL
3161 SS
316L SS
».
?
1
1
1
i
CAS STREAM HO.
RATE. )b/hr « 1000
Kim i 1000
MftTICULATES, 10/lir
SO?. Ib/hr
TENPERA1URE, *F
HjO, Ib/hr
02. 1
MO,. Ib/hr
VELOCITY, ft/tic
(p
100
lf.0.1
410
®
66.*
227.1
122
(p
(T) LIQUID STREAM NO.
RATE. Ib/hr x 100
gpn
TOTAL SOLIDS. 1
PH
TEMPERATURE, *F
H20, Ib/hr
SULFITE, ag/l
SULFATE. ng/t
CHLORIDE, mtt\
SPECIFIC 6MVITT
(D
1500t
(?)
800
8.7
(p
750
^
1SOO
(«)
120
<$
^
(^
0
(^
03
O
(^
-------
to
o
fOHOlOIIC
<^ Figure 14-30. Great Western Sugar, Scotts Bluff,
EQUIPMENT LIS1
EO NO.
n
ME1
.".
n
n
ST1
T1
VI
NAME
r.D, FAN
HIST ELIMINATOR
MCIRCULATION
PUMP
MAKE-UP PUHP
IIASTEHATER PUMP
STACK
RECIRCUIATION
TANK
VAUIABLE TMTOAT
VCNTURI
SI2C, rEET
10. S OIA.
NATEP.1AI
SHELL -3041 SS
XML SS
NO.
?
1
1
1
»
MSSTKMM.
( itgnt mm ».
()
JL
MTC.
MTf • 1k/hr » 00
i I
use
190
PMTIOUm,
ui. a
1M.I
4M
121
Of. I
•%. WOL
A1E,
fOKHT. ft/MC
OUMH.fll/l
vcciFic •wvin
-------
M
O
MSTDMTC* nuncin
Figure 14-31. ITT Rayonier, Inc.
TO sraci
EQUIPMENT LIST
EQNO.
n
PI
SI
T1
VI
NAME
F.D. FAN
RECIRCULATION
PUMP
SEPARATOR
RECIRCULATIQN
TANK
VARIAILE THROAT
VENTURI
SUE. FEET
1035 HP
75 HP
16.5 OIA. x 38 HIGH
MATERIAL
316 SS
3161 SS
31 ft SS
NO.
Z
1
}
1
2
6AS STREAM NO.
RATE. Ib/hr i 1000
•CfB « 1000
PARTICUUTCS. Ik/hr
%0t. Ik/lir
TOrCRATURt, of
HjO, Ik/kr
OZ, 1
Mk, Ib/Nr
VELOCITY. ft/MC
^
its
1300
1132.1
4CO
@
140
1300
9C1.0
460
®
10
u».»
(|) LIQUID STREAM NO.
RATE. Ib/hr • 100
»P»
30 TOTAL SOLIDS, t
144.2 PH
TBVERATURE.^F
HfO. Ib/tir
SULFIIE, q/l
SU.FATE, •)/!
CHLORIDE. •!/)
SPECIFIC 6RAXIT»
(5)
110
<8>
1470
•'(|b
ISO
ci)
1620
(*)
^
^
^
6
ft
ft
4p
V
-------
..... _ I*
vwvws
O
00
Figure 14-32. Kerr-McGee Chemical Corp.
touinvm list
EQ NO.
A1
Fl
HI
PI
NAME
ABSORBER
F.O. FAN
REHEATER
NECIRCULATION
PIMP
SIZE. FEET
30 OIA. i 3S HIGH
SO'F REHEAT
US ftPN
MATERIAL
C.S., F1BER6LASS
LINED. 3161 SS
TRAYS
C.S.
C.S.
C.S.. RMKR-LINEO
NO.
J
t
t
t
MS STKMm.
MU, Ih/kr » 1000 •
•cm « 1000
pMniauns, iwnr
M|. IMw
TOKMTME, *f
mo, iwi*
•I.*
Mil, IVhr .
matin, ft/m
(J)
J6J
320
(|)
29«
ITS
^
0 LIQUID STREAM NO.
RATE. Ib/hr i 100
9»»
TOTAL SOI IDS. S
*
TOVCMTWC. 'F
H}0. Ib/hr
SULFITE. »|/1
SMMTE. «|/1
CMORIDC, B|/1
SPECIFIC 6M«m
cp
d)
(?)
( . 0-
6.5
Q
125
6.5
l|)
w • w™
6.5
^
<9>
1?
"i*
<^
^
&
fo
-------
10
o
VO
TO HLt ma
Figure 14-33. Mead Paperboard Co,
EQUIMBir HIT
IQ. M.
A1
Ft
n
n
Tl
n
NMC
ABSORBER
f.O. FA*
REClRCUUmON
WH»
OUISTIC PUMP
RECIRCULATIM
TANK
SODIUM CAMOHATt
TANK
SIH. FEtT
MTCRIM.
311 SS
FIBER6USS
MO.
1
1
1
1
1
1
MS STREW «.
RATE. Ib/hr « 1000
•cfb • 1000
MftTICWATES. Ik/lMP
S0». Ik/hr
TOKMTUK. *F
H|0. Ib/hr
02. S
"Bb. W*r
mociTt, rt/ttc
0?
175
4SO
(P
IIS
140
qj
(J) LIQUID STREAM NO.
RATE, Ib/hr x 100
9P"
TOTAL SOUOS, 1
(*
TO»IRATyRE,
(^
@
0
3
©
<$
(6>
-------
10 met
M
I-1
O
»>WOHU.l«Dt«
MOCISS *»t:i
Figure 14-34. Minn-Dak Farmer's Coop,
EQUIPMENT LIST
IQNO.
n
NCI
PI
Tl
VI
NAHt
F.O. FAN
MIST
ELIMINATOR
RECIRCUIATION
PUMP
KCIRCUIATION
TANK
VARIABLE THROAT
VINTURI
SUE, fttl
7S HP 3000 6PM
10 i 10 > 10
MATERIAL
31 655
CONCRETE PIT,
TAR LINED
J1H SS
NO.
t
2
t
t
i
MS STREAK NO.
HATE. Ih/hr * 1000
icta « 1000
PMTICUUTES, 1b/Nr
SOfe. Ib/hr
TENPERATURE, t
HfO. Ib/hr
02. »
N0». lk/hr
mOCITT. ft/MK
CO
1»
245.1
"iti
ISO
C?)
10-17
40.0
Q>
0 LIQOIO STREAM NO.
RATE, Ib/hr . 100
9P» '
TOTAL SOLIDS, t
PH
TEMPERATURE, *F
HjO, Ib/hr
SOLFITE. *g/1
SULFATE, «9/l
CHLORIOC, B|/1
SPECIFIC GRAVITY
(5)
tooo«
S.4
Q
2000
S.4
(})
($
486
5.0
®
250
ty>
soo
S.Q
0^
o
(!)
^
(^
ft
-------
ALML1S Oil flftO UUTWHTOI
BMM
Figure 14-35. Mobil Oil Company, Buttonwillow,
EQUIPMENT LIST
EQ NO.
A1
M
M
HAW
ABSORBER
RECIRCULATIW
PUMP
MAKE-UP PUMP
SIZE, FEET
MATERIAL
C.S., EPOXT COATED
NO.
7
7
7
8AS STREAM MO.
RATE, Ib/hr > 1000
•cfn i 1000
PA«TICUUTES. Ib/hr
SOj, tk/kr
TEMPOATURE, f
HlO, tk/kr
0|, I
»0k. IWNr
niociTT. rvtic
(P
11.4
10
Stt
(|3
4.5
OP
0 LIQUID STREAM NO.
RATE, Ib/hr > 100
9P»
TOTAL SOLIDS. I
pH
TEMPERATURE, *r
HjO, Ib/hr
SULriTE, Kg/I
SULFATE. •»/!
CHLORIDE . •»/!
SPECIFIC 6RAVITT
(|)
(?)
(7)
)
t
(|)
15
l|)
1^
d)
j|i
^
•9
6>
<$
-------
to
I-1
to
*VH MS ItSLm
14-36. Mobil
^MUi— -
~~
M
Oil
* (D ^MMAHMMMLni
_ LuTTwSk DIVOSM. KM
•^iH
Corp . f San Ardo .
EQUIPMENT LI 11 Ifllfll 1
EO NO.
AI
F1
n
STI
NAW
ABSORBERS
1.0. FANS
RECIRCULATION
PUMPS
MAKE-UP PUMPS
STACKS
Slit. FEIT
4 OIA. > 20 HIGH
MATERIAL
SHELL AND TRAYS
316L SS
C.S.. 3161 SS LININGS
ON CASINGS
FIBtmAJS
EQUIPMENT LIST SYSTEM I
10 NO.
At
Ft
PI
n
STI
NAME
ABSORBERS
I.D. FANS
RECIRCULATION
PUMPS
MAKE-UP PUMPS
STACKS
SIZE, FEET
6.S OIA. k K H16H
MATERIAL
SHELL AND TRAYS
3161 SS
C.S., 316L SS LININGS
ON CASINGS
FIBEMLASS
NO.
70
10
to
N
M).
B
B
B
B
CAS SIKANNO.
HATE. Ib/hr s 1000
•eta * 1000
PMTICmATES, Ib/hr
SOf. Ik/hr
TENPEMTURC, *F
H?0, Ib/hr
Ot. I
NO., tk/hr
mOCITT. ft/SK
0?
1
<•
410
tip
C.I
Q)
© LIQUID STREAM NO.
RATE, Ib/hr * 100
9P"
TOTAL SOL IDS. t
P«
TEMPERATURE, "f
HfO, Ib/hr
SULFITE. •}/!
SULFATE, ag/l
CHLORIDE. BQ/I
SPECIFIC GRAY ITT
^
75
$
«i9
^
«-9
OP
*.o
$
i.O
y
^
^
11
1^
fft
ft
0^
«M FLO* CMMCTIRISTIU
FOR STSTW 1
^
CAS STREAM NO.
RATE. Ib/hr • 1000
•eta « 1000
PARTICUUTES. Ib/hr
SO}. Ib/hr
TEMPERATURE. *F
H;0. Ib/hr
OZ. 1
NO.. Ib/hr
VELOCITY. Ft/sec
0)
11
15J
470
1S.1
(1)
Cj) LIQUID STREAM NO.
RATE, Ib/hr x 100
9P»
TOTAL SOLIDS, S
PH
TEMPERATURE. *F
H;0, Ib/hr
SULFITE. «g/l
SULFATE, «9/l
CHLORIDE, ag/l
SPECIFIC GRAVITY
Cp
200
$
6.0
(p
6.0
$
6.0
OP
1.0
4r*
4}
$
V
^
rwMPi
n
^
LMCHM
WSTST1
9
Mcrai
EMI
®
mcs
4
-------
KISTMI
(O
I-1
OJ
Figure 14-37. Nekoosa Papers, Inc.
EOUIPNCNT LIST
EQ NO.
ri
•i
n
P3
SI
Tl
T2
VI
NMC
F.D. FAN
RECIRCULATION
PUMP
8LEID-OFF PUMP
MICE -UP PUMP
SEPARATOR
RECIRCULATION
TANK
HAKE -UP TANK
VARIABLE THROAT
VENTURI
SHE, FEET
MATERIAL
NO.
i
2
?
CM STROM NO.
RATE. Ib/hr > 1000
•eta! 1000
MATIOJUTES. lk/hr
M|. lk/kr
TENPCMTUK. f
NlO. lk/kr
«H. I
"0,. lk/kr
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-------
TECHNICAL REPORT DATA
(Please read Instructions, on the reverse before completing)
1, REPORT NO.
EPA-600/7-79-067a
4. TITLE AND SUBTITLE
2.
3. RECIPIENT'S ACCESSION-NO.
EPA INDUSTRIAL BOILER FGD SURVEY: Fourth
Quarter 1978
5. REPORT DATE
February 1979
6. PERFORMING ORGANIZATION CODE
r-AUTHOR(s) J.Tuttle, A.Patkar, D.Welch, M.Hessling,
and M. Eckstein
8. PERFORMING ORGANIZATION REPORT NO.
B. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO.
EHE624
11. CONTRACT/GRANT NO.
68-02-2603, Task 45
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task Final; 10-12/78
14. SPONSORING AGENCY CODE
EPA/600/13
IB. SUPPLEMENTARY NOTES IERL-RTP project officer is R. Michael McAdams, MD-61, 919/
541-2915. Earlier related reports are in the EPA-600/7-78-052 series.
16. ABSTRACT
The report gives detailed technical information concerning application of
flue gas desulfurization (FGD) systems to industrial boilers. Design and operation
data is presented for 172 FGD control systems (132 of them operational), designed to
control SO2 emissions from 206 industrial boilers at 61 plants. With a 1978 capacity
of 9.2 million scfm, an average of more than seven new FGD systems have been put
on line each year since 1972. Information in the report was obtained by a survey of
plant personnel, control system vendors, regulatory agencies, and consulting engin-
eering firms. The data is given in two types of tables: one gives summary informa-
tion; the other, detailed information. Summary tables present information as a func-
tion of control process, control system vendor, disposal technique, operational sta-
tus, startup date, and flue gas capacity. Detailed information includes: control sys-
tem design, economics, operating experience, problems and solutions, waste dis-
posal techniques, and maintenance practices.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Pollution
Flue Gases
Desulfurization
Boilers
Waste Disposal
Maintenance
Pulping
Chemical Industry
Pollution Control
Stationary Sources
Industrial Boilers
13B
2 IB
07A,07D
13A
15E
11H
18. DISTRIBUTION STATEMENT
Unlimited
EPA Form 2220-1 (»-73)
19. SECURITY CLASS (ThisReport)
Unclassified
230
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
223
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