United States      Industrial Environmental Research  EPA-600/7-79-221a
Environmental Protection  Laboratory         September 1979
Agency        Research Triangle Park NC 27711
           Summary for
Full-Scale Dual-Alkali
Demonstration System at
Louisville Gas and Electric
Co. — Final Design and
System Cost

Interagency
Energy/Environment
R&D  Program Report

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                  RESEARCH REPORTING SERIES


Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application  of en-
vironmental technology. Elimination of traditional  grouping was consciously
planned to foster technology transfer and a maximum interface in related  fields.
The nine series are:

    1. Environmental Health Effects Research

    2. Environmental Protection Technology

    3. Ecological Research

    4. Environmental Monitoring

    5. Socioeconomic Environmental Studies

    6. Scientific and Technical Assessment Reports  (STAR)

    7. Interagency Energy-Environment Research and Development

    8. "Special" Reports

    9. Miscellaneous Reports

This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded  under the  17-agency  Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the  public
health and welfare from  adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include  analy-
ses of the  transport of energy-related pollutants and their health and ecological
effects; assessments of,  and development of, control technologies for energy
systems; and integrated assessments of a wide range of energy-related environ-
mental issues.
                       EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for  publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute 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-600/7-79-221a

                                              September 1979
Executive Summary for Full-Scale Dual-Alkali
Demonstration System at Louisville Gas and
Electric Co. — Final Design and System Cost
                              by

                  R.P. VanNess, R.C. Somers. R.C. Weeks (LG&E);
                T. Frank, G.J. Ramans (CEA); C.R. LaMantia, R.R. Lunt,
                         and J.A. Valencia (ADL)

                     Louisville Gas and Electric Company
                         311 W. Chestnut St.
                         Louisville, KY 40201
                        Contract No. 68-02-2189
                       Program Element No. EHE624A
                     EPA Project Officer: Norman Kaplan

                   Industrial Environmental Research Laboratory
                 Office of Environmental Engineering and Technology
                      Research Triangle Park, NC 27711
                            Prepared for

                  U.S. ENVIRONMENTAL PROTECTION AGENCY
                     Office of Research and Development
                         Washington, DC 20460

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                                CONTENTS


                                                                Page No.

List of Figures                                                    iv

List of Tables                                                     iv

Applicable Conversion Factors
 English to Metric Units                                            v

Acknowledgements                                                   vii


  I.  PURPOSE AND SCOPE                                             1

      A.  Purpose of Project                                        1

      B.  Scope of Work                                             1

      C.  Project Schedule                                          2

 II.  CEA/ADL DUAL ALKALI PROCESS TECHNOLOGY                        6

      A.  System Chemistry and Process Configuration                6

      B.  Pollution Control Capabilities                           10

III.  DESCRIPTION OF THE DUAL ALKALI PROCESS APPLICATION
       AT CANE RUN STATION                                         12

      A.  System Design                                            12

      B.  Dual Alkali Plant Configuration and  Equipment            20

      C.  Mechanical Testing of Equipment                          23

 IV.  CAPITAL COSTS FOR THE DUAL ALKALI SYSTEM                    25
                                     iii

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                                  FIGURES


Figure No.                                                          Page No.

    1-1      Dual Alkali Demonstration Overall Project
             Schedule                                                   4

    1-2      Phase II Schedule                                          5

   II-l      Dual Alkali Process Flow Diagram                           7

  1II-1      Overall View of Cane Run Unit No. 6 and the Dual
             Alkali System                                             21

  III-2      Overall View of the Chemical Plant                        22
                                   TABLES


 Table No.                                                           Page No_.

  III-l      Dual Alkali Process Design Basis                          13

  III-2      Process Operating Requirements at Design Conditions       19

   IV-1      Capital Costs for the Dual Alkali System at Cane
             Run Unit No.  6                                            26

   IV-2      Capital Cost Breakdown by Sub-System                      27
                                      iv

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APPLICABLE CONVERSION FACTORS

British
5/9 (8F-32)
1 ft
1ft2
1 ft3
1 grain
1 in
lin2
lin3
1 Ib (avoir.)
1 ton (long)
1 ton (short)
1 gal
1 Btu
ENGLISH TO METRIC UNITS
Metric
°C
0.3048 meter
0.0929 meters2
0.0283 meters3
0.0648 gram
2.54 centimeters
2
6.452 centimeters
3
16.39 centimeters
0.4536 kilogram
1.0160 metric tons
0.9072 metric tons
3.7853 liters
252 calories

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                            ACKNOWLEDGEMENTS
This report was prepared by Arthur D.  Little,  Inc.;  however,  the informa-
tion and data contained in the report  represent the  work of many individuals
from several organizations who have been involved in this project.   The
principal participating organizations  are Louisville Gas and  Electric, Inc.,
Combustion Equipment Associates, Inc., and Arthur D. Little,  Inc.

In addition, we would like to acknowledge the efforts and contributions
from persons in other organizations.  Norman Kaplan, the EPA  Project
Officer for this demonstration program, has made important technical
contributions and has been instrumental in the management of  the entire
project.  Mike Maxwell, the Director of Emissions/Effluent Technology at
EPA's Industrial Environmental Research Laboratory,  was responsible for
overall planning and review of this program and has  provided  invaluable
guidance and support.  And Randall Rush of the Southern Company Services
has made important contributions of a technical nature to the design of
the system.
                                   vii

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                          I.  PURPOSE AND SCOPE
A.  PURPOSED OF PROJECT

The project covers the full scale application of the Combustion Equipment
Associates (CEA)/Arthur D.  Little, Inc.  (ADL) dual alkali flue gas desul-
furization (FGD) system to Unit No.  6, a coal-fired boiler at Louisville
Gas and Electric Company's (LG&E) Cane Run Station in Louisville, Kentucky.

The system has been installed on this existing 300 MM (gross peak capacity)
unit to comply with requirements3 of the Jefferson County Air Pollution
Control District, the Kentucky State Division of Air Pollution, and
Region IV of the U.S. EPA.  EPA selected the dual alkali S02 control
process at LG&E as a demonstration system for dual alkali technology and
is participating in funding of the operation, testing, and reporting of
the project.

The dual alkali system has the capability to control the SO2 emissions
to less than 200 ppm dry basis without additional air dilution when
burning coal containing up to 5% sulfur.  When burning coal containing
greater than 5% sulfur, the system will remove at least 95% of the sulfur
dioxide in the inlet flue gas.  The dual alkali system is not designed
for removal of particulate matter; however, it is designed not to increase
the loading of particulate matter in the flue gas.  As a demonstration sys-
tem, the purpose of the installation and operation is to establish:

     •  overall performance - SO- removal, lime utilization, sodium
        makeup, regeneration of spent liquor, water balance, scaling
        and solids buildup problems, materials of construction, waste
        cake properties, reliability, and availability.

     •  economics - capital investment and operating cost.

B.  SCOPE OF WORK

The scope of work for  the project includes the design, construction,
startup, acceptance testing, and one year of operation of a  CEA/ADL
concentrated mode dual alkali system  on Unit No.  6, a 280 Mw coal-fired
boiler at LG&E's Cane Run Station.  The system is  to be  designed to
treat all of the flue  gas emitted at  the nominal  rated capacity  (280 Mw)
with the capability for treating  flue gas equivalent to  a minimum boiler
load of 60 Mw  and a maximum load of 300 Mw.
 ^Removal  of  85% of  the  S02  present  in  the  flue  gas  at  the scrubber inlet.

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LG&E is the prime contractor with overall responsibility for all aspects
of the project.  CEA, as a subcontractor to LG&E, is responsible for the
engineering design, for the supply of all process equipment, and for
engineering assistance during startup and acceptance testing.  CEA is
also responsible for compliance with all process guarantees and equipment
warranties.  ADL, a subcontractor to CEA, is providing process engineering
support to CEA during design, startup, and acceptance testing; and will
provide process assistance to LG&E in the operation of the system during
the one year test program.  ADL is also responsible for the preparation
of all reports required under the EPA/LG&E contract.

The work is divided into four phases:

     •  Phase I   - preliminary design and cost estimates;

     •  Phase II  - engineering, design, construction, and mechanical
                    testing;

     •  Phase III - startup and performance testing; and

     •  Phase IV  - one year of operation and testing.

Baseline testing on the boiler and monitoring of the system performance
during acceptance testing and the one year test program is not included
as a part of this contract.  This work will be carried out by Bechtel
National,  Inc. under a separate contract with EPA.

This summary covers work performed in Phase II of the project as presented
in the Final Design and System Cost report, (EPA-600/7-79-221b, Sept. 1979).

The Final Design and System Cost report describes in detail the plant, as
built, and its planned mode of operation.  It includes:  a description of
the process; the operating and control philosophy; material balances and
utility requirements; plant layout; a description of major items of process
equipment; a description of offsites and auxiliaries; results of the mechani-
cal testing; and actual capital costs for the system.

C.  PROJECT SCHEDULE

The overall project schedule covering all phases of the dual alkali
demonstration project is given in Figure 1-1.  The overall project,
including  the one-year test program, was originally scheduled for 40
months (with an additional one month for completion of the final draft
report).

Phases I and II were scheduled to begin simultaneously to expedite  the
overall project.  Phase I  (preliminary design) was scheduled for five
months including preparation of the draft report.  Phase II  (engineering
design and construction) was scheduled for 24 months starting with  the
signing of the contract.  A detail of the schedule for Phase II is  given
in Figure  1-2.

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As indicated in Figures 1-1 and 1-2,  the project has been delayed due to
the severe winter of 1977/1978.  The  project schedule for completion of
the project is shown in Figure 1-1.

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                                 1976
                                               1977
                                                           -I   I-
                                                                       1978
                                                                                                 1979
                                                                                                                    1980
  Phase I
                                ONDJFMAMJJASONDJFMAMJJASONDJFMAMJJASONDJFMAMJJ
                                04               12       16       20	24      28      32      36 _.     40       44
       Preliminary Engineering  -
    •  Cost Estimation

    •  Phase  I Report



  Phase II
    •  Detailed Engineering

    •  Material and Equipment
       Specification

    •  Purchasing

    •  Field Construction

    •  Operating Manual

    •  Operator Training

    •  Maintenance Plan

    •  Mechanical Testing

.P.   •  Phase II Report
  Phase III
    •  Process Startup

    •  Acceptance Testing

    •  Phase III Report
  Phase IV
    •  Review/Input Test Plan

    •  Test Program

    •  Phase IV Report


    •  Final Report
                                   •••••  Initial  Project  Plan
                                   	  Actual Schedule
                                   - —--  Projected

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      1976
               -\  \-
                                                                  1977
1978
                                                                                                       -\  h
1979
AMJJOSONDJFMAMJJOSONDJFMAMJJASQNDJFMAMJ
 •  Engineering




 •  Material &  Equipment  Specification




 •  Purchasing




 •  Delivery




 •  Site Work




 •  Foundations & Pump Buildings




 •  Breeching Tie-in




 •  Fan & Reheater Erection




 •  Absorber Erection




 •  Tank Erection




 •  Duct Erection & Insulation




 •  Vacuum Filter Building




 •   Pumps & Piping Installation




 •   Electrical  & Control




•  Mechanical  Testing




•  Operator  Training




•  Maintenance  Plan




•  Operating Manual




•  Phase  II Report
          Initial Project Plan



          Actual Schedule
                       Figure 1-2:  Phase II Schedule

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                II.   CEA/ADL DUAL ALKALI PROCESS TECHNOLOGY


 A.   SYSTEM CHEMISTRY AND PROCESS CONFIGURATION

 The  CEA/ADL dual alkali S02 control process Involves scrubbing of the flue
 gas  with a solution  of alkaline sodium salts.  Spent scrubbing solution is
 regenerated using lime to produce a solid waste consisting principally of
 a mixture  of calcium-sulfur salts.

 The  system can be conveniently broken down into four processing sections-
 gas  scrubbing; absorbent regeneration; waste solids dewatering; and raw
 materials  preparation.  The equipment utilization and operation of each
 process section depends on specific requirements of the particular applica
 tion.  Figure II-l shows a generalized flow schematic of a dual alkali
 process as applied to a boiler equipped with a high efficiency electro-
 static precipitator.  The following discussion provides a description of
 the  basic  system configuration and process flow scheme.

 1.   Flue Gas Scrubbing

 In the generalized system, shown in Figure II-l, flue gas from the elec-
 trostatic precipitator (or induced draft fan for the boiler) is forced bv
 a booster  fan through an absorber.   In the absorber the gas passes upward
 through a  set of sprays to quench the gas, then through a set of sieve
 trays for  S02 removal by an alkaline solution, and finally through a de-
 mister to remove entrained liquor.   The clean flue gas leaving the tower
 is reheated before being discharged to the stack.
            on             t0 remDVe S°2 from the flue 8«B contains sodium
sulfite (Na2S03), hydroxide (NaOH) , carbonate (Na2C03) , sulfate (NaoSO/?"
and chloride (NaCl).  During the process of removing so,, the carbonate
hydroxide, and some sulfite are consumed resulting in a spent sodium   *
sulfite/bisulfite liquor.  The S02 removal process can be represented by
the following overall reactions:                                       y

     2Na2C03 + S02 + H20 -f Na2S03 + 2NaHC03                     (1)

      NaHC03 + S02       + NaHS03 + C02t                        (2)

     2NaOH   + S02       •* Na2S03 + H20                         (3)

      Na2S03 + S02 + H2° "* 2NaRS03                              (4)

Although the actual reactions within the absorber are more complex, involving
various intermediate ionic dissociations, the above set of simplified, over-
all reactions is an accurate representation of the overall consumption and
generation of the various components.

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                                            Soubbt'd G.is
      CM
     silo
Wa
       Stoker
  Slurry
  Storage
I  Tank


^
                                               Reactor
                                               System
                                                                             H0O
>? Funl fill * »

.. — Ho(c|
Tank
Sr






ml


H2O
I
I f~

* Mix
Tank
J
"O



                                                                                                           Na2CO3

                                                                                                             Silo
                                                                                                                          Solids
                                  Figure  II-l:   Dual Alkali Process Flow Diagram

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Sodium sulfite plays the most important role in the absorption of 862 since
it is usually present in the greatest concentration.  The hydroxide and
carbonate are present in the absorber feed only in small amounts.  The con-
centration of these three  alkaline  components is a measure of the SOo removal
capacity of the absorbing  liquor.  This capacity is conveniently expressed
in terms of the "active sodium" concentration where [active sodium] = 2 x
[Na2S03] + [NaOH] + 2 x [Na2C03].  It must be pointed out that the use of
the term "active sodium" is simply one of convenience since it is only an
indirect indication of the absorptive capacity of the liquor.  SOo is
actually absorbed by or reacts with the sulfite, hydroxide, or carbonate
ions rather than the sodium ion.

Sodium sulfate and sodium chloride do not participate in the St^ removal
process.  In this sense, they are considered "inactive" components.  The
presence of sodium sulfate and sodium chloride is principally the result
of secondary absorption reactions.  Sodium sulfate is formed by the
oxidation of sodium sulfite via reaction with oxygen absorbed from the
flue gas.  Oxidation also occurs in other parts of the system where
process solutions are exposed to air; however, the amount of oxidation
is small relative to the oxidation which occurs in the absorber.

The SC>2 removal efficiency in the absorber is principally a function of
the inlet S02 concentration, the number of gas /liquid contacting stages,
and the pH at which the absorber is operated.  For a given scrubber con-
figuration and inlet S02 level, SC>2 removal can be adjusted simply by
varying the scrubber operating pH.  In most utility boiler applications,
better than 95% SC>2 removal can be easily achieved.

2.  Absorbent Regeneration

A bleed stream from the absorber recirculation loop is sent to the re-
generation reactor system where it is reacted with hydrated lime.  The
CEA/ADL reactor system incorporates a novel design developed to produce
solids with good settling and filtration characteristics over a broad
range of operating conditions.   The reactor system consists of two
reactor vessels in series:  a short -residence time first stage (3-15
minutes) followed by a longer residence time second stage (30-60 minutes).
The process can be operated in conjunction with a lime slaker or can use
purchased hydrated lime (e.g.,  commercial hydrate or carbide sludge).

The lime neutralizes the bisulfite acidity in the scrubber bleed and
further reacts with sodium sulfite and sodium sulfate to produce sodium
hydroxide.   These reactions precipitate mixed calcium sulfite and sulfate
solids, resulting in a slurry containing up to 5 wt.% insoluble solids,
as shown below:
     2NaHS03 + Ca(OH)2 •*• Na2S03 + CaS03 • 1/2 H20+ + 3/2
     Na2S03 + Ca(OH)2 + 1/2 H20 -»• 2NaOH + CaS03 • 1/2 H2
     Na2S04 + Ca(OH)2 ->• 2NaOH

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The CEA/ADL dual alkali process is designed to operate in a relatively
"concentrated" active alkali mode (roughly 0.5M active Na+ — where active
sodium is defined as that sodium attributable to OH~, C03, HCOo, SOo,  and
HSO^ in solution).  In this mode, sulfate removal cannot be effected by
precipitation of gypsum (CaS04 •  2^0), since the high sulfite levels
prevent soluble calcium concentrations from reaching levels required to
exceed the gypsum solubility product.  Thus, the system operates unsat-
urated with respect to calcium sulfate, thus minimizing scale potential.
However, calcium sulfate is coprecipitated with calcium sulfite in the
regeneration reactor, which allows the system to keep up with absorbent
oxidation.

3.  Solid/Liquid Separation and Solids Dewatering

Slurry from the regeneration reactor system is fed to a thickener where
the slurry is concentrated to 20 to 45% solids.  Clarified liquor from the
thickener is collected in a hold tank from which it is returned to the
absorber.  The thickened slurry is sent to rotary drum vacuum filters,
where the solids are filtered to a cake containing 55 to 70% solids.  The
filter cake is the only waste material generated by the process.  There
are no other solid or liquor purges from the system.

The high solids content of the filter cake and the excellent handling
properties of the material are a direct result of the controlled conditions
for crystallization in the reactor system.  The material is much like a
moist silty to sandy soil and is easy to manage in solids handling and
transport equipment.  If further chemical treatment is required, these
excellent physical properties should prove to be an advantage.

On the filter the cake is washed using a series of water spray banks.
This wash removes a large fraction (approximately 90%) of the occluded
soluble salts from the cake and returns these salts along with the fil-
trate to the system, thereby reducing sodium losses and minimizing sodium
carbonate makeup.

The exact chemical composition of the solids will depend somewhat upon fly
ash loading  (if any), the chemical composition of the flue gas and fly ash,
and the degree of oxidation of sulfite to sulfate encountered in the system.
The following general chemical composition  (ash-free, dry cake basis) is
typical for a high sulfur coal application:

                 CaS03  ' 1/2 H20        - 80-85 wt.%

                 CaS04  • 1/2 H20        - 10-15 wt.%

                 Na2S04 + Na2S03 + NaCl = 1-3 wt.%

                 CaC03 + Inerts         - 5-10 wt.%

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 The mix of sodium salts  in the cake is  importantly  dependent upon the
 chloride content  of the  coal.   Essentially  all  of the  chloride in the
 coal is released  to the  flue gas  as HC1 gas,  and it  is efficiently
 removed in the absorber.   The  chloride  is purged from  the system in
 the filter cake (as NaCl)  at the  rate at which  it is absorbed.  Thus,
 the higher the chloride  content of  the  coal,  the higher the fraction
 of sodium salts as sodium  chloride.

 4.  Raw Materials Preparation

 The operation  of  the dual  alkali  system requires the addition of lime  for
 absorbent regeneration and of  sodium carbonate  to make up for the sodium
 lost in the occluded liquor in the  waste cake.

 Typically,  lime would be slaked and hydrated  prior  to being fed to the
 reactor system.   Alternatively, commercial  hydrated  lime or carbide sludge
 could be fed directly to the reactor system.

 The sodium carbonate solution  can be prepared either with clarified liquor
 from the thickener or with fresh  water.  Makeup sodium carbonate solution
 is fed to the  system to  replace sodium  value  lost in the filter cake.  The
 sodium carbonate  is not  intended  for use as a softener, since soluble  cal-
 cium concentrations in the regenerated  liquor runs  less than 100 ppm.  The
 quantity of sodium carbonate required,  therefore, is quite small, and  the
 sodium carbonate  costs represent  a  negligible element in the overall cost
 of operating the  system.

 B.   POLLUTION  CONTROL CAPABILITIES

 1.   SOp Control

 A  sodium-based dual alkali process,  operating in the concentrated active
 sodium mode, is capable of S02 removal  efficiencies in excess of 95% and
 almost  any  range  of inlet  SCv  concentrations  encountered in coal-fired
 utility boiler applications.   In  most high  sulfur coal applications,
 removal efficiencies  approaching  99% can be achieved on a continuous basis
 in low-energy,  tray-type absorbers  .  862 removal efficiencies can be
 easily  varied  by  adjusting the operating pH of the absorber with little
 or no  effect on the overall lime  stoichiometry or the sodium makeup
 requirement.

 The high SC^ removal  capability of  this  process, when used in conjuction
 with  a  boiler  equipped with adequate control of particulate matter, allows
 the option  of  removing virtually  all of  the S02 from the flue gas treated
 in  the  scrubber.   Thus, there  is  the option of bypassing hot, untreated
 gas to  provide part or all of  the reheat while still meeting the overall
^LaMantia, C.R., et al., "Final Report:  Dual Alkali Test and Evaluation
 Program," Volume III, EPA Contract 600/7-77-050, May 1977.
                                  10

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plant 862 emission regulations in the combined treated and untreated flue
gas.  In such a system, the scrubber size can be reduced, since not all
flue gas is treated.  Also, reheat requirements are reduced or eliminated.
In the system for Cane Run Unit No. 6, bypass for reheat is not provided.
All of the flue gas will be treated with reheat provided by injection of
hot gas from the combustion of No. 2 fuel oil.

2.  Control of Particulate Matter

While the dual alkali system at the Cane Run Station is not designed to
remove particulate matter, this capability can be accommodated in the
process by appropriate selection of the type of scrubber system to be
used.  If particle removal is to be performed by the system, then a
higher energy particulate matter removal device, such as a venturi scrub-
ber, would be required.  This scrubber alone can be used for both S02 and
particulate control; or, if additional SC>2 removal is required (>95%), a
venturi can be used in combination with one or more trays at a small incre-
mental cost.  Removal of particulate matter down to 0.02 grains/scfd or
lower can be accomplished using venturi scrubbers at moderate pressure
drops (about 20 inches WG).

Where particulate matter control is already provided ahead of the scrubber
system, the S02 scrubbing system will not result in any increase in par-
ticulate emissions.  Because a solution is used for SC«2 absorption rather
than a slurry, any entrainment of scrubbing solution in the gas can be
efficiently and reliably removed using standard mist eliminators without
wash water prior to exhausting the gas.

3.  Chloride Control

Most of the chloride in coal (>90%) is volatilized and appears in the flue
gas as HC1.  Any aqueous-based scrubbing system would be highly effective
in absorption of HC1 (as well as HF) from the flue gas.  As a result,
chloride concentrations will build in the closed liquor loop to levels
such that the rate at which chloride is discharged from the system in
the washed filter cake will equal the rate at which chloride enters the
system with the flue gas.  The CEA/ADL dual alkali system has been suc-
cessfully operated for extended periods with  steady-state levels of
chloride in the closed liquor loop as high as 11,000 ppm (consistent
with 0.05-0.10 wt.% chloride in the coal)1.
J-Ibid.
                                     11

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         III.  DESCRIPTION OF THE DUAL ALKALI PROCESS APPLICATION
                         AT THE CANE RUN STATION


 This  chapter provides a description of the application of the dual alkali
 technology to the specific flue gas desulfurization requirements for LG&E's
 Cane  Run Unit No. 6.  In designing the system, consideration was given to
 the sources, characteristics, and amounts of flue gas to be cleaned as
 well  as to the type and sources of the required raw materials.

 A.  SYSTEM DESIGN

 1.  Design Basis

 Cane  Run Unit No. 6 consists of a pulverized coal-fired steam boiler, built
 by Combustion Engineering, with a Westinghouse turbine-generator.  The unit
 operates from a minimum of 60 Mw during off-peak hours to a maximum load of
 300 Mw during peak hours.  The annual average load is equivalent to approx-
 imately 180 Mw (about 60% of the gross peak capacity).  The boiler is
 equipped with a high efficiency electrostatic precipitator capable of 99.4%
 particulate matter removal.   The dual alkali system for Cane Run Unit No. 6°
 is designed for S02 removal only.

 Coal  for Unit No. 6 is received from a number of sources.  The average sul-
 fur content on a dry basis is 4.8% and varies from 3.5% to 6.3%.  The
 average chloride content of the coal is 0.04% and varies from 0.03% to
 0.06%.  The average 4.8% sulfur content and 11,000 Btu/lb will result in
 an S02 emission level equivalent to about seven times that allowed by the
 present Federal New Source Performance Standards (1.2 Ibs of S02/MM Btu).

 The design basis for the dual alkali system is summarized in Table III-l.
 Design conditions correspond to coal containing 5% sulfur and 0.04% chloride
 and having a heating value of 11,000 Btu/lb on a dry basis.  The design gas
 capacity of 3,372,000 Ibs of flue gas per hour (combined flow to both
 scrubbers) corresponds to the boiler peak load capacity of 300 Mw.

 The dual alkali system is designed to meet all applicable federal, state
 and local pollution control and safety regulations.  The maximum S0? con-
 centration in the scrubbed gas will be 200 ppm (for coal containing up to
 5% sulfur), well below requirements of the current NSPS.  There will be no
 discharge of process liquor from the system; and the disposal of the waste
 solids produced will meet all applicable federal, state, and local solid
waste disposal regulations currently in effect.  None of the wastes will
be discharged to or allowed to enter any naturally occurring surface water.
 Plans for disposal are discussed as a part of this report.
                                    12

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                          TABLE III-l
                DUAL ALKALI PROCESS DESIGN BASIS
Coal (Dry Basis);

     Sulfur
     Chloride
     Heat Content

jnlet Gas;

     Flow Rate  (Volumetric)
                (Weight)
     Temperature
     so2

     °2
     Participate Matter

Outlet Gas;

     so2
     Particulate Matter
5.0% S
0.04% Cl~
11,000 Btu/lb
1,065,000 acfm
3,372,000 Ib/hr
300 °F
3471 ppm (dry basis)
5.7 vol %
^0.10 lb/106 Btu
*200 ppm (-0.45 lb/10  Btu)
*0.10 lb/106 Btu
                                 13

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 2.   Guarantees

 The  process  guarantees listed below include minor revisions since publica-
 tion of  the  project manual containing the preliminary design and cost
 estimate (EPA-600/7-78-010, January, 1978).

     a.   Sulfur Dioxide Emission

 The  system shall provide such control that emissions from the stack shall
 be no greater than 200 ppm by volume S02 dry basis not including S02 added
 from the operation of the reheaters and without additional air dilution
 when burning the coal containing less than 5% sulfur.  When burning coal
 containing 5% sulfur or greater, the system shall remove at least 95% of
 the  sulfur dioxide in the inlet flue gas.

     b.   Particulate Matter Emission

 In addition  to meeting applicable regulations, the system shall also meet
 Federal  New  Source Performance Standards for emissions of particulate
 matter under all conditions of boiler operation.  The dual alkali system
 shall not add any particulate matter to the emissions of particulate
 matter that  is received by the system from the LG&E Cane Run Unit No. 6
 electrostatic precipitator.

     c.  Lime Consumption

 The  consumption of lime in the system shall not exceed 1.05 moles of
 available CaO in the lime feed per mole of SO- removed from the flue gas.

     d.   Sodium Carbonate Makeup

 Soda ash makeup shall not exceed 0.045 moles of Na^COg per mole of SO-
 removed  from the flue gas provided that the chloride content of the coal
burned averages 0.06% or less.  If the average chloride content of the
coal is above 0.06%, then additional sodium carbonate consumption will
be allowed at the rate of 1/2 mole Na2CO.j for each mole of chloride (Cl~)
in the flue gas resulting from chloride in excess of 0.06% in the coal.
The Seller as part of the guarantees shall perform the necessary research
and design to reduce the makeup requirements of N2C03 from the guarantee
point to a level approaching minimal makeup.

     e.  Power Consumption

At the peak operating rate (300 Ha), the system shall consume a maximum
of 1.2% of the power generated by the unit.

     f.   Waste Solids Properties

The waste produced by the vacuum filter shall contain a minimum of 55%
insoluble solids.
                                    14

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     g.  SOp System Availability

The system shall have an availability (as defined by the Edison Electric
Institute for power plant equipment)  of at least 90% for one year.   Thus,
the system shall be available for operation at least 90% of the calendar
time.

3.  Process Description

The system configuration and operation will differ slightly from the
generalized process discussed previously.  The principal difference is
that the system will utilize locally available carbide lime, a calcium
hydroxide byproduct from acetylene production, rather than slaked
quicklime.

The system design is modular in nature, with spare capacity provided both
as excess capacity within modules as well as spare modules and equipment
where appropriate.  Redundant instrumentation has also been provided for
critical control operations.

     a.  Absorber Section
The absorber section consists of two identical scrubber modules.  Each
module is made up of a booster fan, an absorber, an oil-fired flue gas
reheater, and two recirculation pumps (one operating and one back up).

Flue gas is drawn from the existing induced draft fans and is forced
through the absorbers by means of the booster fans.  The basic design
and control philosophy is predicated on both absorbers operating simul-
taneously with each handling half the boiler load.  However, during
periods of low boiler load, one absorber is capable of handling all of
the gas.  Hence, in order to allow for greater flexibility in operation
and provide for the possibility of allowing maintenance on one module
while the system is still in service, a common duct connecting the two
booster fan inlets has been incorporated.  A bypass is also provided
to allow complete shutdown of the scrubbers while the boiler is still
on line.  The bypass and FGD system inlet dampers have been properly
interlocked to enable bringing the absorbers on- or off-line without
interruption of the boiler operation.

Hot flue gas (^300°F) entering each absorber is first cooled by a set of
sprays which direct scrubbing solution at the underside of the bottom
tray.  In addition to providing temperature control at the bottom of the
absorbers, these sprays keep the underside of the tray and the bottom
of the absorber free of any buildup of fly ash solids.  The cooled,
saturated gas passes through a set of two trays where S02 is removed
and then through a chevron-type demister.  After leaving the absorber,
the scrubbed gas is reheated 5QF°  (to a temperature of about 1758F) by
mixing it with hot flue gas from oil-fired reheater to avoid condensation
and corrosion as it is exhausted to the stack.
                                     15

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 The  scrubbing  solution which  flows  counter-current to the gas is collected
 at the bottom  of  the  absorber.  This  liquor is used for the quench sprays
 and  as a  recycle  stream  to  the  top  tray for pH control.  Since the scrub-
 bing solution  is  regenerated  with lime, the feed to the absorber contains
 sodium hydroxide  and  therefore  is very alkaline.  A high tray feed pH
 increases  the  absorption of C02 which in turn increases the potential for
 CaCC>3 scaling  in  the  absorber.  The recycle also ensures proper liquid
 loading on the trays.  A bleed  stream from the bottom of the absorber
 is sent to the reactor system for regeneration to an active sodium solu-
 tion.  Provisions have been made for  an automatic emergency water supply
 to spray and quench the  hot flue gas  in the event that the recycle pump fails

      b.  Reactor  Section

 This section of the system  consists of two identical reactor trains each
 containing a primary  and secondary  reactor.

 At operation under design conditions, each reactor train would handle the
 regeneration of solution from the corresponding absorber; although for
 short periods  of  time, a single reactor train is capable of handling the
 solutions  from both absorbers operating at design conditions.  When the
 boiler is  firing  typical or average coal (3.5-4.0% sulfur), only one
 reactor train  is normally required.

 The  spent  scrubbing solution  is introduced to the primary reactor along
 with slurried  carbide lime  from the lime day tank.  The slurry from the
 secondary  reactor is  fed to the thickener feed well where the separation
 of the regenerated solution from the solid waste is initiated.

     c.  Solids Dewatering

 The  reactor effluent, a  slurry containing 2-5% insoluble solids, is dir-
 ected to the feed well of the thickener.  The thickener is generally
 operated to provide an underflow (thickened) slurry containing about 25
wt % solids.  The thickener underflow slurry is recirculated past the
 filters in a recycle loop that returns the slurry to the solids zone of
 the  settler.  A bleed from this recirculation loop is fed to the filters.
 Each filter is  equipped with an overflow pipe returning to the solids
 zone in the thickener to allow for operation in an overflow mode and
 thereby provide against  inadvertent overflow of the filter hold tank.

There are three filters, each rated to handle 50% of the total solids
 produced at the design conditions.   Each filter can be operated independ-
 ently.  The number of filters in operation is determined by the quantity
of solids accumulated in the thickener,  which is reflected in the solids
 concentration in the underflow slurry and the position of the thickener
rake lift  indicator.   For operation at typical conditions (3.5% S and an
average daily load of 60-70%), it  is anticipated that only 2 filters need
to be operated about  one shift per day.
                                    16

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The solid cake is washed on the filter using a series  of water spray banks.
This wash removes a large fraction (approximately 90%) of the occluded
soluble salts from the cake and returns these salts  to the system,  thereby
reducing sodium losses and minimizing sodium carbonate makeup.

Clear liquor overflow from the thickener is collected  in the thickener
hold tank which both provides surge capacity for the absorbent liquor
feed to the scrubber system and maintains overall control of the volume
of liquor in the system.  Water is added to this hold  tank to make  up
for the difference between total system water losses (evaporation and
cake moisture) and total water inputs from other sources (sodium makeup
solution, pump seals, lime feed, and cake wash).

     d.  Raw Materials Preparation

Two chemicals are required for the operation of the  dual alkali system:
lime for absorbent regeneration and soda ash to make up for sodium losses.

Carbide lime, a byproduct of acetylene production, is  available to  LG&E
at a significantly lower price than commercial lime.  The carbide lime is
barged to the Cane Run Station as a slurry containing approximately 30%
insoluble solids.  From the main storage tank, the lime slurry will be
pumped to a grinding system consisting of a hydroclone and wet ball mill
to prevent feeding of oversized material.  From the grinding system, the
lime will be pumped to the dual alkali system day tank which supplies lime
to the primary reactor at the appropriate rate.  Since  installation of
the grinding equipment has been delayed beyond  the startup  dat°  for the
dual alkali system, a disintegrator with coarse screens has been tempor-
arily  installed  upstream of  the day tank for rough sizing of  the raw car-
bide lime until  the permanent  grinding  facility is completed.


The addition of  sodium carbonate to the system is to  compensate for the
losses of sodium in the cake.  Despite washing the cake, some liquor,
containing soluble sodium salts, will inevitably remain occluded in the
cake.

Dry, dense soda  ash is received at the plant and stored in  the soda ash
silo from which  it is fed to the soda ash solution tank by means of a
weigh  feeder.  Soda ash solution can be made up using either clarified
liquor drawn from the thickener hold tank or fresh water.   Provisions
have also been made to feed  the soda ash solution either directly to the
absorbers or to  the thickener.  The normal mode of operation ±s to
prepare the soda ash makeup  solution using clarified  liquor and to feed
it to  the absorbers.
                                     17

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      e.   Waste Disposal

 A long-range  plan for  the  disposal  of the  dual alkali filter cake has been
 developed as  a part  of an  overall disposal plan  for all FGD wastes produced
 at the Cane Run Station.   The  plan  involves  stabilization of the wastes
 generated by  each of the three FGD  systems via the addition of lime and
 fly ash  and dry landfill of  the stabilized material adjacent to the plant.
 Waste from the dual  alkali system on Unit  No. 6 will be handled, processed
 and disposed  of independently  of the wastes  produced by the direct lime
 scrubbing systems on Unit  Nos.  4 and 5.  Wastes  from these latter two units
 will be  combined and handled in a common processing plant.

 Installation  of the  waste  processing plant is scheduled for completion in
 the fall of 1979.  In  the  interim,  the filter cake conveyor will discharge
 through  a feed chute directly  into  trucks  which will transport the waste
 to a temporary storage area.   Once  the processing plant is operational,
 this waste will be reclaimed from the storage area and processed along
 with fresh filter cake.

      f.   Provisions  for Spills  and  Leaks

 Filter cake is the only product  of  the dual  alkali system.  The system
 will be  operated in  a  closed loop and there will be no other solid or
 liquid discharge from  the  system.   In order  to avoid inadvertent discharge
 of any process liquor,  provisions have been made in the process design.
 All  pump and  piping  flush water, pump seal water leaks, and equipment
 and  building wash  down water is  collected  in sumps and returned to the
 system.

 The  thickener  and  thickener  hold tank have a combined surge capacity equi-
 valent to  the  total  capacity of  all process vessels in the system.  The
 additional  capacity was incorporated in the system to allow for temporary
 storage  of  liquor  from other process vessels and to prevent any short-term
 spills of  liquor due to water imbalances resulting from extreme process
 upsets.   In addition,  the  thickener hold tank is equipped with an emergency
 overflow  tank which will begin to fill when extreme levels have been reached
 in the thickener and hold  tank.

 4.   Operating  Requirements

 System operating requirements at design conditions are summarized in Table
 III-2.  The power required to operate the process (exclusive of reheat)
will be approximately  1% of  the peak power generation for Unit No. 6.
 Of this, approximately  60% is required for the booster fans, 10% for
 reheater  fans, and 30%  for the remainder of the system.  Including oil
 for  reheat, the  total  energy requirement for the system amounts to about
 2.7% of the peak power  generation.
                                   18

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                              TABLE III-2
          PROCESS OPERATING REQUIREMENTS AT DESIGN CONDITIONS
                  Basis;   Coal - 5.0% sulfur
                               - 0.04% chloride
                               - 11,000 Btu/lb
                          Full Load (300 megawatts)
                          FGD Inlet S02 - 390 Ibs/min
                          S02 Removal - 94.4%
Energy Requirements

      Power
      Fuel Oil (for reheat)
Makeup Materials

      Water
      Lime (as Ca(OH)2)
     . Soda Ash
                                 Consumption Rate
 3.1 megawatts
48 x 10° Btu/hr
                                 Consumption Rate
   450 gpm
   460 Ibs/min.
   13.7 Ibs/min.
                     Equivalent % of
                     Boiler Capacity
      1.03
      1.68

      2.7

Ibs/lb Coal Fired
      0.111
      0.003
Cake Production

      Dry Basis
      Wet Basis
   804 Ibs/min.
   1,246 Ibs/min.
      0.194
      0.300
                                    19

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The lime and soda ash makeup requirements correspond to feed stoichiometries
of 1.0 moles Ca(OH>2 per mole of S02 removed and 0.022 moles Na2C03 per mole
of SC>2 removed.  These feed requirements include the alkali needed for
chloride removal.  The total wet cake produced is equivalent to 30 Ibs of
moist filter cake per 100 Ibs of coal (5% sulfur) fired.

B.  DUAL ALKALI PLANT CONFIGURATION AND EQUIPMENT

1.  Plant Layout

Cane Run Unit No. 6, the last and largest of six boilers at the Cane Run
Station, is located at the north end of the plant complex.  A photographic
overview of the north end of the plant in Figure III-l shows the boiler/
turbine house, the two parallel electrostatic precipitator sections and
exhaust stack of Unit No. 6 and the dual alkali facility.   The two SOo
absorbers have been installed behind the precipitators one on each side
of the stack.  The chemical plant consisting of the reactor system, dewater-
ing equipment, and raw materials preparation areas are sited north of the
boiler and scrubbers.

The building shown behind the thickener houses the filters and associated
filtration equipment; the reactor, lime feed, and hold tank pumps, and
the system sumps.  The two reactor trains are located next to and are
accessed from the filter building.  The soda ash silo and  soda ash solu-
tion tank are located in the north-east corner of the facility, adjacent
to the thickener in the foreground of Figure III-l.  The thickener over-
flow tank is located between the thickener and the filter  building; and
the lime feed day tank is located behind the filter building.

The relative location of the reactor trains and the lime slurry tank is
shown in more detail in Figure III-2.  The elevation of the primary reac-
tors, secondary reactors, and thickener is designed to allow operation of
the regeneration system completely in an overflow mode.

2.  Materials of Construction

The system is designed with appropriate corrosion resistance where required
using stainless steel (316 or 317) or linings (polyester or rubber).  The
expected chloride levels in the process liquor range from  10,000 ppm to
15,000 ppm, but levels can vary from as low as a few thousand ppm to almost
20,000 ppm depending upon the chloride content of the coal and the degree
of cake washing.   Liquor pH's range from about 5.0 in the  absorber loop
to greater than 12.0 in the reactor and dewatering systems.

With the exception of the primary reactors, all tanks and  vessel linings
in contact with process liquor are lined with flake-reinforced polyester.
The primary reactor is constructed of 316L stainless steel; the filtration
equipment is both 317L stainless steel and fiberglass; and the absorber
trays are 317L stainless steel.
                                     20

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Figure III-l:  Overall View of Cane Run Unit No. 6 and the Dual Alkali System

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KJ
                                      Figure  III-2:   Overall  View  of  the  Chemical  Plant

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All pumps and agitators in contact with process liquor are rubber-lined.
Process liquor piping is FRP.  Hot flue gas ducting is carbon steel,  and
the booster fan housing and blades are A441 steel.   Saturated flue  gas
ducting is polyester-lined between the absorbers and reheater section
and is 317L stainless steel between the reheater and stack.

3.  Instrumentation

The system is designed for minimal operator interface consistent  with
safe and reliable operation.  Feed rates for all raw materials and  the
flows of all principal process streams are automatically controlled
according to process operating conditions (tank liquid levels, process
flows, and stream compositions).  Non-critical internal process flows
are preset and adjusted intermittently as dictated by process require-
ments.

All remote controls are located in a centralized control room from which
the system can be started up, operated, and shut down.  The control room
is furnished with appropriate controllers, indicators, recorders, alarms,
and other necessary instrumentation for the safe and convenient operation
of the system.

Redundancy has been provided in critical control elements to ensure
smooth operation and minimize downtime.  Instrumentation in addition to
that required to operate the process has also been provided to permit
accurate calculation of process material and energy balances.  In particu-
lar, instruments are included for continuous monitoring of inlet and out-
let SOo concentrations, the measurement of all chemicals and water entering
the system, and the weighing of all filter cake leaving the system.

4.  Offsites

The offsites required  for the dual alkali system include:  services for
electrical supply, water supply, and instrument air; oil for reheating
the saturated flue gas; raw materials receiving and storage facilities;
a wet chemicals analytical laboratory; and appropriate shop facilities
for repair and maintenance of machinery and instruments.  Except for
electrical service, all of these offsites including lime receiving and
storage facilities, existed at Cane Run Station and are available.   An
electrical substation  including appropriate step-down transformers has
been installed for the dual alkali system.

C.  MECHANICAL TESTING OF EQUIPMENT

Mechanical testing of  the dual alkali system began in December,  1978 and
concluded in March, 1979.  Start-up operations were initiated in early March.
In general, the mechanical testing consisted of checking  the  tanks for
leaks and inspecting the internal linings; checking and operating  the
pumps and agitators; flushing all lines;  zeroing and  checking the  instru-
mentation for proper operation.  Additional tests were  carried out on
equipment which serve  special functions.   In  the absorber section, these
                                     23

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tests involved checking and operating the booster fans,  the  gas  reheaters
the dampers as well as checking the ductwork.   The flow  distribution  in
the absorber trays and the operation of the absorber  sprays  was  also
checked.  In the dewatering section, the thickener rake,  its driving  and
lift mechanisms were checked and operated.  For the filters, the drum
and tub agitator drives, the vacuum pumps, and the blow-back fans were
checked and operated.  For the soda ash silo,  the vibrating  bin, the  dust
collector and weigh feeder were checked and operated.

In general, the individual pieces of equipment performed well during  the
testing period.  Corrective measures, however, were required for the
following items:

     •  Booster fans - Shaft gap corrections were needed in  the  fluid
        drives and the booster fan speed controller was  modified.

     •  Dampers - The gear boxes in the outlet dampers had to be re-
        placed.  The blades in the inlet dampers  had  a tendency  to  drift
        apart.   This problem was caused by defective motor brakes.
        The possibility of providing additional seals for the dampers
        to further reduce gas leakage is currently being considered.

     •  Pumps - The large capacity of the reactors and thickener under-
        flow pumps caused excessive chatter and vibration.   The  pumps
        were slowed down to the required range by changing the pump
        sheaves.

     •  Agitators - The excessive amount of current drawn by the agita-
        tors was reduced by trimming the edges  off the impellers.   At
        the same time, the impeller arms were  reinforced to  minimize
        flexing.

     •  Valves - Two butterfly valves in the absorber recirculation loop
        failed and had to be replaced by heavy duty butterfly valves.

     •  Lime slurry supply - As previously indicated  in  the  raw  materials
        section, a hydroclone-ball mill grinding  system  will be  installed
        to prevent feeding of oversized material.   As a  temporary measure
        a disintegrator was installed in the lime supply system.

     •  Soda ash make-up - During loading of the  system  with soda ash,
        warm vapor from the solution tank caused  crystallization of the
        soda ash on the feed chute to the solution tank.  A  blow-back
        fan was installed to prevent the vapors from  entering and
        plugging the chute.
                                   24

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               IV.  CAPITAL COSTS FOR THE DUAL ALKALI SYSTEM

                          AT THE CANE RUN STATION
The installation of the dual alkali system at Cane Run Station Unit No. 6
required capital investment in three different facilities:  the flue gas
desulfurization (FGD), the lime slurry feed system, and a waste processing
and disposal system.  Each of these facilities has involved independent
design and installation efforts, and their costs are reported separately.
While construction of the FGD system was essentially completed in February,
1979, a significant amount of work remained on the lime feed and waste
processing facilities.  Therefore, the costs presented here represent the
actual expenditures incurred plus estimates for completion of the system.

Table IV-1 gives a summary of the capital investment for all three facil-
ities.  The total projected cost of $20.6 million includes actual expendi-
tures reported through February 28, 1979 and the estimated capital required
for completion.  Approximately 80% of this total projected capital cost was
expended through the end of February.  Most of the remaining 20% is related
to the waste processing plant.

A breakdown of capital investment by sub-system is given in Table IV-2.
This table also provides information on the capital expenditures incurred
through February 28, 1979 as a. percent of the estimated total capital re-
quired for each facility.

The capital costs in Tables IV-1 and IV-2 have been reported on an "as-
incurred plus estimate for completion" basis, and therefore do not represent
a constant dollar value of the capital investment.  The cash flow records
kept by LG&E have been used to escalate  the costs from the time of expendi-
ture to June, 1979.  The total capital investment for the dual alkali system
(including all three systems) is $22.0 million in June, 1979 dollars.
                                    25

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                            TABLE IV-1

            CAPITAL COSTS  FOR THE DUAL ALKALI  SYSTEM
                  AT CANE  RUN UNIT NO.  6,  LG&E

        "As-Incurred Plus  Estimate for Completion  Basis"


MATERIAL  COSTS:

•   FGD  System                                        $10,093,200

•   Lime Slurry  Feed System                               788,000

•   Solid  Waste  Disposal System3                        1,929.500

                  TOTAL MATERIAL  COSTS                 $12,810,700

ERECTION  COSTS:

•   Direct Labor                                       $ 3,058,500

•   Field  Supervision1*                                     337,200

•   Construction Overhead                               2,038.900

                  TOTAL ERECTION  COSTS                 $ 5,434,600

ENGINEERING COSTS:b

•   System Supplier's Engineering                     $ 1,162,700

•   Owner's Consultant Engineering                         985.OOP

                 TOTAL ENGINEERING COSTS              $ 2,147,700

SPARE PARTS                                               203,900

                 TOTAL CAPITAL INVESTMENT             $20,596,900
aBattery limits:  cake discharge from filters.

bOwner's engineering is included in field supervision.
                                26

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                               TABLE IV-2

                  CAPITAL COST BREAKDOWN BY SUB-SYSTEM3

              LOUISVILLE GAS & ELECTRIC CANE RUN UNIT NO.  6
                                         Engineering and
  Sub-System          Material Costs"     Erection Costs         Total

FGD



Lime Slurry



Waste Disposal0



           Total        13,014,600          7,582,300        20,596,000
10,256,200
(91%)
800,000
(69%)
1,958,400
( 0%)
6,206,800
(95%)
416,200
(71%)
959,300
( 0%)
16,463,000
(93%)
1,216,200
(70%)
2,917,700
( 0%)
aNumbers in parentheses represent expenditures incurred as of
 February 28, 1979 as percent of the estimated total costs.

"Includes spare parts at 1% of total costs.

C1he estimates for waste disposal system are based on a
 contract awarded to IUCS to provide LG&E with the waste
 disposal facilities and estimated costs for the erection
 of the system.
                                   27

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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing}
1. REPORT NO. 2.
EPA-600/7-79-221a
4. TITLE AND SUBTITLE Executive Summary for Full-Scale Dual
Alkali Demonstration System at Louisville Gas and
Electric Co. — Final Design and System Cost
7.AUTHOR1S) R>p< Van NegS) R>c> Somers> R-C< weeks, *T.
Frank, *G.J. Ramans, **C.R. La Mantia, **R.R. Lunt,
j,r,rl **.T.A. V^llPnMa
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Louisville Gas and Electric Company
311 W. Chestnut St.
Louisville, KY 40201
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
3. RECIPIENT'S ACCESSION- NO.
6. REPORT DATE
September 1979
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
EHE 624 A
11. CONTRACT/GRANT NO.
68-02-2189
13. TYPE OF REPORT AND PERIOD COVERED
Exec. Summary; 9/76 - 3/79
14. SPONSORING AGENCY CODE
EPA/600/13
15. SUPPLEMENTARY NOTES iERL_RTP project officer is Norman Kaplan, MD-61, 919/541-2556
(*) CEA. (**) A.D. Little, Inc. EPA-600/7-78-010 and -OlOa are related reports.
6. ABSTRACT
         The report describes phase 2 of a 4-phase demonstration program  involving
the dual alkali process for controlling S02 emmissions  from Unit 6, a  coal-fired
boiler at Louisville Gas and Electric Co.'s Cane Run Station.  The process was
developed by Combustion Equipment Associates, Inc., and Arthur D. Little, Inc.  The
program consists of four phases:  (1) preliminary design and cost estimation;  (2)
engineering design, construction, and mechanical testing;  (3) startup  and performance
testing; and (4) 1-year operation and test programs.  The  report describes final
engineering design, construction and mechanical testing, and installed system capital
cost.  Construction of the system was completed in February 1979 and system startup
was initiated in March 1979.  Total capital investment  for the entire  plant,
including waste disposal, is estimated to be  $20.4 million (construction  of the
waste disposal facilities is not complete).

1? KEY WORDS AND DOCUMENT ANALYSIS
, DESCRIPTORS
Pollution Design
Scrubbers Construction
Alkalies Testing
Sulfur Dioxide Capitalized Costs
Coal
Combustion
Desulfurization
Rn1 1 01"a 	 	 	
187 DISTRIBUTION STATEMENT
Release to Public
b.lDENTIFIERS/OPEN ENDED TERMS
Pollution Control
Stationary Sources
Dual Alkali Process
19. SECURITY CLASS (This Report f
Unclassified
20. SECURITY CLASS (Thbpege)
Unclassified
. COSATI Field/Group
13B MB
07A 13M
07D
07B !*A
21D
21B .
13A
21. NO. OF PAGES
37
22. PRICE
gpA Form 2220-1 (t-73)
                                           29

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