&EPA
United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 2771 1
EPA-600/ 7-80-029a
January 1980
EPA Utility FGD Survey:
October - December 1979
Interagency
Energy/Environment
R&D Program Report
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of, and development of, control technologies for energy
systems; and integrated assessments of a wide range of energy-related environ-
mental issues.
EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
-------
EPA-600/7-80-029a
January 1980
EPA Utility FGD Survey:
October - December 1979
by
M. Smith, M. Melia,
and N. Gregory
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-01-4147
Task No. 113
Program Element No. EHE624
EPA Project Officers:
N. Kaplan
Industrial Environmental Research Laboratory
Office of Environmental Engineering and Technology
Research Triangle Park, NC 27711
J.C. Herlihy
Division of Stationary Source Enforcement
Office of Enforcement
Washington, DC 20460
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
-------
NOTICE
This report, (prepared by PEDCo Environmental, Inc., Cincin-
nati, Ohio, under EPA Contract No. 68-01-4147, Task No. 113) is
provided as an information transfer document. Data in this
report are supplied voluntarily by utility representives; flue
gas desulfurization (FGD) system designers, and suppliers; regu-
latory 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 (generally, one copy per
company) is limited to organizations and individuals indicating
a specific interest in the field of FGD technology. Additional
copies of this report and succeeding issues can be purchased
from National Technical Information Service, Springfield, Vir-
ginia 22151.
11
-------
USE OF THIS REPORT
This report is the first in a series of four issues. The
succeeding three issues will be supplemental in nature; there-
fore, it is suggested that the user retain this issue for refer-
ence throughout the year. Much of the design and performance
data contained in this issue will not be published again until
February 1981. Supplemental issues are cumulative in nature, so
that it is necessary only to retain the latest issue and this
report to have all the available information.
It should be noted that along with the design and perform-
ance data for operational FGD systems contained in Section 3,
this report also contains a number of tables presenting tabu-
lations of some of the key data. The Executive Summary contains
the number and capacity of FGD systems as of the end of
December, 1979, future projections (January 1990) of controlled
and uncontrolled generating capacity, and unit by unit summaries
of status changes and performance during the period.
Recent additions to this report include a section con-
taining design and performance data for U.S. operational
particle scrubbers (Section 14) and a section containing design
and performance data for some coal fired operational foreign FGD
systems (Section 15). The regulatory classifications were
recently modified to accomodate the revised New Source Perfor-
mance Standards (6/79) and, as a result, the categories will
differ slightly from those of previous issues.
Appended to this report is a section containing reported
and adjusted cost data for U.S. FGD systems in which operational
systems are stressed (Appendix A). Also included in the appen-
dices are FGD process flow diagrams, definitions, and a glossary
of units.
111
-------
ABSTRACT
This report, is "the first full compilation (not a supple-
ment) since the December 1978 - January 1979 report. Because
the next three reports are to be supplements, this issue should
be retained for reference throughout the year. This report
differs from the previous series in that a new section includes
design and performance data for some foreign operational FGD
systems and the regulatory classifications have been revised to
accomodate the revised New Source Performance Standards (6/79).
The report surveys operational, under construction, and planned
utility FGD systems and operational particle scrubbers in the
U.S., and some foreign operational FGD systems. It summarizes
information contributed by the utility industry, system sup-
pliers, regulatory agencies and consulting engineering firms.
It presents data on system design, fuel characteristics, opera-
ting history and actual performance. Unit by unit dependability
parameters are included and problems and solutions associated
with the boilers, scrubbers, and FGD systems are discussed. The
domestic FGD systems are tabulated alphabetically by development
status (operational, under construction, or in the planning
stages), utility company, system supplier, process, waste dis-
posal practice, and regulatory class. Process flow diagrams and
FGD system economic data are appended to the report. Current
data for operational domestic FGD systems show 62 systems in
operation, 39 systems under construction, and 75 planned sys-
tems. Projected 1990 FGD controlled capacity in the U.S. is
84,511 MW.
IV
-------
CONTENTS
Notice
Use of This Report
Abstract
Tables
Executive Summary and Highlights
Section 1
Section 2
Section 3
Summary List of FGD Systems 1
Status of FGD Systems 7
Design and Performance Data for Operational 37
FGD Systems
Alabama Electric
Tombigbee 2 37
Tombigbee 3 41
Allegheny Power System
Pleasants 1 44
Arizona Electric Power
Apache 2 46
Apache 3 49
Arizona Public Service
Cholla 1 51
Cholla 2 63
Big Rivers Electric
Green 1 66
Central Illinois Light
Duck Creek 1 68
Central Illinois Public Service
Newton 1 77
Colorado Ute Electric Assn
Craig 2 79
Columbus & Southern Ohio Electric
Conesville 5 81
Conesville 6 89
Cooperative Power Association
Coal Creek 1 94
Duguesne Light
Elrama 1-4 97
Phillips 1-6 106
Indianapolis Power & Light
Petersburg 3 H9
-------
CONTENTS (continued)
Page
Kansas City Power & Light
Hawthorn 3 124
Hawthorn 4 132
LaCygne 1 140
Kansas Power & Light
Jeffrey 1 155
Lawrence 4 158
Lawrence 5 166
Kentucky Utilities
Green River 1-3 173
Louisville Gas & Electric
Cane Run 4 180
Cane Run 5 185
Cane Run 6 186
Mill Creek 3 192
Paddy's Run 6 195
Minnkota Power Cooperative
Milton R. Young 2 204
Montana Power
Colstrip 1 210
Colstrip 2 215
Nevada Power
Reid Gardner 1 220
Reid Gardner 2 230
Reid Gardner 3 241
Northern Indiana Public Service
Dean H. Mitchell 11 250
Northern States Power
Sherburne 1 258
Sherburne 2 271
Pacific Power & Light
Jim Bridger 4 281
Pennsylvania Power
Bruce Mansfield 1 283
Bruce Mansfield 2 295
Philadelphia Electric
Eddystone 1A
Public Service Company of New Mexico
San Juan 1 309
San Juan 2 313
San Juan 3 316
Salt River Project
Coronado 1 318
South Carolina Public Service Authority
Winyah 2 320
South Mississippi Electric
R.D. Morrow 1 324
R.D. Morrow 2 327
vi
-------
CONTENTS (continued)
Section 4
Section 5
Section 6
Section 7
Section 8
Section 9
Section 10
Section 11
Section 12
Section 13
Page
Sourthern Illinois Power Coop
Marion 4 329
Sourthern Indiana Gas & Electric
A.B. Brown 1 332
Springfield City Utilities
Southwest 1 335
St. Joe Zinc
G.F. Weaton 1 343
Tennessee Valley Authority
Shawnee 10A 346
Shawnee 10B 348
Widows Creek 8 361
Texas Utilities
Martin Lake 1 369
Martin Lake 2 374
Martin Lake 3 378
Monticello 3 381
Utah Power & Light
Hunter 1 385
Huntington 1 387
Summary of FGD Systems by Company 391^
Summary of FGD Systems by System Supplier 393
Summary of FGD Systems by Process 395
Summary of Operating FGD Systems by Process 396
and Unit
Summary of End-Product Disposal Practices 398
for Operational FGD Systems
Summary of FGD Systems in Operation 400
Summary of FGD Systems Under Construction 403
Summary of Contract Awarded FGD Systems 405
Summary of Planned FGD Systems 406
Total FGD Units and Capacity (MW) Installed 409
by Year
vn
-------
CONTENTS (continued)
Section 14
Section 15
Appendix A
Page
Design and Performance Data for Operational 410
Particle Scrubbers
Commonwealth Edison
Will County 1 410
Detroit Edison
St. Clair 6 422
Minnesota Power and Light
Aurora 1 428
Aurora 2 430
Clay Boswell 3 432
Montana-Dakota Utilities
Lewis & Clark 1 434
Pacific Power and Light
Dave Johnston 4 436
Potamac Electric Power
Dickerson 1 438
Dickerson 2 439
Dickerson 3 440
Public Service of Colorado
Arapahoe 4 445
Cherokee 1 447
Cherokee 4 449
Valmont 5 451
Southwestern Public Service
Harrington 1 456
Design and Performance Data for Operational 458
Japanese FGD Systems
Chugoku Electric
Shimonoseki 1 458
Electric Power Development Company
Isogo 1 459
Isogo 2 462
Matsushima 1 465
Matsushima 2 467
Takasago 1 469
Takasago 2 473
Takehara 1 476
FGD System Cost Data: Operational and A-l
Nonoperational Systems
Vlll
-------
CONTENTS (continued)
A-l Major FGD System Equipment Summary
A-2 Cost Element Factors
A-3 Description of Cost
A-4 Categorical Results of Reported and
Adjusted Capital and Annual Costs for
Operational FGD Systems
A-5 Costs for Operational FGD Systems A-20
A-6 Costs for Nonoperational FGD Systems A-25
Appendix B FGD Process Flow Diagrams B-l
Appendix C Definitions C-l
Appendix D Glossary of Units D-l
IX
-------
TABLES
No. Page
I Number and Total Capacity of FGD Systems xi
II Summary of Changes, October - December 1979 xiii
III Performance of Operational Units, October - xv
December 1979
-------
EXECUTIVE SUMMARY
This report is prepared quarterly (every three months) by PEDCo
Environmental, Inc., under contract to the Industrial Environ-
mental Research Laboratory/Research Triangle Park and the Divi-
sion of Stationary Source Enforcement of the U.S. Environmental
Protection Agency. It is generated by a computerized data base
system, the structure of which is illustrated in Figure 1.
Table 1 summarizes the status of FGD systems in the United
States at the end of December 1979. Table II lists the units
that have changed status during the fourth quarter 1979, and
Table III shows the performance of operating units during this
period.
TABLE 1. NUMBER AND TOTAL CAPACITY OF FGD SYSTEMS
Status
Operational
Under construction
Planned:
Contract awarded
Letter of intent
Request! ng/eval ua-
ting bids
Considering only
FGD systems
TOTAL
No. of
units
62
39
23
2
15
35
176
Total
Control led
Capacity, MW*
23,297
17,270
11,949
842
11,131
20,022
84,511
Equivalent
Scrubbed
Capacity, MWt
21,510
16,051
11,651
842
10,281
19,902
80,237
Total Controlled Capacity (TCC) is the summation of the gross unit
capacities (MW) brought into compliance with FGD systems regardless
of the percent of the flue gas scrubbed by the FGD system(s).
t Equivalent Scrubbed Capacity (ESC) is the summation of the
effective scrubbed flue gas in equivalent MW based on the percent of
flue gas scrubbed by the FGD system(s).
XI
-------
X
H-
H-
1
»BSORBt»S
(900)
BOILED-
STACK
(100)
FUEL DATA
(300)
Fro
(300)
1
PILOT
PLANT
(400)
ECONOMICS
[IATA
(VXM
PARTICULATE
CONTROL
(2700)
1
FABRIC
FILTER
(2800)
LITERAL
(3200)
1 1
ESP
(?900)
I
SPWI
CAPACITY
INOEI
(600)
SPAtE
COMPONENT
IHCX1
(NKII
OE51C.N
INFORMATION
(SOOI
1
UNT11FUC4
110001
1
FANS
11000)
VACUUM
FILTER
n,>no)
1
"1ST
ELI" NATO*
linn)
PROCESS
CHEMISTRY
CONTROL
11400)
HECHAN1CAL
COLLECTOR
(3000)
PARTICIPATE
SCRUBBER
(3100)
1 1 1
PUMPS
(1500)
TANKS
(1600)
REHEATER
(1700)
THICKENER
(1800)
1IKOVAI
PtBFORHftUCE
DATA
(33001
SWIM
DEPENOAEIL IT*
PERFORMANCE
(3400)
1
S'STEM
MODULE
PERFORMANCE
13440)
PROBLEMS
SOLUTIONS
COMMENTS
(3460)
1
SOLUTION
DESCRIPTION
(3470)
PROBLEM
MODULE
(3480)
1 1 1
DUCTWORK
(1TOO)
HATER LOOP
(2000)
BEAOtIT
PREPARAT10H
EOU1PMENT
(2100)
END PRODUCT
(2200)
1
BV. PRO DUCT
(2300)
SLUDGE
(2400)
1
TREATMENT
(2Sin)
DISPOSAL
(2600)
Figure 1. Computerized data base structure diagram.
-------
TABLE II. SUMMARY OF CHANGES
FOURTH QUARTER 1979
x
H-
H-
H-
FGO tt»tu» report
9/30/79
Basin Electric Power Coop
Antelope Valley 1
Antelope Valley 2
Big divert Electric
0. B. WiUon 1
D. B. Hilton 2
Green 1
Colorado UTE Electric Assn.
Craig 2
Craig 3
Oelnarva Power & Light
Vienna Maryland 9
East Kentucky Power Coop
J. K. Sailth 1
J. K. Sailth 2
General Public Utilities
Gilbert 9
Scotsvllle 1
Wehrua 1
Indianapolis Power &
Light
Patriot 1
Patriot 2
Patriot 3
Lakeland Utilities
Hclntosh 3
Northern Indiana Public
Service
Ballly 7
Ballly 6
Schahfer 17
Schahfer 18
Operational
No.
56
+1
+1
MW*
19.397*
242
447
Under
construction
No.
42
+1
-1
-1
+1
VH*
17,250
440
242
447
364
Contract
awarded
No.
19
-1
-1
MM*
9,415
440
364
Letter
of Intent
No.
0
+1
+1
HW*
421
421
Requesting/
eval. bids
No.
18
»1
-1
-1
MW*
12,163
440
421
421
Considering
FGD
No.
26
-1
+1
»1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
-1
-1
HW*
13.930
440
440
440
447
550
650
650
625
625
625
650
650
650
190
400
Total
No.
161
+1
»1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
-1
-1
<*f
72.175
440
440
447
550
650
650
625
625
625
650
650
650
190
400
(continued)
-------
TABLE II (continued)
x
H-
FGO status report
Northern States Power
Riverside 6,7
Pacific Power & Light
Ji«t BHdger 4
Public Service of New
Mexico
San Juan 3
Salt River Project
Coronado 1
St. Joe Zinc
C. f. Ueaton
Texas Power ft Light
Twin Oaks 1
Twin Oaks 2
Tucson Gas 1 Electric
Sprlngervllle 1
Sprlngervtlle 2
Utah Power I Light
Hunter 3
Hunter 4
TOTAL
Operational
No.
+1
+1
+1
+1
62
Kir
550
534
280
60
21.510
Under
construction
No.
+1
-1
-1
-1
-1
39
NW*
110
550
534
280
60
16,051
Contract
•warded
No.
+1
+1
+1
»1
+1
*1
23
HW*
750
750
370
370
400
400
11,651
Letter
of Intent
No.
2
HW*
842
Requesting/
eval. bids
No.
-1
-1
15
HW*
750
750
10,281
Considering
FGO
No.
35
Hw*
19,902
Total
No.
+1
»1
+1
+1
»1
176
HW*
110
370
370
400
400
80,237
* Equivalent scrubbed capacity.
* This value was modified slightly due to a HW correction.
-------
TABLE III. PERFORMANCE OF OPERATIONAL UNITS
FOURTH QUARTER 1979
Plant
TMb1gb«« 2
Toafclgbee 3
•Uasants 1
Apache 2
Apach* 3
Cholla 1
Cholli 2
Grt«n 1
Duck CrMk 1
Newton 1
Craig 2
CoiMtvfll* 5
Conesvllle 6
Coal CrMk 1
ElrtM 1-4
Mil 11 1p* 1-6
Petersburg 3
Hawthorn 3
Hawthorn 4
La Cygrw 1
Jeffrey 1
Lawrence 4
Lawrence S
Green R1v«r 1-3
Can* Run 4
Can* Run 5
Cane Run 6
Hill Creek 3
Pattty't Run 6
FGO tysteo
capacity,
179
179
S19
19S
195
119
350
242
378
617
447
411
411
327
510
410
532
90
90
874
540
125
420
64
188
200
288
442
72
Flu* gat
X scrubbed
70
70
83
100
100
100
100
100
90
100
100
100
100
60
100
100
100
100
100
100
75
100
100
100
100
100
100
100
100
FGO capacity
on line
during
"XJW'
179
179
519
195
195
119
242
378
617
447
411
411
327
510
410
532
874
188
200
288
442
No Information
for this
period, HIT
350
90
90
540
125
420
Shut d(M
through-
out
period.
64
72
n
October 1979 ,
Dependability Jf6'*
AVI
0
99
90
50
59
85
69
94
100
OPR
0
95
96
84
77
45
82
79
30
84
81
82
REL
99
91
78
45
UTL
0
95
44
84
46
43
80
69
0
12
66
29
76
Novenber 1979
Dependability IT'
AVL
100
96
100
89
32
72
59
80
61
0
100
OPR
0
91
100
90
38
89
54
86
88
94
95
96
0
REL
100
90
41
90
54
UTL
0
91
6
90
31
51
45
80
61
0
58
46
64
0
December 1979r .
Dependability % '*
AVl
96
100
100
99
39
0
87
0
100
OPR
23
95
0
100
53
0
82
39
82
95
0
REL
0
100
58
0
82
UTL
4
83
0
100
39
0
82
0
20
63
90
0
(continued)
-------
TABLE III (continued)
Plant
Milton R. Young 2
Col (trip 1
Colstrlp 2
told Gardner 1
told Gardner 2
told Gardner 3
Dean H. Mitchell 11
Sherburne 1
Sherburne 2
J1a> Brldger 4
Bruce Mansfield 1
Brace Minefield 2
Eddyston* 1A
San Juan 1
San Juan 2
San Juan 3
Ceronado 1
Wlnyah 2
*.0. Morrow 1
R.O. Morrow 2
Marlon 4
A.B. Brown 1
Southwest 1
G. F. Htaton 1
Shawn** 10A
Shawnee 108
Widows Creek 8
Martin Laka 1
Martin Laka 2
FGD system
capacity.
405
360
360
125
125
125
115
740
740
550
917
917
120
361
350
534
280
140
124
124
184
265
194
60
10
10
550
595
595
Flue gas
X scrubbed
92
100
100
100
100
100
100
100
100
100
100
100
N/Ad
100
100
100
80
50
62
62
100
100
100
N/Ad
M/Ad
N/Ad
100
75
75
FGO capacity
on line
during
405
360
360
125
125
125
115
740
740
550
917
917
361
350
534
280
265
194
60
10
10
550
595
595
No Information
for this
period, MtT
120
140
164
Shut dow
through-
out
period.
124
124
i
October 1979
Dependability V'
AVL
31
92
92
45
38
97
81
77
94
96
97
0
0
100
87
OPR
31
62
100
97
0
0
98
91
REL
31
62
100
97
72
0
0
98
UTL
31
45
39
97
71
0
0
85
64
November 1979
Dependability X '
AVl
16
97
98
99
43
81
0
97
97
90
100
0
0
97
20
91
OPR
17
97
96
95
0
0
96
21
93
REL
17
99
97
100
0
0
0
97
21
UTL
16
88
43
77
0
0
0
88
20
68
December 1979
Dependability f'
AVL
36
98
97
39
95
97
99
96
56
50
UK)'
0
0
81
59
95
OPR
43
99
98
72
38
38
0
0
81
32
80
REL
43
99
98
75
0
0
81
32
UTL
36
99
98
40
11
32
6f
0
0
81
29
65
X
H-
(continued)
-------
TABLE III (continued)
Plant
Martin Lake 3
Monttctllo 3
Hunter 1
Hunt Ing ton 1
TOTAL
FGD system
capacity,
S95
800
360
366
Flue gas
X scrubbed
75
100
90
85
FGD capacity
on line
during
P#?g-
595
800
360
366
19.067
No Information
for this
period, MWa
2.059
Shut dent
through-
out
period.
384
n
October 1979
Dependability X '
AVL
OPR
REL
UTL
November 1979
Dependability X '
AVL
OPR
REL
UTL
December 1979
Dependability Xc>e
AVL
OPR
REL
UTL
X
<
H-
p-
" Equivalent scrubbed capacity.
This category includes the flue gas capacity being handled by the FGD system at least part of the tie* during the report period.
. The percent figures lifted are average values for all system scrubbing trains during the period.
Flue gas X scrubbed for prototype and demonstration units Is not applicable unless the system is designed to bring a unit Into compliance
with SO, emliflon standard.
* Availability, operablllty. reliability, and utilization as defined In Appendix C of this report.
The figures represent only one module presently In operation.
-------
As indicated in Table 1, 62 power generating units (all coal-
fired) are now equipped with operating FGD systems. These units
represent a total controlled capacity of 23,297 MW. Current
projections indicate that the total power generating capacity of
the U.S. electric utility industry will be approximately 931 GW
by 1990. (This value reflects the annual loss resulting from
the retirement of older units, which is considered to be 0.4
percent of the average generating capacity at the end of each
year. ) Approximately 382 GW or 41 percent of the 1990 total
will come from coal-fired units. The distribution of power
generation sources, both present (April 1979) and future
(January 1990) is as follows:
Coal Nuclear Oil Hydro Gas Other GW (total)
April 1979 39% 9% 26% 12% 13% 1% 588
January 1990 41% 22% 18% 10% 8% 1% 931
Based on the known commitments to FGD by utilities as presented
in Table 1, the percentage of electrical generating capacity
controlled by FGD for both the present (December 1979) and the
future (Janaury 1990) is as follows:
% of coal-fired % of total
generating capacity generating capacity
December 1979a 10.2 4.0
January 1990 22.1 9.1
In light of the revised New Source Performance Standards, actual
FGD control is expected to be greater than what is reflected by
the figures above. For example, about 55 to 60 systems repre-
senting approximately 36,000 to 41,000 MW of generating capacity
presently fall into the uncommitted category. These are systems
that cannot be included in the committed group at this time
because information regarding their status is not ready for
public release.
HIGHLIGHTS: FOURTH QUARTER 1979
The following paragraphs highlight FGD system developments
during the fourth quarter, 1979.
Tombigbee 3 of Alabama Electric Cooperative achieved availabili-
ties of 99%, 96%, and 100% for October, November and December.
Tombigbee 2 was largely available throughout the quarter,
however, boiler-related problems limited scrubbing operations.
The number of committed FGD systems is as of December 1979;
however, the figure used for the total generating capacity
and coal fired generating capacity is based on April 1979
figures.
xvi 11
-------
Apache 3 of Arizona Electric Power Cooperative achieved availa-
bilities of 89% and 99% for November and December respectively
and no problems were reported. Actual performance data was not
available for the month of October. The Apache 2 FGD system was
available most of October, November and December, however, the
boiler was shutdown for annual inspection after only 40.5 hours
of operation in November.
Arizona Public Service reported that the Cholla 1 FGD, system
demonstrated an average operability and reliabilty of 96% and
99%, respectively, during October, however, the system was not
required for part of the month because of boiler-related prob-
lems. Figures were not available for November and December.
The lime/spray drying FGD system at Antelope Valley 1 of Basin
Electric Power Cooperative is now under construction. The FGD
system will consist of 5 Niro Atomizer spray dryers followed by
two Western Precipitation baghouses. The system is designed to
accomodate flue gas from the 440 MW unit with a 4% bypass for
reheat. Basin Electric Power Coop is currently requesting/
evaluating bids for the Antelope Valley 2 FGD system. Startup
dates for Units 1 and 2 are scheduled for November 1981 and 1983
respectively.
FGD operations began at Green 1 of Big Rivers Electric in
Sebree, Kentucky during the fourth quarter. Particulate matter
from this 242 MW unit is collected by a cold side ESP upstream
of an American Air Filter lime slurry spray tower FGD system.
The design includes chevron mist eliminators followed by a hot
air injection reheat system. Sludge is stabilized by a POZ-O-
TEC treatment system at this closed loop facility. The FGD
system is currently undergoing shakedown/debugging operations.
Although a specific process has not been decided, Big Rivers
Electric announced plans for the installation of lime or lime-
stone slurry, or dual alkali type FGD systems on the utility's
new 440 MW D.B. Wilson 1 and 2 units for control of SO2- D.B.
Wilson 1 and 2 are scheduled to begin operations in 1984 and
1985 respectively.
Craig 1 of Colorado Ute Electric Association began FGD opera-
tions during the fourth quarter. Flue gas from this 447 MW unit
passes through hot side ESP's and four parallel magnesium pro-
moted limestone slurry spray towers for particulate matter and
SO2 control. The wet gas temperature is boosted with an in-line
steam coil reheater before entering the acid brick-lined 600 ft
stack. Sludge is stabilized before disposal on this closed loop
system. FGD system operations have not yet stabilized as shake-
down/debugging operations continue.
xix
-------
During the report period Colorado Ute announced plans for an
additional 447 MW (gross) unit at Craig Station. Particulate
matter will be controlled with a baghouse downstream of a lime
spray dryer FGD system. Craig 3 is scheduled to begin opera-
tions sometime in 1982.
Delmarva Power and Light announced plans for a new coal-fired
500 MW (net) unit at DP&L's Vienna Maryland station. SO2 emis-
sions from Vienna Maryland 9 will be controlled with a limestone
slurry FGD system. The unit is currently scheduled to begin
operations in June 1987.
East Kentucky Power Cooperative announced plans for the instal-
lation of FGD systems on two new coal-fired 650 MW units, J.K.
Smith 1 and 2. No process has been selected for SO2 control.
J.K. Smith 1 and 2 are currently scheduled for operation in
January 1985 and 1986 respectively.
General Public Utilities announced plans for three new coal-
fired 625 MW units; Scottsville 1, Wehrum 1 and Gilbert 9 to be
built in Pennsylvania (Scottsville and Wehrum) and New Jersey
(Gilbert). Because the units are not scheduled to begin opera-
tions until 1991, 1995 and 1990 respectively, specific plans for
particulate matter and SO2 control equipment have not yet been
made.
Indianapolis Power and Light will be building three new 650 MW
coal-fired units at the utility's Patriot station site in
Patriot, Indiana. These units will burn coal having a 3.5%
(maximum) sulfur content. IP&L intends to control SO2 emissions
with double loop type lime or limestone wet scrubbing systems.
Initial startup for the first unit (Patriot 1) is tentatively
scheduled for 1987.
At La Cygne 1 of Kansas City Power and Light, an average system
availability of 94% was reported for October. The unit was
shutdown on October 19 through December for a unit overhaul.
Lakeland Utilities reported that construction of the Mclntosh 3
FGD system began during the fourth quarter. Particulate matter
and SO2 emissions from this 364 MW unit will be controlled by a
cold side ESP and a Babcock and Wilcox limestone slurry FGD
system. The closed loop system design includes an acid brick-
lined 250 ft stack and a POZ-O-TEC sludge stabilization facil-
ity. The unit startup is scheduled for October 1981.
The Dual alkali system on Cane Run 6 of Louisville Gas and
Electric achieved operabilities of 81%, 98% and 95% during
October, November and December, respectively. The utility
reported that only normal maintenance was required during the
fourth quarter of 1979.
xx
-------
Montana Power reported that Colstrip 1 achieved average FGD
availabilities of 92% and 97% for October and November, respec-
tively. Reported availabilities for Colstrip 2 were 92% and 98%
for the same period. Performance data for the month of December
was not available for either unit.
A letter of intent was signed with FMC for the installation of a
dual alkali FGD system on Schahfer 17 and 18 of Northern Indiana
Public Service Company. Schahfer 17 and 18 are 421 MW (gross)
coal-fired units which will be built at the Shahfer station in
Wheatfield, Indiana. Operations are scheduled to begin in June
1983 and 1985 for Units 17 and 18, respectively.
The Northern Indiana Public Service Company reported during the
fourth quarter that plans for FGD systems on Bailly 7 and 8 in
Chesterton, Indiana, have been dropped.
A demonstration lime/spray drying FGD system is scheduled to
begin operations in July 1980 at Northern States Power's River-
side station in Minneapolis, Minnesota. NSP reported that the
110 MW system is designed to accomodate flue gas from the exis-
ting 55 MW Riverside boilers 6 and 7. The retrofit FGD system
is currently under construction and will include a lime spray
dryer upstream of a baghouse for control of S02 and particulate
matter.
At Sherburne 1 of Northern States Power, the FGD system had
availabilities of 77%, 97% and 95% for October, November and
December, respectively. The low October availability was due to
an annual boiler/turbine outage during which time some scrubber
related work was performed. The Sherburne 2 FGD system availa-
bilities were 94%, 97%, and 97% for October, November, and
December, respectively. No boiler or FGD system problems were
encountered at Unit 2 during the fourth quarter.
Jim Bridger 4 of Pacific Power and Light began FGD operations
during the fourth quarter. SO2 is controlled with an Air Correc-
tion Div., UOP sodium carbonate FGD system preceded by a cold
side ESP for particulate matter collection. The closed loop
system design includes three sieve tray absorbers to accomodate
flue gas from this 550 MW unit. Comments about early operations
were not reported for this period.
Bruce Mansfield 1 of Pennsylvania Power achieved FGD system
availabilities of 96%, 90%, and 99% for October, November, and
December, respectively. The Bruce Mansfield 2 FGD system had
reported availabilities of 97%, 100%, and 96% for the period.
No major problems were reported other than the requirement of
frequent sludge pump overhauls.
xxi
-------
The first of four Wellman Lord absorber modules at San Juan 3 of
the Public Service Company of New Mexico began operations in
December. The balance of the FGD system will not be complete
until 1982. The material collected by the Unit 3 FGD module is
currently handled by the San Juan 1 and 2 chemical plant.
Boiler operations during the period were irregular, however, no
scrubber-related problems were reported.
Salt River Project reported that operations began at Coronado 1
in St. Johns, Arizona. Two limestone slurry Weir horizontal
spray towers remove SO2 from the flue gas downstream of two
ESP's. 20% of the flue gas generated by this 350 MW unit bypass
the scrubbing system remixing with the scrubbed gas for reheat
before entering the 500 ft stack. Sludge is disposed in an
unlined pond at this open loop facility. The utility reported
that Coronado 1 had passed compliance testing during the period.
A.B. Brown 1 of Southern Indiana Gas and Electric Company
achieved total system availabilities of 100%, 97%, and 81% for
October, November, and December, respectively. Thickener rake
problems contributed to the low availability during December.
The U.S. EPA/U.S. Bureau of Mines (USBM)- sponsored demonstra-
tion citrate FGD system installed on the 60 MW coal-fired boiler
at the G. F. Weaton Station of the St. Joe Zinc Company in
Monaco, Pennsylvania began operations in November. The citrate
process, which has been developed through two separate pilot
plant programs conducted by USBM and Pfizer Chemical Company,
recovers the scrubbed SO2 as elemental sulfur. Although the
installation site is an industrial facility, this system is
included in the utility FGD survey report because the G. F.
Weaton Station is interconnected via a 25 MW interchange to the
Duquesne Light Company (in addition to supplying the steam and
electric load for smelting operations at the plant). The FGD
system was originally designed to accomodate the entire 60 MW
boiler; however, the St. Joe Zinc smelter has been shut down
and, as a result, the FGD system has operated at 20-30 MW.
During the fourth quarter electric motor failures occurred in
the scrubber liquor recycle loop and piping leaks were encoun-
tered. Initial data indicates that the system SO2 removal
efficiency has been approximately 80-90%.
Tennessee Valley Authority reported October, November, and
December availabilities of 88%, 91% and 95%, respectively, for
Widows Creek 8. TVA reported limestone conveyor problems contri-
buted to the lower system availability in October. Forced
oxidation testing is continuing.
During the fourth quarter a contract was awarded to Chemico for
the installation of FGD systems on the two new 750 MW Twin Oaks
units (1 and 2) of Texas Power and Light. SO2 generated by the
xxn
-------
lignite-fired boilers will be controlled with limestone slurry
FGD systems. The units are scheduled to begin operations in
August 1984 and 1985 respectively.
Tucson Gas and Electric will be building two new 350 MW
(nominal) coal-fired units, Springerville 1 and 2, in Springer-
ville, Colorado. The boilers will fire pulverized subbituminous
coal having a heating value of 8500 to 8900 Btu/lb and a sulfur
content of 0.53 to 0.69%. The contract for the emissions con-
trol systems was awarded to Joy Manufacturing/Niro Atomizer.
The FGD system design includes a lime spray dryer followed by a
baghouse on each unit with accomodations made for the possible
installation of reheaters. The FGD systems will operate in a
closed loop. The cleaned flue gas will exit via a 500 ft con-
crete stack at each unit. Operations are scheduled to begin in
1985 and 1987 for Units 1 and 2 respectively.
Utah Power and Light reported that a contract was awarded to
Chemico for the installation of FGD systems on the two new 400
MW units planned for Hunter Station. Like Hunter 1 and 2, SO2
emissions from Hunter 3 and 4 will be controlled with lime
slurry spray towers (designed to achieve 90% SO2 removal),
however, unlike Units 1 and 2, particulate matter will be col-
lected up stream of the FGD systems with baghouses. Hunter 3
and 4 should begin operations in 1983 and 1985 respectively.
REFERENCES
a. U.S. Department of Energy. Energy Information Administra-
tion. Office of Energy Data Interpretation. Division of
Coal Power Statistics. Inventory of Power Plants in the
United States, April 1979. Pub. No. DOE/EIA-0095.
b. Rittenhouse, R.C. New Generating Capacity: When, Where
and By Whom. Power Engineering 82(4):57. April 1978.
XXlll
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 1
SUMMARY LIST OF FGD SYSTEMS
COMPANY NAME/
UNIT NAME
ALABAMA ELECTRIC COOP
TOMBIGBEE
TOHBIG6EE
ALLEGHENY POWER SYSTEM
MITCHELL
PLEASANTS
PLEASANTS
ARIZONA ELECTRIC POWER COOP
APACHE
APACHE
ARIZONA PUBLIC SERVICE
CNOLLA
CHOLLA
CHOLLA
FOUR CORNERS
FOUR CORNERS
FOUR CORNERS
FOUR CORNERS
FOUR CORNERS
ASSOCIATED ELECTRIC COOP
THOMAS HILL
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY
ANTELOPE VALLEr
LARAMIE RIVER
LARAHIE RIVER
LARAMIE RIVER
BIG RIVERS ELECTRI C
D. B. WILSON
D. B. WILSON
GREEN
GREEN
CENTRAL ILLINOIS LIGHT
DUCK CREEK
DUCK CREEK
UNIT NO.
2
3
33
1
2
2
J
t
2
4
1
2
3
4
5
3
1
2
1
2
3
1
2
1
2
1
2
UNIT LOCATION
LEROY
LEROY
COURTNEY
BELMONT
BELMONT
COCHISE
COCHISE
JOSEPH CITY
JOSEPH CITY
JOSEPH CIT»
FARMINGTON
f ARMINGTON
FARMINGTON
FARMINGTON
FARMINGTON
MOBERLV
BEULAH
BEULAH
WHEATLAND
WHEATLAND
WHEATLAND
SEBREE
SEBREE
CANTON
CANTON
ALABAMA
ALABAMA
PENNSYLVANIA
WEST VIRGINIA
WEST VIRGINIA
ARIZONA
ARIZONA
ARIZONA
ARIZONA
ARIZONA
NEW MEXICO
NEW MEXICO
NEW MEXICO
NEW MEXICO
NEW MEXICO
MISSOURI
NORTH DAKOTA
NORTH DAKOTA
WYOMING
WYOMING
WYOMING
KENTUCKY
KENTUCKY
ILLINOIS
ILLINOIS
START-UP
DATE
9/78
6/79
8/82
3/79
9/80
8/78
6/79
10/73
4/78
6/80
11/79
11/79
11/79
0/82
0/82
1/82
11/81
11/83
4/80
10/80
7/81
0/84
0/85
12/79
11/80
9/76
1/86
STATUS
1
1
3
1
2
1
1
1
1
2
2
2
2
3
3
2
2
5
2
2
3
6
6
1
2
1
5
REG
CLASS
B
B
C
B
B
D
D
A
C
B
B
B
A
CENTRAL ILLINOIS PUBLIC SERV
NEWTON
CENTRAL MAINE POWER
SEARS ISLAND
CINCINNATI GAS t ELECTRIC
EAST BEND
COLORADO UTE ELECTRIC ASSN.
CRAIG
CRAIG
CRAIG
NEWTON
ILLINOIS
PENOBSCOT BAY MAINE
COLUMBUS & SOUTHERN OHIO ELEC.
CONESV1LLE 5
CONESVILLE 6
POSTON 5
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
RABBITHASH
CRAIG
CRAIG
CRAIG
CONESVILLE
CONESVILLE
ATHENS
KENTUCKY
COLORADO
COLORADO
COLORADO
OHIO
OHIO
OHIO
9/79
11/87
9/80
4.
5.
6.
7.
4/80
8/79
0/82
1/77
6/78
0/83
2
1
6
1
1
6
D
D
D
D
D
D
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
PLANNED - CONSIDERING ONLY FG» SYSTEMS
PLANNED - CONSIDERING FGD SYSTEMS; ALSO ALTERNATIVE METHODS
A. FEDERAL NSPS(6/79)
B. FEDERAL NSPSC12/71)
C. STANDARD(S) MORE STRINGENT THAN NSPS(6/79>
D. STANDARDS) MORE STRINGENT THAN NSPS<12/71> BUT NOT MORE STRINGENT THAN NSPS(6/79)
E. STANDARD(S) EBUAL TO OR LESS STRINGENT THAN NSPSC12/71)
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 1
SUMMARY LIST OF FGD SYSTEMS
COMPANY
UNIT NAME.
UNIT NO. UNIT LOCATION
START-UP REG
DATE STATUS CLASS
COLUMBUS & SOUTHERN OHIO ELEC .
POSTON 6
COMMONWEALTH EDISON
POyERTON 51
COOPERATIVE POWER ASSOCIATION
COAL CREEK 1
COAL CREEK 2
DELMARVA POWER & LIGHT
DELAWARE CITY 1-3
VIENNA MARYLAND 9
DUQUESNE LIGHT
ELRAHA 1-1
PHILLIPS 1-t
EAST KENTUCKY POWER COOP
J. K. SMITH 1
J. K. SMITH 2
SPURLOCK 2
GENERAL PUBLIC UTILITIES
COHO 1
GILBERT 1
SCOTTSVILLE 1
SEWARD 7
WEHRUM 1
ATHENS
PERKIN
UNDERWOOD
UNDERWOOD
OHIO
ILLINOIS
NORTH DAKOTA
NORTH DAKOTA
DELAWARE CITY DELAWARE
VIENNA MARYLAND
ELRAHA PENNSYLVANIA
SOUTH HEIGHT PENNSYLVANIA
MAYSVILLE
KENTUCKY
0/89
4/80
8/79
10/80
A/80
0/87
10/75
7 /73
1/85
1/86
10/80
ERIE
MILFORD
SCOTTSVILLE
SEWARD
WEHRUM
PENNSYLVANIA
NEW JERSEY
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
12/88
0/90
0/91
12/87
0/95
6
6
6
6
6
HOOSIER ENERGY
MEROM
MEROM
HOUSTON LIGHTING K POWER
W.A. PARISH
CO.
INDIANAPOLIS POWER 8 LIGHT
PATRIOT
PATRIOT
PATRIOT
PETERSBURG
PETERSBURG
KANSAS CITY POWER K LIGHT
HAWTHORN
HAWTHORN
LA CYGhE
KANSAS POKER & LIGHT
JEFFREY
JEFFREY
LAWRENCE
LAWRENCE
KENTUCKY UTILITIES
GREEN RIVER
LAKELAND UTILITIES
MC1NTOSH
1-3
SULLIVAN
SULLIVAN
THOMPSONS
PATRIOT
PATRIOT
PATRIOT
PETERSBURG
PETERSBURG
KANSAS CITY
KANSAS CITY
LA CYGNE
WAHEGO
WAMEGO
LAWRENCE
LAWRENCE
INDIANA
INDIANA
TEXAS
INDIANA
INDIANA
INDIANA
INDIANA
INDIANA
MISSOURI
MISSOURI
KANSAS
KANSAS
KANSAS
KANSAS
KANSAS
CENTRAL CITY KENTUCKY
LAKELAND
FLORIDA
5/82
7/81
11/82
0/87
0/87
0/87
12/77
10/83
11/72
8/72
2/73
8/78
6/80
1/76
11/71
9/75
10/81
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
«. PLANNED - LETTER OF INTENT SIGNED
5. PLANNED - REQUESTING/EVALUATING BIOS
6. PLANNED - CONSIDERING ONLY FGD SYSTEMS
7. PLANNED - CONSIDERING FGD SYSTEMS; ALSO ALTERNATIVE METHODS
A. FEDERAL NSPS«6/79)
B. FEDERAL NSPSC12/71)
C. STANDARDS) MORE STRINGENT THAN NSPS(6/79>
D. STANDARD(S) MORE STRINGENT THAN NSPS<12/71) BUT NOT MORE STRINGENT THAN NSPS(6/79)
E. STANDARD(S) E«UAL TO OR LESS STRINGENT THAN NSPS<12/71>
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 1
SUMMARY LIST OF FGD SYSTEMS
COMPANY NAME/
UNIT NAME
LOUISVILLE GAS & ELECTRIC
CANE RUN
CANE RUN
CANE RUN
MILL CREEK
MILL CREEK
MILL CREEK
MILL CREEK
PADDY'S RUN
TRIMBLE COUNTY
TRIMBLt COUNTY
MIDDLE SOUTH UTILITIES
ARKANSAS COAL
ARKANSAS COAL
LOUISIANA COAL
LOUISIANA COAL
MISSISSIPPI COAL
MISSISSIPPI COAL
UNIT
4
5
6
1
2
3
4
6
1
2
5
6
1
2
1
2
NO. UNIT LOCATION
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
BEDFORD
BEDFORD
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
ARKANSAS
ARKANSAS
LOUISIANA
LOUISIANA
MISSISSIPPI
MISSISSIPPI
START-UP
DATE
8/76
12/77
4/79
4/81
4/82
8/78
7/81
4/73
7/84
7/86
1/86
1/88
0/86
0/88
0/85
0/87
REG
STATUS CLASS
1 D
1 D
1 D
2 E
2 E
1 D
2 B
1 E
6
6
5
5
5
5
5
5
MINNESOTA POWER K LIGHT
CLAY BOSwELL
MINNKOTA POUER COOPERATIVE
HILTON R. YOUNG
MONTANA POWER
COLSTRIP
COLSTR1P
COLSTRIP
COLSTRIP
MUSCATINE POUER K WATER
MUSCATINE
NEVADA POWER
HARRY ALLEN
HARRY ALLEN
HARRY ALLEN
HARRY ALLEN
REID GARDNER
REID GARDNER
REID GARDNER
REID GARDNER
WARNER VALLEY
WARNER VALLEY
NEW YORK STATE ELE C ft
SOMERSET
GAS
NIAGARA MOHAWK POWER COOP
CHARLES R. HUNT LEY 66
NORTHERN INDIANA PUB SERVICE
DEAN H. MITCHELL 11
SCHAHFER 17
SCHAHFER 18
NORTHERN STATES POWER
RIVERSIDE
SHERBURNE
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
6,7
1
4.
5.
6.
7.
COHASSET
CENTER
COLSTRIP
COLSTRIP
COLSTRIP
COLSTRIP
MUSCATINE
N.E. LAS VEGAS
N.E. LAS VEGAS
N.E. LAS VEGAS
N.E. LAS VEGAS
MOAPA
MOAPA
MOAPA
MOAPA
ST. GEORGE
ST. GEORGE
SOMERSET
BUFFALO
GARY
WHEATFIELD
WHEATFIELD
MINNEAPOLIS
BECKER
MINNESOTA
NORTH DAKOTA
MONTANA
MONTANA
MONTANA
MONTANA
IOWA
NEVADA
NEVADA
NEVADA
NEVADA
NEVADA
NEVADA
NEVADA
NEVADA
UTAH
UTAH
NEW YORK
NEW YORK
INDIANA
INDIANA
INDIANA
MINNESOTA
MINNESOTA
2/80
9/77
9/75
5/76
1/84
0/84
9/82
6/86
6/87
6/88
6/89
4/74
4/74
6/76
4/83
6/85
6/86
6/84
4/82
7/76
6/83
6/85
7/80
3/76
6
6
6
6
1
1
1
6
6
6
A
A
A
A
B
B
B
A
A
A
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
PLANNED - CONSIDERING ONLY FGD SYSTEMS
PLANNED - CONSIDERING FGD SYSTEMS; ALSO ALTERNATIVE METHODS
A. FEDERAL NSPS(6/79)
B. FEDERAL NSPS(12/71)
C. STANDARD(S) MtRE STRINGENT THAN NSPSC6/79)
D. STANDARDfS) MORE STRINGENT THAN NSPS<12/71> BUT NOT MORE STRINGENT THAN NSPSC6/79J
E. STANDARD(S) EBUAL TO OR LESS STRINGENT THAN NSPSO2/71)
-------
EP* UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 1
SUMMARY LIST OF FGD SYSTEMS
COMPANY NAME/
UNIT NAME
NORTHERN STATES POWER
SHERBURNE
SHERBURNE
OTTER TAIL POWER
COYOTE
PACIFIC GAS t ELECTRIC
MONTEZUMA
MONTEZUMA
PACIFIC POWER & LIGHT
JIM BRIOGER
PENNSYLVANIA POWEI
BRUCE MANSFIELD
BRUCE MANSFIELD
BRUCE MANSFIELD
PHILADELPHIA ELECTRIC
CROMBY
EDDVSTONE
EDDVSTONE
EDDVSTONE
POTOMAC ELECTRIC POWER
DICKER SON
POWER AUTHORITY OF NEW YORK
ARTHUR KILL
PUBLIC SERVICE OF INDIANA
GIBSON
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
SAN JUAN
SAN JUAN
SAN JUAN
SALT RIVER PROJECT
CORONA DO
CORONADO
CORONADO
SAN MIGUEL ELECTRIC COOP
SAN MIGUEL
SEM1NOLE ELECTRIC
SEMINOLE
SEMINOLE
SIKESTON BOARD Of HUNIC. UTIL.
SIKESTON
SOUTH CAROLINA PUBLIC SERVICE
WINYAH
WINYAH
WINYAH
UNIT
2
3
1
1
2
4
1
2
3
1A
1B
2
4
5
1
2
3
4
1
2
3
1
1
2
1
2
3
4
NO. UNIT LOCATION
BECKER
BECKER
BEULAH
COLLINSVILLE
COLLINSVILLE
ROCK SPRINGS
SHIPPINGPOIT
SHIPPINGPORT
SHIPPINGPORT
PHOENIXVILLE
EDDVSTONE
EODVSTONE
EDDVSTONE
D1CKERSON
STATEN ISLAND
PRINCETON
WATERFLOW
WATERFLOW
WATERFLOW
WATEHFLOW
ST. JOHNS
ST. JOHNS
ST. JOHNS
SAN MIGUEL
PALATKA
PALATKA
SIKESTON
GEORGETOWN
GEORGETOWN
GEORGETOWN
MINNESOTA
MINNESOTA
NORTH DAKOTA
CALIFORNIA
CALIFORNIA
WYOMING
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
MARYLAND
NEW YORK
INDIANA
NEW MEXICO
NEW MEXICO
NEW MEXICO
NEW MEXICO
ARIZONA
ARIZONA
ARIZONA
TEXAS
FLORIDA
FLORIDA
MISSOURI
SOUTH CAROLINA
SOUTH CAROLINA
SOUTH CAROLINA
START-UP
DATE
4/77
5/84
3/81
6/86
6/87
9/79
12/75
7/77
5/80
6/80
9/rs
6/80
6/80
0/87
11/87
0/82
4/78
8/78
12/79
1/62
11/79
10/80
O/ 0
9/80
6/83
6/85
1/81
7/77
5/80
7/81
STATUS
1
5
2
6
6
1
1
1
2
3
1
3
3
6
6
3
1
1
1
2
1
2
6
2
5
5
2
1
2
3
REG
CLASS
D
c
D
C
C
D
D
D
D
D
D
D
D
A
C
A
C
C
C
c
D
D
A
B
A
A
B
B
B
A
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
4. PLANNED - LETTER OF INTENT SIGNED
5. PLANNED - REQUESTING/EVALUATING BIDS
6. PLANNED - CONSIDERING ONLY FGO SYSTEMS
7. PLANNED - CONSIDERING FGD SYSTEMS; ALSO ALTERNATIVE METHODS
A. FEDERAL NSPSC6/79)
B. FEDERAL NSPSC12/71)
C. STANDARD(S) MORE STRINGENT THAN NSPS(6/79)
D. STANDARD(S) MORE STRINGENT THAN NSPSM2/71) BUT NOT MORE STRINGENT THAN NSPS(6/79>
E. STANDARD(S) EQUAL TO OR LESS STRINGENT THAN NSP-S(12/71)
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
SECTION 1
SUMMARY LIST OF FGO SYSTEMS
COMPANY NAME/
UNIT NAME
SOUTH MISSISSIPPI ELEC PUR
R.O. MORROW
R.O. MORROW
SOUTHERN ILLINOIS POVER COOP
MAR ION
MARION
SOUTHERN INDIANA 6 AS & ELEC
A.B. BROUN
SOUTHWESTERN ELECTRIC POWER
HENRY W. PERKEV
SPRINGFIELD CITY UTILITIES
SOUTHWEST
SPRINGFIELD WATER, LIGHT & PWR
DALLMAN
ST. JOE ZINC
G.F. WEATON
TAMPA ELECTRIC
BIG BEND
TENNESSEE VALLEY AUTHORITY
JOHNSONVILLE
PARADISE
PARADISE
SHAWNEE
SHAWNEE
WIDOWS CREEK
WIDOWS CREEK
TEXAS MUNICIPAL POWER AGENCY
GIBBONS CREEK
TEXAS POWER & LIGHT
SANDOW
TWIN OAKS
TWIN OAKS
TEXAS UTILITIES
FOREST GROVE
MARTIN LAKE
MARTIN LAKE
MARTIN LAKE
MARTIN LAKE
MILL CREEK
MILL CREEK
MONTICELLO
TUCSON GAS t. ELECTRIC
SPRINGERVILLE
SPRINGERVILLE
UTAH POWER I LIGHT
HUNTER
HUNTER
HUNTER
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
A. FEDERAL NSPSC6/79)
B. FEDERAL NSPS<12>71>
C. STANDARD(S) MORE STRINGENT
D. STANDARDfS) M«R£ STRINGENT
UNIT
1
2
4,
5
1
1
1
3
1
4
1-10
1
2
10A
106
7
8
1
I
1
2
1
1
2
3
4
1
2
3
1
2
1
2
3
4.
5.
6.
7.
THAN
THAN
NO. UNIT LOCATION
HATTISBUR6 MISSISSIPPI
HATTISBUR6 MISSISSIPPI
MARION ILLINOIS
MARION ILLINOIS
WEST FRANKLIN INDIANA
HALLSVILLE TEXAS
SPRINGFIELD MISSOURI
SPRINGFIELD ILLINOIS
HONACA PENNSYLVANIA
TAMPA FLORIDA
NEW JOHNSONVILLTENNESSEE
PARADISE KENTUCKY
PARADISE KENTUCKY
PADUCAH KENTUCKY
PADUCAH KENTUCKY
BRIDGEPORT ALABAMA
BRIDGEPORT ALABAMA
CARLOS TEXAS
ROCKOALE TEXAS
BREMOND TEXAS
BREMOND TEXAS
ATHENS TEXAS
TATUM TEXAS
TATUM TEXAS
TATUM TEXAS
TATUM TEXAS
HENDERSON TEXAS
HENDERSON TEXAS
HT. PLEASANT TEXAS
SPRINGERVILLE ARIZONA
SPRINGERVILLE ARIZONA
CASTLE DALE UTAH
CASTLE DALE UTAH
CASTLE DALE UTAH
START-UP
DATE
8/78
6/79
5/79
0/84
3/79
12/84
4/77
9/80
11/79
3/8S
12/81
6/82
3/82
4/72
4/72
10/80
5/77
1/82
7/80
8/84
8/85
0/81
4/77
5/78
2/79
0/85
0/85
0/86
5/78
0/85
0/87
5/79
6/80
0/83
STATUS
1
1
1
6
1
3
1
2
1
5
5
3
3
1
1
2
1
3
2
3
3
5
1
1
1
3
6
6
1
3
3
1
2
3
REG
CLASS
B
B
B
A
B
A
B
B
B
A
E
E
E
E
E
E
E
A
B
A
A
A
B
B
B
A
A
A
B
B
B
B
B
A
PLANNED - LETT |R Of INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
PLANNED - CONSIDERING ONLY FGO SYSTEMS
PLANNED - CONSIDERING F6D SYSTEMS;
NSPSC6/79)
NSPS<12/71> BUT NOT MORE STRINGENT
ALSO ALTERNATIVE
METHODS
THAN NSPSC6/79)
E. STANDARD(S) EQUAL TO OR LESS STRINGENT THAN NSPSC12/71)
-------
EPA UTILITY F&D SURVEY: FOURTH QUARTER 1979
SECTION 1
SUMMARY LIST OF FGD SYSTEMS
COMPANY NAME/ START-UP REG
UNIT NAME UNIT NO. UNIT LOCATION DATE STATUS CLASS
UTAH POWER & LIGHT
HUNTER 4 CASTLE DALE UTAH 0/85 3 A
HUNTINGTON 1 PRICE UTAH 5/78 1 B
WISCONSIN POWER £ LIGHT
COLUMBIA 2 PORTAGE WISCONSIN 1/82 3 B
1. OPERATIONAL UNITS 4. PLANNED - LETTER OF INTENT SIGNED
2. UNITS UNDER CONSTRUCTION 5. PLANNED - REQUESTING/EVALUATING BIDS
3. PLANNED - CONTRACT AWARDED 6. PLANNED - CONSIDERING ONLY FGD SYSTEMS
7. PLANNED - CONSIDERING FGD SYSTEMS; ALSO ALTERNATIVE METHODS
A. FEDERAL NSPSC6/79)
B. FEDERAL NSPSOZ/71)
C. STANDARD(S) MORE STRINGENT THAN NSPS(6/79)
D. STANDARD MORE STRINGENT THAN NSPS<12'71> BUT NOT MORE STRINGENT THAN NSPS<6/79>
E. STANOARD(S) EQUAL TO OR LESS STRINGENT THAN NSPS(12/71)
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
ALABAMA ELECTRIC COOP
TOneiGBEE
2
NEU 255.0 MU (GROSS)
179.0 MU
COAL
1.15 XS BITUMINOUS
LIMESTONE
PEA60DV PROCESS SYSTEMS
ENERGY CONSUMPTION: 3.1Z
STATUS 1 STARTUP 9/78
TOHBIGBEE 2 OF ALABAMA ELECTRIC COOP IS A PULVERIZED COAL BOILER LOCATED
IN LtROY, ALABAMA. THE BOILER GENERATES A MAXIMUM FLUE GAS FLOW OF 953.000
ACFM AND BURNS BITUMINOUS COAL WITH AN AVERAGE SULFUR CONTENT OF 1.2* AND
AN AVERAGE HEAT CONTEHT OF 11,500 BTU/LB. THE UNIT S02 EHMISSION LIMITA-
TION VALUE IS 1.2 LB/MMBTU. PRIMARY PARTICULATE MATTER CONTROL IS PROVID-
ED BY A HOT SIDE ESP. THE S02 REMOVAL EQUIPMENT CONSISTS OF TWO SPRAY
TOWERS SUPPLIED BY PEABODY PROCESS SYSTEMS WHICH UTILIZE A LIMESTONE REA-
GENT. A CHEVRON MIST ELIMINATOR IS INCLUDED FOR EACH TOWER AND THE FLUE
GAS IS REHEATED WITH BYPASSED GAS BEFORE BEING VENTED TO A 400 FOOT ACID-
BRICK LINED STACK. THE SYSTEM OPERATES IN AN OPEN WATER LOOP MODE AND
SPENT ABSORBENT IS DISPOSED OF IN AN ON-SITE LINED POND.
ALABAMA ELECTRIC COOP
TOMBIGBEE
3
NEW 255.0 MU (GROSS)
179.0 Mw
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
ARIZONA ELECTRIC POWER COOP
APACHE
3
NEW 195.0 HU (GROSS)
195.0 My (ESC)
COAL
.55 ZS BITUMINOUS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: 4.11
STATUS 1 STARTUP 6/79
APACHE 3 OF ARIZONA ELECTRIC POWER COOP IS A DRY BOTTOM, PULVERIZED COAL
FIRED UNIT IN COCHISE , ARIZONA. LOU (0.7Z) SULFUR BITUMINOUS COAL WITH AN
AVERAGE HEATING VALUE OF 10,000 BTU/LB PRODUCES A MAXIMUM FLUE GAS FLOW O
735,000 ACFM. THE FLUE CAS PASSES THROUGH A HOT SIDE ESP TO TUO RESEARCH
COTTRELL PACKED TOWERS, WHERE LIMESTONE IS USED TO REMOVE 85Z (DESIGN) Or
THE S02. THE GAS EXITS A HORIZONTAL CHEVRON NjST ELlMlNATQR INTO ITS OWN
CEILCOTE LINED FLUE IN THE 400 FOOT STACK IT SHARES WITH UNIT 2. THE FGD.
UHICH HAS BEEN OPERATIONAL SINCE JUNE OF 1979, USES NO REHEAT. THE SYSTEM
OPERATES IN AN OPEN WATER LOOP AND SLUDGE IS DISPOSED OF IN TWO OFF SITE
LINED PONDS WITH 20 YEARS EXPECTED LIFESPAN. TUO ADDITIONAL PONDS ARE
PLANNED, UHICH WOULD 'DO ANOTHER 20 YEARS' CAPACITY.
ARIZONA PUBLIC SERVICE
CHOLLA
1
RETROFIT 119.0 MW (GROSS)
119.0 MW (ESC)
COAL
.50 ZS BITUMINOUS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: 3.4Z
STATUS 1 STARTUP 10*73
ARIZONA PUBLIC SERVICE'S CHOLLA 1 IS LOCATED IN JOSEPH CITY, ARIZONA ANO
is A TANGENTIALLY FIRED, WET BOTTOM PULVERIZED COAL UNIT. IT is FUELED BV
BITUMINOUS COAL THAT HAS A SULFUR CONTENT OF 0.5Z AND A HEATING VALUE Of
10,150 BTU/LB. PART1CULATE MATTER IS CONTROLLED BY TUO FLOODED DISC SCRUB-
BERS. THE FGD SYSTEM BEGAN IN OCTOBER, 1973 AND IS NOW OPERATIONAL. S02 J$
CONTROLLED BY ONE TOUER WITH MUNTERS PACKING EMPLOYING A LIMESTONE
ABSORBENT. THE UNIT HAS SUPPLIED BV RESEARCH COTTRECL AND HAS A DESIGN
REMOVAL OF 92Z. CHEVRON MIST ELIMINATORS ARE LOCATED PRIOR TO AN IN-LINE
STEAM REHEAT STSTEM. THE TREATED FLUE GAS IS VENTED TO A 256 FT ACID BRICK
LINED STACK. THE FGD SYSTEM OPERATES IN AN OPEN HATER LOOP MODE AND THE
UNTREATED WASTE IS DISPOSED Of IN AN ON-SITE UNLINED POND.
ARIt ONA PUBLIC SERVICE
CHOLLA
2
NEW 350.0 MW (GROSS)
350.0 MU
COAL
.50 ZS BITUMINOUS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: "***Z
STATUS 1 STARTUP 4/78
CHOLLA 2 OF ARIZONA PUBLIC SERVICE IS LOCATED IN JOSEPH CITY, ARIZONA. THE
BOILER BURNS PULVERIZ ID BITUMINOUS COAL (0.5Z S. 10,150 BTU/LB). MECHANI-
CAL COLLECTORS PROVIDE PRIMARY PARTICULATE CONTROL. FOUR PARALLEL
FLOODED DISC AND PACKED TOUER S02 ABSORBER TRAINS (THREE ARE REQUIRED FOR
FULL LOAD) REMOVE THE FLUE GAS S02. THE DESIGN S02 REMOVAL FOR THE
SYSTEM, UHICH BEGAN OPERATIONS IN APRIL, 1978, IS 75Z. THE CLEANED GAS
PASSES THROUGH AN IN-LINE STEAM REHEATER INTO AN ACID BRICK LINED STACK.
THE OPEN WATER LOOP SYSTEM DEPOSITS ITS SLUDGE INTO A FLY ASH POND.
ARIZONA PUBLIC SERVICE
CHOLLA
4
NEU 350.0 MU (GROSS)
126.0 MU (ESC)
COAL
.50 ZS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: *«**Z
CHOLLA 4 OF ARIZONA PUBLIC SERVICE IS PRESENTLY UNDER CONSTRUCTION IN
JOSEPH CITY. ARIZONA. START UP IS SCHEDULED FOR JUNE. 1980. THE PULVERIIElk
COAL (0.5Z S. 10,150 BTU/LB) FIRED BOILER UILL EXHAUST FLUE GAS THROUGH Ah
ESP TO A PACKED TOUER UHICH UILL TREAT 361 OF THE GAS WITH LIMESTONE.
STATUS 2
STARTUP 6/80
ARIZONA PUBLIC SERVICE
FOUR CORNERS
1
RETROFIT 175.0 MU <6ROSS)
175.0 MU t ESO
COAL
.75 ZS SUBBITUH1BOUS
LIME/ALKALINE FLYASH
CHENICO
ENERGY CONSUMPTION: *•*•!
STATUS 2 STARTUP 11/79
ARIZONA PUBLIC SERVICE IS UPGRADING THE OPERATIONAL PARTICULATE SCRUBBERS
AT FOUR CORNERS 1, 2, AND 3 IN FARM1N6TON, NEU MEXICO TO HANDLE ADDITIONAL
S02 REMOVAL. CURRENTLY, THE FRONT FIRED, DRY BOTTOM, PULVERIZED COAL (SUfit
BITUMINOUS, 0.7SZ S. 8650 BTU/LB) UNITS 1 AND 2 SUPPLY 814,000 ACFM EACH
INTO 2 CHEMICO VENTURE SCRUBBERS PER UNIT FOR PRIMARY PARTICULATE CONTROL
AND APPROXIMATELY 30Z S02 REMOVAL USING ALKALINE FLY ASH. THE DESIGN SOZ
REMOVAL EFFICIENCY AFTER THE CONVERSION TO LIME AND ALKALINE FLY ASH
SCRUBBING IS 67.SZ. START UP IS EXPECTED SOMETIME IN 1979.
ARIZONA PUBLIC SERVICE
FOUR CORNERS
RETROFIT 175.0 MU
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
ARIZONA PUBLIC SERVICE
FOUR CORNERS
3
RETROFIT 229.0 nw (GROSS)
229.0 HW (ESC)
COAL
.75 XS SUBBITUHINOUS
LIME/ALKALINE FLYASH
CHEM1CO
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 11/79
ARIZONA PUBLIC SERVICE IS UPGRADING THE OPERATIONAL PARTICULATE SCRUBBERS
AT FOUR CORNERS 1i2, AND 3 IN FARMINGTON, NEW MEXICO TO HANDLE ADDITIONAL
S02 REMOVAL. CURRENTLY, THE FRONT FIRED, DRV BOTTOM, PULVERIZED COAL (SUB-
BITUMINOUS. 0.75X S, 8650 BTU/LB) UNIT 3 SUPPLIES 1.030,000 ACFM INTO 2
CHEMICO VENTURI SCRUBBERS FOR PRIMARY PARTICULATE CONTROL AND APPROXIMATE-
LY 3d S02 REMOVAL USING ALKALINE FLY ASH. THE DESIGN S02 REMOVAL EFFICI-
ENCY AFTER THE CONVERSION TO LIME AND ALKALINE FLY ASH SCRUBBING IS 67.SZ.
STARTUP IS EXPECTED SOMETIME IN 1979.
ARIZONA PUBLIC SERVICE
FOUR CORNERS
4
RETROFIT 755.0 MU (GROSS)
75S.O MU (ESC>
COAL
.75 ZS
LIME
UNITED ENGINEERS
ENERGY CONSUMPTION: **«*X
STATUS 3 STARTUP 0/82
ARIZONA PUBLIC SERVICE AWARDED A CONTRACT TO UNITED ENGINEERS FOR A LIME
FGD SYSTEM TO BE RETROFITTED ONTO UNITS 4 AND 5 AT ITS FOUR CORNERS STA-
TION IN FARHINGTON, NEW MEXICO. BASED. ON THE PROTOTYPE HORIZONTAL SCRUB-
BING PROGRAM CONDUCTED BY THE UTILITY, A HORIZONTAL SYSTEM WAS CHOSEN TO
CONTROL THE EMISSIONS FROM THESE COAL (0.75X S, 8650 BTU/LB) FIRED UNITS.
THE PARTICULATE EMISSIONS ARE HANDLED BY AN ESP. START UP IS EXPECTED IN
1982.
ARIZONA PUBLIC SERVICE
FOUR CORNERS
5
RETROFIT 755.0 MU (GROSS)
755.0 MU (ESC)
COAL
.75 XS
LIME
UNITED ENGINEERS
ENERGY CONSUMPTION: ****X
STATUS 3 STARTUP 0/82
ARIZONA PUBLIC SERVICE AWARDED A CONTRACT TO UNITED ENGINEERS FOR A LIME
FGD SYSTEM TO BE RETROFITTED ONTO UNITS 4 AND 5 AT ITS FOUR CORNERS STA-
TION IN FARHINGTON. NEW MEXICO. BASED ON THE PROTOTYPE HORIZONTAL SCRUB-
BING PROGRAM CONDUCTED BY THE UTILITY, A HORIZONTAL SYSTEM WAS CHOSEN TO
CONTROL THE EMISSIONS FROM THESE COAL (0.75X S, 8650 BTU/LB) FIRED UNITS.
THE PARTICULATE EMISSIONS ARE HANDLED BY AN ESP. START UP IS EXPECTED IN
1982.
ASSOCIATED ELECTRIC COOP
THOMAS HILL
3
NEW 730.0 MM ( GROSS)
670.0 MU (ESC)
COAL
4.60 XS
LIMESTONE
PULLMAN KELLOGG
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 1/82
THOMAS HILL 3 OF ASSOCIATED ELECTRIC COOP IS A PULVERIZED COAL (4.8X S.
9.70C BTU/LB) FIRED UNIT LOCATED IN HOBERLY, MISSOURI. TUO COLD SIDE ESP'S
WILL PRECEDE THE FOUR 91.5X EFFICIENT PULLMAN KELLOGG HORIZONTAL WEIR FGD
MODULES USING MAGNESIUM-PROMOTED LIMESTONE AS THE ABSORBENT. THE CLEANED
GAS KILL PASS THROUGH A VERTICAL CHEVRON MIST ELIMINATOR TO A 620 FOOT
BRICK LINED STACK. REHEAT WILL BE ACCOMPLISHED BY BYPASS. DRV FIXATED
SLUDGE WILL BE TRUCKED TO AN ACTIVE STRIP MINE. THE SYSTEM WILL USE A
CLOSED WATER LOOP. THE FGO SYSTEM IS UNDER CONSTRUCTION AND START UP IS
EXPECTED IN JANUARY, 1982.
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY
1
NEW 440.0 MW (GROSS)
440.0 MW (ESC)
COAL
.68 XS LIGNITE
LIME/SPRAY DRYING
JOY MFG/NIRO ATOMIZER
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 11/81
UNIT 1 OF BASIN ELECTRIC POWER COOP'S ANTELOPE VALLEY PLANT IS PRESENTLY
UNDER CONSTRUCTION IN BEULAH, NORTH DAKOTA. THIS UNIT WILL BURN PULVERIZED
COAL (0.68X S, 6600 BTU/LB LIGNITE) AND SUPPLY 2,055,000 ACFM TO A DRV
LIME FGD SYSTEM SUPPLIED BY WESTERN PRECIPITATION. THE 62X EFFICIENT
SYSTEM WILL CONSIST OF 5 NIRO ATOMIZER SPRAY DRYERS AND TWO BA6HOUSES.
THE CLEANED GAS, ALONG WITH A 4X BYPASS REHEAT, WILL EXIT A 60C FOOT
PVC LINED STACK. THE SYSTEM WILL USE A CLOSED WATER LOOP AND THE DRY
POWDER WILL BE USED FOR LANDFILL IN A COAL MINE. START UP IS EXPECTED
IN NOVEMBER , 1981.
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY
2
NEW 440.0 MW (GROSS)
440.0 MW (EbC)
COAL
.68 XS LIGNITE
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ••••X
STATUS 5 STARTUP 11/83
ANTELOPE VALLEY 2 OF BASIN ELECTRIC POWER COOP WILL BE LOCATED IN BEULAH,
NORTH DAKOTA. THE UTILITY IS PRESENTLY CONSIDERING VARIOUS FGD PROCESSES
FOR THIS LIGNITE (0.68X S, 6600 BTU/LB) FIRED UNIT. THE UNIT WILL BE
REQUIRED TO COMPLY WITH STATE EMISSIONS STANDARDS VIA BEST AVAILABLE
CONTROL TECHNOLOGY. START UP IS SCHEDULED FOR NOVEMBER, 1983.
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
BASIN ELECTRIC POWEI COOP
LARAMIE RIVER
1
NEW 600.0 MW
BASIN ELECTRK POWER COOP
LARANIE RIVER
2
NEW 6CO.O MW (GROSS)
600.C MW (ESC)
COAL
.80 XS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 10/80
BASIN ELECTRIC POWER COOP'S LARAMIE RIVER 2 IS PRESENTLY UNDER CONSTRUC-
TION IN WHEATLAND, WYOMING. THE PULVERIZED COAL (0.81* S, 8139 BTU/LB)
FIRED BOILER WILL FEED 2,300,000 ACFM OF FLUE GAS THROUGH A OLD SIDE
ESP TO FIVE RESEARCH COTTRELL LIMESTONE PACKED TOWER MODULES, WHICH WILL
REMOVE 90X OF THE SoZ. THE CLEANED GAS WILL EXIT FROM A VERTICAL CHEVRON
DEMISTER INTO A 600 FOOT ACID BRICK LINED STACK. NO REHEAT WILL BE USED.
THE FLYASH FIXATED SLIDGE WILL BE DEWATERED TO 83* SOLIDS BEFORE BEING
LANDFILLEO, AND THE S»STEM WILL EMPLOY A CLOSED WATER LOOP. START UP IS
SCHEDULED FOR OCTOBER, 1980.
BASIN ELECTRIC POWER COOP
LARAMIE RIVER
3
NEW 6CO.O MW (GROSS)
600.0 MW
COAL
.54 ZS
LIME/SPRAY DRYING
BABCOCK K WILCOX
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 7/81
LARAMIE RIVER 3 OF BASIN ELECTRIC POWER COOP IS TO BE CONSTRUCTED IN
WHEATLAND, WYOMING, AID WILL UTILIZE FOUR DRV LIME INJECTION MODULES,
EACH FOLLOWED BY AN ESP. THE BOILER WILL FIRE PULVERIZED COAL <0.54X S,
8100 BTU/LB) AND WILL SUPPLY 2.800,000 ACFN OF FLUE GAS TO THE FGD
SYSTEM, WHICH WILL REMOVE 85* OF THE S02 BEFORE THE GAS EXITS THROUGH
A 600 FOOT ACID BRICK LINED STACK. A 3* BYPASS WILL BE USED FOR REHEAT.
THE SYSTEM WILL OPERATE IN » CLOSED WATER LOOP, AND WILL LANDFILL THE
DRV P3WDER WASTE. CONSTRUCTION IS SLATED TO BEGIN IN JANUARY, 1980,
AND START UP IS SCHEDULED FOR JULY, 1981.
BIG RIVERS ELECTRIC
&• 6. WILSON
1
NEW 440.0 MW
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
BIG RIVERS ELECTRIC
GREEN
2
NEW 242.0 MU (GROSS)
242.0 My I ESC)
COAL
3.75 XS BITUMINOUS
LIME
AMERICAN AIR FILTER
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 11/80
UNIT 2 OF BIG RIVERS ELECTRIC'S GREEN STATION IS BEING CONSTRUCTED IN
SEBREE, KENTUCKY. THE DRY BOTTOM PULVERIZED COAL (3.751 St 9750 BTU/LB)
FIRED BOILER WILL SUPPLY 1,000,000 ACFM TO A COLD SIDE ESP FOLLOWED BY
TWO AMERICAN AIR FILTER LIME SPRAY TOWERS WHICH WILL REMOVE 9QX OF THE
S02. THE CLEANED GAS WILL PASS THROUGH A CHEVRON MIST ELIMINATOR AND
WILL EXIT A SAUERISEN 72 LINED STACK AFTER IT IS HEATED BV STEAM COIL
REHEATER. THE SLUDGE FROM THE CLOSED WATER LOOP SYSTEM WILL BE P02-0-TEC
STABILIZED. START UP IS SCHEDULED FOR JUNE, 1980.
CENTRAL ILLINOIS LIGHT
DUCK CREEK
1
NEW 416.0 NW (GROSS)
378.0 MW (ESC)
COAL
3.30 ZS BITUMINOUS
LIMESTONE
RILEY STOKER/ENVIRONEERING
ENERGY CONSUMPTION: 2.9Z
STATUS 1 STARTUP 9/76
DUCK CREEK 1 OF CENTRAL ILLINOIS LIGHT IS LOCATED IN CANTON, ILLINOIS. THE
BALANCED DRAFT, FRONT FIRED, DRY BOTTOM UNIT BURNS PULVERIZED BITUMINOUS
COAL (3.3* S, 10,500 BTU/LB) AND SUPPLIES 2.415,000 ACFM OF FLUE GAS TO
TWO COLD SIDE ESP'S FOLLOWED BY FOUR RILEY STOKER/ENVIRONEERING ROD DECK
SPRAY TOWER MODULES. THE FGD SYSTEM HAS BEEN OPERATIONAL
-------
EP* UTILITY FGD SURVEY; FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
COLORADO UTE ELECTRIC ASSN.
CRAIG
1
NEW 447.0 NW ( GROSS)
447.0 HU (ESC)
COAL
.45 ZS SUBBITUNINOUS
LIMESTONE
PEABODY PROCESS SYSTEMS
ENERGY CONSUMPTION: 5.4X
STATUS 2 STARTUP 4/80
THE COLORADO UTE ELECTRIC ASSN IS PRESENTLY CONSTRUCTING TUO IDENTICAL
UNITS IN CRAIG, COLORADO, CRAIG 1 AND 2. BOTH UNITS UILL FIRE PULVERIZED
SUBBITUMINOUS COAL (0.45X S, 10,000 BTU/LB). EACH UNIT'S HOT SIDE ESP AND
FOUR MAGNESIUM PROMOTED LIMESTONE SPRAY TOUERS UILL REMOVE 8 5X OF THE S02.
THE SCRUBBER EXHAUST HILL BE WARMED BY AN IN-LINE STEAM COIL REHEATER AND
UILL PASS THROUGH A 600 FOOT TALL ACID BRICK LINED STACK. THE SYSTEM UILL
OPERATE IN A CLOSED UATER LOOP, AND THE STABILIZED SLUDGE UILL BE DISPOSED
OF 1H AN OFF SITE HINEFILL. UNIT 1 START UP IS EXPECTED IN APRIL, 1980.
COLORADO UTE ELECTRIC ASSN.
CRAIG
2
NEU 447.0 MU (GROSS)
447.0 MU (ESC)
COAL
.45 ZS SUBBITUMINOUS
LIMESTONE
PEABODY PROCESS SYSTEMS
ENERGY CONSUMPTION: 5.4X
STATUS 1 STARTUP 8/79
THE CRAIG 2 UNIT OF THE COLORADO UTE ELECTRIC ASSN IS LOCATED
IN CRAIG, COLORADO. THE CRAIG 2 UNIT FIRES PULVERIZED
SUBBITUMINOUS COAL (0.45Z S, 10,000 BTU/LB). THE UNIT'S HOT SIDE ESP AND
FOUR 1AGNESIUM PROMOTED LIMESTONE SPRAY TOUERS UILL REMOVE 85X OF THE S02.
THE SCRUBBER EXHAUST IS WARMED BY AN IN-LINE STEAM COIL REHEATED AND
PASSES THROUGH A 600 FOOT TALL ACID BRICK LINED STACK. THE SYSTEM
OPERATES IN A CLOSED UATER LOOP, AND THE STABILIZED SLUDGE IS DISPOSED
OF IN AN OFF SITE MINEflLL. START UP OF UNIT 2 WAS IN AUGUST, 1979.
COLORADO UTE ELECTRIC ASSN.
CRAIG
3
NEU 447.0 MU (GROSS)
447.0 MU
-------
EPA UTILITY FGD SURVEY: FOURTH OUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
COLUMbUS £ SOUTHERN OHIO ELEC. COLUMBUS AND SOUTHERN OHIO ELECTRIC HAS PLANS FOR TWO NEU UNITS, POSTON
POSTON
6
NEW 375.0 MW (GROSS)
375.0 MW (ESC)
COAL
2.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 0/89
AND e, TO BE LOCATED IN ATHENS, OHIO. THE COAL (2.5X S, 11,000 BTU/LB)
FIRED UNITS WILL UTILIZE EITHER A LIME, LIMESTONE, OR DUAL ALKALI FCD
SYSTEM. START UP OF UNIT 6 IS EXPECTED IN 1989.
COMMONWEALTH EDISON
POUERTON
51
RETROFIT 450.0 MW (GROSS)
450.0 MW (ESC)
COAL
3.53 XS
LIMESTONE
AIR CORRECTION DIVISION, UOP
ENERGY CONSUMPTION: 5.6X
STATUS 2 STARTUP 4/80
COMMONWEALTH EDISON IS PRESENTLY RETROFITTING BOILER NUMBER 51 AT ITS
POUERTON STATION WITH A UOP LIMESTONE F6D SYSTEM. UNIT 51 IS ONE OF TWO
IDENTICAL BOILERS SUPPLYING STEAM TO AN 850 NW TURBINE. THE PULVERIZED
COAL (3.6X S, 10,500 BTU/LB) FIRED BOILER FEEDS FLUE GAS THROUGH AN ESP
TO 3 TCA MODULES WHICH ARE DESIGNED TO REMOVE 74X OF THE S02. A STEAM
INDIRECT HOT AIR REHEATER WILL BOOST THE TEMPERATURE BEFORE THE GAS EXITS
AN ACID BRICK LINED STACK. THE SYSTEM WILL UTILIZE A CLOSED WATER LOOP,
AND THE SLUDGE WILL BE POZ-0-TEC STABILIZED AND DISPOSED OF IN A LANDFILL.
THE FGD SYSTEM IS UNDER CONSTRUCTION, AND THE START UP IS EXPECTED IN
NOVEMBER, 1979.
COOPERATIVE POWER ASSOCIATION
COAL CREEK
1
NEW 545.0 MW (GROSS)
327.0 MW
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
DUQUESNE LIGHT
ELRANA
1-4
RETROFIT 510.0 nw (GROSS)
510.0 nu < ESC)
COAL
2.20 XS
LIME
CHEHICO
ENERGY CONSUMPTION: 3.5*
STATUS 1 STARTUP 10/75
ELRAHA 1-4 OF DUQUESNE LIGHT CONSISTS OF FOUR PULVERIZED COAL (2.2X S,
11,350 BTU/LB) FIRED UNITS LOCATED IN ELRAMA, PENNSYLVANIA. THE EMISSION
CONTROL SYSTEM ON THIS SITE CONSISTS OF AN ESP FOLLOWED BY A MECHANICAL
COLLECTOR AND FIVE VARIABLE THROAT VENTURI LIME ABSORBER MODULES SUPPLIED
BY CHE«1CO» WHICH ARE DESIGNED TO REMOVE ?3X OF THE S02 FROM THE FLUE GAS,
THE CLEANED GAS PASSES THROUGH A DIRECT OIL FIRED REHEATER BEFORE EXITING
A 40C FOOT ACID BRICK LINED STACK. THE SYSTEM OPERATES IN AN OPEN WATER
LOOP, AND THE POZ-0-TEC STABILIZED SLUDGE IS HAULED TO AN OFF SITE LAND-
FILL. THE SYSTEM HAS BEEN OPERATIONAL SINCE OCTOBER, 1975.
DUOUESNE
PHILLIPS
1-6
RETROFIT
LIGHT
408.0 MU (GROSS)
410.0 MU (ESC)
COAL
1.92 XS BITUMINOUS
LIME
CHEMICO
ENERGY CONSUMPTION: 3.4X
STATUS 1 STARTUP 7/73
THE PHILLIPS POWER STATION OF DUQUESNE LIGHT CONSISTS OF SIX DRY BOTTOM
PULVERIZED COAL (2.2X S, 11,350 BTU/LB) FIRED UNITS LOCATED IN SOUTH
HEIGHT, PENNSYLVANIA. PART1CULATE CONTROL IS ACCOMPLISHED BY SIX ESP/
MECHANICAL COLLECTOR COMBINATIONS (ONE/BOILER). ONE TWO STAGE AND THREE
SINGLE STAGE VARIABLE THROAT VENTURI LIME FGD MODULES SUPPLIED BY CHEMICO
ARE DESIGNED TO REMOVE 83X OF THE S02 FROM THE FLUE GAS. TWO CHEVRON MIST
ELIMINATORS/MODULE ARE FOLLOWED BY A DIRECT OIL FIRED REHEATER WHICH RAIS-
ES THE GAS TEMPERATURE BY 20 DEG F BEFORE IT LEAVES VIA A 340 FOOT TALL
ACID BRICK LINED STACK. THE SYSTEM OPERATES IN AN OPEN WATER LOOP, AND
THE POZ-0-TEC STABILIZED SLUDGE IS TRUCKED TO AN OFF SITE LANDFILL. THE
SYSTEM HAS BEEN OPERATIONAL SINCE JULY, 1973.
EAST KENTUCKY POWER COOP
J. K. SMITH
1
NEW 6SO.O MW (GROSS)
650.0 MW (ESC)
COAL
•••*• XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *•***
STATUS 6 STARTUP 1/85
THE EAST KENTUCKY POW IR COOP HAS PLANS TO FIRE TWO NEW UNITS. THE J.K.
SMITH 1 AND 2 WILL UTILIZE EITHER A DRY PROCESS OR A WET LIME PROCESS
FOR EMISSION CONTROL. UNIT 1 IS EXPECTED TO START UP IN JANUARY 1985.
EAST KENTUCKY POWER COOP
•»• K. SMITH
2
NEW 650.0 MW (GROSS)
650.0 MW (ESC)
COAL
••*** XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 1/86
THE EAST KENTUCKY POWER COOP HAS PLANS TO FIRE TWO NEW UNITS. THE J.K.
SMITH 1 AND 2 WILL UTILIZE EITHER A DRY PROCESS OR A WET LIME PROCESS
FOR EMISSION CONTROL. UNIT 2 IS EXPECTED TO START UP IN JANUARY 1986.
EAST KENTUCKY POWER COOP
SPURLOCK
NEW 500.0 MW (GROSS)
500.0 MW (ESC)
COAL
3.50 XS
LINE
AOL/COMBUSTION EQUIP ASSOCIATE
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 10/80
SPURLOCK 2 OF EAST KENTUCKY POWER COOPERATIVE IS A BALANCED DRAFT PULVER-
IZED COAL (3.5X S. 11,000 BTU/LB) FIRED UNIT UNDER CONSTRUCTION IN MAYS-
VILLEt KENTUCKY. THE EMISSION CONTROL SYSTEM WILL CONSIST OF AN ESP FOL-
LOWED BY AN ADL/COMBUSTION EQUIPMENT ASSOCIATES LIME FGD SYSTEM (901
DESIGN so2 REMOVAL EFFICIENCY). FLUE GAS FROM UNIT ONE WILL BE USED TO
REHEAT THE CLEANED GAS. THE SYSTEM, SLATED FOR START UP IN OCTOBER, 198Q,
WILL EMPLOY A CLOSED hATER LOOP AND FtOZ-0-TEC SLUDGE STABILIZATION.
GENERAL PUBLIC UTILITIES
COHO
1
NEW 800.0 MW (CROSS)
800.0 MW (ESC)
COAL
3.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 12/88
COHO 1 IS A 3.5X S COAL FIRED UNIT PLANNED BY GENERAL PUBLIC UTILITIES TO
BE LOCATED IN ERIE, PENNSYLVANIA. PRIMARY CONSIDERATION IS BEING GIVEN TO
LIME AND LIMESTONE NON-SLURRY TYPE FGD SYSTEMS. THE UNIT AND FGD SYSTEM
ARE SCHEDULED TO START UP IN DECEMBER, 1988.
14
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
GENERAL PUBLIC UTILITIES
GILBERT
1
NEW 625.0 My (GROSS)
625.0 ny (ESC)
COAL
3.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTEDD
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 0/90
GENERAL PUBLIC UTILITIES HAS PLANS FOR A NEW UNIT, GILBERT 9, TO BE
LOCATED IN MILFORD, NEW JERSEY. THE UTILITY IS CONSIDERING F6D AS AN
EMISSION CONTROL STRATEGY. THE EXPECTED START UP DATE IS IN 1990.
GENERAL PUBLIC UTILITIES
SCOTTSVILLE
1
NEW 625.0 MW (GROSS)
625.0 My < ESC)
COAL
3.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTEDO
ENERGY CONSUMPTION: *««*X
STATUS 6 STARTUP 0/91
GENERAL PUBLIC UTILITIES IS PLANNING A NEW UNIT TO BE LOCATED IN
SCOTTSVILLE, PENNSYLVANIA. THE SCOTTSVILLE 1 UNIT IS EXPECTED TO START
UP IN 1991. THE UTILITY IS PRESENTLY CONSIDERING ONLY FGD AS A EMISSION
CONTROL STRATEGY.
GENERAL PUBLIC UTILITIES
SEWARD
7
NEW 800.0 My (GROSS)
800.0 My (ESC>
COAL
****• XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 12/87
GENERAL PUBLIC UTILITIES IS PLANNING A NEW UNIT, SEUARD 7, TO BE BUILT IN
SEWAKD, PENNSYLVANIA. THE UTILITY IS PRESENTLY CONSIDERING ONLY FGD AS THE
EMISSION CONTROL STRATEGY, WITH NON-SLURRY TYPE LIME AND LIMESTONE SYSTEMS
LOOKING THE HOST PROMISING. START UP IS EXPECTED IN DECEMBER. 1987.
GENERAL PUBLIC UTILITIES
yEH RUM
1
NEW 625.0 My (GROSS)
625.0 MV (ESC)
COAL
3.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTEDD
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 0/95
THE WEHRUM 1 UNIT PLANNED BY GENERAL PUBLIC UTILITIES IS TO BE LOCATED
IN yEHRUM, PENNSYLVANIA. THE UTILITY IS PRESENTLY CONSIDERING FGO AS AN
EMISSION CONTROL STRATEGY. THE UNIT IS EXPECTED TO COMMENCE OPERATIONS
IN 1995.
HOOSIER ENERGY
MEROM
1
NEW 490.0 My (GROSS)
441.0 My (ESC)
COAL
3.50 XS
LIMESTONE
MITSUBISHI HEAVY INDUSTRIES
ENERGY CONSUMPTION: »***X
STATUS 3 STARTUP 5/82
MEROH 1 AND 2 ARE TWO NEW UNITS BEING BUILT BY HOOSIER ENERGY IN SULLIVAN.
INDIANA. THESE PULVERIZED COAL (3.5X S) FIRED UNITS WITH PRODUCE 1,732,000
ACFM OF FLUE GAS WHICH WILL BE CLEANED BY A COLD SIDE ESP UPSTREAM OF A
MITSUBISHI LIMESTONE 6RID TOWER ABSORBER C90X DESIGN S02 REMOVAL). THE
SYSTEH WILL UTILIZE BYPASS REHEAT AND A 700 FOOT STACK. THE SLUDGE WILL
BE STABILIZED AND LANOFILLED, AND THE SYSTEM WILL OPERATE IN A CLOSED
WATER LOOP MODE. START UP OF UNIT 1 IS SCHEDULED FOR APRIL. 1981.
HOOSIER ENERGY
MEROM
2
NEW 490.0 My (GROSS)
441.0 My (ESC)
COAL
3.50 XS
LIMESTONE
MITSUBISHI HEAVY INDUSTRIES
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 7/81
MEROM 1 AND 2 ARE TWO NEW UNITS BEING BUILT BY HOOSIER ENERGY IN SULLIVAN,
INDIANA. THESE PULVERIZED COAL (3.52 S) FIRED UNITS WITH PRODUCE 1.732.000
ACFM OF FLUE GAS WHICH WILL BE CLEANED BY A COLD SIDE ESP UPSTREAM OF A
MITSUBISHI LIMESTONE ERID TOWER ABSORBER (90X DESIGN S02 REMOVAL). THE
SYSTEM WILL UTILIZE BYPASS REHEAT AND A 700 FOOT STACK. THE SLUDGE HILL
BE STABILIZED AND LANOFILLED, AND THE SYSTEM WILL OPERATE IN A CLOSED
WATER LOOP MODE. START UP OF UNIT 2 IS SCHEDULED FOR JANUARY. 1982.
15
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
HOUSTON LIGHTING & POWER CO.
W.A. PARISH
8
NEW SSO.O MW (GROSS)
512.0 MW < ESC)
COAL
.60 XS SUBblTUHINOUS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *»«*X
STATUS 3 STARTUP 11/82
y.A. PARISH 8 IS A PULVERIZED COAL (0.62 St 8700 BTU/LB) FIRED UNIT PLAN-
NED BY HOUSTON LIGHTING AND POWER CO TO BE LOCATED IN THOMPSONS, TEXAS.
THE UTILITY HAS AWARDED A CONTRACT TO CHEMICO FOR A LIMESTONE
FGD SYSTEM WHICH WILL REMOVE 85X OF THE FLUE GAS S02. REHEAT
WILL BE PROVIDED BY BYPASSING 7% OF THE PARTICULATE CLEANED FLUE GAS.
SLUDGE WILL BE DEWATERED. BLENDED WITH FLVASH, AND DISPOSED IN AN ON
SITE LANDFILL. START UP IS EXPECTED IN NOVEMBER, 1982.
INDIANAPOLIS POWER K LIGHT
PATRIOT
1
NEW 650.0 MW (GROSS)
650.0 MW (ESC)
COAL
3.50 IS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 0/87
INDIANAPOLIS POWER AND LIGHT HAS PLANS FOR THREE NEW UNlT$t PATRIOT 1, 2
AND 3, TO BE LOCATED IN PATRIOT, INDIANA. THE UTILITY PLANS ON UTILIZING
A LIMESTONE FGD PROCESS FOR EMISSION CONTROL.
INDIANAPOLIS POWtR K LIGHT
PATRIOT
2
NEW 6SO.O MW (GROSS)
650.0 MW (ESC)
COAL
3.50 ZS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 0/87
INDIANAPOLIS POWER AND LIGHT HAS PLANS FOR THREE NEW UNITS, PATRIOT 1, 2
AND 2, TO BE LOCATED IN PATRIOT, INDIANA. THE UTILITY PLANS ON UTILIZING
A LIMESTONE FGD PROCESS FOR EMISSION CONTROL.
INDIANAPOLIS POWER I LIGHT
PATRIOT
3
NEW 650.0 MW (GROSS)
650.0 MW (ESC)
COAL
3.50 XS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 0/87
INDIANAPOLIS POWER AND LIGHT HAS PLANS FOR THREE NEW UNITS, PATRIOT 1, 2.
AND 3, TO BE LOCATED IN PATRIOT, INDIANA. THE UTILITY PLANS ON UTILIZING
A LIMESTONE FGD PROCESS FOR EMISSION CONTROL.
INDIANAPOLIS POWER & LIGHT
PETERSBURG
3
NEW 532.0 MW (GROSS)
532.0 «W
-------
EPA UTILITY FCD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
KANSAS CITY POWER 8 LIGHT
HAWTHORN
3
RETROFIT 90.0 MW (GROSS)
90.0 MW
COAL
.60 XS BITUMINOUS
LIME
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 2.2X
STATUS 1 STARTUP 11/72
HAWTHORN 3 OF KANSAS CITY POWER AND LIGHT IS A DRY BOTTOM PULVERIZED
BITUMINOUS COAL (0.6X S, 9800 BTU/LB) FIRED UNIT LOCATED IN KANSAS CITY,
MISSOURI, WHICH WAS CONVERTED FROM LIMESTONE FURNACE INJECTION AND TAIL
END SCRUBBING TO A LIME SLURRY SYSTEM. TWO COMBUSTION ENGINEERING MARBLE
BED ABSORBERSt WHICH WERE DESIGNED TO REMOVE 70X OF THE fLUE GAS S02,
BEGAN OPERATION IN JANUARY, 1977. ONE HORIZONTAL CHEVRON MIST ELIMINATOR
PER MODULE IS UPSTREAM OF AN IN-LINE FINNED TUBE REHEATER, WHICH RAISES
THE TEMPERATURE OF THE CLEANED GAS BEFORE IT EXITS THROUGH A GUNITE LINED
200 FOOT STACK. THE FLYASH STABILIZED SLUDGE IS DEPOSITED IN AN UNLINED
SLUDGE POND. THE SYSTEM OPERATES IN A CLOSED WATER LOOP MODE.
KANSAS CITY POWER & LIGHT
HAWTHORN
l>
RETROFIT 90.0 HW
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
KANSAS POWER ft LIGHT
LAURENCE
5
RETROFIT 420.0 MU (GROSS)
420.0 MW
COAL
.55 XS
LIMESTONE
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: •**•*
STATUS 1 STARTUP 11/71
LAWRENCE 5 OF KANSAS POWER AND LIGHT IS A BALANCED DRAFT, TANGENTIAL FIRED
PULVERIZED COAL (0.55X S. 10.000 8TU/LB) UNIT LOCATED IN LAWRENCE. KANSAS.
A NEfc COMBUSTION ENGINEERING LIMESTONE ROD DECK/SPRAY TOWER SYSTEM
REPLACED THE EXISTING MARBLE BFD TAIL END SCRUBBER IN APRIL. 1976. THE
SYSTEI TREATS 4o3,ooo *CFM OF FLUE GAS> UITH A DESIGN so2 REMOVAL OF
73*. MIST ELIMINATION IS ACCOMPLISHED BY TWO CHEVRONS AND ONE BULK
ENTRAPMENT SEPARATOR FOLLOWING EACH OF THE TWO MODULES* A FINNED TUBE
HEHEATER BOOSTS THE TEMPERATURE OF THE CLEANED GAS BY 20 DEC F BEFORE
IT IS EXHAUSTED THROUCH A 120 FOOT STACK. THE SLUDGE IS DISPOSED IN AN
UNLINED INTERIM POND. WHICH OVERFLOWS INTO A FINAL DISPOSAL POND. THE
SYSTEI OPERATES IN A CLOSED WATER LOOP.
KENTUCKY UTILITIES
6REEN RIVER
1-3
RETROFIT 64.0 Hw (GROSS)
64.0 MW « ESC)
COAL
4.00 XS BITUMINOUS
LIME
AMERICAN AIR FILTER
ENERGY CONSUMPTION: 3.13!
STATUS 1 STARTUP 9/75
GREEN RIVER 1-3 OF KENTUCKY UTILITIES ARE THREE DRV BOTTOM PULVERIZED
BITUMINOUS COAL <4X S, 11.000 BTU/LB) FIRED UNITS LOCATED IN CENTRAL
CITY. KENTUCKY. EACH BOILER SUPPLIES 360.000 ACFM OF FLUE GAS TO A
VARIABLE THROAT VENTURI FOLLOWED BY AN AMERICAN AIR FILTER LIME MOBILE
BED CONTACTOR (80* DESIGN S02 REMOVAL EFFICIENCY). A RADIAL VANE HIST
ELIMINATOR IS FOLLOWED BY A STEAM TUBE REHEATER AND A 165 FOOT STACK.
SLUDGE is DISPOSED IN AN ON-SITE UNLINEO POND, AND THE SYSTEM OPERATES
IN A CLOSED WATER LOOP. THE SYSTEM HAS BEEN OPERATIONAL SINCE SEPTEMBER.
1975.
LAKELAND UTILITIES
MCINTOSH
3
NEW 364.0 MW (GROSS)
364.0 MW (ESC)
COAL
2.56 XS BITUMINOUS
LIMESTONE
BABCOCK g WILCOX
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 10/81
MCINTOSH 3 OF LAKELAND UTILITIES IS BEING CONSTRUCTED IN LAKELAND,
FLORIDA. BABCOCK AND WILCOX HAS BEEN AWARDED A CONTRACT TO SUPPLY AN
85X EFFICIENT (S02) LIMESTONE FGD SYSTEM FOR THIS UNIT. THE EMISSION CON-
TROL SYSTEM WILL CONSIST OF A COLD SIDE ESP FOLLOWED BY TWO PARALLEL FGD
MODULES AND A 250 FOOT ACID BRICK LINED STACK. THE SYSTEM WILL OPERATE IN
A CLOSED WATER LOOP, AND THE POZ-0-TEC STABILIZED SLUDGE WILL BE USED AS
A CONSTRUCTION BASE. CONSTRUCTION BEGAN IN NOVEMBER, 1979 AND START
UP IS SCHEDULED TO BE IN OCTOBER, 1981.
LOUISVILLE GAS & ELECTRIC
CANE RUN
I
RETROFIT 168.0 MW (GROSS)
U8.0 MW ( ESC)
COAL
3.75 XS BITUMINOUS
LIME
AMERICAN AIR FILTER
ENERGY CONSUMPTION: 1.6X
STATUS 1 STARTUP 8/76
UNIT 4 AT LOUISVILLE GAS AND ELECTRIC'S CANE RUN STATION IS A PULVERIZED
BITUMINOUS COAL (3.751 S, 11,500 BTU/LB) FIRED UNIT IN LOUISVILLE, KEN-
TUCKY. AN ESP AND TWO AMERICAN AIR FILTER CARBIDE LIME MOBILE BED ABSORBER
MODULES (85X DESIGN S»2 REMOVAL) TREAT 734,000 ACFM OF FLUE GAS FROM THE
BOILER. TWO CHEVRON MIST ELIMINATORS/MODULE ARE FOLLOWED BY A DIRECT
COMBUSTION REHEATER AND A 250 FOOT STACK. THE WATER LOOP IS OPEN, AND
THE SLUDGE IS DISPOSED IN AN ON-SITE LINED POND. THIS RETROFIT SYSTEM
HAS BEEN OPERATIONAL SINCE AUGUST. 1976.
LOUISVILLE GAS & ELECTRIC
CANE RUN
5
RETROFIT 200.0 MW (GROSS)
2CO.O MW (ESC)
COAL
3.75 XS BITUMINOUS
LIME
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 1.5X
STATUS 1 STARTUP 12/77
CANE RUN 5 OF LOUISVILLE GAS AND ELECTRIC IS A PULVERIZED BITUMINOUS COAL
(3.75X S, 11,500 BTU/LB) FIRED UNIT LOCATED IN LOUISVILLE, KENTUCKY. THE
BOILER SUPPLIES 700,000 ACFM OF FLUE GAS TO AN EMISSION CONTROL SYSTEM
CONSISTING OF AN ESP FOLLOWED AND TWO COMBUSTION ENGINEERING 851 EFFICIENT
(DESIGN) CARBIDE LIME SPRAY TOWERS. A STEAM TUBE REHEATER RAISES THE GAS
TEMPERATURE 40 DEG F. THE SYSTEM OPERATES IN AN OPEN WATER LOOP MODE. AND
THE SLUDGE IS POZ-0-TEC STABILIZED. OPERATION OF THIS RETROFIT SYSTEM
BEGAN IN DECEMBER, 1977.
LOUISVILLE GAS ft ELECTRIC
CANE RUN
6
RETROFIT 288.0 MW (GROSS)
268.0 HW (ESC)
COAL
4.80 XS BITUMINOUS
DUAL ALKALI
AOL/COMBUSTION EQUIP ASSOCIATE
ENERGY CONSUMPTION: 1.0X
STATUS 1 STARTUP 4/79
LOUISVILLE GAS AND ELECTRIC'S CANE RUN 6 IS A PULVERIZED BITUMINOUS COAL
(3.75% S, 11,500 BTU/LB) FIRED UNIT IN LOUISVILLE, KENTUCKY. ADL/COMBUS-
TION EQUIPMENT ASSOCIATES SUPPLIED A RETROFIT DUAL ALKALI DEMONSTRATION
FGD SYSTEM FOR THIS UNIT. THE EMISSION CONTROL SYSTEM, DESIGNED TO REMOVE
95X OF THE FLUE GAS S02, CONSISTS OF A COLD SIDE ESP AND TWO TRAY TOWER
MODULES. THE CLEANED CAS PASSES THROUGH A CHEVRON MIST ELIMINATOR AND TWO
DIRECT COMBUSTION REHEATERS BEFORE EXITING A 518 FOOT STACK. THE WATER
LOOP IS OPEN, AND THE SLUDGE IS DISPOSED IN AN ON-SITE CLAY LINED POND.
FOR A ONE YEAR PERIOD FOLLOWING THE FIRST QUARTER OF OPERATION (WHICH BE-
GAN IN APRIL. 1979), THE U.S.EPA WILL SUBSIDIZE A MAX OF S4.S MM FOR OPER
ATION, R&D, AND REPORT WRITING (NOT APPLIED TO ANY CAPITAL EXPENDITURES).
18
-------
EPA UTILITY F60 SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF F6D SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
LOUISVILLE GAS & ELECTRIC
MILL CREEK
1
RETROFIT 358.0 MU (GROSS)
358.0 MW (ESC)
COAL
3.75 XS
LIME/LIMESTONE
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 1.4X
STATUS 2 STARTUP 4/81
MILL CREEK 1 OF LOUISVILLE GAS AND ELECTRIC IS LOCATED IN LOUISVILLEt KEN-
TUCKY. A RETROFIT LIME/LIMESTONE FGD SYSTEM IS PRESENTLY UNDER CONSTRUC-
TION ON THIS PULVERIZED COAL (3.75Z S, 11,500 BTU/LB) FIRED UNIT.
COMBUSTION ENGINEERING IS SUPPLYING THE LIME/LIMESTONE FGD SYSTEM
WHICH WILL COMPLY WITH LOCAL EMISSION STANDARDS BY APRIL OF 1981.
LOUISVILLE GAS & ELECTRIC
MILL CREEK
2
RETROFIT 350.0 MU (GROSS)
350.0 MU (ESC)
COAL
3.75 XS
LIME/LIMESTONE
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 1.4X
STATUS 2 STARTUP 4/82
MILL CREEK 2 OF LOUISVILLE GAS AND ELECTRIC IS LOCATED IN LOUISVILLE, KEN-
TUCKY. A RETROFIT LIMB/LIMESTONE FGD SYSTEM IS PRESENTLY UNDER CONSTRUC-
TION ON THIS PULVERIZED COAL (3.75X S, 11,500 BTU/LB) FIRED UNIT.
COMBUSTION ENGINEERING IS SUPPLYING THE LIME/LIMESTONE FGD SYSTEM UHICH
WILL COMPLY WITH LOCAL EMISSION STANDARDS BY APRIL OF 1982.
LOUISVILLE GAS & ELECTRIC
HILL CREEK
3
NEU 442.0 MU (GROSS)
442.0 MU (ESC>
COAL
3.75 XS BITUMINOUS
LIME
AMERICAN AIR FILTER
ENERGY CONSUMPTION: 1.6X
STATUS 1 STARTUP 8/78
LOUISVILLE GAS AND ELECTRIC'S HILL CREEK 3 IS A 3.7SX S COAL (11,500 BTU/
LB> FIRED UNIT LOCATED IN LOUISVILLE, KENTUCKY. AMERICAN AIR FILTER SUP-
PLIED A CARBIDE LIME FGD SYSTEM FOR THIS UNIT UHICH WAS DESIGNED TO REMOVE
85Z OF THE S02 FROM THE FLUE GAS. AN ESP IS FOLLOUED BY FOUR MOBILE BED
SPRAY TOUERS AND A STEAM TUBE REHEATER. THE UATER LOOP IS OPEN, AND THE
FLYASH AND LIME STABILIZED SLUDGE IS PONDED. THIS UNIT HAS BEEN OPERATION-
AL SINCE AUGUST, 1978 .
LOUISVILLE GAS I ELECTRIC
MILL CREEK
4
NEU 495.0 MU (GROSS)
495.0 MU (ESC)
COAL
3.75 XS
LIME
AMERICAN AIR FILTER
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 7/81
MILL CREEK 4 OF LOUISVILLE GAS AND ELECTRIC IS A PULVERIZED BITUMINOUS
COAL (3.75X S, 11,500 BTU/LB) FIRED UNIT UNDER CONSTRUCTION IN LOUISVILLE,
KENTUCKY. THE EMISSION CONTROL SYSTEM UILL CONSIST OF AN ESP AND FOUR
MOBILE BED SPRAY TOUERS. THE SYSTEM'S UATER LOOP UILL BE CLOSED, AND
THE SLUDGE UILL BE STABILIZED WITH LIME AND FLYASH. STEAM TUBES UILL
PROVIDE REHEAT OF THE CLEANED GASES. THE SYSTEM IS SCHEDULED TO START
UP IN JULY OF 1981.
LOUISVILLE GAS & ELECTRIC
PADDY'S RUN
6
RETROFIT 72.0 MU (GROSS)
72.0 MU (ESC)
COAL
2.5C XS BITUMINOUS
LIME
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 2.8X
STATUS 1 STARTUP 4/73
UNIT 6 AT LOUISVILLE GAS AND ELECTRIc'S PADDY'S RUN STATION IS A DRV BOT-
TOM PULVERIZED COAL (2.5X S. 11,500 BTU/LB) FIRED UNIT IN LOUISVILLE, KEN-
TUCKY. A RETROFIT CARBIDE LIME FGD SYSTEM BY COMBUSTION ENGINEERING TREATS
400,COO ACFM OF FLUE GAS FROM THE BOILER. AN ESP IS FOLLOUED BY TUO MARBLE
BED ABSORBERS, A DIRECT COMBUSTION REHEATER, AND A 250 FOOT STACK. MIST
ELIMINATION IS PROVIDED BY ONE CHEVRON/MODULE. THE LIME FIXATED SLUDGE IS
TRUCKED TO AN UNLINED POND, AND THE UATER LOOP IS CLOSED. THE FGD SYSTEM
BEGAN INITIAL OPERATIONS IN APRIL, 1973.
LOUISVILLE GAS & ELECTRIC
TRIMBLE COUNTY
1
N£U 575.0 MU (GROSS)
575.0 NU (ESC)
COAL
4.00 XS BITUMINOUS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: **•**
STATUS 6 STARTUP 7/84
LOUISVILLE GAS AND ELECTRIC UILL BE INSTALLING FGD SYSTEMS ON TUO OF THE
FOUR BOILERS AT THE UTILITY'S PLANNED TRIMBLE COUNTY STATION IN BEDFORD*
KENTUCKY. THE PULVERIZED 4X S (IF NO COAL UASH IS INCLUDED) COAL FIRED
UNITS' FLUE GAS UILL >EE CLEANED BY ESP'S AND WET SCRUBBING (90X REMOVAL
EFFICIENCY). SLUDGE DISPOSAL STRATEGY is UNDECIDED. UNIT 1 is SCHEDULED
FOR START UP IN JULY OF 1984.
19
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
LOUISVILLE GAS & ELECTRIC
TRIMBLE COUNTY
2
NEW 575.0 MU (6ROSS>
575.0 MU
COAL FIRED UNITS. THE UTILITY IS CURRENTLY REQUESTING/EVALUATING BIOS FOR
THE FGD SYSTEMS, ALTHOUGH THE TYPE OF SYSTEM HAS NOT BEEN DECIDED. ARKAN-
SAS COAL 6 IS SCHEDULED TO BEGIN OPERATIONS IN JANUARY, 1988.
MIDDLE SOUTH UTILITIES
LOUISIANA COAL
1
NEW 890.0 MW (GROSS)
890.0 MW (ESC)
COAL
.SO XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: **«*X
STATUS 5 STARTUP 0/86
MIDDLE SOUTH UTILITIES HAS AWARDED CONTRACTS ON SIX NEW LOW SULFUR <0.5X>
COAL FIRED UNITS. THE UTILITY IS CURRENTLY REQUESTING/EVALUATING BIDS FOR
THE FGD SYSTEMS, ALTHOUGH THE TYPE OF SYSTEM HAS NOT BEEN DECIDED. LOUI-
SIANA COAL 1 WILL START UP IN 1986.
MIDDLE SOUTH UTILITIES
LOUISIANA COAL
2
MEM 890.0 MW (GROSS)
890.0 MW (ESC)
COAL
.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 5 STARTUP 0/88
MIDDLE SOUTH UTILITIES HAS AWARDED CONTRACTS ON SIX NEW LOW SULFUR <0.5X)
COAL FIRED UNITS. THE UTILITY IS CURRENTLY REQUESTING/EVALUATING BIDS FOR
THE FGD SYSTEMS, ALTHOUGH THE TYPE OF SYSTEM HAS NOT BEEN DECIDED. LOUI-
SIANA COAL 2 WILL START UP IN 1988.
MIDDLE SOUTH UTILITIES
MISSISSIPPI COAL
1
NEW 890.0 MW (GROSS)
890.0 MU (ESO
COAL
.SO XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 5 STARTUP 0/85
MIDDLE SOUTH UTILITIES HAS AWARDED CONTRACTS ON SIX NEW LOU SULFUR CQ.SX)
COAL FIRED UNITS. THE UTILITY IS CURRENTLY REQUESTING/EVALUATING BIDS FOR
THE FGD SYSTEMS, ALTHOUGH THE TYPE OF SYSTEM HAS NOT BEEN DECIDED. MISSIS-
SIPPI COAL 1 WILL START UP IN 1985.
20
-------
EPA UTILITY fGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF F60 SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
MIDDLE SOUTH UTILITIES
MISSISSIPPI COAL
2
NEW 890.0 My (GROSS)
890.0 MW
COAL
.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 5 STARTUP 0/87
MIDDLE SOUTH UTILITIES HAS AWARDED CONTRACTS ON SIX NEW LOU SULFUR (0.5X)
COAL FIRED UNITS. THE UTILITY IS CURRENTLY REQUESTING/EVALUATING BIDS FOR
THE FGD SYSTEMS, ALTHOUGH THE TYPE OF SYSTEM HAS NOT BEEN DECIDED. MISSIS-
SIPPI COAL 2 WILL START UP IN 1987.
MINNESOTA POWER K LIGHT
CLAY BOSWELL
4
NEW 554.0 MW (GROSS)
475.0 NU
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION
STATUS OF FGD
SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
MONTANA POWER
COLSTRIP
4
NEW
7CO.O
7CO.O
(GROSS)
COAL
..'0 XS BITUMINOUS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: 5 . OX
STATUS 5 STARTUP 9/82
MUSCATINE 9 IS A PULVIRIZED BITUMINOUS COAL <3Z S, 11.200 BTU/LB) FIRED
UNIT PLANNED BY MUSCATINE POWER AND WATER TO BE LOCATED IN MUSCATINE,
IOWA. THE UTILITY IS CONSIDERING LIME AND LIMESTONE SLURRY SYSTEMS FOR
EMISSION CONTROL. THE FGD SYSTEM WILL FEATURE AN ESP, TWO 100X CAPACITY
TOWERS, STEAM COIL REHEAT, A CLOSED WATER LOOP, AND FORCED OXIDATION OF
THE SLUDGE BEFORE LANDFILL. THE DESIGN SO? REMOVAL WILL BE 94X. START UP
WILL TAKE PLACE IN
NEVADA POhEfr
HARRY ALLEN
1
NEW 500.0 MW (GROSS)
SCO.O MW (ESO
COAL
..... js
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERCY CONSUMPTION: ****x
STATUS 6 STARTUP 6/86
NEVADA POWER'S HARRY ALLEN 1 IS A PLANNED COAL FIRED UNIT TO BE LOCATED IN
LAS VEGAS, NEVADA. THE UTILITY IS CONSIDERING A HOT SIDE ESP IN CONJUNC-
TION WITH AN FGD SYSTEM. SPECIFICATIONS HAVE NOT YET BEEN PREPARED. START
UP IS SCHEDULED FOR JUNE, 1986.
NEVADA POWER
HARRY ALLEN
2
NEW SCO.O MW (GROSS)
SCO.O MW (ESC)
COAL
• ••• • XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: •••*X
STATUS 6 STARTUP 6/87
NEVADA POWER'S HARRY ALLEN 2 IS A PLANNED COAL FIRED UNIT TO BE LOCATED IN
LAS VEGAS, NEVADA. THf UTILITY IS CONSIDERING A HOT SIDE ESP IN CONJUNC-
TION WITH AN FGD SYSTEM. SPECIFICATIONS HAVE NOT VET BEEN PREPARED. START
UP IS SCHEDULED FOR JUNE, 1987.
NEVADA POHEN
HARRY ALLEN
3
NEW SCO.O MW (GROSS)
500.0 MW (ESC)
COAL
••••* xs
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ••••X
STATUS 6 STARTUP 6/88
NEVAtA POWER'S HARRY -M.LEN 3 IS A PLANNED COAL FIRED UNIT TO BE LOCATED IN
LAS VEGAS, NEVADA. THE UTILITY IS CONSIDERING A HOT SIDE ESP IN CONJUNC-
TION WITH AN FGD SYSTEM. SPECIFICATIONS HAVE NOT VET BEEN PREPARED. START
UP IS SCHEDULED FOR JUNE, 1988.
NEVADA POWER
HARRY ALLEN
4
NEW 500.0 MW (GROSS)
500.0 MW (ESC)
COAL
••••• XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ••••X
STATUS 6 STARTUP 6/89
NEVADA POWER'S HARRY ALLEN 4 IS A PLANNED COAL FIRED UNIT TO BE LOCATED IN
LAS VEGAS, NEVADA. THE UTILITY IS CONSIDERING A HOT SIDE ESP IN CONJUNC-
TION WITH AN FGD SYSTEM. SPECIFICATIONS HAVE NOT YET BEEN PREPARED. START
UP IS SCHEDULED FOR JUNE, 1989.
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
NEVADA POWER
REID GARDNER
1
RETROFIT 125.0 nu (GROSS)
125.0 MM (ESC)
COAL
.50 IS BITUMINOUS
SODIUM CARBONATE
ADL/COMBUSTION EQUIP ASSOCIATE
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 4/74
REID GARDNER 1 IS A WET BOTTOM LOU SULFUR COAL (Q.5X S, 12,450 PTU/LB)
FIRED UNIT OWNED BY NEVADA POWER, LOCATED IN MOAPA, NEVADA. A SODIUM CAR-
BONATE-BASED (TRONA) SCRUBBING SYSTEM BY ADL/COMBUSTION EQUIPMENT ASSOCI-
ATES CONSISTS OF ONE MODULE CONTAINING THIN VARIABLE THROAT VENTURIS FOL-
LOWED BY A SEPARATOR IN SERIES WITH A SINGLE STAGE PEFORATED PLATE WASH
TOWER. PRIMARY PARTICULATE CONTROL IS PROVIDED BY UPSTREAM MULTICLONES.
A RADIAL VANE MIST ELIMINATOR PRECEDES AN INDIRECT STEAM HOT AIR REHEATED
AND A 2CO FOOT STACK. THE SYSTEM OPERATES IN AN OPEN WATER LOOP, AND THE
SLUDGE is DISPOSED IN AN ON-SITE CLAY LINED SOLAR EVAPORATION POND. THE
DESIGN S02 REMOVAL EFFICIENCY IS 901. THE SYSTEM HAS BEEN OPERATIONAL
SINCE APRIL, 1974.
NEVADA POWER
REID GARDNER
2
RETROFIT 125.0 MW (GROSS)
125.0 NW 1HE UTILITY IS PRESENTLY PREPARING SPECIFICATIONS FOR
A SCRUBBING SYSTEM. NO ANNOUNCEMENTS HAVE VET BEEN MADE CONCERNING THE
EMISSION CONTROL STRATEGY FOR THIS UNIT. START UP IS EXPECTED IN JUNE OF
1986.
23
-------
EPA UTILITY FbD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDtNTIfICATION
ABSTRACT
NEW YORK STATt ELEC K GAS
S0«tRSE T
1
NEW 870.0 MW ( GROSS)
i-7:.0 MW STARTUP 6/84
THE SOMERSET 1 UNIT Of THE NEW YORK STATE ELECTRIC S GAS CORP. IS A
PULVERIZED COAL BOILER LOCATED IN SOMERSET. NEW YORK. THE BOILER
GENERATES A fLUE GAS FLOW OF 3,100,000 ACFN AND FIRES A BITUMINOUS COAL
WITH AN AVERAGE SULFUR CONTENT OF 2.4X AND AN AVERAGE HEAT CONTENT OF
12,4t: BTU/LB. A COLD SIDE ESP WITH A DESIGN EFFICIENCY OF 99.77* WILL
PROVIDE THE PRIMARY PARTICULATE REMOVAL. A LIMESTONE ABSORBER WITH A
DESIbN REMOVAL EFFICIENCY OF >90Z WILL BE USED FOR S02 REMOVAL. THE
SYSTEM WILL OPERATE IN A CLOSED LOOP MODE. THE SLUDGE IS TO BE DEWATERED
AND STABILIZED BEFORE BEING LANDFILLED.
NIAGARA MOHAWK POWER COOP
CHARLES R. HUNTLEV
66
RETROFIT 1CO.O MU (GROSS)
1CO.O MW
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
NORTHERN STATES POWER
SHERBURNE
1
NEW 74C.O ny CGROSS)
740.0 ny (ESC)
COAL
.80 XS SUBdlTUMINOUS
LIMESTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 2.7X
STATUS 1 STARTUP 3/76
NORTHERN STATES POWER'S SHERBURNE 1 IS A BALANCED DRAFT PULVERIZED SUBBI-
TUMINOUS COAL <0.80X S, 8500 BTU/LB) FIRED BOILER IN BECKER, MINNESOTA. A
SOX EFFICIENT (DESIGN) LIMESTONE/ALKALINE FLYASH FGD SYSTEM SUPPLIED BY
COMBUSTION ENGINEERING HAS BEEN OPERATIONAL ON THIS UNIT SINCE MARCH OF
1976. TWELVE VARIABLE THROAT ROD DECK VENTUR1/MARBLE BED ABSORBER TRAINS
ARE FOLLOWED BY ONE CHEVRON MIST ELIMINATORS/TRAIN, AN IN-LINE HOT WATER
REHEATER. AND A 650 FOOT CORTEM LINED STACK. THE SLUDGE IS FORCIBLY OX I
DIZED AND DISPOSED IN A CLAY LINED SETTLING POND. THE WATER LOOP IS OPEN.
NORTHERN STATES POWER
SHERBURNE
2
NEW 740.0 MW CGROSS)
740.0 MW (ESC)
COAL
.SO XS SUBBITUMINOUS
LIMESTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 2.7X
STATUS 1 STARTUP 4/77
NORTHERN STATES POWER'S SHERBURNE 2 IS A BALANCED DRAFT PULVERIZED SUBBI-
TUMINOUS COAL (0.80X S, 8SOO BTU/LB) FIRED BOILER IN BECKER, MINNESOTA. A
SOX EFFICIENT (DESIGN) LIMESTONE/ALKALINE FLYASH FGD SYSTEM SUPPLIED BY
COMBUSTION ENGINEERING HAS BEEN OPERATIONAL ON THIS UNIT SINCE APRIL OF
1977. TWELVE VARIABLE THROAT ROD DECK VENTURI/MARBLE BED ABSORBER TRAINS
ARE FOLLOWED BY ONE CHEVRON MIST ELIMINATORS/TRAIN. AN IN-LINE HOT WATER
REHEATER, AND A 650 FOOT CORTEM LINED STACK. THE SLUDGE IS FORCIBLY OX I
DIZED AND DISPOSED IN A CLAY LINED SETTLING POND. THE WATER LOOP IS OPEN.
NORTHERN STATES POWER
SHERBURNE
3
NEW 860.0 MW
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF F60 SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
PACIFIC POWER t LIGHT
JIM BRIDGER
4
NEW 550.0 MW (GROSS)
5SO.O NW (ESC)
COAL
.56 XS SUBBITUMINOUS
SODIUM CARBONATE
AIR CORRECTION DIVISION. UOP
EMER6V CONSUMPTION: .2X
STATUS 1 STARTUP 9/79
PACIFIC POWER AND LIGHT'S JIM BRIDGER 4 IS * DRY BOTTOM PULVERIZED
SUBBITUMINOUS COAL (0.56X S. 9300 BTU/LB) FIRED BOILER LOCATED IN
ROCK SPRINGS. WYOMING. A 91X EFFICIENT SODIUM CARBONATE FGD SYSTEM FOR
THIS UNIT WAS SUPPLIED BY THE AIR CORRECTION DIVISION OF UOP. A COLD
SIDE ESP TREATS 2,720.000 ACFM OF FLUE GAS, FOLLOWED BY THREE SIEVE
TRAY ABSORBERS. THE SYSTEM OPERATES IN A CLOSED WATER LOOP MODE. A
SYSTEM CHECK OUT WAS CONDUCTED IN JULY OF 1979, AND OPERATIONS BEGAN
IN SEPTEMBER, 1979.
PENNSYLVANIA POWER
BRUCE MANSFIELD
1
NEW 917.0 MW (GROSS)
917.0 MW (ESC)
COAL
3.00 XS BITUMINOUS
LIM£
CHEMICO
ENERGY CONSUMPTION: 6.OX
STATUS 1 STARTUP 12/75
BRUCE HANSFIELD 1 OF PENNSYLVANIA POWER IS A SUPERCRITICAL, BALANCED DRAFT
BOILER FIRING PULVERIfED COAL (3.OX S, 11,500 BTU/LB) IN SHIPPINGPORT,
PENNSYLVANIA. A CHEMICO THIOSORBIC LIME F6D SYSTEM WAS DESIGNED TO REMOVE
FLVASH AND S02 <92.1X> FROM 3.350,000 ACFM OF FLUE GAS. THE FGD SYSTEM
CONSISTS OF SIX VARIABLE THROAT VENTURI SCRUBBERS FOLLOWED BY SIX FIXED
THROAT VENTURI ABSORBERS, HORIZONTAL MIST ELIMINATORS, TWO DIRECT LOMBUS-
TION REHEATERS, AND A 950 FOOT FLAKE6LASS STACK SHARED BY UNITS 1 AND 2.
THE WATER LOOP IS OPEN, AND THE CALCILOX STABILIZED SLUDGE IS DISPOSED IN
AN OFF SITE LANDFILL. THIS SYSTEM HAS BEEN OPERATIONAL SINCE DECEMBER,
1975.
PENNSYLVANIA POWER
BRUCE MANSFIELD
2
NEW 917.0 MW (GROSS)
917.0 MW (ESC)
COAL
3.00 XS BITUMINOUS
LIME
CHEMICO
ENERGY CONSUMPTION: 6.OX
STATUS 1 STARTUP 7/77
BRUCE MNSFIELD 2 OF PENNSYLVANIA POWER IS A SUPERCRITICAL. BALANCED DRAFT
BOILER FIRING PULVERIIED COAL (3.OX S, 11,500 BTU/LB) IN SHIPPINGPORT,
PENNSYLVANIA. A CHEMICO THIOSORBIC LIME FGD SYSTEM WAS DESIGNED TO REMOVE
FLVASH AND S02 (92.1X> FROM 3,350,000 ACFM OF FLUE GAS. THE FGD SYSTEM
CONSISTS OF SIX VARIABLE THROAT VENTURI SCRUBBERS FOLLOWED BY SIX FIXED
THROAT VENTURI ABSORBERS, HORIZONTAL MIST ELIMINATORS, TWO DIRECT COMBUS-
TION REHEATERS, AND A 950 FOOT FLAKE6LASS STACK SHARED BY UNITS 1 AND 2.
THE bATER LOOP IS OPEN. AND THE CALCILOX STABILIZED SLUDGE IS DISPOSED IN
AN OFF SITE LANDFILL. THIS SYSTEM HAS BEEN OPERATIONAL SINCE JULY, 1977.
PENNSYLVANIA POWER
BRUC E MANSFIELD
J
NEW 917.0 MW (GROSS)
917.0 MW (ESC)
COAL
3.00 XS
LIME
PULLMAN KELLObG
ENERGY CONSUMPTION: ••••!
STATUS 2 STARTUP 5/80
BRUCE MANSFIELD 3 OF PENNSYLVANIA POWER IS A SUPERCRITICAL PULVERIZED COAL
(3.OX S, 11,500 BTU/LB) FIRED BOILER UNDER CONSTRUCTION IN SHIPPINGPORT,
PENNSYLVANIA. FOUR ESI'S WILL TREAT 3.308,000 ACFM OF FLUE CAS, FOLLOWED
BY FIVE (ONE SPARE) PULLMAN KELUD66 THIOSORBIC LIME ABSORBERS WHICH
WILL REMOVE 92.2X OF THE S02. THE CLEANED GAS WILL PASS THROUGH
CHEVRON MIST ELIMINATORS AND DIRECT COMBUSTION REHEATERS BEFORE
DISCHARGE THROUGH A 600 FOOT INCONEL 625 LINED STACK. THE FLVASH STA-
BILIZED SLUDGE WILL BE PIPED TO THE EXISTING OFF SITE LANDFILL PRESENTLY
USED BY UNITS ONE AND TWO. START UP IS EXPECTED IN APRIL OF 1980.
PHILADELPHIA ELECTRIC
CROHBV
RETROFIT 150.0 MW I GROSS)
150.0 MW (ESC)
COAL
3.00 XS
MAGNESIUM OXIDE
UNITED ENGINEERS
ENERGY CONSUMPTION: ••••X
PHILADELPHIA ELECTRIC HAS PLANS FOR THE RETROFIT OF AN FGD SYSTEM ON ONE
OF THE TWO 3.OX SULFUR COAL FIRED BOILERS AT CROMBY STATION IN PHOEN1X-
VILLE, PENNSYLVANIA. A CONTRACT HAS BEEN AWARDED TO UNITED ENGINEERS
FOR A MAGNESIUM OXIDE SYSTEM. THE START UP DATE IS SET FOR JUNE, 1980.
STATUS 3
STARTUP 6/80
PHILADELPHIA ELECTRIC
EDDVSTONE
1A
RETROFIT 120.0 MM (GROSS)
120.0 MW (ESC)
COAL
2.60 XS BITUMINOUS
MAGNESIUM OXIDE
UNITED ENGINEERS
ENERGY CONSUMPTION: *»**X
STATUS 1 STARTUP 9/75
UNIT 1 OF PHILADELPHIA ELECTHIC'S EDDVSTONE. PENNSYLVANIA STATION IS A
BITUMINOUS COAL (2.6* S, 13.600 BTU/LB) FIRED UNIT WHICH USES ESP'S.
MECHANICAL COLLECTORS, AND THREE PARTICULATE SCRUBBERS (TWO VENTRI ROD
AND ONE VENTURI) PROVIDE PRIMARY PARiTICULATE CONTROL. THE 1A FGD SYSTEM
CONSISTS OF A MAG OX ROD DECK SPRAY TOWER FOLLOWING THE VENTURI SCRUBBER.
THE 901 EFFICIENT (DESIGN) ABSORBER, A RETROFIT BV UNITED ENGINEERS, LEADS
TO A LOUVER TYPE MIST ELIMINATOR, A DIRECT COMBUSTION REHEATED, AND A
249 FOOT STACK. THE SPENT SLURRY IS REGENERATED AT THE ESSEX SULFURIC
ACID PLANT IN NEWARK. NEW JERSEY, AND THE MAG-OX IS RETURNED TO EDDY-
STONE. THE SYSTEM OPERATES IN AN OPEN WATER LOOP, AND HAS BEEN OPERA-
TIONAL SINCE SEPTEMBER, 1975.
26
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF F6D SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
PHILADELPHIA ELECTRIC
EODYSTONE
IB
RETROFIT 340.0 MU (GROSS)
240.0 NW (ESC)
COAL
2.60 XS
MAGNESIUM OXIDE
UNITED ENGINEERS
ENERGY CONSUMPTION:
UNIT 1 OF PHILADELPHIA ELECTRIC'S EDDYSTONEi PENNSYLVANIA STATION IS A
BITUMINOUS COAL (2.6Z S, 13.600 BTU/LB) FIRED UNIT WHICH USES ESP'St
MECHANICAL COLLECTORS, AND THREE PARiTICULATE SCRUBBERS (TWO ROD DECK
SPRAY TOWERS AND ONE VENTURI) FOR PRIMARY PARTICULATE CONTROL. THE
IB FGD WILL FOLLOW THE TWO ROD DECK SPRAY TOWERS. A CONTRACT HAS
BEEN AWARDED TO UNITED ENGINEERS FOR A MAGNESIUM OXIDE FGD SYSTEM.
THE START UP DATE IS SET FOR JUNE. 1980.
STATUS 3
****X
STARTUP 6/80
PHILADELPHIA ELECTRIC
EODYSTONE
2
RETROFIT 334.0 MW (GROSS)
334.0 MW (ESC)
COAL
2.50 ZS
MAGNESIUM OXIDE
UNITED ENGINEERS
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 6/80
EDDYSTONE 2 OF PHILADELPHIA ELECTRIC IS A 2.5X SULFUR COAL FIRED BOILER
LOCATED IN EDDYSTONE, PENNSYLVANIA. THE PLANT'S GENERATING
CAPACITY IS 334 MW. » CONTRACT HAS BEEN AWARDED TO UNITED ENGINEERS
FOR A MAGNESIUM OXIDE FGO SYSTEM. THE START UP DATE IS SET FOR JUNE, 1980
POTOMAC ELECTRIC POWER
DICKERSON
4
NEW 850.0 MW (GROSS)
800.0 MW (ESC)
COAL
1.90 ZS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 0/87
DICKERSON 4 OF POTOMAC ELECTRIC POWER IS A PULVERIZED COAL (2.CZ S* 11.000
BTU/LB) FIRED UNIT PLANNED FOR LOCATION IN DICKERSON, MARYLAND. THE UTIL-
ITY IS CONSIDERING AN FGD SYSTEM FOR THIS UNIT, BUT THERE ARE NO FIRM
PLANS FOR THE INSTALLATION OF AN FGD SYSTEM. START UP OF THE BOILER IS
EXPECTED IN 1985. FGD SYSTEM START UP, IF ANY, WILL BE IN 1987.
POWER AUTHORITY OF MEW YORK
ARTHUR KILL
NEW 700.0 MW (GROSS)
700.0 MW (ESC)
COAL
3.00 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 11/87
THE POWER AUTHORITY OE NEW YORK PLANS A NEW 3.OX SULFUR COAL FIRED UNIT
WHICH WILL BE LOCATED AT THE ARTHUR KILL FACILITY ON STATEN ISLAND. THE
UTILITY IS PRESENTLY CONSIDERING FGD SYSTEMS FOR THIS UNIT. PUBLIC SERVICE
COMMISSION HEARINGS ARE CURRENTLY IN PROGRESS. START UP IS EXPECTED IN
NOVEMBER, 1987.
PUBLIC SERVICE OF INDIANA
GIBSON
5
NEW 650.0 MW (GROSS)
650.0 MW (ESC)
COAL
3.30 ZS
LIMESTONE
PULLMAN KELLOGG
ENERGY CONSUMPTION: ***«Z
STATUS 3 STARTUP 0/82
GIBSON 5 OF PUBLIC SERVICE OF INDIANA IS A 3.3Z SULFUR COAL FIRED UNIT
PLANNED FOR LOCATION UN PRINCETON, INDIANA. A CONTRACT WAS AWARDED TO
PULLMAN KELLOGG FOR A LIMESTONE FGD SYSTEM CONSISTING OF FOUR KELLOG6-
WEIR ABSORBER-REACTOR MODULES. SYSTEM START UP IS EXPECTED IN 1982. THE
SYSTE1 WILL USE KELLOGG'S PROPRIETARY MAGNESIUM-PROMOTED LIMESTONE.
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
1
RETROFIT 361.0 NW (GROSS)
361.0 NW (ESC)
COAL
.80 XS
UELLHAN LORD
DAVY POWERGAS
ENERGY CONSUMPTION: 4.4X
STATUS 1 STARTUP 4/78
SAN JUAN 1 OF PUBLIC SERVICE OF NEW MEXICO IN WATERFLOW, NEW MEXICO IS A
COAL (0.8X S, 8100 BTI/LB) FIRED BOILER WHICH SUPPLIES 1,319,000 ACFM OF
FLUE GAS TO A RETROFIT WELLMAN LARD FGD SYSTEM BY DAVY POWERGAS. THE EMIS-
SION CONTROL SYSTEM, -(PERATIONAL SINCE APRIL OF 1978, CONSISTS OF A HOT
SIDE ESP FOLLOWED BY FOUR (ONE SPARE) VENTURI SCRUBBER/SPR AY TOWER ABSOR-
BER TRAINS WHICH WERE DESIGNED TO REMOVE 85X OF THE FLUE GAS S02. AN IN-
DIRECT HOT AIR REHEATER PRECEDES A BRICK LINED STACK. END PRODUCT ELEMEN-
TAL SULFUR IS PRODUCED BY THE ALLIED CHEMICAL PROCESS. THE WATER LOOP IS
CLOSED.
27
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
PUBLIC SERVICE OF NEU MEXICO
SAN JUAN
2
RETROFIT 350.0 HW (CROSS)
350.0 Hy (ESC>
COAL
.80 ZS
WELLNAN LORD
DAVY POWERGAS
ENERGY CONSUMPTION: 4.61
STATUS 1 STARTUP 8/78
SAN JUAN 2 OF PUBLIC SERVICE OF NEU MEXICO IN WATERFLOW, NEW MEXICO IS A
COAL (0.82 S, 8100 BTU/L6) FIRED BOILER UHICH SUPPLIES 1,319.000 ACFM OF
FLUE GAS TO A RETROFIT WELLMAN LORD FGD SYSTEM BY DAVY POUER6AS. THE EMIS-
SION CONTROL SYSTEM, OPERATIONAL SINCE AUGUST OF 1978, CONSISTS OF A HOT
SIDE ESP FOLLOWED BY FOUR (ONE SPARE) VENTURI SCRUBBER/SPRAY TOWER ABSOR-
BER TRAINS WHICH WERE DESIGNED TO REMOVE 85* OF THE FLUE GAS S02. AN IN-
DIRECT HOT AIR REHEATER PRECEDES A BRICK LINED STACK. END PRODUCT ELEMEN-
TAL SULFUR IS PRODUCED BY THE ALLIED CHEMICAL PROCESS. THE WATER LOOP IS
CLOSED.
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
3
NEW 534.0 NW (GROSS)
534.0 MU ( ESC)
COAL
.60 tS
WELLMAN LORD
DAVY POWERGAS
ENERGY CONSUMPTION: *«••!
STATUS 1 STARTUP 12/79
SAN JUAN 3 IS A COAL 10.81 S, 8100 BTU/LB) FIRED UNIT OF THE PUBLIC
SERVICE OF NEW MEXICO AND IS LOCATED IN UATERFLOW, NEW MEXICO. THE FGo
SYSTEM, SUPPLIED BY DAVY POWERGAS IS AN INTEGRATION OF THE WELLMAN
LORD SO? RECOVERY PROCESS AND ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR
PROCESS. FIVE (ONE SPARE) VENTURI SCRUBBER/SPRAY TOWER ABSORBER (90* DE-
SIGN S02 REMOVAL) TRA4NS FOLLOW A HOT SIDE ESP. AN INDIRECT HOT AIR
REHEATER BOOSTS THE GAS TEMPERATURE 50 DE6 F. THE SYSTEM OPERATES
IN A CLOSED WATER LOOP MODE. OPERATIONS COMMENCED IN DECEMBER, 1979.
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
4
NEW 534.0 NW (GROSS)
534.0 NW (ESC)
COAL
.80 IS
WELLMAN LORD
DAVY POWERGAS
ENERGY CONSUMPTION: ••••!
STATUS 2 STARTUP 1/82
SAN JUAN 4 IS A COAL 10.8Z S, 8100 BTU/LB) FIRED UNIT OF THE PUBLIC SER-
VICE OF NEW MEXICO UMIER CONSTRUCTION IN WATERFLOW, NEW MEXICO. THE FGD
SYSTEM BEING SUPPLIED BY DAVY POWERGAS IS AN INTEGRATION OF THE WELLMAN
LORD S92 RECOVERY PROCESS AND ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR
PROCESS. FIVE (ONE SPARE) VENTURI SCRUBBER/SPRAY TOWER ABSORBER (90S DE-
SIGN S02 REMOVAL) TRAINS WILL FOLLOW A HOT SIDE ESP. AN INDIRECT HOT AIR
REHEATER WILL BOOST THE GAS TEMPERATURE 50 OE6 F. THE SYSTEM WILL OPERATE
IN A CLOSED WATER LOOP MODE. START UP IS EXPECTED IN JANUARY, 1982
SALT RIVER PROJECT
CORONADO
1
NEW 350.0 NW (GROSS)
280.0 HW (ESC)
COAL
1.00 ZS SUBBITUHINOUS
LIMESTONE
PULLMAN KELLOGG
ENERGY CONSUMPTION: ••••I
STATUS 1 STARTUP 11/79
SALT RIVER PROJECT'S CORONADO 1 IS A DRY BOTTOM PULVERIZED SUBBITUNINOUS
COAL (1.0Z S, 8300 BTl/LB) FIRED BOILER LOCATED IN ST. JOHNS,
ARIZONA. PULLMAN KELLOGG SUPPLIED THE TWO LIMESTONE HORIZONTAL WEIR SPRAY
TOWERS WHICH WILL REMOVE 82.51 OF THE S02 FROM THE FLUE GAS PASSED THROUGH
THEM. VERTICAL HEIL MIST ELIMINATORS PRECEDE A soo FOOT STACK. A MINIMUM
OF 2CX BYPASS PROVIDES REHEAT. THE WATER LOOP IS AN OPEN MODE, AND THE
UNSTABILIZED SLUDGE IS DISPOSED IN AN UNLINED POND. START UP WAS
IN NOVEMBER, 1979.
SALT RIVER PROJECT
CORONADO
2
NEW 350.0 HW (GROSS)
280.0 NW
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
SAN
SAN
1
NEW
MIGUEL ELECTRIC COOP
MIGUEL
400.0 MU CGROSS)
400.0 NU
COAL
1.70 XS LIGNITE
LIMESTONE
BABCOCK I UILCOX
ENERGY CONSUMPTION: 5.OX
STATUS 2 STARTUP 9/80
SAN MIGUEL 1 OF THE SAN MIGUEL ELECTRIC COOP IS A LIGNITE <1.7» S. 5000
BTU/LB) FIRED RADIANT BOILER UNDER CONSTRUCTION IN SAN MIGUELt TEXAS. THE
EMISSION CONTROL SYSTEM ON THIS UNIT WILL CONSIST OF A COLD SIDE ESP FOL-
LOWED BY FOUR BABCOCK AND UILCOX 86X EFFICIENT LIMESTONE TCA MODULES.
CHEVRON MIST ELIMINATORS MILL PRECEDE AN IN-LINE REHEATER AND AN ACID
BRICK LINED STACK. THE HATER LOOP WILL BE CLOSEDt AND THE DEUATERED SLURRY
WILL BE MIXED WITH FLYASH BY RESEARCH COTTRELL AND DISPOSED IN AN OFF SITE
LANDFILL.
SEMINOLE ELECTRIC
SEMINOLE
1
NEW 620.0 MU (GROSS)
620.0 MU (ESC>
COAL
2.75 XS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: • «••*
STATUS 5 STARTUP 6/83
SEMINOLE 1 OF SEMINOLE ELECTRIC IS A COAL C2.75X S, 11.700 BTU/LB) FIRED
UNIT PLANNED FOR LOCATION IN PALATKA, FLORIDA. THE EMISSION CONTROL SYSTEM
MILL CONSIST OF ESP'S AND A LIMESTONE FGD SYSTEM. THE UTILITY IS CURRENTLY
REQUESTING/EVALUATING BIDS FOR THE SYSTEM. START UP IS EXPECTED IN JUNE OF
1983.
SEMINOLE ELECTRIC
SEMINOLE
2
NEW 620.0 MU (GROSS)
620.0 MU
COAL
2.75 XS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 5 STARTUP 6/85
SEMINOLE 2 OF SEMINOLI ELECTRIC IS A COAL C2.75X S. 11,700 BTU/LB) FIRED
UNIT PLANNED FOR LOCATION IN PALATKA, FLORIDA. THE EMISSION CONTROL SYSTEM
WILL CONSIST OF ESP'S AND A LIMESTONE FGD SYSTEM. THE UTILITY IS CURRENTLY
REQUESTING/EVALUATING BIDS FOR THE SYSTEM. START UP IS EXPECTED IN JUNE OF
1985.
SIKESTON BOARD OF MUNIC. UTIL.
SIKESTON
1
NEW 235.0 NU (GROSS)
235.0 MU (ESC)
COAL
2.80 XS
LIMESTONE
BABCOCK K WILCOX
1.6X
1/81
THE SIKESTON BOARD OF MUNICIPAL UTILITIES' SIKESTON 1 IS A PULVERIZED COAL
(2.8X S, 11,340 BTU/LB) FIRED BOILER UNDER CONSTRCTION IN SIKESTON, MIS-
SOURI. BABCOCK AND WItCOX IS SUPPLYING AN EMISSION CONTROL SYSTEM CONSIST-
ING OF TWO ESP'S AND THREE SOX CAPACITY LIMESTONE VENTURI FGD MODULES. THE
CLEANED GAS UILL PASS THROUGH CHEVRON MIST ELIMINATORS BEFORE EXITING A
450 FOOT FRP LINED FLUE (A SECOND CARBON STEEL LINED FLUE, USED FOR EMER-
GENCY BYPASS, IS ALSO IN THE STACK). THE UATER LOOP WILL BE OPEN, AND THE
SLUDGE UILL BE PONDED. START UP IS StiATED FOR JANUARY, 1981.
ENERGY CONSUMPTION:
STATUS 2 STARTUP
SOUTH CAROLINA PUBLIC SERVICE
WINVAH
2
NEW 280.0 NW (GROSS)
140.0 MU (ESC)
COAL
1.70 XS BITUMINOUS
LIMESTONE
BABCOCK > WILCOX
ENERGY CONSUMPTION: 1.1X
STATUS 1 STARTUP 7/77
UINYAH 2 OF SOUTH CAROLINA PUBLIC SERVICE IS A PULVERIZED BITUMINOUS COAL
(1.70X S, 11,500 BTU/LB) FIRED UNIT LOCATED IN 6EOR6ETOUN, SOUTH CAROLINA.
A COLD SIDE ESP AND A BABCOCK AND UILCOX VENTURI SCRUBBER/LIMESTONE TRAY
TOWER ABSORBER TRAIN 'DESIGNED TO REMOVE 69X OF THE S02 FROM THE BOILER
FLUE GAS MAKE UP THE EMISSION CONTROL SYSTEM ON THIS UNIT. THE SYSTEM
OPERATES IN AN OPEN UATER LOOP. AND .THE SLUDGE IS DISPOSED IN AN ON-SITE
UNLINED POND. THIS SYSTEM MAS BEEN OPERATIONAL SINCE JULY OF 1977.
SOUTH CAROLINA PUBLIC SERVICE
UINYAH
3
NEW 280.0 MU (GROSS)
280.0 HU (ESC)
COAL
1.70 XS
LIMESTONE
BABCOCK t UILCOX
ENERGY CONSUMPTION: 2.1X
STATUS 2 STARTUP 5/80
WINYAH 3 IS A DRV BOTTOM BOILER UNDER CONSTRUCTION BY SOUTH CAROLINA PUB-
LIC SERVICE UNICH UILfc BURN 1.7X SULFUR COAL <11,500 BTU/LB) IN GEORGE-
TOWN, SOUTH CAROLINA. AN ESP WILL PRECEDE A BABCOCK AND UILCOX LIMESTONE
FGD SYSTEM AND AN INDIRECT STEAM REHEATER. THE WATER LOOP UILL BE CLOSED.
EXPECTED START UP DATE IS NAV. 1980.
29
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
SOUTH CAROLINA PUBLIC SERVICE
UINVAH
I
NEW 280.0 MU (GROSS)
280.0 MU
-------
EPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
SOUTHWESTERN ELECTRIC POWER
HENRY W. PERKEV
1
NEW 720.0 MW
COAL
.80 ZS LIGNITE
LIMESTONE
AIR CORRECTION DIVISION. UOP
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 12/84
HENRY W. PERKEY 1 IS I WET BOTTOM LIGNITE CO.82 S, 6300 BTU/LB) FIRED UNIT
PLANNED BY SOUTHWESTERN ELECTRIC POWER FOR LOCATION IN HALLSVILLE. TEXAS.
A CONTRACT HAS BEEN ABARDED TO THE AIR CORRECTION DIVISION OF UOP FOR FOUR
LIMESTONE SPRAY TOWERS (99»Z EFFICIENCY). HIST ELIMINATION WILL BE PRO-
VIDED BY TUO STAGE CHEVRONS. AND THE STACK WILL BE ACID BRICK LINED. NO
REHEAT IS PLANNED. THE WATER LOOP WILL BE CLOSED. AND THE SLUDGE HILL BE
P02-C-TEC STABILIZED. START UP IS EXPECTED BY DECEMBER. 1983.
SPRINGFIELD CITY UTILITIES
SOUTHWEST
1
NEW 194.0 MW (GROSS)
194.0 MW IESC>
COAL
3.50 ZS BITUMINOUS
LIMESTONE
AIR CORRECTION DIVISION, UOP
ENERGY CONSUMPTION: 4.6X
STATUS 1 STARTUP 4/77
SPRINGFIELD CITY UTILITIES' SOUTHWEST 1 IS A PULVERIZED BITUMINOUS COAL
(3.5k S, 12.500 BTU/LB) FIRED BOILER LOCATED IN SPRINGFIELD, MISSOURI. THE
EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A COLD SIDE ESP FOLLOWED
BY TbO UOP LIMESTONE TCA MODULES WHICH WERE DESIGNED TO REMOVE 801 OF THE
FLUE GAS S02. ONE CHEVRON/MODULE LEADS TO A 384 FOOT CEILCOTE LINED STACK.
THE DRV FLVASH STABILIZED SLUDGE IS DEWATERED BY A ROTARY DRUM VACUUM AND
TRUCKED TO A LANDFILL. THE SYSTEM HAS BEEN OPERATIONAL SINCE APRIL, 1977.
SPRINGFIELD WATER, LIGHT & PWR
DALLMAN
3
NEW 205.0 MW I GROSS)
205.0 MW
-------
EP* UTILITY FGD SURVEY- FOURTH QUARTER 1979
SECTION 2
STATUS OF F60 SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
TENNESSEE VALLEY AUTHORITY
PARADISE
1
RETROFIT 704.0 MU (GROSS)
704.0 MW (ESC)
COAL
4.20 XS
LIMESTONE
CHEMICO
ENER6V CONSUMPTION: *****
STATUS 3 STARTUP 6/82
PARADISE 1 OF TVA IS A 4.2X SULFUR COAL FIREO UNIT LOCATED IN PARADISE,
KENTUCKY. A CONTRACT HAS BEEN AWARDED TO CHEMICO FOR AN 84.21 EFFICIENT
LIMESTONE FGD SYSTEM TO BE RETROFITTED ON THIS BOILER. SIX VENTURI SCRUB-
BERS AND VENTURI ABSORBER TRAINS WILL FOLLOW AN ESP. INLET FLUE GAS WILL
BE USED TO HEAT WATER, WHICH IN TURN WILL BE USED TO REHEAT THE OUTLET
FLUE GAS. FORCED OXIDATION WILL BE USED IN ONE MODULE TO CONTROL SCALING
THROUGHOUT THE SYSTEM. THE UTILITY EXPECTS TO GET AN 80X SOLIDS LANDFILL-
ABLE GRADE SLUDGE. OPERATIONS SHOULD START IN JUNE, 1982.
TENNESSEE VALLEY AUTHORITY
PARADISE
2
RETROFIT 704.0 HW (GROSS)
704.0 MW I ESC)
COAL
4.20 XS
LIMESTONE
CHEMICO
ENERGY CONSUMPTION: ****X
STATUS 3 STARTUP 3/82
PARADISE 2 OF TVA IS A 4.2X SULFUR COAL FIRED UNIT LOCATED IN PARADISE,
KENTUCKY. A CONTRACT HAS BEEN AWARDED TO CHEMICO FOR AN 84.2X EFFICIENT
LIMESTONE FGD SYSTEM TO BE RETROFITTED ON THIS BOILER. SIX VENTURI SCRUB-
BERS AND VENTURI ABSORBER TRAINS WILL FOLLOW AN ESP. INLET FLUE GAS WILL
BE USED TO HEAT WATER, WHICH IN TURN WILL BE USED TO REHEAT THE OUTLET
FLUE GAS. FORCED OXIDi T10N WILL BE USED IN ONE MODULE TO CONTROL SCALING
THROUGHOUT THE SYSTEM. THE UTILITY EXPECTS TO GET AN SOX SOLIDS LANDFILL-
ABLE GRADE SLUDGE. OPERATIONS SHOULD START IN MARCH, 1982.
TENNESSEE VALLEY AUTHORITY
SHAWNEE
IDA
RETROFIT 10.0 MW (GROSS)
10.0 HW (ESC)
COAL
2.90 XS BITUMINOUS
LIME/LIMESTONE
AIR CORRECTION DIVISION, UOP
ENERGY CONSUMPTION: ****X
STATUS 1 STARTUP 4/72
SHAWNEE 10 OF TVA IS A 2.9X SULFUR BITUMINOUS COAL FIRED BOILER LOCATED IN
PADUCAH, KENTUCKY. MODULE 10A IS A RETROFIT PROTOTYPE LIME/LIMESTONE TCA
SYSTEM SUPPLIED BY THE AIR CORRECTION DIVISION, UOP. THE SYSTEM UTILIZES
A CHEVRON MIST ELIMINATOR AND A DIRECT COMBUSTION REHEATER, AND OPERATES
IN A CLOSED WATER LOO*. THIS TEST PROGRAM IS FUNDED BY THE EPA WITH TVA AS
THE CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN FRANCISCO
IS THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER. THE SYSTEM HAS
BEEN OPERATIONAL SINCE APRIL, 1972.
TENNESSEE VALLEY AUTHORITY
SHAWNEE
10B
RETROFIT 10.0 MW (GROSS)
10.0 MW
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF F60 SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
TEXAS MUNICIPAL POWER AGENCY
GIBBONS CREEK
1
NEW 400.0 HW (CROSS)
4QC.O MU
COAL
.70 XS LIGNITE
LIMESTONE
CHEHICO
ENERGY CONSUMPTION: ****X
STATUS 3 STARTUP 8/85
TWIN OAKS 2 IS A 0.75X SULFUR LIGNITE FIRED "BOILER PLANNED BY TEXAS POWER
AND LIGHT AND ALCOA FOR LOCATION IN BREMOND* TEXAS. A CONTRACT HAS BEEN
AWARDED TO CHEMICO FOR A LIMESTONE FGD SYSTEM ON THIS UNIT. START UP IS
EXPECTED IN AUGUST OF 1985.
TEXAS UTILITIES
FOREST GROVE
1
NEW 750.0 MU (GROSS)
750.0 NW (ESC)
COAL
.80 XS LIGNITE
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ***«X
STATUS 5 STARTUP 0/81
TEXAS UTILITIES IS PLANNING A LIGNITE (0.8X S, 7000 BTU/LB) FIRED BOILER,
FOREST GROVE 1, WHICH WILL BE LOCATED IN ATHENS, TEXAS. THE UTILITY IS
PRESENTLY REQUESTING BIDS ON AN FGO SYSTEM FOR THIS UNIT. TWO ESP'S WILL
PROVIDE PRIMARY PARTICULATE CONTROL, AND NO STACK GAS REHEAT IS PLANNED.
START UP IS EXPECTED iN LATE 1981.
TEXAS UTILITIES
MARTIN LAKE
1
NEW 793.0 MW (GROSS)
595.0 MW (ESC)
COAL
.90 XS LIGNITE
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: 1.3X
STATUS 1 STARTUP 4/77
TEXAS UTILITIES' MARTI* LAKE 1 IS A LIGNITE (0.9X S, 7380 BTU/LB) FIRED
BOILER IN TA1UM, TEXAS. THIS UNIT IS EQUIPPED WITH AN EMISSION CONTROL
SYSTEM WHICH INCLUDES A COLD SIDE ESP AND A LIMESTONE FGD SYSTEM, BOTH
SUPPLIED BY RESEARCH COTTRELL. THE FGD SYSTEM CONSISTS OF SIX PACKED SPRAY
TOWER ABSORBERS WHICH TREAT 75X OF THE TOTAL BOILER FCUE CAS. THE REMAIN-
ING FLUE GAS IS BYPASSED FOR REHEAT. THE TOTAL DESIGN SO 2 REMOVAL EFFICI-
ENCY IS 70.5X. TWO CHEVRONS/NODULE PROVIDE MIST ELIMINATION. THE FLUE GAS
CLEANING WASTES ARE FLVASH STABILIZED AND DISPOSED IN AN ON-SITE LANDFILL.
THE SYSTEM OPERATES IN A CLOSED WATER LOOP. INITIAL SYSTEM OPERATIONS TOOK
PLACE IN APRIL, 1977.
33
-------
EPA UTILITY FtD SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
TEXAS UTILITIES
MARTIN LAKE
2
NEW 793.0 HU 1GROSS)
595.0 My
COAL
.90 XS LIGNITE
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: 1.3X
TEXAS UTILITIES' MARTIN LAKE 2 IS A LIGNITE (0.9X S, 7380 BTU/LB) FIRED
BOILER IN TATUM, TEXAS. THIS UNIT IS EQUIPPED WITH AN EMISSION CONTROL
SYSTEM WHICH INCLUDES A COLD SIDE ESP AND A LIMESTONE FGD SYSTEM, BOTH
SUPPLIED BY RESEARCH COTTRELL. THE FGD SYSTEM CONSISTS OF SIX PACKED SPRAT
TOWER ABSORBERS WHICH TREAT 75X OF THE TOTAL BOILER FLUE GAS. THE REMAIN-
ING FLUE GAS IS BYPASSED FOR REHEAT. THE TOTAL DESIGN S02 REMOVAL EFFICI-
ENCY IS 70.51. TWO CHEVRONS/MODULE PROVIDE MIST ELIMINATION. THE FLUE GAS
CLEANING WASTES ARE FLYASH STABILIZED AND DISPOSED IN AN ON-SITE LANDFILL.
THE SYSTEM OPERATES IN A CLOSED WATER LOOP. INITIAL SYSTEM OPERATIONS TOOK
PLACE IN MAY, 1978.
STATUS 1
STARTUP 5/78
TEXAS UTILITIES
MARTIN LAKE
3
NEW 793.0 MW (GROSS)
595.0 MW (ESC)
COAL
.90 XS LIGNITE
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: 1.3*
STATUS 1 STARTUP 2/79
TEXAS UTILITIES' MARTIN LAKE 3 IS A LIGNITE (0.9X S, 7380 BTU/LB) FIRED
BOILER IN TATUM, TEXAS. THIS UNIT IS EQUIPPED WITH AN EMISSION CONTROL
SYSTEX WHICH INCLUDES A COLD SIDE ESP AND A LIMESTONE FGD SYSTEM, BOTH
SUPPLIED BY RESEARCH COTTRELL. THE FGD SYSTEM CONSISTS OF SIX PACKED SPRAY
TOWER ABSORBERS WHICH TREAT 75X OF THE TOTAL BOILER FLUE GAS. THE REMAIN-
ING FLUE GAS IS BYPASSED FOR REHEAT. THE TOTAL DESIGN S02 REMOVAL EFFICI-
ENCY IS 70.5X. TWO CHEVRONS/MODULE PROVIDE MIST ELIMINATION. THE FLUE GAS
CLEANING WASTES ARE FLYASH STABILIZED AND DISPOSED IN AN ON-SITE LANDFILL.
THE SYSTEM OPERATES IN A CLOSED WATER LOOP. INITIAL SYSTEM OPERATIONS TOOK
PLACE IN FEBRUARY, 1979.
TEXAS UTILITIES
MARTIN LAKE
«
NEW 750.0 MW (GROSS)
750.0 MW
COAL
.90 XS LIGNITE
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: ••**X
STATUS 3 STARTUP 0/85
MARTIN LAKE 4 OF TEXAS UTILITIES IS A LIGNjTE (0.9X S. 7380 BTU/LB) FIRED
BOILER UNDER CONSTRUCTION IN TATUM, TEXAS. A CONTRACT FOR A LIMESTONE FGD
SYSTEM FOR THIS UNIT HAS BEEN AWARDED TO RESEARCH COTTRELL. CONSTRUCTION
HAS NOT VET BEGUN ON THE FGD SYSTEM. FGD START UP IS EXPECTED IN 1985 OR
1986.
TEXAS UTILITIES
MILL CREEK
1
NEW 750.0 MW (GROSS)
750.0 MW (ESC)
COAL
..... x$ LIGNITE
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 0/85
MILL CREEK 1 OF TEXAS UTILITIES IS A PLANNED LIGNITE FIRED UNIT TO BE
LOCATED IN HENDERSON, TEXAS. THE UTILITY WILL INCLUDE AN FGD SYSTEM ON
THIS UNIT. BUT NO DECISIONS HAVE BEEM HADE AS TO THE PROCESS TYPE OR
VENDOR. ESP'S WILL PROVIDE PRIMARY PARTICULATE CONTROL. START UP IS
EXPECTED IN 1985.
TEXAS UTILITIES
MILL CREEK
2
NEW 750.0 MW (GROSS)
750.0 MW (ESC)
COAL
..... 1$ LIGNITE
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: «*««X
STATUS 6 STARTUP 0/86
MILL CREEK 2 OF TEXAS UTILITIES IS A PLANNED LIGNITE FIRED UNIT TO BE
LOCATED IN HENDERSON, TEXAS. THE UTILITY WILL INCLUDE AN FGO SYSTEM ON
THIS UNIT, BUT NO DECISIONS HAVE BEEN MADE AS TO THE PROCESS TYPE OR
VENDOR. ESP'S WILL PROVIDE PRIMARY PARTICULATE CONTROL. START UP IS
EXPECTED IN 1986.
TEXAS UTILITIES
MONTICELLO
3
NEW 800.0 MW (GROSS)
800.0 MW (ESC)
COAL
1.50 XS LIGNITE
LIMESTONE
CHEMICO
ENERGY CONSUMPTION: ••*•!
STATUS 1 STARTUP 5/78
MONTICELLO 3 OF TEXAS UTILITIES IS A LIGNITE (1.5X S, 7000 BTU/LB) FIRED
UNIT IN MT. PLEASANT, TEXAS. THIS UNIT'S EMISSION CONTROL SYSTEM CONSISTS
OF TWO COLD SIDE ESP'S FOLLOWED BY THREE CHEMICO LIMESTONE SPRAY TOWERS
(74X DESIGN S02 REMOVAL EFFICIENCY). ONE HORIZONTAL CHEVRON MIST ELIMINA-
TOR/MODULE, AND AN INDIRECT HOT AIR REHEATER. THE WATER LOOP IS CLOSED,
AND THE FLYASH STABILIZED SLUDGE IS DISPOSED IN AN ON SITE LANDFILL. THIS
SYSTEM HAS BEEN OPERATIONAL SINCE MAY OF 1978.
34
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS Of FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
TUCSON GAS & ELECTRIC
SPRINGERVILLE
1
NEW 370.0 HW < GROSS)
370.C MM tESC)
COAL
***** IS SUBBITUniHOUS
LINE/SPRAY DRYING
JOY MF6/NIRO ATOMIZER
ENERGY CONSUMPTION: ***•!
STATUS 3 STARTUP 0/85
TUCSOM GAS AND ELECTRIC UILL BE BUILDING TUO NEU UNITS IN SPRINGERVILLE.
COLORADO, SPRINGERVILLE 1 AND 2. THE UNITS UILL FIRE PULVERIZED SUBBITU-
MINOUS COAL (0.53-0.69X S AND 8500-8900 BTU/LB). A CONTRACT HAS BEEN
AWARDED TO JOY MANUFACTURING/NIRO ATOMIZER FOR A LIME/SPRAY DRYING FGD
SVSTE1 TO CONTROL PARTICULATE MATTER AND S02 EMISSIONS. THE SYSTEM UILL
BE DESIGNED TO ACCOMOHATE A REHEATER (SHOULD ONE BE REQUIRED) AND UILL
OPERATE IN A CLOSED UATER LOOP. CLEANED FLUE GAS WILL EXIT THE SYSTEM
VIA A 500 FOOT CONCRETE STACK. OPERATIONS ARE SCHEDULED TO BEGIN IN 1985.
TUCSON GAS &CLECTRIC
SPRINGERVILLE
2
NEW 370.0 MM (GROSS)
370.0 MU (ESC)
COAL
***** XS SUBBITUMINOUS
LIME/SPRAY DRYING
JOY MFG/NIRO ATOMIZER
ENERGY CONSUMPTION: ****X
STATUS 3 STARTUP 0/87
TUCSON GAS AND ELECTRIC UILL BE BUILDING TUO NEU UNITS IN SPRINGERVILLE,
COLORADO, SPRINGERVILLE 1 AND 2. THE UNITS UILL FIRE PULVERIZED SUBBITU-
MINOUS COAL (0.53-0.69X S AND 8500-8900 BTU/LB). A CONTRACT HAS BEEN
AUARDED TO JOY MANUFACTURING/NIRO ATOMIZER FOR A LIME/SPRAY DRYING FGD
SYSTEM TO CONTROL PARTICULATE MATTER AND S02 EMISSIONS. THE SYSTEM UILL
BE DESIGNED TO ACCOMODATE A REHEATER (SHOULD ONE BE REQUIRED) AND UILL
OPERATE IN A CLOSED UATER LOOP. CLEANED FLUE GAS UILL EXIT THE SYSTEM
VIA A 500 FOOT CONCRETE STACK. OPERATIONS ARE SCHEDULED TO BEGIN IN 1987.
UTAH POUER & LIGHT
HUNTER
1
NEW 400.0 MU (GROSS)
360.0 HU (ESC)
COAL
.55 XS BITUMINOUS
LIME
CHEMICO
ENERGY CONSUMPTION: ****X
STATUS 1 STARTUP 5/79
HUNTER 1 OF UTAH POWEt AND LIGHT IS A COAL (0.55X S, 12,500 BTU/LB) FIRED
UNIT IN CASTLEDALE, UTAH. CHEHICO SUPPLIED A PEBBLE LIME UET SCRUBBING
SYSTEM UHICH BECAME 0»ERAT10NAL IN HAY, 1979. THE SCRUBBING SYSTEM IS DE-
SIGNED TO OPERATE IN AN OPEN UATER LOOP UITH AN S02 REMOVAL EFFICIENCY OF
SOX. PRIMARY PARTICULATE CONTROL IS PROVIDED BY AN UPSTREAM ESP, AND STACK
GAS REHEAT IS PROVIDED BY BYPASS. THE SLUDGE IS FLYASH STABILIZED AND DIS-
POSED ON-SITE.
UTAH POUER K LIGHT
HUNTER
2
NEW 400.0 Mw (GROSS)
360.C MU (ESC)
COAL
.55 XS
LIME
CHEMICO
ENERGY CONSUMPTION: ****X
UTAH POUER AND LIGHT'S HUNTER 2 IS A COAL (0.55X S, 12,500 BTU/LB) FIRED
UNIT UNDER CONSTRUCTION IN CASTLEDALE, UTAH. CHEMICO IS SUPPLYING A PEBBLE
LIME UET SCRUBBING SYSTEM DESIGNED TO OPERATE IN AN OPEN UATER LOOP UITH
AN S02 REMOVAL EFFICIENCY OF 80X. AN UPSTREAM ESP PROVIDES PRIMARY PARTIC-
ULATE CONTROL. AND A BYPASS SYSTEM PROVIDES STACK GAS REHEAT. THE SLUDGE
WILL BE FLVASH STABILIZED AND DISPOSED ON-SITE. START UP OF BOTH THE BOIL-
ER AND FGD SYSTEM IS EXPECTED IN JUNE, 1980.
STATUS 2
STARTUP 6/80
UTAH POWER k LIGHT
HUNTER
3
NEU 400.0 MU (GROSS)
400.0 MU
-------
CPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
UTAH POWER t. LIGHT
HUNTIN6TON
1
NEW 430.0 MW tGROSS)
366.0 HW «ESO
COAL
.55 XS BITUMINOUS
LINE
CHEMICO
ENERGY CONSUMPTION: 1.6X
STATUS 1 STARTUP 5/78
HUNTIN6TON 1 OF UTAH POKER IS A TANGENTIALLY FIRED PULYERI2ED COAL (O.SSt
S, 12,500 BTU/LB) BOILER IN PRICE. UTAH. A COLO SIDE ESP TREATS 1,7*2,000
ACFM OF FLUE GAS AND IS FOLLOWED BY A CHENICO LIME FGD SYSTEM CONSISTING
OF FOUR SPRAY TOWERS I80X DESIGN EFFICIENCY). ONE FOUR PASS CHEVRON/MODULE
PROVIDES MIST ELIMINATION, AND A COMBINATION OF A STEAM TUBE AND 10-20X
BYPASS REHEATERS BOOST THE GAS TEMPERATURE 45-50 DEC F. THE SYSTEM OPER-
ATES IK A CLOSED HATER LOOP, AND THE FLYASH STABILIZED SLUDGE IS TRUCKED
TO AN ON-SITE LANDFILL. THE SYSTEM INCLUDES A 600 FOOT ACID BRICK LINED
STACK* AND HAS BEEN OPERATIONAL SINCE MAY OF 1978.
WISCONSIN POWER t LIGHT
COLUMBIA
*
RETROFIT 527.0 MW
COAL
.60 XS
LINE/ALKALINE FLYASH
CHEMICO
ENERGY CONSUMPTION: ««*«X
STATUS 3 STARTUP 1/82
UNIT Z AT WISCONSIN POWER AND LIGHT'S COLUMBIA STATION IN PORTAGE, WISCON-
SIN IS A PULVERIZED COAL (0.8* S, 8600 BTU/LB) FIRED BOILER WHICH BEGAN
OPERATIONS IN 1978. CHEMICO HAS BEEN AWARDED A CONTRACT FOR A RETROFIT
LIME/ALKALINE FLYASH FGD SYSTEM CONSISTING OF TWO SPRAY TOWER ABSORBERS A
HORIZONTAL CHEVRON MIST ELIMINATOR AND 2QX BYPASS REHEAT. A HOT SIDE ESP
WILL PROVIDE PRIMARY PARTICULATE CONTROL. THE CLEANED GAS WILL BE DIS-
CHARGED THROUGH A 650 FOOT GUNITE COATED CARBON STEEL LINED STACK. THE
WATER LOOP WILL BE CLOSED, AND THE LIME AND FLYASH" STABILIZED SLUDGE WILL
BE LANDFILLED. CONSTRDCTION SHOULD BEGIN AROUND MARCH OF 1980, AND PRO-
JECTED FtD SYSTEM STA8T UP DATE IS JANUARY, 1982.
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA fOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - MG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - HU
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGC - MW
EQUIVALENT SCRUBBED CAPACITY - Mb
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTE NT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
ALABAMA ELECTRIC COOP
TOMBIGBEE
2
LEROY
ALABAMA
a
****** (•***»« LB/MMBTU)
516. < 1.200 LB/NMBTU)
525.0
255.0
235.0
243.0
179.0
RILEV STOKER
PULVERIZED COAL
BASE
5/78
449.72 ( 953000 ACFM)
143.9 ( 291 F)
122. ( 400 FT)
******* (*****
COAL
BITUMINOUS
26749.
14.00
10-16
7.00
FT>
( 11500 BTU/LB)
11000-12000
1.15
0.8-1.5
********
** ESP
NUMBER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
** PARTICULATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
so2 DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCT ION'INITIATION
CONTRACT AWARDED
ABSORBER- SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
HOT SIDE
RESEARCH COTTRELL
X 99.J
449.7 ( 953000 ACFM)
143.9 1 291 F)
NONE
THROW AWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
PEABCDY PROCESS SYSTEMS
BURNS t MCDONNELL
FULL SCALE
NEW
- X 99.30
85.QO
9/78
9/78
12/75
8/73
.0
.0
SPRAY TOWER
9/78
PEABODY PROCESS SYSTEMS
37
-------
EPA UTILITY FbD SURVEY: FOURTH QUARTER 1979
ALABAMA ELECTRIC COOP: TOMBIGBEE 2 (CONT.)
NUMBER Of STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - Z
GAS FLOW - CU.M/S
GAS UHPtRATURE - C
LIOUID RtClRCULATION RATE - LITER/S
L/G RATIO - L/CU.H
SOI DESIGN REMOVAL EFFICIENCY - I
•• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - MET/DRY
CAPACITY1- CU.M/S
•• "1ST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONF IGURAT10N
NUMBER OF STAGE S
NUMBER OF PASS ES
PRESSURE DROP - KPA
*• "1ST ELIMINATOR
NUMBER
CONFIGURATION
NUMBER OF STAGES
•• PUMPS
SERVICE
ABSORBER RECIRCULATlON
LIMESTONE MILL SLURRY RECIRCULATION
LIMESTONE SLURRY FEED
MIST ELIMINATOR HASH
UASTc SLURRY
SUPERNATE RETURN
?4 DIA X 9C HIGH
CARBON STEEL
RUBBER LINED
35.0
127.41
54. 4
1259.
9.4
85.0
( 270000 ACFM)
( 130 F>
(19980 GPM)
( 70.0 GAL/1000ACF)
2
BOILER
CARBON
DRY
225.10
10
STEEL
( 477000 ACFM)
CHEVRON
PLASTIC
HORIZONTAL
2
T
".0
HORIZONTAL
1
NUMBER
t .1 1N-H20>
TANKS
SERVICE
SLURRY RECYCLE
LIMESTONE SLURRY
WASH WATER
NUMBER
1
1
1
•• REHEATER
NUMBER
TYPE
HEATING MEDIUM
ENERGY REQUIRED
•• THICKENER
NUMBER
«* MATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
.. «EA6E*T PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
BALL MILL CAPACITY- M T/H
BEA6ENT PRODUCT - X SLURRY SOLIDS
•• TREATMENT
•• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
BYPASS
BYPASS GAS
NONE
CLOSED
8.8
1
9.1
3S.O
FINAL
LINED POND
ON-SITE
PUMPED
34.8
( UO GPM)
( 10.0 TPH)
38
-------
EPA UTILITY F6D SURVEY: FOURTH OUARTER 1979
ALABAMA ELECTRIC COOP: TOMBIGBEE 2 (CONT.)
PERIOD
9/78
... . — PERFORMANCE DATA
MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION Z REMOVAL
S02 PART.
A 81.4 20.7
B 63.9 16.3
SYSTEM 81.4 81.4 81.4 81.4
• • PROBLEMS/SOLUTIONS/COMMENTS
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
720 183 149
INITIAL OPERATION OF THE FGO SYSTEM BEGAN ON SEPTEMBER 23.
10/78
11/78
A 57.0 45.7
B 63.9 46.2
SYSTEM 66.3 57.9 57.9 46.4
A 82.4 78.2
B 49.3 46.8
SYSTEM 88.9 88.4 £8.4 83.9
** PROBLEMS/SOLUTIONS/COMMENTS
744 596 345
720 683 604
IN LATE OCTOBER AND EARLY NOVEMBER BREAKS UERE FOUND IN THE FIBERGLASS
PIPING LEADING TO AND FROM THE DISPOSAL POHD . THE PROBLEMS WERE QUICKLY
CORRECTED fcY THE ARCHITECT/ENGINEER.
12/78
1/79
A 97.6 91.8
B 93.1 87.6
SYSTEM 97.8 97.6 97.6 91.8
A 75.3 75.1
B 65.8 65.6
SYSTEM 89.2 89.2 89. 2 89.0
»« PROEtLEMS/SOLUTIONS/CONMENTS
744 700 683
744 742 662
SOME PLUGGING WAS ENCOUNTERED IN THE HIST ELIMINATOR DUE TO AN ESP OUTAGE.
2/79
3/79
4/79
5/79
6/79
A 94.9 41.9
B 96.3 42.6
SYSTEM 98.4 96.? 96.2 42.6
A 93.1 92.9
B 94.4 93.5
SYSTEM 94.5 94.4 94.4 93.5
A 1CO.O 40.6
B 1CO.O 40.6
SYSTEM 100.0 100.0 100.0 40.6
** PftOBLENS/SOlUTIONS/COHMENTS
THE UTILITY HAS REPORTED TH >T NO UNUSUAL PROBLEMS
A 48.8 47.6
B 58.9 57.4
SYSTEM 92.7 92.6 92.6 90.2
A 1.8 1.0
B
SYSTEM 98.3 96.9 96.9 52.6
*• PRObLEMS/SOLUTIONS/COMMENTS
672 297 286
744 737 696
720 292 292
HAVE OCCURRED.
744 725 671
720 391 379
THE UTILITY REPORTED THAT THE FGD SYSTEM OPERATED WELL DURING HAY AND JUNE
WITH THE EXCEPTION THAT THE MIST ELIMINATORS HAD TO BE REPLACED. THE MIST
ELIMINATORS UERE DEFORMED DURING A TEMPERATURE EXCURSION.
7/79
* 2C.9 16.5
B 73.9 55.9
SYSTEM 93.0 91.1 91.1 71.9
744 587 535
8/79 A
88.9
67.6
39
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
ALABAMA ElECTUC COOP: TOMB JGBE E 2 (CONT.)
—PERFORMANCE DATA —
PERIOD HODULE AVAILABILITY OPERABJLITY RELIABILITY UTILIZATION x REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
9/79
10/79
11/79
12/79
B
SYSTEM
24.9
92.3
99.2
PMOSLEMS/SOLUTIONS/COMMENTS
92.3
18.9
70.2
744
566
522
THE SCRUBBER WAS NOT OPERATED FOR ABOUT 6 HOURS DUE TO A NECESSARY
ADJUSTMENT TO THE MODICON CONTROLLER.
THE SCRUBBER WAS ByPASSED FOR ABOUT 37 HOURS DUE TO AN ESP OUTAGE.
A
B
SYSTEM
83.2
21.8
92.9
100.0
•• PROBLEMS/SOLUTIONS/COMMENTS
92.9
68.3
17.9
76.3
720 591
549
THE UTILITY REPORTED THAT THE SYSTEM WAS AVAILABLE AT ALL TIMES DURING
SEPTEMBER.
A
B
SYSTEM
.c
744
.0 .0
•• PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT NO. 2 GENERATOR WAS DOWN THE ENTIRE MONTH OF OCTOBER.
A
b
SYSTEM
.0
.0
.n
.0
.0
.0
100.0
• • PROBLEHS/SOLUTIONS/COMMENTS
THE GENERATOR REMAINED DOWN THROUGH NOVEMBER.
720
A
B
SYSTEM
22.6
6.0
22.6
4.0
1.0
4.0
744
133
30
96.7
*• PROBLEMS/60LUT10NS/COMMENTS
THE OPERABILITY OF THE FGD UNIT WAS LOU DUE TO THE START-UP OF THE BOILER,
THE FGD SYSTEM WAS NOT AVAILABLE FOR 24 HOURS DUE TO A RUPTURED WASTE
SLURRY LINE.
40
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAhE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - My
NET UNIT GENERATING CAPACITY WO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - Mb
** BOILER DA-TA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - I
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - K
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - ft
ALABAMA ELECTRIC COOP
TOMBIGBEE
3
LEROY
ALABAMA
B
******
516.
(****** LB/MMBTU)
< 1.200 LB/MMBTU)
255.0
235.0
243.0
179.0
RILEV STOKER
PULVERIZED COAL
BASE
6/79
449.72
143.9
122.
< 953000 ACFM)
< 291 F)
( 400 FT)
(***** FT)
COAL
BITUMINOUS
26749.
14.00
10-16
7.00
** ****
1.15
0.8-1.5
( 11500 BTU/LB)
11000-12000
** ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
** PARTICULATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEU/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
so2 DESIGN REMOVAL EFFICIENCY - x
INITIAL START-UP
CONTRACT AUADDED
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
SHELL MATERIAL
SHELL LINER MATERIAL
HOT SIDE
RESEARCH COTTRELL
99.3
449.7
143.9
( 953000 ACFM)
t 291 F)
NONE
THROVAWAY PRODUCT
UET SCRUBBING
LIMESTONE
NONE
PEABCDV PROCESS SYSTEMS
BURNS I MCDONNELL
FULL SCALE
NEW
99.30
85.00
6/79
8/75
.C
.0
SPRAY TOMER
PEABODY PROCESS SYSTEMS
CARBON STEEL
CEILCOTE
41
-------
EPA UTILITY FtD SURVEY: FOURTH QUARTER 1979
ALABAMA ELECTKIC COOP: TOMBJGBEE 3 (CONT.)
BOILER LOAD/ABSORBER - J
GAS FLOW - CU.H/S
GAS TEMPiRATuRE - C
LIQUID RECJRCULATION RATE - LITER/S
L/l» RATIO - L/CU.M
S02 DESIGN REMOVAL EFFICIENCY - X
*• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
35.0
158.09
143.9
1259.
9.4
85.0
( 335000 ACFM)
( 291 F>
(19980 GPM)
( 7C.O GAI/100CACF)
BOILER ID (DIRECT COUPLED)
CARBON STEEL
DRY
225.10 ( 477300 ACFM)
•• MIST ELIMINATOR
NUMBER
TYPE
CONFIGURATION
NUMBER OF STAGES
NUHPER OF PASSES
WASH SYSTEM
PRESSURE DROP - KPA
•• »IST ELIMINATOR
NUMBER
CONFIGURATION
NUMBER OF STAGE s
•• PUMPS
SERVICE
ABSORBER RECI"CULATJON
MILL REC1RCULATION
SLURRY FEED
WASH WATER
WASTE SLURRY
SUPERNATE RETURN
•• TANKS
SERVICE
RECYCLE
LIMESTONE SLURRY
WASH WATER
•• REHEATER
NUMPER
TYPE
HEATING MEDIUM
ENERGY REQUIRED
•• THICKENER
NUMBER
WATER LOOP
TYPE CLOSED
(RES* MAKEUP WATER ADDITION - LITERS/S P. 8
REAGENT PREPARATION EQUIPMENT
NUMBER OF 6ALL MILLS 1
bALL MILL CAPACITY- M T/H 9.1
REAGENT PRODUCT - X SLURRY SOLIDS 35.0
2
CHEVRON
HORIZONTAL
2
3
TOP AND BOTTOM
.2
HORIZONTAL
1
NUMBER
6
2
2
3
2
1
NUMBER
1
1
1
1
BYPASS
BYPASS GAS
NONE
( 1.0 IN-M20)
( 140 6PM)
( 10.0 TPH>
•• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
FINAL
L1NEC POND
ON-SITE
PUMPED
34.8
42
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
ALABAMA ELECTRIC COOP: TOHBIGBEE 3
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - N6/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mfc
NET UNIT GENERATING CAPACITY W/FGD - My
NET UNIT GENERATING CAPACITY UO/FGC - MW
EQUIVALENT SCRUBBED CAPACITY - MW
ALLEGHENY POWER SVS.TEH
PLEASANTS
1
BELMONT
WEST VIRGINIA
B
21.
516.
125C.O
635.0
635.0
( .050 LB/MMBTU)
C 1.200 LB/MMBTU)
519.0
'• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME T£R - M
'• FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - Z
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - K
PULVERIZED COAL
BASE
0/79
1152.85
132.2
366.
6.1
COAL
BITUMINOUS
27912.
******
15.00
10-20
3.70
2-4.5
(2443000 ACFM)
( 270 F)
(1200 FT)
( 2-0.0 FT)
( 12000 BTU/LB)
11,000-13,300
•• ESP
NUMBER
TYPE
SUPPLIER
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
• • PARTICULATE SCRUBBER
TYPE
•• F6D SYSTEM
SALEABLE PRODUCT/THROWAWAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - t
INITIAL START-UP
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
BOILER LOAD/ABSORBER - X
1
COLD SIDE
AIR CORRECTION DIVISION, UOP
1152.9 (2443000 ACFM)
132.2
( 270 F)
NONE
THROkAWAV PRODUCT
WET SCRUBBING
LINE
MG/2-6X
BABCOCK t UILCOX
UNITED ENGINEERS K CONSTRUCTORS
UNITED ENGINEERS * CONSTRUCTORS
FULL SCALE
NEW
- X 99.55
9C.OO
3/79
TRAY TOWER
3/79
BABCCCK ( UILCOX
1
CARBON STEEL
RUBBER
316 AND 316L SS
2*1.0
44
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
ALLEGHENY POWLR SYSTEM: PLEASAMS 1
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
L/0 KATlu - L/C U.M
PRESSURE DROP - K.PA
** CIST ELIMINATOR
MUMPER
TYPf
CONSTRUCTION MA TERIAL
CONF IGURATIOM
WASH SYSTEM
»* REHEA1ER
TYPE
TEMPERATURE BOOST - C
tNERtY REQUIRED
** WATER LOOP
TYPE
132.2
7.4
1.2
( 513030 ACFM)
( 270 F)
( 55.0 GAL/1000ACF)
( 5.0 IN-H20)
CHEVRON
FRP
HORIZONTAL
1ST STAGE-CONTINUOUS BOTTOM AND INTERMITTENT TOP
BYPASS
1) .1
NONE
CLOSED
20 F)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/79
4/79
5/79
6/79
7/79
8/79
9/79
10/79
11/79
12/79
SYSTtM
SYSTEM
*• PRObLEMS/SOLUTIONS/COMMENTS
744
720
THE UNIT STARTED ON MARCH 7 1979. NO HOURS ARE YET AVAILABLE BECAUSE OF
THE RECENT OPERATING STATUS.
A-HODULE HAS BEEN REMOVED FROM SERVICE DUE TO WELD FAILURE ON THE AB-
SORBER DOU.NCOMER.
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
THE UTILITY REPORTED THAT THE UNIT WAS TAKEN OUT OF SERVICE ON JUNE 19
DUE TO SEVERE STACK LINER FAILURE. THE UNIT IS PROJECTED TO BE OUT OF
SERVICE UNTIL THE MIDDLE OF AUGUST.
SYSTEM 744 0
SYSTEM 744 0
SYSTEM 720 0
*• PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT RESTARTED IN LATE SEPT. AFTER COMPLETION OF THE STACK RELINING.
SYSTEM 744
SYSTEM 720
SYSTEM 744
• * PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THIS REPORT PERIOD.
45
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AMD PERFORMANCE DATA fOR OPERATIONAL DOMESTIC fCO SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S0< EMISSION LIMITATION - NG/J
NET PLAMT GENERATING CAPACITY - MW
GROSS UMT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGC - MW
EQUIVALENT SCRUBBED CAPACITY - MW
•• BOIL'R DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
*• FUEL DATA
FUEL TYPc
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•• ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL
•* PARTICULATE SCRUBBER
TYPE
•• FfcD SYSTEM
SALEABLE PRODuCT/THROWAUA1 PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
so2 DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AWARDED
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
EFFICIENCY - X
- X
ARIZONA ELECTRIC POWER COOP
APACHE
2
COCHISE
ARIZONA
344.
590.0
195.0
175.0
183.0
19 !.0
fULEY STOKER
PULVERIZED COAL
BASE
0/78
346.85
118.3
13?.
4.9
.100 LB/MMBTU)
.800 LB/MMBTU)
< 735000 ACFM)
( 245 F)
( 400 FT)
< 16.2 FT)
COAL
BITUMINOUS
23260.
15.00
9.00
( 10000 BTU/LB)
10000-11000
.55
0.5-0.8
********
HOT SIDE
AIR CORRECTION DIVISION, UOP
99.6
NONE
THROVAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH COTTRELL
BURNS * MCDONNELL
FULL SCALE
NEU
99.50
85.00
1/79
8/78
8/78
7/76
7/74
.0
.0
GRID/SPRAY TOWER
8/78
RESEARCH COTTRELL
1
46
-------
EPA UTILITY FCO SURVEY: FOURTH QUARTER 1979
ARIZONA ELECTRIC POWER COOP: APACHE 2 (CONT.)
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
PRESSURE DROP - KPA
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
•* HIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
** WATER LOOP
TYPE
RECOVERED WATER RETURN -LlTER/S
FRESH MAKEUP WATER ADDITION - LITERS/S
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.H
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.H
CARBON STEEL
6LAS '.-FLEX
316 SS SPRAY NOZZLES
188.76 ( 400000 ACFM)
132.2 < Z70 F)
126C. (20000 6PM)
1.5 ( 6.0 IN-H20)
BOILER ID
CARBON STEEL
DRY
94.38
4
CHEVRON
POLYPROPYLENE
HORIZONTAL
2
3
OPEN
340.2
115.9
( 200000 ACFM)
5400 GPM)
1840 6PM)
FINAL
POND
OFF-SITE
PUMPED
22 ACRES X 18 FT DEEP
22.0
484308 I
396.0 ACRE-FT>
FINAL
POND
OFF-SITE
PUMPED
64 ACRES X 18 FT DEEP
64.0
1408896
< 1152.0 ACRE-FT)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/78 SYSTEM 744 303 58.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE LIMESTONE CRUSHER WAS UNABLE TO MEET ITS DESIGN CAPACITY.
A COMPLIANCE TEST WAS COMPLETED BUT THE RESULTS ARE NOT YET AVAILABLE.
THE ACCEPTANCE IS SCHEDULED FOR THE BEGINNING OF 1979.
11/78
12/78
A
a
SYSTEM
25.0
44.0
34.5
17.0
30.0
23.5
SYSTEM
*« PROBLEMS/SOLUTIONS/COMMENTS
720
744
488
512
80.7
THE FGD SYSTEM WAS NOT IN SERVICE DURING DECEMBER OR JANUARY DUE TO
VARIOUS "DEBUGGING" PROBLEMS ESPECIALLY IN MAINTAINING RECYCLE PUMP OPER-
ATION.
RESULTS 01 A RECENT COMPLIANCE TEST INDICATED THAT S02 EMISSIONS WERE
BETWEEN 1.2 LB/MH BTU, THE FEDERAL STANDARD, AND 0.8 LB/MM BTU, THE STATE
47
-------
EPA UTILITY FGD SURVEY: fOURTM QUARTER 19/9
ARIZONA ELECTRIC POWER COOP: APACHE 2 (CONT.)
. . PERFORMANCE DATA ...
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION t REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
STANDARD, WITHOUT THE FGD SYSTEM. THE UTILITY IS CURRENTLY BURNING LOU
SULFUR COAL (0.6X S>. IT IS BELUVED THAT THE STATE STANDARD COULD BE
MET WITHOUT FGD SYSTEM OPERATION WHEN THE FURNACE IS "FINE TUNED".
A 30 HOUR OUTAGE OCCURRED DUE TO A RUPTURED PIPE.
1/79
2/79
3/79
4/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
•• PROULENS/SOLUTIONS/COHMENTS
744
672
744
720
662
COMPLIANCE TESTS WERE RUN ON THIS UNIT LAST NOVEMBER AND THE UNIT WAS
DECLARED COMMERCIAL IN FEBRUARY. THE FGD SYSTEM OPERATES ONLY ABOUT 50
PERCENT OF THE BOILER HOURS BECAUSE THE UNIT OPERATES AT SUCH A LOW
RATING SO PERCENT OF THE TIME THAT THE FGD SYSTEM IS NOT NEEDED.
A BOILER EXPLOSION AT THE BURNER FACE CAUSED THE UNIT TO BE DOWN FROM THE
LAST WEEK IN FEBRUARY THROUGH THE MIDDLE OF MARCH.
5/79
6/79
SYSTEM
SYSTEM
•• PROBLENS/SOLUTIONS/COMMENTS
744
720
THE UTILITY REPORTED THAT THE UNIT ITSELF RAN WELL BUT WAS EXPERIENCING
FAILURE OF THE FRP REAGENT FEED PIPELINE. THE PIPING IS NOW BEING RE-
PLACED WITH CARBON STEEL.
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
.. PROBLEMS/SOLUTIONS/COMMENTS
744
744
720
10/79
11/79
DURING THE THIRD QUARTER THE UNIT ONLY OPERATED ABOUT 25X OF THE TIME
BECAUSE OF CONTINUING PROBLEMS WITH THE REAGENT FEED LINE. THE SECTION
FROM THE GRINDER TO THE SCRUBBERS WAS FRP AND IT FAILED. THE LINE HAS
REPAIRED AT THE END Of SEPTEMBER.
ON NOVEMBER THIRD THE UNIT WILL GO DOWN FOR A 4-6 WEEK SCHEDULED OUTAGE.
SYSTEM '**
SYSTEM 100.0 100.0 100.0 6.3 720 41 41
.. PROBLEMS/SOLUTIONS/COHMENTS
THE UNIT WAS DOWN FOR THE ANNUAL INSPECTION.
12/79 SYSTEM 100.0 .0 .0 .0 744 130 0
• • PROBLEMS/SOLUTIONS/CONHENTS
DURIN6 DECEMBER THE BOILER OPERATED 130 HOURS FOR WHICH THE SCRUBBER WAS
AVAILABLE 100Z OF THE TINE.
48
-------
EPA UTILITY FGD SURVEY: fOURTM QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAWt
PLANT NAME
UNIT NUMBEfc
CITY
STATE
REGULATORY CLASSIFICATION
PASTICULATE LMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - Mg
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY W/FGD - MU
NET UNIT GENERATING CAPACITY WO/FGC - My
EQUIVALENT SCRUBBED CAPACITY - MU
ARIZONA ELECTRIC
APACHE
3
COCHISE
ARIZONA
D
47. <
34*. <
59:. 0
195. C
175.0
183.0
195.0
POWER COOP
.100 LP/MMBTU)
.SCO LB/MMBTU)
*• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOlLER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
•* FUEL DATA
FUEL TYPt
FUEL GRAbE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
R1LEY STOKER
PULVERIZED COAL
BASE
* * / * *
*** * ** *
122.
4.9
COAL
BITUMINOUS
232<0.
15.00
9.00
.55
0.5-C.S
(.**...< ACFM)
(.... F)
( 400 FT>
( 16.2 FT)
( 10000 BTU/LB)
10000-11000
•* ESP
NUMBER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY
** PARTICULAR SCRUBBER
TYPE
** FGO SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION COMPLETION
ABSORBER SPARE CAPACITY INDEX - 2
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
HOT SIDE
AIR CORRECTION DIVISION, UOP
99.6
NONE
THROWAUAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH COTTRELL
BURN ! S MCDONNELL
FULL SCALE
NEW
- t 99.50
85.00
4/79
6/75
4/79
.0
.0
GRID/SPRAY TOMER
4/79
RESEARCH COTTRELL
1
CARBON STEEL
GLASS-FLEX
49
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
ARIZONA ELECTRIC POWER COOP: APACHE 3 (CONT.)
GAS FLOW - CU.M/S
GAS TEMPtRATURE - C
LIQUID RtCIRCULATI ON RATE - LITER/S
PRESSURE DROP - KPA
•• "1ST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER Of STAGES
NUMBER OF PASSES
•• WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LlTERS/S
•• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.H
188.76
132.2
1260.
1.5
4
CHEVRON
POLYPROPYLENE
HORIZONTAL
I
OPEN
340.2
( 400000 ACFN)
( 270 F)
(20000 GPM)
( 6.0 IN-H20)
( 5400 GPM)
FINAL
POND
OFF-SITE
PUMPED
22 ACRES X 18 FT DEEP
22.0
484308
< 396.0 ACRE-FT)
FINAL
POND
OFF-SITE
PUMPED
64 ACRES X
64.0
1408896
18 FT DEEP
< 1152.0 ACRE-FT)
. PERFORMANCE DATA — -——
PERIOD MODULE AVAILABILITY OPEP.ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FG& CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/79 SYSTEM
•• PRObLEMS/SOLUTIONS/COMMENTS
7/79
8/79
9/79
720
UNIT »3 COKMENCED OPERATION DURING JUNE. THE UTILITY REPORTED THAT THE
START-UP WAS TYPICAL WITH NUMEROUS MINOR PROBLEMS.
SYSTEM
SYSTEM
SYSTEM
•• PROBLENS/SOLUTIONS/COHMENTS
744
744
720
DURING THE THIRD QUARTER THE UNIT ONLY OPERATED ABOUT 25X OF THE TIME
BECAUSE OF CONTINUING PROBLEMS WITH THE REAGENT FEED LINE. THE SECTION
FROM THE GRINDER TO THE SCRUBBERS U*S FRP AND IT FAILED. THE LINE WAS
REPAIRED AT THE END OF SEPTEMBER.
744
10/79
11/79
12/79
SYSTEM
A
B
SYSTEM
SYSTEM
89.4
99.5
93.3
99.5
90.3
99.5
90.3
99.5
720
744
713
744
741
•• PRObLEMS/SOLUTlONS/COMMENTS
THE OUTAGE TIME DURING DECEMBER WAS CAUSED BY THE FAILURE OF A FLUE DAMPER
TO OPERATE PROPERLY.
50
-------
EPA UTILITY FGD SURVEY: fOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA fOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT N«ME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - KiG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - My
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - My
*• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOlLER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP D1AME TER - M
• * FUEL DATA
FUEL TYPt
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - I
RANGE ASH CONTENT - Z
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - Z
AVERAGE SULFUR CONTENT - 1
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - Z
RANGE CHLORIDE CONTENT - Z
** MECHANICAL COLLECTOR
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - Z
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
LIUU1D RtClRCULATlON RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - 6/CU.K
PARTICULAU DESIGN REMOVAL EFFICIENCY
- Z
ARIZONA PUBLIC SERVICE
CHOLLA
1
JOSEPH CITY
ARIZONA
C
85.
430.
615.0
119.0
115.0
119.0
119.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/62
245.39
136.7
78.
3.7
FGD SYSTEM
SALEABLE PRODUCT/THROUAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - Z
S02 DESIGN REMOVAL EFFICIENCY - z
COMMERCIAL DATE
( .196 LB/MMBTU)
< 1.000 LB/MMBTU)
C 520000 ACfM)
( 278 F>
< 256 FT)
t 12.0 FT>
COAL
BITUMINOUS
236C9.
13.50
9.7-22.5
15.00
( 10150 BTU/LB)
9650-10600
.50
0.44-1.0
.02
0.01-0.04
CYCLONES
RESEARCH COTTRELL
Z 75.0
2
VENTURl
RESEARCH COTTRELL
I
316L SS
CEILCOTE FLAKEGLASS (LOWER PORTION)
TANGENTIAL
5C.O
99.1 210100 ACFM)
13«.7 278 F)
136.7 2170 6PH)
1.4 1C.1 6AL/1000ACO
******* ***** IN-H20)
2.00 GR/SCF)
4.6
99.2
THROWAWAV PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH COTTRELL
EBASCO
FULL SCALE
RETROFIT
81.00
92.00
12/73
51
-------
EPA UTILITY F&D SURVEY: FOURTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CCNT.)
INITIAL START-IP
CONSTRUCTION COMPLETION
CONTRACT AbARDEO
STARTED REQUESTING BIDS
STARTED PRELIM1NAY DESIGN
ABSORBER SPARE CAPACITY INDEX - Z
ABSORBER SPARE COMPONENT INDEX
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLlLR
NUMBER OF STAGE S
DIMENSIONS - FT
SHELL MATERIAL
SHiLL LINER MAT ERIAL
INTERNAL MATERIAL
BOILER LOAD/ABSORBER - X
GAS (LOW - CU.M/S
&AS TEMPERATURE - C
LIQUID RtCIRCULATION RATE - LITER/S
L/& RATIO - L/C U.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - H/SEC
PARTICIPATE INLET LOAD - G/CU.h
PARTICIPATE OUTLET LOAD- G/CU.M
PARTUULATE REMOVAL EFFICIENCY - Z
S02 INLET CONCENTRATION - PPM
S02 CUTLET CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL HATERIAL
NOZZLE TYPE
BOILER LOAD/ABSORBER - X
6AS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RtCIRCULATION RATE - LITER/S
L/6 RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
PARTICULATE INLET LOAD - G/CU.H
PARTICULATE OUTLET LOAD- G/CU.M
S02 INLET CONCENTRATION - PPM
S02 CUTLtT CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
•• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
*• MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANfiLES
WASH SYSTEM
PRESSURE DROP - KPA
10/73
12/73
7/71
4/71
1/71
.0
.0
GRID/SPRAY TO«ER
10/73
RESEARCH COTTRELL
1
22 DIA X 70 HIGH
316L SS
NONE
316L SS
5C.O
113.26
135.6
630.
6.5
.1
2.1
4.6
.0
99.7
42 C
35
92.0
SPRAY TOWER
10/73
RESEARCH COTTRELL
22 DIA X 70 HIGH
316L SS
NONE
316L SS
SPINNER VANE
5C.O
113.26
135.6
( 240000 ACFM)
< 276 F)
(10030 GPM)
( 48.9 GAL/1000ACF)
I .5 IN-HaO)
< 6.9 FT/S)
( 1.99S GR/SCF)
C .301 GR/SCF)
63C.
6.5
.1
2.1
4.6
.0
42C
315
25.0
SCRUBBER FD
CARBON STEEL
DRV
113.26
( 240000 ACFM)
( 276 F)
(10000 GPM)
( 48.9 6ALMOOCACF)
( .5 IN-H20)
( 6.9 FT/S)
( 1.995 GR/SCF)
( .001 GR/SCF)
( 24QOOO ACFM)
4
CHEVRON
POLYPROPYLENE
HORIZONTAL
2
2
4.11
.30
3.8
45 DEC.
VERTICALLY DOWNWARD
.1
<13.5 FT)
< 1.0 FT)
( 1.SO IN)
( .5 1N-H20)
52
-------
ARIZONA PLBL1C SERVICE: CHOLLA 1 (CCNT.)
EPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
** MIST ELIMINATOR
NUMbER
TYPE
CONSTRUCTION MATERIAL
CONF IGuRATION
NUMPER OF STAGE S
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL MANNER
** PUMPS
SERVICE
SCRtbBtR RECIRCULATlON
ABSORBER RECIRCULATION
.* TANKS
SERVICE
SCRUBBER RECYCLE
SLUDGE HCLDUP
ABSORBER TOWER HOLDUP
LIMESTONE SLURRY MAKEUP
** REHEATER
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
•* WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
•* REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
4
SLAT IMPINGEMENT
POLYPROPYLENE
HORIZONTAL
2
4
4.11
.30
18.0
45 DEC.
INTERMITTENT OVERSPRAy
.1
<13.5 FT>
( 1.0 FT)
( 7.10 IN)
5 IN-H20)
MANUAL
NUMBER
2
2
NUMBER
1
2
1
2
IN-LINE
STEAM
2J.2
"MM BTU/HR
OPEN
7.6
40 F)
( 120 CPM)
** DISPOSAL
NATURE
TYPE
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
FINAL
POND
PUMPED
70-100 ACRES X 6 FT DEEP
85.3
623730 (
510.0 ACRE-FT)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
x REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/73 SYSTEM
11/73 SYSTEM
12/73 SYSTEM
744
72 C
744
** PfOuLEMS/SOLUTIONS/COMMENTS
BECAUSE OF A DIFFERENCE IN THE SI2E OF THE MAIN DUCT AND REHEATED TRANS-
ITIOK DUCT, THE GAS FLOW PRODUCES HARMONIC VIBRATIONS IN THE REHEATER.
THE VIBRATIONS WERE PARTIALLY DAMPENED BY INSTALLATION OF BAFFLES.
ONE OF THE REHEATER BUNDLES WAS BADLY CORRODED BY ACID THAT CONDENSED IN
THE UNINSULATED DUCT UPSTREAM OF THE HEHEATERS. THE TUBE BUNDLE WAS RE-
PLACED AND A BAFFLE WAS INSTALLED TO DIVERT CONDENSED ACID FROM REHEATER
TUBES .
53
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
ARIZONA PLBLIC SERVICE: CHOLLA 1 (COM.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
l REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/7*. A
b
SYSTEM
A
B
SYSTEM
3/74 b
A
SYSTtM
4/74 A
8
SYSTEM
5/74 A
b
SYSTEM
6/74 A
B
SYSTEM
7/74 A
B
SYSTEM
8/74 A
U
SYSTEM
9/74 b
A
SYSTEM
10/74 A
B
SYSTEM
THE DUCT UPSTREAM OF THE REHEATER WAS INSULATED. THE ACID CONDENSATION
OCCURRED ONLY IN THE B-MODULE WHICH CONTAINS NO INTERNAL PACKING AND
THEREFORE HAS A LOWER DEGREE OF SULFUR DIOXIDE REMOVAL <25 PERCENT).
SOME LINES PLUGGED, PARTICULARLY WHEN THE SYSTEM OPERATED AT LOW FLCW
RATES .
SOLIDS SETTLED OUT IN STANDBY PUMPS, AND EXCESSIVE FAN VIBRATIONS OCCURRED
BECAUSE Of ACCUMULATION OF SCALE BUILDUP WHEN THE UNIT WAS IDLE. TC
SOLVE THESE PROBLEMS THE PACKING GLAND POSITION WAS REVERSED (INSTALLED
UPSIDE DOUN>. THE FAN WAS SANDBLASTED. THE PIPING WAS MODIFIED TO
ELIMINATE STAGNANT POCKETS, AND PUMPS WERE FLUSHED IMMEDIATELY AFTER
REMOVAL FI.OM SERVICE.
THE UTILITY EXPERIENCED SOLIDS BUILDUP IN THE FDS STUFFING GLAND BOX AND
ON TOP OF THE SPRAY DOME.
98.0
97.5
98.5
98.n
94.5
1 ::.•
97.3
97.0
9^.0
94.0
100.0
94.0
97.0
06.0
100.0
63.0
66.0
57.C
62.0
99.0
99.0
100.0
10C.O
lud.O
97.0
92.0
95.0
97.0
97.0
97.0
99.0
95.0
97.0
83.0
68.0
76.G
97.5
98.5
93.0
94.5
100.C
97.3
744
672
744
72 C
744 744
720
744 744
744 744
72C
744
739
734
PRObLEMS/SOLUTIONS/COMMENTS
11/74
12/74
A
B
SYSTEM
a
SYSTtM
ANNUAL BOILER AND FGD SYSTEM OVERHAUL,
100.0
98.0
99.0
100.0
100.0
72 C
744
54
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CCHtT.)
___...-.. -------PERFORMANCE DATA-—-----———— — — — — —
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/75 B
A
SYSTEM
3/75
4/75
5/75
6/75
99.0
98.0
744
7/75
*• P&ObLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE SYSTEM THROUGHOUT 1975 AND 1976 WAS ACCOMPANIED BY A NUM-
BER OF MINOR PROBLEM AREAS INCLUDING: SIGNIFICANT CORROSION ATTACK IN THE
VESSEL MALLS OF THE VENTURI FLOODED-DISC PARTICIPATE SCRUBBER MODULE; ACID
CORROSION IN THE B-SIDE REHEATER HOUSING; SCALE BUILDUP IN THE PIPE OUTLET
AT THE SLUDGEVFLYASH EVAPORATION POND; PLUGGING IN THE SCRUBBER TOUER PACK
ING AND MIST ELIMINATOR; EROSION IN THE PUMPS; CORROSION IN THE BOILER EX-
HAUST ELBOW OF THE DUCTWORK LEADING FROM THE SCRUBBERS TO THE STACK.
2/75 A
B
SYSTEM
SYSTEM
A
B
SYSTEM 76.9
A
B
SYSTEM 43.7
«. PRObLEMS/SOLUTIONS/COMMENTS
96.0
99.0
98.0
88.0
65.0
77.0
48.0
40.0
44.0
71.5
43.7
672
744
720 670
744
744
515
325
BOTH MODULES WERE OFF LINE FOR HOST OF THE MONTH FOR SCHEDULED REPAIRS AND
CLEANING.
A
B
SYSTEM
100.0
100.0
100.0
720
«* PHObLEMS/SOLUTIONS/COMMENTS
PLUGGING IN THE A-SIDE ABSORBER PACKING WAS OBSERVED.
PLUGGING OCCURRED IN HIST ELIMINATORS.
NO MAJOR PROBLEMS WERE ENCCUNTERED DURING THE PERIOD.
A
B
SYSTEM
97.0
98.0
98.0
744
PROfaLEUS/SOLUTIONS/COMMENTS
MODULES WERE SHUT DOWN TO CLEAN FLOW RESTRICTIONS IN FLOODED-DISC RECIR-
CULATION LINES.
8/75 A
B
SYSTEM
95.0
100.0
98.0
744
«* PROBLEMS/SOLUTIONS/COMMENTS
THE A-SIDE WAS SHUT DOWN FOR INSPECTION.
9/75 A
B
SYSTEM
64.5
93.1
78.7
98.0
97.0
93.0
64.5
93.0
78.7
720 720
566
55
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
. _ PERFORMANC I DATA ...
PERIOD MODULE AVAILABILITY OPERABIL1TV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*« PROfaLEMS/SOLUTIONS/COMMENTS
MINOR OUTAGE RESULTED FROM PLUGGED FDS REC1RCULAT10N LINES
10/75
11/75
12/75
1/76
2/76
3/76
4/76
5/76
A
e
SYSTEM
78.0
24.5
51.3
£4.0
55.0
70.0
56.4
17.7
37.1
744
538
276
PROBLEMS/SOLUTIONS/COMMENTS
OUTAGES RESULTED FROM SCHEDULED EQUIPMENT OVERHAULS AND RECOATING OF VES-
SELS.
A
B
SYSTEM
100.0
71.4
85.7
100.0
80.0
90.0
100.0
71.4
85.7
720 720 617
•* PSOBLEMS/SOLUTIONS/COHMENTS
NO MAJOR OUTAGES OR PROBLEMS OCCURRED DURING THE REPORT PERIOD.
A
B
SYSTEM
10C.O
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
744 744
PROBLEMS/SOLUTIONS/COMMENTS
MINOR PROBLEMS ENCOUNTERED REQUIRED RECYCLE PUMP REBUILDING.
THE B-SIDE REHEATER COIL MALFUNCTIONED.
744
A
B
SYSTEM
96.0
87.9
91.9
99.0
99.0
99.0
96.0
89.9
91.9
744 744 684
•• PROBLEMS/SOLUTIONS/COHMENTS
MINOR VALVE PLUGGING OCCURRED.
MINOR LINE PLUGGING OCCURRED.
MODULE B OPERATING HOURS HERE LOWER BECAUSE OF REDUCED SYSTEM REQUIREMENTS
SYSTEM 696
SYSTEM 744
A 99.0
B 97.4
SYSTtM 98.2 720
». PRObLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM IS CURRENTLY EKPERIENCEING COATING FAILURES IN THE ELBOW OF
THE SCRUBBER EXHAUST DUCT.
THE UTILITY PERFORMED SOME MINOR REPAIRS TO THE HOUSING OF THE B-SIDE
REHEATER.
A 76.0
B 100.0
SYSTEM 88.0
.« PRObLENS/SOLUTIONS/COMMENTS
744
CORROSION AND PLUGGING PROBLEMS OCCURRED ON THE A-SIDE REHEATER
TUBES.
THE UTILITY REPORTED PLUGS.ING IN FOS LINES.
56
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE 0ATA
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/76
A
B
SYSTEM
8/76
9/76
10/76
11/76
PLUGGING OCCURRED IN THE FDS PACKING.
PLUGGING OCCURRED IN THE HIST ELIMINATORS.
64.0
39.0
52.0
72C
PROBLEMS/SOLUTIONS/COMMENTS
LOW RELIABILITY FACTORS FOR THE MONTH OF JUNE RESULTED FROM A SCHEDULED
MID-YEAR SCRUBBER SHUTDOWN FOR MAINTENANCE, INSPECTION AND REPAIRS.
SOME SCALING AND CORROSION PROBLEMS WERE UNCOVERED IN THE SYSTEM'S RECYCLE
TANKS.
7/76 A
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
100.0
98.0
99.0
744
12/76
A
B
SYSTEM
A
B
SYSTEM
•* PRObLEMS/SOLUTIONS/COMMENTS
REPAIRS TC THE COATING IN THE ELBOW Of THE SCRUBBER EXHAUST DUCT WERE COM-
PLETED.
A MALFUNCTIONING SOLENOID VALVE IN THE B-SIDE HIST ELIMINATOR WASH SYSTEM
PREVENTING ADEQUATE WASHING, RESULTED IN A MINOR SCRUBBER OUTAGE.
744
100.0
93.9
96.9
100.0
100.0
100.0
100.0
100.0
100.0
100.0
93.9
96.9
720 720
698
THE BOILER REMAINED OUT OF SERVICE THE ENTIRE MONTH. NO SIGNIFICANT
PROBLEMS WERE REPORTED.
A
B
SYSTEM 46.5 56.5 82.9 744 417 346
A
B
SYSTEM 86.0 97.Q 86.0 720 720 619
•* PROBLEMS/SOLUTIONS/COHMENTS
TWO MINOR FORCED SCRUBBER OUTAGES OCCURRED DURING THE PERIOD.
A REHEATED STEAM LEAK CAUSED A MINOR FORCED OUTAGE.
AN INLET GAS DAMPER ADJUSTMENT PROBLEM IN BOTH THE A-SIDE AND B-SIDE
SCRUBBING TRAINS CAUSED A MINOR OUTAGE.
55.8
37.2
46.5
94.8
77.2
86. 0
56.0
56.0
56.0
96.0
98.0
97.0
99.5
66.4
82.9
94.8
77.2
86.0
A
B
SYSTEM
99.8
67.0
83.4
98.0
100.0
99.0
99.8
67.0
83.4
744 744
620
** PRObLEHS/SOLUTIONS/COMHENTS
ONE OUTAGE WAS REPORTED. THE OUTAGE WAS THE RESULT OF AN ADDITIONAL AD-
JUSTMENT TO THE A-SIDE GAS INLET DAMPER.
1/77 A
71.6
72.0
71.6
57
-------
EPA UTILITY FCC SURVEY: FOURTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CNOLLA 1 (CONT.)
.... --- . --- . — . --- ... ---------- .. ------ . — PERFORMANCE DATA ---- — ---------- -- --------- - --- -- --- .....
PERIOD MODULE AVAILABILITY CPEBA8ILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B 91.9 93.0 91.9
SYSTEM 81.7 83.0 81.7 7*4 744 608
*« PROBLEMS/SOLUTIONS/COMMENTS
THE PERFO FffANCE INDEX VALUES CONTAINED IN THESE TABLES ARE BASED UPON THE
MODULES' ACTUAL SERVICE TIME FOR THE PERIOD VERSUS THE NUMBER OF HOURS THE
MODULES ASE CALLED UPON TO OPERATE FOR THE SAME PERIOD. THE MODULES OPER-
ATE ON A DEMAND-ONLY BASIS. FLUE GAS IS BYPASSED AROUND THE MODULES WHEN
THEY ARE NOT REQUIRED FOR SERVICE.
2/77 A 96.4 99.0 96.4
B 88.0 99.0 88.0
SYSTEM 92.2 99.0 92.2 672 672 619
•• PHOBLEMS/SOLUTIONS/COMNENTS
THE HUNTERS PACKING IN THE A'SIoE TOWER WAS REPLACED.
MINOR SCRUBBER VESSEL PLUGGING OCCURRED.
MINOR CORROSION OCCURRED IN THE SYSTEM.
SOME PROBLEMS OCCURRED WITH THE LIOUIO PIPING.
THERE WERE MECHANICAL DIFFICULTIES WITH THE BY-PASS DAMPERS.
AVERAGE SO? INLET/OUTLET VALUES DURING THE PERIOD WERE 350 PPM AND 175 PPM
3/77 A
a
STSTEM 81.7 83.0 61.7 744 744 608
4/77 A
98.6 100.0 87.
720 638 632
71.6
91.9
81.7
99.6
98.6
99.1
100.0
1 00.0
100.0
72.0
93.0
83.0
100.0
100.0
100.0
87.0
87.0
87.Q
71.6
91.9
81.7
88.2
87.3
87.7
86.3
86.7
86.7
5/77 .
"
SYSTEM 100.0 87.Q 86.7 744 645 645
•• PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIKE FOR THE BOILER AND FGD SYSTEM WAS A RESULT OF THE SCHEDULED
MID-YEAR SCRUBBER CLEANOUT.
DURING MAY RESEARCH-COTTRE LL PERSONNEL CONDUCTED FORCED OXIDATION TESTS BY
BLOWING AIR INTO THE FLOODED DISC SCRUBBED AND CONVERTING ALL CAS03 TO
CAS04 YIELDING SUPERIOR SLUDGE OEWATERING HANDLING AND SCALE-FREE
OPERATION.
720 720 72C
744 744
•• PROBLEMS/SOLUT10NS/COMMENTS
A MINOR LEAK OCCURRED IN THE LIMESTONE SLURRY TANK.
A MINOR LEAK OCCURRED IN THE B-SIDE RETURN LINE FROM THE FOS TO THE FDS
TANK.
RESEARCH-COTTRELL PERSONNEL ARE STILL ON THE PLANT SITE CONTINUING FORCEDD
OXIDATION STUDIES.
6/77
7/77
A
B
SYSTEM
A
B
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
97.0
99.0
98.0
100.0
100.0
100.0
S'77 A 97.2 97.2 97.0
58
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FG6 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/77
B
SYSTEM
A
B
SYSTEM
98
97
100
100
100
.6
.9
.0
.0
.0
98
97
99
99
99
.6
.9
.7
.7
.7
99
98
100
100
100
.0
.0
.0
.0
.0
98
97
99
99
99
.6
.9
.7
.7
.7
744 744 728
720 720 718
>* PRObLEMS/SOLUTIONS/COMMENTS
DOWN TIME WAS REQUIRED TO REPAIR LEAKS IN THE SLURRY DISPOSAL TANK AND THE
FDS RE TURK LINE.
A LEAK OCCURRED AT THE SLUfRY DISPOSAL TANK.
10/77 A 99.9
B 99.9
SYSTEM 99.9
99.9
99.9
99.9
100.0
100.0
100.0
99.9
99.9
99.9
744
744
743
** PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WERE REPORTED FOR OCTOBER.
11/77
A
B
SYSTEM
100.0
97.4
98.7
99.7
84.3
92.0
100.0
98.0
99.0
23.3
19.7
21.5
720 169
155
«* PKOBLEHS/SOLUTIONS/COMMENTS
THE 6-SIDt OUTAGE UAS DUE TO LEAKS IN THE VENTURI SECTION OF THE SCRUBBER
AND AN EXPANSION JOINT FAILURE IN A RECYCLE PUMP.
ATHE P-SIDE OUTAGE WAS DUE TO LEAKS IN THE VENTURI SECTION OF THE SCRUBBER
AND AN EXPANSION JOINT FAILURE IN A RECYCLE PUMP.
THE BOILER OPERATED ONLY 168.5 HOURS BECAUSE OF A SHUTDOWN FOR OVERHAUL I
IN THE LAST HALF OF NOVEMBER. THE UNIT IS SCHEDULED TO START UP IN MID-
DECEMBER.
12/77 A
B
SYSTEM
.0
.0
.0
744
*« PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBING SYSTEM WERE DOWN AS THE OVERHAUL PERIOD
CONTINUED. THIS MAJOR OVERHAUL CONTINUED INTO JANUARY 1978.
1/78
A
B
SYSTEM
97.0
90.9
94.0
97.0
9C.9
93.9
97.0
91.0
94.0
17.6
16.5
17.0
744 135
127
•• PROBLEMS/SOLUTIONS/COMMENTS
THE FLOODED DISC SCRUBBER TANK HEADER FOR THE LIMESTONE SLURRY WAS REPAIR-
ED AITER BEING DAMAGED DURING THE OVERHAUL. THE BOILER WAS OPERATED ONLY
135 HOURS DURING JANUARY AS THE OVERHAUL HAD EXTENDED INTO THIS MONTH.
2/78
A
B
SYSTEM
99.1
87.9
93.5
99.0
88.0
94.0
94.7
84.0
89.3
672 642
600
PROBLEMS/SOLUTIONS/COMMENTS
SOME MINOR LEAK REPAIRS WERE REQUIRED AFTER THE OVERHAUL/CLEANING TOOK
PLACE DURING FEBRUARY.
3/78 A
B
SYSTEM
100.0
98.8
99.4
74.0
74.0
74.0
100.0
98.8
99.4
744 744
740
59
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
AMI20NA PtBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE OAT*
PERIOD MODULE AVAILABILITY OPERA8JL1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER F6D CAP,
S02 PART. HOURS HOURS HOURS FACTOR
5/78
6/78
7/78
8/78
9/78
10/78
11/78
•* PROULEMS/SOLUTtONS/CONMENTS
ONE FORCED SHUTDOUN OCCURRED ON THE A-SIDE.
4/78
A
B
SYSTEM
92.7
100.0
96.3
100.0
100.0
100.0
92.7
100.0
96.3
720 720
*• PRObLEMS/SOLUTIONS/COMMENTS
A MINOR LEAK REPAIR WAS NECESSARY AFTER AN OVERHAUL/CLEANING.
694
A
B
SYSTEM
86.7
96.2
91.4
87.0
98.0
93.0
86.7
96.2
91.4
744
744
680
•• PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO SIGNIFICANT PROBLEMS REPORTED. ONLY GENERAL MAINTENANCE WAS
PERFORMED ON THE SYSTEM.
A
B
SYSTEM
100.0
99.2
99.6
100.0
100.0
100.0
•• PROfaLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WERE REPORTED.
A
B
SYSTEM
99.4
100.0
99.7
100.0
100.0
100.0
99.2
99.6
99.4
100.0
99.7
720 720
717
744
744
742
•* PROBLEMS/SOLUTIONS/COMMENTS
ONLY ROUTINE MAINTENANCE WAS REQUIRED.
A
B
SYSTEM
10C.O
95.2
97.6
100.0
95.1
98.0
100.0
95.2
97.6
744
744
726
PRObLEMS/SOLUTIONS/COMMENTS
REPAIRS WERE NECESSARY TO PLUGGED B-SIDE REHEAT COILS.
B
A
SYSTEM
95.2
100.0
98.9
100.0
100.0
100.0
»« PRObLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WERE REPORTED.
B
A
SYSTEM
95.9
100.3
97.9
100.0
100.Q
100.0
97.8
100.0
98.9
95.9
100.0
97.9
720 720
712
744 434
712
•* PROBLEMS/SOLUTIONS/COMNENTS
ONLY ROUTINE MAINTENANCE W-AS REQUIRED.
A
B
SYSTEM
100.0
91.3
95.7
100.0
100.0
100.0
100.0
91.3
95.7
720 720
688
60
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CHOLLA 1
-------
EPA UTILITY FGD SURVEY: FOUfcTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CHOLLA i (CONT.)
ptRFORMANCE OAT*
PERIOD MODULE AVAILABILITY OPERA8ILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
INFORMATICS WAS NOT AVAILABLE FOR THE MONTH OF SEPTEMBER.
10/79 A 97.7 100.0 45.0
b 94.T 98.J 43.3
SYSTEM 96.C 99.0 44.C 744 342 328
*• PRObLEMS/SOLUTIONS/COMMENTS
DURINt OCTOBER ROUTINE MAINTENANCE WAS PERFORMED.
11/79 SYST£M 720
12/7S SYSTEM 744
•• PRObLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE MONTHS OF NOVEMBER AND DECEMBER.
62
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY KAKE
PLANT NAHE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mb,
NET UNIT GENERATING CAPACITY W/FGD - MU
NET UNIT GENERATING CAPACITY UO/FGD - HW
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUpPLItR
TYPE
SERVICE LOAD
COMMERCIAL SERWICE DATE
MAXIMUM 60ILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTE NT - X
AVERAGE MOISTURE CONTENT - 5!
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** KECHAMCAL COLLECTOR
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
<* PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
L/G RATIO - LITER/CU.M
PRESSURE CROP - KPA
*• FGO SYSTEM
SALEABLE PRODUCT/THROWAWAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - Z
S02 DESIGN REMOVAL EFFICIENCY - x
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
ARIZONA PUBLIC SERVICE
CHOLLA
2
JOSEPH CITY
ARIZONA
C
7?. <
344. t
615.0
350.0
25?.0
.167 LB/MBBTU)
.800 LB/MMBTU)
350.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/75
******** (•**•*** »CFM)
******* «••*. F)
168. < 550 FT)
4.5 < U.7 FT)
COAL
BITUMINOUS
236C9.
13.50
9.7-22.5
15.00
( 1C150 BTU/LB)
965-1Ct600
.50
0.44-1.0
.02
3.C1-0.04
75.0
4
VENTURI
RESEARCH COTTRELL
316L
CEILCOTE FLAKEGLASS
185.0 t 392000 ACFN)
5?.0 < 122 F)
1.4 (10.1 GAL/1000ACF)
******* (•**•* JN-H20)
THROWAUAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH COTTRELL
EBASCO
FULL SCALE
NEW
99.70
75.00
4/7?
7/75
12/74
33.0
1.0
GRID/SPRAY TOWER
63
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
ARIJONA PUBLIC SERVICE: CHOLLA 2 (CtNT.)
INITIAL START UP
SUPPLIES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATER1AL
BOILER LOAD/ABSORBER - *
GAS FLOW - CU.M/S
GAS TEMPcRATURE - C
L/G RATIO - L/C U.M
PRESSURE DROP - KPA
•* HIST ELIMINATOR
TYPE
• • REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
• • HATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
•* REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
bALL MILL CAPACITY- M T/H
•• DISPOSAL
NATURE
TYPE
6/7*
RESEARCH COTTRELL
22 (DIA) X 70
316L SS
POPYPROPYLENE PACKING
PACKING MATRIX
2 :.c
184.98 ( 392000 ACFM)
50.0 C 122 F)
1.5 ( 48.9 GAL/100GACF>
.1 ( .5 IN-H20)
CHEVRON
IN-L INE
STEAM
2 ;.2
OPEN
7.6
2
6.3
( 40 F>
( 120 GPM)
( 7.0 TPH)
FINAL
POND
_. PERFORMANCE DATA —
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78 SYSTEM 720
•• PROULEMS/SOLUTIONS/CONMENTS
SOME PROBLEMS HAVE OCCURRED WITH VIBRATIONS THROUGH THE SYSTEM.
THE EPA HAS GRANTED THE UTILITY AN EXTENSION FOR COMPLIANCE.
5/73 SYSTEM 744
6/78 SYSTEM 72£»
•• PROfaLEMS/SOLUTIONS/COMMENTS
SHAKEDOWN/DEBUGGING OPERATIONS ARE CONTINUING.
THE SLURRY RECYCLE PIPING HAS EXPERIENCED CONTINUAL VIBRATION. THE CON-
TRACTOR HAS BEEN INJECTING NITROGEN GAS INTO THE LINES TO DAMPEN THE
VIBRATIONS (AIR WAS NOT USED BECAUSE THE SULFITE WOULD BE OXIDIZED TO
SULFATE AND RESULT IN SCALE FORMATION),
THE CORROSION RESISTANT COATING IN THE DOUNCOMER AREA IN ONE OF THE
AbSOPBER MODULES HAS BEEN PEELING AWAY.
7/78 SYSTEM 7*4
8/78 SYSTEM 744
*• PRObLEHS/SOLUTIONS/COMMENTS
THE SLURRY COMPONENTS ARE STILL EXPERIENCING RESONANT VIBRATIONS.
SHAKEDOWN/DEBUGGING OPERATIONS ARE CONTINUING.
9/78 SYSTEM 72C
10/78 SYSTEM 744
64
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
ARIZONA PUBLIC SERVICE: CHOLLA 2
-------
EPA UTILITY FbO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY NAME
PLANT NAPE
UNIT NUMBEfc
CITY
STATE
REGULATORY CLASSIFICATION
PARTKULATE (.MISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - Mtf
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY W/fGD - Mu
NET UNIT GENERATING CAPACITY WO/FGt - MW
EQUIVALENT SCRUBBED CAPACITY - Kta
BIG HVERS ELECTRIC
GREE C
1
SEBREE
KENTUCKY
B
****** l.*.*«. LB/MMBTU>
516. ( 1.200 LB/MMBTU)
484.?
242.0
2DC.O
242.0
BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP D1AME TER - M
FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE MEAT CONTENT - 6TU/LB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - x
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - x
RANGE CHLORIDE CONTENT - 2
BABC (CK g WiLCOX
PULVERIZED COAL
BASE
<**/•**
471.90
148.9
COAL
BITUMINOUS
22673.
2C.OO
15-25
11.00
8-14
3.75
(1COOOOO ACFM)
( 300 F)
(.».. fT)
<*«.«« fj)
< 9750 BTU/LB)
9COO-10500
ESP
TYPE
SUPPLIER
PARTJCULATt
PART ICULATE
TYPE
DESIGN REMOVAL EFFICIENCY -
SCRUBbEfc
•• FGD SYSTEM
SALEABLE PRODUCT/THROwAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FI RM
DEVELOPMtNT LEVEL
NEy/RETROFIT
PARTICIPATE DESIGN
S02 DESIGN REMOVAL
COMMERCIAL DATE
INITIAL START-UP
•• AbSORbER
NUMBER
REMOVAL EFFICIENCY
EFFICIENCY - X
- X
TYPE
INITIAL START UP
S02 DESIGN REMOVAL
MIST ELIMINATOR
NUMBER
TYPE
EFFICIENCY - I
COLD SIDE
AMERICAN AIR FILTER
99.0
NONE
THROhAUAY PRODUCT
WET SCRUBBING
LIME
M6 PROMOTED
AMERICAN AIR FILTER
BURNS t ROE
AMERICAN AIR FILTER
FULL SCALE
NEW
99.00
9f .00
12/79
12/79
SPRAY TOWER
6/79
9C.O
2
CHEVPON
66
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
BIG RIVERS ELECTRIC: GREEN 1 (CONT.)
** REHEATER
TYPE HOT AIR INJECTION
HEATING MEDIUM STEAM
** WATER LOOP
TYPE CLOSED
** TREATMENT
TYPE P07-0-TEC
SUPPLIER IUCS
PERFORMANC E DATA
PERIOD MODULE AVAILABILITY OPEM81L1TY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGP CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/79 SYSTEM 74*
** PROfcLEMS/SOLUTIONS/COMMENTS
THE FGD OPERATION COMMENCED IN MID-DECEMBER 1979. THE UNIT IS PRESENTLY
IN STARTUP PHASE.
67
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY SAKE
PLANT NAPE
UNIT NUMbER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICUIATE EMISSION LIMITATION - HG/J
SOi EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mfc
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY UO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MU
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME T£R - M
•• FUEL DATA
FUEL TYPd
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AViRAGE ASH CONTENT - X
NANCE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - 1
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - ft
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•• ESP
NUMBER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICULATE OUTLET LOAD - G/CU.M
•• PARTICULATE SCRUBBER
TYPE
•• FGO SYSTEM
SALEABLE PRODUCT/TMROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-fc FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
$02 DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
CONTRACT AWARDED
>• AbJORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
CENT IAL ILLINOIS LIGHT
DUCK CREEK
CANTON
ILLINOIS
B
43.
516.
376.0
416.0
378.0
39C.O
37i.O
( .100 LP/MMBTU)
( 1.200 LB/MHBTU)
RILEY STOKER
PULVERIZED COAL
CYCLING
0/7i
667.7*
135.0
152.
5.8
(H15000 ACFM)
< 275 F»
< 500 FT)
I 19.0 FT)
COAL
BITUMINOUS
24423.
18.0
18.00
******
3.30
2.4-4.0
.03
( 10500 BTU/LB)
11COO
COLD SIDE
POLLUTION CONTROL-WALTHER
99.8
358.6 ( 760000 ACFM)
135.0 < 275 F)
****.<** (***** IN-H20)
.02 ( .01 GR/SCF)
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RILE1 STOKER/ENVIRONEERING
GILBERT/COMMONWEALTH ASSOCIATES
FULL SCALE
NEW
99.80
85.00
8/78
9/76
8/76
GRID TOWER
7/76
RILEY STOKER/ENVIRONEERING
7
68
-------
EPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
DIMENSIONS - FT
SHELL MATERIAL
INTERNAL MATER1AL
NUMBER OF NOZZLES
NOZZLE TYPE
BOILER LOAD/ABSORBER - *
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - ("I/SEC
S02 INLET CONCENTRATION - PPM
S02 CUTLET CONTRAT10N - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
•• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRV
CAPACITY - CU.M/S
.* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - n
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
.* PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL MANNER
MODE
*» PUMPS
SERVICE
POND RETURN
WASTE SLURRY
MIST ELIMINATOR WASH
ABSORBER RECIRCULATION
SLURRY TRANSFER
>* TANKS
SERVICE
RECYCLE
yASTE COLLECTION
LIMESTONE SLURRY
M.E. WASH
** REHEATER
NUMBER
TYPE
** UATER LOOP
TYPE
FRESH MAKEUP HATER ADDITION - LITEHS/S
** REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
BALL MILL CAPACITY- M T/H
• * DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
40 X 5 X 40
316L & HASTALLOY G.
316L & HASTALLOV G.
1?
OPEN PIPE ARRANGEMENT
25.0
167.01
135.0
945.
6.7
2.0
4.0
300C
252
91.0
BOILER I.D.
CARBON STEEL
DRY
205.28
< 353900 ACFfO
< 275 F)
<15000 6PM)
( 50.0 GAL/1000ACF)
t 8.0 IN-H20)
C 13.0 FT/S)
( 435000 ACFM)
4
CHEVRON
HASTALLOV G
VERTICAL
2
3.66 (12.0 FT)
.24 ( .8 FT)
6.3 ( 2.50 IN)
90 DEG.
CONTINUOUS. LOW PRESSURE, FRONT AND BACK OF FIRS
4.0 C 13.0 FT/S)
.2 ( 1.0 1N-H20)
PH. SOLIDS CONTENT OF SLURRY. LEVEL CONTROL
AUTOMATIC
FEEDBACK
NUMBER
2
2
12
12
7
NUMBER
4
1
7
4
0
NONE
CLOSED
37.8
1
36.3
FINAL
LINED POND
ON-SITE
PUMPED
f 600 6PM)
( 40.0 TPH)
69
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS LIGHTt DUCK CREEK 1 (CONT.)
DIMENSIONS 65 ACRES X 4 FEET DEEP
AREA - ACRES 65.0
CAPACITY - CU.M 317980 < 260.0 ACRE-FT)
. PERFORMANC E DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION I REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
7/76 SYSTEM 1.1 744 g
** PRObLEMS/SOLUTlONS/COMMENTS
CONSTRUCTION OF DUCK CREEK 1 BEGAN IN EARLY 1972 AND UAS VIRTUALLY
COMPLETED bY SPRING 1976. IOMMERCIAL OPERATION WAS INITIATED IN JUNE 1976
WITH THE EiP MODULES IN THE GAS PATH. THE FIRST MODULE OF THE 4-MOOULE
SCRUBBING SYSTEM UAS INSTALLED BY JUNE 1976 AND START-UP FOR S HAKE DON/ DE -
BUGGING PURPOSES OCCURRED IN JULY 1976. THE REMAINING THREE MODULES WILL
BE INSTALLED LATER WITH A 4-MODULE START-UP SCHEDULED fOR THE SUMMER
OF 1978.
INITIAL OPERATION OF THE FIRST SCRUBBER MODULE FOR SHAKEDOWN AND DEBUGGING
PURPOSE OCCURRED DURING THE MONTH. LIMITED SERVICE TIME RESULTED FROM
PROBLEMS WITH BAD WELDS. FAULTY PIPE HANGES. AND ABSORBER LEAKS.
fl/76 SYSTEM 2.4 744 18
•• PRObLEHS/SOLUTlONS/COMHENTS
LIMITED OPERATIONS CONTINUEt THROUGHOUT AUGUST BECAUSE OF THE START-UP AND
CONSTRUCTION PROBLEMS MEMT1CNEO FOR JULY, 1976. THE MODULE UAS TAKEN OUT
OF THE GAS PATH AT THIS POINT TO CONCENTRATE ON RESOLVING THESE PROBLEM
AREAS.
9/76 SYSTEM 50.0 744 360
*• PRObLEMS/SOLUTIONS/COMMENTS
MODULE RESTART OCCURRED ON SEPTEMBER 9. OPERATION CONTINUED THROUGHOUT THE
REMAINDER OF THE MONTH ON AN INTERHITTANT BASIS. MAJOR PROBLEMS INCLUDED
PIPE BREAKING, PUMP LINER FAILURES, PLUGGING AND SEALING OF HIST
ELIMINATORS, AND SOME BOILER-RELATED PROBLEMS. THE MODULE REMAINED IN SER-
VICE FOR APPROXIMATELY 15 DAYS OF NON-CONTINUOUS OPERATION. THE PCW ESP
MODULES HAVE REMAINED IN SERVICE WITHOUT THE OCCURRENCE OF ANY MAJOR
PROBLEMS.
10/76 SYSTEM 51.8 744 585
«• PRObltMS/SOLUTIONS/COMMENTS
TOTAL OPERATION TIME DURING THE MONTH UAS APPROXIMATELY 16 DAYS (NON-
CONTINUOUS). THE MAJOR PROBLEM AREA UAS THE CONTINUATION OF MASSIVE SCALE
DEVELOPMENT ON THE MIST ELIMINATORS, RESULTING IN PLUGGING OF THE PIPING
AND NOZZLES TO THE COMPONENTS SPRAY SYSTEM.
11/76 SYSTEM 3.3 720 2*
•• PROBLEMS/SOLUTIONS/COMMENTS
SPORADIC OPERATION RESULTED FROM CONTINUED SCALING PROBLEMS IN THE MIST
ELIMINATOR SECTION. RILEVt.ND CILCO INITIATED MODIFICATIONS TO THE DESIGN
OF THE MODULE. SPECIFICALLY, A ROD DECK WAS CHANGED IN THE ABSORBER,
PRESSURE DROP ACROSS THE ABSORBER WAS INCREASED, PIPING AND PUMP LINER
MATERIALS hERE MODIFIED/REPLACED, AND A FRESH WATER WASH SYSTEM WAS IN-
STALLED FOR THE MIST ELIHINtTOR.
12/76 SYSTEM .0 744 C
«• PRObLEMS/SOLUTIONS/COMMENTS
THE MODULE REMAINED OUT OF SERVICE THE ENTIRE MONTH. DURING THIS life,
THE BOILER FIRED LOW SULFUR (0.6Z) KENTUCKY COAL.
1/77 SYSTEM .(? 744 C
2/77 SYSTEM .0 672 C
70
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
__ ------------------ ---------------------- PERFORHANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTlONS/COMMENTS
THE NO. 1 UNIT WAS DOWN THROUGHOUT THE ENTIRE PERIOD FOR TURBINE /B01 LER
OVERHAUL. DURING THE UNIT OUTAGE, A NUMBER OF MODIFICATIONS WERE MADE TO
THE SCRUBBER.
3/77 SYSTEM
*» PRObLENS/SOLUTIONS/COMMENTS
47.0
744
J50
THE NO. 1 LNI.T WAS RETURNED TO SERVICE IN MID-MARCH. THE SCRUBBER WAS
PLACED IN SERVICE TO TEST THE MODIFICATIONS HADE DURING THE PRECEDING OUT-
AGE. THESE MODIFICATIONS INCLUDED:
THE UST ELIMINATOR SPRAY WASH SYSTEM PIPING WAS CHANGED FROM PVC TO
FRP MATERIALS. ALSO, AN ADDITIONAL SPRAY HEADER WAS ADDED.
THE SLURRY CIRCULATION SYSTEM WAS REVAMPED.
NEOPhENE PUMP FILTERS HAVE REPLACED THE ORIGINAL RUBBER LINES.
FLUSH/DRAIN SYSTEMS HAVE BEEN INCLUDED TO MINIMIZE SOLIDS BUILD UP.
PIPING VALVES MOVED CLOSER TO THE RECYCLE TANK.
SLURRY STORAGE TANKS EQUIPPED WITH FLUSH/DRAIN SYSTEMS.
ADDITIONAL MIXERS ADDED FOR GREATER AGITATION TO PROMOTE PROCESS
CHEMISTRY.
DURING THE LAST PART OF MARCH THE MODULE REMAINED IN SERVICE ON A CONTINUAL
BASIS WITH THE EXCEPTION OF A FEW MINOR BOILER OUTAGES. CILCO INTENDS TO
CONTINUE EXPERIMENTAL OPERATIONS THROU6HOUT THE APRIL-MAY PERIOD, TESTING
THE MECHANICAL MODIFICATIONS AND THE AUTOMATIC CONTROL LOOPS (SYSTEM
CHEMISTRY WILL BE CONTROLLED BY INLET/OUTLET SO? LOADING, SOLUTION PH.
SOLUTION SOLIDS. OPERATION UP TO THIS POINT HAS PROCEEDED IN A MANUAL
CONTROL MODE). CONTINUED OPERATION BEYOND THIS TIME FRAME WILL DEPEND
UPON THE SUCCESS OF EXPERIMENTAL OPERATIONS. CILCO HAS THE OPTION OF
FIRING LOW SULFUR COAL UNTIL THE ENTIRE 4-MODULE SCRUBBER PLANT IS READY
FOR SERVICE IN AUGUST 1978.
4/77 SYSTEM
5/77 SYSTEM
6/77 SYSTEM
7/77 SYSTtM
fi/77 SYSTEM
9/77 SYSTEM
10/77 SYSTEM
11/77 SYSTEM
12/77 SYSTEM
1/78 SYSTEM
2/78 SYSTEM
3/78 SYSTEM
4/78 SYSTEM
5/78 SYSTEM
6/78 SYSTEM
*» PROBLEMS/SOLUTIONS/COMMENTS
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
73 C
744
720
744
744
720
744
720
744
744
672
744
72 C
744
720
C
C
0
C
0
C
0
C
0
C
0
C
0
C
0
THE UNIT CONTINUED TO FIRE LOU-SULFUR COLORADO COAL DURING THE REPORT
PERIOD. THE RESTART OF SCRUBBER OPERATIONS CONTINUES TO BE SCHEDULED FOR
AUGUST 19?8.
7/78 SYSTEM
.0
.0
.0
.0
720
71
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPESA8ILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•• P&ObLEMS/SOLUTlONS/COMMENTS
ALL FOUR MODULES BECAME OP (RATIONAL ON JULY 2t.
MODIFICATIONS WERE MADE TO THE UNDER DESIGNED SLURRY TRANSFER TANK.
A PLUGGING PROBLEM CAUSED BY COAL FINES IN THE SLURRY WAS EXPERIENCED.
THE FINES RESULTED FROM A COMMON COAL AND LIMESTONE HANDLING SYSTEM.
THE COMMON COAL AND LIMESTONE HANDLING SYSTEM ALLOWED COAL FINES TO PLUG
THE FGD SYSTEM.
8/78 SYSTEM 45.0 *6.0 46.0 4?.0 744 691 315
9/78 SYSTEM 46.0 46.0 46.0 44.0 7ZC 691 317
•• PRObLEMS/SOLUTIONS/COMMENTS
SCREEN BASKETS WERE USED TO KEEP COAL PARTICLES FROM THE LIMESTONE. THE
COAL PARTICLES RESULT FROM COMMON HANDLING SYSTEM.
THE SLURRY TRANSFER SYSTEM PREVENTED PROPER SLURRY FLOW DUE TO UNDER
DESIGN. THE OLD SYSTEM HAS REPLACED *>ITH A NEW PIPING SYSTEM.
PLUGGING OF THE RECYCLE PUMP SHUT-OFF VALVES OCCUREB. THE VALVES ARE
BEING REPLACED WITH PINCH VALVES.
THE SCRUBBER UASTE WATER SIMP PUMPS HAVE BEEN PLUGGING. NEW PUMPS ARE
BEING INVESTIGATED.
10/78 SYSTEM 16.0 26.0 26.0 16.0 74<- 449 118
•* PRObLEMS/SOLUTIONS/COMMENTS
A LEAKING VALVE RESULTED IN CONTAMINATION OF THE RECYCLE PUMP GLAND SEAL
WATER SYSTEM WITH POND RETURN WATER CAUSING SCALING AND PLUGGING FORCING
SHUTDOWN OF THE RECYCLE PUMPS. A NEW VALVE SYSTEM WAS INSTALLED AND THE
OPERATING PRESSURES WERE CHANGED.
THE RECYCLE PUMPS WERE SHUT DOWN WHEN CONTAMINATION OF THE GLAND SEAL
WATER SYSTEM CAUSED BY A FAULTY VALVE OCCURRED.
t FLOW CONTROL VALVE WAS REMOVED BECAUSE IT CAUSED ABRASION AND FAILURE
Of THE RECYCLE HEADER. NONE OF THE MODULES NOW UTILIZE FLOW CONTROL
VALVES.
THE MIST ELIMINATOR SPRAY tOZZLES PLUGGED BY COAL PARTICLES HERE CLEANED
THE COAL PARTICLES RESULT FROM A COMMON COAL/LIMESTONE HANDLING SYSTEM.
A LIQUID/SOLID SEPARATOR HAS BEEN INSTALLED IN THE SLURRY SYSTEM TO PRE-
VENT REOCCURRENCE.
EXCESSIVE LIMESTONE CARRYOVER TO THE MIST ELIMINATOR WAS NOTED. THE TOP
ROD DECK kAS REMOVED TO IMPROVE GAS FLOW AND ELIMINATE THE CARRYOVER
PROBLEM.
BLANK OFF PLATES WERE A&DED TO THE LOWER SEVEN RQD DECKS TO MAINTAI*
PRESSURE tROP REQUIREMENTS- THIS HAS BEEN FOUND TO BE AN ACCEPTABLE
SOLUTION AT OTHER ENV1RONEEHING FGD SYSTEM INSTALLATIONS.
THE COMMON COAL/LIMESTONE HANDLING SYSTEM ALLOWED COAL PARTICLES TO PLUG
MIST ELIMINATOR SPRAY NOZZLES. A LIQUID/SOLID SEPARATOR HAS BEEN INSTAL-
LED TO PREVENT FUTURE PLUGGING.
11/78 SYSTEM 8.0 '.0 '-0 8.0 720 661 59
72
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
___ . PERFORMANCE DATA -- —
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*• PRObLEMS/SOLUTIONS/COMMENTS
THE B-NOOULE SLURRY TANK PUMP LINER EXPERIENCED A FAILURE RESULTING IN
SCRUBBER SYSTEM SHUTDOWN. THE SPARE PUMP WAS ALREADY OUT OF SERVICE TO
REPLACE ITS ORIGINAL SO-HP MOTOR WITH A ?S-HP MOTOR.
A SPARE SLURRY TANK PUMP WAS OUT OF SERVICE TO REPLACE THE ORIGINAL SO-HP
MOTOR WITH A 75-HP MOTOR.
THE PINION BEARING ON THE BALL MILL DRIVE FAILED. THE FAILURE IS BEING
INVESTIGATED. FGD SYSTEM OPERATION WAS HALTED DUE TO THE FAILURE.
THE LEVEL AND DENSITY INSTRUMENTS ON RECYCLE TANKS ARE BEING MODIFIED.
THE LEEDS K NORTHRUP LEVEL AND DENSITY TRANSMITTERS ARE BEING REPLACED
WITH ROSEMOUNT TRANSMITTERS.
12/78
A
B
C
D
SYSTEM
23.0
26.0
21.0
10.0
2C.O
25.0
28. 0
23.0
11.0
21.0
2S.O
28.0
23.0
11.0
21.0
23.0
26.0
21.0
10.0
20.0
744 706 151 66.C
** PRObLEMS/SOLUTIONS/COMMENTS
ISOLATION I/AMPER FAILURES AND SLURRY RECYCLE DISCHARGE VALVE FAILURES
OCCURRED DURING DECEMBER.
LIMESTONE MILL PROBLEMS AND A PLUGGED LIMESTONE FEEDER HAMPERED SCRUBBER
OPERATIONS DURING DECEMBER.
FROZEN INSTRUMENT CONTROL LINES WERE A PROBLEM.
1/79
A
B
C
0
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.C
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
744 738 0
** PRObLEMS/SOLUTIONS/COMMENTS
FROZEN INSTRUMENT CONTROL LINES, RECYCLE TANK SUCTION LINES* MAIN MODULE
DRAIN LINES AND MIST ELIMINATOR DRAIN LINES WERE MAJOR PROBLEM AREAS
DURING JANUARY.
SLURRY RECYCLE VALVE PLUGGAGE AND SLURRY TRANSFER PUMP FAILURE CONTRIBUTED
TO THE SYSTEM OUTAGE TIME.
2/79
A
B
C
D
SYSTEM
.0
..0
.0
.0
.0
.0
.0
.0
.0
.0
.0
•0
.0
.3
.0
.0
.0
.0
.0
.0
3/79
672 533 0 80.5
** PROBLEMS/SOLUTIONS/COMMENTS
RECYCLE PUMP SUCTION VALVE FAILURES AND A SLURRY TRANSFER PUMP FAILURE
CONTRIBUTED TO THE NON-OPERATION OF THE FGD SYSTEM.
FROZEN MIST ELIMINATOR DRAINS* ABSORBER DRAINS AND INSTRUMENT LINES WERE
A MAJOR PROBLEM DURING FEBRUARY.
744 744 70
A
B
C
0
SYSTEM
33.7
6.7
.0
.0
10.1
31.1
6.7
.0
.0
9.4
31.1
6.7
.0
.0
9.4
31.1
6.7
.0
.0
9.4
73
-------
EPA UTILITY FCD SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 CCGNT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPESAB1L1TY RELIABILITY UTILIZATION t REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
•• PROfcLEMS/SOLUTIONS/COMMENTS
FREEZING PROBLEMS CONTINUED TO HAMPER FGD OPERATIONS DURING MARCH.
BROKEN MIST ELIMINATOR SPRAY LINES AND PLUGGED MIST ELIMINATOR NOZZLES
UERE PROBLEM AREAS DURING MARCH.
RECYCLE PUMP FAILURES AND WASTE WATER PUMP FAILURES WERE EXPERIENCED
DURING MARCH.
PLUGGED SLURRY NOZZLES AND GENERAL INSTRUMENTATION PROBLEMS WERE REPORTED
BY THE UTILITY.
4/79
6/79
7/79
A
B
c
D
SYSTEM
100.0
84.3
86. 5
21.3
73.0
71.9
5C.5
81. 2
22.7
56.4
67.3
47.3
76.0
21.3
72.0 53. C
720 674 80
•• PRO&LEMS/SOLUTIONS/COHMENTS
INLET DAMPLR MALFUNCTIONS HINDERED FGO OPERATION DURING APRIL.
PLUGGED MIST ELIMINATOR SPRAY NOZZLES CUBING APRIL HINDERED FGD OPERATION.
SLURRY CONTROL VALVE MALFUNCTIONS WERE REPORTED BY THE UTILITY.
RECYCLE TAKK MIXER FAILURES HERE EXPERIENCED DURING APRIL.
RECYCLE PUMP BELT AND BEARING FAILURES AND SLURRY SUPPLY LINE FAILURES
WERE REPORTED BY THE UTILITY.
S/79
63
A
t>
C
0
SYSTEM
95.7
95.7
94.6
1.3
71.9
37.4
44.2
41.8
5.0
3?.1 51.4
1.3
11.7
11.1
1.3
8.5
744 197
OLUTIONS/COMMENTS
MIST ELIMIkATOR PUMP MALFUNCTIONS WERE DEPORTED DURING MAY.
MILL SHAKER BASKET DRIVE MOTOR FAILURES WERE ENCOUNTERED.
720 661
A
b
C
0
SYSTEM
70.6
79.9
76.1
82.6
8 7.4
76.9
86.9
83.1
9Q.O
84.2 86.1
70.5
79.9
76.3
82.6
77.3
557
•• PRObLEMS/SOLUTIONS/COHNENTS
DURING JUNl SOME PROBLEMS WITH THE HIST ELIMINATOR WERE ENCOUNTERED. THESE
PROBLEMS INCLUDED PLUGGING IN THE HIST ELIMINATOR AND THE HIST ELIMIMTOH
LINES AND A BROKEN MIST ELIMINATOR RETURN LINE.
A
B
C
D
SYSTEM
6 1.6
6 1.6
60.3
95.0
85.6
88.3
87.9
86.5
87.1
59.8
61.6
61.4
60.5
95.9 60.9
8/79
744 520 453
•• PfcOBLEMS/SOLUTIONS/COHMENTS
IN JULY THE HIST ELIMINATOR PLUGGED CAUSING OPERATIONAL PROBLEMS.
RECYCLE PUMP FAILURES HERE ENCOUNTERED DURING JULY.
A 3.0 4.2 3.1
74
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
____ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
C
D
SYSTEM
23.4
13.6
9.5
13.0
31.4
18.4
12.8
16.6
22.9
23.4
13.7
9.5
12.3
744
555
92
«* PRObLEMS/SOLUTIONS/COMMENTS
IN AUGUST TH£ MIST ELIMINATOR AND THE MIST ELIMINATOR DRAIN LINES PLUGGED
CAUSING SOME DOWN TIME.
FAILURES WITH THE LIMESTONE SLURRY FORWARDING PUMP AND THE RECYCLE PUMP
WERE ENCOUNTERED.
DAMPER MALFUNCTIONS WERE REPORTED BY THE UTILITY.
9/79
A
B
C
D
SYSTEM
49.9
44.6
35.9
79.6
65.7
54.0
48.4
38.9
86.2
56.8 64.8
49.9
44.7
35.9
79.6
52.5
72C 665
378
«• PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING IK THE MIST ELIMINATOR, MIST ELIMINATOR HEADER AND NOZZLES
MERE ENCOUNTERED IN SEPTEMBER.
THE DAMPER FAILED CAUSING A PROBLEM DURING SEPTEMBER.
THE UTILITY REPORTED MIST ELIMINATOR CAVITAT10N PROBLEMS.
PLUGGED SLURRY NOZZLES AND LIMESTONE CONVEYOR FAILURES CONTRIBUTED TO THE
OUTAGES EXPERIENCED.
10/79
A
B
C
D
SYSTEM
82.1
86.2
75.8
91.9
90.9
82.3
86.2
75.8
91.9
84.0
85.7
93.7
90.9
93.8
91.4
82.3
86.2
75.8
91.9
84.0
744
744
625
** PROblEMS/SOLUTlONS/COMMENTS
DURING THE MONTH OF OCTOBER PROBLEMS WERE ENCOUNTERED WITH THE HIST
ELIMINATOR SECTION. THE MIST ELIMINATOR PUMP MALFUNCTIONED, THE LINES
PLUGGED AND A HEADER FLANGE GASKET FAILED.
OUTAGE TIME RESULTED FROM THE MODULE ISOLATION DAMPER FAILURE INCLUDING
DAMPER MOTOR MALFUNCTION.
THE SLURRY SUPPLY LINE NEEDED REPAIRS.
11/79
A
B
C
D
SYSTEM
42.2
12.4
18.3
52.9
32.2
52.1
15.3
22.6
61.9
38.0
58.7
42.9
48.7
63.7
40.8
42.2
12.4
18.3
50.1
30.8
720 583 221
•* PRObLEMS/SOLUTIONS/COMMENTS
MODULE ISOLATION DAMPER PROBLEMS CONTINUED DURING NOVEMBER.
THE MIST ELIMINATOR AND THE MIST ELIMINATOR DRAIN PLUGGED CAUSING DOWN
TIME.
REPAIR WAS NEEDED ON THE SUCTION VALVE OF THE RECYCLE PUMP.
SLURRY SUPPLY LINES FAILED AGAIN. DURING NOVEMBER.
12/79
53.6
35.1
72.6
47.6
60.3
51.5
53.5
35.1
-------
£P» UTILITY f&D SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE PATA
PERIOD MODULE AVAILABILITY GPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
C *3.0 58.4 54.9 43.?
D 25.5 34.7 45.6 25.5
SYSTEM 39.5 53.3 58.3 39.3 744 548 292
•« PROtLEMS/SOLUTIONS/COMMENTS
THE ISOLATION DAMPER FAILURES CONTINUED.
THE MIST ELIMINATOR PROBLEMS WITH PLUGGING AND HEADER FAILURES OCCURRED
DURING DECEMbER.
THt RECYCLE TANK LINERS WERE REPAIRED AND TANK COVERS WERE INSTALLED.
76
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY NAME
PLANT NAHE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULAR EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY UO/FGb - MW
EOUIVALEM SCRUBBED CAPACITY - Kh
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM UOILER FLUE GAS FLOU - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIANE TER - M
** FUEL DATA
FUEL TYPE
fUEL GRADE
AVERAGE HEAT CONTENT - J/t
RANGE MEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
CENTRAL ILLINOIS PUBLIC SERV
NEWTON
1
NEWTON
ILLINOIS
B
43. ( .100 LB/MMBTU)
516. C 1.200 LB/MMB1U)
617.0
575.0
617.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/78
102C.95 (2163480 ACFM)
163.9 < 327 F)
162. t 530 FT)
•«..<** c***«* FT>
COAL
BITUMINOUS
253.3.
4.00
********
4.00
< 10900 BTU/LB)
.20
** ESP
NUMBER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY
FLUE GAS TEMPERATURE - C
** PART1CULATE SCRUBBER
TYPE
«* FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PROfcUcT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - t
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
SHELL LINER MATERIAL
L/6 RATIO - L/CU.M
SUPERFICAL GAS VELOCITY - M/SEC
S02 INLET CONCENTRATION - PPM
S02 CUTLET CONTRATION - PPM
1
COLD SIDE
RESEARCH COTTRELL
- x 99.5
162.8 < 325 F)
NONE
THRQVAWAY PRODUCT
WET SCRUBBING
DUAL ALKALI
BUELL/ENV1ROTECH
SARGENT t LUNDV
FULL SCALE
NEW
- X 99.50
95.00
12/7?
9/79
11/76
MOBILE PACKED/TRAY TOWER
11/79
BUELL ENVIFOTECH
CEILCOTE
1.3 ( 10.0 6AL/1000ACF>
2.5 C 8.3 FT/S)
2591
200
77
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
FANS
NUMBER
TYPF
VACUUM FILTER
TYPE
MIST ELIMINATOR
NUMBER
TYPE
CONfIGURATION
REHEATER
NUMBER
TYPE
REHEATER
NUMBER
TYPE
TEMPERATURE
BOOST - C
THICKENER
NUMBER
CONSTRUCTION
DIAMETER - M
MA TER1AL
THICKENER
NUMPER
CONSTRUCTION MATERIAL
DIAMETER - M
MATER LOOP
TYPf
TREATMENT
TYPE
CONTRACTOR
4
BOOSTER
EXTRACTION F ILTE R S ,HORI ZON TAL ,B EL T T
8
CHEVRON
VERTICAL
BYPASS
IN-LINE
13.9
CONCRETE
30.5
25 ft
(ICO FT)
COATED STEEL
15.2 < 50 FT)
CLOSED
P07-0-TEC
IUC S
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION I REMOVAL PER BOILER FGb CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/79 SYSTEM
*• PKObLEMS/SOLUTIONS/COMMENTS
720
INITIAL OPERATIONS BEGAN AT THIS UNIT ON SEPTEMBER 1 WHEN FLUE GAS WAS
PASSED THROUGH THE INDIVIDUAL FGD MODULES FOR TESTING PURPOSES. TESTING
OF THE SYSTEM IN AN INTEGRATED MODE IS EXPECTED TO BEGIN IN DECEMBER.
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
.. PROBLEMS/SOLUTIONS/CCMMENTS
744
720
744
THE UNIT BEGAN BURNING H16H SULFUR COAL ON NOVEMBER 18-19 AT WHICH TIME
THE FGD SYSTEM BEGAN OPERATIONS IN AN INTEGRATED MODE FOR THE FIRST TIME.
INITIAL START UP PROBLEMS HAVE INCLUDED MIST ELIMINATOR PLUGGAGE.
LINING FAILURES HAVE ALSO BEEN ENCOUNTERED DURING START UP PHASE.
THE UNIT PASSED A COMPLIANCE TEST ON DECEMBER 5t 1979 AT WHICH TIME IT
WAS DETERMINED THAT THE UNIT WAS WELL BELOW THE ALLOWABLE EMISSION
STANDARD OF 1.2 L6/MMBTU.
78
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
ff\-y cMT^CTfiM 1 1 M I TA TI ON — h(i / J
5 U C t"A33iW L A n i in » A u n nv r it
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY b/FGD - MU
NET UNIT GENERATING CAPACITY WO/FGD - MU
EfiUlVALEKT SCRUBBED CAPACITY - MU
COLORADO UTE
CRAIG
2
CRAIG
COLORADO
D
******
90C.O
447.0
400.0
424.0
447.0
ELECTRIC ASSN.
(*****• LB/MMBTU)
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMfcTER - M
** FUEL DATA
FUEL Ttp£
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - 2
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - I
** ESP
NUMBER
TYPE
SUPPLIER
** PARTICIPATE SCRUBBER
TYPE
•• FGD SYSTEM
SALEABLE PRODUCT/THROWAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEU/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
soa DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
** ABSORBER
NUMBER
TYPE
INITIAL START U P
SUPPLIER
SHELL MATERIAL
SHELL LINER MATERIAL
** CENTRIFUGE
NUMBER
BABCI CK & UILCOX
PULVERIZED COAL
BASE
0/79
**••»•*• <•
ACFM)
183.
1C.9
COAL
SUB8ITUMINOUS
23260.
8.00
10-12
C**** F>
C 600 FT)
( 35.8 FT)
< 10000 BTU/LB)
9100-10300
10-12
.45
••*••*
******
HOT SIDE
BELCO
NONE
THROUAMAV PRODUCT
yET SCRUBBING
LIMESTONE
N6 PROMOTED
PEABODY PROCESS SYSTEMS
STEARNS-ROGER
FULL SCALE
NEW
99.80
85.00
11/7?
8/79
SPRAY TOWER
3/79
PEABODY PROCESS SYSTEMS
STEEL
RUBBER
79
-------
EPA UTILITY FliD SURVEY: FOURTH QUARTER 1979
COLORADO LTE LLECTRIC ASSN.: CRAIG L (CONT.)
•• *1ST ELIMINATOR
NUMBER
TYPE
•• REHEATED
TYPE
HEATING MEDIUM
»* THICKENER
NUMBER
>• WATER LOOP
TYPE
'• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
CHEVRON
IN-LINE
STEAM
CLOSED
FINAL
MINEFILL
OFF-SITE
TRUCK
... PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM 744
11/79 SYSTEM '20
12/79 SYSTEM 7**
•• PRObLEMS/SOLUTIONS/COMMENTS
THE CRAIG i UNIT COMMENCED COMMERCIAL OPERATION IN NOVEMBER 1979.
DURIN6 A SCHEDULED OUTAGE FOR MAINTENANCE AND INSPECTION THE FINE SCREEN
ON THE THROTTLE VALVE TO THE TURBINE WAS REMOVED AND CLEANED.
80
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAKE
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - t»G/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY -Mb
MET UNIT GENERATING CAPACITY W/FGD - MU
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILEH FLUE GAS fLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP OIAME T£R - M
*• FUEL DATA
fUEL TYPE
FUEL GRADE
AVERAGE MEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - i
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - 1
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE
5
CONESVILLE
OHIO
0
430.
210C.O
411.0
775.0
391.0
411.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/76
657.78
146.7
< .100 LB/MMBTU)
( 1.300 LB/MMBTU)
344.
7.9
COAL
BITUMINOUS
25237.
15.1C
12-19
7.50
(1393893 ACfM)
( 296 F)
( 800 FT)
( 26.C FT)
( 10850 BTU/LB)
10300-11220
4.67
4.2-5.1
** ESP
NUMBER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
** PAHTICULATE SCRUBbER
TYPE
.. FGD SYSTEM
SALEABLE PROOUCMTHROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEy/RETROFIT
PARTICIPATE DESIGN REMOVAL EFFICIENCY - X
so2 DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
ABSORBER SPARE CAPACITY INDEX - *
ABSORBER SPARE COMPONENT INDEX
•• ADSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
COLD SIDE
RESEARCH COTTRELL
99.6
657.8
U6.7
(1393893 ACFM)
( i.96 F)
NONE
THRQWAWAV PRODUCT
WET SCRUBBING
LIME
MG (2-6X)
AIR CORRECTION DIVISION. UOP
BLACK t VEATCH
FULL SCALE
NEW
99.60
89.50
2/77
1/77
5/75
10/74
.0
.0
1
MOBILE PACKED TOWER
11/77
AIR CORRECTION DIVISION. UOP
81
-------
EP* UTILITY FuO SURVEY: FOURTH QUARTER 1979
COLu.»bUS *. SOuTHERN OHIO EltC.: CONtSVlLLE 5 (CONT.)
NUMh tR 0 f STAGE S
SHtlL MATERIAL
SHELL LINE* MATERIAL
1NTE BNAL MATERI AL
u01L£R LUAD/ABSORBER - X
1>AS FLO - CU.M/S
uAS TEHPtRATURE - C
LlbUID RtCIRCULAT10N RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
•• AUSORfaER
NUMB ED
TYPE
INI MAL START UP
SUPPLIER
NUMBER OF STAGE S
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
bOILEQ LOAD/ABSORBER - *
tAS fLOy - Cu.M/S
GAS TEMPERATURE. - C
LIUU1D RtCIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
•• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
•• VACUUM FILTER
NUHPER
OUTLET SOLIDS - X
CARBON STEEL (CARPENTER 20 PRESATURATOR
CHLOROBUTYL RUBBER
CARPENTER 20 SUPPORT GRIDS
60.0
298.44 ( 632416 ACFM)
141.1 ( 286 F)
2394. (J8uOO GPM)
6.7 ( 50.0 GAL/100CACF)
1.8 < 7.3 IN-H20)
3.9 < 12.8 FT/S)
MOBILE PACKED TOWER
1/77
AIR CORRECTION DIVISIONt UOP
4
CARBON STEEL (CARPENTER 20 PRESATURATOR
CHLOROBUTYL RUBBER
CARPENTER 20 SUPPORT GRIDS
6C.O
29E.44 ( 632416 ACFM)
141.1 ( 286 F>
2394. (38GOO GpM)
6.7 ( SO.O GAL/100CACF)
1.8 ( 7.3 IN-H20)
3.9 ( 12.8 FT/S)
4
BOILER ID
CARBON STEEL
DRY
401.11 I 850000 ACFM)
73.0
•• MIST ELIMINATOR
NUHPER
TYPE
CONSTRUCTION MA TERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTA NCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY -
PRESSURE DROP - KPA
•• MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MA TERIAL
CONFIGURATION
NUMPER OF STAGES
SUPERFICIAL GAS VELOCITY -
•• PUMPS
SERVICE
N/S
M/S
ABSORBER RECIRCULATION
TRANSFER TANK
SLURRY TRANSFER
RECYCLE TANK SLUDGE TRANSFER
MIST ELIMINATOR bASH
TANKS
SERVICE
CHEVRON
NORYL PLASTIC
HORI20NTAL
I
T
3.05 MC.O FT)
1.37 (4.5 FT)
'.1 ( 2.20 IN)
90 DEGREES
CONTINUOUS TOP AND BOTTOM WASH 1ST STAGE; BOTTOM
4.2 ( 13.7 FT/S)
.5 ( 1.9 1N-H20)
TRAPOUT TRAY
CARPENTER 20
HORI20NTAL
RECYCLE
RECLAIMED bATER
4.2
NUMBER
11
1
1
2
2
NUMBER
1
1
( 13.7 FT/S)
82
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
COLUMBUS £ SOUTHERN OHIO ELEC.: CONESVILLE 5 (CONT.)
SLURRY TRANSFER TANK 1
SLURRY STORAGE 1
M.E. WASH 1
** REMEATER
TYPE BYPASS
«* THICKENER
NUMBER
CONSTRUCTION MATERIAL
DIAMETER - M 44.2
OUTLET SOLIDS - X 32.5
•* WATER LOOP
TYPE OPEN
FRESH MAKEUP WATER ADDITION - LITERS/5 31.5
** REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS 3
** TREATMENT
TYPE POZ-0-TEC
CONTRACTOR IOCS
PRODUCT CHARACTERISTICS 73% SOLIDS
•* DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION ON-SITE
TRANSPORTATION PUMPED
AREA - ACRES 5(.0
1
CARBON STEEL WITH CONCRETE FLOOR
1145 FT>
( 500 6P1O
_ PERFORMANCE DATA —--.
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/76 SYSTEM
•* PRObLEMS/SOLUTIONS/COMMENTS
744
1/77
A MAJOR FIRE IN MODULE A DELAYED THE UNIT START-UP. THE (IRE CAUSED S2.1
MILLION DAMAGE. THE UTILITY'S INSURANCE COVERED THE DAMAGE AND A NEW
SCRUBBER MODULE WILL BE PURCHASED FROM AND INSTALLED BY UOP.
THE UTILITY IS CURRENTLY CONDUCTING AIR AND WATER TESTS ON MODULE B.
SYSTEM 744
•• PRObLEMS/SOLUTIONS/COMMENTS
INITIAL START-UP FOR DEBUGGING AND COMMISSIONING PURPOSES OCCURRED IN
EARLY JANUARY. COMMERCIAL AVAILABILITY FOR SERVICE OCURRED ON JANUARY
27.
EARLY OPERATIONS WERE MARKED BY COLD WEATHER RELATED PROBLEMS SUCH AS
FROZEN LINES AND GEARS, CRACKED FLANGES, A FROZEN LIME BELT CONVEYOR, AND
A FROZEN PIPELINE FROM THE THICKENER TO THE IUCS FACILITY.
2/77
a
A
SYSTEM
43.3
• V
21.5
PROBLEMS/SOLUTIONS/COMMENTS
<.5.0
.c
21.5
672 668
COMMERCIAL START-UP OF MODULE B OCCURRED ON FEBRUARY 13, 1977.
EST PERIOD OF CONTINUOUS OPERATION WAS 132 HOURS.
1*3
THE LON6-
TME UTILITY REPORTED THAT THE ESP OPERATED SATISFACTORILY.
PRESSURE SURGES OCCURRED IN THE PRESATURATOR PIPING.
THE CONTINUOUS S02 ANALYZERS OPERATED UNSATISFACTORILY.
MODULE B EXPERIENCED POOR VELOCITY DISTRIBUTION THROUGH THE TCA BEDS.
83
-------
EPA UTILITY FCO SURWEY: FOURTH QUARTER 1V a
COLUMbUi » SOUTHERN OHIO ELtC.: CONtSVILLE 5
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
COLUMBUS & SOUTHERN OHIO EL£C .: CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
SYSTEM
53.9
26.5
39.9
2C.O
46.9
23.5
26.0
13.0
720 469
** PRObLEMS/SOLUTIONS/COMMENTS
THE PARTICULATE DROP TEST SCHEDULED FOR SEPTEMBER 1977 WAS PUSHED BACK TO
THE WEEK OF OCTOBER 24 1971.
10/77
A
B
SYSTEM
.0
32.0
16.0
.0
24.0
12.0
.0
25.Q
12.5
.
18.C
9.0
744
559
68
** PRObLEMS/SOLUTIONS/COMMENTS
THE SCRUBbER WAS DOWN FROM OCTOBER 10 TO NOVEMBER 10.
B-MODULE HAD TO BE RELINED IN SOME AREAS MITH NEOPRENE RUBBER.
11/77 A 10.0
B 33.0
SYSTEM 21.5
4.0
33.0
18.5
4.0
33.0
18.5
4.0
33.0
18.5
720
715
122
•• PRObLEMS/SOLUTIONS/COMHENTS
MODULE A WENT BACK ON LINE NOVEMBER 21. DURING LOU LOAD PERIODS SOLIDS
BUILD UP TENDED TO CAUSE PLUGGING BECAUSE OF LOU FLOW RATES. DURING THE
LOW LOAD PERIODS ALL GAS MAS DUCTED THROUGH ONE MODULE WHILE THE OTHER WAS
SHUT DOWN.
12/77
A
B
SYSTEM
93.0
97.0
95.0
64.0
79.0
71.5
62.0
76.0
69.0
22.0
27.0
24.5
744 252
180
PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT WENT DOWN DECEMBER 12 FOR A 3-MONTH SCHEDULED OUTAGE. MODULE A
BEGAN COMMERCIAL OPERATIONS DECEMBER 3 OPERATING AS MUCH AS POSSIBLE
THROUGH DECEMBER 12. MODULE B OPERATED DECEMBER 1 THROUGH 12. DURING THE
SHUTDOWN THE UTILITY WILL DECIDE IF THE SYSTEM SUPPLIERS HAVE NET SPECS
ON THE BOILER AND TURBINES. THE UNIT IS SCHEDULED TO BE BACK ON LltE IN
MID-MARCH BUT THIS MAY BE PUSHED BACK TO APRIL 1.
DURING THE DECEMBER TO MARCH 1978 SHUTDOWN THE CARBON STEEL FLUE WILL BE
REPLACED WITH AN ACID-BRICK LINING.
1/78
2/78
3/78
4/78
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
20.0
20.0
20.0
19.0
15.8
17.5
64.0
54.0
59.0
.0
10.0
8.0
9.0
744
672
744
379
66
** PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT STARTED UP AGAIN ON MARCH 16.
PH CONTROLS AND S02 ANALYZERS HAVE EXPERIENCED OPERATIONAL PROBLEMS.
IMPURITIES IN THE LIME HAVE CAUSED PLUGGING PROBLEMS.
A
B
SYSTEM
67.0
65.0
66.0
58.0
59.0
58.5
61.0
63.0
62.0
58.0
59.0
58.5
720 716
421
85
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
COLUMfaUS * SOUTHERN OHIO ELEC.: CONESVILLE 5 CCONT.)
PERIOD NODULE AVAILABILITY OPESAB1L1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•- PfcOBLENS/SOLUTIONS/COHMENTS
THE SYSTEh WAS DOWN DUE TO AN EXCESS OF FLOCCULANT IN THE THICKENER.
EXCESS fLGCCULANT IN THE THICKENER YIELDED
OVERFLOW AND RESULTED IN PLUGGING PROBLEMS
5/78
A
U
SYSTEH
52. D
54.0
53.0
45.0 45.0
50.0 51.0
47.5 48.0
44.0
49.0
46.5
A HIGH SOLIDS LEVEL IN THE
IN THE ABSORBER MODULES.
744 720 346
•« PRObLEHS/SOLUTIONS/COHHENTS
THE SYSTEM hAS TAKEN OUT OF SERVICE BECAUSE
FLOCCULANT FEED SYSTEM. THE THICKENER WAS
CULAMT BALANCE.
6/78
A
B
SYSTEH
48.0
30.0
39.0
37.T 37.0
3:.C 30.0
33.5 33.5
37.0
30.0
33.5
OF CONTINUED PROBLEMS WITH THE
EMPTIED TO RESTORE PROPER FLOC-
720 720 243
•• PKObLEMS/SOLUTIONS/COMHENTS
AN FRP PIPING FAILURE IN THE HIST ELIMINATOR HASH SYSTEH OCCURRED.
7/78
A
B
SYSTEH
66.0
43.0
54.5
66.3 66.0
33.0 33.0
49.5 49.5
64.0
32.0
49.0
744 727 359
•• PROblEMS/SOLUTIONS/COMMENTS
OUTAGE TIKE WAS DUE TO PLUGGING IN THE HIST
REGIONS.
8/78
A
B
SYSTEH
18.0
18.0
18.0
20.0 20.0
21. C1 21.0
2C.5 20.5
18.0
18.0
18.0
ELIMINATOR AND SCRUBBER BALL
744 667 135
•• PROuLEHS/SOLUTIONS/COHHENTS
THE FORCED OUTAGE TIME WAS
FROM THE HIST ELIMINATOR.
THE FORCED OUTAGE TIME WAS
OF THE PIKG PONG BALLS IN
DUE. IN PART. TO
DUE. IN PART, TO
THE MODULES.
TIME REflUIRED TO REHOVE SCALE
TIME REflUIRED TO REPLACE SOME
THE UTILITY EXPERIENCED BYPASS DAHPER PROBLEHS DURING THE PERIOD.
9/78
10/78
A
B
SYSTEH
A
B
SYSTEH
6 1.0
5 4.3
57.5
7 2.0
82.0
77.0
PROBLEMS OCCURRED RELATED
SLURRY FEED LINES.
46. 1 55.0
44. D 53.Q
45.0 54.0
37.0 38.0
47.0 47.0
42.0 42.5
TO BROKEN SLUDGE
45.0
43.0
44.0
36.0
45.0
40.5
LINES AND PLUGGING IN THE LIME
720 707 316
744 713 301
•• PRObLEHS/SOLUTIONS/COMMENTS
11/78
A
B
SYSTEM
43.0
84.0
63. 5
DAMPER DRIVE PROBLEHS WERE
MINIMAL RUBBER LINER FAILU
SCRUBBER MODULES AND JUST
29.0 29.0
74.3 75.0
51.5 52.0
REPORTED BY TH€ UTILITY.
IE WAS OBSERVED AT THE TOP OF ONE OF THE
IFTER THE PRESATURATOR .
26.0
66.0
46.0
720 642 331
86
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
COLUMBUS 8 SOUTHERN OHIO ELEC.: CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABIL1TY RELIABILITY UTILIZATION 1 REMOVAL PER BOILER FGD CAP.
$02 PART. HOURS HOURS HOURS FACTOR
12/78 A 6.6 .3 .3 .3
B 13. 1 36.3 36.6 30.0
SYSTEM 19.8 18.7 18.4 15.1
744 609 112
1/79
2/79
3/79
4/79
5/79
** PKObLEMS/SOLUTIONS/COMMENTS
THE LOy HOURS FOR THIS PERIOD ARE ATTRIBUTED TO FREEZE UPS.
6/79
A
b
SYSTEM
A
b
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.?
.D
.3
.3
.0
.0
.0
.0
.0
.0
,c
.0
.c
n
• t.
.0
.0
744
60?
672 C
>* PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEM DID NOT OPERATE DURING FEBRUARY BECAUSE OF SEVERE WINTER WEATHER
A
e
SYSTEM
A
B
SYSTEM
s :..o
.0
2 5.0
1 7.0
.0
8.5
49.0
.?
24.5
58.0
.•5
29.?
50.0
.0
25.0
73.0
.0
36.5
43.0
.0
21.5
12.0
.0
6.0
744
72 C
652
149
160
43
PRObLEMS/SOLUTIONS/COMMENTS
MODULE B DID NOT OPERATE DURING APRIL BECAUSE OF SEVERE CORROSION
AT THE PRESATURATOR INLET DUCT WHICH UOP HAS BEEN REPAIRING SINCE MARCH.
A
B
SYSTEM
.0
.0
.0
.0
.0
.0
.c
n
. *J
n
744 744 C
PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS WERE MADE TO THE SEAL BETWEEN THE 'THICKENER BASE AND SIDEWALL.
THE FED SYSTEM WAS DOWN DURING MAY FOR AN ANNUAL OUTAGE.
A
B
SYSTEM
69.0
50.0
59.5
35.0
21.0
28.a
36.0
22.0
29.Q
33.C
20.0
26.5
7/79
8/79
9/79
10/79
720 670
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGED PH LINES WERE A PROBLEM DURING MAY AND JUNE.
FLYASH CONVEYING PROBLEMS RESULTED IN ABOUT 2 DAYS OUTAGE.
OUTLET DAMPER PROBLEMS WERE REPORTED BY THE UTILITY.
744
744
720
191
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
75.3
93.4
84.4
86.6
85.6
86.1
89.3
95.9
92.6
76.3
89.8
82.8
24.7
22.7
23.7
52.6
51.3
51.9
77.6
90.8
84.2
25.0
23.0
24.Q
59.5
58.0
58.8
69. C
80.6
74.8
10.1
9.3
9.7
27.9
27.2
27.6
53.2
76.3
77.0
45.4
87
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
COLUMBUS K SOUTHERN OHIO ELEC.: CONtSVILLE 5 (CONT.>
PERIOD MODULE AVAILABILITY
B
SYSTEM
11/79 A
b
SYSTEM
12/79 A
b
SYSTEM
47.8
5 0.5
74.0
70.0
72.0
.0
.0
.0
OPEfi ABILITY
77.4
76.9
9C.O
88. D
8-5. o
.0
.C
0
RELIABILITY
78.1
77.6
91.0
89.0
93.0
.0
.0
.0
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
46.1
45.8
52.0
51. C
51.2
• '«,
!•»
•
.2
744
720
74*.
•• PRObLENS/SOLUTlONS/COMMENTS
DURING THE LAST HALF OF 1979 THE UNIT EXPERIENCED PROBLEMS WITH THE LIME
BLOMER COMPRESSOR MOTOR.
CAVITAT10N yAS SITED IN THE SLUDGE PUMP.
THE FLYASH CONVEYOR SYSTEM CAUSED PROBLEMS DURING THE LATTER HALF OF THE
YEAR.
PLUGGING IK THE REAGENT CIRCULATION SYSTEMS yAS ENCOUNTERED.
THERE MERE PROBLEMS WITH THE GUIDE BARS AND SEALS IN THE INLET DAMPER
DURING THE LAST HALF OF 1979.
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAUE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - HU
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY UO/FGb - MU
EQUIVALENT SCRUBBED CAPACITY - MM
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP OIAME TER - M
«* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - I
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - Z
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE
6
CONESVILLE
OHIO
( .100 LB/MMBTU)
t 1.000 LB/MMBTU)
43.
430.
2100.0
411.0
375.0
391.0
411.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/77
6S7.78 (1393893 ACFM)
146.7 ( 296 F)
244. < 800 FT)
7.9 ( 26.0 FT>
COAL
BITUMINOUS
25237.
15.10
12-19
;.so
C 1C8SO BTU/L8)
10300-11220
4.67
4.2-5.1
«• ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
** PARTICULATE SCRUBBER
TYPE
.« FGD SYSTEM
SALEABLE PRODUCT/THROUAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-t FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - Z
S02 DESIGN REMOVAL EFFICIENCY - Z
INITIAL START-UP
CONSTRUCTION. INITIATION
CONTRACT AyAROED
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
•* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
1
COLO SIDE
RESEARCH COTTRELL
99.6
657.8
146.7
(1393893 ACFM)
( 296 F)
NONE
THROWAWAV PRODUCT
NET SCRUBBING
LINE
MG (2-6Z)
AIR CORRECTION DIVISION. UOP
BLACK I VEATCH
FULL SCALE
NEW
99.60
89.50
6/78
5/75
10/74
.0
.0
MOBILE PACKED TOWER
6/78
AIR CORRECTION DIVISION. UOP
4
89
-------
EPA UTILITY F(.D SURVEY: FOURTH QUARTER 1979
COLUMBUS t SOUTHERN OHIO ELEC.: CONtSVILLE 6 (CONT.)
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATER1AL
BOILER LOAp/ABSOSBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULAT10N RATE - LITEH/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
S02 DESIGN REMOVAL EFFICIENCY - X
FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - MET/DRY
CAPACITY - CU.M/S
VACUUM FILTER
NUMBER
MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
HASH SYSTEM
SUPERFICIAL 6AS VELOCITY - M/S
CARBON STEEL (CARPENTER 20 PRESATURATOR>
CHLORQBUTYL RUBBER
CARPENTER 20 SUPPORT GRIDS
6* .0
298.44 ( 632416 ACFM)
141.1 < 286 F)
tSBOOO GPM)
6.7 ( 50.0 GAL/100CACF)
1.8 ( 7.J IN-M20)
3.9 I 12.8 FT/SJ
89.5
4
BOILER 10
CARBON STEEL
DRV
401.11 C 850000 ACFM)
CHEVRON
NORYL PLASTIC
HORIZONTAL
j.05 MC.O FT)
1 .37 ( 4.5 FT)
5.1 < 2.00 IN)
90 DEG.
CONTINUOUS TOP AND BOTTOM WASH 1ST STAGE; BOTTOM
4.2
« 13.7 FT/S>
•• MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
SUPERFICIAL GAS VELOCITY -
*• PUMPS
SERVICE
M/S
ABSORBER RECIRCULATlON
TRANSFER TANK
SLURRY TRANSFER
RECYCLE TANK SLUDGE TRANSFER
HIST ELIMINATOR WASH
TANKS
SERVICE
TANK
RECYCLE
RECLAIMED HATER
SLURRY TRANSFER
SLURRY STORAGE
N.E. MASH
•• REHEATER
TYPE
«• THICKENER
NUMBER
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
.. WATCH LOOP
TYPE
MESH MAKEUP HATER ADDITION - LITERS/S
TRAPOUT TRAY
CARPENTER 20
HORIZONTAL
1
4.2
NUMBER
C 13.7 FT/S)
NUMBER
1
1
1
1
BYPASS
CARBON STEEL WITH CONCRETE FLOOR
44.? (145 FT)
32.5
OPEN
31.5
( 500 6PM)
90
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
COLUMBUS t, SOUTHERN OHIO ELtC.: CONESVILLE 6 (CONT.)
** REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
** TREATMENT
TYPE
CONTRACTOR
PRODUCT CHARACTERISTICS
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
P07-0-TEC
IUCS
73* SOLIDS
FINAl
LANDFILL
ON-SITE
PUMPED
5C.O
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
502 PART. HOURS HOURS HOURS FACTOR
6/78 A 56.0 49.0 51. 0 42.0
B 44.0 33.0 34.0 30. C
SYSTEM 50.0 41.0 42.5 36.0
720 524 174
7/78
8/78
9/78
** PRObLENS/SOLUTIONS/COMMENTS
10/78
CONTROL Of THE LOUVERED DAMPER OF THE BYPASS SYSTEM MAS LOST. THE
RESULT WAS BACK PRESSURE BUILDUP THAT AUTOMATICALLY SHUT DOWN THE BOILER.
SCRUBBER CONTROLS WERE NOT OPERATING PROPERLY AND NEEDED ADJUSTMENT.
A
b
SYSTEM
83.0
70.0
76.5
37.0
19.0
28.0
63.0
33.0
48.0
25.C
13.0
19.0
744
502
141
PROBLEMS/SOLUTIONS/COMMENTS
THE LOUVERED DAMPER PROBLEM CONTINUED.
THE FRP TRANSFER LINE FROM THE THICKENER TO THE IUCS SYSTEM RUPTURED AS A
RESULT OF WATER HAMMER IN THE LINE AND HAD TO BE REPAIRED.
A
B
SYSTEM
47.0
62.0
54.5
5C.O
60.0
55.0
66.0
81.Q
73.5
43.0
52.0
47.5
744 642
354
PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH THE SLUDGE LINE.
THAT THIS IS TYPICALLY A HIGH MAINTENANCE AREA.
THE UTILITY REPORTS
PROBLEMS WERE ENCOUNTERED WITH THE BYPASS CONTROL DAMPERS.
REPORTS THAT THIS IS TYPICALLY A HIGH MAINTENANCE AREA.
THE UTILITY
A
B
SYSTEM
55.0
69.0
62.0
5C.O
55.0
52.5
53.0
57.0
55.0
49.0
54.0
51.5
720 706
** PROBLEMS/SOLUTIONS/COMMENTS
A PROBLEM AREA WAS THE PLUGGING OF THE LINE SLURRY FEED LINES.
BY-PASS DAMPER CONTROL PROBLEMS CONTINUED THROUGH SEPTEMBER.
372
A
B
SYSTEM
98.0
37.0
67.5
29.0
35.0
32.0
30.0
36.0
33.0
24.0
29.0
26.5
744
603
199
«« PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS fclTH DAMPER SEALS AND GUIDEBARS WERE ENCOUNTERED. THE UTILITY
PLANS TO REPLACE THEM DURING THE NEXT BOILER OUTAGE.
11/78 B
26.0
9.0
6.0
8.0
91
-------
EPA UTILITY FCD SURVEY: FOURTH QUARTER 1979
COLUMBUS & SOUTHERN OHIO ELEC.: CONfcSVILLE 6 (CONT.)
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
SYSTEM 26.0 6.0 4.5 5.0
** PRObLEMS/SOLUTIONS/CONNENTS
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720 4»0 32
LIME TRANSFER BAGHOUSE SHAKER PROBLEMS WERE EXPERIENCED.
THE THICKENER RAKE MOTOR BURNED OUT AND HAD TO BE REWOUND.
12/78 A 34.8 26.3 26.8 24.2
U 26.6 19.0 19.3 17.5
SYSTEM 30.7 22.6 23.0 20.8
•• PROBLEMS/SOLUTIONS/COMMENTS
744 67Z 155
FREEZE UPS WERE A SERIOUS PROBLEM DURING THIS PERIOD.-
1/79 A 5.0 2.0 2.0 2.0
B .0 .0 .0 «0
SYSTEM 2.5 1.0 1.0 1.0
2/79 A .0 .0 .0 .C
b .0 .0 .0 .0
SYSTEM .0 .^ .0 .0
•• PROBtENS/SOLUTIONS/CONNENTS
THE FGD SYSTEM DID NOT OPERATE DURING
3/79 A 43.0 37.0 39.0 33.0
B 32.0 28.0 29.0 25.0
SYSTEM 37.5 32.5 34.0 29.0
4/79 A 82.0 79.0 79.0 78.0
B 72.0 59.0 59. 0 58.0
SYSTEM 77.0 69. C 69. 0 68.0
5/79 A .0 .0 .0 .0
B .0 .0 .0 .0
SYSTEM .0 .0 .0 .0
«« PRObLEMS/SOLUTIONS/COHNENTS
REPAIRS UEKE MADE TO THE SEAL BETWEEN
THE BCILER DID NOT OPERATE DURING NAY.
6/79 A 43.0 37.0 39.0 27.0
B 49.0 49.0 S2.0 31.0
SYSTEM 46.0 43.0 45.5 29.0
•• PROBLEMS/SOLUTIONS/COMMENTS
FLYASH CONVEYING PROBLEMS RESULTED IN
PLUGGED PH LINES WERE A PROBLEM DURING
7/79 A 83.9 29.5 29.7 22.0
b 88.7 41.2 41.4 30.8
SYSTEM 86.3 35.4 35. 6 26.4
8/79 A 76.2 40.8 40.8 40.8
B 77.6 42.6 42.6 42.6
SYSTEM 76.9 41.7 41.7 41.7
9/79 A 87.6 58.5 57.4 S4.4
a 86.5 55.5 56.2 53.3
SYSTEM 87.0 57.0 56.8 53.9
10/79 A 75.9 66.2 66.5 63.3
744 730 8
672 o
FEBRUARY DUE TO SEVERE WINTER HEATHER
744 664 216
720 711 489
744 0 0
THE THICKENER BASE AND SIDEwALL.
720 433 186
ABOUT 2 DAYS OUTAGE.
THIS PERIOD.
744
744
720
92
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
COLUMBUS 8 SOUTHERN OHIO ELEC.: CONESVILLE 6 (CONT.)
PERIOD
11/79
12/79
MODULE
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
AVAILABILITY
43.1
59.5
67.0
52.0
59.5
84.0
91.0
87.5
OPERAB1L1TY
23.6
44.9
58.0
49.5
53.5
76. C
37.0
31.5
PtNfORMAI
RELIABILITY
23.7
45.1
58.0
49.0
53.5
76.0
87.0
81.5
UE DATA
UTILIZATION
22.6
43.0
48.0
41.0
44.5
76. C
87.0
81.5
s REMOVAL PER BOILER
S02 PART. HOURS HOURS
744
720
744
FGD CAP.
HOURS FACTOR
PRObLtMS/SOLUTIONS/COMMENTS
DURING THE LAST HALF OF 1979 THE UNIT EXPERIENCED PROBLEMS WITH THE LIME
BLOWER COMPRESSOR MOTOR.
CAVITATION WAS SITED IN THE SLUDGE PUMP.
THE FLYASH CONVEYOR SYSTEM CAUSED PROBLEMS DURING THE LATTER HALF OF THE
YEAR.
FLOGGING IK THE REAGENT CIRCULATION SYSTEMS WAS ENCOUNTERED.
THERE WERE PROBLEMS WITH THE GUIDE BARS AND SEALS IN THE INLET DAMPED
DURING THE LAST HALF OF 1979.
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAPE
UNIT NUMBED
CITY
STATt
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGL - My
EQUIVALENT SCRUBBED CAPACITY- MW
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS UMPERATUKE - C
STACK HEIGHT - M
STACK TOP OIAME TE R - M
•• FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTEST - BTU/LB
AVERAGE ASH CONTENT - I
RANGE ASH CONTE NT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - *
MANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•• ESP
SUMP EH
TYPE
SUPPLIER
PARTKULAU DESIGN REMOVAL EFFICIENCY - Z
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
PARTICIPATE OUTLET LOAD - G/CU.M
PARTICULATE
TYPE
SCRUBBER
•• FbO SYSTEM
SALEABLE PRODUCT/THROWAUAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
CONSTRUCTION INITIATION
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGE S
DIMENSIONS - FT
SMELL MATERIAL
- X
COOPERATIVE POWER ASSOCIATION
COAL CREEK
1
UNOEDWOOD
NORTH DAKOTA
B
43.
516.
1100.0
545.0
495.0
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
327.0
COMBUSTION ENGINEERING
PULVHRIZED LIGNITE
BASE
* * / * *
******** (•..*».* ACFM)
16C.O I 320 F)
198. ( 653 FT)
6.7 ( 22.0 FT)
COAL
LIGNITE
14556.
7.14
J.89-15.95
39.83
J7.7P-52.55
.63
0.13-1.41
.02
3.30-0.08
COLD SIDE
HHEELABRATOR-FRVE
99.5
( 6258 BTU/LB)
3C68-7660
1090.1
16C.6
.02
NONE
THROWAW AY PRODUCT
WET SCRUBBING
LIMEi .ALKALINE FLVASH
NONE
COMBUSTION ENGINEERING
BLACK t VEATCN
FULL SCALE
NEW
99.50
90.00
8/79
8/77
SPRAY TOWER
8/79
COMBUSTION ENGINEERING
3
22 I 22 X 20
316L SS
(2310000 ACFM)
< 321 F)
( .01 GR/SCF)
-------
COOPERATIVE POWER ASSOCIATION: COAL C&EEK
SHELL LINER MATERIAL
NOZZLE TYPE
L/G RATIO - L/C U.M
S02 INLET CONCENTRATION - PPM
S02 CUTLET CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
** FANS
NUMBER
TYPE
** MIST ELIMINATOR
NUMBED
TYPE
CONSTRUCTION MATERIAL
NUMBER OF STAGES
*• HIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
•• PUMPS
SERVICE
BLEED STREAM
SLURRY FEED
REACTION TANK TRANSFER
TANKS
SERVICE
REACTION-RECYCLE-THICK ENER
FLYASH WETTING
LIME FEED
REHEATER
TYPE
TEMPERATURE BOOST - C
WATER LOOP
TYPE
REAGENT PREPARATION EQUIPMENT
NUMBER OF SLAKERS
TREATMENT
TYPE
DISPOSAL
NATURE
TYPE
AREA - ACRES
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
1 (CONT.)
NONE
PROPRIETARY ATOMIZING
?.0 ( 60.0 GAL/1000ACF)
1COO
10C
9C.O
4
I.D.
CHEVRON
FRP
I
SLAT IMPINGEMENT
FRP
NUMBER
3
****
6
NUMBER
BYPASS
47.2
OPEN
FLYASH STABILIZATION
FINAL
LINED POND
101 .0
85 F)
PERFORMANCE DATA ———- — --
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION t REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/79 SYSTEM
9/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
THIS UNIT STARTED COMMERCIAL OPERATIONS ON AUGUST 1, 1979. SOME MINOR
PROBLEMS WERE REPORTED DURING START UP.
744 711
7ZO 703
744 719
95
-------
EPA UTILITY FGt> SURVEY: FOURTH QUARTER 1979
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILlTY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
SOE PART. HOURS HOURS HOURS FACTOR
•• PRObLEMS/SOLUTIONS/CCNMENTS
SINCE STARTUP THE UNIT HAS EXPERIENCED NUMEROUS SHAKE DOWN PROBLEMS.
AFTER THE NEXT SCHEDULED OUTAGE IN APRIL, THEY EXPECT FAIRLY STABLE
OPERATIONS.
DURING DECEMBER 2 OF 8 PULVERIZERS WERE OUT DUE TO A PRIMARY AIR DUCT
EXPLOSION.
96
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - *k
MET UNIT GENERATING CAPACITY W/FGO - MU
NET UNIT GENERATING CAPACITY WO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
«* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
.100 LP/MMBTU)
.600 LB/MMBTU)
DUOUESNE LIbHT
ELRAMA
1-4
ELRAMA
PENNSYLVANIA
D
43. <
258. (
494.C
51C.C
475.C
493.0
510.0
BABCCCK & UILCOX
PULVERIZED COAL
BASE
0/52
******** (*.***** ACFM)
******* (.... F)
122. < 400 FT)
******* (**•** FT1
*• ESP
NUMBER
TYPE
SUPPLIER
** MECHANICAL COLLECTOR
SUPPLIER
** PARTICULATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODUCT/THROUAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEU/RETROFIT
PAHTKUIATE DESIGN REMOVAL EFFICIENCY
502 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AUARDE D
ABSORBER SPARE CAPACITY INDEX - 1
ABSORBER SPARE COMPONENT INDEX
COLOSIDE
RESEARCH COTTRELL
RESEAHCH COTTRELL
VENTURI
THROWAUAV PRODUCT
WET SCRUBBING
LIME
CHEHICO
GIBB ! & HILL
PULL SCALE
RETROFIT
99.00
83.00
10/75
10/75
12/7'
12/70
3?.0
1.3
«* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERI»L
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/6 RATIO - L/C U.N
PRESSURE DROP - KPA
PARTICULATE REMOVAL EFFICIENCY - %
.* FANS
NUMBER
TYPE
VENTURI
10/75
CHEMICO
1
30 DIA. X 60 HIGH
CARBON STEEL
CEILCOTE
316L SS AND CEILCOTE
254.83
150.6
1COf .
5.3
4.0
99.0
SCRUBBER ID
( 540000 ACFM)
C 303 F)
(16000 6PM)
( 40.0 6AL/100QACF)
116.2 IN-H20)
97
-------
EPA UTILITY FLD SURVEY: FOURTH OUARTER 1979
OUOUEiNE LIGHT; ELRAHA 1-4 (CONT.)
CONSTRUCTION MATERIALS
SERVICE - i.ET/0 RY
•• HIST ELIMINATOR
TYPE
CONSTRUCTION MA TE R 1 AL
CONF 1GURATION
NUMBER Of STAGE S
NUMBER OF PASSE S
FREEBOARD DISTANCE - M
VANE SPACING - CM
VANE ANGLES
SUPERFICIAL GAS VELOCITY - M/S
•• "1ST ELIMINATOR
TYPE
•• PUMPS
SERVICE
SCRUBBER/AbSORBER RECIRCULATION
•• REHEATER
TYPE
TEMPERATURE BOOST - c
•• THICKENER
NUMBER
OUTLET SOLIDS - 1
•• WATER LOOP
TTPE
•• TREATMENT
TYPE
CONTRACTOR
PRODUCT CHARACTERISTICS
•• DISPOSAL
NATURE
TTPE
LOCATION
TRANSPORTATION
CARBON STEEL UITH 0.25 INCH RUBBER LINING IN HOU
WET
CHEVRON
F9P
HORIZONTAL
1
I 4.5 FT>
( .0? IN)
( 1.0 FT/S)
1.37
.1
.3
CHEVRON
NUMB ER
10
DIRECT COMBUSTION
16.7 ( 33 F)
32.Q
OPEN
POZ-O-TEC
IUCS
70Z SOLIDS
FINAL
LANDFILL
OFF-SITE
TRUCK
— ..... ._..—... ... PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/75 SYSTfcM
•• PfiOuLEMS/SOLUTIONS/COMMENTS
THE FIRST ELRAMA SCRUBBER WAS PLACED IN SERVICE ON OCTOBER 26 » 1975. IT
HAD HEEN SCHEDULED FOR AN EARLIER STARTUP DATE BUT BECAUSE Of THE SEUER1TV
AND NUMBER OF PROBLEMS ENCCUNTEREO AT PHILLIPS, STARTUP WAS DELAYED UNTIL
MANY OF ThE PROBLEMS AT PHILLIPS WERE RESOLVED AND THE MODIFICATIONS COULD
HE INCORPORATED AT BOTH STATIONS.
BCILER NO. c WAS INITIALLY CONNECTED TO THE FGD SYSTEM ON OCTOBER 2t,
1V75. THIS BOILER HAS AN EOUIVALENT CAPACITY OF APPRO*JWATELr 700 KW AND
THE EMISSIONS ARE HANDLED BY ONE SCRUBBER. TO ENSURE RELIABILITY IN THE
CASE OF A SCRUBBER MALFUNCTION, TwO SCRUBBERS ARE OPERATED AT PARTIAL
LCAD TO PROTECT THE BOILER AND TURBINE GENERATOR AGAINST A TRIP-OFF.
THE UOILEf. OPERATED CONTINUOUSLY ON THE SCRUBBER SYSTEM THROUGH JANUARY
1976. TWC MINOR OUTAGES OCCURRED. ON FEBRUARY 4, 1976 A SECOND BOILER
WAS COUPLED INTO THE SCRUBBER COMPLEX. PRESENTLY, 2 UNITS ARE THE HAXI-
MOM THAT CAN 6£ TIED INTO THE SCRUBBER PLANT. TO DATE, THE UTILITY HAS
ENCOUNTERED THE USUAL MINOR STARTUP PROBLEMS AND SOME MAJOR PROBLEMS AS
WELL. THE MAJOR PROBLEMS HAVE BEEN FROZEN PIPES AND THICKENERS, THE LAT-
TER INVOLVING HARDWARE AND DESIGN ASSOCIATED UITH REC1RCULATI ON OF THE
SLUDGE WITHIN THE THICKENERS TO ATTAIN 30 TO 40Z SOLIDS CONCENTRATION.
10/75 1C1
98
-------
EPA UTILITY FGC SURVEY: FOURTH QUARTER 1979
OUOUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
301
401
SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
38.0
2952
1123
ONE BOILER WAS CONNECTED TO THE SCRUBBER SYSTEM ON OCTOBER 26t 1975.
SECO»D BOILER WAS CONNECTED ON FEBRUARY 4, 1976. FOUR OF THE SC«UBbE«
VESSELS HAVE BEEN IN SERVICE IN VARIOUS COMBINATIONS. THE FIFTH VESSEL
HAS NOT BEEN IN SERVICE BEI AUSE IT IS BEING REVISED FOR TRIAL INSTALLA-
TION RUBBER-LINED RECYCLE PUMPS.
11/75 SYSTEM
12/75 SYSTEM
0/76 SYSTEM
1/76 SYSTEM
*« PROBLEMS/SOLUTIONS/COMMENTS
72 C
744
744
69.5
DURING JANUARY ONE OUTAGE WAS CAUSED BY A LIME FEEDER BELT FAILURE.
ONE OUTAGE WAS CAUSED BY INOPERATIVE THROAT DAMPERS.
2/76 SYSTEM 696
3/76 SYSTEM 744
«• PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEM OPERATED DURING THE REPORT PERIOD WITH TVO BOILERS COUPLED INTO
THE SCRUBBING SYSTEM. REVISIONS TO THE FIFTH SCRUBBING VESSEL HAVE BEEN
COMPLETED AND OPERATIONS ARE PROCEEDING WITH TWO RUBBER-LINED RECYCLE
PUMPS.
4/76 SYSTEM
5/76 SYSTEM
•* PRObLEMS/SOLUTIONS/COMMENTS
72C
744
6/76 SYSTEM
7/76 SYSTEM
THE SYSTEM IS STILL OPERATING WITH TWO BOILERS COUPLED INTO THE SCRUBBING
SYSTEM. THE IUCS SLUDGE FIXATION SYSTEM IS CONTINUING TO OPERATE AT THIS
STATION.
THE FIFTH SCRUBBING VESSEL WAS TAKEN OUT OF SERVICE FOR REPAIRS AND MQDIFI
CATIONS REQUIRED FOR THE RUBBER-LINED RECYCLE PUMPS.
THE UTILITY IS CURRENTLY CONDUCTING A PERFORMANCE TEST ON THE SCRUBBING
SYSTEM IN THE TWO BOILER OPERATION MODE.
720
744
*• PRObLEMS/SOLUTIONS/COMMENTS
8/76 SYSTEM
9/76 SYSTEM
THE FIFTH SCRUBBING VESSEL EMPLOYING TWO RUBBER-LINED RECYCLE PUMPS WAS
OPERATIONAL FOR A SHORT PERIOD OF TINE DURING THE REPORTING MONTHS. TWO
BOILERS REMAIN COUPLED INTO THE SCRUBBING SYSTEM. THE CONSTRUCTION OF AD-
DITIONAL LIME STORAGE SILOS AMD A THICKENER WILL BE REQUIRED FOR FULL
SCALE OPERATION. THE UTILITY HAS SIGNED A LETTER OF INTENT WITH IUCS FOR
A LONG TERM SLUDGE FIXATION SYSTEM. HIGH CALCIUM LIME IS STILL BEING
EMPLOYED IN THE SCRUBBING SYSTEM.
744
720
99
-------
EPA UTILITY FfcD SURVEY; FOURTH QUARTER 1979
DUQUESNE LIGHT: ELRAMA 1-- (COMT.)
PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*• PROoLEMS/SOLUTlONS/COMMENTS
OPERATIONS AT THIS STATION DURING THE REPORT PERIOD PROCEEDED WITH TWO
BOILERS COUPLED INTO THE 5-MODULE SCRUBBING SYSTEM. THE 5TH SCRUBBING
VESSEL WAS OPERATIONAL DURING THE REPORT PERIOD WITH THE RUBBER-LINED
RECYCLE PLMPS IN SERVICE. OPERATIONS ARE STILL PROCEEDING ON AN OPEN
WATER-LOOP BASIS. PART OF THE THICKENER OVERFLOW IS STILL BEING DIVERTED
TC THE ASH POND AND NOT RECYCLED BACK TO THE PROCESS. BECAUSE BOTH
BfcAVER VALLEY AND BRUCE MANSFIELD STATIONS ARE FULLY OPERATIONAL, THIS
STATION HAS BEEN RELEGATED TO PEAK LOAD OPERATIONS. GENERAL LOAD OPERA-
TIONS ARE FULL CAPACITY IN THE DAYTIME AND 50 TO 63X REDUCTION AT NIGHT.
TtSTS hERt CONDUCTED DURING THE PERIOD TO DETERMINE PARTICIPATE AND SC2
REMOVAL EFFICIENCIES. S02 REMOVAL EFFICIENCY WAS 5C PERCENT. PARTICULATE
EMISSIONS WERE BEING REDUCED WELL BELOW 0.1 LB/MM BTU STANDARD (ACTUAL
RESULTS: L.04 LB/M1 BTU). THESE RESULTS WERE BASED O'N TWO BOILERS
COUPLED INTO THE 5 SCRUBBING MODULES WHILE BURNING MEDIUM-SULFUR (1.0 TO
2.SX) COAL. THE MECHANICAL COLLECTORS AND ESP'S WERE IN SERVICE DURING THE
TESTS .
10/7fc SYSTEM 744
11/76 SYSTEM 72i
•• PRObLEMS/SOLUTIONS/COMMENTS
The SCRURLER REMAINED IN SERVICE THROUGHOUT THE REPORT PERIOD WITH TWO
TOILERS COUPLED INTO THE SCRUBBING SYSTEM. A RECYCLE PUMP EVALUATION IS
bclNG CONDUCTED BY THE UTILITY AT BOTH PHILLIPS AND ELRAMA STATIONS.
ObSERVATICNS OF THE RUBBER-LINED RECYCLE PUMPS INDICATE SOME SEVERE ABRAS-
ICS AND GOUfeING HAVE OCCURRED AFTER 1000 HOURS OF SERVICE TIME.
12/76 SYSTEM 744
1/77 SYSTtM 744
*• PHObL£MS/SOLUTIOMS/COMMENTS
TESTING ON THIOSORBIC LIME WAS CONDUCTED DURING THE PERIOD.
THE SCRUBLE* PLANT CONTINUED OPERATIONS DURING THE REPORT PERIOD WITH TuO
BOILERS COUPLED INTO THE SYSTEM. INSTALLATION OF THE ADDITIONAL THICKENER
LIME FEEDERS AND SILOS IS STILL IN PROGRESS. FULL COMPLIANCE OPERATION FOR
THIS STATION IS SCHEDULED FOR EARLY 1978. THE FULL COMPLIANCE STRATEGY
WILL CONSIST OF THE FOLLOWING: 83X S02 REMOVAL FOR , FIXATING THE SCRUBBER SLUDGE WITH THE
IUCS POZ-0-TEC STABILIZATION METHOD AND HAULING THIS MATERIAL TO AN OFF-
SITE DISPOSAL/LANDFILL AREA. CURRENT SC2 AND PARTICULATE REMOVAL
EFFICIENCIES ARE 50 AND 99 -X, RESPECTIVELY. THE INTERIM IOCS UNIT hOW in
SERVICE CONSISTS OF THE OLD MOHAVE PROTOTYPE PLUS A VACUUM FILTER. THE
STABILIZATION MATERIAL HAS BEEN UTILIZED IN A PARKING LOT CONSTRUCTION
PROJECT. 1UCS HAS BEEN AWARDED A 10-YEAR CONTRACT FOR THE CONTINUED USE
OF THIS SYSTEM FOR FUTURE PLANT OPERATIONS.
2/77 SYSTEM 672
3/77 SYSTEM 744
4/77 SYSTEM 72C
•• PRObLEMS/SOLUTIONS/COMHENTS
CONSTRUCTION OF TWO 120-FOOT DIAMETER THICKENERS IS CONTINUING. DUE TO
THE GOUGING OF THE RUBBER-MINED RECYCLE PUMPS DURING THEIR TESTING, THEY
HAVE BEEN REMOVED. THE UTILITY IS CONSIDERING TRYING ANOTHER SET OF
RUBBER-LINED PUMPS. DUOUESNE LIGHT ALSO is CONTINUING EFFORTS TO OBTAIN
ALTERNATE LANDFILL AREAS FOR SLUDGE DISPOSAL.
5/77 SYSTtM 744
100
-------
EPA UTILITY FGO SURVEY: FOURTH OUARTER 1979
DUQUESNE LIGHT: ELBA MA 1-*. tCONT.)
— ._— PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEPABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6777 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DUQUESNE LIGHT REPORTED THE FOLLOWING ITEMS FOR THE ELRAMA SCRUBBER PLANT
DURING THE REPORT PERIOD:
-TWC BOILERS (2^0 MU) MERE COUPLED INTO THE SCRUBBER PLANT.
-THE INTERIM IUCS STAB1LI?ATION UNIT CHOHAVE PROTOTYPE) CONTINUED TO FIX-
ATE SCRLBBER WASTES.
-CONSTRUCTION OF THE TUO ADDITIONAL THICKENERS CONTINUED (CONSTRUCTION IS
ON SCHEDULE).
-FULL PLANT COMPLIANCE is PROJECTED ion FEBRUARY 1978.
-S02 REMOVAL EFFICIENCY is APPROXIMATELY 50X.
-ELRAMA IS OPERATING IN A BASE I INTERNED1ATE LOAD MODE (FULL LOAD DAYTIME/
HALF LOAD NIGHT-TIME). 1976 CAPACITY FACTOR UAS 69.SX.
7/77 SYSTEM 744
8/77 SYSTEM 744
•« PRObLEMS/SOLUTIONS/COMMENTS
THE T»0 ADDITIONAL THICKENERS WERE COMPLETELY INSTALLED. THE IUCS SYSTEM
WAS UPGRADED. END OF CONSTRUCTION IS PROJECTED FOR FEBRUARY 1978. FULL
PLANT COMPLIANCE IS PROJECTED FOR APRIL 1978.
9/77 SYSTEM 720
10/77 SYSTEM 744
•* PROBLEMS/SOLUTIONS/COMMENTS
MODULE 101 fcAS UNAVAILABLE OCTOBER 4 DUE TO A BLEED VALVE LEAK AND kAS TA-
KEN OUT OF SERVICE AT THE END OF THE MONTH FOR CLEANUP.
MODULE 231 yAS AVAILABLE FOR THE ENTIRE MONTH.
MODULE 301 AND 401 HAD OUTAGES IN OCTOBER RESULTING FROM A RUBBER LINING
FAILURE OK AN I.D. FAN.
MODULE 501 EXPERIENCED RECYCLE PUMP OUTAGES IN LATE NOVEMBER.
NEW RUBBER LINED WORNEN RECYCLE PUMPS WERE INSTALLED. THE LIME HANDLING
SYSTEM INSTALLATION WORK CONTINUED. THE LAST TWO BOILERS ARE EXPECTED TO
BE TIED INTO THE FGD SYSTEM BY JANUARY 1978.
TUBE LEAKS FORCED A BOILER OUTAGE IN NOVEMBER.
11/77 1:1 .C
201 11.7
301 93.3
401 22.5
501 59.2
SYSTEM 37.3 720 268
** PRObLEMS/SOLUTIONS/COMMENTS
MODULE 101, 201 AND 401 HAVE LOU OPERATIONAL HOURS BECAUSE ONLY TWO BOILER
ARE TIED INTO THE FGD STSTEN TO DATE.
THE SLUDGE HANDLING SYSTEM is FUNCTIONING PROPERLY AND is NOW IN FULL SER-
VICE.
12/77 SYSTEM 744
101
-------
EPA UTILITY fGD SURVEY: FOURTH QUARTER 1979
OUQUESNE LIGHT: ELRANA 1-4 (COM.)
PERFORMANCE DATA .
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•• PHOriLEMS/SOLUTIONS/COMMENTS
DURING THE PERIOD A NEW WORMEN RECYCLE PUMP INSTALLED IN NOVEMBER EXPER1
EMCED JACK SHAFT BEARING PROBLEMS RESULTING IN REMOVAL OF SCRUBBER TRAIN
5C1 FROM SERVICE.
BCILfcR NO. 4 WAS CONNECTED, ADDING AN ADDITIONAL 176 MW OF FLUE GAS LOAD
THE FGD SYSTEM.
THE IUCS SLUDGE DISPOSAL FACILITY IS IN SERVICE PRODUCING GOOD PRODUCT.
LOW LOAD AND A COAL STRIKE HAVE HAMPERED GOOD SCRUBBER OPERATIONS. THERE
IS SOME OUTAGE TIME SCHEDULED FOR MARCH.
1/78 101 9*.1
201 90.5
301 5.1
401 2«.3
501 3.5
SYSTtM *3.5 744 3Z3
2/78 1C1 30.4
201 41.2
JC1 .0
401 15.9
sci IB.?
SYSTEM 21.1 672 U1
*• PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEr WAS SHUTDOWN ON FEBRUARY 11 AS A RESULT OF A COAL SHORTAGE.
BOILERS 1, I AND 4 ARE NOW COMPLETELY CONNECTED TO THE FGD SYSTEM. BOILER
5 IS UNDERGOING Ah EXTENSIVE OVERHAUL AND WILL BE CONNECTED TO THE SYSTEM
IN LATE AFRIL.
BOILER EXIT DAMPERS WERE LINED WITH 316 SS ON AREAS OF HIGH EROSION CAUSED
BY FLYASH IMPINGEMENT.
EXPANSION JOINTS IN THE UPSTREAM DUCTWORK WERE SHIELDED BY METAL PLATES
WHICH WERE WELDED AT ONE END. EXPANSION JOINTS IN THE DOWNSTREAM DUCTWORK
WERE COMPLETELY REPLACE. THE DOWNSTREAM DUCTWORK WAS RELINED WITH
CEILCOTE.
MODULE 431 INTERNALS WERE CLEANED AND SOME HOLES IN THE UPPER CONICAL RE-
GION WERE REPAIRED.
3/78 1C1 .0
291 .0
301 .0
401 . 3
501 .C
SYSTEM .- 744 0 C
• • PRObLEMS/SOLUTIONS/COMMENTS
DURING THl APRIL-MAY PERIOD BOILER NUMBER 3 WAS STILL BEING OVERHAULED.
FfcD SYSTEM CONSTRUCTION WAS COMPLETED AND PRELIMINARY TESTING VERIFIED
SYSTEM SOi REMOVAL EFFICIENCY.
4/78 SYSTEM 720 475
S/78 SYSTEM 744 547
6/7g SYSTEM 720 492
•• VRObLEMS/SOLUTIONS/COMMENTS
MODULE 331 WAS PULLED OFF FOR A MAJOR CLEANING DURING THE PERIOD.
MIST ELIMINATOR PLUGGING WAS EXPERIENCED AS A RESULT OF LOW PH.
102
-------
EPA UTILITY FED SURVEY: FOURTH QUARTER 1979
DUOUESNE LIGHT: EL RAMA 1-4 (COMT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE CHRONIC INABILITY TO CONTROL CHEMISTRY (PH) IS DIRECTLY RELATED TO
GRIT BUILD-UP IN THE LIME HANDLING AND SLURRY PREPARATION SYSTEM.
THE UTILITY IS CURRENTLY STUDYING WAYS TO TIGHTEN THE WATER BALANCE BY US-
ING THICKENER SUPERNATANT INTERMITTENTLY WITH CLEAR SERVICE WATER FOR THE
MIST ELIMINATORS. A COMPLIANCE TEST SHOULD TAKE PLACE DURING THE NEXT RE-
PORT PERIOD.
7/78 101 63.8 59.9
201 100.0 100.0
3?1 72.8 66.5
4C1 100.0 99.1
501 82.1 77.2
SYSTEM 85.7 80.5 744 699 599
8/78 1C1 84.4 76.9
201 1CC.O 100.0
301 55.6 50.7
401 100.0 100.0
501 77.9 70.9
SYSTEM 87.5 79.7 744 678 593
•• PftOuLEMS/SOLUTIONS/COMMENTS
DURING AUGUST, MODULES 301 AND 501 WERE TAKEN OFF LINE FOR CLEANING.
RUBBER LINING ON THREE FAN HOUSINGS WAS REPAIRED.
IT WA5 NECESSARY TO SHUT DOWN THE LIME MIXING BASIN IN ORDER TO CLEAN OUT
EXCESSIVE GRIT AND SOLIDS BUILD UP.
A COMPLIANCE TEST WAS RUN IN DECEMBER WHICH SHOWED THE UNITS TO BE IN
COMPLIANCE.
9/78 101 78.2 72.1
2C1 61.0 56.3
3?1 96.5 89.n
401 84.6 78.1
501 100.0 93.6
SYSTEM 84.3 77.8 72C 664 560
10/78 101 84.9 76.6
201 1C 0.0 98.9
301 133.0 100.0
401 89.3 eD.5
501 87.2 78.6
SYSTEM 96.4 66.9 744 671 647
11/78 101 100.0 1CO.C1
201 94.2 78.4
301 100.0 84.2
401 10C.D 66.t
501 75.0 62.5
SYSTEM 98.8 82.4 72 C 600 593
12/78 101 10C.P 94.7
201 77.8 72.7
301 91.7 85.6
401 69.4 64.8
501 74.4 69.5
SYSTEM 82.8 77.4 744 695 576
•* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS STARTED HAULING SLUDGE OFF SITE TO AN AREA ABOUT 10 MILES
AWAY.
1/79 101 45.9 39.8
103
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
DUQUESNt LIGHT: ELRAMA 1-4
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
OUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANC E DATA —*—
PERIOD HOOULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD C»P.
S02 PART. HOURS HOURS HOURS FACTOR
12/79
201 15.2 16.9
301 92.4 97.9
401 100.0 10C.O
501 95.0 10C.O
SYSTEM 80.5 85.5
SYSTEM
15.2
92.5
98.3
93.9
80.0 720 67*
744
576
*» PHOBLEMS/SOLUTIONS/CONMENTS
THERE HAVE BEEN NO SCRUBBER-RELATED OUTAGES OVER THE SEPTEMBER THRU
DECEMBER PERIOD.
THE SLUDGE IS NOW BEING TRUCKED TO A REMOTE SITE 10 MILES AUAY CAUSING
OPERATING COSTS TO INCREASE
THE NEW SOI MONITOR HAS PLUGGED ONLY ONCE SINCE OCTOBER AND HAS REQUIRED
ONLY 4 HOURS OF MAINTENANCE PER WEEK.
105
-------
EPA UTILIIY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PI A XT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
SOi EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITf - MW
6ROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY UO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
DUQUESNE LIGHT
PHILLIPS
1-6
SOUTH HEIGHT
PENNSYLVANIA
D
34.
258.
387.0
40S.O
373.0
387.0
41C.O
.080 LB/MMBTU)
.600 LB/MMBTU)
BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
fLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/L8
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - Z
FOSTER WHEELER
PULVERIZED COAL
BASE
* * / * *
873.01
182. 2
104.
.9
COAL
BITUMINOUS
26S10.
16.27
5.02
1.92
1.0-3.8
(1850000 ACFM)
( 360 F)
( 340 FT)
( 2.9 FT)
( 11535 BTU/LB)
ESP
NUMBER
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY -
MECHANICAL COLLECTOR
NUMBER
TYPE
SUPPLIER
PARTICULATE SCRUBBER
TYPE
RESEARCH COTTRELL
X 80.0
MULTICVCLONES
RESEARCH COTTRELL
VENTURI
•• FGD SYSTEM
SALEABLE PHOOUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AhARDE D
STARTED REQUESTING BIDS
STARTED PRELIMINAY DESIGN
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
THROUAUAY PRODUCT
WET SCRUBBING
LIME
NONE
CHEMICO
GIBB ! 8 HILL
FULL SCALE
RETROFIT
- X 99.00
83.00
7/73
7/73
12/71
7/71
10/70
12/69
1 1.0
106
-------
DUOUESNE LIGHT: PHILLIPS 1-6
3300 GPM)
40.0 GAL/1000ACF)
(16.0 IN-H20)
4Q.O FT/S)
.340 GR/SCF)
SCRUBBER ID
CARBON STEEL WITH 0.25 INCH RUBBER LINING IN HOU
WET
235.95 ( 500000 ACFM)
544.2
( 600 T/D)
a
CHEVRON
FRP
HORIZONTAL
1
T
1.37 ( 4.5 FT)
90
INTERMITTENT TOP HASH AND UNDER HASH
.3 ( 1.0 FT/S)
1.0 ( 4.0 IN-H20)
CHEVRON
NUMBER
SCRUBBER RECIRCULATION
THICKENER OVERF LOU
THICKENER UNDERFLOW
10
6
1
107
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
iLURRY FEED
MAKE-UP -ATEfl
ABSORBtR RtClRCULAT10N
•* TANKS
SERVICE
RECYCLE
SLAKED TRANSFER
THICKENER OVERF LOW
SLUDGE STAblLIZATION MIXING
•* REHEATER
NUMBER
TYPE
TEMPERATURE BOOST - C
•• THICKENER
NUMBER
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
•• WATER LOOP
TYPE
•* TREATMENT
TYPE
CONTRACTOR
•* DISPOSAL
NATURE
TYPE
LOCATION
CAPACITY - CU.M.
•• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
NUMBER
1
1
1
1
DIRECT COMBUSTION
16.7 <
30 F)
MILD STEEL, CEILCOTE LINED
22.9 < 75 FT)
32.0
OPEN
POZ-0-TEC
IUCS
INTERIM
LINED POND
ON-SITE
4892 ( 4.0 ACRE-FT)
FINAL
LANDFILL
OFF-SITE
TRUCK
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEBABJLJTY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/73 SYSTEM
•• PRObLEMS/SOLUTIONS/COMMENTS
7/73 SYSTEM
8/75 SYSTEM
DETERMINATION OF THE AVAILABILITY OF THE PHILLIPS SYSTEM HAS BEEN DIF-
FICULT. UNTIL ALL BOILERS WERE CONNECTED TO THE SCRUBBERS, THERE HAS AT
LEAST ONE SPARE TRAIN AND AS MUCH AS 10CX SPARE SCRUBBER CAPACITY.
THEREFORE HAVING A TRAIN OUT OF SERVICE FOR MAINTENANCE DID NOT REDUCE
THE CAPABILITY OF THE SCRUBBER SYSTEM. UNTIL ALL SIX BOILERS WERE CON-
NECTED, MEANINGFUL AVAILABILITY FACTORS COULD NOT BE COMPUTED. ON MARCH
17, 1975, THE SIXTH BOILER WAS CONNECTED, AND ALL FOUR SCRUBBER TRAINS-
WERE REQUIRED TO BE IN SERVICE. OPERATION IN THAT NODE CONTINUED UNTIL
AUGUST 4. 1975, WHEN THE NO. 6 BOILER WAS REMOVED FROM THE SCRUBBER
SYSTEM BECAUSE THE PH LEVEL COULD NOT BE MAINTAINED AND DEPOSITS BECAME
UNMANAGEABLE TO THE POINT THAT SCRUBBER OUTAGES HERE REDUCING GENERATING
CAPABILITY OF THE STATION.
STARTUP OF A PORTION OF THE PHILLIPS SCRUBBER SYSTEM BEGAN JULY 1973.
SEVERAL PROBLEMS THEN DEVELOPED IN THE FORM OF EROSION OF FANS AND THE
LIME FEED SYSTEM CAUSING OUTAGES OF THE SCRUBBER SYSTEM. AFTER AN EX-
TENDED OUTAGE, THE SCRUBBER SYSTEM WAS RETURNED TO SERVICE IN MARCH 1974.
THE SYSTEM HAS BEEN OPERATING CONTINUOUSLY SINCE IT RETURNED TO SERVICE
WITH VARIOUS NUMBERS OF BOILERS CONNECTED TO THE SCRUBBER SYSTEM AND
SCRUBBER TRAINS IN SERVICE.
81.0
31.2
744
744
232
138
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
DUOUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERIOD
9/73
10/73
11/73
12/73
1/7*
2/74
3/7*
4/74
5/74
6/74
7/74
8/74
9/7*
10/74
11/74
12/74
1/75
2/75
3/75
4/75
5/75
6/75
7/75
PERFORMANCE DATA
MODULE AVAILABILITY OPEPABIL1TY RELIABILITY UTILIZATION
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
101 79.1 53.8
201 35.5 2*. 2
301 10C.O 71.4
401 10C.O 97.2
SYSTEM 90.5 61.6
x REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720
744
72 C
744
744
672
744
720
744
72 u
744
744
720
744
720
744
744
672
744
72 G
744
720
744 506 458
** PRObLEMS/SOLUTIONS/COMHENTS
THE FOURTH FGD TRAIN AND SIXTH BOILER WERE TIED IN ON MARCH 17, 1975.
PARTICULATE TESTS IN HAY SHOWED OUTLET LOADINGS OF C.C4 LB/MILLION ETU.
THE 2-STAGE TRAIN HAS BEEN OUT OF SERVICE FROM JUNE 19 FOR GENERAL
CLEANING AND REPAIR OF A LEAK IN THE FIRST-STAGE SCRUBBER.
8/75
301
401
101
201
SYSTEM
66.1
65.2
97.8
100.0
92.0
43.4
42.9
64.2
91.7
60.5
744
489
450
«* PRObLEHS/SOLUTIONS/CONNENTS
SCRUBBER UNAVAILABILITY FORCED RETURNING BOILER (NO.6) TO THE SCRUBBER BY-
PASS PATH IN ORDER TO PREVENT LOSS OF BOILER CAPACITY.
109
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANC I DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
* REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PLUGGING AND MAINTENANCE PROBLEMS HAVE BEEN ENCOUNTERED.
EVALUATION OF VARIOUS RECYCLE PUMPS IS CONTINUING.
9/75 101
201
301
401
SYSTEM
10/75 101
2C1
301
401
SYSTEM
11.0
100.0
103.C
1CC.O
88.6
98.1
33.4
81.6
78.7
72.9
7.9
77.9
95.1
74.4
63.8
81.6
27.8
67.9
65.5
60.7
72C 519
744 619
460
451
*• PRObLEMS/SOLUTIONS/COMMENTS
IN OCTOBER 1975, PHILLIPS INITIATED THIOSORBIC LIME SCRUBBING IN THEIR
SINGLE-STAGE MODULES ON AN EXPERIMENTAL BASIS. THE PURPOSE IS TO STUDY
COMPLIANCE FEASIBILITY, SO? REMOVAL EFFICIENCY, AND QUALITY OF THE SLUDGE
GENERATED BY THE SINGLE-STAGE MODULES.
11/75
101
2C1
301
401
SYSTEM
12/75 101
201
301
401
SYSTEM
1CC.O
100.0
.0
16. C
75.9
77.8
100.0
39.3
83.4
85.7
86.9
100.0
.0
10.4
49.3
48.4
88.8
24.5
51.9
53.4
720 468
744 463
355
397
•« PRObLEMS/SOLUTIONS/COMMENTS
THE UTILITY CONCLUDED THE THIOSORBIC LIME TESTING PROGRAM IN MID-DECEMBER
FOUR BOILERS MERE COUPLED TO THE SCRUBBING SYSTEM DURING THE RUN. THE
UTILITY IS NOW ANALYZING THE DATA GENERATED DURING THE TEST PROGRAM. THE
SCRUBBERS HAVE BEEN PUT BACK ON REGULAR LIME. NO UNUSUAL PROBLEMS WERE EN
COUNTERED DURING THE TEST RUN.
1/76
1 ?1
201
301
401
SYSTEM
56.2
100.0
20.5
1CO.O
82.2
37.2
72.0
13.6
95.0
54.4
744 493
405
«• PRObLEMS/SOLUTIONS/COMMENTS
2/76 101
201
301
401
SYSTEM
3/76 101
201
301
401
SYSTEM
4/76 SYSTEM
THE 2.5-MCNTH TEST PROGRAM WITH THIOSORBIC LI«E INCLUDED 1612 HOURS ON ONE
TRAIN AND 1309 HOURS ON ANOTHER TRAIN. RESULTS INDICATE THAT THE REQUIRED
DEGREE OF SC2 REMOVAL C83 PERCENT) CAN BE OBTAINED WITH AN M60 CONTENT OF
8-10* IN THE LIME WITH SINGLE-STAGE SCRUBBING.
1CC.O
1CC.O
34.2
63.7
97.3
94.4
95.1
23.9
58.3
67.9
93.4
47. *
88.6
62.0
72.8
696 485
744
720
472
542
110
-------
EPA UTILITY FGD SURVET: FOURTH QUARTER 1979
OUOUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS STILL EXPERIENCING PROBLEMS WITH SOLIDS DEPOSITION IN THE
VENTURI THROAT OF THE SCRUBBING MODULE, CAUSING MOVEMENT INHIBITION AND
GREATER PRESSURE DROPS.
THE SLUDGE STABILIZATION PRACTICES ARE STILL CONTINUING AT THIS FACILITY.
PLANT OPERATION IS PROCEEDING WITH A TOTAL OF FOUR BOILERS COUPLED INTO
THE SCRUBbING SYSTEM (EQUALING 336 NW . WHICH IS 87X OF THE TOTAL PLANT.
CAPACITY). THE FGD SYSTEM OPERATED ON HIGH CALCIUM LIME DURING THE REPORT
PERIOD. THE GENERAL OPERATION MODE AT THIS FACILITY HAS ONE OF THE FOUR
SCRUBBING TRAINS OUT CONTINUALLY FOR REPAIRS, CLEANING, AND PREVENTIVE
MAINTENANCE. THE FGD SYSTEM AVAILABILITY FOR THE FIRST QUARTER OF 1976
WAS 72X.
5/76 SYSTEM 74*
6/76 SYSTEM 720
** PRObLEMS/SOLUTIONS/COMMENTS
REDUCED LOAD OPERATIONS WERE REPORTED BY THE UTILITY FOR THE MAY-JUNE
PERIOD BECAUSE OF A SCHEDULED TURBINE OVERHAUL ON UNIT NO. 6.
THE UTILITY IS PROCEEDING WITH THE INSTALLATION OF THREE ADDITIONAL LIME
STORAGE SILOS AND A THIRD THICKENER.
THE SCRUBbING SYSTEM WAS SMUT DOWN ON JUNE 27 FOR A SCHEDULED FOUR MEEK
REPAIR PERIOD. THE MAJORITY OF THE WORK HILL BE CONCENTRATED ON THE STACK
ASSOCIATED DUCTWORK AND BOILER DAMPERS.
7/76 SYSTEM 744
8/76 SYSTEM 744
«• PROBLEMS/SOLUTIONS/COMMENTS
THE FOUR-WEEK SYSTEM OVERHAUL WAS COMPLETED JULY 25. THE THREE ADDITIONAL
LIME STORAGE SILOS AND THE FOUNDATION FOR THE ADDITIONAL 75-FOOT DIAMETER
THICKENER HAVE BEEN INSTALLED. THE UTILITY HAS SIGNED A LETTER OF INTENT
WITH IUCS FOR A LONG-TERN SLUDGE TREATMENT SYSTEM.
REPAIRS WERE MADE ON THE TURNING VANES TO THE SCRUBBER MIST ELIMINATOR.
REPAIR WORK WAS NECESSARY ON THE EXPANSION JOINT SEAL WHERE THE DUCTWORK
TIES INTO THE MAIN STACK.
THE STEEL BANDS AROUND THE INNER STACK STRUCTURE WERE REPAIRED.
THE I.D. FANS WERE OVERHAULED.
THE BOILER EXIT DAMPERS WE(E REPAIRED.
REPAIRS WERE HADE TO STOP LEAKAGE OF THE ACID-BRICK LINING IN THE MAIN
STACK .
9/76 SYSTEM 720
** PRObLEMS/SOLUTIONS/COMMENTS
BOILER NUMBERS 2 THROUGH 6 WERE COUPLED INTO THE SCRUBBING SYSTEM. BOILER
NO. 1 IS DOWN FOR OVERHAUL AND REPAIRS. THE IUCS INTERIM SLUDGE PROCESS-
ING PLANT IS UNDER CONSTRUCTION AND WILL BE IN SERVICE BY DECEMBER 1976.
THE TEMPORARY FACILITIES WILL PROCESS THE THICKENER UNDERFLOW AND PONDED
SLUDGE UNTIL THE POND IS DEPLETED OF SLUDGE AND THE PERMANENT FACILITY HAS
BEEN INSTALLED. SCRUBBING OPERATIONS ARE STILL PROCEEDING IN AN OPEN WATE
LOOP MODE WITH PART OF THE THICKENER OVERFLOW BEING DIVERTED TO THE ASH
POND. BECAUSE BOTH THE BEAVER VALLEY AND BRUCE MANSFIELD STATIONS ARE
111
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
OUOUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
FULL* OPERATIONAL. THIS ST/TION HAS BEEN RELEGATED TO PEAK LOAD OPERATIONS
GENERAL LOAD OPERATIONS ARE FULL LOAD CAPACITY IN THE DAYTIME AND 5C TO 67
X LOAD REDUCTION AT NIGHT.
TOTAL SCdUBBER HOURS: 23.274 THE FIGURES AT THE LEFT UERE COMPlLEr,
TOTAL BOILER HOURS: 83,642 BY THE UTILITY FOR SYSTEM OPERATIONS
TOTAL SCRUBBER OUTAGE TIME: 5,500 FOR THE PERIOD FOLLOWING START-UP IN
TOTAL SCRUBBER AVAILABLE JULY 1973 INCLUSIVE TO OCTOBER 19?6
HOURS: 23.274 THE TOTAL SCRUBBER HOURS VALUE INCLUfc
AVERAGE NW LOAD/SCRUBBER OPERATION OPERATION TIME WHEN ONE OR MORE OF
HOUR: 243 THE MODULES WERE IN SERVICE. TOTAL
TOTAL OPERABILITV INDEX: 28* BOILER AND UNAVAILABILITY VALUES APPi
TOTAL RELIABILITY INDEX: SIX FOR ALL THE CORRESPONDING UNITS. THE
TOTAL SCRUBBER AVAILABILITY INDEX IN-
CLUDES THE TIME WHEN ONE OR MORE
MODULES WERE AVAILABLE FOR SERVICE.
UNTIL THE IUCS INTERIM SLUDGE PROCESSING PLANT IS COMPLETE THE TEMPORARY
FACILITIES WILL PROCESS THE THICKENER UNDERFLOW AND PONDED SLUDGE UNTli Tu
POND IS DEPLETED OF SLUDGE.
10/76 SYSTEM 7*4
11/76 SYSTEM 720
•« PRObLENS/SOLUTIONS/COMMENTS
THE RECYCLE PUMP EVALUATION IS CONTINUING.
THE UTILITY REPORTED THAT BOILERS TWO THROUGH SIX REMAINED COUPLED INTO
THE SCRUBBING SYSTEM DURING THE REPORT PERIOD. THE INTERIM IUCS FIXATION
FACILITY WAS INSTALLED AND COMMENCED OPERATIONS IN DECEMBER* THE UTILITY
REPORTED THAT THE VENTURI SCRUBBERS ARE S.TILL DEVELOPING LARGE AMOUNTS OF
SCALE ON THE INTERNALS, RESULTING IN TWICE THE NORMAL PRESSURE DROPS.
RECYCLE PUMP EVALUATION HAS BEEN IN PROGRESS. APPROXIMATELY 2500 TO 280Q
HOURS OF OPERATION TIME HAVE BEEN ACCUMULATED ON THE VARIOUS UNITS WITH Nn
FAILURES OR APPRECIABLE WEAR OBSERVED. THE ADDITIONAL DEWATERING AND RE-
AGENT PREPARATION EQUIPMENT IS NOW BEING INSTALLED. THE CONTRACT HAS BE EM
AWARDED TO DRAVO TO PROVIDIE THIOSORBIC LINE FOR THIS SCRUBBING SYSTEM ?
ALL BOILERS HAVE BEEN HEADERED INTO THE SCRUBBER PLANT. A NUMBER OF THE S
UNITS WERE DOWN FOR OVERHAUL AND REPAIR. THE INTERIM IUCS P02-0-TEC UNIT*
REMAINED IN SERVICE, FILTERING OUT HATER ONLY. THE RECYCLE PUMP EVALUA-
TION IS CONTINUING. AFTER 4000 HOURS OF OPERATION THE CARBORUNDUM
IMPELLERS AND HEAR RINGS STILL LOOK GOOD. S02 AND PARTICULATE REMOVAL
EFFICIENCIES ARE 50 AND 99 + Z RESPECTIVELY. INSTALLATION OF THE
ADDITIONAL SILOS. THICKENER. AND LIME FEEDERS IS STILL IN PROGRESS. FULI
COMPLIANCE PLANT OPERATIONS ARE SCHEDULED FOR DECEMBER.
THE VENTURI SCRUBBERS ARE STILL DEVELOPING LARGE AMOUNTS OF SCALE ON THE
INTERNALS. THE PRESSURE DROPS HAVE DOUBLED AS A RESULT.
12/76 SYSTEM 744
1/77 301
401
101
201
SYSTEM 744
•• PRObLENS/SOLUTIONS/COMHENTS
1977 FULL COMPLIANCE OPERATIONS WILL INCLUDE 83S 502 REMOVAL FOR 2Z SULfliB
COAL UTILIZING THIOSORBIC LIME (6-12X H6) AND FIXATING THE SCRUBBER HASTc«
HITH THE IUCS POZ-0-TEC METHOD. THE FIXATED NATTER HILL BE HAULED AWAY Tn
AN OFF-SITE DISPOSAL AND LANDFILL. IUCS HAS BEEN AWARDED A TEN YEAR COM
TRACT FOR THE USE OF THIS METHOD. THE CARBORUNDUM INPELLORS AND HEAR R.Z,
CONTINUE TO LOOK GOOD AFTER MORE THAN 5000 HOURS OF OPERATION. *
2/77 SYSTEM 672
3/77 SYSTEM 744
112
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
OU8UESNE LIGHT: PHILLIPS 1-6 (CONT.)
., PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGD CAP.
SO* PART. HOURS HOURS HOURS FACTOR
4/77 SYSTEM 72C
** PHObLEMS/SOLUTIONS/COMMENTS
DAMPER AMI MIST ELIMINATOR REPAIRS WILL BE CORRECTED DURING A SCHEDULED
OUTAGE. OVERALL SCRUBBER AVAILABILITY IS ABOUT 751. THE INTERIM SLUDGE
DISPOSAL SYSTEM IS STILL OPERATIONAL. THE PERMANENT SLUDGE DISPOSAL FACIL
ITY IS ON SCHEDULE FOR TH£ DECEMPER 1977 COMPLETION DATE.
THIOSORBIC LIME TESTS BEGAN IN LATE MAY BUT LASTED ONLY ABOUT ONE WEEK.
THE SCRUBtER SYSTEM WAS SHUT DOWN FOR THREE TO FOUR DAYS IN MAY DUE TO
LtAKING IN THE WET DUCT HEADER THAT LEADS TO THE STACK. WHEN THE LEAK WAS
REPAIRED FLUE GAS FROM FOUR BOILERS BEGAN TO BE SCRUBBED.
WhlLE FIXING A DUCT LEAK INSPECTION OF OTHER COMPONENTS REVEALED THAT THE
BOILER EXIT DAMPERS WERE ERODING.
ONE ZC1 EXTERNAL HIST ELIMINATOR WAS SEVERLY ERODED AND PLUGGED.
5/77 SYSTEM 75.D 744
6/77 SYSTtM 72C,
*» PRObLEMS/SOLUTIONS/COMMENTS
ALL SIX BOILERS ARE COUPLED INTO THE SCRUBBER PLANT. FLUE GAS FRO" FIVE 0
THESE UNITS is BEING TREATED BY THE SCRUBBERS. ONLY FOUR OF THE six BOIL-
ERS ARE ACTUALLY OPERATING BECAUSE OF THE CURRENT TURBINE REPAIR OUTAGE.
OPERATIONS ARE PROCEEDING WITH ONE SCRUBBING TRAIN BEING SPARED AT ALL
TIMES (MAINTENANCE AND CLEANOUT). S0£ REMOVAL EFFICIENCY IS APPROXIMATELY
5CX.
BCILER NO. 6 HAS BEEN DOWN FOR AN EXTENDED TURBINE REPAIR OUTAGE.
THE RECYCLE PUMP EVALUATION STUDY CONTINUED DURING THE PERIOD. COMPONENTS
BEING EVALUATED INCLUDE: CARBORUNDUM IMPELLERS, CARBORUNDUM WEAR RINGS, I
TITANIUM IMPELLERS, 31?SS WEAR RINGS (STELLITE TIPPED).
A THIOSORbU LIME TEST WAS PREMATURELY TERMINATED BECAUSE OF SOME MINOR
SLAKES/FEEDER PROBLEMS. HIGH CALCIUM VIRGIN LIME WAS UTILIZED DURING THE
MAJORITY OF OPERATIONS THROUGHOUT THE PERIOD.
7/77 SYSTEM 744
8/77 SYSTEM 744
*• PRObLEMS/SOLUTIONS/COMMENTS
LIME HANDLING AND SOLID UASTE DISPOSAL FACILITIES WERE BEING SCALED UP TO
HANDLE FULL CAPACITY AND A THIRD THICKENER WAS INSTALLED AND BROUGHT INTO
SERVICE DURING THIS REPORT PERIOD. THE IUCS SYSTEM IS IN THE INTERIM
PHASE. UASTE WATER IS BEING MIXED WITH FLYASH AND DISPOSED OF. CURRENT
CONSTRUCTION WORK IS EXPECTED TO bE COMPLETED BY THE END OF JANUARY WHEN
ALL SIX BOILERS WILL BE BAU ON LINE FOR A TWO MONTH TEST PERIOD. THIO-
SCRBIC LIKE IS STILL BEING TESTED. RESULTS ARE NOT YET AVAILABLE. THE F6
SYSTEM WILL BE DOWN FOR THE FIRST WEEKEND OF NOVEMBER. THE SYSTEM WILL
ALSO BE CHECKED FOR MAIN DUCT LEAKS AT THIS TIME. THE SCRUBBER AND STACK
LININGS AND RECYCLE PUMPS WILL BE THOROUGHLY CHECKED AS WELL. NECESSARY
REPLACEMENTS AND REPAIRS WILL BE CARRIED OUT. CURRENT S02 REMOVAL EFF-
ICIENCY IS SOX. BY EARLY APRIL THE SYSTEM IS EXPECTED TO REACH COMPLIANCE
WITH AN SG2 REMOVAL EFFICIENCY OF 83X.
9/77 SYSTEM 720
10/77 101 92.6
301 88.3
401 87.6
113
-------
EPA UTILITY FC.D SURVEY: FOURTH QUARTER 1979
DUOUESNE LIGHT: PHILLIPS 1-6 (COST.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAPILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2C1 4.2
SYSTEM 744
•• PKOuLEMS/SOLUTIONS/COMHENTS
MODULE 101 *AS DOWN A TOTAL OF 113 HOURS IN OCTOBER.
MODULE 231 uAS PUT IN SERVICE ON OCTOBER 26 AFTER EXTENSIVE CLEAN UP AND
REPAIRS TO fcUbBER LINING AND I.D. FAN.
MODULE 3C1 WAS DOWN A TOTAL OF 57 HOURS IN OCTOBER.
MODULE 4C1 WAS DOWN A TOTAL OF 36 HOURS IN OCTOBER FOR REPAIR OF HOLES IN
FAN LININt AND TYING IN THE THICKENER BLE£0 LINE.
11/77 1M 92.1
2M 91.7
301 28.1
401 56.3
SYSTEM 67.0 72C 482
•• P&ObLiMS/SOLUTIONS/COMMENTS
DURING THE SHUTDOWN OUTLET DUCT LEAKS WERE REPAIRED.
BOILER EXIT DAMPERS WERE REPLACtD DUE TO EROSION BY FLYASH.
CORROSION OF STEEL BANDS IN STACK WAS DISCOVERED DURING THE PERIOD.
DtwATERINl OPERATIONS ARE NOT WORKING PROPERLY, CAUSING PROBLEMS IN SLUDGE
HANDLING.
THE RESULTS FROM THIOSORBIC LIME USE CAN NOT YET bE QUANTIFIED DUE TO LIME
FEED SYSTEM PROBLEMS.
LIME FEED SYSTEM PROBLEMS OCCURRED OVER THE PERIOD.
12/77 SYSTEM 744
•• PBOfcLEMS/SOLUTIONS/COMMENTS
CliMUL ATIVL HOURS FOR JANUARY 1977 THROUGH 1-8-78 WERE 22391 FOR MODULE 101
2C99f FOR MODULE 201, 22229 FOR MODULE 301 AND 22259 FOR MODULE 401.
SCRUBBER TRAIN 301 WAS DOWN FOR AN OVERHAUL FROM NOVEMBER 17 TO MONDAY FE-
BRUARY 6, 1978 WHEN IT WAS RETURNED TO SERVICE.
SCRUf-BtR TRAIN 4C1 toAS REMOVED FROM SERVICE ON THE 6TH OF FEBRUARY.
THE IUCS INTERIM SLUDGE TREATMENT SYSTEM HAS SOME DEWATERING PROBLEMS.
DURING DECEMBER PHILLIPS EXPERIENCED POOR SLUDGE REMOVAL. THE IUCS PLANT
IS WORKING ON A PART TIME BASIS. FULL OPERATIONS ARE EXPECTED LATE THIS
SPRING. THE POOR QUALITY SLUDGE IS SENT TO AN EMERGENCY POND AND THEN RE-
CIRCULATEt) BACK TO THE THICKENER.
TESTING WITH THIOSOBBIC LIME AT 51 MGO HAS SHOWN THAT THE MGO CONCENTRA-
TION IS NCT GREAT ENOUGH TO EFFECT ADEQUATE S02 REMOVAL ON A SINGLE STAGE
SCRUBBER. THEY ARE GOING TO TEST AT A GREATER MGO CONCENTRATION BY START-
ING AT 101 AND THEN DROPPING BACK UNTIL THE CONCENTRATION IS SATISFACTORY.
THIS TESTING, AS WELL AS SCRUBBER OPERATIONS, HAVE, HOWEVER, BEEN HAMPER-
ED BY LOW LOADS AS A RESULT OF THE COAL STRIKE.
THERE KILL BE AN OUTAGE AT PHILLIPS TO REPLACE THE CARBON STEEL BANDS IN
THE STACK WITH STAINLESS STEEL BANDS.
1/78 JC1 .0
401 65.1
101 84.3
201 77.2
SYSTEM 56.6 744 421
114
-------
EPA UTILITY F60 SURVEY: FOURTH QUARTER 1979
DUQUESNE LIGHT: PHILLIPS 1-t (CONT.)
PERFORMANCE DATA "
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER (GO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/78
1?1
201
301
401
SYSTEM
31.1
41.8
2.7
22.6
24. 6
672 167
*• PRObLEMS/SOLUTIONS/COMMENTS
AN OUTAGE OCCURRED BETWEEN JANUARY 6 AND JANUARY 8 WHEN THE STACK DRAIN
LEAKS WERE REPAIRED BY SANDBLASTING THE OUTER WALL AND REPLACING THE CAR-
BON STEEL BANDS WITH STAINLESS STEEL BANDS.
THE SYSTEK. WAS SHUTDOWN ON FEBRUARY 11 DUE TO THE COAL SHORTAGE. THE OUT-
AGE CONTINUED THROUGH MARC »• *Nc> THE SYSTEM IS SCHEDULED TO BE ON LINE BY
APRIL 15. DURING THE OUTAGE A NUMBER OF REPAIRS AND MODIFICATIONS WERE
MADE.
THE BOILEf. EXIT DAMPENS WERE LINED WITH 316SS ON AREAS OF HIGH EROSION
CAUSED BY FLYASH IMPINGEMENT.
EXPANSION JOINTS ON THE INLET DUCTWORK WERE SHIELED BY METAL PLATES WHICH
WERE WELDED AT ONE END.
NUMEROUS HOLES IN THE WET GAS DUCT WORK WERE REPAIRED AND THE DUCTS WERE
RELINED WITH CEILCOTE.
THE THROAT DAMPERS WERE CLEANED ON ALL THE SCRUBBERS.
INTERNAL MIST ELIMINATORS WERE CLEANED. THE EXTERNAL MIST ELIMINATORS,
WHICH ARE BADLY DETERIORATED, MAY BE REPLACED.
THE S1*CK BRICKLINING WAS INSPECTED AND SOME BRICKS WERE REPLACED AT THE
TOP OF THE STACK.
CONSTRUCTION WORK ON ADDITIONAL EQUIPMENT SUCH AS THE THICKENER AND SILOS
IS ALMOST COMPLETE. IT WAS NOTED THAT THE CEILCOTE LINER COROLINE 505AR
HAS HELD UP WELL OVER THREE YEARS ON THE CONICAL APEX OF MODULE *01.
3/78 SYSTEM 7*4
4/78 SYSTEM 720 517
** PRObLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM CAME BACK ON LINE AFTER THE COAL STRIKE IN LATE MARCH. IT
IS NOT OPERATING AT FULL LOAD BECAUSE THE NO. 6 BOILER IS STILL OUT AND
SHOULD BE BACK ON LINE IN MID-JULY. COMPLIANCE TESTS WILL TAKE PLACE IN
JULY, AFTER BOILER 6 IS BACK ON LINE, TO SEE IF THE SYSTEM IS MEETING THE
83% SC2 REMOVAL REQUIREMENT FOR 21 SULFUR COAL. THERE WERE NO HOURS RE-
PORTED FOR THIS PERIOD BECAUSE OF PRELIMINARY TESTING BEING CONDUCTING IN
PREPARATION FOR THE COMPLIANCE TESTS. SO FAR, TESTS INDICATE THAT THE
SYSTEM WILL COMPLY WITH THE REQUIRED STANDARDS. THE AVAILABILITY FCR ALL
FOUR TRAINS WAS BETWEEN 65 AND 751.
5/78 SYSTEM 70.0 744 531
6/78 SYSTEM 720 512
*• PRObLEMS/SOLUTIONS/COMMENTS
THE INTERNAL MIST ELIMINATOR ON MODULE 201 WAS REMOVED AND CLEANED OVER
THE PERIOD.
THE FGD SYSTEM HAS ACCUMULATED APPROXIMATELY 24000 HOURS OF OPERATION ON
ALL FOUR MODULES SINCE START-UP.
WATER BALANCE PROBLEMS HAVE CONTRIBUTED TO THE OCCURRAN3E OF LOW PH. RE-
SULTING IN MIST ELIMINATOR PLUGGING.
115
-------
EPA UTILITY Ft.0 SURVEY: FOURTH QUARTER 1979
OUOuEbNt LIGHT: PHILLIPS 1-6 (CONT.)
PERFORNANC E DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
» REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
THE I" 1ST ELIMINATOR PLUGGING IS ALSO RELATED TO LOU PH RESULTING FROM LIME
HANDLING AND SLURRY PREPARATION SYSTEM FAILURE.
THE UTILITY IS CURRENTLY SlUDYING WAYS TO TIGHTEN THE WATER BALANCE BY
USING THICKENER SUPERNATANT INTERMITTENTLY WITH CLEAR SERVICE WATER FOR
THE PIST ELIMINATORS. THE COMPLIANCE TEST SHOULD TAKE PLACE DURING THE
NEXT REPORT PERIOD.
7/76 1C1
8/78
3M
4C1
SYSTEM
101
SYSTEM
82.8
75.3
1C3.0
1 CO.O
1C2.0
100.0
48.3
43.9
78.7
76.0
61.7
97.3
744 434
459
744
607
9/78 101
201
301
401
SYSTEM
•• PRObLEMS/SOLUTIONS/COMHENTS
THE RUBBER LINING IN MODULE 101 WAS REPAIRED.
HIGH PRESSIRt WATER CLEANING WAS PERFORMED ON MODULES 101 AND 401.
91.6
1
99.2
81.8
95.9
62.4
75.5
67.5
55.7
65.3
72C 490
47C
•• PROoLEMS/SOLUTION5/COMNENTS
11/78
Id
201
301
401
SYSTEM
101
201
301
401
SYSTEM
12/78 101
201
301
401
SYSTEM
DURING THE AUGUST-SEPTEMBER PERIOD MIST ELIMINATOR CLEANING TOOK PLACE IN
ORDER TO CORRECT THE PLUGGING PROBLEM.
IN AUGUST THE INTERNAL MIST ELIMINATOR ON MODULE ?01 WAS REPLACED.
THE LINE MIXING BASIN HAD TO BE SHUT DOWN OVER A WEEKEND SO THAT EXCESSIVE
GRIT AND SCLID PARTICLES THAT HAD BUILT UP COULD BE CLEANED OUT.
HIGH PRESSCRl WATER CLEANING WAS PERFORMED ON MODULES 101 AND 401.
THE RUBBER LINING IN MODULE 101 WAS REPAIRED.
A MAJOR PROBLEM AREA CURING THE PERIOD WAS CAUSED BY INSUFFICIENT SUPPLIES
OF DRY fLYASh TO MIX WITH THE SLUDGE. AS A RESULT THE SLUDGE HAS BEEN
LEAKING OUT OF THE TRANSPORT TRUCKS WHILE IN TRANSIT TO THE FINAL DISPOSAL
SITE. APPARENTLY NOT ENOUGH FLYASH IS BEING COLLECTED WITH THE PRESENT
SYSTEM.
1CC.O
1:0.3
1 C3.0
3.3
98.5
51.5
1CC.P
1CO.O
86.4
93.6
100.0
1CC.O
38.5
100.0
1CO.O
96.1
87.5
87.9
2.2
68.4
41.1
100.0
88.9
69.0
74.7
9D.9
88.3
<:7.8
87.5
73.5
744 517 509
720 575 538
744 537 547
116
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
BUOUESNE LIGHT: PHILLIPS 1-6 PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPESAB1L1TY RELIABILITY UTILIZATION
* REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*• PRObLEMS/SOLUTIONS/COMMENTS
1/79
2/79
3/79
4/79
5/79
6/79
7/79
8/79
9/79
10/79
11/79
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
101 88.8
201 94.8
301 99.6
401 .0
SYSTEM 70.8
101 99.4
201 86.5
301 93.8
401 .0
SYSTEM 69.9
101 53.0
201 99.0
301 83.6
10C.O
95.5
69.0
100.0
100.0
5C.3
93.4
100.0
100.0
96.9
.0
100.0
100.0
10C.O
96.2
100.0
9.3
100.0
100. D
100.0
100.0
.0
100.0
100.0
100.0
1CO.O
34.2
100.0
100.0
97.6
1CO.O
100.0
89.8
32.1
91.7
100.0
100.0
100.0
.0
100.0
1 00.0
100.0
.0
103.0
103.0
103.0
10C.O
.0
78.5
72.7
72.7
100.0
100.3
DURING THE PERIOD A LACK OF FLVASH FOR MIXING UITH SLUDGE UAS A PROBLE".
86.7
69.?
50.0
83.7
72. 4
38.8
72.1
88.2
100.0
74.8
.0
96.2
88.0
100.0
71.1
86.8
5.8
85. 0
64.9
65.7
100.0
.0
96.6
99.1
73.9
70.6
22.2
83.8
77.2
63.4
98.7
95.8
71.4
25.5
72.8
100.0
89.5
89.2
.0
81.8
80.3
85.6
.0
61.9
97.0
86.6
93.0
.0
69.1
50.6
99.0
83.6
7*4 539
672 519
744 550
720 453
744 543
720
744
468
591
539
503
529
473
550
457
542
744 561
72C 376 446
744 656 515
117
-------
EPA UTILITY FOO SURVEY: FOURTH QUARTER 1979
DUOUESNE LIGHT: PHILLIPS 1-6 (CONT.)
_. . . PERFORMANCE DATA ___
PERIOD MODULE AVAILABILITY CPE (ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
401 11.5 16.5 11.5
SYSTEM 61.8 87.8 61.3 720 502 441
12/79 SYSTEM 7*4
"• PROfaLEMS/SOLUTIONS/COMMENTS
PRESENTLY THE UTILITY HAS Bl EN ADDING SODIUM THIOSULFATE TO THE LIME TO
PREVENT SCALE FORMATION. THIS PROCESS HAS IMPROVED SO 2 COLLECTION AS
WELL.
THE SCRUBBER FAN HOUSING LINERS ARE BEING REPLACED.
THE MECHANICAL COLLECTORS ARE BEING UPGRADED TO IMPROVE THE QUALITY OF
WET SLUDGE.
118
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAHE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
502 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/F6D - MU
NET UNIT GENERATING CAPACITY WO/FGO - MM
EQUIVALENT SCRUBBED CAPACITY - MU
*• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
INDIANAPOLIS POUER t LIGHT
PETERSBURG
PETERSBURG
INDIANA
B
43.
516.
118C.O
532.0
515.0
528.0
532.0
( .100 LB/NHBTU)
( 1.200 LB/MHBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/77
******** (******* ACFN)
137.2 ( 279 F)
188. ( 616 FT)
6.1 ( ZO.O FT1
COAL
BITUMINOUS
2 SOU.
9-10
10.5-16.5
3.2S
1.5-A.5
********
******
( 10750 BTU/LB)
ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY
PARTICULATE SCRUBBER
TYPE
COLD SIDE
RESEARCH COTTRELL
X 99.3
•* F6D SYSTEM
SALEABLE PRODUCT/THROUAUAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
S02 DESIGN REMOVAL EFFICIENCY - t
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AUARDED
*• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
NONE
THROUAUAV PRODUCT
WET SCRUBBING
LIMESTONE
NONE
AIR CORRECTION DIVISION, UOP
GIBBS ft HILL
FULL SCALE
NEW
99.30
85.00
12/77
8/77
10/75
1/75
MOBILE PACKED TOUER
12/77
AIR CORRECTION DIVISION, UOP
3
30 X 30 X 100
CARBON STEEL
NEOPRENE RUBBER
119
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
INDIANAPOLIS POKED K LIGHT: PETERSBURG 3 (CONT.)
INTERNAL MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
L/G RATIO - L/C U.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
PARTICULATE INLET LOAD - G/CU.M
S02 INLET CONCENTRATION - PPM
S02 CUTLET CONTRftTION - PPM
302 DESIGN REMOVAL EFFICIENCY - Z
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
CAPACITY - CU.M/S
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTA NCE - M
WASH SYSTEM
** PUMPS
SERVICE
ABSORBER RECIRCULATlON
TANKS
SERVICE
LIMESTONE SLURRY
WASTE SLURRY
RECYCLE
THICKENER OVERFLOW
NITRYL FOAM BALLS
25.0
176.96
47.8
6.7
1.7
4.4
.1
3400
385
85.0
375000 ACFM)
118 F)
50.0 6AL/1000ACF)
7.0 IN-H20)
14.5 FT/S)
.025 GR/SCF)
SCRUBBER FO
CARBON STEEL
224.15
( 475000 ACFM)
8
CHEVRON
PLASTIC
HORIZONTAL
.37 < 1.2 FT)
1ST STAGE. VERTICALLY UPWARD AND DOWNWARD; 2ND S
NUMBER
12
NUMBER
**»*
** **
**»»
** **
*• REHEATER
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
** THICKENER
NUMBER
CONSTRUCTION MATERIAL
DIAMETER - N
OUTLET SOLIDS - Z
•• WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
• * REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
BALL MILL CAPACITY- M T/H
*• TREATMENT
TYPE
CONTRACTOR
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
HOT AIR INJECTION
STEAM. 365 F AT 187 PSIG
16.7 < 30 F)
249 MM BTU/HR.
1
RUBBER LINED CARBON STEEL
50.3 (165 FT)
35.0
CLOSED
55.6
1
38.1
POZ-O-TEC
IUCS
FINAL
POND
ON-SITE
TRUCK
( 882 6PM)
( 42.0 TPH)
120
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 (CONT.)
— PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION * REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/77 SYSTEM 744
•* PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF ALL FOUR MODULES COMMENCED DURING DECEMBER.
REPAIRS TC THE RECYCLE TANK AGITATOR HERE REQUIRED.
1/78 SYSTEM 744
•* PRObLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH THE FLVASH HANDLING SYSTEM FORCING FGD
SHUTDOWN. THE UNIT WAS RESTATED IN THE MIDDLE OF APRIL.
2/78 SYSTEM 672
** PROfaLEHS/SOLUTIONS/COMMENTS
PIPE FREEZE-UP DAMAGE WAS HNCOUNTERED AND REPAIRED.
3/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/CCMMENTS
INSULATIOIv WAS INSTALLED DURING THE SYSTEM OUTAGE.
A BROKEN PINION GEAR WAS REPAIRED DURING THE SYSTEM OUTAGE.
INSTRUMENTATION MAINTENANCE PERFORMED DURING THE SYSTEM OUTAGE.
4/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMEN1S
ALL CONTROL VALVES WERE RETURNED TO THE FACTORY FOR MODIFICATIONS.
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE MAIN POWER TRANSFORMER FAULTED CAUSING THE SYSTEM TO SHUTDOWN.
6/78 SYSTEM 720
7/78 SYSTEM 744
8/78 SYSTEM 744
•• PRObLEHS/SOLUTIONS/COMMENTS
PROBLEMS HAVE BEEN EXPERIEM E6 WITH CONTROLS.
CRACKING PROBLEMS HAVE BEEN EXPERIENCED WITH FIBERGLASS PIPING. THE PROB-
LEM WAS SOLVED BY REPLACING SECTIONS WITH RUBBER LINED STEEL PIPING, NEW
FOP PIPING, AND PROVIDING ADDITIONAL PIPE SUPPORTS.
9/78
SYSTEM 720
10/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
BYPASS DAMPER PROBLEMS WERE EXPERIENCED.
AN SO 2 COMPLIANCE TEST WAS INVALID DUE TO BYPASS DAMPER PROBLEMS.
11/78 SYSTEM 720
1Z1
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 (CONT.)
_ PERFORMANC E DATA — — .
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION x REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*» PRObLEMS/SOLUTIONS/COMMENTS
FREEZE-UPS IN THE LIME DELIVERY SYSTEM WERE EXPERIENCED.
AN INSTRUMENTATION POWER TRANSFORMER FAILURE CAUSED ABOUT 6 DAYS OUTAGE.
12/78 SYSTEM 744
• * PROtiLEHS/SOLUTIONS/COMHENTS
OPERATIONAL HOURS ARE NOT YET AVAILABLE. THE UTILITY REPORTED THAT THE
SYSTEM HAS NOT VET BEEN ACCEPTED.
1/79 SYSTEM 744
2/79 SYSTEM 672
• * PRObLENS/SOLUTIONS/COMMENTS
THE UTILIZATION FIGURES GIVEN BELOW ARE FOR THE PERIOD SEPTEMBER-DECEMBER
1978.
3/79 A 31.2
B 30.0
C 48.0
D 48.C
SYSTEM 39.0 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOUN FROM JANUARY 1 TO MARCH 15 DUE TO SEVERE WINTER
WEATHER.
4/79 SYSTEM 722
*• PROBLEMS/SOLUTIONS/COMMENTS
DUE TO THE FORMER STACK LINING PEELING AWAY, THE STEEL
SHELL WAS SAND BLASTED AND RIGIFLAKE 4050 APPLIED 6V TROWEL.
ALL MIST ELIMINATORS WERE CLEANED DUE TO SEVERE SCALING PROBLEMS.
EXTENSIVE REPAIRS UERE MADE TO THE INLET DAMPERS. THE OUTLET DUCTS WERE
LINED WITH RESISTIFLAKE 1150, AND MAJOR REPAIRS WERE MADE TO BONNETS
BECAUSE OF ACID CORROSION.
THE SYSTEM HAS BEEN DOWN SINCE MID-MARCH FOR INSPECTION AND MAINTENANCE.
5/79 SYSTEM 744
6/79 SYSTEM 720
*« PROfaLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SYSTEM RAN ABOUT THREE DAYS TOTAL DURING THIS
PERIOD .
PROCESS CONTROL HAS BEEN A VERY MAJOR PROBLEM AREA.
MIST ELIMINATOR PLUGGING CONTRIBUTED TO THE OUTAGE EXPERIENCED DURING THIS
PERIOD .
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
122
-------
EPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•* PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FROM THE UTILITY FOR THE THIRD QUARTER 1979.
10/79 SYSTEM 744
11/79 SYSTEM 730
12/79 SYSTEM 744
** PRObLENS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER T IE UTILITY REPORTED THAT THERE WERE NO NEK
MAJOR PROBLEMS.
123
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EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mli
NET UNIT GENERATING CAPACITY W/FGD - My
NET UNIT GENERATING CAPACITY UO/FGC - MV
EQUIVALENT SCRUBBED CAPACITY - My
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 1
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*• PARTICULATE SCRUBBER
TYPE
•* FGD SYSTEM
SALEABLE PRODUCT/THROUAUAY PRODUCT
GENERAL PROCESS TYPE
KANSAS CITY POWER & LIGHT
HAWTHORN
KANSAS CITY
MISSOURI
D
64.
( .ISO LB/MMBTU)
(****** LB/MMBTU)
836.0
90.0
85. 0
87.0
90.0
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLIC
0/S3
235.95 ( 500000 ACFM)
148.9 < 300 F)
61. ( ZOO FT)
5.5 ( 18.0 FT)
COAL
BITUMINOUS
22795.
11.00
******
.60
******
COAL
BITUMINOUS
26S16.
14.00
******
3.00
***** *
********
***** 1*
**** **
227 «5.
14.00
******
.60
( 9800 BTU/LB)
( 11400 BTU/LB)
< 9800 BTU/LB)
MOBILE PACKED TOWER
THROUAUAV PRODUCT
UET SCRUBBING
124
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: HAWTHORN 3 (CONT.)
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REMOVAL EFFICIENCY - X
S02 DESIGN REMOVAL EFFICIENCY - 1
INITIAL START-UP
• • ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
GAS FLOW - CU.N/S
L/G RATIO - L/C U.M
PRESSURE DROP - K.PA
SUPERFICAL GAS VELOCITY - M/SEC
** FANS
NUMBER
TYPE
SERVICE - UET/DRY
LIME
NONE
COMBUSTION ENGINEERING
BLACK I VEATCH
FULL SCALE
RETROFIT
99.00
7' i.00
11/72
MOBILE PACKED TOWER
11/72
COMBUSTION ENGINEERING
1
18 X 26 X 56
316L SS UP TO BED WITH BALANCE, CARBON STEEL
CEILCOTE FLAKEGLASS
316L SS
63
76.45 ( 162000 ACFM)
3.5 ( 26.0 GAL/100CACF)
2.7 (11.0 1N-H20)
3.0 ( 1G.O FT/S)
SCRUBBER ID
DRV
«* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
** TANKS
SERVICE
S02 SCRUBBER TOWER HOLDUP
CHEVRON
ffiP
HORIZONTAL
~t
2
3.05 UO.O FT)
•1.83 ( 6.0 FT)
7.6 ( 3.00 IN)
45 DEG.
EIGHT WASH LANCES; CLARIFIED AND MAKE-UP WATER (
3.0 C 10.0 FT/S)
.3 ( 1.2 IN-H20)
PH
4.5-6.5
NUMBER
*»*•
REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
THICKENER
NUMBER
DIAMETER - H
WATER LOOP
TYPE
REAGENT PREPARATION EQUIPMENT
NUMBER OF SLAKERS
SLAKER CAPACITY - H T/H
TREATMENT
TYPE
DISPOSAL
NATURE
TYPE
IN-LINE
HOT WATER 325F, 150 PSIG
27.8 ( SO F)
35.1
CLOSED
1
51.7
<115 FT)
( 57.0 TPH)
FLVASH STABILIZATION
FINAL
POND
125
-------
EPA UT1LITT FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER 8 LIGHT: HAWTHORN 3 CCONT.)
LOCATION ON-SITE
AREA - ACRES 16C.O
CAPACITY - CU.M 3130880 < 2560.0 ACRE-FT)
PERFORMANCE DATA .__
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION x REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/75 3A .0
38 42.0
SYSTEM 21.0
.0
33.2
16.6 744 584 123
•• PRObLEMS/SOLUTIONS/COMMENTS
A-MODULE ENCOUNTERED A LEAK IN THE CITY WATER LINE.
THE DUCT TO THE I.D. FAN BECAME PLUGGED.
AN OUTLET DAMPER IN MODULE A MALFUNCTIONED.
MARBLES WERE LOST FROM THE BED IN MODULE B.
A SPRAY HtADER WAS BROKEN IN MODULE B.
8/75 3A .0
3B .n
SYSTEM .0 744 0 0
** PHOfcfLEMS/SOLUTIONS/COMMENTS
THE I.D. FAN FOR HALF THE BOILER WAS LOST.
THE PROBLEMS ENCOUNTERED IN JULY CONTINUED INTO AUGUST.
9/75 3A 69.0 34.7
3B 23.0 11.3
SYSTEM 46.0 22.E 720 358 164
•* PRObLEMS/SOLUTIONS/COMMENTS
AN OUTAGE DUE TO CLEANING AND MECHANICAL REPAIRS OCCURRED. POTS, COVERS
AND MARBLES IN THE MARBLE BED OF MODULE 3B WERE REPLACED. '
10/75 3A 65.0 15.7
3B 81." 19.5
SYSTEM 73.0 17.6 744 180 131
.. PRObLEHS/SOLUTIONS/CONMENTS
MODULE 3A OUTAGE WAS DUE LARGELY TO REPLACEMENT OF A RECYCLE PUMP MOTOR.
A SCHEDULED BOILER OVERHAUL REDUCED BOILER OPERATION HOURS.
11/75 3A .C
38 .0
SYSTEM .0 720 0 C
** PROfaLEMS/SOLUTlONS/COMMENTS
BOILERS AKD SCRUBBERS WERE SHUT DOWN FOR A SCHEDULED TURBINE OVERHAUL. THE
SYSTEM IS SCHEDULED TO GO BACK ON-LINE IN JANUARY 1976. THE SYSTEM WAS
ALL MONTH BECAUSE OF FROZEN EQUIPMENT, LINES AND A MANPOWER SHORTAGE
DUE TO A BOILER AND TURBINE OVERHAUL ON ANOTHER UNIT AT THIS STATION.
12/75 3A .0
3B .0
SYSTEM .0 744 0 0
1/76 3A .0
38 .0
SYSTEM .0 744 0 0
2/76 3A 29.4 21.3
126
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS CUT POWER g LIGHT: HAWTHORN 3 (CONT.)
PERf OR NANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS fACT OH
3B
SYSTEM
1.0
15.2
1.C
11.1
696 503
77
«* PRObLEMS/SOLUTIONS/CONMENTS
SCRUBBER OUTAGES RESULTED FROM PLUGGING IN THE SCRUBBER BED, CAUSED BY
CONVERSION FROM AN UNDEft-BED TO OVER-BED SPRAY SYSTEM.
3/76 3A
3B
SYSTEM
744
•• PROfaLtMS/SOLUTIONS/CONMENTS
RECONVERSION OF MODULE 3B'S SPRAY SYSTEM TO AN UNDER-BED CONFIGURATION HAS
BEEN COMPLETED.
THE tYPASS SYSTEM HAS BEEN MODIFIED AND CHANCED TO A SLIDE-GATE DAMPER
ARRANGEMENT.
4/76
3*
3B
SYSTEM
5/76 3A
3B
SYSTEM
720
744
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS SHUT DOWN DURING THE MONTH DUE TO THE CONTINUATION OF MAN-
POWER SHORTAGE PROBLEMS. THE UTILITY DID PERFORM SOME CLEANING AND REPAIRS
DURING THE MONTH.
6/76
3A
3B
SYSTEM
39.0
44.0
41.5
27.6
30.4
29.0
720 505
209
•• PROBLEHS/SOLUTIONS/COMMENTS
THE UTILITY IS IN THE PROCESS OF MODIFYING THE DEMISTER WASH SYSTEM ON
BOTH UNITS 3 AND <.. THE WATER LANCES ARE BEING CHANGED FROM FHP TO CARBON
S^EEt TO ATTEMPT TO PREVENT THE LOSS OF THE NOZZLES AND THE SUBSEQUENT
SHATTERING OF THE LANCES.
7/76 SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
744
THE UTILITY IS PRESENTLY CONVERTING THIS SYSTEM FROM LIMESTONE INJECTION
AND TAIL END SCRUBBING TO A LIME SLURRY BASED SCRUBBING SYSTEM.
8/76 SYSTEM
9/76 SYSTEM
«« PRObLEMS/SOLUTIONS/CONMENTS
744
720
10/76 SYSTEM
11/76 3A
3B
SYSTEM
THE SYSTEM WAS VIRTUALLY OUT OF SERVICE THE ENTIRE DEPORT PERIOD. MANPOWER
COMMITMENTS WERE SERIOUSLY HAMPERED BY A MAJOR EXPLOSION WHICH OCCURRED IN
THE COAL MILL PULVERIZING AREA OF HAWTHORN NO. 5.
744
720
127
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER R LIGHT: HAWTHORN 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*• PROBLEMS/SOLUTIONS/COMMENTS
12/76 3A
3B
SYSTEM
1/77 3A
3B
SYSTEM
2/77
4/77
THE UNIT DID NOT OPERATE BECAUSE OF THE ONGOING MAJOR MODIFICATIONS BEING
IMPLEMENTED ON THE SCRUBBING SYSTEM. THE SYSTEM SHOULD BE READY FOR OPERA-
TION FEB 1. THE UNIT MUST UNDERGO A SERIES OF TESTS TO INSURE COMPLIANCE
WITH CITY AND FEDERAL REGULATIONS.
744
744
•* PKOBLEMS/SOLUTIONS/COM1ENTS
UNIT NO. J WAS DOWN FOR THE ENTIRE MONTH OF JANUARY FOR THE COMPLETION OF
MODIFICATIONS AND REPAIRS ON THE SCRUBBERS AND BOILER. THE UNIT BECAME
AVAILABLE FOR SERVICE AND TESTING ON FEB 7. THE UNIT'S MEASURED PART1CU-
LATE EMISSIONS AT THE SCRUBBER OUTLET WAS 0.12 LB/MM BTU (WELL BELOk THE
REQUIRED C.17 LB/MM BTU) BURNING APPROXIMATELY 2.0 * SULFUR COAL. THE
CONVERSION FROM LIMESTONE TO LIME HAS GONE SMOOTHLY. SOME INITIAL PROBLEMS
WITH PROCESS CHEMISTRY CONTROL HAVE BEEN CORRECTED. OTHER MINOR PROBLEMS
INCLUDED PUMP MALFUNCTIONS AND LOSS OF SLAKING WATER PRESSURE. SYSTEM
OPERATIONS ARE CONTINUING AT OX SOLIDS AND 100* SLOWDOWN WITH A FRESH
WATER MAKl-UP OF APPROXIMATELY 7.0 GPM/MH.
3A
38
SYSTEM
3/77 3A
36
SYSTEM
3A
3B
SYSTEM
78.3
88.0
83.1
99.0
85.0
92.0
57. 3
57.0
57.0
44.6
50.1
47.3
63.9
55.3
59.6
56.7
56.7
56.7
672 383
744
482
722 720
318
443
408
PRObLEMS/SOLUTIONS/CCMMENTS
THE SYSTEM IS NOW OPERATING AT ABOUT 15-252 BLOWDOWN. THE PH CONTROL
SYSTEM OPERATIONS HAVE BEEN EXCELLENT.DURING HAY THE BOILER BURNED GAS fOR
216 HOURS (NOT INCLUDED IN OPERABILITY FIGURES). S02 REMOVAL EFFICIENCY IS
ESTIMATED AT 50-601 FOR BOTH MODULES. ALTHOUGH ACTUAL TESTS HAVE NOT
BEEN RUN FOR ABOUT A YEAR AND A HALF. BOTH MODULES ARE CURRENTLY OPERATING
SIMULTANEOUSLY.
5/77 3A
3B
SYSTEM
6/77 3A
3B
SYSTEM
41.0
41.0
41.0
10.0
40.6
40.6
40.6
10.0
10.0
10.0
744
736
720 730
302
72
•• PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT FIRED NATURAL GAS THROUGHOUT THE MONTH WITH THE EXCEPTION OF A
72-HOUR PERIOD DURING WHICH COAL WAS FIRED AND THE SCRUBBERS HERE OPERATED
FOR SCRUBbER PERSONNEL PURPOSES ONLY.
THE UNIT FIRED NATURAL GAS FOR THE ENTIRE PERIOD, MAKING SCRUBBER
OPERATION UNNECESSARY.
7/77 SYSTEM
8/77 3A
.0
.0
.0
744 744
128
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EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: HAWTHORN 5 (CONT.)
PERI OD
9/77
10/77
MODULE AVAILABILITY
JB
SYSTEM
3A
3B
SYSTEM
3A
3e
SYSTEM
. --PERFORMANCE DATA —
OPERAB1LITV RELIABILITY UTILIZATION X REMOVAL PER BOILER f60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
.0
.0 744 0
.0
.0
.0 720 C
.0
.0
.C 744 0 0
*• PROBLEMS/SOLUTIONS/COMMENTS
11/77
12/77
SYSTEM 57.0
SYSTEM 73.0
THE UNIT WAS SHUT DOWN BECAUSE OF A LACK OF NATURAL GAS UNTIL NOVEMBER 3,
WHEN IT BEGAN FIRING COAL. (NOTE:THE BOILER AND FGD SYSTEM MUST RUN SIMUL-
TANEOUSLY BECAUSE NO BYPASS IS ALLOWED EXCEPT DURING EMERGENCIES. WHENEVER
THE BOILER IS DOWN, THE SCRUBBER IS EFFECTIVELY UNAVAILABLE BECAUSE THE
DOWN TIME IS UTILIZED FOR SCRUBBER MAINTENANCE AND REPAIR, MAKING AVAILA-
BILITY AND UTILIZATION FACTORS IDENTICAL FOR THIS SYSTEM.
DURING BOILER DOWN TIME, THE REACTION TANKS AND SPRAY HEADERS WERE
REPLACED BY STAINLESS STEEL COMPONENTS; THE INTERCONNECTING PIPING IS
RUBBER LINED.
100.0 57.0 720 411 411
100.0 70.0 744 541 541
** PROBLEMS/SOLUTIONS/CONMENTS
1/78
2/78
SYSTEM 46. 5
SYSTEM 25.0
THE FGD MODULES WERE CLEANED DURING BOILER OUTAGES (THERE WERE NO FGD-
RELATED OUTAGES).
SOME LEAKS IN THE FGD PIPING WERE REPAIRED.
100.0 46.5 744 346 346
1QC.O 24.9 672 167 167
•• PROBLEMS/SOLUTION S/CONMENTS
3/78
4/78
SYSTEM 56.0
SYSTEM 76..0
DURING FEBRUARY THE UNIT WAS DOWN FOUR TINES WITH ECONOMIZER AND WATER
WALL LEAKS (504 HOURS TOTAL). WATER WALL LEAK REPAIR AS WELL AS ACID
CLEANING CF THE BOILER CAUSED ADDITIONAL OUTAGE TIME DURING THE LAST WEEK
OF MARCH.
A TWO WEEK OUTAGE WAS SCHEDULED DURING MARCH FOR SEASONAL MAINTENANCE.
100.0 54.6 744 406 406
30.5 40.0 720 548 220
*• PROfaLEHS/SOLUTIONS/COMHENTS
5/78
6/78
7/78
8/78
29.5
54.0
41.8
SYSTEM 41.8
SYSTEM
SYSTEM
SYSTEM
AN AIR PREHEATER FIRE DISCOVERED ON HAY 12 CAUSED DAMAGES THAT FORCED
MODULE A TO BE DOWN THE REST OF THE MONTH.
NC INFORMATION WAS AVAILABLE FOR THE JUNE-JULY REPORT PERIOD DUE TO A
PLANT STRIKE.
100.0 54.2
100.0 54.2 744 403 403
720
744
744
129
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: HAWTHORN ? (CONT.)
PERFORMANC E DATA . _
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
$02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
THE SCRUBfcING SYSTEM IS OPERATING EVEN THOUGH THE UTILITY IS STIIL IN THE
MIDST OF A STRIKE. FGD PERFORMANCE FIGURES ARE NOT AVAILABLE SINCE THE
UTILITY IS NOT RECORDING FCO SYSTEM OPERATING HOURS DURING THE STRIKE.
9/78
10/78
11/78
12/78
10/79
11/79
12/79
SYSTEM
SYSTEM
•* PHObLEMS/SOLUTIONS/COMMENTS
72 C
744
ALTHOUGH THE STRIKE IS OVER NO OPERATIONAL DATA IS AVAILABLE.
SYSTEM IS IN OPERATION.
THE FGD
SYSTEM
SYSTEM
** PfiObLEMS/S OLUTIONS/COMMENTS
720
744
130 9.0
29.0
HOURS OF OPERATION ARE STILL NOT AVAILABLE. THE fGO SYSTEM IS IN OPERATIC
BUT AT PRESENT PERSONNEL ARE BEING REASSIGNED PREVENTING ACCURATE DATA
RECORDING.
1/79 SYSTEM 744
2/79 SYSTEM 672
3/79 SYSTEM 744
•« PHObLEMS/SOLUTIONS/COMMENTS
OPERATING INFORMATION IS STILL NOT AVAILABLE FOR UNIT 3.
4/79 SYSTEM 18.0 1CC.O 18.1 72C 130
«* PRObLEMS/SOLUTIONS/CCMMENTS
THE BOILER WAS DOWN IN APRIL FOR 543 HOURS FOR TURBINE OVERHAUL.
5/79 SYSTEM 55.0 10C.O 55.0 744 409 409
•• PRObLEMS/SOLUTIONS/COMMENTS
IN MAY THE OUTAGE TIME WAS DUE TO BOILER TUBE LEAKS.
6/79 SYSTEM 96.0 720 696
7/79 SYSTEM 1CO.O 744 744
8/79 SYSTEM 75.0 744 558
9/79 SYSTEM 84.0 720 605
** PRObLEMS/SOLUTIONS/COMMENTS
THE UTILITY BURNED PRIMARILY GAS DURING JUNE, JULY AND AUGUST. THE UM1T
RETURNED TO FIRING ALL COAL IN SEPTEMBER. THE SCRUBBER WAS LARGELY
AVAILABLE fcUT WAS NOT NEEDED FOR MOST OF THE PERIOD. THE UTILITY REPORTED
ONLY REGULAR MAINTENANCE TOOK PLACE WITH NO PROBLEMS ENCOUNTERED.
744
720
744
SYSTEM
SYSTEM
SYSTEM
130
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: HAyTHORN 3 fCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLENS/SOLUT10NS/COMMEN1S
NO INFORMATION WAS AVAILABLE FOR THE FOURTH QUARTER 1979.
131
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EP* UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - My
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
*• FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - Z
RANGE ASH CONTENT - Z
AVERAGE MOISTURE CONTENT - Z
RANGE MOISTURE CONTENT - Z
AVERAGE SULFUR CONTENT - Z
RANGE SULFUR CONTENT - Z
AVERAGE CHLORIDE CONTENT - Z
RANGE CHLORIDE CONTENT - X
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - Z
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - Z
RANGE MOISTURE CONTENT - Z
AVERAGE SULFUR CONTENT - Z
RANGE SULFUR CONTENT - Z
AVERAGE CHLORIDE CONTENT - Z
RANGE CHLORIDE CONTENT - Z
•• PARTICULATE SCRUBBER
TYPE
•• FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - Z
S02 DESIGN REMOVAL EFFICIENCY - Z
INITIAL START-UP
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
KANSAS CITY POWER & LIGHT
HAWTHORN
4
KANSAS CITY
MISSOURI
64.
.150 LB/MMBTU)
>**** LB/MMBTU)
836.0
9 (.0
35.0
8 7.C
90.0
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLIC
0/55
235.95
148.9
61.
5.5
COAL
BITUMINOUS
22795.
11.00
( 500000 ACFM)
( 300 F)
( 200 FT)
( 18.0 FT)
( 9800 BTU/LB)
.60
********
******
COAL
BITUMINOUS
26516.
U.OO
( 1UOO BTU/LB)
:.oo
********
******
MOBILE PACKED TOWER
THROUAWAY PRODUCT
WET SCRUBBING
LIME
NONE
COMBUSTION ENGINEERING
BLACK t VEATCH
FULL SCALE
RETROFIT
99.00
70.00
8/72
MOBILE PACKED TOWER
8/72
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER £ LIGHT: HAWTHORN 4 (CONT.)
SUPPLIER
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
L/G RATIO - L/C U.M
PRESSURE DROP - KPA
SUPERF1CAL GAS VELOCITY - M/SEC
«• FANS
NUMBER
TYPE
SERVICE - hET/D RY
•* MIST ELlMjNATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
MUMPER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANF SPACING - CK
VANE ANGLES
WASH SYSTEM
SUPERFICIAL &AS VELOCITY - N/S
PRESSURE DROP - KPA
«• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL HANGE
** TANKS
SERVICE
SO2 SCRUbBER TOWER HOLDUP
** REHEATER
TYPF
HEATING MEDIUM
TEMPERATURE BOOST - C
•* THICKENER
NUMBER
DIAMETER - M
COMBUSTION ENGINEERING
18 X 26 K 56
316L SS UP TO BED WITH BALANCE, CARBON STEEL
CEILCOTE FLAKEGLASS
316L SS
63
76.43 ( 162000 ACFM)
148.9 < 300 F>
3.5 ( 26.0 GAL/1000ACF)
2.7 <11.0 1N-H20)
3.0 t 10.0 FT/S)
SCRUBBER ID
DRY
2
CHEVRON
FRP
HORIZONTAL
c
2
3.05 (10.0 FT)
1.83 < 6.0 FTJ
7.6 ( 3.00 IN)
45 DEG.
EIGHT WASH LANCES; CLARIFIED AND MAKE-UP WATER <
3.0 ( 1C.O FT/S)
.3 ( 1.2 IN-H20)
PH
4.5-6.5
NUMBER
I.-4-LINE
HOT WATER ?25F, 15& PSIG
27.8 ( 50 F>
35.1
FT>
•* WATER LOOP
TYPE
>* REAGENT PREPARATION EQUIPMENT
NUMBER OF SLAKERS
SLAKER CAPACITY - M T/H
»* TREATMENT
TYPE
»* DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
CAPACITY - CU.M
CLOSED
1
51.7
( 57.0 TPH)
FLVASH STABILIZATION
FINAL
POND
ON-SITE
16> .0
3130880
t 2560.0 ACRE-FT)
. .. — -PERFORHANC I DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION
X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/75 *A
4B
SYSTEM
a.o
25.0
16.3
5.5
U.2
11.4
744 518
84
133
-------
EPA UTILITY F&D SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER 8 LIGHT: HAWTHORN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/75 4*
4B
PRObLEMS/SOLUTIONS/COMMENTS
BOTH MODULES ENCOUNTERED MARBLE BED PLUGGING AND STRAINER PROBLEMS.
22. 6
2».5
25.5
SYSTEM 25.5 744 190
11/75
12/75
** PRObLtMS/SOLUTIONS/COMMENTS
A NEW PROCESS CHEMISTRY IS BEING TRIED- ATTEMPTING TO RUN AT 100* SLOWDOWN
AND NEAR IEKO PERCENT SOLIDS WITH Ph faElMG MAINTAINED AT 5 WITHOUT LIME
STONE INJECTION. EMPHASIS IS BEING PLACED ON PART1CULATE CONTROL.
LCST HALf OF BOILER TO I.D. FAN OUTAGE CAUSING BOTH FGD MODULES TO BE SMUT
DOWN TO PhEVENT LOSS OF THE ENTIRE UNIT.
9/75 4A
4B
SYSTEM
53.C
52.7
28.6
29.2
28.9
720 395
208
*• PROt-'LEMS/S OLUTIONS/COMMENTS
SCRUBBER MODULES WERE RETURNED TO SERVICE ON SEPT. 21 AFTER REPLACEMENT Of
THE CRIGIKAL I.D. FAN ON MODULE 46 SIDE.
ThE MARBLE BED WAS REMOVED FROM MODULE A AND REPLACED WITH A STAINLESS
STEEL PERFORATED bED. THE MARBLES WERE REMOVED BECAUSE OF CONTINUING
OPERATIONAL DIFFICULTIES. NEW DESIGN RESULTED IN INCREASED AVAILABILITY
AND CONTINUED HIGH PARTICULATE EFFICIENCY <97X>.
10/75 4A
48
SYSTEM
91.0
75.2
51.7
88.2
72.9
744 721
542
•* PROBLEMS/SOLUTIONS/COMMENTS
THE EXPERIMENT WITH A PROCESS CHEMISTRY OF 10OX SLOWDOWN AND OX
SOLIDS IS STILL IN PROGRESS. S02 REMOVAL EFFICIENCY IS IN THE 50 TO 6CX
RANGE. KCFSL IS CONCENTRATING ON PARTICULATE CONTROL.
THERE WAS A MINOR BOILER RESTRICTION ON THE A-SIDE BETWEEN THE ECONOMIZER
AND THE INLET DRAFT DUCT.
4A
4B
SYSTEM
.0
99.3
49.5
.0
99.0
49.5
720 720
356
PROBLEMS/SOLUTIONS/COMMENTS
MODULE 4A WAS SHUT DOWN DURING THE REPORT PERIOD DUE TO LOSS OF DRAFT
THROUGH THE DUCTWORK FROM 'HE ECONOMIZER TO THE AIR PREHEATER , RESULTING
IN FREQUENT PLUGGING OF TH ( REHEATER UNTIL THE SYSTEM WAS SHUT DOWN.
4A
48
SYSTEM
.0
16.0
8.0
.0
13.8
6.9
744 640
52
PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER OUTAGE OF 5 DAYS WAS DUE TO A SCHEDULED OVERHAUL.
1/76 4A
46
SYSTEM
.0
.0
.0
744
134
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POUER & LIGHT: HAWTHORN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS DOUN ALL MONTH DUE TO FROZEN EQUIPMENT AND LINES; MANPOWER
WAS ASSIGNED TO A BOILER AtO TURBINE OVERHAUL ON ANOTHER UNIT.
2/76 4A .0 .0
4B 78.3 64.7
SYSTEM 38.9 32.3 696 579 225
** PRObLEMS/SOLUTIONS/COMMENTS
MODULE 4A WAS SHUT DOUN THE ENTIRE MONTH BECAUSE OF CONTINUING LOSS OF
DRAFT THROUGH THE DUCTWORK FROM THE ECONOMIZER TO THE AIR PREHEATER.
MODULE B EXPERIENCED PLUGGING IN THE MARBLE BED.
A RECYCLE PUMP MALFUNCTIONED ON THE B-SIDE.
3/76 4A .7 .0
4B 3.0 3.2
SYSTEM 1.7 1.6 744 7C6 12
•• PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT'S BYPASS SEALS WERE REPLACED WITH SLIDE-GATE DAMPERS.
4/76 4» 42.0 32.1
4B 4C.O 30.6
SYSTEM 41.3 31.3 720 550 226
5/76 4A 39.3 26.7
4B 43.4 29.5
SYSTEM 41.3 28.1 744 506 209
** PROBLEMS/SOLUTIONS/COMMENTS
ONE OF THE REHEAT TUBE BUNDLES WAS REMOVED TO FACILITATE CLEANING AND
MAINTENANCE DUE TO PLUGGING PROBLEMS.
CURRENTLY, THE UTILITY IS IN THE PROCESS OF MODIFYING THE SCRUBBING SYSTEM
FROM A L1HESTONE INJECTION AND TAIL-END SCRUBBING BASED SYSTEM TO A LIME
SLURRY BASED SYSTEM.
6/76 4A 65.0 40.8
*B 5.0 3.2
SYSTEM 34.5 22.C 720 460 158
7/76 SYSTEM 744
8/76 SYSTEM 744
9/76 SYSTEM 720
•» PROBLENS/SOLUTIONS/COMMENTS
THE SYSTEM bAS OUT OF SERVICE VIRTUALLY THE ENTIRE REPORT PERIOD DUE TO A
MAJOR EXPLOSION WHICH OCCURRED IN THE COAL MILL PULVERIZING AREA OF UNIT 5
5, WHICH SERIOUSLY HAMPERED OPERATIONS AND MANPOWER COMMITMENTS.
10/76 SYSTEM 744
11/76 4A 91.0 61.4
*B .: .0
SYSTEM 45.5 30.7 720 486 221
135
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER 8 LIGHT: HAWTHORN 4 (CONT.)
. . PERFORNANC C DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION
* REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMNENTS
3/77
THE UTILITY IS IN THE PROCESS OF CONVERTING THE SYSTEM TO A WET LIME
SCRUBBING SYSTEM, WHICH WILL COMMENCE OPERATIONS IN THE FIRST PART OF
JANUARY.
12/76 4A
4B
SYSTEM
1/77 4A
4B
SYSTEM
85.0
74.0
79.7
.0
.0
.0
65.5
57.0
61.3
744
744 572
456
*« PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT fcECAME AVAILABLE FOR SERVICE IN THE LIME SCRUBBING MODE ON JAN.
1, 1977. TESTING FOR COMPLIANCE WITH PARTICULATE CODES OCCURRED DURING
THE MONTH. THE UNIT WAS FOUND TO MEET THE EMISSION REGULATION OF 0.17 LB/T
MM BTU BURNING 2.OX SULFUR COAL. SYSTEM OPERATIONS ARE STILL CONTINUING
SOLIDS AND 1C ox SLOWDOWN. THE FRESH WATER MAKE-UP REQUIREMENT is 7.0GPH/Mw.
AT OX SOLIDS AND 1001 SLOWDOWN. THE FRESH WATER MAKE-UP REQUIREMENT
is 770 GPM/MH.
2/77 4A
4B
SYSTEM
4A
4B
SYSTEM
4/77 4A
4B
SYSTEM
8C.O
5C.O
65.0
82.0
97.D
89.5
43.0
43.0
43.0
69.6
43.5
56.5
59.1
70.5
64.8
43.2
43.2
43.2
672 591
744 539
72C 720
38C
482
311
*• PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEM IS NOW OPERATING WELL AT AbOUT 15-25* SLOWDOWN. THE PH CONTROL
SYSTEM OPERATIONS HAVE BEEN EXCELLENT. DURING MAY THE BOILER BURNED GAS FO
4C8 HOURS (NOT INCLUDED IN THE OPERABILITV VALUES). S02 REMOVAL EFFICIENCY
IS ESTIMATED AT 50-602 FOR BOTH MODULES. ALTHOUGH ACTUAL TESTS HAVE NOT
BEEN RUN FOR ONE-AND-A-HAUF YEARS. CURRENTLY BOTH MODULES ARE BEING OPERA.
TED SIMULTANEOUSLY.
5/77 4A
46
SYSTEM
6/77 SYSTEM
54.D
54. C
54.3
24.2
24.2
24.2
.0
744
720
740
720
180
C
** PRObLEMS/SOLUTIONS/COMMENTS
UNIT NO. 4 FIRED GAS THROUGHOUT THE MONTH, ALLOWING THE SCRUBBER PLANT TO
BE SHUT DOWN FOR MODIFICATIONS DURING THE PERIOD.
MODIFICATIONS TO THE SCRUBBER MODULES INCLUDED: REPLACEMENT OF THE UNDER-
BED SPRAY HEADERS WITH 316L SS. INSTALLATION OF A NEW REACTION
TANK LINE!., AND REPLACEMENT OF THE ORIGINAL CARBON STEEL PIPING WITH
RUBBER-LIKED PIPING (FROM THE RECYCLE PUMPS TO THE SPRAY MANIFOLD).
7/77 4A
4B
SYSTEM
17.2
17.2
17.2
16.1
16.1
16.1
744 696
120
136
-------
EPA UTILITY FGO SURVEY: FOURTH OUARTER 1979
KANSAS CITY POWER 8 LIGHT: HAWTHORN 4
-------
EPA UTILITY F&D SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: HAWTHORN 4 (CONT.)
. PERFORMANCE DATA .
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE UNIT I.AS DOWN ONCE IN FEBRUARY AND AGAIN FOR 32 HOURS IN MARCH FOR
GENERAL MAINTENANCE.
3/78 SYSTEM 63.3 63.3 744 744 471
4/78 SYSTEM 76.? 76.C 72C 720 220
** PROBLEMS/SOLUTIONi/COMMENTS
FGD OUTAGE IN MAY WAS DUE TO CLARIFIES PLUGGING.
APRIL OUTAGE TIME UAS FOR SCHEDULED GENERAL MAINTENANCE AND CLEANING.
5/78 SYSTEM 42.0 42.D 744 744 403
6/78 SYSTEM 720
«* PROBLEMS/SOLUTIONS/CCHMENTS
NC INFORMATION WAS AVAILABLE FOR THE JUNE-JULY PERIOD BECAUSE OF A PLANT
STRIK E.
7/78 SYSTEM 7*4
8/78 SYSTEM 744
•• PROBLEMS/SOLUTIONS/CCMMENTS
THE SCRUBbING SYSTEM IS OPERATING ALTHOUGH THE UTILITY IS STILL IN THE
MIDST OF * STRIKE. FGD PERFORMANCE FIGURES ARE NOT AVAILABLE BECAUSE THE
UTILITY IS NOT RECORDING FGO OPERATION HOURS DURING THE STRIKE.
9/78 SYSTEM 72C
10/78 SYSTEM 744
•• PRObLEMS/SOLUTIONS/COMMENTS
ALTHOUGH THE STRIKE IS OVER NO OPERATIONAL DATA IS AVAILABLE. THE FGD
SYSTEM IS IN OPERATION.
11/78 SYSTEM 720
12/78 SYSTEM 744
*• PROBLEMS/SOLUTIONS/COMMENTS
HOURS OF OPERATION ARE STJIL NOT AVAILABLE. THE FGD SYSTEM IS IN OPERATIC
BUT AT PRESENT PERSONNEL ARE BEING REASSIGNED PREVENTING ACCURATE DATA
RECORDING.
1/79 SYSTEM 744
2/79 SYSTEM 67i
3/79 SYSTEM 744
*• PRObLEMS/SOLUTIONS/COMMENTS
OPERATING INFORMATION FOR UNIT 4 IS STILL NOT AVAILABLE.
4/79 SYSTEM 57.0 1CC.O 57.0 720 410 41C 30.0
•• PROBLEMS/SOLUTIONS/COMMENTS
AN EXCITER FAILURE ON THE GENERATOR CAUSED THE APRIL OUTAGE TIME.
5/79 SYSTEM 94.0 10C.O 94.0 744 699 699 49.C
138
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER 8 LIGHT: HAWTHORN 4 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
502 PART. HOURS HOURS HOURS FACTOR
•• PRObLEMS/SOLUTIONS/COMMENTS
MAY OUTAGE TIME WAS FOR SCRUBBER CLEANING AND GENERAL MAINTENANCE.
6/79 SYSTEM 14.0 72C 101
7/79 SYSTEM 93.0 74*. 692
8/79 SYSTEM 100.0 744 744
9/79 SYSTEM 69.0 720 497
«* PRObLEMS/SOLUTIONS/COMMENTS
DURING JULY AND AUGUST MOSTLY GAS WAS FIRED. THERE taERE NO MAJOR SCRUBBER
PROBLEMS AND HIGH AVAILABILITY RESULTED BECAUSE OF THE LOU DEMAND FOR THE
UNIT.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PRObLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE FOURTH QUARTER 1979.
139
-------
EPA UTILITY F&D SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F&D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY V./FGD - My
NET UNIT GENERATING CAPACITY WO/FGfc - MU
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
•* FUEL DATA
FUEL TYPc
FUEL GRADE
AVERAGE HEAT CONTENT - J/t
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTE NT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - Z
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*• PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
NUMBE" OF NOZ2LES
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIUU1D RtCIRCULATION RATE - LITER/S
L/G RATIO - LITEH/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
S02 INLET CONCENTRATION - PPM
*• FGD SYSTEM
SALEABLE PRODUCT/TMROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
KANSAS CITY POWER £ LIGHT
LA CYGNE
1
LA CYGNE
KANSAS
55.
645.
U50.0
874.0
82C.O
£44.0
874.0
BABCCCK g WILCOX
CYCLONE
BASE
0/73
1202.44
14C.6
213.
7.0
( .128 LB/MMBTU)
( 1.500 LB/MMBTU)
(2760000 ACFM)
( 285 F)
( 700 FT)
( 23.0 FT)
( 9421 BTU/LB)
9COO-9700
COAL
SUBBITUMINOUS
21913.
24.36
24-25
?.6G
9-10
5.39
5-6
.33
0.02-0.03
8
VENTURI
BABCOCK g WILCOX
1
316L SS
KAOCRETE CERAMIC
NONE
80
SPINNER VAN£, COORS CERAMIC
162.8
140.6
315.0
1.6
39.6
98.2
450C.OOO
( 345000 ACFM)
( 285 F)
( 5000 GPM)
(12.0 GAL/1000ACF)
(*•*** IN-H20)
( 13C.O FT/S)
THROWAWAY PRODUCT
U£T SCRUBBING
LIMESTONE
NONE
BABCOCK & UILCOX
BLACK t VEATCH
FULL SCALE
NEW
99.50
8C.OO
6/73
2/73
4/69
140
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER ft LIGHT: LA CYGNE 1 (CONT.)
** AbSORBEfl
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER Of STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
NOZZLE TYPE
bOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/C RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
S02 OUTLET CONTRAT10N - PPM
•* FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
*• FANS
NUMBER
TYPE
SERVICE - WET/DRV
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
•• MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
•* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - N
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
SENSOR LOCATION
8
TRAY TOWER
3/73
BABC (CK I WILCOX
2
32 X 16 X 65
316L SS
NONE
316L SS SIEVE TRAY, CERAMIC NOZZLES
SPIN tER-VANE,
12.5
112.55
5C.O
567.
3.5
1.5
4.6
1000
CERAMIC
( 238500 ACFM)
( 122 F)
( 9GOO GPM)
( 26.5 6AL/1000ACF)
( 6.0 IN-H20)
( 15.0 FT/S)
SCRUBBER ID
CARBON STEEL WITH SS CLAD BLADES; THE HOUSINGS A
DRY
210.09 ( 445200 ACFM)
BOILER I.D.
DRY
8
SIEVE TRAY
SS
HORIZONTAL
CHEVRON
FRP (DURAKANE)
HORIZONTAL
2
3
3.66 112.0 FT)
.24 ( .8 FT)
7.6 ( 3.00 IN)
45 DEG.
FIRST STAGE.VERTICALLY UPWARD; SECOND STAGE VERT
2.6 < 8.4 FT/S)
.3 ( 1.4 IN-M20)
CHEVRON
FRP (DURAKANE)
HORIZONTAL
1
3
3.66 (12.0 FT)
.24 ( .8 FT)
7.6 ( 3.00 IN)
45 DEG.
FIRST STAGE VERTICALLY UPWARD; SECOND STAGE VERT
2.6 ( 8.4 FT/S)
.3 ( 1.4 IN-H20)
PH, SOLIDS Z
PHC5.6-5.8)
AUTOMATIC
PH AT VENTURI. SOLIDS AT VENTURI RECIRC. LINE
141
-------
EPA UTILITY FOD SURVEY: FOUhTH QUARTER 1979
KANSAS CITY POWER S LIGHT: LA CYGNE 1
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER 8 LIGHT: LA C YGNE 1 (COMT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABJLITY RELIABILITY UTILIZATION t REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
c
D
E
F
0
SYSTEM
2/74 A
e
c
o
t
T
G
SYSTEM
3/74 SYSTEM
32.0
44.0
67.0
23.0
37.0
81.0
50.0
66.0
68.0
59.0
76.0
52.0
100.0
65.0
69.0
744
672
744
PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUTDOWN FOR THE ENTIRE MONTH OF MARCH.
4/74
5/74
6/74
7/74
8/74
A
a
c
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
I
F
G
SYSTEM
67.0
73.0
75.0
88.0
74.0
100.0
68.0
83.0
69.0
83.0
78.0
85.0
78.0
b4. 0
80.0
bO.O
92.0
64.0
83.0
90.0
82.0
83.0
87.0
86.0
75.0
80.0
80.0
8 1.0
85.0
79.0
77.0
80.0
90.0
90.0
73.0
8 1.0
81.0
78.0
99.0
85.0
720
744
72:
744
744
9/74 A
69.0
143
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: LA CYGNE 1
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: LA C YGNE 1 (CONT.)
PERFORMANCE DATA —
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
b
C
D
i
f
G
SYSTEM
7/75 A
b
C
D
E
F
G
SYSTEM
8/75 A
B
C
D
E
F
G
SYSTEM
85.0
84.0
85.0
84.0
86.0
89.0
86.0
78.0
90.0
90.0
84.0
85.0
87.0
85.0
86.0
75.0
68.0
87.0
78.0
92.0
85.0
83.0
84.0
720 667
744 590
744 630
** PR06LEMS/SOLUTIONS/COHMENTS
MODULES A AND D ARE USED FOR RESEARCH TESTS.
EACH EVENING FOR CLEANING.
ONE MODULE IS SHUT DOteN
9/75
10/75
A
b
C
0
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
78.0
84.0
84.0
85.0
79.0
78.0
74.0
80.0
66.0
77.0
46.0
74.0
72.0
73.0
65.0
68.0
72 C 610
744 231
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS DOUN OCTOBER 16 TO NOVEMBER 13 OWING TO PROBLEMS WITH
THE GENERATOR AND I.D. AIR FAN.
AVAILABILITY FRGURES FOR OCTOBER AND NOVEMBER DO NOT INCLUDE THE OUTAGE
TIME FROM OCTOBER 16 TO NOVEMBER 13.
11/75 A 93.0
B 90.0
C ttO.O
0 93.0
E 96.0
F 89.0
G 94.0
SYSTEM 91.0
12/75 A 91.0
B 87.0
C 81.0
720 346
145
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
x REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/76
5/76
D
E
F
G
SYSTEM
85.0
87.0
89.0
84.0
86.0
597
•« PROBLEMS/SOLUTIONS/COMMENTS
THREE BOILER OUTAGES OCCURRED DURING DECEMBER.
1/76 A
b
C
D
E
F
G
SYSTEM
A
b
C
D
E
F
SYSTEM
3/76 A
b
C
D
E
F
G
SYSTEM
4/76 SYSTEM
66.0
65.0
91.0
72.0
84.0
52.0
84.0
83.0
94.0
90.0
66.0
91.0
92.0
93.0
y 5.3
92.0
92.0
90.0
88.0
93.0
94.0
91.0
91.0
91.0
744 618
696 594
744 643
720
*• PRObLEMS/SOLUTJONS/COMMENTS
THE SYSTEM kAS SHUT DOWN ON APRIL 6 FOR A SCHEDULED BOILER, AIR PREHEATER
AND STACK BREECHING OVERHAUL. THE UNIT WAS RESTARTED ON MAY 10. '
DURING THE OUTAGE SOME MAINTENANCE WAS PREFORMED ON THE SCRUBBER DUCTUQRK
PRIMARILY BECAUSE OF CORROSION PROBLEMS. *
A
B
C
D
£
F
G
SYSTEM
96.0
92.0
93.0
96.0
89.0
95.0
96.0
94.0
744 436
PROBLEMS/SOLUTIONS/COMMENTS
FROM MAY 10 TO THE END OF THE MONTH FOUR UNIT OUTAGES WERE ENCOUNTERED.
6/76 A
B
C
D
F
G
SYSTEM
93.0
94.0
94.0
95.0
93.0
93.0
91.0
93.0
720
146
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CON'.)
PERFORMANCE DATA .
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP*
S03 PART. HOURS HOURS HOURS FACTOR
*« PKObLEMS/SOLUTIONS/COMMENTS
7/76
FOUR FORCED MINOR SCRUBBER OUTAGES OCCURRED DURING JUNE.
A
B
C
D
E
F
G
SYSTEM
96.0
95.0
92.0
93.0
93.0
94.0
94.0
94.0
744
** PHOfaLEMS/SOLUTIONS/COMNENTS
TWO MINOR SCRUBBER OUTAGES OCCURRED DURING JULY.
THE UNIT RECORDED ITS LARGEST MU-HOUR MONTH SINCE INITIATION OF COMMERCIAL
OPERATION.
8/76 A
B
C
D
E
F
G
SYSTEM
94.0
93.0
92.0
94.0
92.0
90.0
88.0
92.0
744
•* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT bAS TAKEN OUT OF SERVICE AUGUST 24 FOR REPAIR OF A TURBINE BLADE,
THE UNIT WAS RETURNED TO SERVICE ON OCTOBER 20. OPERATION WAS INTERMIT-
TENT PENDING TURBINE BLADE REBALANCING AND REESTABLISHMENT OF NORMAL
OPERATING CONDITIONS.
DURING THE TURBINE REPAIR PERIOD THE UTILITY COATED THE STACK INNER
STRUCTURE WITH PLASTITE 4005.
THE AUGUST AVAILABILITY FKURES DO NOT INCLUDE THE OUTAGE TIME.
9/76 SYSTEM .C 720 0 0
*• PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS DOWN DUE TO TURBINE REPAIR.
10/76 SYSTEM
11/76 A 95.0
B 93.0
C 94.0
D 95.0
E 94.0
F 93.0
G 94.0
SYSTEM 94.0
12/76 A 87.0
0 89.0
C B 1.0
D 94.0
E 94.0
F 95.0
G 91.0
SYSTEM 90.0
744
7ZO 627
744
706
147
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER 8 LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA _
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•* PRObLEMS/SOLUTIONS/COMMENTS
4/77
THE A-MODULE VENTURI RECYCLE PUMP EXPERIENCED SOME PROBLEMS AND WAS
HfcPAI RED.
THE C-MODtLE'S REHEAT STEAM TUBE BUNDLES WERE INCREASED IN NUMBER FROM
FOUR TO EIGHT.
1/77
2/77
3/77
A
B
C
D
i
f
G
SYSTEM
A
b
C
D
E
F
G
SYSTEM
A
B
C
D
t
F
G
SYSTEM
94.0
90. g
95.0
95.0
95.0
92.0
90.0
93.0
93.0
93.0
93.0
94.0
93.0
9 4.0
B8.0
93.0
94.0
92.0
86.0
94.0
91.0
94.0
90.0
92.0
744 714
672 634
744
»* PROfaLEMS/SOLUTIONS/COMMENTS
THE EIGTH MODULE HAS BEEN INSTALLED.
THE MIST ELIMINATORS IN TWO MODULES HAVE BEEN MODIFIED TO THE POINT WHERE
THEY HAVE BEEN OPERATING CONTINUOUSLY CLEAN.
ADDITIONAL BANKS OF STEAM TUBE BUNDLES HAVE BEEN INSTALLED IN SOME MODULES
5C f OF REHEAT HAS BEEN DETERMINED AS THE NECESSARY AMOUNT FOR THE
LA CYNGE NO. 1 UNIT.
THE WATER LOOP IS NOW 9SZ CLOSED.
A NEW SETTLING POND IS BEING INSTALLED AT THE PLANT.
THE PLANT IS STILL GENERATING 700-720 MW DURING THE DAY AND 500-570 MU
AT NIGHT.
A
B
C
D
E
f
6
SYSTEM
96.0
94.0
97.0
94.0
95.0
96.0
95.0
95.0
*« PROULEMS/SOLUT10NS/COMMENTS
5/77 SYSTEM
THE EIGHT NODULE HAS BEEN RUN FOR TWO DAYS.
.0
720
744
148
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: LA CVGNE 1 (CONT.)
» PERFORMANCE DATA —
PERIOD NODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
• * PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN IN HAY DUE TO TURBINE PROBLEMS. THE UNIT RESTARTED
JULY 5, 1977.
THE MIST ELIMATOR WASHING CONFIGURATION IS BEING CHANGED TO WORK
COUNTERCURRENT TO THE GAS (LOW.
ADDITIONAL TUBE BUNDLES ARE BEING ADDED TO INCREASE THE REHEAT AREA.
THE NEW SETTLING POND IS STILL BEING DRAWN UP. EXCAVATION HAS NOT BEGUN.
6/77 SYSTEM ,C 720 0 0
*« PROBLEHS/SOLUTIONS/COMMENTS
MINOR CLEANOUT AND REPAIR WORK WAS DONE ON THE SCRUBBING SYSTEM DURING
THE TURBINE OUTAGE.
7/77 A
B
C
D
E
F
G
H
SYSTEM
95.0
93.0
94.0
95. 0
95.0
95.0
95.0
95.0
95.0
744
528
** PROBLEMS/SOLUTIONS/COMMENTS
RESUMPTION OF OPERATIONS WAS CONDUCTED WITH EIGHT SCRUBBER MODULES IN THE
FLUE GAS PATH, ENABLING THE UNIT TO OPERATE AT A MAXIMUM CONTINUOUS LOAD
CAPACITY OF 800-820 Hw
8/77 A
B
C
D
E
F
G
H
SYSTEM
89.0
$5.0
93.0
93.0
90.0
93.0
93.0
94.0
87.0
744
507
** PRObLENS/SOLUTIONS/COMMENTS
PARTICULATE REMOVAL TESTS WERE CONDUCTED IN LATE AUGUST AND UNIT N0.1 HAS
PASSED THE COMPLIANCE REQUIREMENTS (0.13 LB/MM BTU).
MODULE B HAD LOW AVAILABILITY DUE TO THE BURNING OF THE MOTOR ON
THE RECIRCULATING PUMP. IT WAS REMOVED AND STARTED AGAIN
AFTER 12 DAYS.
9/77
10/77
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
D
93.0
94.0
89.0
90.0
93.0
95.0
92.0
93.0
92.0
91.0
96.0
89.0
94.0
72.80
720 524
149
-------
EPA UTILITY FfaO SURVEY: FOURTH QUARTER 1979
KANSAS CITY POUcR 8 LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA . .
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/77
E
f
G
H
SYSTEM
93.0
94.0
89.0
93.0
92.0
744 456
*• PROBLEMS/SOLUTIONS/COMMENTS
A 12 DAY CUTAGE IN OCTOBER WAS REQUIRED TO DESLA6 THE BOILER.
A
B
C
D
E
F
G
H
SYSTEM
93.0
96.0
93.0
94.0
92.0
93.0
96.0
95.0
94.0
720 234
•* PROBLEMS/SGLUT JONS/COMMENTS
THE BOILEfc MAS SHUT DOWN NOVEMBER 15 BECAUSE OF A NECESSARY TURBINE
OVERHAUL. THE BOILER WENT BACK ON LINE DECEMBER 25.
12/77 A 98.0
b 98.0
C 96.0
D 96.0
E 96.0
F 97.0
G 98.0
H 99.0
SYSTEM 97.0
7*4 300
«• PRObLEMS/SOLUTIONS/COMMENTS
THERE WERE A FEW SMALL BOILER RELATED OUTAGES IN DECEMBER.
1/78 A
b
C
D
E
F
G
H
SYSTEM
90.0
95.0
95.0
95.0
93.0
94.0
94.0
94.0
94.0
744 300
*• PROBLEMS/SOLUTIONS/COMMENTS
2/78 A
B
C
E
F
G
H
SYSTEM
3/78 A
B
C
92.0
93.0
9S.O
94.0
91.0
97.0
96.0
93.0
94.0
95.0
95.0
90.0
THERE UEPE SOME BOILER RELATED OUTAGES IN JANUARY, TOTALING ABOUT 5C
HOURS.
THE FGD SYSTEM CONTINUED TO OPERATE WITHOUT ANY PROBLEMS.
672 578
150
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
D
E
F
G
H
SYSTEM
95.0
94.0
95.0
89.0
93.0
93.0
744 741
4/78 A
B
C
D
E
F
G
H
SYSTEM
6/78
7/78
91.0
92.0
93.0
91.0
90.0
92.0
9 1.0
91.0
91.0
720 620
«* PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN A TOTAL OF 1CO HOURS IN APRIL. THIS TIME INCLUDED
THREE OUTAGES DUE TO BOILER LEAKS AND LACK OF LOAD REQUIREMENT.
DURING THE BOILER OUTAGES MODIFICATIONS TO THE FGD SYSTEM INCLUDED
CHANGING THE REHEAT TUBE BUNDLES.
5/78 A
B
C
D
E
F
G
H
SYSTEM
89.0
92.0
92.0
93.0
92.0
91.0
93.0
86.0
91.0
744 593
*« PROBLEMS/SOLUTIONS/COMMENTS
IN MAY THE BOILER WAS DOWN TWICE FOR A TOTAL OF 15 HOURS.
AGAIN CAUSED BY BOILER LEAKS.
OUTAGES WERE
GENERAL MAINTENANCE AND REPAIRS ON THE FGD SYSTEM CONTINUED.
SYSTEM 720 150
•* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS UP FOR ONLY 15 HOURS IN JUNE. IN THE FIRST PART OF JUNE
THERE WERE BOILER TUBE LEAKS. FROM JUNE 8 TO JUNE 17 A BOILER OUTAGE WAS
NECESSARY FOR GENERATOR REPAIR.
A
B
C
D
E
F
G
H
SYSTEM
88.0
97.0
92.0
94.0
88.0
93.0
93.0
95.0
93.0
744 341
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE JULY-SEPTEMBER PERIOD TWO I.D. FAN ROTERS WERE REPLACED.
8/78
92.0
93.0
95.0
46.0
93.0
151
-------
EPA UTILITY F&O SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER 8 LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA ..... __„__
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAp"~
S02 PART. HOURS HOURS HOURS FACTOR
9/78
10/78
F
G
H
SYSTEM
94.0
95.0
95.0
94.0
744 577
PROBLEMS/SOLUTIONS/COMMENTS
THERE HERE TWO BOILER OUTAGES IN AUGUST.
THE UTILITY IS EXPERIMENTING WITH A 3-STAGE HIST ELIMINATOR AND SOME
DOUBLE STAGE MIST ELIMINATORS. BETTER MIST ELIMINATION AT THE SCRUBBER
EXIT WOULD REDUCE THE FREQUENCY OF REHEATER CLEANING.
A
B
C
D
£
F
G
H
SYSTEM
A
B
C
0
E
F
G
H
SYSTEM
96.0
96.0
96.0
96.0
96.0
96.0
95.0
97.0
96.0
96.0
96.0
98.0
97.0
97.0
98.0
97.0
96.0
97.0
720 7?0
744 255
'• PRObLEMS/SOLUTIONS/COMHENTS
THE UTILITY REPORTED THAT NO UNUSUAL OPERATING PROBLEMS WERE ENCOUNTERED,
11/78 A 92.0
B 95.0
C 94.0
D 93.0
E 94.0
F 93.0
G 94.0
H 96.0
SYSTEM 94.0
12/78 A 93.9
b 92.9
C 94.0
D 95.0
E 94.7
F 90.5
G 94.4
H 94.7
SYSTEM 93.7
•• PROBLEMS/SOLUTIONS/COMMENTS
720 720
744 239
DURING THIS PERIOD THE UNIT EXPERIENCED A MULTITUDE Of COILER OUTAGES.
1/79 A
B
C
D
E
F
G
H
SYSTEM
95.6
96.5
97.2
96.3
90.7
97.2
97.2
95.4
95.7
744 205
152
-------
EPA UTILITY FGO SURVEY: FOURTH OUARTER 1979
KANSAS CITY POWER & LIGHT: LA CY6NE 1 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
z REMOVAL PER BOILER
S02 PART. HOURS HOURS
F6D CAP.
HOURS FACTOR
2/79 A
fa
C
D
E
F
G
H
SYSTEM
3/79 A
B
C
D
E
f
G
H
SYSTEM
95.0
94.6
92.6
93.5
95.1
94.3
94.1
93.8
94.1
96.1
96.0
93.2
95.6
96.5
94.8
95.7
93.4
95.2
672 3*2
744 314
«* PROULEMS/SOLUT10NS/CCMMENTS
NO MAJOR FGD SYSTEM PROBLEMS WERE REPORTED BY THE UTILITY FOR FEBRUARY OR
MARCH.
THE UTILITY HAS REPORTED THAT MANY TUBE LEAKS AND CYCLONE LEAKS HERE
EXPERIENCED WITH THE BOILER.
4/79 A
B
C
D
E
F
G
H
SYSTtCI
5/79 A
B
C
D
E
F
b
H
SYSTEM
95.5
95.7
94.4
91.4
95.5
96.2
95.9
95.7
95.0
96.5
96.3
96.7
95.3
95.4
95.7
96.3
95.5
96.3
720 638
744 476
PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD PROBLEMS HAD OCCURRED.
6/79 SYSTEM .0 720 0 0
•* PROBLEHS/SOLUTIONS/COMMENTS
THE UNIT WAS REMOVED FROM SERVICE THE LATTER PART OF MAY FOR SCHEDULED
BOILER OVERHAUL AND REMAINS I OUT OF SERVICE THROUGH JUNE.
7/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
.0
744
THE TURBINE WAS OVERHAULED DURING JULY. DURING THE OUTAGE SOME MINOR
MAINTENANCE WAS PERFORMED ON THE SCRUBBING SYSTEM.
8/79 A
B
86.8
95.9
153
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS CITY POWER & LIGHT: LA CY6NE 1
-------
EPA UTILITY fGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESI6N AND PERFORMANCE DATA FOR OPERATIONAL OOHESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PAHTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - HW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/FGD - My
NET UNIT GENERATING CAPACITY KO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
»* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
• * FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PAHTICULATE OUTLET LOAD - G/CU.M
** PARTICULATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODUCT/THROWAyAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
soz DESIGN REMOVAL EFFICIENCY - x
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - t
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
SHELL MATERIAL
.100 LB/MMBTU)
.300 LB/MMBTU)
KANSAS POWER I LIGHT
JEFFREY
1
WAMEGO
KANSAS
D
43. <
129. <
272C.O
720.0
680.0
*******
540.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
** / * *
******** (******* ACFM)
135.6 ( 276 F)
183. < 600 FT)
7.9 ( 26.0 FT>
COAL
******
18899.
5.80
******
28.00
( 8125 BTU/LB)
.32
.01
COLO SIDE
C.E. WALTHER
98.6
1327.9
139.4
.07
(2814000 ACFM)
( 283 F)
(***** IN-H
( .03 GR/SCF)
NONE
THROUAWAV PRODUCT
WET SCRUBBING
LIMESTONE
NONE
COMBUSTION ENGINEERING
BLACK 8 VEATCH
FULL SCALE
NEW
99.00
80.00
8/78
20.0
1.0
SPRAY TOWER
8/78
COMBUSTION ENGINEERING
316L SS
155
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS POtaER & LIGHT: JEFFREY 1 (COM.)
SHELL LINER MATERIAL
INTERNAL MATER1AL
PRESSURE DROP - KPA
*• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
•* MIST ELIMINATOR
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOAR6 DISTANCE - M
VANE SPACING - CM
VANE ANGLES
UASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
•* PUMPS
SERVICE
ABSORBER RE CIRCULATION
TANKS
SERVICE
REACTION
** REHEATER
NUMBER
TYPE
•* WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LlTERS/S
** REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
BALL MILL CAPACITY- M T/H
NONE
316L SS (2 SPRAY HEADERS)
1.0 ( 4.0 IN-H20)
BOILER I.D.
CARBON STEEL
DRY
CHEVRON
FIBE'GLASS
HORI20NTAL
2
1.22 C 4.0 fT)
5.1 ( 2.00 IN)
45 DEG
POND yATER, 150 PSIG
.3 < 1.0 FT/S)
NUMBER
6
NUMBER
4
1
BYPASS
CLOSED
35.1
1
10.9
< 557 6PM)
< 12.0 TPH)
** TREATMENT
PRODUCT CHARACTERISTICS
•• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
MIXED WITH BOTTOM ASH
FINAL
POND
ON-SITE
PUMPED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A/78 SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
744
9/78 SYSTEM
10/78 SYSTEM
THE SYSTEM IS IN THE SHAKEDOWN PHASE OF OPERATION. EACH OF THE SIX
MODULES OPERATED DURING THIS PERIOD. NO MAJOR PROBLEMS WERE REPORTED.
INTEGRATED OPERATION OF THE SYSTEM IS EXPECTED DURING THE FIRST HALF OF
OCTOBER.
720
744
156
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS POWER t, LIGHT: JEFFREY 1 (COM.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
«* PROBLEMS/SOLUT10NS/CONMENTS
INTEGRATED OPERATION FOR THIS UNIT HAS NO.T VET BEEN ACHIEVED. A CERTIF-
ICATION TEST WHICH HAD BEEN SCHEDULED HAD TO BE CANCELLED DUE TO A BOILER
OUTAGE. AT THIS TIME THE COLD WEATHER HAS FORCED POSTPONMENT OF THE TEST
INDEFINITELY. MEANWHILE INTERMITTENT FGD OPERATIONS CONTINUE.
11/78
12/72
1/79
2/79
3/79
4/79
5/79
SYSTEM
SYSTEM
** PROULEMS/SOLUT10NS/COMMENTS
NO PROBLEMS HAVE BEEN REPORTED FOR THIS PERIOD.
SYSTEM
SYSTEM
SYSTEM
SYSTEM .:
720
744
SYSTEM
• * PROBLEMS/SOLUTIONS/COMMENTS
.0
744
672
744
720 0
744 0
C .0
0 .0
7/79
8/79
9/79
10/79
11/79
12/79
THE BOILER WAS SHUT DOWN FOR WARRANTY INSPECTION ON APRIL 1 AND REMAINED
OUT OF SERVICE DURING NAY.
6/79 SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
72!
THE UTILITY REPORTED THAT THE UNIT RETURNED TO SERVICE THE FIRST WEEK OF
JUNE AND HAS SUFFERED NO OPERATIONAL DIFFICULTIES SINCE RESTART.
SYSTEM
SYSTEM
SYSTEM
•* PRObLEMS/SOLUTIONS/COMMENTS
744
744
720
SYSTEM
SYSTEM
OPERATIONS WERE NOT UNUSUAL THROUGH JULY AMD AUGUST. THE UNIT PASSED THE
COMPLIANCE TEST DURING THE JUNE-JULY PERIOD. THE UNIT WILL SHUT DOUN
IN MID-SEPTEMBER FOR THE NORMAL 2 WEEK INSPECTION AND MAINTENANCE OUTAGE.
THE UNIT IS EXPECTED BACK ON LINE ON OCTOBER 1.
744
720
SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
744
THE UTILITY HAS REPORTED THAT THERE HAS BEEN NO MAJOR OPERATING PROBLEMS
DURING THIS REPORT PERIOD. SOME HIGH BALL WEAR IN THE LIMESTONE BALL
MILL WAS DETECTED.
AGITATOR FAILURES IN THE REACTION TANK HAVE OCCURRED.
157
-------
EPA UTILITY FtD SURVEY: FOUfcTH UUARTEf. 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - M h.
NET UNIT GENERATING CAPACITY U/FGD - My
NET UNIT GENERATING CAPACITY UO/FGt - MU
EQUIVALENT SCRUBBED CAPACITY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FL 0 U - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
•• FUEL DATA
FUEL TYPt
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/Lb
AVERAGE ASH CONTENT - 2
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
SANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
KANSAS POWER & LIGHT
LAWRENCE
LAWRENCE
KANSAS
D
43. <
129. (
576.0
125.0
115.0
125.0
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLIC
0/5 «
19C.18
137.8
37.
2.4
.100 LB/MMBTU)
.300 LB/MMBTU)
COAL
23260.
9.80
******
1Z.OO
******
.55
( 403000 ACFM>
( 280 F)
< 120 FT)
( 6.0 FT)
( 10000 BTU/LB)
.03
•* ESP
NUMPER
TYPE
PARTKULATt DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
fLUE GAS TEMPERATURE - C
PARTICULATE OUTLET LOAD - G/CU.M
•* PARTICULATE SCRUBfcER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATER1AL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - I
FLUE GAS CAPACITY - CU.M/S
fLUE GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - G/CU.M
S02 INLET CONCENTRATION - PPH
*• FGD SYSTEM
SALEABLE PRODUCT/THROUAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
- X
1
COLD SIDE
99.0
165.2
147.2
.05
( 350000 ACFM)
( 297 F)
( .02 GR/SCF)
VENTURI
COMBUSTION ENGINEERING
1
316L SS
NONE
RUBBER COATED FIBERGLASS (NORVL) RODS CSPRAY NOZ
NON-ATOMIZING, FAN TYPE SPRAY
50.0
( 201500 ACFM)
( 280 F)
( 3600 GPM)
(18.0 GAL/1000ACF)
(***** 1N-H20)
( 3.03 GR/SCF)
95.1
137.8
226.8
2.4
*******
6.9
.748
THROUAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
COMBUSTION ENGINEERING
BLACK g VEATCH
FULL SCALE
158
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS POuER t LIGHT: LAURENCE 4 (CCMT.)
NEW/RETROFIT
PARTICULATt DESIGN REMOVAL EFFICIENCY
$02 oEsibN REMOVAL EFFICIENCY - x
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - '.
ABSORBER SPARE COMPONENT INDEX
RETROFIT
98.90
73.00
«* AbSOBUER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINEk MATERIAL
1NTFRNAL MATERIAL
NUMBER Of NOZZLES
bOlLER LOAD/ABSORBER - X
(,AS FLOW - CU.M/S
GAS TEMPtRATURE - C
LlUUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
PARTICULATE OUTLET LOAD- G/CU.C
PARTICULATE REMOVAL EFFICIENCY - X
S02 CUTLET CONTRATION - PPM
SOI DESIGN REMOVAL EFFICIENCY - X
•« FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - wET/DRY
CAPACITY - CU.M/S
.* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMPER OF STAGE S
NUMBER OF PASSES
FREEBOARD DISTANCE - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
** MIST ELIMINATOR
NUMPER
CONSTRUCTION MATERIAL
CONF1GURATION
NUMBER OF STAGES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY -
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
SENSOR LOCATION
** PUMPS
SERVICE
SPRAY TOWER
M/S
SLURRY FEED
MIST ELIMINATOR WASH
HILL SLURRY
CLASSIFICATION TANK TRANSFER
VENTUR1 RECIRCULATION
ABSORBER RtCIRCULATION
COMBUSTION ENGINEERING
2
316L SS
MONE
FttP SPRAY HEADERS, CERAMIC NOZZLES, 316L SS SuPP
3?
5 C.O
( 174500 ACFM)
( 124 F)
( 5330 GPM)
t 30.0 GAL/100CACF)
( 2.5 IN-H20)
( .332 GR/SCF)
8?.35
51.1
334.
4.0
.6
.1
98.9
20?
73.0
2
BOILER ID
CARBON STEEL
DRY
80.22
C 173000 ACFM)
8
CHEVRON
f RP
HORIZONTAL
3
2
1 .07 ( 3.5 FT)
B.9 < 3.50 IN)
90 DEG.
1ST STAGE, VERTICALLY UPWARD AND DOWNWARD; 2ND S
1.8 t 6.0 FT/S)
4
FRP
HORIZONTAL
1
INTERMITTENT, HIGH PRESSURE WATER WASH DIRECTED
I-.8 < 6.0 FT/S)
S02, SLURRY FLOWS, PH. X SOLIDS, PRESSURE DROP
PH = 5.5-5.7
AUTOMATIC
FEEDBACK
PH PROBES IN REACTION TANKS
NUMBER
159
-------
EPA UTILITY FliD SURVEY: FOURTH QUARTER 1979
KANSAS PObER S. LIGHT: LAURENCE 4 (CONT.)
• * TANKS
SERVICE
TOMER RE CIRCULATION TANK
VENTURI RECYCLE
CLARIFICATION A NO COLLECTION
DILUTION AND STORAGE TANK
REACTION TANK BLEED TANK
*• REHEATER
NUMRER
TYPE
HEATING MEDIUM
TEMPERATURE BOO ST - C
ENERGY RcOUIRED
•• THICKENER
NUMBER
•» WATER LOOP
TYPE
** REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
POINT OF ADDITION
** TREATMENT
TYPE
INLET- Kb/S
INLET SOLIDS - X
** DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
•* DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
** DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
TANK
NUMBER
2
2
1
1
1
IN-LINE
HOT WATER
27.8 C 50 F)
1.25V OF BOILER OUTPUT
CLOSED
REACTION TANK
FORCED OXIDATION
(13392 LB/MIN)
101.2
32.5
INTERIM
POND
ON-SITE
1: .0
FINAL
POND
ON-SITE
OVERFLOW FROM INTERIM SLUDGE POND
4.0
FINAL
POND
ON-SITE
OVERFLOW FROM INTERIM SLUDGE POND
28.0
FINAL
POND
ON-SITE
28.0
FINAL
POND
ON-SITE
4.0
_.___-------—------- — -- .... --PERFORMANC I DATA ———-———— — — —— —......—.__
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 P'ART. HOURS HOURS HOURS FACTOR
0/69 SYSTEM
160
-------
EPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
KANSAS PO.ER & LIGHT: LAWRENCE 4 (CCNT.)
. . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPcRABILITV RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
PROBLEMS U1TH THE FGD SYSTEM ON BOILER NO. I INCLUDED BUILDUP AND PLUGGING
OF THE INLET DUCT WHERE HOT GASES ENTER THE SCRUBBERS, EROSION OF SCRUBBER
WALLS, CORROSION OF SCRUBBERS INTERNALS, BUILDUP ON l.D. FAN ROTORS, AND
PLUGGING OF DRAIN LINES, MARBLE BEDS, AND DENISTERS. LOW S02 REMOVAL WAS
CAUSED BY OVERBURNING OF THE LIMESTONE AND DROPOUT OF THE LIME WITH THE
ASH IN THL BOTTOM OF THE SCRUBBER.
THE SCRUBEERS WERE MODIFIED IN 1969 BY RAISING THE DEMISTER AND ADDING
SOOT BLOWERS IN THE INLET DUCT AND REHEATER TO REDUCE PLUGGING. NE« SPRAY
NOZZLES WERE ALSO INSTALLED. REHEATER PLUGGING WAS ELIMINATED BY REPLAC1N
COPPER REHEAT COILS WITH A CARBON STEEL UNIT HAVING WIDELY SPACED FINS.
0/70 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
MAJOR MODIFICATIONS IN 1973 WERE SANDBLASTING AND COATING OF THE INTERIOR
OF THE SCRUBBERS, REPLACEMENT OF ALL INTERNAL STEEL PIPES WITH PLASTIC AND
FIBERGLASS, AND REPLACEMENT OF STAINLESS STEEL DEMISTERS WITH FIBERGLASS.
SINCE DEMISTER PLUGGING WAS NOT COMPLETELY ELIMINATED, THE UNIT WAS WASHED
MANUALLY EVERY NIGHT TO MAINTAIN THE REQUIRED OUTPUT.
0/72 SYSTEM
*• PRObLEMS/SOLUTIONS/COMMENTS
THE MODIFICATIONS IN THE SUMMER OF 1972 ON THE TWO FGD MODULES INCLUDED
ENLARGEMENT OF THE CRYSTALLIZATION TANK, AND INSTALLATION OF NEW PLASTIC
SPRAY NOZ2LES, NEW SLURRY PUMPS AND STRAINERS, AND NEW MULTIPLE MIXERS
IN THE TANK. PROBLEMS THAI REMAINED INCLUDED CORROSION, INEFFICIENT
DAMPERS, EXPANSION JOINT FAILURE, DEMISTER FOULING, RAPID EROSION OF THE
SLURRY PUMP, AND VALVE FAILURE.
0/73 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE FGD SYSTEM SINCE THE FALL OF 1973 HAS BEEN THE MOST
SUCCESSFUL TO DATE.
0/74 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
IN 1974 THIS UNIT WAS AVAILABLE FOR OPERATION 343 DAYS. FIFTY PERCENT OF
THE FUEL CONSUMED WAS COAL, TWO PERCENT FUEL OIL, AND FOURTY-EIGHT PERCENT
NATURAL GAS.
0/75 SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
DURING 1975 THIS UNIT WAS AVAILABLE FOR OPERATION 333 DAYS. SIXTY-FOUR
PERCENT OF THE FUEL CONSUME I WAS COAL, THREE PERCENT FUEL OIL, AND
THIRTY-THREE PERCENT NATURAL GAS.
6/75 SYSTEM 7ZO
*• PROBLEMS/SOLUTIONS/COMMENTS
STATION LOAD IS REDUCED TO 50 PERCENT EVERVNIGHT. THEREFORE, ONE OF THE
MODULES CAN BE TAKEN OFF-LINE NIGHTLY FOR CLEANING OR REPAIR. WYOMING
COAL (C.5X SULFUR) IS BEING BURNED IN THE BOILER. SOME NATURAL GAS HAS
BEEN BURNED SINCE JUNE 20.
7/75 SYSTEM 744
161
-------
EPA UTILITY F&D SURVEY: FOURTH QUARTER 1979
KANSAS POWER & LIGHT: LAWRENCE 4 (CtNT.)
PERFORMANCE DATA — .....
PERIOD MODULE AVAILABILITY OPERAB1LIT* RELIAOILITY UTILIZATION X REMOVAL PER BOILER (GO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** pnobLEMS/s OLUTIONS/CGMMENTS
EACH MODULE IS SHUT DOWN ONCE PER WEEK FOR INSPECTION AND CLEAN-UP.
SYSTEM . 744
SYSTEM 720
SYSTEM 74*
SYSTEM 720
SYSTEM 744
8/75
9/75
10/75
11/75
12/75
1/76
2/76
3/76
4/76
5/76
6/76
7/76
8/76
91 7 b
SYSTEM
744
OLUTIONS/CONMENTS
THE UTILITY IS REPLACING THE SCRUBBING SYSTEM WITH A ROD-DECK VENTURI
FOLLOWED EY A SPRAY TOWER.
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
•* PRObLEMS/SOLUTIONS/CCMMENTS
696
744
720
744
720
744
744
72 6
A SCHEDULED UNIT OUTAGE COMMENCED IN MID-SEPTEMBER FOR A TURBINE OVERHAUL
AND RESTARTED IN EARLY JANUARY.
10/76 SYSTEM 744
11/76 SYSTEM 720
12/76 SYSTEM 744
•* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT CONTINUES TO FIRE LOW SULFUR WYOMJNG COAL.
1/77 SYSTEM 744
** PHObLEMS/SOLUTIONS/COMMENTS
THE NEW LIMESTONE FGD SYSTEM BECAME COMMERCIALLY OPERABLE IN EARLY
JANUARY 1577. THE UTILITY REPORTS THAT BOTH PARTICULATE AND SO I REMOVALS
ARE QUITE SATISFACTORY.
MINOR PROLLEMS HAVE BEEN RELATED TO MAINTAINING DESIRED SOLIDS LEVEL IN
THE KAKE-tP TANK. MODIFICATION PLANS INCLUDE CESSATION OF SLURRY DILU-
TION, WHICH CURRENTLY PRECEDES THE INTRODUCTION OF THE FRESH LIMESTONE
SLURRY INTO THE RECIRCULATION LOOP. THE UTILITY PLANS TO PUMP THE 35X
SOLIDS SLURRY DIRECTLY FROM THE SLURRY TANK INTO THE REC1RCULAT ION LOOP.
CURRENTLY SEVERAL DIFFERENT MAKES OF SLURRY PUMPS ARE BEIN6 USED. ALL
ARE FUNCTIONING WELL SO FAR. THE PUMPS HAVE NOT BEEN IN SERVICE LONG
ENOUGH FOR COMPARISONS TO BE DRAWN.
162
-------
EPA UTILITY FGO SURVEY: FOURTH OUARTER 1979
KANSAS POȣR & LIGHT: LAURENCE 4 (CCNT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/77
3/77
4/77
SYSTEM
SYSTEM
SYSTEM
•• PHObLiMS/SOLUTlONS/COMMENTS
5/77
6/77
7/77
8/77
672
744
72G
THE SCRUBbER WAS NOT REQUIRED FOR SERVICE DURING THE REPORT PERIOD BECAUSE
NATURAL GAS WAS FIRED IN THE BOILER.
SYSTEM
SYSTEM
** PKObLENS/SOLUTIONS/COMMENTS
744
720
THE NO. 4 BOILER HAS BEEN FIRING 100X NATURAL GAS FOR ALL BUT 8-10 DAYS
SINCE THE BEGINNING OF APRIL 1977.
MIST ELIMINATOR CRACKS HAVE BEEN A PROBLEM.
A COMPRESSOR BREAKDOWN IN THE RECYCLE TANK AIR AGITATION SYSTEM AND THE
RECYCLE TANK STRAINER SCREEN WASH HAVE BEEN PROBLEM AREAS.
SOOT BLOUtR PROBLEMS WERE ENCOUNTERED.
THE DENVER SLURRY PUMPS ARE EXPERIENCING SOME ON-GOING PROBLEMS. WHILE
THE ALLEN-SHERMAN-HOFF PUMPS ARE OPERATING SATISFACTORILY.
SYSTEM 744
SYSTEM 744
** PROuLEMS/SOLUTIONS/COMMENTS
THE BOILER BURNED NATURAL GAS THROUGHOUT AUGUST.
THE KIST ELIMINATOR CRACKS HAVE BEEN REPAIRED.
THE RECYCLE TANK STRAINER PROBLEMS PERSISTED AND THE AIR AGITATION SYSTEM
COMPRESSOR WAS MALFUNCTIONING.
THE DENVER SLURRY PUMPS ARE FUNCTIONING ADEQUATELY AT PRESENT. THE PUMP
GLAND PACKING ARE BEING REDESIGNED.
9/77 SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
AS OF SEPTEMBER 15 THE UNIT BURNED COAL.
10/77 SYSTEM
•• PROBLEMS/SOLUTIONS/COMFIENTS
72 Q
744
THE SYSTEK CAPACITY WAS CUT BACK TO 50 PERCENT IN OCTOBER BECAUSE A NEW
COOLING TOWER IS BEING CONSTRUCTED.
11/77 SYSTEM
•* PRObLEMS/SOLUTIONS/COHMENTS
72:
12/77 SYSTEM
ON NOVEMBER 15 A MAJOR FGD SYSTEM OVERHAUL TOOK PLACE WHILE THE TURBINE
WAS DWON FOR INSPECTION AND THE NEW COOLING TOWER WAS BEING CONNECTED.
74 i.
163
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
KANSAS POWER & LIGHT: LAURENCE 4 (CCNT.)
PERFORMANCE DATA ...
PERIOD MODULE AVAILABILITY OPEC ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
«* PRObLEMS/SOLUTlONS/COMMENTS
THE UNIT CAME BACK ON LINE DECEMBER 20 AT FULL CAPACITY.
1/78 SYSTEM 744
** PROfaLiMS/SOLUTlOsS/COMMENTS
THE FGD SYSTEM OPERATED WITHOUT ANY PROBLEMS OTHER THAN SOME FREEZING OF
THE PIPELINES.
DISCHARGE LINE FREEZING CAUSED CLARIFIER PLUGGING.
2/78 SYSTEM 672
** PfiObLEMS/SOLUTIONS/COMMENTS
THE THICKtNER UNDERFLOW LINE IS STILL FROZEN AND TWO 3 INCH DIAMETER FIBF
HOSES ARE BEING USED TO PUMP THE UNDERFLOW SOLIDS TO THE POND.
3/78
4/78
5/78
6/78
A
b
SYSTtM
A
B
SYSTEM
SYSTEM
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
1C3.0
100.0
10:. o
100.0
100.0
1CC.O
7/78
8/78
10/78
11/78
12/78
100.0
100.0
100.0
100.0
100.0
100.0
744
720
744
720
720
744
720
744
«* PRObLEMS/SOLUTIONS/COMMENTS
THE BOILEK AND FGD SYSTEM BOTH OPERATED THROUGHOUT THE PERIOD WITHOUT
ANY FORCED OUTAGES.
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
744
THE UTILITY REPORTED THAT THE SYSTEM RAN WITH NO FORCED OUTAGES DURING THF
PERIOD.
THE SYSTEK RAN CONTINUOUSLY THROUGHOUT THE PERIOD WITH THE EXCEPTION OF A
ONE WEEK OUTAGE FOR A BOIL)R-TUHBINE INSPECTION.
9/78 SYSTEM
•« PROBLEMS/SOLUTIONS/COMMENTS
720
THE LNIT bAS DOWN THE LAST WEEK AND A HALF IN SEPTEMBER FOR A SCHEDULED
FALL TURBINE/BOILER OUTAGE. ROUTINE MAINTENANCE INCLUDED BOILER AND
TURBINE CLEANING AND REPAIR.
SYSTEM
SYSTEM
SYSTtM
*• PROBLEMS/SOLUTIONS/COMMENTS
744
720
744
1/79 SYSTEM
AN EPA SPONSORED CONTINUOUS MONITORING TEST BEGAN AT THIS UNIT AT THE
btGIfcNING OF DECEMBER AND WILL CONTINUE THROUGH THE END OF JANUARY. THE
TEST INVOLVES 24 HOUR MONITORING OF S02, OPACITY AND NOX.
744
164
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS POWER k. LIGHT: LAURENCE 4 (CCNT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/79
SYSTEM
*« PRObLEMS/SOLUTIONS/COMMENTS
672
3/79
4/79
5/79
6/79
7/79
8/79
9/79
10/79
11/79
12/79
ONE MODULI HAS FORCED OUT OF SERVICE FOR 2 DAYS WHEN ITS TANK AGITATOR
FAILED.
ONE MODULI WAS FORCED OUT OF SERVICE FOR AN 8 DAY PERIOD DUE TO A F*N
MOTOR MALFUNCTION
SYSTEM
•* PRObLEMS/SOLUTIONS/COMMENTS
74*
UNIT 4 EXPERIENCED A MOTOR IAILURE ON AN I.D. FAN DURING THE FEBRUARY-
MARCH PERICD.
SYSTEM
SYSTEM
SYSTEM
•* PROULEMS/SOLUTIONS/COMMENTS
730
7*4
720
THE UTILITY REPORTED THAT THE SYSTEM RAN HELL. THE ONLY FGD SYSTEM RELATED
OUTAGES UEfcE DUE TO* MIXER FAILURE AND GENERAL MAINTENANCE.
SYSTEM
SYSTEM
SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
744
744
720
DURING THE THIRD QUARTER AN OUTAGE UAS CAUSED BY MIXER MOTOR AND OTHER
MIXER RELATED PROBLEMS. DURING THE OUTAGE MAINTENANCE UAS DONE ON THE
BOILER AND SCRUBBERS AND REPAIR WORK WAS DONE ON THE MIXERS.
THE UNIT WAS OPERATED AT HALF LOAD DURING THE LAST WEEK OF SEPTEMBER AND
UAS SHUT DCUN COMPLETELY IN EARLY OCTOBER FOR THE ANNUAL FALL OUTAGE.
SYSTEM
SYSTEM
SYSTEM
•* PRObLEMS/SOLUTIONS/COHMENTS
744
720
744
THE UNIT UAS DOUN FOR APPROXIMATELY 10 DAYS OF SCHEDULED OUTAGE FOR FALL
MAINTENANCE.
SOME AGITATOR SHAFT FAILURES OCCURRED IN THE REACTION TANK CAUSING
MAINTENANCE ATTENTION.
165
-------
EPA UTILITY FtiD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMbER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - KiG/J
NET PLANT GENERATING CAPACITY - Mu
GROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY W/FGD - Mw
NET UNIT GENERATING CAPACITY KO/FGC - MU
EQUIVALENT SCRUBBED CAPACITY - MW
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYpt
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - DTU/LB
AVERAGE ASH CONTENT - 4
RANGE ASM CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVEP-Gt SULFUR CONTENT - V.
RANGE iULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - x
KANSAS POWER 8, LIGHT
LAWRENCE
LAURENCE
KANSAS
D
4?. <
215. (
57.6
420.0
400.0
.100 LB/MMBIU)
.500 LR/MMBTU)
420.0
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLIC
0/7.1
599.78 (1271000 ACFM)
148.9 ( 303 F)
114. ( 375 FT)
4.9 ( 16.0 FT)
COAL
******
23260.
9.80
12.00
.55
( 100CO BTU/LB)
.03
******
*• PARTICULATE SCRUBBER
NUMPER
TYPE
SUPPLIER
NUM9ER OF STAGE S
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUbBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIUUID RLCIRCULATION RATE - LITER/S
L/G RATIO - LlTEfi/CU.M
PRESSURE DROP - KPA
S02 INLET CONCENTRATION - PPM
•* FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
VENTURI
COMBUSTION ENGINEERING
1
316L SS
NONE
316L SS RODS, 2 LEVELS OF SPRAY NOZZLES
NON-ATOMIZING, FAN TYPE SPRAY
5C.O
299.7 ( 635000 ACFMJ
148.9 t 300 r>
655.2 (1J400 GPM)
2.1 (16.0 GAL/1000ACF)
******* <*•*** IN-H20)
.748
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
COMBISTION ENGINEERING
BLACK g VEATCH
FULL SCALE
RETROFIT
98.90
52.00
11/71
.0
.0
166
-------
KANSAS POfcER i LIGHT: LAURENCE 5 (CCNT.)
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
** AbSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEMPtRATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
PARTICULATE REMOVAL EFFICIENCY - I
502 CUTLET CONTRAT10N - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
FREEBOARD DISTANCE - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
PRESSURE DROP - KPA
** MIST ELIMINATOR
NUMBER
CONSTRUCTION MATERIAL
CONFIGURATION
WASH SYSTEM
*• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
SENSOR LOCATION
** PUMPS
SERVICE
REACTION/RECULE TANK BLEED
VENTURI RECIRCULATION
SLURRY FLED
MIST ELIMINATOR WASH
MILL SLURRY
CLASSIFICATION TANK TRANSFER
ABSORBER RECIRCULATION
TANKS
SERVICE
CLARIFICATION AND COLLECTION TANK
DILUTION AND STORAGE TANK
REACTION/RECYCLE
REHEATER
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOO ST - C
SPRAY TOWtR
4/78
COMBUSTION ENGINEERING
1
316L SS
NONE
FRP HEADERS, CERAMIC NOZZLES C1 LEVEL)
16
5C.O
256.71 ( 544000 ACFM)
52.2 ( 126 F>
655. (1C400 GPM)
2.5 < 19.0 GAL/1000ACF)
.6 ( 2.5 IN-H20)
9£.9
359
52.0
BOILER ID
CARBON STEEL
DRV
283.14 { 600000 ACFM)
CHEVRON
FRP
HORIZONTAL
3
c
1.07 < 3.5 FT)
8.9 ( 3.50 IN)
90 DEG.
1ST !TAGE, VERTICALUY UPWARD AND DOWNWARD; 2ND S
.2 ( 1.0 IN-H20)
2
FRP
HORIZONTAL
INTERMITTENT, HIGH PRESSURE WATER WASH DIRECTED
SJ2, SLURRY FLOWS, PH, X SOLIDS, PRESSURE CHANGE
PH=5.5-5.7
AUTOMATIC
FEEDEACK
PH PROBES IN REACTION TANKS
NUMBER
.* * *
2
3
* * * •
2
2
2
NUMBER
1
1
1
IN-LINE
HOT hATER
2i .8
50 F)
167
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KANSAS POUER & LIGHT: LAWRENCE 5 (CCNT.)
ENERGY REQUIRED
** WATER LOOP
TYPE
** REAGENT PREPARATION EQUIPMENT
NUMBER OF bALL MILLS
POINT OF ADDITION
•* TREATMENT
TYPE
INLET SOLIDS - T.
*• DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
1.25Z OF BOILER OUTPUT
CLOSED
REATION TANK
FORCED OXIDATION
1C.O
INTERIM
POND
ON-SlTE
16.0
FINAL
POND
ON-SITE
OVERFLOW FROM INTERIM SLUDGE POM)
? .0
FINAL
POND
ON-SITE
OVERFLOW FROM INTERIM SLUDCE POND
38.0
PERFORMANCE DATA — ————_. _,_
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/75 SYSTEM 744
»* PROBLENS/SOLUTIONS/COMMENTS
OIL AND GAS WERE FIRED IN JULY AND AUGUST. RESULTING IN NO FGD OPERATION.
8/75 SYSTEM 744
9/75 SYSTEM 720
** PROfaLENS/SOLUTIONS/COMMENTS
CAS AND OIL HERE BURNED ON A PART TIME BASIS DURING SEPTEMBER AND OCTOBER
BOILER OUTAGE WAS DUE TO INSPECTION AMD TURBINE REPAIR. *
ADDITIONAL BOILER OUTAGE WAS DUE TO REPLACEMENT OF THE SLURRY TANK SCREEN.
SYSTEM 744
SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
PROJECTIONS BY THE UTILITY FOR THIS UNIT CALL FOR 330 DATS OF OPERATION
ON 1S76 WITH FUEL CONSUMPTION BEING 60X COAL, 251 FUEL OIL, AND
15X NATURAL GAS.
LIKE UNIT 4 THIS UNIT MAY BE CONVERTED TO A ROD-DECK VENTURI AND SPRAT
TOWER SCRUBBING SYSTEM.
10/75
11/75
12/75
1/76
2/76
SYSTEM
SYSTEM
SYSTEM
744
744
696
168
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
KANSAS POWER & LIGHT: LAURENCE 5 (CCNT.)
— PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROfaLEMS/SOLUTIONS/COMMENTS
3/76 SYSTEM
4/76 SYSTEM
5/76 SYSTEM
6/76 SYSTEM
7/76 SYSTEM
8/76 SYSTEM
9/76 SYSTEM
NO INFORMATION UAS REPORTED BY THE UTILITY FOR THE PERIOD.
720
744
720
744
744
720
10/76 SYSTEM
•* PRObLEMS/SOLUTIONS/COMMENTS
744
THE BOILEK FIRES NO. 2 FUEL OIL IN ADDITION TO LOU SULFUR WYOMING CCAL
WHILE THE NEW SCRUBBING FACILITIES ARE BEING INSTALLED. THE ORIGINAL
INJECTION AND TAIL-END SCRUBBING SYSTEM IS STILL AVAILABLE FOR SERVICE
AND OPERATED WHEN THE UNIT FIRES COAL. THE SYSTEM WILL TREAT FLUE GAS
RESULTING FROM THE BURNING OF LOW SULFUR (0.5 PERCENT) WYOMING COAL.
THE UTILITY REPORTS THAT THE INSTALLATION OF THE NEW ROD AND SPRAY TOWER
SCRUBBING SYSTEM IS NOW IN PROGEESS. THE SYSTEM WILL CONSIST OF TWO SCRUB-
BING TRAIKS EACH HANDLING 53X OF TMt FLUE GAS CAPACITY. FOUNDATION
AND STRUCTURAL STEEL ERECTION HAS BEEN COMPLETED, AND SOME OF THE BREECH-N
ING HAS BEEN INSTALLED. THE UNIT WILL OPERATE IN A FULLY AUTOMATIC MODE.
KP8L REPORTED THAT C-E HAS ENCOUNTERED SOME PROBLEMS WORKING OUT AND FINE
TUNING SOKE OF THE LOGIC CIRCUITS.
11/76 SYSTEM
12/76 SYSTEM
•* PRObLEMS/SOLUTIONS/COMMENTS
72E
744
1/77 SYSTEM
2/77 SYSTEM
3/77 SYSTEM
4/77 STSTEM
KP&L REPORTED THAT CONSTRUCTION OF THE NEW SCRUBBING SYSTEM IS STILL IN
PROGRESS. THE ERECTION OF THE STRUCTURAL STEEL AND BREECHING IS
CONTINUING. THE MODULES ARE NOW BEING ERECTED AT THE PLANT SITE,
PARALLEL TO THE EXISTING MARBLE-BED SYSTEM.
744
672
744
720
5/77 STSTEM
6/77 SYSTEM
•* PRObLEMS/SOLUTIONS/COMMENTS
744
720
7/77 SYSTEM
OPERATION OF THE EXISTING MARBLE BED SCRUBBERS HAS BEEN QUITE SATISFACTORY
AND NEARLY PROBLEM FREEL. THE CONNECTING DUCTWORK IS CURRENTLY BEIK6 IN-
STALLED LED AS CONSTRUCTION CONTINUES. THE TWO PARALLEL SCRUBBING MODULES
EACH DESIGNED TO HANDLE 200 MW OF GENERATING CAPACITY ARE INSTALLED, AS
ARE THE REHEATER TUBE BUNDLES. THE EXISTING MARBLE BED SCRUBBERS WILL BE
REMOVED WHEN THE NEW SCRUBBING SYSTEM IS READY FOR SO 2 REMOVAL OPERATIONS.
744
169
-------
EPA UTILITY FCiD SURVEY: FOURTH QUARTER 1979
KANSAS POhER k. LIGHT: LAWRENCE 5 (CONT.)
PERFORMANCE DATA ..._._
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/77 SYSTEM 744
9/77 SYSTEM 730
** PRObLEMS/SOLUTIONS/COMMENTS
THE CONSTRUCTION ON THE NEW SCRUBBER PLANT IS CONTINUING ACCORDING TO
SCHEDULE AND IS EXPECTED TO BE COMPLETE BY APRIL 1978. KP*L INDICATED
THAT MORE DETAILED INFORMATION WOULD BE AVAILABLE FOR THE NEXT REPORT.
10/77 SYSTEM 744
•* PROBLEMS/SOLUTIONS/CCMMENTS
THE SYSTEM OPERATED UNDER NORMAL CONDITIONS THROUGHOUT OCTOBER AND
NOVEMBER UITH NO PROBLEMS.
11/77 SYSTEM 7ZC
12/77 SYSTEM 744
•* PKOoLEMS/SOLUTIONS/COMMENTS
THE CONSTRUCTION OF THE RO:-DECK SCRUBBERS IS NOW COMPLETE. THE INLET
DUCTWORK IS BEING INSTALLED, AND THE OUTLET DECTWORK WILL BE INSTALLED
ALONG WITH ADDITIONAL CONTROLS DURING THE SCHEDULED OUTAGE IN APRIL 1978,
THE PRESENT FGD SYSTEM OPERATED WITHOUT ANY PROBLEMS.
1/78 SYSTtM 744
2/78 SYSTEM 673
** PRObLEMS/SOLUTIONS/COMNENTS
THE ORIGINAL FGD SYSTEM WAS PULLED OFF LINE ON MARCH iC SO THAT THE NEW
SCRUBBER-ABSORBER SYSTEM COULD BE TIED INTO THE GAS PATH. THIS NEW SYSTEM
CONSISTS OF TWO MODULES EACH WITH A ROD SCCTION FOR PARTICULATE REMOVAL
AND A SPRAY TOWER FOR S02 REMOVAL. THE CAPACITY IS 2MJ MW EACH MODULE.
INITAL OPERATION SHOULD BEGIN BY THE FIRST OF MAY.
3/78 SYSTEM 744
4/78 SYSTEM 72Q
** PROfaLEMS/SOLUTIONS/COMMENTS
THE NEW UMT WENT IN SERVICE ON APRIL 14 AND HAS OPERATED UITH NO OUTAGES
SINCE START-UP.
5/78 SYSTEM 744
6/78 SYSTEM 720
•* PRObLEMS/SOLUTIONS/COMMfcNTS
THE BOILER OPERATED ALL BUT TWO DAYS OF THE JUNE-JULY PERIOD, WHEN A
BOILER DRAIN LINE LEAK CAU !ED AN OUTAGE.
THE fGD SYSTEM OPERATED THE ENTIRE TIME THE BOILER WAS ON-LINE, WITH NO
REPORTED PROBLEMS.
7/78 SYSTEM 744
8/78 SYSTEM 7I>I>
170
-------
EPA UTILITY FGD SURVEY: fOURTH QUARTER 1979
KANSAS POWER 4. LIGHT: LAWRENCE 5 (CCNT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOf
PROBLEMS/SOLUTIONS/COMMENTS
9/78
10/78
11/78
12/78
1/79
2/79
3/79
4/79
5/79
6/79
7/79
8/79
9/79
THE SYSTEM RAN WITH NO FORCED OUTAGES DURING THE AUGUST-SEPTEMBER PERIOD.
THE UNIT WAS TAKEN DOWN AT THE END OF SEPTEMBER FOR A SCHEDULED TyO WEEK
TURBINE/BOILER OUTAGE. ROUTINE MAINTENANCE IS BEING PERFORMED ON THE
BQILE R ANb TURBINE.
SYSTEM
SYSTEM
•• PRObLEMS/SOLUTIONS/COMMENTS
744
THE SYSTEK RAN THROUGHOUT THE PERIOD WITH ONLY ONE OUTAGE FOR AN ANNUAL
ONE-WEEK BOILER/TURBINE INSPECTION IN OCTOBER.
SYSTEM 72C
SYSTtM 744
*« PROuLEMS/SOLUTIONS/COMMENTS
A 30 HOUR OUTAGE WAS REQUIRED DUE TO A RUPTURED PIPE.
SYSTtM 744
SYSTEM 672
SYSTEM 744
SYSTtM 72C
SYSTEM 744
«• PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS BROUGHT DOWN TO 1/2 CAPACITY FOR A SCHEDULED 3 WEEK
OUTAGE TO REBUILD AN AIR PREHEATER FAN MOTOR.
10/7"
11/79
12/79
SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
720
THE UTILITY REPORTED THAT THE SYSTEM RAN WELL. THE ONLY FGD SYSTEM RELATED
OUTAGES WEfcE DUE TO MIXER FAILURE AND GENERAL MAINTENANCE.
SYSTEM
SYSTEM
SYSTEM
«• PRObLEMS/SOLUTIONS/COMMENTS
744
744
720
SYSTEM
SYSTEM
SYSTtM
THE UNIT OPERATED NORMALLY THROUGHOUT THE THIRD QUARTER. THE UNIT WILL
COME DOWN (01! THE ANNUAL FALL OUTAGE ON THE 1STH OF OCTOBER. DURING THE
OUTAGE SOME BOILER WORK WILL BE DONE. THE SCRUBBER WILL BE CLEANED AND
MAINTENANCE WORK WILL BE PERFORMED ON THE MIXERS. THE OUTAGE IS TO LAST
TWO WEEKS.
744
72 C
744
171
-------
EPA UTILITY F&D SURVEY: FOURTH QUARTER 1979
KANSAS PObER £ LIGHT: LAWRENCE 5 (CtNT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTO*
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FOR APPROXIMATELY 10 DAYS OF SCHEDULED OUTAGE FOR FALL
MAINTENANCE.
SOME AGITATOR SHAFT FAILURES OCCURRED IN THE REACTION TANK CAUSING
MAINTENANCE ATTENTION.
172
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F60 SYSTEMS
COMPANY NAME
PLANT MAKE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mti
NET UNIT GENERATING CAPACITY W/FGD - MU
NET UNIT GENERATING CAPACITY UO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MU
*» BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
• * FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** MECHANICAL COLLECTOR
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
PRESSURE DROP - KPA
** PARTICULATE SCROBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID RtCIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - 6/CU.M
S02 INLET CONCENTRATION - PPH
• * F6D SYSTEM
SALEABLE PROOUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
KENTUCKY UTILITIES
GREEN RIVER
1-3
CENTRAL CITY
KENTUCKY
42.
718.
242.0
64.0
60.0
62.0
64.0
BABCCCK ft WILCOX
PULV fRIZED COAL
PEAKING
0/5i I
169.88
148.9
50.
4.9
< .097 LB/MMBTU)
( 1.670 LB/MMBTU)
( 360000 ACFH>
< 300 F)
( 1t>5 FT)
( 16.0 FT)
COAL
BITUMINOUS
255?6.
13.40
( 11000 BTU/LB)
12.10
***** *
4.00
******
CYCLONES
WESTERN PRECIPITATION
X 85.C
49.5 ( 105000 ACFH)
******* (***** IN-H20)
VENTURI
AMERICAN AIR FILTER
1
MILD STEEL
ACID PROOF PRCCRETE
STAINLESS STEEL THROAT
SPINNER VANE
100.0
136.0 t 288200 ACFM)
52.2 < 126 F)
85.7 ( 1360 6PM)
4.6 (34.5 GAL/1000ACF)
******* {***** IN-H20)
5.0 ( 2.20 GR/SCF)
220C.OOO
THROUAUAY PRODUCT
WET SCRUBBING
LIME
NONE
AMERICAN AIR FILTER
FLUOR - PIONEER
FULL SCALE
RETROFIT
173
-------
EPA UTILITY FGD SURVEY: FOURTH UUARTER 1979
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
PARTICULAR DESIGN REKCVAL EFFICIENCY - 7.
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWAROE 0
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLOU - CU.M/S
GAS TEMPERATURE - C
LIOUID REC1RCULATI ON RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
PARTKULATE OUTLET LOAD- G/CU.PI
S02 INLET CONCENTRATION - PPM
S02 OUTLET CONTRATION - PPM
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
** MIST ELIMINATOR
NUMBER
TYPE
CONFIGURATION
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
SENSOR LOCATION
•* PUMPS
SERVICE
SCRUBBER/ABSORBER RECIRCULATIOK
SLURRY TRANSFER
POND RETURN
BLEED STREAM
** TANKS
SERVICE
SLAKED SLURRY 6ILUTION/HOLDING TANK
REACTION/RECYCLE
SLAKING TANK
** REHEATER
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
•* WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
*• REAGEUT PREPARATION EQUIPMENT
POINT OF ADDITION
99.50
til .00
6/76
9/75
4/74
6/71
.0
.0
MOBILE PACKED TOWER
9/75
AMERICAN AIR FILTER
1
20X2CX27.5
CARBON STEEL
.75 IN. ACID PROOF PRECRETE REFRACTORY COATING
SOLID POLYURETHANE BALLS, CERAMIC NOZ2LES
10C.O
15 «.00
52.2
614.
4.5
1.0
4.3
.1
22QC
400
1
SCRUBBER FD
CARBON STEEL
DRY
169.88
CHEVRON
HORIZONTAL
288?00 ACFM)
126 F)
9750 GPM)
34.0 GAL/100CACF)
4.0 IN-H20)
14.0 FT/S)
.044 GR/SCF>
( 360000 ACFM)
S02, &AS FLOW PRESSURE DROP, PH, PERCENT SOLIDS
PH-5 TO 8.5; 101 SOLIDS IN RECYCLE
PH-REACTANT TANK; DENSITY METERS-RECYCLE LINE
NUMBER
NUMBER
** **
1
2
1
HOT AIR INJECTION
STEAM
22.2 ( 40 F)
CLOSED
4.7
75 GPM)
DRY STORAGE BIN INTO SLAKER
174
-------
10/75 SYSTEM
11/75 SYSTEM
12/75 SYSTEM
1/76 SYSTEM
74.0
42.0
65. C 78.0
11.0 14.0
35. r
9.'
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
«* DISPOSAL
NATURE FINAL
TYPE LINED POND
LOCATION ON-SITE
TRANSPORTATION PUMPED
AREA - ACRES 7.4
CAPACITY - CU.M 233629 ( 166.5 ACRE-FT)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEKABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/75 SYSTEM 72C
** PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEK BECAME OPERATIONAL SEPTEMBER 13, 1975 ON A HALF-LOAD BASIS
BECAUSE OF TURBINE OVERHAUL LOGGING OF OPERATING DATA BEGAN DECEMBER
1975.
74 A
72 C
744 398 257
744 572 64
** PRObLEMS/SOLUTlONS/CONMENTS
A MAJOR PkObLEM WAS FAILURE OF THE RECYCLE PUMPS.
THAWING AND REPAIR OF NUMEROUS FROZEN LINES WAS REQUIRED.
SHUTDOWN OF SUMP PUMPS WAS NECESSARY.
A MAJOR PROBLEM AREA MAS THE FEED TANK AGITATOR.
2/76 SYSTEM 7C.O 42.0 42.0 30.0 696 499 211
** PRObLEMS/SOLUTIONS/COMMENTS
REPAIRS WERE MADE TO THE TANK AGITATORS, SLAKE TANKS AND MIX-HOLD TANKS
CONTRIBUTING TO OUTAGE TIME.
REPAIRS AMD CLEANOUT OF RE<»CTANT PUMPS CONTRIBUTATED TO OUTAGE TIME.
3/76 SYSTEM 97.0 85.0 95.0 52.? 744 458 386
** PRObLEMS/SOLUTIONS/COMMENTS
ALL RUBbEh-LINED IMPELLERS WERE REPLACED IN THE PUMPS.
72u 552 552
744 456 456
720 597 589
744 584 574
744 744 722
** PRObLEMS/SOLUTIONS/COMMENTS
VIBRATION IN THE SCRUBBER BOOSTER I.D. FAN NECESSITATED SYSTEM SHUTDOWN
AND R EPAIh.
9/76 SYSTEM 86.0 1CC.O 103.0 79.C 72C 571 571
4/76
5/76
6/76
7/76
8/76
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
90.0
81.0
100.0
9C.O
97.0
100.0
1CO.O
99. n
98.0
97.0
100.0
103.0
99.0
99. C
97.2
77.0
61. C
62. C
72.0
97. C
175
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
PERFORMANCE DATA — —.. --„...
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTO*
** PRObLEMS/SOLUTIONS/COMMENTS
MINOR FAN PROBLEMS OCCURRED BUT NO FORCED OUTAGE TIME WAS REQUIRED.
HALF-LOAD OPERATIONS WERE CONDUCTED THROUGHOUT THE PERIOD BECAUSE Of
BEARING PROBLEMS TO ONE OF THE TWO TURBINE GENERATING UNITS.
10/76 SYSTEM 100.0 100.0 100.0 94.Q ?** 699 699
11/76 SYSTEM 100.0 100.0 98.0 98.0 720 704 704
** PROBLEMS/SOLUT10NS/COMHENTS
DURING NOVEMBER AND DECEMBER, 1976 SOME FLUE GAS HAS BY-PASSED AROUND
THE SYSTEM WHILE THE UTILITY CONDUCTED A CHECKOUT OF THE SCRUBBER INTEftHAl
AND REPLACED SOME OF THE PACKING SPHERES IN THE MOBILE BED.
12/76 SYSTEM 73.0 97.0 87.0 70.0 744 536 517
1/77 SYSTEM 94.0 94.0 94.0 94.0 744 744 698
*« PROBLEMS/5OLUTIONS/COMMENTS
DURING THE MONTH OF JANUARY NO PROBLEMS OCCURRED.
2/77 SYSTEM 36.0 91.0 91.0 36.0 672 266 243
*• PROBLEMS/SOLUTIONS/COHMENTS
DURING THE MONTH OF FEBRUARY IT WAS FOUND THAT THE CARBOLINE STACK LINER
WAS BADLY DETERIORATED. SCRUBBER AND BOILER OPERATIONS WERE TERMINATED
UNTILL THE STACK LINING WAS REPAIRED. THE STACK WAS REPAIRED FIRST bV
WELDING A BACKUP METAL PLATE TO THE PORTIONS OF THE STACK WHERE PITTING
OCCURRED. THE ENTIRE STACK WAS THEN LINED WITH REFRACTORY COATING CALLED
PRECRETE G-8 BY AAF. THE REPAIRS WERE COMPLETED MARCH 7.
THE bOILER IS NOT OPERATED WITHOUT THE SCRUBBER BECAUSE THERE IS NO ESP
FOR PARTICULATE CONTROL.
744 0 0
72C 167 164
744 527 513
720 34 34
• * PROBLEMS/SOLUTIONS/COMMENTS
WORK ON THE SCRUBBER MODULE INCLUDED REPAIRS TO THE UNOERBED DAMPER
SYSTEM AND LEAKING IN THE VENTURI.
LIME SLAKING OPERATIONS WA ! REPAIRED.
7/77 SYSTEM .0 744 Q C
** PRObLENS/SOLUTIONS/COMMENTS
A STRIKE 6V PLANT OPERATING PERSONNEL RESULTED IN BOILER AND FGD SYSTEM
SHUTDOWN.
8/77 SYSTEM .0 744 0 0
9/77 SYSTEM ,C 720 0 0
10/77 SYSTEM .5 744 Q Q
11/77 SYSTEM 86.0 91.0 91.0 41.0 720 332 301
176
3/77 SYSTEM
4/77 SYSTEM
5/77 SYSTEM
6/77 SYSTEM
.0
40.0
(9.0
100.0
98.0
98.0
100.0
98.0
98.0
100.0
.0
23. P
69. C
5.0
-------
tPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
fENTUCKY UTILITIES: GREEN RIVER 1-3
-------
EPA UTILITY FbO SURVEY: FOURTH QUARTER 1979
KENTUCKY UTILITIES: GREEN RIVEP 1-3 (cONT.)
PERFORMANCE DATA ..__.
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
•* PRObLEMS/SOLUTlONS/COMMENTS
THE FGD SYSTEM EXPERIENCED RECYCLE TANK SCREEN PLUGGING.
THE FGD SYSTEM EXPERIENCED VIBRATING FAN PROBLEMS.
11/78 SYSTEM 24.0 100.0 74.0 24.0 720 175 175
** PRObLENS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN THE LAST TWO WEEKS OF NOVEMBER DUE TO LOW LOAD DEMAND.
12/78 SYSTEM .0 «C 744 0 0
1/79 SYSTEM .0 .0 .0 .? 744 1 C
2/79 SYSTEM .0 ." 672 0 0 .0
** PRObLEMS/SOLUTlONS/COMMENTS
THE PROBLEMS IK JANUARY AND FEBRUARY WERE A RESULT OF FREEZING WEATHER.
3/79 SYSTEM 11.2 10C.C 100.0 11.2 744 83 83
** PROuLEMS/SOLUTIONS/COMMENTS
THE LOW OPERATIONAL HOURS FOR MARCH AND APRIL WERE DUE TO RECYCLE PUMP
PROBLE MS.
4/79 SYSTEM 18.2 1CC.O 102.0 18.2 720 131 131
5/79 SYSTEM .C •C 744 ° 0.0
•* PRObLEMS/SOLUTlONS/COMMENTS
THE BOILER WAS TAKEN DOWN IN MAY FOR REPAIRS THAT ARE PROJECTED TO LAST
THROUGH THE END OF SEPTEMBER.
6/79 SYSTEM 100.0 -c 7Z& 0 C .0
*« PRObLEMS/SOLUTlONS/COMMENTS
THE UNIT REMAINED OUT OF SERVICE DURING JUNE FOR BOILER REPAIRS. IT IS
NOT EXPECTED TO RETURN TO SERVICE UNTIL OCTOBER OR NOVEMBER.
7/79 SYSTEM 102.0 •- 744 0 0
8/79 SYSTEM 100.0 .0 744 0 C
9/79 SYSTEM 100.0 .C 720 0 0
• * PRObLEMS/SOLUTlONS/COMMENTS
THE BOILER REMAINED OUT OF SERVICE DURING JULY, AUGUST AND SEPTEMBER. THE
BOILER TEMPERATURE VALVES AND PIPING BETWEEN THE PRIMARY AND SECONDARY
SUPERHEATERS MUST STILL BE REPLACED. THE BOIL£R IS NOT EXPECTED TO RETURN
ON LINE UNTIL THE FIRST OF THE YEAR OR POSSIBLY AS LATE AS MARCH.
THE NEW INDIRECT REHEAT SYSTEM IS IN PLACE AND READY FOR OPERATION AS SOON
AS THE BOILER RETURNS TO SERVICE.
10/79 SYSTEM 100.0 .0 744 0 0
11/79 SYSTEM 100.0 .0 720 0 C
12/79 SYSTEM 100.0 .0 744 0 0
178
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILEH FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROtfLEMS/SOLUTIONS/COMMENTS
WORK IS CONTINUING ON THE REPAIRS OF THE OLD BOILER. THE UNIT MAY BE
SHUT DOWN INTO MARCH 1980. THE FGD SYSTEM UAS AVAILABLE THROUGHOUT THE
PERIOD BUT WAS NOT OPERATED.
179
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMbEH
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - t«G/J
502 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mt,
NET UNIT GENERATING CAPACITY W/FGO - My
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
LOUISVILLE GAS & ELECTRIC
CANE RUN
4
LOUISVILLE
KENTUCKY
D
5C.
516.
992.0
188. 0
175.0
175.0
188.0
( .116 LB/MNBTU)
( 1.200 LB/MMBTU)
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•* ESP
NUMBER
TYPE
PARTICIPATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
*• PARTICULATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDSD
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
DIMENSIONS - FT
SHELL MATERIAL
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/6?
346.37
16C.O
76.
( 734000 ACFM)
< 320 F)
( 250 FT)
<*„*., ft)
COAL
BITUMINOUS
26749.
17.10
15.5-Z4.5
9.00
8.0-10.75
3.75
3.5-4.0
.04
0.03-0.06
1
COLD SIDE
- X 99.0
346.4
160.0
NONE
THROUAWAV PRODUCT
WET SCRUBBING
LIME
AMERICAN AIR FILTER
FLUOR - PIONEER
FULL SCALE
RETROFIT
- X 99.00
85.00
9/77
8/76
10/74
4/74
.0
.0
MOBILE PACKED TOWER
8/76
AMERICAN AIR FILTER
20 X 20 X 27.5
CARBON STEEL
( 11500 BTU/LB)
10,400-11,900
< 734000 ACFM)
< 320 F)
180
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1579
LOUISVILLE GAS fc ELECTRIC: CANE RUN A (CONT.)
SHELL LINER MATERIAL
INTERNAL HATERIAL
BOILER LOAD/ABSORBER - X
bAS FLOW - CU.M/S
GAS TEMPERATURE - C
L/G RATIO - L/C U.H
PRESSURE DROP - (CPA
S02 DESIGN REMOVAL EFFICIENCY - X
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
*« WIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
MUMPER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE ' M
VANE ANGLES
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
*• PUMPS
SERVICE
ABSORBER REC1RCULATION
TANKS
SERVICE
REACTION
REHEATED
TYPE
TEMPERATURE BOOST - C
THICKENER
NUMBER
DIAMETER - M
WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION
TREATMENT
CONTRACTOR
DISPOSAL
NATURE
TYPE
LOCATION
PRECRETE AND PLASITE 4035
POLYURETHANE BALLS, CERAMIC NOZZLES
5.0
173.52 I 367700 ACFM>
16C.O ( 330 F)
£.0 ( 6C.G GAL/100CACF)
1.0 ( 4.0 IN-H20)
87.5
SCRUBBER FD
CARBON STEEL
DRY
173.19 ( 3670UO ACFM)
CHEVRON
ss, PLASITE 4005 LINING
22.9
OPEN
LUERS/S 6.3
IUCS
FINAL
LINED POND
ON-S1TE
< 75 FT)
( 100 GPN)
PERFORMANCE I DATA
PERIOD MODULE AVAILABILITY OPERA8IL1TV RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/76 SYSTEM 9C.O
•* PROULEMS/SOLUTIONS/COMMENTS
90.0
744
740
666
OUTAGE TIKE DURING THE MONTH WAS DUE PRIMARILY TO EQUIPMENT INSPECTIONS,
REPAIR/REPLACEMENT OF AUXILIARY MOTOR PARTS. AND DEPLETION OF ABSORBENT
SUPPLY BECAUSE OF A LATE B JR6E DELIVERY.
THE SCRUBBING SYSTEM HAS BEEN GENERALLY OPERATING AT APPROXIMATELY 50 TO
8CZ FLUE GAS CAPACITY.
SOME MINOR PROBLEMS HAVE BEEN ENCOUNTERED WITH AUXILIARY EQUIPMENT MOTORS.
181
-------
EPA UTILITY FOD SURVEY: FOURTH QUARTER 197?
LOUISVILLE CAS it ELECTRIC: CANE PUN 4 (CONT.)
PERFORMANCE DATA -— -
PERIOD MODULE AVAILABILITY OPESABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 FART. HOURS HOURS HOURS FACTOR
SOME MINOfc PROBLEMS HAVE BEEN ENCOUNTERED WITH SPRAY NOZZLES IN THE MOBILE
BED CONTACTOR. THE SPRAY NOZZLES ARE SPINNER-VANS COMPONENTS ORIGINALLY
CONSTRUCTED OF PLASTIC. OPERATING TEMPERATURES AND PRESSURES HAVE CAUSED
THt PL«STIC HOUSING TO EXPAND RESULTING IN THE VANES EXTRUDING OUT THE
FRONT ENOt SUBSEQUENTLY CAUSING A BLOCKAGE OF TNE SLURRY FEED. THE
NOZZLES HAVE BEEN REPLACED WITH CERAMIC CONSTRUCTED COMPONENTS.
9/76 SYSTEM 9:.C 90.C 730 720 65C
10/76 SYSTEM 93.0 73.0 744 600 540
** pRObLEMs/sOLUTIONS/COMMENTS
THE UNIT &.AS TAKEN OUT OF SERVICE ON OCTOBER 25. 1976 TO IMPLEMENT
ADDITIONAL MODIFICATIONS TO THE SCRUBBING SYSTEM. MAJOR SYSTEM MODIFICA-
TIONS INCLUDE INCREASING PUMP CAPACITY AND DECREASING PRESSURE DROP.
THESE TWO PROBLEMS HAVE HINDERED OPERATION OF THE UNIT AT FULL LOAD
CAPACITY.
TC BATE, THE MECHANICAL RELIABILITY OF THE SYSTEM AS A FUNCTION Of
S£RVIC£ TINE VERSUS OUTAGE TIME, HAS BEEN VERY GOOD.
11/76 SYSTEM 95.C 72G
1Z/76 SYSTEM 9C.O 74g ?2Q 0 c
182
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
LOUISVILLE faAS & ELECTRIC: CANE fOjN 4
PERFORMANC E DATA
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/77 SYSTEM 93.0 43.6 83.70 744 360 324
** PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEK WAS PLACED BACK IN SERVICE ON JULY 17, 1977 AFTER SYSTEM
MODIFICATIONS WERE COMPLETED.
8/77 SYSTtM 94.C ' 93.0 83.90 744 657 588
** PROULENS/SOLUTIONS/COMNENTS
COMPLIANCE TESTING OCCURED DURING AUGUST AND SEPTEMBER 1977 BY EPA
PERSONNEL AND WAS OFFICIALLY APPROVED TO HAVE ACHIEVED COMPLIANCE.
9/77 SYSTEM 99.3 99.C 720 539 524
10/77 SYSTtM 99.0 98.0 99.0 69.0 64.30 744 677 662
** PkOuLEMS/SOLUTIONS/COMMENTS
DURING DECENBERt "A1RCO", THE LIME SUPPLIERt HAD 1200 FT OF THEIR FEED
LINE FREEZE UP.
83.70 720 *83 453
744 715 608
744 742 494
** PROBLEMS/SOLUTIONS/COMMENTS
LINE BECAME UNAVAILABLE FOR A TIME BUT THERE HERE NO SCRUBBER BREAKDOWNS.
2/78 SYSTEM .0 672 0 C
«« PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN THE ENTIRE MONTH OF FEBRUARY DUE TO A COAL SHORTAGE
AND A LACK. OF AVAILABLE LI« RESULTING FROM THE SEVERE WINTER WEATHER.
THE UNIT CAME BACK ON LINE MARCH 21. 1978.
J/78 SYSTEM 33.5 34.n 744 249
4/78 SYSTEM 100.0 1C3.0 100.0 <«7.0 720 303 303
.» PfcObLEMS/SOLUTlONS/COMMENTS
DURING APRIL THE BOILER WAS DOWN FOR REPAIRS.
5/78 SYSTEM 31.0 35.0 35.0 12.0 744 352 115
*• PRObLEMS/SOLUTIONS/COMMENTS
THE BOILEfc WAS DOWN AGAIN IN MAY FOR REPAIRS.
DURING THE MAY BOILER OUTAGE A NUMBER OF MODIFICATIONS WERE MADE TO THE
DAMPERS IK THE FGD SYSTEM.
6/78 SYSTtM 99.3 99.: 99.3 99.C 720 720 715
7/76 SYSTtM 98.8 99.0 98.7 91.0 744 687 678
8/78 SYSTtM 94.0 94.C 744 744 701
9/78 SYSTEM 1CO.O 19.0 720 138 13?
11/77 SYSTEM
12/77 SYSTEM
1/78 SYSTEM
96.0
85.0
90.0
94.0
85.:
67.?
94.0
100.0
87.0
63.0
82.0
67.0
183
-------
EPA UTILITY F(jD SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS 8. ELECTRIC: CANE RUN 4 7906 0 - .0
6/79 SYSTEM 46.2 17.1 720 266 123
** PROuLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED DOWN DURING HAY FOR CONTINUED REPAIRS AT THE BOILER.
THE UNIT WAS PLACED BACK IN SERVICE IN JUNE.
7/79 SYSTEM 99.3 «•? 7" 701 692
8/79 SYSTEM 89.0 89.C 744 744 664
9/79 SYSTEM .0 .0 720 168 0
•• PROfaLENS/SOLUTIONS/COMHENTS
THE ONLY MAJOR PROBLEMS OCCURRED DURING SEPTEMBER. TUBE FAILURES MERE
ENCOUNTERED CAUSING THE BOILER OUTAGE AND MECHANICAL FAILURE WITH THE
DAMPER GATES CAUSED THE SCRUBBED DOWNTIME.
10/79 SYSTEM 3C.1 12.0 744 296 89
11/79 SYSTEM 93.9 58.1 720 44S 418
12/79 SYSTEM 38.5 20.2 744 390 15Q
•* PRObLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER 1979 THERE WERE NO MAJOR PROBLEMS. THE LOW
SCRUBBER HOURS WERE A RESULT OF NECESSARY MAINTENANCE.
184
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA fOR OPERATIONAL DOMESTIC f&6 SYSTEMS
COM PANT MAKE
PLANT NAME
UNIT NUMBE*
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - *h
NET UNIT GENERATING CAPACITY W/FGO - My
NET UNIT GENERATING CAPACITY UO/FGb - MW
SCRUBBED CAPACITY - Mfc
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASM CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - 2
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** ESP
NUMBER
TYPE
PARTICIPATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
*• PARTICULATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODUC T/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEU/HETROf IT
PARTICULATE DESIGN REMOVAL EFFICIENCY
so2 DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDS D
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
( .116 LB/MMBTU)
( 1.200 LB/MMBTU)
LOUISVILLE CAS & ELECTRIC
CANE RUN
5
LOUISVILLE
KENTUCKY
0
50.
516.
993.C
200.0
192.0
195.0
20C.O
RILEV STOKER
PULVERIZED COAL
BASE
0/66
306.73 t 650000 ACFM>
162.8 ( 325 F)
( 250 FT)
(***** n
< 11500 BTU/LB)
10,400-11.900
< 650000 ACFM)
< 325 F)
76.
*******
COAL
BITUMINOUS
26749.
17.10
15.5-24.5
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS & ELECTRIC: CANE RUM 5 (CONT.)
SHELL MATERIAL
SHELL LINER MAT ERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
NOZZLE TYPE
BOILER LOAD/ABSORBfcR - X
GAS FLOW - CU.M/S
GAS TEKPtRATURE - C
LIQUID RtCIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - N/SEC
S02 DESIGN REMOVAL EFFICIENCY - i
316L STAINLESS STEEL
PRECRETE
CERAMIC NOZZLES
84
CERAMIC
5t .0
153.37 ( 325030 ACFM)
16 i.8 < 325 F)
110!;. (17500 GPn>
7.4 ( 55.C GAL/100CACF)
.1 < .5 IN-H20)
2.1 { 7.0 FT/S)
91.C
FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - UET/DRY
CAPACITY - CU.M/S
FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SCRUBBER FD
CARBON STEEL
DRY
165.16 ( 350900 ACFM)
2
I . D.
CARBON STEEL
'* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSE S
MASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
>* MIST ELIMINATOR
NUMBER
NUMBER OF STAGES
'• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
SENSOR LOCATION
* PUMPS
SERVICE
ABSORBER RECIRCULATION
SPRAY PUMP
LIME FEED
THICKENER UNDERFLOW
WATER RECYCLE
MIST ELIMINATOR WASH
•• TANKS
SERVICE
RECYCLE
REACTION
LIME FEED
REHEATER
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
THICKENER
NUMBER
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
2
CHEVRON
FRP
HORIZONTAL
2
2
FRESH MAKE UP ONCE/24 H
2.1 ( 7.3 FT/S)
.1 ( .5 IN-H20>
PH
9-10 (RECYCLE SLURRY)
AUTOMATIC
REACTION TANK
NUMBER
2
Z
2
2
2
** * *
NUMBER
IN-LINE
STEAM
2 .2 ( 40 F>
1
RUBBER-LINED CARBON STEEL
33.5 (110 FT)
25.0
186
-------
EPA UTILITY FGt> SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS & ELECTRIC: CANE BUN 5 (CONT.)
>* WATER LOOP
TYPE
•* TREATMENT
TYPE
CONTRACTOR
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
OPEN
POZ-0-TEC
IUCS
FINAL
LINE C POND
ON-SITE
PIPELINE
, PERFORMANC I DATA
PERIOD HODULE AVAILABILITY OPERA3IL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
$02 PART. HOURS HOURS HOURS FACTOR
12/77 SYSTEM
** PRObLEMS/SOLUTIONS/CCMMENTS
71,1,
3/78
4/78
5/78
6/78
OPERATION OF THE FGD SYSTEM BEGAN ON DECEMBER 29, 1977. INITIAL OPER-
ATIONS WERE NOT CONTINUOUS.
1/78 SYSTEM
*« PRObLEMS/SOLUUONS/COMMENTS
744
SOME OF THE CONTROLS WERE NOT WORKING PORPERLY AND MODIFICATIONS WERE
NECE SSARY.
2/78 SYSTEM 672
** PfcObLEMS/SOLUTlONS/COMMENTS
THE PLANT REMAINED OFF LINE THROUGHOUT FEBRUARY AND RESTARTED ON MARCH 24.
VARIOUS INITIAL START-UP PROBLEMS WERE STILL BEING ENCOUNTERED CAUSING
FCD S YSTEK, OUTAGES.
7/78
8/78
9/73
10/78
SYSTEM 5C.C
SYSTEM 97.^
** PfiOcLEMS/SOLUTIONS/COMMENTS
12.2
90.0
744
720
182
669
94
648
FGD SYSTEK MODIFICATIONS WERE MADE DURING THIS TIME IN PREPARATION FOR
PERFORMANCE TESTS. HOWEVER, THE EPA TEST METHODS WERE NOT FOLLOWED
ACCURATELY.
SYSTEM
SYSTEM
66.8
84.?
86. ~
66.1
49.0
82.0
744
720
432
685
364
590
** PROfcLEMS/SOLUTIONS/CCNMENTS
THE STEAM REHEAT COIL INSTALLATION HAS BEEN A CHRONIC PROBLEM AREA. WELDS
HAVE BEEN FAILING EVER SINCE INITIAL OPERATIONS.
80.1
68.C
62.C
SYSTEM 83.1 s:.o
SYSTEM 86.0
«* PRObLEMS/SOLUTICNS/COMMENTS
PROBLEMS CONTINUED WITH THE REHEAT COILS.
SYSTEM 8C.O 67.0
SYSTEM 96.0 71.0
744
744
72 C
744
632
540
609
530
506
464
485
528
187
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD C AP ~~
S02 PART. HOURS HOURS HOURS FACTOR
•* PRObLEMS/SOLUTIONS/CCNNENTS
THE SYSTEM WAS SHUTDOWN FOR REPAIRS TO THE STEAM REHEATER COILS. THE
OUTAGE LASTED ABOUT TWO WEEKS.
11/78 SYSTEM 94.0 33.0 730 253 333
12/78 SYSTEM 54.7 46.2 46.2 40.6 74*. 654 302
1/79 SYSTEM 69.6 67.4 67.4 62.E 744 693 467
2/79 SYSTEM 7C.6 50.1 672 477 337
•* PRObLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY FREEZING CAUSED PROBLEMS WITH LIME DELIVERY.
3/79 SYSTEM 71.8 57.5 744 596 428
4/79 SYSTEM 99.? 49.6 730 360 357
•• PROfaLEMS/SOLUTIONS/CCMMENTS
SOME PROBLEMS WERE EXPERIENCED WITH DAMPERS AND THERE WERE PUMP FAILURES
5/79 SYSTEM 34.3 49.1 744 433 365
6/79 SYSTEM 77.1 58.2 720 544 419
•* PRObLEMS/SOLUTIONS/COMMENTS
THE ONLY PROBLEMS REPORTED BY THE UTILITY WERE SPRAY PUMP PACKING FAILURES
ANO WELDING FAILURES ON THE REHEATER.
7/79 SYSTEM 72.0 56.0 744 583 4ZC
8/79 SYSTEM 88.0 73.0 744 613 540
9/79 SYSTEM 84.0 54.C 720 469 393
•* PROBLEMS/SOLUTIONS/COMMENTS
THE WELDING PROBLEMS WITH THE REHEATER WERE ENCOUNTERED IN JULY AND
SEPTEMBER. THE FAILURES ARE CONTINUING AND ARE EXPECTED TO BE RESOLVED
BY THIS WINTER.
10/79 SYSTEM 83.7 65.6 744 583 488
11/79 SYSTEM 95.2 46.4 720 351 334
12/79 SYSTEM 82.2 63.4 744 574 47?
«• PRObLEMS/SOLUTIONS/COMHENTS
DURING THE FOURTH 8UARTER 1979 THE UTILITY REPORTED THAT NO MAJOR PROBLEMS
OCCURRED. THE UNIT REQUIRED ONLY NORMAL MAINTENANCE.
188
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
SOZ EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - Mw
GROSS UMT GiNERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY U/FGD - MU
NET UNIT GENERATING CAPACITY UO/FGO - My
EQUIVALENT SCRUBBED CAPACITY - Mb
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
** FUEL DATA
FUEL TYPt
FUEL GfcAbE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - Bill/IB
AVERAGE ASH CO.ITENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - %
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** ESP
NUMBER
TYPE
PARTICIPATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
• * PARTICIPATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PR00UC T/THROyAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
SO2 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
CONTRACT AWARDED
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL NATERIAL
LOUISVILLE GAS & ELECTRIC
CANE HUH
6
LOUISVILLE
KENTUCKY
50. <
516. (
992.0
288.0
?69.0
272.0
288.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/69
502.57
14S.9
.116 LB/MMBTU)
1.200 LB/MMBTU)
(1065003 ACFM)
t 3DO F>
< 518 FT)
( 16.0 FT)
C 11QOO BTU/LB)
10,400-11,900
(1C65C30 ACFM)
( 300 F)
158.
4.9
COAL
BITUMINOUS
255f6.
17.10
15.5-24.5
<.OQ
8.0-10.75
«.80
3.5-.«.3
.04
0.03-0.06
COLD SIDE
- X 99.4
502.6
148.9
NONE
THROWAUAY PRODUCT
MET SCRUBBING
DUAL ALKALI
AOL/COMBUSTION EQUIP ASSOCIATE
FLUOS - PIONEER
DEMORSTRATION
RETROFIT
95.00
4/79
10/76
2C.O
.3
TRAY TOMER
12/78
COMBUSTION EQUIP ASSOCIATES
2
32 DIA X 45
A283 CARBON STEEL
FLAKE REINFORCED POLYESTER
317L SS, 316 SS, FRP PIPING
189
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS & ELECTRIC: CANE PUN 6 (CONT.)
601LER LOAD/ABSORBER - X 6C.O
GAS FLOW - CU.M/S 251.39
GAS TEMPERATURE - C 8D.O
L/G RATIO - L/CU.M 1 .3
PRESSURE DROP - KPA 2.2
SUPERFICAL GAS VELOCITY - M/SEC 2.7
S02 INLET CONCENTRATION - PPM 3471
502 OUTLET CONTRATION - PPM 2CC
S02 DESIGN REMOVAL EFFICIENCY - X 95.0
** CENTRIFUGE
NUMBER 0
( 532500 ACFM)
( 176 F)
( 10.0 GAL/1000ACF)
( 9.0 IN-H20)
( 9.3 FT/S)
FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - MET/DRY
CAPACITY - CU.M/S
BOOSTER, CENTRIFUGAL
A441 CARBON STEEL
DRY
251.52 ( 533000 ACFM)
VACUUM FILTER
NUMBER
TYPE
CONSTRUCTION MA TERIAL
CAPACITY - M T/D
INLET SOLIDS - X
OUTLET SOLIDS - X
ROTARY-DRUM WITH WATER WASH
316 SS [FILTER DRUM}, FRPCBELT CLOTH3
684.8 ( 755 T/0)
25.0
63.0
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
FREEfcOARD DISTANCE - M
PRESSURE DROP - KPA
1
CHEVRON
POLYPROPYLENE
HORIZONTAL
1
A
1.52
.2
( 5.0 FT)
( 1.0 IN-H20)
** PUMPS
SERVICE
REACTOR TRANSFE R
ABSORBER RECIRCULATION
THICKENEK HOLD TANK TRANSFER
LINE SLURRY
SODA ASH
THICKENER UNDER FLOt.
VACUUM
«* TANKS
SERVICE
PRIMARY REACTION TANK
SECONDARY REACTION TArNK
FEED FORWARD TANK
FILTRATE SUMP
THICKENER HOLD TANK
NUMBER
2
4
2
2
2
2
3
NUMBER
2
2
** * *
*** *
** REHtATER
NUMB ER
TYPE
TEMPERATURE BOOST - C
ENERGY REQUIRED
** THICKENER
NUMBER
TYPE
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
"• WATER LOOP
TYPE
EVAPORATOR WATER LOSS - LITER/S
DIRECT COMBUSTION
27.8 ( 50 F)
2563JOOO BTU/HR FOR FLUE GAS PLUS 1282000 BTU/HR
1
FLAT BOTTOM
CONCRETE SHELL, CARBON STEEL INTERIOR, FLAKE REI
38.1 (125 FT)
25.0
CLOSED
17.5
( 278 GPU)
190
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
LOUISVILLE tAS fc ELECTRIC: CANE RUN 6 (CONT.>
** TREATMENT
CONTRACTOR
PRODUCT CHARACTERISTICS
** DISPOSAL
NATURE
TYPE
LOCATION
IUCS
2CASC3-H2C 18SX],CAS04 [10-15*3, CAC03 [5-10*3,N
FINAL
LINE C POND
ON-SITE
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
4/79 SYSTEM 43.3
** PRObLEMS/SOLUTIONS/CCMMENTS
37.9
62
475
237
THIS UNIT STARTED OPERATING ON APRIL 4, 1979. COMPLIANCE TESTING IS
SCHEDULED FOR THE WEEK OF JUNE 3.
5/79 SYSTEM
6/79 SYSTEM
21.5
12.3
PRObLEMS/SOLUTIONS/COMMENTS
14.7
10.3
744
720
5C6
601
109
74
THE UTILITY REPORTED THAT THE StSTfcM IS STILL CONSIDERED IN START-UP AND
THAT NO UNISUAL PROCESS PROELEMS HAVE BEEN ENCOUNTERED. HOWEVER THE SYS-
TEM IS NOW OUT OF SERVICE DUE TO THE COMPLETE FAILURE OF THE MIST ELIM-
INATORS. IT IS EXPECTED TO BE DOWN FOR A MONTH.
7/79 SYSTEM .0
** PRObLEMS/SOLUTIONS/CCMMENTS
.0
744
529
THE UNIT DID NOT OPERATE IN JULY AS PROCEDURES CONTINUED TO REPLACED THE
MIST ELIMINATORS.
8/79 SYSTEM 7.?
9/79 SYSTEM 6j.0
•• PRObLEMS/SOLUTIONS/COMMENTS
44.0
744
720
683
531
51
317
DUfclNC AUGUST AND SEPTEMBER THE UNIT DOWNTIME WAS DUE TO THE COMPLETE
FAILURE OF FIVE PUMPS. THE PUMP PROBLEMS WERE THE LOSS OF THE IMPELLERS
OFF OF THE SHAFTS.
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
81.4
97.7
94.9
28.9
63.5
89.7
744
720
744
246
468
703
215
457
667
** PROULEHS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS OCCURRED DURING THE FOURTH
QUARTER 1979. THE UNIT REQUIRED ONLY NORMAL MAINTENANCE.
191
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAPE
UNIT NUMfaEN
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGC - MU
EQUIVALENT SCRUBBED CAPACITY - My
*• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•* ESP
NUMBER
TYPE
SUPPLIER
*• PARTICIPATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODUCT/THROUAUAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
soz DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
GAS FLOW - CU.M/S
GAS TEMPtRATURE - C
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
- X
& ELECTRIC
( .100 LB/MMBTU)
C 1.200 LB/MMBTU)
LOUISVILLE GAS
MILL CREEK
3
LOUISVILLE
KENTUCKY
D
4*.
516.
107<5.C
442.0
420.0
427.0
442.0
BABCOCK K WILCOX
PULVERIZED COAL
BASE
0/78
.*..».** (...**** ACFM)
******* <**** f)
183. C 600 FT)
6.4 ( 21.0 FT)
COAL
BITUMINOUS
26749.
11.50
< 11500 BTU/LB)
3.75
3.5-4.0
.04
.345
COLD SIDE
AMERICAN AIR FILTER
NONE
THROUAUAY PRODUCT
MET SCRUBBING
LIME
AMERICAN AIR FILTER
FLUOR - PIONEER
FULL SCALE
NEW
99.00
85.00
3/79
8/76
MOBILE PACKED TOMER
8/78
AMERICAN AIR FILTER
CARBON STEEL
PRECRETE
POLYLRETHANE BALLS, CERAMIC NOZZLES
212.35 ( 45GOOO ACFM)
143.9 ( 300 F)
8-7 ( 65.0 GAL/100CACF)
1.6 ( 6.5 IN-H20)
192
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
LOUISVILLE tAb Ik ELECTRIC: MLL CREEK 3 (CONT.)
»* FANS
NUMPE"
TYPE
SERVICE - WET/D RY
CAPACITY - CU.M/S
.* «IST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
MASH SYSTEM
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
** REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
•* TREATMENT
TYPE
** DISPOSAL
NATURE
TYPE
SCRUPBER FD
DRY
312.35
( 450000 ACFM)
CHEVRON
PLAS TIC
HORIZONTAL
I
2
FRESH MAKE-UP (RIVER)
CHEVRON
316SS
HORIZONTAL
IN-LINE
STEAM
2 1.8
OPEN
S.4
50 F>
( 150 6PM)
FLYASH/LIME STABILIZATION
FINAL
POND
_ --PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1T* RELIABILITY UTILIZATION \ REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/78
SYSTEM 744
*« PRObLEMS/SOLUTIONS/COMMENTS
OPERATION BEGAN ON AUGUST 13, 1978.
9/78 SYSTEM 81.0 80.0 720 714 576
«« PROBLEMS/SOLUTIONS/COMMENTS
FRP PIPING PROBLEMS WERE ENCOUNTERED.
PUMP PROBLEMS WERE RELATED TO BEARING AND SHAFT FAILURES.
10/78 SYSTEM 84.0 81.0 74* 710 607
11/78 SYSTEM 85.0 42.0 720 351 299
** PRObLEMS/SOLUTIONS/COMNENTS
THE UNIT WAS SHUT DOWN NOVEMBER 18, 1978 FOR SCHEDULED INSPECTION. T
RESTART is PROJECTED FOR FEBRUARY 1, 1979.
12/78 SYSTEM .0 744 0 C
•• PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT DID NOT OPERATE DURING DECEMBER OR JANUARY.
1/79 SYSTEM .0 744 0 0
2/79 SYSTEM 18.0 17.4 672 651 117
19J
-------
EPA UTILITY FbD SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS i. ELECTRIC: KILL CREEK 3 (CONT.)
PERFORMANCE DATA _
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP."
SO? PART. HOURS HOURS HOURS FACTOR
3/79 SYSTEM 53.1 52.4 744 735 390
** PROdLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTING WAS PERFORMED DURING MARCH AND THE UNIT WAS DECLARED
COMMERCIAL.
4/79 SYSTEM 63.6 44.4 730 503 330
** PROdLEMS/SOLUTIONS/COMMENTS
TH£ ONLY PfcObLEMS REPORTED WERE WITH DAMPERS AND PUMP FAILURES.
5/79 SYSTEM 97.8 64.7 744 492 481
6/79 SYSTtM 51.9 47.9 72u 665 345
•• PRObLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO UNUSUAL OPERATING PROBLEMS WERE ENCOUNTERED.
7/79 SYSTEM 63.3 55.0 744 686 411
8/79 SYSTEM 744 550
9/79 SYSTEM 93.D 84.0 720 667 6C4
»* PROBLEMS/SOLUTIONS/COMMENTS
IN JULY AND AUGUST REHEATER PROBLEMS WERE ENCOUNTERED. THE REHEATER WILL
HAVE TO BE REPLACED DURING EITHER NOVEMBER OR DECEMBER OF THIS YEAR.
10/79 SYSTEM 82.0 76.1 744 690 566
11/79 SYSTEM .0 .C 720 0 C
12/79 SYSTEM .? .0 744 Q 0
** PfcObLEMS/SOLUTIONS/COMMENTS
AT THE END OF OCTOBER THE UNIT WENT DOWN FOR A TURBINE OVERHAUL AND IS
SCHEDULED TO BE DOWN UNTIL LATE JANUARY OR EARLY FEBRUARY.
DURING THE OVERHAUL GENERAL SCRUbBER MAINTENANCE WAS DONE BUT NO MAJOR
MODIFICATIONS WERE MADE.
194
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY W/fGD - MW
NET UNIT GENERATING CAPACITY WO/FGC - MW
fcOUIVALElU SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
*• FUEL DATA
FUEL TVPc
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASM CONTENT - X
AVERAGE MOISTURE CONTENT - f.
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - 2
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
& ELECTRIC
( .100 LB/MMBTU)
t 1.200 LB/MM8TU>
LOUISVILLE GAS
PADDY'S RUN
6
LOUISVILLE.
KENTUCKY
E
43.
516.
302.0
72.0
67.0
60.0
72.0
FOSTER WHEELER
PULVERI2ED COAL
SUMMER PEAKING LOAD
0/52
189.76 ( 4CQOOO ACFM)
179.4 I 355 F)
76. { 250 FT)
******* (***** FT)
COAL
BITUMINOUS
26749.
11.50
( 11500 BTU/LB)
11150
2.50
2.0-3.5
ESP
NUMBER
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
PARTICULATE SCRUBBER
TYPE
FbD SYSTEM
SALEABLE PRODUCT/THROWAwAY PROtUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION F1RW
DEVELOPMENT LEVEL
NEW/HETRGFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
so2 DESIGN REMOVAL EFFICIENCY - x
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AWARDED
STARTED REQUESTING BIDS
STARTED PRELIMINAY DESIGN
ADSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
AaSO^bEK
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
RESEARCH COTTRELL
99.1
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIME
COMBUSTION ENGINEERING
FLUOR - PIONEER
PIONEER SERVICES
FULL SCALE
RETROFIT
99.10
9C.OO
W73
4/7:
6/72
7/71
12/7C
0/7C
.C
.0
2
MOBILE PACKED TOWER
4/73
COMBUSTION ENGINEERING
2
195
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 CCONT.)
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
S02 INLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
** FANS
NUMBER
TYPE
SERVICE - WET/DRY
CAPACITY - CU.M/S
** VACUUK FILTER
NUMBER
TYPE
CONSTRUCTION MATERIAL
CAPACITY - M Ty D
INLET SOLIDS - *
OUTLET SOLIDS - X
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
** PUMPS
SERVICE
17X18X50 HIGH
CARBON STEEL
2 1/2 INCH THICK FRP
316 SS
82.58
176.7
2.2
2.9
2.7
2000
9T.O
2
DRY
DRY
82.58
ROTARY DRUM
NYLO ^ BELT
21i .7
22.0
45.0
CHEVPON
FIBERGLASS
HORIZONTAL
2
7
1.37
( 175000 ACFM)
( 350 F)
( 16.5 GAL/1GOOACF)
(11.5 1N-H20)
( 9.0 FT/S)
( 175COO ACFM)
( 240 T/0)
< 4.5 IT)
1.52 ( 5.0 FT>
4.4 ( 1.75 IN)
45 DEG.
WATER WASH-RIVER 40-65t 10-15 MIN/8 H
3.0 < 10.0 FT/S)
.4 ( 1.5 IN-H20)
NUMBER
*• TANKS
SERVICE
REACTION
SCRUBBER RECYCLE
REACTION SURGE TANK
ADDITIVE SLURRY TANK
** REHEATER
TYPE
TEMPERATURE BOOST - C
** THICKENER
NUMBER
DIAMETER - M
OUTLET SOLIDS - X
** WATER LOOP
TYPE
fRESH MAKEUP WATER ADDITION - LITEHS/S
** TREATMENT
TYPE
• • DISPOSAL
NATURE
TYPE
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
NUMBER
****
***•
DIRECT COMBUSTION
21.7 ( 39 F)
15.2
22.0
CLOSED
3.1
( 50 FT)
50 GPM)
LIME STABILIZATION
FINAL
POND
TRUCK
ir.o
30575
25.0 ACRE-FT)
196
-------
EPA UTILITY FGD SURVEY: fOURTH QUARTER 1979
LOUISVILLE 6AS & ELECTRIC: PADDY'S RUN 6 (CONT.)
......... ....... — — —PERFORMANCE DATA — —-———- ——— — - —
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/73
5/73
6/73
7/73
6A
6B
SYSTEM
18.0
56. 0
37.0
720
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES WERE OPERATED ONE AT A TIME, WITH FREQUENT SHUTDOWNS FOR INSPEC-
TION OF EQUIPMENT AND MINOR REPAIRS.
6A
6B
SYSTEM
11.0
65.3
38.0
744
PROBLEMS/SOLUTIONS/COMMENTS
SINGLE-MODULE OPERATION CONTINUED THROUGH MAY 19. WHEN THE UNIT WAS SHUT
DOUN FOR MODIFICATIONS.
EQUIPMENT WAS INSTALLED FOR INJECTION OF A FLOCCULATING AGENT INTO THE
CLARIFIER TANK.
6A
66
SYSTEM
1.0
6.0
3.5
720
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION WAS INTERMITTENT FROM JUNE 19 TO JULY 11 BECAUSE OF MECHANICAL
PROBLEMS KITH THE SLURRY PUMPS.
6A
6B
SYSTEM
21.0-
21.3
21.0
744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING A SCHEDULED OUTAGE FROM JULY 12 TROUGH AUGUST 1, SEVERAL REPAIRS
WERE MADE TO THE LIME SLURRY MAKE-UP SYSTEM. A DISINTEGRATOR UNIT WAS
INSTALLED TO REDUCE PLUGGING OF STRAINERS AND SLURRY CONTROL VALVES.
8/73 6A
66
SYSTEM
53.0
64.0
58.5
744
** PROBLEHS/SOLUTIONS/CONMENTS
THE OPERATION WAS CONTINUOUS FROM AUGUST 2 TO AUGUST 18 EXCEPT FOR A BRIEF
SHUTDOWN DUE TO A BOILER-RELATED PROBLEM.
FROM AUGUST 19 TO SEPTEMBER 5, THE SYSTEM HAS SHUT DOWN TO REPLACE THE
CLARIFIER'S UNDERFLOW LINE WITH ONE OF LARGER DIAMETER AND TO INSTALL
ADDITIONAL PUMP CAPACITY IN THE CLARIFIERS'S OVERFLOW SYSTEM.
9/73 6A
6B
SYSTEM
85.0
72.0
78.5
720
PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT OPERATED CONTINUOUSLY BETWEEN SEPTEMBER 6 AND 20 EXCEPT FOR A
7-HOUR SHUTDOWN TO REPAIR A MARBLE BED SUPPORT PLATE.
THE UNIT HAS SHUT DOUN FROM SEPTEMBER 20 TO THE END OF THE MONTH.
10/73 6A
66
SYSTEM
49.0
94.0
71.5
744
197
-------
EPA UTILITY FGD SURVEY: FOURTH OUARTER 1979
LOUISVILLE GAS * ELECTRIC: PADDY'S RUM 6 (COST.)
PERFORMANCE DATA ...... — .—______
PERIOD MODULE AVAILABILITY OPEKABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLENS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OPERATED UNTIL DECEMBER 20 AFTER WHICH THE BOILER AND
THE SCRUBbER MODULES UERE SHUT DOUN BECAUSE OF NO DEMAND (THIS IS A
PEAK1NG-LCAO BOILER).
11/73 6A 35.0
6B 100.0
SYSTEM 67.5 720
12/73 6A 44.3
68 78.0
SYSTEM 61.0 ™*
1/74 SYSTEM .C 744 0 C
•* PROBLEHS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN BECAUSE OF NO DEMAND.
2/74 SYSTEM .0 672 0 0
3/74 SYSTEM .0 '"•'• 0 C
4/74 SYSTEM .0 720 0 0
5/74 SYSTEM .0 744 0 C
6/74 SYSTEM .0 720 0 C
7/74 SYSTEM -0 744 0 C
8/74 6A 5C.O
6B 77.0
SYSTEM 63.5 ?**
*• PROBLEMS/SOLUTIONS/COMMENTS
UNIT HAS BEEN ON AND OFF FREQUENTLY DUE TO FLUCTUATION IN POWER DEMAND.
9/74 SYSTEM «° 7*G 0 0
** PROBLEMS/SOLUTIONS/COHMENTS
THE BOILER WAS SHUT DOWN BECAUSE OF NO DEMAND.
10/74 6A 100.0
6B 1CO.O
SYSTEM 1CO.O 744
»* PROBLEMS/SOLUTIONS/COMMENTS
BOILER WAS TURNED ON TO PERFORM LIMESTONE TESTS ON THE FGD SYSTEM.
11/74 SYSTEM .0 720 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN BECAUSE OF NO DEMAND.
12/74 SYSTEM .0 744 0 0
1/75 SYSTEM .0 744 0 C
2/75 SYSTEM .0 672 0 0
3/75 SYSTEM .0 744 0 0
4/75 SYSTEM ,0 720 Q 0
198
-------
EPA UTILITY FED SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS fc ELECTRIC: PADDY'S RUN 6
— . PERFORMANCE DATA —-————— fc—•
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/75 SYSTEM
6/75 SYSTEM
7/75 SYSTEM
8/75 SYSTEM
9/75 6A
6B
SYSTEM
.0
.0
.0
.0
100.0
100.0
100.0
744
720
744
744
720
0
0
0
0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM HERE OPERATIONAL ALL OF SEPTEMBER AND THE FIRST
TWO WEEKS IN OCTOBER. OPERABILITV FOR BOTH MODULES DURING THE OPERATIONAL
PERIOD WAS 100X (BASED UPON LGtE'S PEAK LOAD DETERMINATION). S02
REMOVAL HAS REPORTED TO BE OVER 98Z.
SYSTEM OUTAGE IN THE LAST TUO WEEKS OF OCTOBER WAS DUE PRIMARILY TO BREECH
ING IN THE BOILER SECTION.
10/75
11/75
6A
6B
SYSTEM
6A
6B
SYSTEM
100.0
1GO.O
1CO.O
100.0
100.0
100.0
744
720
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBER SYSTEM RAN HOST OF THE REPORT PERIOD ON MONDAY-
FRIDAY BASIS.
TWO MINOR OUTAGES IN DECEMBER WERE DUE TO MALFUNCTION AND REPAIR OF THE
DUAL STRAINER SWITCH SHAFT IN THE BOTTOM OF THE SCRUBBER MODULE.
12/75 6A
6B
SYSTEM
1/76
6A
6B
SYSTEM
9C.O
90.3
90.0
100.0
100.0
100.0
100.0
744
744
** PROBLEMS/SOLUTIONS/COMMENTS
S02 REMOVAL EFFICIENCY WAS REPORTED TO BE 99X DURING JANUARY.
2/76 SYSTEM 696
** PROBLEMS/SOLUTIONS/CONMENTS
EXTENSIVE SLUDGE STUDY: FIXATION, LEACHATES, SEASONAL VARIATIONS.
SCRUBBER/SLUDGE STUDY SCHEDULED FOR JUNE OR JULY. THE SCRUBBER WILL NOT
BE OPERATED UNTIL THE START OF THE STUDY PROGRAM UNLESS THE BOILER IS
REQUIRED FOR PEAKING POWER DEMANDS. HIGHLIGHTS OF THE SCRUBBER/SLUDGE
STUDY PROGRAM ARE AS FOLLOWS.
6 MONTHS DURATION.
ONE SCHEDULED SHUTDOWN FOR TEST MODIFICATIONS.
DELIBERATE HIGH CHLORIDE CONCENTRATION OPERATION.
HGO INNOCULATION.
3/76 SYSTEM
.0
744
199
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 CCONT.)
PERFORMANCE DATA ____
PERIOD MODULE AVAILABILITY OPERAB1LITV RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT DID NOT OPERATE DURING THE REPORT PERIOD IN ANTICIPATION OF THE
EPA SCRUBBER/SLUDGE STUDY. THE UTILITY IS NOW COMPLETING SYSTEM CODIFICA-
TIONS FOR THE OPERATION OF THE TEST PROGRAM.
4/76 SYSTEM .0 720 0 C
5/76 6» 100.0
6B 100.0
SYSTEM 100.0 100.0 74*
** PROBLEMS/SOLUTIONS/COHMENTS
THIS PEAK LOAD UNIT UAS OPERATED PART OF THE TIME DURING THE REPORT PERlOfc
CAPPROXIMATELY 2 WEEKS IN MAY AND TWO WEEKS IN JUNE). THE SCRUBBER UAS
AVAILABLE TO THE BOILER 100Z OF THE TIME AND S02 REMOVAL EFFICIENCY
UAS 98 TO 99X DURING THIS OPERATING SEGMENT.
6/76 SYSTEM 100.0 100.0 720
7/76 6A 100.0
6B 100.0
SYSTEM 100.0 100.0 744
•* PROBLEMS/SOLUTIONS/COMMENTS
THIS UNIT WAS OPERATIONAL PART OF THE TINE DURING THE JULY-AUGUST PERIOD
THE SCRUBBING SYSTEM WAS AVAILABLE TO THE BOILER ON A 100Z BASIS.
NO MAJOR SCRUBBER-RELATED PROBLEMS WERE ENCOUNTERED.
8/76 6A 100.0
66 100.0
SYSTEM 100.0 100.0 744
9/76 SYSTEM -0 720 0 C
*• PROBLENS/SOLUTIONS/COMHENTS
THE UNIT DID NOT OPERATE THROUGHOUT SEPTEMBER AND THE FIRST 3 WEEKS IN
OCTOBER. THE EPA-FUNDED SCRUBBER/SLUDGE STUDY PROGRAM COMMENCED OCTOBER
25. THE IMTIAL PHASE OF THE PROGRAM CALLS FOR OPERATIONS TO PROCEED FOR
A 20-30 DAY PERIOD WITH CARBIDE LIME SCRUBBING ABSORBENT. FOLLOWING COM-
PLETION OF THIS RUN, THE UNIT HILL BE SHUT DOWN AND MODIFICATIONS MILL Bf
INCORPORATED INTO THE SYSTEM FOR OPERATION WITH COMMERCIAL GRADE (HIGH
CALCIUM) LIME.
10/76 SYSTEM 744
11/76 6* 99.0
6B 99.0
SYSTEM 99.0 72Q
** PROBLEMS/SOLUTIONS/COMHENTS
THE UNIT WAS IN SERVICE DURING THE REPORT PERIOD. THE SCRUBBING SYSTEM
OPERATED 99.5X OF THE TIME THAT THE BOILER WAS IN SERVICE. CARBIDE LIME
WAS EMPLOYED AS THE S02 ABSORBENT. THE HICH CALCIUM (VIRGIN) LIME RUN
SCHEDULED AS PART OF THE SCRUBBER/SLUDGE STUDY, WILL COMMENCE ON MARCH 1
12/76 6* 99.0
66 99.0
SYSTEM Q9.0 744
1/77 SYSTEM ,0 744
200
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
LOUISVILLE bAS 4. ELECTRIC: PADDY'S RUN 6 (CONT.)
_ — _ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
SO* PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
BECAUSE OF SEVERE WEATHER CONDITIONS THERE UERE NO BOILER OPERATIONS AND
NO SCRUbBtR OPERATIONS UNTIL MARCH 15, 1977.
2/77 SYSTEM
3/77 SYSTEM
4/77 SYSTEM
5/77 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
.c
67 I
744
720
744
IN MID MARCH LOSE BEGAN TESTS FOR EPA WITH REGULAR LIME SINCE ONE OF THE
ObJECTIVES CF THE TEST WAS TO DETERMINE WHETHER THERE WERE APPRECIAELE
DIFFERENCES BETWEEN REGULAR LIME AND CARBIDE LIME AT THIS FACILITY. DURING
OPERATION WITH REGULAR LIME, SCALING PROBLEMS OCCURRED, INDICATING THAT TH
SCALING RESULTED FROM INCREASED OXIDATION LEVELS. AVAILABLE OPTIONS FOR
CONTROLLING SCALING WERE LIMITED BY THE FIXED DESIGN FEATURES OF THE SCRUB
BER HARDWARE. THE OPTION SELECTED WAS ADDITION OF MGO TO THE SCRUBBING
MEDIUM. WHEN MGO WAS ADDED, THE SCALING PROBLEM WAS ELIMINATED, ALLOWING
COMPLETION OF THE TEST PROGRAM.
6/77 SYSTEM
«• PRObLEMS/SOLUTIONS/COMMENTS
720
THE SCRUBtER/SLUDbE EVALUATION STUDY CONTINUED DURING THE PERIOD. THE
SCRUfBER PLANT (ONE MODULE IS BEING UTILIZED FOR THIS EXPERIMENTAL PRO-
GRAM WAS IN SERVICE ON A VIRTUALLY CONTINUOUS BASIS FROM JUNE 18 TO
AUGUST 0 OPERATING ON MAGNESIUM INNOCULATED COMMERCIAL LIME. SYSTEM OPER-
AcILITY DURING THIS PERIOD bAS APPROXIMATELY 96X. S02 REMOVAL EFFICIENCY
WAS MEASURED IN EXCESS OF 99.St. THE SYSTEM WAS SHUT DOWN AT THIS POINT
TO PERFORM A NUMBER OF SCHEDULED MODIFICATIONS TO THE SYSTEM FOR TEST
PURPOSES. SPECIFICALLY, MODIFICATIONS ARE BEING IMPLEMENTED TO THE SYSTEM
IN ORDER TO BYPASS THE REACTION TANK SO A SHORT TERM RETENTION TIME TEST
COULD BE CONDUCTED. THE TESTING WAS COMPLETED IN AUGUST 1977 AFTER THE
MODIFICATIONS WERE MADE.
7/77 SYSTEM 744
8/77 SYSTEM 744
9/77 SYSTEM .3 720 0
•* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS CURRENTLY NOT OPERATING DUE TO THE LACK OF POWER REQUIREMENT.
10/77 SYSTEM ,fj 744 0
11/77 SYSTEM .C 720 0
12/77 SYSTEM .0 744 0
1/78 SYSTEM .C 744 0
2/78 SYSTEM .0 672 0
3/78 SYSTEM ,C 744 0
4/78 SYSTEM 720
201
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 19/9
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANC E DATA —— _._
PERIOD MODULE AVAILABILITY OPESABIL1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGO CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
PADDY'S RUN WAS ON LINE ONLY A FEU HOURS DURING THIS PERIOD. NO
OPERATIONAL PROBLEMS WERE REPORTED BY THE UTILITY.
5/78 SYSTEM 744
6/78 SYSTEM 72:
** PRObLEMS/SOLUTIONS/CCMMENTS
THE UNIT fcAN INTERMITTENTLY FOR ABOUT EIGHT TO TEN DAYS OVER THIS PERIOD.
7/78 SYSTEM 744
8/78 SYSTEM 744
«* PRObLEMS/SOLUTIONS/COMMENTS
THIS UNIT WAS OPERATED FOR TWO WEEKS IN SEPTEMBER SO THAT TESTING OF A N£y
FLOCCULANT COULD BE CARRIED OUT. THE RESULTS OF THESE TESTS WILL DETERMINE
THE TYPE CF FLOCCULANT THAT WILL BE USED IN THE FUTURE AT THE OTHER LG&E
UMTS .
9/78 SYSTcM 72C
10/78 SYSTEM .? 744 D Q
•* PROfaLEMS/SOLUTIONS/COMMENTS
THE BOILEK WAS NOT OPERATED DURING OCTOBER OR NOVEMBER.
11/7S SYSTcM' .0 720 0 0
12/78 SYSTEM .: 744 0 C
•* PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT b>AS NOT OPERATED DURING DECEMBER OR JANUARY.
1/79 SYSTEM .? 74* 2 r
2/79 SYSTcM 100.0 .3 672 0 0 .0
3/79 SYSTEM 109.0 .0 744 0 0 .0
4/79 SYSTEM 100.0 .0 720 0 C .C
** PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS NOT OPERATED DURING THESE MONTHS BECAUSE OF LACK OF DEMAND.
5/79 SYSTEM 1JC.O .C 744 0 0 .Q
6/79 SYSTEM 100.0 .0 720 0 C .C
•• PRObLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT DID NOT OPERATE DURING HAY OR JUNE DUE
TO INSUFFICIENT DEMAND.
7/79 SYSTEM .0 .0 744 19 C
8/79 SYSTtM 45.0 13.0 744 218 99
9/79 SYSTEM .3 .? 720 36 0
202
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
LOUlSwILLE GAS k ELECTRIC: PADDY'S RUN 6
PERFORMANCE DATA
PEPIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS HERE REPORTED WITH RESPECT TO OPERATION AT THIS UNIT DURING THE
THIRD UUARTER 1979.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 74*
•* PRObLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE FOURTH QUARTER 1979.
Z03
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAKE
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - Mw
GROSS UNIT GENERATING CAPACITY - Hk
NET UNIT GENtRATING CAPACITY W/FGD - Mw
NET UNIT GENLRATING CAPACITY WO/FGL - MW
EQUIVALENT SCRUBBED CAPACITY - MW
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE.
MAXIMUM bOILER FLUE CAS FLOU - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE MEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - %
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVeRAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** ESP
NUMBER
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY
- X
PARTICULATE
TYPE
SCRUBBE R
REMOVAL EFFICIENCY
EFFICIENCY - X
FGD SYSTEM
SALEABLE PRODUCT/THROUAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN
S02 DESIGN REMOVAL
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
ABSORBER SPARE CAPACITY INDEX -
ABSORBER SPARE COMPONENT INDEX
ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
MINNKOTA POWER COOPERATIVE
MILTON R. YOUNG
2
CENTER
NORTH DAKOTA
D
****** <****** LB/MMBTU)
516. ( 1.200 LB/MMBTU)
690.0
440.0
402.C
40".C
405.0
UABC CCK g WILCOX
CYCLONE
BASE
0/77
953.90
179.4
COAL
LIGNITE
151 '9.
(2021400 ACFM)
< 355 F)
( 550 FT)
(***** FT)
( 6500 BTU/LB)
5-?
6.50
3?.00
.70
UHEELABRATOR-FRYE
99.6
NONE
THROUAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
AOL/COMBUSTION EQUIP ASSOCIATE
SANDERSON I PORTER
FULL SCALE
NEW
99.60
85.00
6/78
9/77
9/75
4/75
.0
.0
SPRAY TOWER
9/77
AOL/COMBUSTION EQUIP ASSOCIATES
(
40 OIA X 120
CARBON STEEL
204
-------
EPA UTILITY fGD SURVEY: FOURTH QUARTER 1979
MINNKOTA PObER COOPERATIVE; MILTON ft. YOUNG 2 (CONT.)
SHELL LINER MATERIAL
INTERNAL MATER1AL
BOILER LOAD/ABSORBER - J
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
L/G RATIO - L/C U.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - G/CU.K
S02 INLET CONCENTRATION - PPM
S02 CUTLtT CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
•* CENTRIFUGE
NUMBER
FLAKEGLASS
316L SS TRAY
60.0
405.36
168.3
10.7
2.0
.0
1900
475
75.0
8S9000 ACFH)
335 F)
80.0 GAL/10COACF)
8.0 IN-H20)
.005 6R/SCF)
*• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
** VACUUM FILTER
NUMBER
TYPE
CAPACITY - M T/D
OUTLET SOLIDS - I
• * MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
NUMBER OF STAGES
NUMBER OF PASSES
WASH SYSTEM
PRESSURE DROP - KPA
.. PUMPS
SERVICE
ABSORBER RECIRCULATION
*• TANKS
SERVICE
REACTION/RECYCLE
MIX TANK
** REHEATER
TYPE
TEMPERATURE BOOST - C
•• THICKENER
NUMBER
CONSTRUCTION MATERIAL
OUTLET SOLIDS - X
• * yATE.fi LOOP
TYPE
FRESH MAKEUP UATER ADDITION - LITERS/S
«* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
BOILER I.D.
CARBON STEELt RUBBER LINED
DRV
330.33 ( 700000 ACFM)
ROTARY DRUM
45.3 < 50 T/D)
60.0
CHEVRON
FLAKELINEO JUL ss
UNDERSPRAV
.2
NUMBER
( 1.0 IN-H20)
NUMBER
2
****
BYPASS
13.9 C 25 F)
CONCRETE UlTH POLYETHYLENE COATING
40.0
OPEN
44.1
FINAL
MINEFILL
OFf-SITfc
TRUCK
< 700 6PM)
——• PERFORMANCE DATA— — — — ——
PERIOD NODULE AVAILABILITY OPED ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/77 SYSTEM
720
205
-------
EPA UTILITY F6D SURVEY: FOURTH OUARTER 1979
MJNNKOTA POWER COOPERATIVE: MiLTON f.. YOUNG 2 (CONT.)
------ _ ----------------------------------- PERFORMANCE DATA ------------------------ - -------- . --------
PERIOD MODULE AVAILABILITY CPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLENS/S OLUTIONS/CCMNENTS
THE UTILITY REPORTED INTERMITTENT OPERATION SINCE INITIAL START-UP.
11/77
12/77
OPERATIONAL PROBLEMS HAVE OCCURRED AS A RESULT OF SEVERE WINTER
WEATHER CONDITIONS, PARTICULARLY NUMEROUS INSTANCES Of FROZEN AND RUPTURED
LINE!. THE SYSTEM WAS SHUT DOWN DURING THE FIRST PART OF THE MONTH CF
DECEMBER TO INSTALL HEAT TRACING IN THE LIQUID CIRCUIT.
SOME MINOR PROBLEMS HAVE OCCURRED WITH THE FLOU METERS (ROT AME TE RS >.
SOME MINOt PROBLEMS HAVE BEEN REPORTED WITH THE SYSTEM'S GUILLOTINE GAS
DAMPE RS.
10/77 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
WORK CONTINUED ON INSTALLATION OF ELECTRICAL HEAT TRACING ON SLURRY LINES
AND WATER PIPING.
SYSTEM
SYSTEM
*• PROtLEMS/SOLUTlONS/COMMENTS
720
744
THERE WAS AN EMERGENCY SHUTDOWN ON DECEMBER 5 AS A RESULT OF BEARING DAN-
AGE WITHIN THE TURBINES.
A COMPLIANCE TEST ORIGINALLY SCHEDULED TO BE WITHIN THIS PERIOD HAS BEEN
TENTATIVELY RESCHEDULED WITH THE EPA FOR THE END OF MARCH. THE UNIT IS
TO HAVE THE SYSTEMS IN EQUILIBRIUM (WATER BALANCE).
0/78
1/78
2/78
A
b
SYSTEM
SYSTEM
SYSTEM
93.3
28.5
23.0
28.0
25.9
28.2
27.0
22.2
20.4
22.3
8760 6926 1950 66.7
744
672
•• PROBLEMS/SOLUTIONS/COMHENTS
3/78 SYSTEM
4/78 SYSTEM
BOTH THE fcOILER AND FGD SYSTEM CAME BACK ON LINE FEBRUARY 21 AFTER COM-
PLETION OF THE TURBINE REPAIRS. THE COMPLIANCE TEST HAS AGAIN BEEN RE-
SCHEDULED WITH EPA FOR THE END OF MAY.
ONE FORCED-DRAFT FAN (UPSTREAM OF THE FGD SYSTEM) HAD AN OIL LEAK AND A
SHAFT ALIGNMENT PROBLEM. THE FAN WAS TAKEN OFF LINE AND SHIPPED TO
BUFFALO FORGE FOR REPAIRS. THE AFFECTED MODULE WAS DOWN FROM FEBRUARY 23
THROUGH APRIL 10. WHEN THE REPAIRED UNIT WAS RE-IN STALLED.
THE VACUUM FILTER MALFUNCTIONED! ALLOWING LARGER SIZE PARTICLES TO ESCAPE
THE FILTER. THIS CAUSED T-»E RUBBER LINING DOWN STREAM TO PEEL WHICH. IN
TURN, CREATED A PLUGGING PROBLEM. EIMCO ENGINEERS ARE PRESENTLY STUDYING
THE PROBLEM AND HOPE TO INCORPORATE MODIFICATIONS TO IMPROVE THE PERFOR-
MANCE OF THE FILTERS.
744
720
** PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTING TOOK PLACE DURING THE WEEK OF JUNE 5. THE REPORT
SHOULD BE AVAILABLE TO THE UTILITY BY THE END OF JUNE.
THE UNIT bAS DOWN WITH DAMPER PROBLEMS (DOWN ON THE 24TH OF JUNE). «p-
206
-------
EPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
MINNKOTA POhER COOPERATIVE: MILTON I,. YOUNG ? tCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION I REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PARENTLY THE CHAINS THAT PULL THE GUILLOTINE DAMPERS MERE UNOERDESIGNED
AND HAVE bEEN REPLACED.
5/78
6/78
7/78
8/78
SYSTEM
SYSTEM
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
744
744
OFFICIAL RESULTS OF THE COMPLIANCE TEST PERFORMED ON JUNE 6 ARE STILL NOT
AVAILABLE. BECAUSE OF INTERMITTENT OPERATION, HOURS ARE NOT AVAILABLE.
THE THICKENER HAS BEEN A MAJOR PROBLEM AREA. THE POLYETHYLENE LINER UAS
ACCIDENTLY PIERCED DURING REPAIRS AND HAD TO BE PATCHED.
9/78
10/78
SYSTEM
SYSTEM
*• PROBLEMS/SOLUTIONS/COMMENTS
720
744
11/78
12/78
SYSTEM
A
B
SYSTEM
THE UTILITY HAS REPORTED OPERATIONAL PARAMETERS FOR THE ENTIRE YEAR OF
1978. NO INDIVIDUAL MONTHLY FIGURES yERE AVAILABLE.
THE UTILITY REPORTED THAT OPERATION OF THE BOILER AND FGD SYSTEM CONTINUED
ON AN INTERMITTENT BASIS THROUGHOUT THE PERIOD.
THICKENER LINING PROBLEMS WERE ENCOUNTERED.
EROSION IN THE SPRAY TOUERS UAS SEVERE ENOUGH TO CAUSE HOLES IN THEM.
F.D. FAN PROBLEMS HAVE BEEN ENCOUNTER AND ARE A MAJOR CONCERN.
12 C
4.6
37.7
5.1
28.4
16.8
4.6
25.7
15.1
1488 1345
744
225
1/79 SYSTEM
** PRO&LEMS/SOLUTIONS/COMNENTS
THE ABOVE FIGURES ARE FOR THE PERIOD DECEMBER THROUGH JANUARY.
THE UTILITY REPORTED THAT THE A-TOWER UAS OUT OF SERVICE FOR A PERIOD IN
JANUARY DUE TO BROKEN INLET ISOLATION DAMPER CHAINS.
A-TOUER UAS OUT OF SERVICE TO REPAIR A BOOSTER FAN SERVO MECHANISM.
THE B-TOUER UAS OUT OF SERVICE DURING DECEMBER DUE TO PLUGGING OF THE
THICKENER UNDERFLOW BY RUBBER LINING. THE THICKENER UAS PUMPED OUT AND
REPAIRED.
THE B-TOUER UAS OUT OF SERVICE THROUGH JANUARY DUE TO A FAN MOTOR.
2/79
3/79
SYSTEM
A
B
SYSTEM
25.8
35.2
25.8
1416 1036
744 1034
365
207
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
RINNKOTA POWER COOPERATIVE: HILTON R. YOUNG 2 CCONT.J
... PERFORMANCE DATA-— —— —- — — -..._..__
PERIOD NODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COHNENTS
THE ABOVE FIGURES ARE FOR THE PERIOD FEBRUARY THROUGH MARCH.
A BOOSTER FAN MOTOR FIRE WAS EXPERIENCED.
HOLES IN THE ABSORBER TOWER HERE REPAIRED.
4/79
6/79
7/79
8/79
A
B
SYSTEM
3.0
57.1
30.0
3.2
61.6
32.4
3.0
57.1
30.0
U64
744
1358
440
5/79 SYSTEM
** PROBLENS/SOLUTIONS/COMHENTS
THE ABOVE FIGURES ARE FOR THE PERIOD APRIL THROUGH MAY.
A
B
SYSTEM
17.2
36.3
26.7
17.2
36.3
26.7
17.2
36.3
26.7
720 720
192
** PROULEMS/SOLUTIONS/COMMENTS
THE A-TOWES HAS DOWN FOR REPAIR TO THE FLAKE LINING.
A-TQWER TRAY RECYCLE DISTRIBUTION HEADER WAS CLEANED.
THE SYSTEM WAS FORCED OUT OF SERVICE WHEN BOILER PROBLEMS CAUSED AN EX-
CESSIVE AMOUNT OF HEAVY PARTICLES TO ENTER THE FGD SYSTEM RESULTING IN THE
PLUGGING OF SEVERAL LINES AND STOPPING THE THICKENER RAKE.
THE A-TOWER WAS OUT OF SERVICE DUE TO PROBLEMS WITH THE WATER BALANCE AND
THE VACUUM FILTERS AS WELL AS TO UNPLUG THE ABSORBER BLEED LINE. LIME
WAS USED FOR SEVERAL DAYS TC EASE THE HIGH SOLIDS PROBLEM.
A
B
SYSTEM
44.5
.0
44.0
44.5
.0
44.0
44.3
44. 5
.0
44.0
744 744
331
•• PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS REPORTED THAT THE TRAY RECYCLE VALVE AND THE ABSORBER
TRAIN VALVE FAILED DURIN6 SEPTEMBER.
THE UTILITY REPORTED PROBLEMS WITH PLUGGING IN THE MIST ELIMINATORS,
THE THICKENER AND IN THE ABSORBER FEED LINE.
THE UNIT EXPERIENCED A BOOSTER FAN TRIP.
PROBLEMS WITH THE VACUUM FILTERS AND THE SEAL WATER PUMP WERE ENCOUNTERED.
THE ABSORBER AGITATOR WAS REPLACED DURING THE THIRD QUARTER.
A
B
SYSTEM
28.8
10.6
39.0
28.8
10.6
39.0
39.0
28.8
10.6
39. C
744 744
293
*• PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST HIGH VIBRATIONS AND BEARING TEMPERATURE IN THE BOOSTER FAN
WERE ENCOUNTERED CAUSING SOME DOWN TIME.
THE INABILITY TO ADD ALKALI. FLYASH OR LIME TO THE SYSTEM CAUSED SOME
OPERATIONAL PROBLEMS.
DURING AUGUST THE THICKENER RAKE WAS BURIED IN THE SLUDGE AND ALL OF THE
SLUDGE HAD TO BE REMOVED BY MINING IT FROM THE TOP.
208
-------
EPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
MINNKOTA POhER COOPERATIVE: MILTON R. YOUNG 2 (CONT.)
_ PERFORMANCE DATA
PERIOD NODULE AVAILABILITY CPERABILITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PLUGGING OF THE FLYASH TANK AND THE LIME SLURRY FEED LINE CAUSED SOME
OUTAGE TIME DURING AUGUST.
DUE TO A LACK OF LIME THE SYSTEM HAD TO GO OFF LINE.
THE HOLES IN THE SIDES OF THE ABSORBER TOWER HAD TO BE REPAIRED CAUSING
AN OUTAGE.
9/79 A 21.4 21.4 21.4
b 1.2 1.2 1.2
SYSTEM 23.0 23.Q 23.0 23.C 720 717 163
«* PROBLEMS/SOLUTIONS/COMMENTS
DURINf. SEPTEMBER THE A-SIDE WAS DOuN DUE TO HEAVY SOLIDS IN THE THICKENER
AND CLARIFIED. HIGH VIBRATIONS WERE EXPERIENCED WITH THE BOOSTER FAN.
THE B-SIDE REMAINED OUT OF SERVICE DUE TO PROBLEMS WITH THE THICKENER AND
CLARIFIER.
10/79 A .0 .0 .0
b 31.3 31.? 31.3
SYSTEM 31.3 31.4 31.4 31.3 7*4 743 233
•* PRObLEMS/SOLUTIONS/COMMENTS
THE CLARIFIER WAS CLEANED DURING OCTOBER.
THE CLARIFIER MECHANISM GEAR FAILED CAUSING DOWN TIME FOR REPAIR.
THE BLEED LINE TO THE THICKENER PLUGGED AND NEEDED MAINTENANCE.
THE GEAR HOUSING FAILED ON THE THICKENER LIFT MECHANISM CAUSING OUTAGE
TIME FOR REPAIR.
11/79 A .7 .7 .7
B 15.4 16.8 15.4
SYSTEM 16.0 17.4 17.4 16.0 720 661 115
•« PRObLEMS/SOLUTIONS/COMMENTS
AN EXCESS OF SOLIDS IS CAUSING PLUGGING IN THE THICKENER AND THE CLARIFIER'
12/79 A 26.6 31.5 26.6
B 9.7 11.5 9.7
SYSTEM 36.3 43.0 43.0 36.3 744 628 270
*• PROBLEMS/SOLUTIONS/COMMENTS
SEAL WATER PLUGGING CAUSED SOME OUTAGE TIME DURING DECEMBER.
PROBLEMS WERE ENCOUNTERED WITH THE BOOSTER FAN ON MODULE B DUE TO HIGH
VIBRATION.
A HOLE IN A BLOCKING VALVE CAUSED SOME PROBLEMS.
THE GEAR HOUSING FAILED ON THE THICKENER LIFT MECHANISM.
209
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY W/FGD - «W
NET UNIT GENERATING CAPACITY WO/FGfc - MW
EQUIVALENT SCRUBBED CAPACITY - MW
MONTANA POWER
COLSTRIP
1
COLSTRIP
MONTANA
B
43.
516.
664.0
36C.O
333.0
344.0
36C.O
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIKUM bOILtR FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP OIAME TER - M
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTE NT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•* PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID REC1RCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - NG/J
PARTICULATE OUTLET LOAD - NG/J
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
SO2 INLET CONCENTRATION - NG/J
•* FGD SYSTEM
SALEABLE PRODUCT/THROWAWAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
soz DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
11/75
674.83
141.9
152.
5.0
COAL
SUBBITUMINOUS
20569.
8.60
6.1-12.6
23.90
21.6-28.8
.77
0.4-1.0
.01
(1430000 ACFM)
C 291 F)
< 500 FT)
< 16.5 FT>
( 8843 BTU/LB)
8,162-8,8967
VENTURI
COMBUSTION EQUIPMENT ASSOCIATES
1
CARBON STEEL
ACID BRICK
316 SS PLUMB BOB, CERAMIC NOZZLES
12
OPEN PIPE
40.0
224.9
143.9
415.8
2.0
476667 ACFM)
291 F)
6600 GPM)
15.0 6AL/1000ACF)
61.0
3452.
26.
99.5
989.
•*«•• IN-H20)
200.0 FT/S)
8.030 LB/MMBTU)
.060 LB/MMBTU)
( 2.300 LB/MMBTU)
THROWAUAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLVASH
NONE
ADL/COMBUSTION EQUIP ASSOCIATE
BECHTEL
BECHTEL
FULL SCALE
NEW
99.50
6» .00
11/75
210
-------
EPA UTILITY FOB SUKVE1: FOURTH OUORTIR 1979
MONTANA POWER: COLSTR1P 1 (C.ONT.)
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AWARDED
ABSORBcR SPARE CAPACITY INDEX - 1
ABSORBER SPARE COMPONENT INDEX
** AbSORfaER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
NOZZLE TYPE
BOILER LOAD/ABSORBER - x
GAS FLOW - CU.M/S
6AS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
PAHTICULATE OUTLET LOAD- G/CU.M
PARTICIPATE OUTLET LOAD - NG/J
PARTKtLATE REMOVAL EFFICIENCY - X
S02 CUTLET CONTRATION - PPM
S02 CUTLcT CONCENTRATION- NG/J
S02 CUTLET CONCENTRATION- NG/J
S02 DESIGN REMOVAL EFFICIENCY - Z
«* FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRV
CAPACITY - CU.M/S
•• MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
HASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
•* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
yASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
•* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
• • PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
9/75
8/75
6/73
10/72
2(.0
.5
SPRAY TOVER
9/75
COMBUSTION EQUIP ASSOCIATES
1
70.5 X 35 DIA.
CARBON STEEL
FLAKEGLASS POLYESTER. (PLASITE IN ONE MODULE)
316L SS TRAY
1?
REFRACTORY FULL CONE (CERAMIC:
4C.O
201.31
4 (.9
479.
.1
2.7
.0
26.
99.5
425
60.0
426600 ACFM)
120 F)
7600 GPM)
18.0 6AL/100CACF)
.5 1N-H20)
8.7 FT/S)
.018 GR/SCF)
.360 LB/MHBTU)
•••• LB/MMBTU)
*••• LB/MMBTU)
SCRUBBER ID
CARBON STEEL IMPELLER, RUBBER-LINED HOUSING
DRY
223.21 ( 473000 ACFM)
CHEVRON
NORYL PLASTIC
HORIZONTAL
1
4
3.96 C13.0 FT)
.30 < 1.0 FT)
2.5 ( 1.00 IN)
120 DEGREES
CONTINUOUS UNDERWASH (POND OVERFLOW AND RIVER MA
2.7 t 8.7 FT/S)
.6 C 2.3 1N-H20)
1
MESH PAD
NORYL PLASTIC
HORIZONTAL
1
INTERMITTENT WASH
2.7 C 8.7 FT/S)
VALVE TRAY
316L SS
HORIZONTAL
1
UNDERUASH
2.7
( 8.7 FT/S)
PH
4.0 TO 5.0
MANUAL
211
-------
EPA UTILITY FfcD SURVEY: FOURTH QUARTER 1979
MONTANA POWER: COLSTRIP 1 (CONT.)
MODE
SENSOR LOCATION
** POMPS
SERVICE
VENTUR1 RECIRCULAT10N
ABSORBER RECIRCULATION
»• TANKS
SERVICE
VENTURI/A6SORBER RECYCLE TANK
** REHEATER
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
*• THICKENER
NUMBER
*» yATER LOOP
TYPE
EVAPORATOR WATER LOSS - LITER/S
SLUDGE WATER LOSS - LITER/S
PURGE WATER LOSS - LITER'S
OTHER WATER LOSSES - LITER/S
FRESH MAKEUP WATER ADDITION - LITERS/S
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
FEEDBACK
RCCIRCULATION TANK
NUMBER
NUMBER
3
3
IN-LINE
STEAM C150 PSIG, 350 F3
27.& I 50 F)
2.7$2 OF BOILER INPUT
CLOSED
18.9
4.4
.0
.0
23.3
300 CPM)
70 GP«>
0 GPM>
0 6PM)
370 GPM)
INTERIM
DIKED LINED POND
ON-SITE
PUMPED
20 FT. DEEP
26.0
635960 C
INTERIM
DIKED LINED POND
ON-SITE
PUMPED
20 FT. DEEP
26.0
635960 (
FINAL
POND
OFF-SITE
PUMPED
20 FT. DEEP
112.0
2590314
520.0 ACRE-FT)
520.0 ACRE-FT)
( 2118.0 ACRE-FT)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/75
10/75
11/75
12/75
1/76
2/76
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM 90.0
SYSTEM 98.0
720
744
720
744
744
696
72
456
576
720
672
624
1.0
19.0
42.0
60.0
64.0
65.0
212
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
MONTANA POWER: COLSTRIP 1 (CONT.)
PERIOD
3/76
4/76
5/76
6/76
7/76
8/76
9/76
10/76
PERFORMANCE DATA
MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
98.0
74.0
97.0
.0
93.0
95.0
89.0
83.0
744
720
744
.0 730
744
744
720
744
576
672
336
0
480
552
720
720
57.0
5C.O
26.0
0
28.0
38.0
65.0
73.0
** PROBLEMS/60LUTIONS/CONMENTS
A TEMPERATURE EXCURSION RESULTED IN DAMAGE TO SYSTEM COMPONENTS CAUSING
SYSTEM DOkNTIME.
THE EMERGENCY SCRUBBER QUENCH WATER SUPPLY SYSTEM FAILED TO OPERATE
DURING A TEMPERATURE EXCURSION.
THE LININGS WERE DAMAGED DURING A TEMPERATURE EXCURSION.
MIST ELIMINATOR DAMAGE OCCURRED AS THE RESULT OF A TEMPERATURE EXCURSION
IN OCTOBER.
11/76 SYSTEM
63.0
720 720
56.0
** PR06LENS/SOLU1IONS/COMMENTS
12/76 SYSTEM
1/77 SYSTEM
2/77 SYSTEM
3/77 SYSTEM
4/77 SYSTEM
5/77 SYSTEM
6/77 SYSTEM
7/77 SYSTEM
8/77 SYSTEM
9/77 SYSTEM
10/77 SYSTEM
11/77 SYSTEM
12/77 SYSTEM
1/78 SYSTEM
2/78 SYSTEM
3/78 SYSTEM
4/78 SYSTEM
5/78 SYSTEM
A FAILURE Of AN ID FAN MOTOR OCCURRED.
74.0
93.0
95.0
.0
83.0
85.0
87.0
85.0
93.0
93.0
96.0
96.0
98.0
96.0
100.0
92.0
100.0
66.0
744 744
744 744
672 480
744 0
720 600
744 624
7ZO 672
744 696
744
720
744
720
744
744
672
744
720
744
67.0
73.0
3.0
C
50.0
64.0
69.0
72.0
213
-------
EPA UTILITY F&D SURVEY: FOURTH QUARTER 1979
MONTANA POWER: COLSTHIP 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT UAS RESTARTED AFTER ITS ANNUAL OVERHAUL DURING MAY.
THE I.D. FAN MOTOR WAS NOT AVAILABLE DURING UNIT RESTART.
6/78 SYSTEM
7/78 SYSTEM
8/78 SYSTEM
9/78 SYSTEM
10/78 SYSTEM
11/78 SYSTEM
12/78 SYSTEM
1/79 SYSTEM
2/79 SYSTEM
3/79 SYSTEM
A/79 SYSTEM
5/79 SYSTEM
6/79 SYSTEM
76.0
96.0
97.0
96.0
95.0
9 1.0
96.7
97.6
90.3
97.3
98.9 88.4 80.2
89.7
95.2
72 C
744
744
720
744
720
744
744
672
744
72C 597
744
720
«•> PRObLEHS/SOLUTIONS/COMMENTS
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM
10/79 SYSTEM
11/79 SYSTEM
DURING NAY AND JUNE THE UNIT WAS BEING
THESE PERIODS IS BASED UPON OPERATIONS
98.0
97.3
95.2
92.9
«7.5
OVERHAULED. THE AVAILABILITY FOR
BEFORE AND AFTER OVERHAUL.
744
744
720
744
720
PROBLEMS/SOLUTIONS/COMMENTS
THE ROUTINE MAINTENANCE CAN BE PERFORMED WHILE THE MODULES ARE ON LINE
SO THE AVAILABILITY REMAINS HIGH.
214
-------
EPA UTILITY FGD SURVEY: fOURTH QUARTER 1979
SECTION J
DESIGN AND PERFORMANCE DATA fOf OPERATIONAL DOMESTIC FGp SYSTEMS
COMPANY
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE C.M1SSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - Mw
NET UNIT GENERATING CAPACITY UO/FGl) - MW
EQUIVALENT SCRUBBED CAPACITY- MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.N/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
•• FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASM CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.H
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - »G/J
PARTICULATE OUTLET LOAD - NG/J
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - NG/J
** FGD SYSTEM
SALEABLE PRODUCT/THROUAUAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
.100 LB/MMBTU)
1.200 LB/NMBTU)
MONTANA POWER
COLSTR1P
2
COLSTRIP
MONTANA
B
43. I
516. (
664.0
360.0
332.0
344.0
36r.O
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
11/75
674.82 (1430000 ACFM)
143.9 i 291 F)
152. < 500 FT)
5.0 ( 16.5 FT>
COAL
SUBBITUMINOUS
20569.
?.60
6.1-12.6
23.90
21.6-28.8
.77
0.4-1.0
.01
( 8843 BTU/LB)
8.162-8.8967
3
VENTURI
COMBUSTION EQUIPMENT ASSOCIATES
CARBON STEEL
ACID BRICK
316 SS PLUMB
12
OPEN PIPE
40.0
224.9
143.9
415.8
2.0
61.0
3452.
26.
X 99.5
989.
RESISTANT
BOB. CCRAMIC NOZZLES
( 476667 ACFM)
( 291 r)
< 6600 6PM)
(15.0 6AL/1000ACF)
(*.*** IN-H20)
( 200.0 FT/S)
( 6.030 LB/MMBTU)
( .C6C LB/MMBTU)
( 2.300 LB/MMBTU)
- X
THROUAMAY PRODUCT
MET SCRUBBING
LIME/ALKALINE FLYASH
NONE
ADL/COMBUST10N EQUIP ASSOCIATE
BECHTEL
BECHTEL
FULL SCALE
NEW
99.50
60.00
10/76
215
-------
EPA UTILITY FGO SURWEt: FOURTH OUARTER 1979
MONTANA POWER: COLSTRIP 2 (CONT.)
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AUARDE D
ABSORBER SPARE CAPACITY INDEX - Z
ABSORBER SPARE COMPONENT INDEX
•* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER Of STAGE S
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
NOZ7LE TYPE
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIUUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
PARTICIPATE OUTLET LOAD- G/CU.M
PARTICIPATE OUTLET LOAD - NG/J
PARTKULATE REMOVAL EFFICIENCY - X
S02 CUTLET CONTRAT10N - PPM
S02 CUTLET CONCENTRATION- NG/J
S02 OUTLET CONCENTRATION- NG/J
S02 DESIGN REMOVAL EFFICIENCY - X
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRV
CAPACITY - CU.P/S
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
*• MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - H/S
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
SENSOR LOCATION
** PUMPS
SERVICE
5/76
8/75
6/73
10/72
20.0
.5
SPRAY TOWER
5/76
COMBUSTION EQUIP ASSOCIATES
1
70.5 X 35 DlA.
CARBON STEEL
FLAKEGLASS POLYESTER. CPLASITE IN ONE MODULE)
316L SS TRAY
12
REFR KTORV FULL CONE CCERAHIC3
40.0
426600 ACFM)
120 F>
7600 GPM)
18.0 6AL/MOOACF)
.5 IN-H20)
8.7 FT/S)
.018 GR/SCF)
.060 LB/HMBTU)
201.31
48.9
479.
2.4
.1
2.7
.0
26.
99.5
425
(*.»•* LB/MHBTU)
(***•• LB/HMBTU)
6C.O
VENTURI RECIRCULATION
ABSORBER RECIRCULATION
SCRUBBER ID
CARBON STEEL IMPELLER. RUBBER-LINED HOUSING
DRV
223.21 < 473000 ACFH)
CHEVRON
NORVL PLASTIC
HORIZONTAL
1
4
3.96 C13.0 FT)
.30 C 1.0 FT)
2.5 C 1.00 IN)
120 DEGREES
CONTINUOUS UNOERUASH CPONO OVERFLOW AND RIVER WA
2.7 « 8.7 FT/S)
.6 I 2.3 IN-H20)
VALVE TRAY
316L SS
HORIZONTAL
1
UNDERWASH
Z.7 < 8.7 FT/S)
PH
4.0 TO 5.0
MANUAL
FEEDBACK
RECIRCULATION TANK
NUMBER
6
6
216
-------
MONTANA POWER: COLSTRIP 2 (CONT.)
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
** TANKS
SERVICE
VENTIR1/ABSORBER RECYCLE TANK
** REHEATER
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
*• THICKENER
NUMBER
** WATER LOOP
TYPE
EVAPORATOR WATER LOSS - LITER/S
SLUDGE WATER LOSS - L1TER/S
PURGE WATER LOSS - LITER/S
OTHER HATER LOSSES - LITER/S
FRESH KAKEUP WATER ADDITION - LITERS/S
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
NUMBER
3
IN-LINE
STEAK C15C PS1G. 350 FJ
27.8 ( 5? F)
2.751 OF BOILER INPUT
CLOSED
16.9
<..*
.0
.0
2 ?.3
300 GPM)
70 GP»O
0 GPM)
? GPM)
370 GPM)
INTERIM
DIKED LINED POND
ON-S 1TE
PUMPED
20 FT. DEEP
2 (.0
635960 <
INTERIM
DIKED LINED POND
ON-SITE
PUMPED
20 FT. DEEP
24.0
635960 (
FINAL
POND
OFF-SITE
PUMPED
20 FT. DEEP
112.0
2590314
520.0 ACRE-FT)
520.0 ACRE-FT)
t 2118.0 ACRE-FT)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/76
6/76
7/76
8/76
9/76
10/76
11/76
12/76
1/77
2/77
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
100.0
100.0
99.0
96.0
98.0
90.0
94.0
93.0
83.0
44.0
744
720
744
744
720
744
720
744
744
672
72
384
312
240
720
744
720
744
720
648
1.C
23.0
2C.O
13.0
65.0
77.0
80.0
82.0
68.0
75.0
217
-------
EP* UTILITY FGD SURVEY: fOURTH QUARTER 1979
MONTANA POWER: COLS TRIP 2 (COM.)
PERIOD
3/77
4/77
5/77
6/77
7/77
8/77
9/77
10/77
11/77
12/77
1/78
2/78
3/78
MODULE AVAILABILITY OPERAFUL1TY RELIABILITY UTILIZATION X REMOVAL
S02 PART
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
97.0
85.0
63.0
88.0
9 1.0
8 1.0
90.0
98. 3
98.0
98. C
97.0
95.0
89.0
PER BOILER FGD CAP.
. HOURS HOURS HOURS FACTOR
744 672
720 696
744 312
72C 672
744 672
744
720
744
720
744
744
672
744
71.0
68. C
23.0
61.0
58.0
*« PkObLEMS/S OLUTIONS/COMMENTS
4/7«
5/7?
6/78
7/78
8/78
9/78
10/78
11/78
12/78
1/79
2/79
3/79
4/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
THE BOILEf WAS SHUT DOWN FOR ANNUAL OVERHAUL.
8 7.0
99.0
97.0
96.0
99.0 .0
94.0 .0
99.0 .0
99.0 .C
91.2
94.3
98.3
94.3
100.0
720
744
720
744
744 0
720 0
744 0
720 0
744
744
672
744
720
0
0
0
C
** PHOBLEHS/SOLUTIONS/COMMENTS
DURING APRIL THE UNIT UAS BEING OVERHAULED. THE AVAILABILITY
TIME IS BASED UPON OPERATION BEFORE AND AFTER THE OVERHAUL.
5/79
6/79
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
94.4
98.4
96.4
99.3
92.3
744
720
744
744
720
FOR THIS
218
-------
EPA UTILITY fGD SURVEY: fOURTH OUARTE* 1979
MONTANA PCWtR: COLSTRIP 2 (CONT.)
PERfORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION t REMOVAL P£" BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM 92.9 74*
11/75 SYSTEM 98.4 72C
•* PSObLEMS/SOLUTlONi/COMMENTS
THE ROUTINE MAINTENANCE CAN BE PERFORMED bHILE THE MODULES ARE ON LIKE
so THE AVAILABILITY REMAINS HIGH.
219
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
302 EMISSION LIMITATION - KG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - MW
MET UNIT GENERATING CAPACITY WO/FGC - MW
EQUIVALEflT SCRUBBED CAPACITY - MW
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TEA - M
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - t
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** MECHANICAL COLLECTOR
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY -
•* PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGE S
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
LIQUID REC1RCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL 6AS VELOCITY - M/S
PARTICULATE INLET LOAD - 6/CU.M
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
S02 INLET CONCENTRATION - PPM
*• FGD SYSTEM
SALEABLE PRODUCT/THROWAWAf PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-£ FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
NEVADA POWER
REID GARDNER
1
MOAPA
NEVADA
B
43.
516.
( .100 LB/MNBTU)
( 1.200 LB/MMBTU)
125.0
110.0
***• ***
125.0
FOSTER WHEELER
PULVERIZED COAL
BASE
0/65
223.21 ( 473000 ACFH)
176.7 < 350 F)
61. ( 2CO FT)
COAL
BITUMINOUS
289.19.
8.00
9.
5.50
5.5
.50
0.5-1.0
.05
<***** FT)
( 12450 BTU/LB)
MULTICLONES
RESEARCH COTTRELL
X 75.0
VENTURI
ADL/COHBUSTION EQUIPMENT ASSOCIATES
1
INCOLOY 825 AT THROAT
RUBBER (AREAS OTHER THAN THROAT)
TWIN VARIABLE THROATS
TANGENTIAL
50.0
223.2 473000 ACFM)
176.7 350 F)
157.5 2500 GPM)
1.3 10.0 GAL/1000ACF)
******* ***** IN-H20)
50.3 165.0 PT/S)
1.4 .60 GR/SCf)
97.0
375.000
THROWAWAV PRODUCT
WET SCRUBBING
SODIUM CARBONATE
NONE
AOL/COMBUSTION EQUIP ASSOCIATE
BECHTEL
FULL SCALE
RETROFIT
220
-------
EP* UTILITY F6D SURVEY: FOURTH OUARTER 1979
NEVADA POhER: REID GARDNER 1 (CONT.)
PART1CULATE DESIGN REMOVAL EFFICIENCY - 1
SO 2 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
•• AbSORBER
NUMHER
TYPE
INITIAL START UP
SUPPLUR
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LlfeER MATERIAL
INTERNAL MATERIAL
bOILER LOAD/ABSORBER - X
LltiUID RE.C1RCUL ATION RATE - LITER/S
L/& RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERF1CAL GAS VELOCITY - H/SEC
S02 CUTLtT CONTRATION - PPM
97.00
90.00
4/74
12/72
7/71
.0
.0
TRAY TOWER
4/74
AOL/COMBUSTION EQUIPMENT ASSOCIATES
30 DIA.
CARBON STEEL
RUBBER
316L SS (MASH TRAY)
100.0
38. <
(
.2
.7
7.4
17
600 GPM>
1.6 GAL/100QACF)
( 3.0 IN-H20)
( 11.0 FT/S)
•* FANS
NUMPfcR
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
•• "1ST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
HASH SYSTEM
PRESSURE DROP - KPA
• * PUMPS
SERVICE
SCRUBBER RECIRCULATION
ABSORBER RECIRCULATION
SCRUBBER FD
CARBON STEEL
DRY
223.21
( 473000 ACFM)
RADIAL VANE
316L SS (BOTH ME AND WASH TRAY)
HORIZONTAL
1
1
NONE
.1 t .5 IN-H20)
NUMBER
•* TANKS
SERVICE
VENTURI RECYCLE
** REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
«• THICKENER
NUMBER
NUMBER
HOT AIR INJECTION
STEAM
27.8 < 50 F)
15.2 MM BTU/HR; 4 MW
*• WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
•• DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
CLOSED
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NEVADA POhER: REID GARDNER 1 (CONT.)
AREA - ACRES 45.0
PERFORMANCE DATA ___
PERIOD MODULE A VAIL*B1LIT1 CPEKABILITT RELIABILITY UTILIZATION X REMOVAL PER BOILER FG0 CAP.
SO? PART. HOURS HOURS HOURS FACTOR
4/74 SYSTEM 72C
•* PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEK WAS FIRST PLACED IN SERVICE IN APRIL 1974. THE SCRUBBING UNITE
DESIGN WAi bASED ON INFORMATION AND DATA OBTAINED FROM AN BCOO-ACFM PILOT
PLANT PROGRAM CONDUCTED AT REID GARDNER STATION IN 1971 AMD 1972.
1/75 SYSTEM 744
2/75 SYSTEM t>7i
** PRObLEMS/SOLUTIONS/COMMENTS
FROZEN SOUUM CARBONATE FEED LINES ACCOUNTED FOR OUTAGE TII»E.
A 2-DAY LACK OF CHEMICALS RESULTED IN OUTAGE TIME.
3/75 SYSTEM 744
4/75 SYSTEM 72 C,
** PRObLEMS/SOLUTIONS/COMMENTS
THE fcOILER k.AS SHUT DOWN APRIL 17 FOR ROUTINE MAINTENANCE AND PLACED BACK
ON LI NE HAY M.
5/75 SYSTEM 744
** PJ.ObLE«S/SOLUTIONS/COMMENTS
A HIGH ASh CONTENT OF UP TC 20X BY WEIGHT OF THE COAL BURNED
RECENTLY HAD NO EFFECT ON EMISSIONS.
6/75 SYSTEM 72ii
«* PROBLEMS/SOLUTIONS/COMMENTS
ROUTINE MECHANICAL PROBLEMS WERE REPORTED.
ROUTINE INSTRUMENTAL PROBLEMS WERE REPORTED.
AbRASlON CF RUBBER LINED PIPES WAS A PROBLEM.
THE UTILITY HAS REPORTED THAT A SECOND PERFORMANCE TEST WAS RECENTLY
COMPLETED AND PASSED.
7/75 SYSTEM 744
** PRObLEMS/SOLUTIONS/COMMENTS
ONE OUTAGE, UNRELATED TO THE FGD SYSTEM, WAS REPORTED FROM JULY THRCUGH
SEPTEMBER.
OUTAGES DURING JULY THROUGH SEPTEMBER WERE CAUSED BY SCRUBBER MALFUNCTIONS
8/75 SYSTtM 744
9/75 SYSTtM 78.^ 78.7 72G 716 559
10/75 SYSTEM 67.0 14.0 744 303 106
•• PRObLEMS/SOLUTIONS/COMMENTS
LOW OPERATING TIME DURING OCTOBER WAS DUE TO SCHEDULED BOILER MAINTENANCE
ONE OUTAGE WAS DUE TO THE IALFUNCTION OF A SODA ASH BLOWER.
11/75 SYSTEM 620 55.0 72G 654 394
222
-------
EPA UTILITY FGD SURVEY: FOURTH OUARTER 1979
NEVADA PGwER: REID GARDNER 1 (CONT.)
12/75 SYSTEM
1/76 SYSTtM
2/76 SYSTEM
81.3
91.0
29. n
76. C
57.0
89.0
27.0
75.0
PERFORMANc E OAT*
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PfiObLEMS/S OLUTIONS/COMMENTS
OPERABILITY WAS LOW FOR THE MONTH OF NOVEMBER BECAUSE OF DELAYS IN
DELIVERY OF REPAIR MATERIALS.
THE COLLAFSE OF A VENTURI STRAINER RESULTED IN FGD SYSTEM OUTAGE DURING
NCVEKfacR.
REHEATER STEAM LEAKS CAUSED AN OUTAGE DURING NOVEMBER.
THE SYSTEM yAS SHUT DOWN FOR 16 DAYS FOR COMPLETION OF PIPING CONVERSION.
THIS OUTAGE WAS NOT DUE TO SCRUBBER MALFUNCTION.
A FROZEN lOSBONATE LINE RESULTED IN AN FGD SYSTEM OUTAGE DURING NOVEMBER.
744
744 6*7 186
696 664 520
*• PfcOoLEMS/SOLUTIONS/COMMENTS
A DEPLETION OF CHEMICALS DURING FEBRUARY WAS REPORTED.
FIVE SCRULBER INOPERATIVE FER10DS WERE REPORTED DURING FEBRUARY. THREE OF
THESE OUTAGES WERE NOT RELATED TO THE FGD SYSTEM.
SEAL WATER PROBLEMS WERE REPORTED DURING FEBRUARY.
CHEMICAL LINE PLUGGING PROBLEMS WERE NOTED DURING FEBRUARY.
3/76 SYSTEM 99.0 72.^ 99.0 39.? 744 398 287
*• PKOcLENS/SOLUTIONS/COMMENTS
ONE FORCED SCRUBBER OUTAGE WAS CAUSED BY A VENTURI LEAK.
4/76 SYSTEM 15.0 51.0 100.0 15.C 72C 106 97
*• PRObLEMS/SOLUTIONS/COMMENTS
THE lOILEt UAS TAKEN OUT OF SERVICE IN APRIL FOR INSPECTION OF VALVES AND
COAL CONDUITS.
5/74 SYSTEM .? 744 0 C
** PROcLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN FOR A SCHEDULED TURBINE OVERHAUL AND BURNER LINE
CCNDUIT REPLACEMENT.
6/76 SYSTtM .C 723 0 C
7/76 SYSTEM .0 744 0 0
8/76 SYSTEM 97.0 75.C 94.0 49.0 744 479 36C
*« PROULEMS/SOLUTIONS/COMMENTS
PLUGGING IN THE THICKENER CAUSED AN OUTAGE DURING AUGUST.
PLUGGING IN THE TRAY RECYCLE TANK DURING AUGUST RESULTED IN A FGD OUTAGE.
9/76 SYSTEM 95.0 97.c 95.0 89.C 72C 656 639
223
-------
EPA UTILITY FCD SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REID GARDNER 1 (CONT.)
. . . . PERFORMANCE DATA — —— _ ..___
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•* PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING IN THE VENTURI SPRAY HEADERS CAUSED A SCRUBBER OUTAGE.
AN ID FAN MALFUNCTION RESULTED IN SCRUBBER OUTAGE DURING SEPTEMBER.
10/76 SYSTEM 98.0 96.0 98.0 87.3 744 676 «48
•* PRObLEMS/SOLUTIONS/COMMENTS
SCRUBBER OUTAGE TIME WAS REQUIRED FOR INSTALLATION OF A NEW CARBONATE FEED
LINE.
A MINOR SCRUBBER TRIP WAS CAUSED BY PLUGGING IN THE SCRUBBER EFFLUENT
SUCTION LINE.
11/76 SYSTEM 87.0 81.0 64.0 71.0 72C, 631 508
•* PRObLEMS/SOLUTIONS/COMMENTS
ONE FORCE[> SCRUBBER OUTAGE OCCURRED BECAUSE OF A SCREU CONVEYOR FAILURE,
RESULTING IN AN INABILITY TO MIX THE CHEMICAL ABSORBENT.
12/76 SYSTEM 93.0 88.0 92.0 8D.C 7*4 677 599
•• PRObLEMS/SOLUTIONS/COMMENTS
A FORCED IGD OUTAGE RESULTED FROM CHEMICAL DEPLETION.
A PLUGGED SENSING LINE FORCED AN FGD OUTAGE DURING DECEMBER.
1/77 SYSTEM 72.0 67.? 87.0 59.C1 744 6*5 437
«* PRObLEMS/SOLUTIONS/COMMENTS
RUBBER LIKING REPAIRS WERE INITIATED IN THE SEPARATOR SECTION OF THE
SCRUBBING MODULE ON JANUARY 22. THE LINING WAS DAMAGED BY A HIGH
TEMPERATURE EXCURSION RESULTING FROM A MALFUNCTION IN THE UNIT'S AIR
PKEHEATER.
2/77 SYSTEM .0 .C 672 599 :
3/77 SYSTEM .0 .n 74* 669 C
4/77 SYSTEM .!) .0 72 C 400 C
5/77 SYSTEM .9 .0 7*4 705 C
6/77 SYSTEM 47.0 45.0 44.0 44.0 720 701 315
• * PROcLtMS/SGLUT IONS/COMMENTS
REPAIRS OK THE DAMAGED RUBBER LINING WERE COMPLETED BY MID-JUNE AND THE
SYSTEM REMAINED IN SERVICE THROUGHOUT THE MAJORITY OF THE MONTH.
A MINOR FORCED OUTAGE RESULTED FROM A HIGH-LOW PRESSURE TRIP CAUSED BY
A PLUGGED SENSING LINE.
7/77 100.0 1CO.D 100.0 100.0
SYSTEM 744 7*4
** PRObLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS TAKEN OUT OF THE GAS PATH ONLY ONCE DURING THE MONTH
BECAUSE Of A SCHEDULED INSPECTION OF THE NEWLY REPLACED RUBBER LINER IN
THE SEPARATOR SECTION.
8/77 SYSTEM 19.0 21.0 19.0 19.0 7*4 662 138
224
-------
EPA UTILITY fGD SURVEY: FOURTH QUARTER 1979
NEVADA POWER: RtIO GARDNER 1 (CONT.)
. PERFORMANCE DATA — - — .—
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FCD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUlIONS/COMMENTS
ID FAN RELAYS WERE INSTALLED BECAUSE OF HIGH FAN VIBRATIONS.
9*77 SYSTEM 84.0 73.0 69.0 35.0 72 C 343 252
** PROuLEMS/SOLUTIONS/COMMENTS
THE BOILEK WAS OUT OF SERVICE FOR MOST OF THE MONTH.
TtiE SCRUPLES HAD LIMIT SWITCH PROBLEMS WITH 14 A t 6 &ULLOTINE DAMPERS.
10/77 SYSTEM 99.0 99.0 99.0 84.7 744 635 63C
*• PR06LEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FOR 5 HOURS DURING OCTOBER TO REPAIR AN ID FAN LEAK.
11/77 SYSTEM 78.7 81.5 78.6 78.1 72C 690 562
•* PRObLEMS/SOLUTIONS/COHMENTS
SCREEN PLUGGING IN THE RECYCLE TANK WAS A PROBLEM DURING NOVEMBER.
SCRUBBER INSTRUMENTATION DIFFICULTY WAS EXPERIENCED DURING NOVEMBER.
THE SYSTEM WAS DOWN FOR THE INSTALLATION OF AN OUTLET NOZZLE IN THE
BOOSTER TANK.
12/77 SYSTEM 85.0 82.0 83.0 71.0 744 631 522
** PRObLEMS/SOLUTIONS/CCMMENTS
THE SCRUPLES WAS OFF-LINE FOR APPROXIMATELY 109 HOURS DUE TO HIGH TRAY
DIFFERENTIAL PRESSURE AND SOME PLUGGING IN THE ID FAN SENSING LINE.
THE BOILER WAS DOWN ABOUT 113 HOURS Ik DECEMBER.
1/78 SYSTEM 56.0 68.0 69.0 56.0 744 616 416
*• PROULEMS/SOLUTIONS/COMMEN1S
TbO OUTAGES WERE CAUSED BY HIGH TRAY DIFFERENTIAL PRESSURE.
ELECTRICAL PROBLEMS IN THE 1A FORCED DRAFT FAN CAUSED AN FGD SYSTEM
OUTAGE.
2/78 SYSTEM 97.0 75.0 94.0 43.0 67i 389 292
** PRObLEMS/SOLUTIONS/COMMENTS
A DUCT HI-LO PRESSURE TRIP CONTRIBUTED TO THE FEBRUARY OUTAGE TIME.
THE BOILEK WENT OUT OF SERVICE ON FEBRUARY 17 FOR A THREE WEEK OUTAGE.
PLUGGED SENSING LINES CONTRIBUTED TO THE OUTAGE TIME DURING FEBRUARY.
3/78 SYSTEM 28.0 58.0 58.0 28.D 7*4 355 207
** PRObLEMS/SOLUTIONS/COMMENTS
THE bOILEfi WAS OFF LINE UNTIL MARCH 16.
A PROBLEM WAS ENCOUNTERED WITH THE REHEAT STEAM REGULATOR DURING MARCH
PROBLEMS WITH THE GUILLOTINE SWITCHES DELAYED START-UP OF THE FGD SYSTEM
UNTIL MARCH 22.
4/78 SYSTEM 100.0 97.0 100.0 75.0 720 560 541
225
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
THERE WERE NO FGD SYSTEM FORCED OUTAGES. ALL DOWNTIME WAS BOILER
RELATED.
5/78 SYSTEM 97.0 92.C 96.0 78.0 74 4 630 582
** PRObLEMS/SOLUTIONS/COMMENTS
THE REPAIRS TO THE CONDENSER AND PRODUCTION CONTROL CONTRIBUTED
TO THE BOILER OUTAGES.
HIGH TEMPERATURE ON AN ID FAN BEARING CAUSED AN OUTAGE.
6/78 SYSTEM 89.0 89.0 100.0 89.0 720 720 644
** PRObLEMS/SOLUTIONS/COMMENTS
THERE WAS ONE SCHEDULED FGD OUTAGE TO REPAIR A LEAK ON THE VENTUR1 uATEH
BOX.
7/78 SYSTEM 100.0 99.0 tOG.O 99.C 744 744 736
** PROuLEMS/SOLUTIONS/COMMENTS
A SCHEDULED FGD OUTAGE WAS REQUIRED TO RECTIFY A HIGH TRAY DIFFERENTIAL
PRESSURE F-ROBLEM. THE TRAY WAS CLEANED OUT DURING THE OUTAGE.
8/78 SYSTEM 94.3 94.? 93.3 89.? 744 706 661
•• PKOKLEMS/SOLUTJONS/COMNENTS
THE SCRUtbER WAS FORCED OFF LINE ON AUGUST 5 BECAUSE OF A LOSS OF THE
ASH PANEL CONTROL POWER. THIS LEFT THE UNIT WITHOUT EMERGENCY SPRAY TO
THE SCRUBL-ERS.
A FORCED OUTAGE OCCURRED ON AUGUST 20 WHEN THERE WAS A SCRUBBER VENTURI
HIGH TEMPERATURE ALARM. THE EXACT CAUSE WAS NOT KNOWN BUT A BOILER TUBE
LEAK WAS SUSPECTED.
THERE WAS ONE SCHEDULED OUTAGE DURING THE MONTH TO CLEAN THE TRAY.
9/78 SYSTEM 99.0 97.D 99.0 67.T 720 644 626
«• PRObLEMS/SOLUTIONS/COMMENTS
THERE WERE THREE BOILER RELATED OUTAGES DURING SEPTEMBER. A BOILER TUBE
LEAK AND BOILER BURNER WERE REPAIRED.
DURING THE MONTH A BOILER TRIP OCCURRED WHICH WAS CAUSED BY SCRUBBER
HIGH DUCT PRESSURE.
TO/78 SYSTEM 100.0 1C3.0 100.0 90.0 744 667 667
•* PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF LINE FOR ABOUT 77 HOURS FOR REMOVAL OF AN ASH CLINKER.
11/78 SYSTEM 100.0 1CO.O 100.0 90.0 720 598 598
•* PROfaLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN FOR SCRUBBER OUTLET TEMPERATURE PROBE REPAIRS.
OUTAGE TIKE RESULTED WHEN BOILER PROBLEMS CAUSED THE VENTURI OUTLET GAS
TEMPERATURE TO BECOME TO HIGH (TEMPERATURE ALARM HIGH TRIP).
12/78 SYSTEM 95.6 92.? 92.9 92.r 744 737 684
226
-------
EPA UTILITY fGO SURVEY: FOURTH OUARTER 1979
NEVADA PO.ER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEHAB1L1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUfcbING SYSTEM WAS OUT OF SERVICE TO REPAIR A LEAK IN A VENTURI
LINE.
THE FGD SYSTEM WAS DOWN TO CLEAN THE VENTURI RACE TRACK AND CLEAN PRESSURE
SENSING LINES.
THE POILEfc WAS OFF LINE APPROXIMATELY 1 DAY FOR PULVERIZER REPAIRS.
1/79 SYSTEM 83.9 73.7 73.7 67.0 74* 681 502
•• PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER UAS DOWN ABOUT 5 DAYS TO REMOVE A CLINKER FROM THE BOTTOM
HOPPER.
A FORCED OUTAGE WAS CAUSED WHEN THE 2C LOAD CENTER TRIPPED RESULTING IN
LOSS OF POWER TO TRAY SPRAY PUMP. REPAIRS WERE MADE ON THE TRAY AND SPRAY
SYSTEMS.
THE FGD SYSTEM WAS DOWN FOR A SHORT PERIOD TO INSPECT THE BEARING OK THE
II FAN.
THE FGD SYSTEM WAS DOWN TO REPAIR A LEAK IN THE VENTURI LINE.
2/79 SYSTEM 85.6 85.9 85.9 85.6 672 670 575
*« PRObLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN TO CLEAN THE VENTURI RACE TRACK NOZZLES, CLEAN THE
EFFLUENT LINE AND REPAIR A LEAK IN THE VENTURI LINE.
A BREAK IN THE ASH CIRCULATING WATER LINE RESULTING IN LOSS OF EMERGENCY
COOLING WATER FORCED THE FGD SYSTEM OFF LINE.
3/79 SYSTEM 97.9 96.5 96.5 78.3 744 603 582
•* PHObLEMS/SOLUTIONS/COMMENIS
THE FGD SYSTEM WAS OFF TO UNPLUG VENTURI NOZZLES AND TO CLEAN SENSING
LINES. THE DOWNTIME WAS ABOUT IS HOURS.
THE FGD SYSTEM WAS OFF FOR ABOUT U6 HOURS FOR REPAIR OF BOILER TUBE
LEAKS.
4/79 SYSTEM 1CO.O 98.7 98.6 25.7 720 188 185
** PRObLENS/SOLUTIONS/COMMENIS
THE BOILER AND FGD SYSTEM WERE OFF FOR APPROXIMATELY 533 HOURS FOR SCHED-
ULED MAINTENANCE.
5/79 SYSTEM 99.8 74.4 74.4 27.5 744 275 204
*• PRObLEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBER WERE RETURNED TO SERVICE ON THE 22ND AFTER
MAINTENANCE.
THE BOILER WAS FORCED OUT OF SERVICE TO REPAIR A COAL LEAK ON THE *8
BURNER LINL.
6/79 SYSTEM 97.7 95.1 95.2 84.7 720 641 610
227
-------
EPA UTILITY FGO SURWEY: FOURTH QUARTER 1979
NEVADA POhER: REID GARDNER 1 (CONT.)
. PERFORMANCE DATA — .....
PERIOD MODULE AVAILABILITY OPERAGILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
502 PART. HOURS HOURS HOURS FACTOR
«* PROBLEMS/SOLUTIONS/COMMENTS
A fEW DAYS OUTAGE TIME WAS REQUIRED TO REPAIR A BOILER TUBE LEAK.
OUTAGE TIME. WAS REQUIRED TO UNPLUG A VENTURl LINE.
TRAY SPRAY VALVES WERE REPLACED DURING JUNE.
7/79 SYSTEM 81.2 80.5 80.5 80.3 744 742 598
*• PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGO SYSTEM WAS TRIPPED OFF FOR TURBINE OVERSPEE6 GOVERNOR
TEST. THE DOWNTIME WAS ABOUT 7 HOURS.
THE SCRUBBER WAS OFF ABOUT 67 HOURS TO CLEAN THE SCRUBBER TRAYS.
LOST INSTRlNENT AIR TO THE SCRUBBER CONTROLS CAUSED A LOSS OF POWER TO THE
SCRUBBER AIR COMPRESSOR. THE SCRUBBER WAS OFF-LINE FOR ABOUT 74 HOURS.
8/79 SYSTEM 96.8 96.8 96.8 96.8 744 744 721
*« PRObLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS REMOVED FROM SERVICE TO CLEAN THE SCRUBBER PRESSURE
SENSING LINES. THE SCRUBBER WAS DOWN FOR ABOUT 11 HOURS.
THE SCRUBBtR WAS DOWN AT THE END OF THE MONTH TO CLEAN THE PRESSURE
SENSING LIKE ON THE SCRUBBER. THE SCRUBBER WAS OFF-LINE FOR ABOUT 4 HOURS.
9/79 SYSTEM 100.0 10C.O 100.0 53.2 720 383 363
•• PRObLEMS/SOLUTIONS/COMMENTS
IN SEPTEMBER THE SCRUBBER WENT OFF WITH THE BOILER AND TURBINE FOR
SCHEDULED MAINTENANCE.
10/79 SYSTEM 45.4 61.7 62.1 45.2 744 545 337
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS OFF LINE WITH THE BOILER AND TURBINE FOR SCHEDULED
MAINTENANCE DURING THE BEGINNING OF OCTOBER.
PLUGGING OF THE VENTURl AND EFFLUENT LINE CAUSED THREE OUTAGES DURING
THE MONTH.
THE SCRUBBER WENT OFF LINE SO WORK COULD BE DONE ON THE ID FAN DAMPER.
THE SCRUBBER WAS TAKEN OFF LINE WITH THE BOILER DUE TO A TURBINE TRIP.
11/79 SYSTEM 99.4 96.7 99.4 88.1 72; 656 635
*« PRObLENS/SOLUTIONS/COMMENTS
THE SCRUBBER WENT OFF-LINE WITH THE BOILER TO REPAIR A GN-1 SWITCH AND THE
EMERGENCY GOVERNING TEST SWITCH ON THE TURBINE.
TWO OUTAGES DURING NOVEMBER WERE CAUSED BY A BOILER TUBE LEAK.
THE VENTURl RACE TRACK NOZZLES NEEDED CLEANING CAUSING THE SCRUBBER TO
00 OFF-LINE.
TWICE DURING THE MONTH THE TURBINE TRIPPED CAUSING THE SECTION 1B BREAKER
TO BE LOST. ON THE SECOND TRIP THE 1B COOLING TOWER FAN MOTOR SHORTED
TO GROUND.
12/79 SYSTEM 98.5 98.5 98.5 98.5 744 7*4 733
228
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NEVADA PCUER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•» PRObLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE SCRUBBER WENT OFF LINE DUE TO A MALFUNCTIONING VALVE
ON THE EMERGENCY SPRAY SVSTtM.
229
-------
EPA UTILITY FOO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - M*.
NET UNIT GENERATING CAPACITY U/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGL - MM
EQUIVALENT SCRUBBED CAPACITY - KW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM UOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - I
NEVADA POWER
REID GARDNER
2
MOAPA
NEVADA
B
47.
516.
< .100 LB/MMBTU)
( 1.200 LB/MMBTU)
125.0
11C.O
12 '.0
FOSTER WHEELER
PULVERIZED COAL
BASE
0/68
223.21 < 473000 ACFM)
176.7 ( 350 F>
61. ( 200 FTI
******* (***** ff)
COAL
BITUMINOUS
28959.
e.oo
8.-1C.
5.50
5-6
.50
0.5-1.0
.05
< 12450 BTU/LB)
MECHANICAL COLLECTOR
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY
PARTICULATE SC RUBE-EH
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGE S
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
LIQUID REC1RCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - G/CU.p.
PAHTICULATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
FGD SYSTEM
SALEABLE PR OOUC T/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-t FIRM
DEVELOPMENT LEVEL
NEU/RETRuFIT
MULTICLONES
RESEARCH COTTRELL
X 75.0
1
VENTURI
AOL/COMBUSTION
1
INCO IOY 825 AT
RUBBER CAREAS
TWIN VARIABLE
TANGENTIAL
5C.O
223.2
176.7
157.5
1 .3
50.3
1 .4
97.0
375.000
EQUIP ASSOCIATES
THROAT
OTHER THAN THROAT)
THROATS
473000 ACFM)
353 F)
2500 GPK)
1C.O GAL/1000ACF)
***** IN-H20)
165.0 FT/S)
.60 GR/SCF)
THROWAWAY PRODUCT
WET SCRUBBING
SODIUM CARBONATE
NONE
AOL/COMBUSTION EQUIP ASSOCIATE
BECHTEL
FULL SCALE
RETROFIT
23;
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REID GARDNER <. (CONT.)
PARTKULATE DESIGN REMOVAL EFFICIENCY - X 97.00
S02 DESICN REMOVAL EFFICIENCY - 1 90.00
INITIAL START-UP 4/74
ABSORBER SPARE CAPACITY INDEX - I .0
ABSORBER SPARE COMPONENT INDEX .0
** AbSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATER1AL
BOILER LOAD/ABSORBER - X
LIQUID REC1RCULATION RATE - LITER/S
L/G RATIO - L/C U.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - H/SEC
S02 OUTLtT CONTRATION - PfM
S02 OESIC.N REMOVAL EFFICIENCY - X
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
TRAY TOWER
4/74
ADL/COMBUST10N EQUIPMENT ASSOCIATES
30 DIA.
CARBON STEEL
RUBBER
316L SS (WASH TRAY)
100.0
J6.
• e.
.7
3.4
17
91.2
SCRUBBER FD
CARBON STEEL
DRV
223.21
( 630 GPM)
( 1.6 GAL/1000ACF)
( 3.0 IN-H20)
< 11.0 FT/S)
( 473000 ACFN)
MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONF IGURAT10N
NUMPER OF STAGE S
NUMBER OF PASSES
WASH SYSTEM
PRESSURE DROP - KPA
PUMPS
SERVICE
SCRUBBER RECIRCULATION
ABSORBER RECIRCULAT ION
1
RADIAL VANE
316L SS (BOTH ME AND WASH TRAY)
HORIZONTAL
1
1
NONE
.1 ( .5 IN-H20)
NUMBER
TANKS
SERVICE
VENTURI RECTCLE
REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
THICKENER
NUMBER
NUMBER
HOT AIR INJECTION
STEAF
27.8 ( 50 F)
15.2 MM BTU/H (RATING)i 4 MU
•* WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
•• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
** DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
CLOSED
9.8
( 155 GPM)
FINAL
LINE [ POND
ON-SITE
GRAVITY FLOW FRO" INTERIM SLUDGE POND
45.C
INTERIM
LINED POND
ON-SITE
5 .3
231
-------
EPA UTILITY fGD SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REID GARDNER £ (COM.)
PERFORNANC E DATA
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
4/74 SYSTEM 720
•* PRObLEMS/SOLUTlONS/COMMENTS
THE FGD SYSTEM HAS PLACED IN SERVICE IN APRIL 1974. THE SCRUBBING SYSTEM
DESIGN WAS BASED ON INFORMATION AND DATA OBTAINED FROM AN gOOO-ACFtt PILOT
PLANT PROGRAM CONDUCTED AT REID GARDNER IN 1971 AND 1972.
2/75 SYSTEM 9C.C 672
*• PROBLEMS/SOLUTIONS/COMMENTS
ROUTINE MECHANICAL PROBLEMS WERE ENCOUNTERED DURING FEBRUARY.
ROUTINE INSTRUMENTAL PROBLEMS MERE EXPERIENCED.
ABRASION OF RUBBER-LINED PIPES WERE A PROBLEM.
A SECOND PERFORMANCE TEST WAS PASSED.
THE UNIT kAS RESTARTED AFTER SHUTDOWN FOR S-TEAR TURBINE OVERHAUL.
SEAL NATEK FILTERS WERE A PROBLEM.
BOILER CONTROLS WERE A PROBLEM.
A PLUGGED RECYCLE LINE STRAINER HAS A PROBLEM.
3/75 SYSTEM 744
4/75 SYSTEM 720
5/75 SYSTEM 744
6/75 SYSTEM 720
7/75 SYSTEM 85.0 744
8/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
A BROKEN bUCKET ELEVATOR CAUSED A FORCED F6D OUTAGE.
WORN RECIRCULATION PIPING CONTRIBUTED TO FORCED FGD OUTAGE.
A FORCED FGD OUTA6E WAS CAUSED BT A RUBBER LINER LEAKAGE.
STRAINER PLUGGING CONTRIBUTED TO FORCED FfiO OUTAGE TIME.
THREE FORCED OUTAGES OCCURRED DURING AUGUST AND SEPTEMBER.
9/75 SYSTEM 77.3 69.0 720 645 496
10/75 SYSTEM 87.0 62.0 744 531 464
«• PRObLEMS/SOLUTIONS/COHMENTS
PUMP REPAIR NECESSITATED AN FGD OUTAGE.
INSTRUMENT PLUGGING CAUSED AN F6D OUTAGE.
REPAIR OF PIPING LEAKAGE NfCESSITATED AN FGD OUTAGE.
11/75 SYSTEM 95.0 83.0 723 603 596
12/75 SYSTEM 744
232
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REID GARDNER Z (CONT.)
.. PERFORMANCE DATA . —
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•« PROBLEMS/SOLUTIONS/COMMENTS
FROZEN CARBONATE LINES CONTRIBUTED TO FGD OUTAGE TINE.
A FGD OUTAGE WAS CAUSED BY A PLUGGED PRESSURE-SENSING LINES.
DUCT PRESSURE TRIPS CONTRIBUTED TO FGD OUTAGE TIME.
AN OVERHAUL OF A TRAY RECYCLE PU"P WA S NECESSARY DURING DECEMBER.
1/76 SYSTEM 72.0 66.0 66.0 62.0 7*4 691 458
2/76 SYSTEM 84.0 86.0 86.0 63.0 696 675 578
*• PR06LEMS/SOLUTIONS/COMNENTS
A VENTURI PUMP HAD TO BE UNPLUGGED CONTRIBUTING TO DOWN TIME.
CHEMICAL DEPLETION CONTRIBUTED TO FGD OUTAGE TIME.
StAL WATER PROBLEMS HAVE BEEN ENCOUNTERED DURING FEBRUARY.
THE UTILITY REPORTED FOUR SCRUBBER INACTIVE PERIODS DURING FEBRUARY, THREE
OF WHICH WERE SCRUBBER-RELATED OUTAGES.
3/76 SYSTEM 67.0 6C.C 62.0 53.C 7*4 660 395
** PRObLEMS/SOLUTIONS/COMMENTS
TWO FGD FORCED OUTAGES OCCURRED DURING MARCH.
AN ELECTRICAL FAILURE RESULTED IN AN FGD SYSTEM OUTAGE.
PLUGGING IN THE TRAY SYSTEM RESULTED IN A SUBSEQUENT OVERHAUL OF THE TRAY
CYCLE PUMPS.
4/76 SYSTEM 85.0 77.3 83.0 68.0 720 629 488
•* PRObLEHS/SOLUTIONS/COMMENTS
PLUGGED SENSING LINES RESULTED IN FGD OUTAGE TIME.
A REHEATE* LEAK DURING APRIL CAUSED DOWN TIME FOR REPAIRS.
VENTURI SPOOL RECYCLE REPLACEMENT REQUIRED FGD OUTAGE TIME.
A TANK NEEDED PATCHING DURING THE MONTH.
FOUR FORCED SCRUBBER OUTAGES WERE REPORTED BY THE UTILITY FOR APRIL.
5/76 SYSTEM 99.0 83.0 98.0 79.0 744
*• PROBLEMS/SOLUTIONS/COMMENTS
PLUGGED VENTURI LINES WERE A PROBLEM DURING NAY.
A PROBLEM WITH A PLUGGED SENSING LINE WAS EXPERIENCED.
TOTAL SCRCBBER OPERATION TIME TO DATE is 9488 HOURS.
6/76 SYSTEM 99.1 83.3 98.9 78.8 72C 682 568
7/76 SYSTEM 91.0 81.0 96.0 57.? 744 518 421
•* PROBLEMS/SOLUTIONS/COMMENTS
A PROBLEM WITH A HIGH SOLIDS CONCENTRATION IN THE VENTURI SCRUBBING CYCLE
CONTRIBUTED TO FGD OUTAGE TIME.
233
-------
EPA UTILITY FOD SURVEY: FOURTH QUARTER 1979
NEVADA POkER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE REPLACEMENT OF A RUBBER-LINED PIPE IN THE VENTURI SCRUBBER WAS D
NtCES S1RY DURING JULY.
8/76 SYSTEM 95.D 75.D 94.0 71. C 744 709 53C
•• PHObLEMS/SOLUTIONS/COMMENTS
DEPLETION OF CHEMICAL ABSORBENT (TRONA) CONTRIBUTED TO FGD OUTAGE TIKE.
BCILEH TRIPS WERE ENCOUNTERED DURING AUGUST.
LEAKAGE IK THE VENTURI RFCKLfc LINE WAS A PROBLEM.
THE THICKENER PLUGGED CAUSING FGD DOWN TIME.
FORCED OUTAGE TIME TOTALED 34.5 HOURS FOR THE FGD SYSTEM.
9/76 SYSTEM 94.? 96.0 94.0 91.0 720 681 653
•• PROoLEMS/SOLUTIONS/COMMENTS
P1MOR TRIFS WERE CAUSED BY PLUGGING IN THE I.0. FAN REFERENCE LINES.
A MINOR SYSTEM TRIP WAS CAUSED BY A FALSE HIGH TEMPERATURE READING IN
THE VENTUKI DUE TO MATER IN THE INSTRUMENT.
10/76 SYSTEM 95.0 95.: 95.0 88.0 744 694 656
•• PNObLEHS/SOLtmONS/COMMENTS
SCRUbbER TRIPS WERE CAUSED BY VENTURI GAS DAMPER PROBLEMS.
REPLACEMENT OF THE CARBONATE FEED LINE CAUSED AN FGD OUTAGE.
PLUGGING IN THE SCRUBBER EFFLUENT LINE CONTRIBUTED TO FGD DOWN TIME.
SCRUBBER OUTAGE TIME DUE TO BOILER TRIPS AMOUNTED TO APPROXIMATELY (5
HOURS.
11/76 SYSTEM 52.0 58.0 51.0 50.r 72C 621 363
12/76 SYSTEM .0 .0 744 275 C
** PKObLEMS/SOLUTIONb/CCMMENTS
THE l-OILFF. WAS DOWN FOR REPAIR OF A CONDEMSER TUBE LEAK AND BOTTOM ASH
NOZZLE.
DURING THE bOiLER OUTAGE THE SCRUBBER'S GUILLOTINE DAMPERS WERE BADLY
DAMACED. THE SCRUBBER REMAINED OUT OF SERVICE DURING THE MONTH OF
DECEMBER.
1/77 SYSTEM .0 744 0 0
*• PKOcLEMS/SOLUTIONS/COMMENTS
THE EOILEt I.AS OFF LINE DURING JANUARY FOR MAINTENANCE.
2/77 SYSTtP 93.0 75." 68.0 56.0 672 516 387
•• PROlLEMS/SOLUTIONS/COMIENTS
A MINOS SIPLDBER OUTAGE RESULTED FROM A VENTURI PIPING LEAK.
AT' THE tNt CF FEBRUARY THERE toERE SOME ELECTRICAL PROBLEMS.
A MINOS SCFUPbER OUTAGE WAS REQUIRED TO CLEAN THE WASH TRAY RECYCLE TANK.
J/77 SYSTEM 92.0 86.7 V7.3 76.C 744 659 567
234
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
NEVADA POWER: RtID GARDNER I (CONT.)
PERFORMANCE DATA - — — "
PERIOD MODULE AVAILABILITY CPERA8IL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROE'LEMS/SOLUTIONS/COMMENIS
A PLUGGED SPRAY TRAY CONTRIBUTED TO FGD OUTAGE TIME.
ELECTRICAL PROBLEMS WERE EXPERIENCED DURING MARCH.
HIGH-LOW DUCT PRESSURE CAUSED FGD DOUN TIME.
DUE TO AN I.D. FAN SMING THE fGO SYSTEM WENT OFF LINE.
4/77 SYSTEM 95.0 95.0 95.3 95.0 720 720 685
•* PROuLEMS/SOLUTIONS/COMMENTS
FORCED FGD OUTAGE TIME RESULTED FROM A LEAK IN THE VENTURI DISCHARGE LINE.
5/77 SYSTEM 99.0 85.3 98.0 60.0 ?** 52* 445
** PRObLEMS/SOLUT10NS/COMMENTS
ONE BOILER OUTAGE OCCURRED DURING MAY.
THE ASH SERVICE PUMPS WERE OUT OF SERVICE FOR APPROXIMATELY 10 HOURS
RESULTING IN NO EMERGENCY SPRAY THUS FORCING THE FGD SYSTEM OUT OF SERVICE
6/77 SYSTEM 94.0 93.? 94.0 83.C 72C 639 596
*• PROBLEMS/*OLUTIONS/COMMENTS
THREE FORCED SCRUBBER OUTAGES WERE REPORTED IN JUNE.
ONE FORCED OUTAGE WAS DUE TO PLUGGING OF THE I.D. FAN SENSING LINE.
A BREAKER TRIP RESULTED IN A LOSS OF CONTROL POWER CAUSING DOUN TIME.
THE SPRAY NOZZLES IN THE VENTURI PLUGGED CAUSING AN FGD OUTAGE.
7/77 SYSTEM 40.0 41.C 40.0 40.0 744 733 298
«« PROfcLEMS/SOLUTlONS/COMMENTS
SEVEN FORCED FGD OUTAGES WERE DUE TO A HIGH/LOW TRIP IN THE SCRUBBER DUCT
DURING JULY.
ONE TWO HOUR OUTAGE WAS REQUIRED TO CORRECT A PLUGGING PROBLEM IN THE
VENTURI SI-RAY NOZZLES DURING JULY.
8/77 SYSTEM 87.0 91.0 87.0 79.0 744 629 59C
«« PRObLEMS/SOLUTIONS/COMMENTS
A LEAK IN THE VENTURI RECYCLE HEADER RESULTED IN AN FGD OUTAGE.
A SCRUObEf) DUCT HIGH/LOU BOILER TRIP PROBLEM RESULTED IN OUTAGE TIKE.
THERE WAS ONE BOILER RELATED OUTAGE DURING AUGUST.
9/77 SYSTEM 74.0 67.0 71.0 64.0 720 716 462
*• PROBLEMS/SOLUTIONS/COMMENTS
A LEAK IN THE VENTURI RECYCLE LINES RESULTED IN FORCED FGD OUTAGE TIME.
TRAY RECYCLE PUMP REPAIR NECESSITATED FGD OUTAGE TIME.
DUCT PRESSURE HIGH/LOU SENSING LINE PLUGGING OCCURRED DURING SEPTEMBER. E
AN OUTAGE OCCURRED WHEN THE ASH SLUICE SYSTEM WENT OUT OF SERVICE (NO
EMERGENCY SPRAYS) DURING SEPTEMBER.
235
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F.PA UTILITY FGD SURV£Y: FOURTH QUARTER 1979
NEVADA PObEs: REID GARDNER 2 (CONT.)
._ . ---PERFORMANCE DATA - — —
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION I REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
AN OUTAGE OCCURRED WHEN A TRAY PLUGGED.
THE FGD SYSTEM WAS TAKEN OFF-LINE TO ALLOW CLEANING OF A SUCTION SCREEN
IK THE TRAY RECYCLE TANK.
10/77 SYSTEM 76.C 80.0 76.0 80.0 74* 704 562
** PRObLEMS/SOLUTIONS/COMMENTS
AFGD OUTAGE TIME WAS NEEDED TO CLEAN A PLUGGED TRAY RECYCLE TANK SCREEN.
A VENTURI TANK SEPARATOR REQUIRED CLEANING CAUSING FGD DOWN TIME.
A HIGH SOLIDS PROBLEM IN THE VENTURI RECYCLE SYSTEM HAD TO BE CORRECTED.
A SCRUBBER DUCT HIGH/LOW PRESSURE BOILER TRIP UAS-REPAIRED.
I.D. FAN LEAKS WERE PATCHED DURING OCTOBER.
11/77 SYSTEM 86.0 .0 .0 .0 720 98 C
** PSObLEHS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FROM OCTOBER 31 UNTIL NOVEMBER 26.
THE SCRUBLER WAS OUT OF SERVICE FOR AN I.D. FAN ROTOR REPAIR.
12/77 SYSTEM .0 .0 .0 .0 744 742 C
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBfcER MODULE WAS OUT OF SERVICE TO INSTALL NEW WEAR PLATES ON AN
I.D. FAN ROTOR.
1/78 SYSTEM 67.0 74.D 67.0 67.0 744 675 499
•* PRObLEHS/SOLUTIONS/COMMENTS
THE SCRUBLER WENT BACK ON LINE ON JANUARY 4 AFTER THE INSTALLATION OF
WEAR PLATES ON AN I.D. FAN ROTOR.
REPAIRS ON THE THICKENER OVERFLOW PUMP CONTRIBUTED TO FGD OUTAGE TIKE.
SOME BUILD UP IN THE VENTURI WAS ENCOUNTERED DURING
JANUARY.
2/78 SYSTEM 93.0 92.0 92.0 87.0 672 636 585
•* PRObLEMS/SOLUTIONS/CONMENTS
A DUCT HIGH/LOW PRESSURE TRIP CONTRIBUTED TO OUTAGE TIME.
THE BOILER WAS OUT OF SERVICE FOR 34 HOURS DURING FEBRUARY.
3/78 SYSTEM 98.0 89.0 97.0 80.0 744 672 595
•* PRObLEMS/SOLUTIONS/COMNENTS
THERE WAS ONLY ONE FORCED FGD OUTAGE DURING MARCH WHICH LASTED APPROXIMATE
LV 18 HOURS.
A SCHDULED BOILER OUTAGE AT THE BEGINNING OF MARCH TO REMOVE ASH BUILDUP
WAS CANCELLED.
4/78 SYSTEM 100.0 93.0 100.0 44.0 720 320 317
236
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EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REID GARDNER i (CONT.)
PERFORMANCE BATA — — - — -----
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COHMENTS
THERE WAS ONE SCHEDULED BOILER OUTAGE WHICH LASTED ABOUT 403 HOURS.
5/78 SYSTEM 100.0 10C.O 100.0 97.0 7*4 726 724
•• PROtoLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF FOR APPROXIMATELY 18 HOURS FOR REPAIRS ON THE MILL
SPOKES.
THE 2A SEC. BREAKER TRIPPED AND CAUSED AN OUTAGE OF ABOUT ONE HOUR.
6/78 SYSTEM 100.0 92.0 100.0 92.0 72C 720 661
** PRObLEMS/SOLUTIONS/COMMENTS
THERE WERt TWO SCHEDULED FGD OUTAGES TO UNPLUG THE TRAYS AND TO CHANGE
THE OIL Oh THE I.D. FAN.
A FOKEO FGD OUTAGE OCCURRED WHEN HIGH DUCT PRESSURE CAUSED A BOILEfl TRIP.
7/78 SYSTEM 8C.O 82.0 79.0 74.0 744 676 553
•* PROULEHS/SOLUTIONS/COHMENTS
THE BOILER WAS OUT OF SERVICE DUE TO A BOILER TUBE LEAK.
HIGH DUCT PRESSURE WAS THE CAUSE OF A BOILER TRIP. THE HIGH DUCT PRESSURE
AWAS CAUSED BY A FAULTY POSITIONER ON THE 1.0. FAN CONTROLLER.
THE I.D. FAN EXPANSION JOINT ON THE SCRUBBER UAS REPLACED.
AN ftO OUTAGE OCCURRED WHEN A BOLT, WHICH FELL FROM THE FAN, CAUSED
VIBRATIONS.
A SECOND tOILER TRIP DURING JULY WAS CAUSED BY AN UNDETERMINED SOURCE.
THE SUCTION LINE FROM THE VENTURI DISCHARGE LINE TO THE EFFLUENT PUMPS
HAD TO BE CLEANED BECAUSE OF PLUGGING.
b/78 SYSTEM 81.0 82.0 93.0 81.0 744 733 601
•• PROfaLEMS/SOLUTIONS/COMMENTS
TWO SCHEDULED OUTAGES DURING AUGUST WERE NECESSARY TO CLEAN THE SCRUBBER
TRAY.
A SCHEDULED OUTAGE UAS NECESSARY TO CLEAN THE NOZZLES ON THE SCRUBBER SPRA
RACK. THE STAINLESS STEEL PIPE TO THE TRAY SPRAY NOZZLES WAS ALSO
REPLACED.
ON AUGUST 1 THE SCRUBBER EXPERIENCED HIGH DUCT PRESSURE.
ON AUGUST I IT WAS NECESSA IV TO TAKE THE SCRUBBER OFF LINE TO REPACK THE
VENTURI PUMPS.
A THIRD OUTAGE IN AUGUST WAS CAUSED BY A LOSS OF THE ASH PANEL CONTROL
POWER. THIS LEFT THE SCRUBBER WITHOUT EMERGENCY SPRAY.
9/78 SYSTEM 100.0 97.0 100.0 94.0 720 693 675
«* PRObLEMS/SOLUTIONS/COMMENTS
A SCHEDULED SCRUBBER OUTAGE TOOK PLACE DURING SEPTEMBER IN ORBER TO CLEAN
THE TRAY RECYCLE TANK AS WELL AS THE TRAY AND SOME OF THE LINES.
THREE BOILER RELATED OUTAGES WERE CAUSED BY PROBLEMS WITH A 10-KW
GENERATOR. CONTROL POWER SURGES WERE BEING CAUSED BY OVERVOlTACE MOTOR
237
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
NEVADA PO*ER: RLID GARDNER i (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY GPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
TRIPS .
10/78 SYSTEM 96.0 95.D 99.0 92.0 744 721 685
** PRObLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE SCRUBBER INSTRUMENTS WERE WORKED ON DURING A SCHEDULED
OUTAGE.
THE tOILEt hAS FORCED OUT OF SERVICE FOR ABOUT 28 HOURS BECAUSE OF BOILER
DRUM PROBLEMS.
11/78 SYSTEM 98.0 93.? 93.0 36.0 720 277 258
** PRObLEMS/SOLUTIONS/CCMMENTS
A FORCED FGD OUTAGE OCCURRED DUE TO HIGH DUCT PRESSURE.
WORK nAS LONE ON I.D. FAN CONTROLS DURING NOVEMBER.
THE UNIT kAS SHUT DOWN NOVEMBER 12 FOR SCHEDULED BOILER MAINTENANCE. THE
UNIT REMAINED OUT OF SERVICE THE REMAINDER OF THE MONTH.
12/7? SYSTEM 95.9 1CG.C 1C3.0 13.7 744 99C 99C
** PSOuLEMS/SOLUTIONS/COMflENTS
THE SCRUBfcEK UAS DOWN TO UNPLUG EFFLUENT LINE.
WHILE THE SCRUBBER WAS DOWN THE BOILER UAS ALSO DOWN FOR PULVERIZER
REPAIRS.
THE E-OILER WAS OFF UNTIL DECEMBER 26 FOR SCHEDULED MAINTENANCE.
1/79 SYSTEM 82.9 81.3 81.3 73.9 744 676 549
*• PRObLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM UAS DOUN TO CLEAN A TRAY SCREEN.
THE FGO SYSTEM UAS DOWN TO REPAIR A LEAK IN THE VENTURI RECYCLE LINE.
THE BOILER WAS DOUN TO REPAIR TUBE LEAKS.
REPAIRS UERE MADE ON THE T IAY AND SPRAY PUMP SYSTEMS.
THE VENTURI RECYCLE PUMP LOST POWER.
THE SCRUBE.ER TRAY PUMP MOTOR UENT TO GROUND. THE 2C LOAD CENTER TRIPPED.
THERE WAS A SCRUBBER TRIP DUE TO HIGH DUCT PRESSURE.
A HIGH DUCT PRESSURE TRIP WAS RESPONSIBLE FOR A SHORT OUTAGE. THE R
PRESSURE SENSING LINES UERE ALSO CLEANED.
2/79 SYSTEM 96.5 93.1 93.2 87.9 672 634 591
«* PRObLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM UAS DOUN TO REPAIR A LEAK IN THE VENTURI LINE.
THE FGD SYSTEM UAS FORCED OUT OF SERVICE DUE TO A 28 LOAD CENTER POfcER
LOSS.
THE SCRUBfcER UAS FORCED DOWN DUE TO A BREAK IN THE ASH UATER CIRCULATING
WATER LINE RESULTING IN LOSS OF EMERGENCY COOLING UATER.
THE FGD SYSTEM UAS DOUN BECAUSE OF A LEAK ON THE VENTURI RACE TRACK AND
TC CLEAN THE VENTURI RACE TRACK NOZZLES.
238
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NEVADA POtaER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEPAB1LITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE BOILER WAS DOyN TO REPAIR A TUBE LEAK.
3/79 SYSTEM 97.8 96.6 96.6 89.2 744 688 665
** PROULEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBER WERE OFF F.OR ABOUT TWO DAYS FOR REPAIR OF BOILER
TUBE LEAKS.
THE BOILER TRIPPED DUE TO HIGH FURNACE PRESSURE. WHILE THE BOILER MAS
DOWN SENSING LINES WERE CLEANED ON THE SCRUBBER.
4/79 SYSTEM 88.8 95.9 96.0 88.8 720 666 640
** PROfcLEMS/SOLUTIONS/CCMMENTS
A HIGH PRESSURE ALARM ON THE SCRUBBER DUCT TRIPPED THE SCRUBBER OFF LINE.
THE SCRUBBER PRESSURE SENSING LINES MERE CLEANED. THIS OCCURRED TWICE
DURING THE MONTH OF APRIL.
A CONTROL PQkER FAILURE OCCURRED CAUSING A SCRUBBER TRIP WHEN THE 10 KW
GENERATOR kAS PUT bACK IN SERVICE.
5/79 SYSTEM 99.8 99.4 99.5 83.9 744 627 624
«• PRObLtMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FOR ABOUT 5 DAYS TO REPAIR TUBE LEAKS.
PRESSURE SENSING LINES ON THE SCRUBBER CONTROLS WERE CLEANED.
6/79 SYSTEM 93.2 86.8 86.9 73.2 720 607 527
** PROfaLEMS/SOLUTIONS/COMMENTS
THE SCRUBBLR WAS FORCED OUT OF SERVICE DUE. TO VENTURI PUMP POWER LOSS.
SOME OUTAGE TIME WAS REQUIRED TO REPAIR VENTURI PUMP DISCHARGE VALVES.
SOKE BOILER OUTAGE WAS REQUIRED DURING JUNE TO REPAIR HIGH PRESSURE HEATER
TUBE LEAKSt TO WELD A CAP ON THE HIGH PRESSURE HEATER, TO WORK ON PRIMARY
Aid FANS, AND TO REPAIR A BOILER TUBE LEAK.
SCRUBBER OUTAGE TINE WAS REQUIRED TO CLEAN PRESSURE SENSING LINES.
7/79 SYSTEM 86.8 9C.6 85.5 78.1 744 642 646
** PRObLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS OFF AT THE START OF THE MONTH WITH A BAD VENTURI PROBE
TEMPERATURE AND A BLOWN BOILER TUBE. THIS OUTAGE LASTED ABOUT 76 HOURS.
THE BOILER AND SCRUBBER WAS OFF TO REPAIR BOILER TUBE LEAK.
SCRUBBER AND BOILER TRIPPED OFF FOR ABOUT 50 HOURS. THIS OUTAGE WAS CAUSED
BY LOST CONTROL AIR TO THE SCRUBBER AND POWER LOSS TO SCRUBBER AIR
COHPRt SSOR.
THE SENSING LINES ON THE SCRUBBER MERE CLEANED TO PREVENT HIGH SCRUBBER
DUCT PRESSURE. THE SYSTEM WAS OFF FOR ABOUT 16 HOURS.
8/79 SYSTEM 93.2 98.9 93.2 93.1 744 701 694
*« PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER AND THE BOILER WENT DOWN FOR ABOUT 40 HOURS TO REPAIR A
BOILER TUBE LEAK.
THE SCRUBBER WAS OFF TO REPAIR LEAK IN VENTURI PUMP DISCHARGE BODY. THE
239
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EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NEVADA POhER: REID GARDNER i (COMT.)
PERFORMANCE DATA — —
PERIOD MODULE AVAILABILITY OPERA81L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
REPAIR TOOK ABOUT 9 HOURS.
HIGH PRESSURE IN SCRUBBER DUCT CAUSED THE SCRUBBER TO 60 DOWN TO CLEAN THE
SCRUBBER PRESSURE SENSING LINES.
9/79 SYSTEM 85.8 83.7 82.3 66.2 720 569 477
** P»ObL£MS/SOLUT10NS/COHMENTS
DURING SEPTEMBER THE SCRUBBER WENT OFF LINE WITH THE BOILER TO REPAIR
BOILER TUBE LEAKS. THIS OCCURRED TWICE CAUSING A TOTAL OF 126 HOURS OF
DOWN TIME.
SOME OUTAGE TIME WAS REQUIRED TO UNPLUG EFFLUENT AND VENTURI LINES AND
TO CLEAN THE VENTURI RACE TRACK.
HIGH PRESSURE WAS ENCOUNTERED TWICE IN THE SCRUBBER DUCT AND ONCE IN THE
BOILER FURNACE. THIS CAUSE I SOME OUTAGE TIME TO CLEAN THE SCRUBBER
PRESSURE SENSING LINES.
THE SCRUBBER WAS DOWN WITH THE BOILER SO REPAIRS TO THE MAIN STEAM DRAIN
LINE COULD BE CONDUCTED.
THE SCRUBBER WAS DOWN FOR APPROXIMATELY 7 HOURS TO WORK ON THE CONTROLS.
10/79 SYSTEM 38.5 1CO.O 100.0 38.5 744 263 286
•• PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS DOWN WITH THE BOILER DUE TO A MASTER FUEL TRIP ON THE
BOILER AND ANOTHER TINE TO REPAIR A TUBE LEAK.
DURING A BOILER TRIP ON, HI6H FURNACE PRESSURE CAUSED AN EXPLOSION WHICH
BLEU AN EXPANSION JOINT ON THE DISCHARGE OF 2A PRIMARY AIR FAN.
SCHEDULED MAINTENANCE WAS THE CAUSE FOR THE LOW SCRUBBER AVAILABILITY
DURING OCTOBER.
11/79 SYSTEM <«3.3 96.0 97.4 43.3 720 325 312
•* PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER AND BOILER 010 NOT OPERATE AT THE BEGINNING OF NOVEMBER.
DUE TO SCHEDULED MAINTENANCE.
THE SCRUBBER WENT DOWN FOR /PPROX1MATELY 3 HOURS DUE TO THE VIBRATIONS
IN THE REHEATER FAN.
THE SCRUBBER WENT OFF LINE WHEN THE 3C TRAY SPRAY PUMP SHORTED TO GROUND
TRIPPING THE 2C LOAD CENTER.
12/79 SYSTEM 97.7 97.7 97.7 97.7 744 744 727
** PROBLEHS/SOLUTIONS/COMMENTS
THE SCRUBBER AND BOILER TRIPPED DUE TO H16H OUT PRESSURE. THE SCRUBBER
PRESSURE SENSING LINES WERE CLEANED.
THE CONTROL SYSTEM ON THE VENTURI DAHPER NEEDED REPAIR CAUSING APPROXI-
MATELY 3 HOURS DOWN TIME.
THE EMERGENCY SPRAY AND THE RE HEATER FAN BEARING NEEDED REPAIRS CAUSING
THE SCRUBBER TO GO OFF LINE.
DURING A MAINTENANCE CHECK FOR D.C. GROUNDING THE BOILER AND SCRUBBER
TRIPPED.
240
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA fOH OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY SAKE NEVADA POWER
PLANT NAME REID GARDNER
UNI T NUMticfi J
CITY MOAPA
STATE NEVAtA
REGULATORY CLASSIFICATION B
PARTICULATE LMISSION LIMITATION - SG/J 43.
502 EMISSION LIMITATION - NG/J 516.
NET PLANT GENE&AT1HG CAPACITY - M* •**•***
GROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY W/FGD - MU
NET UNIT GENERATING CAPACITY UO/FGt - MW
EQUIVALENT SCRUBBED CAPACITY - «ta
** BOILER DATA
SUPPLIER
TYPE
SEkVlCt. LOAD
COMMERCIAL SERVICE DATE
MX I HUM bOILER FLUt GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HC1&HT - !"!
STACK TOP DIAMETER - M *****.*
** FUEL DATA
FUEL TYPE COAL
FUfcL GRADE BITUMINOUS
AVLPAGs. HEAT CONTENT - J/G 38959.
RANGE HEAT CONTENT - F'TU/LE
AV£"AGfc ASH CONTENT - X 8.00
RANGE ASH CONTENT - X 8.
AVERAGE MOISTURE CONTENT - X 9.QQ
HAMGE MOISTURE CONTENT - X 5.5
AVtGAGt SULFUR CONTENT - \ .5^
RANGE SULFUR CONTENT - X 0.5-1.0
AVERAGE CHLORIDE CONTENT - X .05
RANGE CHLORIDE CONTENT - ?. ******
t .100 LB/HMBTU)
( 1.200 LB/MMBTU)
125.0
11C.O
125.0
FOSTER WHEELER
PULVERIZED COAL
BASE
0/76
223.21 ( 473000 ACFM)
176.7 t 350 F>
61. { ZOO fT)
(***** FT)
( 12450 BTU/LB*
MECHANICAL COLLECTOR
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY -
PARTICULATE SCRUDfcEft
NUMPER
TYPE
SUPPLHR
NUMBED OF STAGE S
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF U02ZLES
BOILER LOAD/SCR UbBfcR - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
LIQUID RECIRCUL ATI UN RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - kPA
SUPERFICIAL GAS VELOCITY - M/S
PARTKULAU INLET LOAD - G/CU.K
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
NULTICLONES
RESEARCH COTTHELL
X 75.0
VENTURI
ADL/COMBUST10N EQUIP ASSOCIATES
INCOLOY 8i5 AT THROAT
RUBBER (AREA OTHER THAN THROAT)
TUIN VARIABLE THROATS
TANGENTIAL
5i .0
223.2 ( 473000 ACFM)
176.7 ( 350 F)
157.5 ( 2500 6P«)
1.3 (1C.O GAL/1000ACF)
•*»..*. (*.<** IN-H20)
50.3 ( 165.0 FT/S)
1.4 ( .60 GR/SCF)
FGD SYSTEM
SALEABLE PROD UC T/THROw AWAY PROtUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-t FICM
DEVELOPMENT LEVEL
NEW/RETROFIT
- X 97.C
375.CCO
THROWAWAY PRODUCT
WET SCRUBBING
SODIUM CARFtONATE
NONE
ADL/COMbUSTION EQUIP ASSOCIATE
BECHTEL
FULL SCALE
NEW
241
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NEVADA POtaER: REID GARDNER 3 (CONT.)
PARTICuLATE DESIGN REMOVAL EFFICIENCY
502 DESIGN REMOVAL EFFICIENCY - i
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDE o
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
99.OC
85.00
7/76
6/76
0/74
D/73
.0
.0
ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
BOILER LOAD/ABSORBER - X
LIQUID RECIRCULATION RATE - L1TER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPEHF1CAL GAS VELOCITY - M/SEC
S02 CUTLET CONTRAT10N - PPM
SO? DESIGN REMOVAL EFFICIENCY - X
1
TRAY TOWER
6/76
AOL/COMBUSTION EQUIP ASSOCIATES
1
30 DIA.
CASBCN STEEL
RUBBER
1.6
10?. 0
if .
.2
.7
3.4
17
91.2
( 6uO GPK)
( 1.6 GAL/1000ACF)
< 3.3 1N-H20)
( 11.0 FT/S)
*• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
WASH SYSTEM
PRESSURE DROP - KPA
SCRUBBER FD
CARBON STEEL
DRY
223.21 t 4730uO ACFM)
1
RADIAL VANE
316L SS (bOTH ME AND yASH TRAY)
HORIZONTAL
1
1
NONE
.1 < .5 IN-H20>
PUMPS
SERVICE
SCRUBBER RECIRCULATION
ABSORBER RECIRCULATION
NUMBER
3
3
TANKS
SERVICE
VENTUR1 RECYCLt
REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOO ST - C
ENERGY REQUIRED
THICKENER
NUMBER
NUMBER
HOT AIR INJECTION
STEAM
27.8 » 50 F»
15.2 NM6TU/H; 4 MU
MATES LOOP
TYPE CLOSED
FRESH MAKEUP WATER ADDITION - L1TERS/S 9.8
DISPOSAL
NATURE INTERIM
TYPE LINED POND
LOCATION ON-SITE
AREA - ACRES 6.0
DISPOSAL
NATURE FINAL
T»PE LINED POND
< 155 GPI»>
242
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
NEVADA POWEK: REID GARDNER 3 CCONT.)
LOCATION ON-SITE
TRANSPORTATION GRAVITY FLOW FROM INTERIM SLUDGE POND
AREA - ACRES 45.0
PERFORMANCE DATA "
PERIOD MODULE AVAILABILITY GPERAHILJTY RELIABILITY UTILIZATION t REMOVAL PER BOILER FGO CAP.
502 PART. HOURS HOURS HOURS FACTOR
7/76 SYSTEM 45.0 44.T 73.0 4Z.O 744 692 316
** PROULEMS/SOLUT10NS/COMNENTS
A HIGH SOLIDS CONCENTRATION IN THE VENTURI SCRUBBING SOLUTION CYCLE WAS
A PROBLEM DURING JULY.
FCUR OUTAGES WERE REPORTED FOR THE MONTH, THREE OF WHICH WERE FORCED
SCRUBBER OUTAGES'.
THE UNIT 3 SYSTEM WAS PLACED IN OPERATION ON JULY 12, 1976. THE SCRUBBING
SYSTEM DESIGN WAS BASED ON INFORMATION AND DATA OBTAINED FROM AN 8CCO-ACFM
PILOT PLANT PROGRAM CONDUCTED AT THIS STATION IN 1971 AND 1972.
A BUCKET ELEVATOR MALFUNCTION WAS A PROBLEM DURING JULY.
8/76 SYSTEM 56.C 43.0 50.0 43.0 744 744 323
** PRObLEMS/SOLUTIONS/COMMEMTS
RtHEATER KOTOR BURNOUT RESULTED IN FGO OUTAGE TIME.
DiSTRUCTICN OF THE VENTURI FLOOR WAS A PROBLEM DURING AUGUST.
FORCED SCRUBBER OUTAGE WERE CAUSED BY AN I.D. FAN ELECTRICAL MALFUNCTION
AND I.D. FAN INSULATION PROBLEMS.
THICKENER TANK PLUGGING CAUSED FGD DOWN TIME.
9/76 SYSTEM 49.0 46.D 46.0 44.C 72C 679 314
** PRObLEMS/SOLUTIONS/COMMENTS
A VENTURI VIBRATION TRIP RESULTED IN fGO OUTAGE TIME.
THE SYSTEK WAS PLACED BACK IN SERVICE ON SEPTEMBER IN FOLLOWING EXTENSIVE
REPAIRS AND MODIFICATIONS FROM THE PRECEEDING MONTH.
IkO REHEATER FAN TRIPS OCCURRED IN SEPTEMBER.
10/76 SYSTEM 22.0 29.3 21.0 21.0 744 548 159
«* PRObLtMS/SOLUTIGNS/COMMENIS
HIGH SOLIDS CONTENT IN THE VENTURI RECYCLE SOLUTION RESULTED IN OUTAGE
TIME.
A SCRUBBER GAS DAMPER MALFUNCTION CAUSING THE FGD UNIT TO GO DOWN.
VENTURI BOX PROBLEMS WERE ENCOUNTERED DURING OCTOBER.
11/76 SYSTEM 28.0 8:.0 29.0 29.0 72C 264 212
** PRObLEMS/SOLUTIONS/COMMENTS
THE SCRUPbER SYSTEM WAS NOT IN OPERATION THE FIRST HALF OF NOVEMBER DUE TO
REPAIRS OF LEAKS IN THE VENTURI SCRUBBER BOX. THE SYSTEM WAS RESTARTED
NCVEKUER 19.
A SCREW CONVEYOR MALFUNCTION (PREVENTING CHEMICAL MIXING) RESULTING IN
SCRUBBER DOWN TIME.
12/76 SYSTEM 99.0 97.: 99.0 97.0 744 744 721
243
-------
EP* UTILITY F&D SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REIO GARDNER 3 (CONT.)
PERFORMANCE DATA —
PERIOD HODULE AVAILAblUTT OPERA8ILITY RELIABILITY UTILIZATION % REMOVAL PtR BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
ONE MINOR SCRUBBER OUTAGE OCCURRED BECAUSE OF REPAIRS TO THE I.D. FAN
EXPANSION JOINT.
1/77 SYSTEM 98.0 93.? 9E.O 91.C 744 690 676
** PRObLEMS/SOLUTlOfjS/COMWENTS
A PLUGGED TRAY OCCURRED IN JANUARY RESULTING IN FGD OUTAGE TIME.
A HEHEATEfe STEAM LEAK RESUMED IN A MINOR FORCED OUTAGE.
Z/77 SYSTEM 81.0 74.0 72.0 63.C t>? £ 575 i>iZ
»* PRObLEMS/SOLUTIONS/COMMENTS
THREE FORCED SCRUBBER OUTAGES WERE CAUSED BY PROBLEMS WITH THE UPPER TRAY.
AN OUTAGE RESULTED FOR CLE INING OUT THE SODIUM CARBONATE LINE.
3/77 SYSTEM 44.0 51.? 52.0 44.C 744 639 324
•* PRObLEMS/SOLUTIONS/COMMENTS
THE RUBBER LINING IN THE SEPARATOR REuUIRED DOWNTIME FOR CURING.
THE SCRUBBER FAN EXPANSION JOINT BLEW OUT CAUSING OUTAGE TIME.
MINOR OUTAGES WERE CAUSED BY A PLUGGED TRAY.
THE 035 LIMIT SWITCH TRIPPED CAUSING PROBLEMS DURING MARCH.
4/77 SYSTEM 86.0 85.0 85.0 83.0 730 709 600
*• PHObLEMS/SOLUTIONS/COMMENTS
A HIGH TRAY DIFFERENTAL RESULTED IN FGD OUTAGE TIME.
A PLUGGED STRAINER IN THE TRAY RECYCLE TANK OCCURRED CAUSING DOWN TIME.
5/77 SYSTEM 63.0 26.0 21.0 16.C 744 470 124
** PROflLEMS/SOLUTIONS/CONNENTS
THE MODULE WAS UNAVAILABLE DURING THE FIRST THREE WEEKS OF THE MONTH
BECAUSE OF A FORCED OUTAGE REQUIRED FOR THE REPLACEMENT OF THE FRP LINER
IN THE MODULE'S SEPARATOR SECTION.
6/77 SYSTEM 98.0 63.0 64.0 62.0 7ZC 705 443
•• PROBLEMS/SOLUTIONS/COMNENTS
A HIGH TRAY DIFFERENTIAL PRESSURE READING WAS A PROBLEM.
A VENTURI RECYCLE LINE THROTTLE VALVE MALFUNCTIONED DURING JANUARY.
FOUR SCRUBBER OUTAGES WERE REPORTED, THREE OF WHICH WERE FORCED.
7/77 SYSTEM 73.0 73.0 73.0 73.0 744 744 542
*« PROBLEMS/SOLUTIONS/COMMENTS
FIVE FORCED SCRUBBER OUTAGES WERE ENCOUNTERED DURING JULY.
REPAIRS TO THE VENTURI DISCHARGE VALUE CONTRIBUTED TO FGD OUTAGE TIME.
8/77 SYSTEM 70.0 63.0 63.0 50.C 744 629 375
244
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
NEVADA POhER: REID GARDNER 3 (CONT.)
__. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY GPERAB1LITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
«* PRObLEMS/SOLUTIONS/COMHENTS
DUE TO A LEAK IN VENTURI RECYCLE LINE THE UNIT WAS OFF LINE PART OF THE
PI/NTH.
SCRUBBER FAN VIBRATION PROBLEMS CONTRIBUTED TO FORCED SCRUBBER OUTAGES.
A FALSE ALARM DUE TO SCRUBBER OUTLET TEMPERATURE CAUSED SHUTDOWN FOR ABOUT
A DAY.
THE BOILER WAS OUT OF SERVICE FOR AbOUT A WEEK DURING AUGUST.
9/77 SYSTEM 90.0 9C.O 99.0 90.0 720 720 646
«* PROBLEMS/SOLUTIONS/COHMENTS
HIGH SOLUS IN THE VENTURI RECYCLE SYSTEM CAUSED SOME OUTAGE TIME IN
SEPTEMBER.
NEU EFFLUENT AND POST NEUTRALIZATION LINES HERE INSTALLED.
10/77 SYSTEM 99.0 9C.O 99.0 61.C 744 506 455
• * PRObLEMS/SOLUTIONS/CONMENTS
THE SCRUBBER HAS OOUN 284.43 HOURS DURING OCTOBER FOR A SCHEDULED BOILER
OUTAGE.
4.45 HOURS OUTAGE TIME OCCURRED AS A RESULT OF HIGH VIBRATION PROBLEMS ON
A SCRUBBED FAN.
11/77 SYSTEM 89.0 88.0 89.0 87.0 720 709 624
** PHOfcLEMS/SOLUTlONS/COHNENTS
THE SCRUBfcER HAS DOUN ROUGHLY 80 HOURS FOR THE INSTALLATION OF AN OUTLET
NOZZLE IN THE BOOSTER TANK.
THE BOILED WAS OUT OF SERVICE APPROXIMATELY 15 HOURS IN NOVEMBER.
12/77 SYSTEM 38.0 92.0 96.0 93.0 744 692 635
• * PROBLEMS/SOLUTIONS/COHNENT.S
A FAULTY THERMOCOUPLE CAUSED "SEPARATOR HIGH TEMPERATURE" WHICH IN TURN
CONTRIBUTED TO FGD OUTAGE TIME.
BOILER OUTAGE TIME AMOUNTED TO 51 HOURS IN DECEMBER.
THE INSTALLATION OF TRAY SPRAY STRAINER CAUSED DOWN TIME.
THE FGO SYSTEM HAS TAKEN OFF LINE TO INSTALL NEU SENSING LINES.
1/78 SYSTEM 103.0 1CO.O 100.0 100.0 744 744 740
•• PRObLEMS/SOLUTIONS/COHMENTS
A PLUGGED VENTURI NOZZLE CAUSED THE ONLY FGD OUTAGE DURING JANUARY.
THE ROILEK OPERATED THE ENTIRE MONTH MITH NO OPERATIONAL PROBLEMS.
2/78 SYSTEM 96.0 95.5 95.0 88.0 672 619 588
•• PRObLEMS/SOLUTIONS/COMNENTS
AN FGO SYSTEM OUTAGE DUE TO A HI6H VENTURI TEMPERATURE CCAUSED BY FAULTY
WIRING) OCCURRED DURING FEERUARY.
A MINOR OLTAGE HAS NECESSARY TO CHECK THE VENTURI TEMPERATURE INDICATOR.
245
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EPA UTILITY FuD SURVEY: FOURTH QUARTER 1979
NEVADA P0*5k: RtIO GAkDNEfi 5 (CONT.)
PERFORMANCE DATA -__
PERIOD MODULE AVAILABILITY OPtfABlLITr RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
AN FGD OUTAGE WAS CAUSED BY THE PLUGGING OF THE MIX TANK WHICH MADE IT
IMPOSSIBLE TO MIX CHEMICALS.
3/75 SYSTEM 97.0 97.: 97.0 96 . C 744 741 718
** PROL
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT WENT DOWN ON SEPTEMBER 1C FOR A TURBINE OVERHAUL WHICH LASTED
THROUGH THE END OF THE MONTH.
10/78 SYSTEM 100.0 ,C 744 0 C
*« PRObLENS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN THE ENTIRE MONTH OF OCTOBER FOR TURBINE OVERHAUL.
11/78 SYSTEM 98.0 91.0 91.0 62.0 720 4B9 447
*« PHObLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS BROUGHT BACK ON LINE THE 1CTH OF NOVEMBER.
THE FGD SYSTEM WAS DOWN ABOUT 2 HOURS FOR REPAIRING VENTURI TEMPERATURE
PROBES.
12/78 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
• * PRObLEMS/SOLUTIONS/COMMENTS
NO FGD OUTAGES WERE REPORTED DURING DECEMBER.
1/79 SYSTEM 66.4 67.2 67.2 66.4 744 735 494
** PRObLEMS/SOLUTIONS/COMMENTS
OUTAGE TIKE WAS NtCESSARY TO REPAIR A HOLE IN THE VENTURI BOX.
TWO FORCED OUTAGES OCCURREC BECAUSE EFFLUENT SOLIDS WERE HIGH. THE SYSTEM
UAS CLEANED.
A MAJOR OUTAGE OCCURRED WHEN THE SCRUBBER REHEATER FAN MOTOR BURNED OUT.
2/79 SYSTEM 40.6 45.7 45.7 40.6 672 660 302
*« PRObLEMS/SOLUTIONS/COMMENTS
A STEAM LEAK IN THE SCRUBBER REHEATER COIL RESULTED IN OUTAGE TIME.
THE FGD SYSTEM WAS OFF FOR A FEW HOURS TO REPAIR A LEAK IN THE VENTURI
LINE.
THE SCRUBLER WAS DOWN TO REPAIR LEAKS IN EFFLUENT AND VENTURI LINES.
THE SCRUBBER WAS OFF WITH HIGH FURNACE PRESSURE ON THE BOILER.
THE RACE TRACK NOZZLES WERE CLEANED DURING FEBRUARY.
3/79 SYSTEM 100.0 97.9 10C.O 67.7 744 246 241
•• PROBLEMS/SOLUTIONS/CONMENTS
THE BOILER AND FGD SYSTEM WERE OFF FOR ABOUT 2 DAYS TO REPAIR AND BALANCE
A BOILER I.D. FAN.
THE BCILE* AND FGD SYSTEM WERE OFF FOR ABOUT 19 DAY FOR SCHEDULED MAIN-
UN ANC E.
4/79 SYSTEM 100.0 100.0 100.0 100.0 720 719 719
•* PRObLEMS/BOLUTIONS/COMMENTS
NO OUTAGES WERE REPORTED FOR APRIL.
5/79 SYSTEM 98.7 97.7 97.7 97.5 744 742 725
247
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EP* UTILITY FGO SURVEY: FOURTH QUARTER 1979
NEVADA PO^ER: REID GARDNER 3 (COST.)
PERFORMANCE DATA .-..
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•* PROBLEMS/SOLUTIONS/CCMMENTS
THE SCRUBBER WAS INADVERTENTLY REMOVED FROM SERVICE FOR A FEV HOURS.
THE SCRUBBER PRESSURE SENSING LINES WERE CLEANED AFTER A BOILER TRIP
ON HIGH FURNACE PRESSURE.
6/79 SYSTEM 100.0 91.3 100.0 83.5 72c 659 601
** PROtLENS/SOLUTIONS/COMMENTS
SOME bOILER OUTAGE WAS REQUIRED DURING JUNE TO REPAIR A BOILER TUBE LEAK.
THE SCRUBBER WAS OUT OF SERVICE WHILE REPAIRS WERE MADE ON THE FIRE WATER
SYSTEM.
7/79 SYSTEM 93.2 93.1
*• PRObLEMS/SOLUTIONS/CONMENTS
93.2
93.2
744 642
694
THE VENTURI RECYCLE PUMP HAD A BAD PUMP CASING LEAK CAUSING ABOUT 5C HOURS
OFF TIME.
THE VENTURI PUMP WAS OUT OF SERVICE FOR MAINTENANCE.
8/79 SYSTEM 87.6 92.9 87.6 87.5 744
** PRObLEMS/SOLUTIONS/CONMENTS
701
6S2
THE SCRUBBER AND BOILER WERE BOTH DOWN TO REPLACE THE EXPANSION JOINTS ON
THE CIRCULATING WATER PUMPS.
THE SCRUBBER WAS OFF TO CLEAN TRAY AND VENTURI RACE TRACK NOZZLES. THE
SCRUBBER WAS DOWN FOR ABOUT 31 HOURS.
THE SCRUBBER WAS OFF TO REPAIR BROKEN FIRE LINES SO THE SCRUBBER WILL HAVE
EMERGENCY kATER.
9/79 SYSTEM 100.0 98.8
*• PRO&LEMS/SOLUTIONS/CONMENTS
10C.O
90.2
720 657
650
DURING SEPTEMBER THE SCRUBBER yENT OFF LINE WITH THE BOILER TO REPAIR
BOILER TUBE LEAKS.
10/79 SYSTEM 97.2 97.3
•• PROULEMS/SOLUT10NS/COMMENTS
97.3
97.3
744 744
724
DURING OCTOBER THE SCRUBBER WENT OFF LINE BECAUSE THERE WAS NO EMERGENCY
SPRAY TO THE SCRUBBER. THE 2A LOAD CENTER WAS OUT FOR MAINTENANCE;
THEREFOREi THERE WAS NO POWER TO OPERATE THE FIRE PUMP.
11/79 SYSTEM 81.5 94.6
*• PROBLEMS/SOLUTIONS/COMMENTS
100.0
77.0
720 586
555
TWO OUTAGES OCCURRED DURING NOVEMBER DUE TO NIGH FURNACE PRESSURE CAUSING
A BOILER TRIP.
THE SCRUBBER AND BOILER HERE OFF TOWARDS THE END OF THE MONTH FOR SCHEDULED
MAINTENANCE.
12/79 SYSTEM
39.7
72.4
74.7
39.7
744
408
295
243
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
NEVADA POWER: REID GARDNER 3 (CONT.)
---PERFORMANCE DATA .-. — --—-—......
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
THE UNIT MAS OFF FOR THE FIRST TWO WEEKS OF DECEMBER FOR SCHEDULED
MAINTENANCE.
TWO OUTAGES OCCURRED LATER IN THE MONTH DUE TO THE REHEATER BLOuER MOTOR
MALFUNCTION.
249
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EPA UTILITY FbD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AMD PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLAMT NAME
UNIT NUI"bER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICUIATE EMISSION LIMITATION - MG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGl - MW
EQUIVALENT SCRUBBED CAPACITY - f
-------
EPA UTII1TV FGO SURVEY: FOURTH QUARTER 1979
NORTHERN INDIANA PUB SERVICE: DEAN h. MITCHELL 11 (COwT.)
SHELL MATERIAL
SHELL LlrtER MAT ERI AL
INTERNAL MATER1AL
bOILEH LOAD/ABSORBED - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
PRESSURE DROP - KPA
S02 INLET CONCENTRATION - PPM
S02 CUTLcT CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY -
** CENTRIFUGE
NUMBER
TYPE
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - UET/DRY
CAPACITY - CU.M/S
•* FANS
NUMBER
TYPE
SERVICE - WET/D HY
** PUMPS
SERVICE
DISSOLVING TANK TO AbSORBER FEED TAN
FLYASH PURGE TO POND TRANSFER
ABSORBER RECIRCULATION
EVAPCRATOR-CRYSTALLIZER FEED
SLUSHY FEED
** TANKS
SERVICE
ABSORBER FEED
ABSORBER SURGE
NACC3 MAKEUP, NA2SG3 DISSOLVING
** REHEATER
TYPE
TEMPERATURE BOOST - C
** yATER LOOP
TYPE
.« REAGENT PREPARATION EQUIPMENT
POINT OF ADDITION
*» BYPRODUCTS
BYPRODUCT NATURE
BYPRODUCT QUALITY - X
( 420000 ACFM)
( 288 F)
C12.0 IN-H20)
CARBON STEEL
ACID BRICK
316L SS TRAYS
10C.O
198.2C
U2.2
3.C
2185
20C
91.0
SODIUM SULFITE CRYSTAL REMOVAL
SCRUBBER FD
INCONEL SHIELDS ON BLADE EDGES
DRY
198.20 ( (20000 ACFM)
BOILER I.D.
DRV
NUMBER
**• *
* ** *
NUMBER
****
*** *
*** *
DIRECT COMBUSTION
27.8 ( 50 F>
CLOSED
PNEUMATIC CONVEYOR
ELEMENTAL SULFUR
99.9
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
11/76 SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
720
FOLLOWING COMPLETION OF CONSTRUCTION IN Mio-1976, START-UP OF THE VARIOUS
SUBSYSTEMS AND COMPONENT PARTS WAS INITIATED. DURING THE PERIOD JULY
THROUGH NOVEMBER, THREE SUSTAINED RUNS Of THE S02 ABSORBER AND REGEMERATIO
SYSTEM UNDER NORMAL OPERATING CONDITIONS bERE ACHIEVED. SO? REMOVAL EFFI-
CIENCY WAS EQUAL TO OR GREATER THAN THE 9OX PERFORMANCE CRITERIA. UNIT 11
BOILER OPERATED 121 FULL DAYS AND 10 PARTIAL DAYS. THE WELLMAN-LORD S02
RECOVERY UNIT OPERATED 71 FULL DAYS AND 23 PARTIAL DAYS. DURING THIS PER-
IOD, NUMEROUS MODIFICATIONS AND CORRECTIONS TO THE SYSTEM HERE COMPLETED.
THESE INCLUDED MODIFYING T«E ABSORBER KOCH VALVE TRAYS TO IMPROVE TURN-
251
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EPA UTILITY FbD SURVEY: FOURTH QUARTER 1979
NORTHERN INDIANA PUB SERVICE: DEAN h. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILJTY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
302 PART. HOURS HOURS HOURS FACTOR
DCUN, RUBIER LINING THE BOTTOM ABSORBER COLLECTOR TRAY, RELOCATING AND IK-
PROVING TEMPERATURE CONTROL OF TH£ LOW PRESSURE STEAM SUPPLY, INSTALLING
IMPROVED S02 SAMPLE PROBES AND SEVERAL REPLACEMENTS AND MODIFICATIONS TO
THE PURGE SALT RECOVERY AREA. FULLY INTEGRATED OPERATIONS INCLUDING S02
REDUCTION AND SULFUR RECOVERY OCCURRED IN NOVEMBER, 1*76. JANUARY THROUGH
MAY 1977 - UNIT 11 BOILER WAS OUT-OF-SERV1CE FOR ABOUT FIVE MONTHS FOLLOW-
ING A BOILER-RELATED MISHAP WHICH OCCURRED ON JANUARY 15, 1977, DURING
START-UP AFTER A SCHEDULED MAINTENANCE TURN AROUND.
ON JUNE 13, 1977 fGD OPERATIONS RESUMED FOLLOWING RETURN TO FULL SERVICE 0
UNIT 11 BOILER. faY JUNE 15 FULLY INTEGRATED OPERATION OF THE ENTIRE FGO
PLANT MAS ACHIEVED. THROUGH JUNE AND JULY, SEVERAL HUNDRED HOURS OF TOTAL
SYSTEM OPERATION AT BOTH PARTIAL AND FULL LOAD WERE ACCRUED.
12/76
1/77
2/77
3/77
4/77
5/77
6/77
7/77
8/77
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
** PROdLEMS/SOLUTIONS/COMMENTS
89.80
744
744
672
744
72 0
744
720
744
744
PERFORMANCE TESTS COMMENCED ON AUGUST 29, 1977 AND WERE SUCCESSFULLY COM-
PLETED ON SEPTEMBER 14, 1977. THE TEST PERIOD INCLUDED 1Z DAYS AT 9? My
FLUE GAS EQUIVALENT AND 3.' DAYS AT 110 MW FLUE GAS EQUIVALENT. DURING
THIS PERIOD, 91% OF THE S02 WAS REMOVED WHILE BURNING COAL CONTAINING 3»
SULFUR ANt 204 TONS OF ELEMENTAL SULFUR WERE RECOVERED. ALL PERFORMANCE
CRITERIA WERE MET INCLUDING S02 REMOVAL, PARTICULATE EMISSION, RAW
MATERIAL AND UTILITY CONSUMPTIONS AND RECOVERED SULFUR QUALITY. THE FGD
UNIT SHUT DOWN SEPTEMBER 19 AND REMAINED IDLE THROUGH SEPTEMBER 3C DUE TO
CCAL FEED PROBLEMS RESULTING FROM WET COAL ON THE UNIT 11 BOILER.
9/77
10/77
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
91.00
720
744
A DEMONSTRATION PERIOD OF ONE YEAR BEGAN SEPTEMBER 16. IN OCTOBER, THE
FGD UNIT OPERATED 132 HOURS. OPERATIONS WERE INTERUPTED WHILE HEAT BAL-
ANCE TESTS WERE CONDUCTED ON THE UNIT 11 BOILER BY NIPSCO AND TRW AND HERE
INTERRUPTED FURTHER TO HAKE REPAIRS TO THE S02 REDUCTION SECTION, THE EVAP
ORATOR, AND THE UNIT 11 BOILER.
11/77 SYSTEM 74.0
«* PROBLEMS/SOLUTIONS/COMMENTS
72.0
90.0
720
THE FGD UNIT OPERATED FOR 18 CONSECUTIVE DAYS, AVERAGING 90S S02 REMOVAL
WITH 285 LONG TONS OF SULFUR RECOVERED. FGD OPERATION WAS INTERRUPTED BT
UNIT 11 BOILER TUBE LEAK AND RESUMPTION OF FGD OPERATION WAS FURTHER
DELAYED BY MAINTENANCE IN THE EVAPORATOR SECTION.
THE FLUE CAS ISOLATION DAMPER NEEDED REPAIRS.
MAINTENANCE WAS PERFORMED ON THE FLUE GAS BOOSTER BLOyER.
THE S02 REDUCTION SECTION (EOUIRED MAINTENANCE DURING NOVEMBER.
252
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EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (CONT.)
PERFORMANCE PATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/77 SYSTEM 49.0 .0 .C 74 4 C
"* PROtLEMS/SOLUTIONS/CONNENTS
THE FLUE MS BOOSTER BLOWER MALFUNCTIONED CAUSING MAINTENANCE ATTENTION.
MAINTENANCE WAS PERFORMED ON THE ABSORBER SOLUTION REGENERATION SECTION.
THE FGD SYSTEM WAS NOT OPERATED DURING THIS PERIOD DUE TO ABNORMAL BOILER
OPERATING CONDITIONS RELATED TO HIGH SILICA LEVELS IN THE FEED yATEfi. THE
HIGH SILICA LEVELS RESULTED FROM HIGH MAKE-UP WATER REQUIREMENTS DUE IN
PART TO A HIGHER THAN NORMAL FGD PLANT USAGE, AS WELL AS UNIT 11 COAL FEED
PROBLEM AND A PRECIPITATION MALFUNCTION.
1/78 SYSTEM 8C.O .0 .0 744 0
** PROuLEMS/SOLUTIONS/COMMENTS
THE F60 SYSTEM REMAINED DOWN THROUGHOUT JANUARY AS HIGH SILICA LEVELS IN
THE UNIT 11 BOILER FEED WATER PERSISTED.
MAINTENANCE WAS PERFORMED ON THE UNIT 11 PRLCIPITATOR.
PROBLEMS CONTINUED WITH THE FLUE GAS BOOSTER BLOWER.
THE FCD SYSTEM S02 COMPRESSOR MALFUNCTIONED AND NEEDED MAINTENANCE.
Z/7S SYSTEM 47.0 .0 .0 673 C
• * PRObLEMS/SOLUTIONS/CONMENTS
THE FCD SYSTEM HAS NOT OPERATED DUE TO ABNORMAL BOILER OPERATING CONDITION
RELATED TO HIGH SILICA LEVELS IN THE BOILER FEED WATER, COUPLED WITH UNIT
11 COAL FEED PROBLEMS. STOF VALVE PROBLEMS, PRECIPITATOR MALFUNCTICH AND A
LEAKING BOILER TUBE AND WORK ON THE FLUE «AS ISOLATION DAMPER.
MAINTENANCE WAS PERFORMED ON THE FLUE GAS BOOSTER BLOWER.
THE FLUE GAS ISOLATION DAMPER WAS REPAIRED DURING FEBRUARY.
THE EVAPORATOR CIRCIRCULATING PUMP NEEDED MAINTENANCE ATTENTION.
THE S02 SUPERHEATER PIPING REPAIRS WERE PERFORMED DURING THE MONTH.
3/78 SYSTEM 90.0 77.0 30.0 744 ?15
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED FOR TEN DAYS. OPERATION WAS INTERRUPTED BY A
SHUTDOWN OF THE UNIT 11 BOILER FOR REPAIR OF COAL GRINDING MILLS AND PRE-A
CIPITATORS. PROPER CONDITIONS COULD NOT BE RE-ESTABLISHED FOR RE-START
OF THE FGD OPERATION BECAUSE OF COAL FEED AND GRINDING PROBLEMS CAUSED BYE
EXTREMELY POOR QUALITY COAL.
MAINTENANCE WAS PERFORMED ON THE BOOSTER BLOWER.
OPERATING PROBLEMS WERE ENCOUNTERED WITH THE FLUE GAS ISOLATION DAHPER.
4/78 SYSTEM .0 .0 .0 7ZC C
** PROBLENS/SOLUTlONS/COHNENTS
THE FLUE 6AS BOOSTER BLOWER WAS OUT OF SERVICE FOR THIS ENTIRE PERIOD FOR
REBLADIN6. THE FGD SYSTEM MAS INOPERABLE.
A FAILURE OF THE FLUE GAS ISOLATION DAHPER OCCURRED.
A NEW SUPPLY OF HIGH SULFUR COAL MAS OBTAINED AND SUCCESSFULLY TESTED ON
UNIT 11 BOILER. THIS COAL IS EXPECTED TO ALLEVIATE PAST DIFFICULTIES WITH
2 53
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EP» UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN INDIANA PUB SEHVICb: DEAN h. MITCHELL 11 (CONT.)
PERFORMANCE DATA .
PERIOD MODULE AWA1LARILITY OPE9ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
ThE COAL FEED AND GRINDING SYSTEM.
MAINTENANCE WAS PERFORMED ON THE BOILER I.D. FANS.
I»*1NT£NANCE WAS PERFORMED ON THE BOILER I.D. FANS.
THE FGD AtSORbER REQUIRED MAINTENANCE DURING APRIL.
5/78 SYSTEM 744
•* PRObLtMS/SOLUTIONS/CCMMENTS
THE S02 RtCOVERY PORTION OF THE FGD SYSTEM OPERATED FOR 26 DAYS. THE COM-
PLETED FGl SYSTEM OPERATED FOR 11 DAYS.
FCD OPERATIONS WERE INTERRUPTED PY FAILURE OF THE FLUE GAS ISOLATION DAMP-
EN.
FGD OPERATIONS WERE INTERRUPTED PY PROBLEMS WITH WET COAL WHICH REQUIRED
THE UMT 11 BOILER TO OPERATE ON LOW SULFUR COAL FOR A SHORT PERIOD.
PLUGGING CF AN ENTRAPMENT SEPARATOR IN THE S02 REDUCTION UNIT CAUSED
Pf-ObL EMS LURING MAY.
6/76 SYSTEM 13.0 1.J .? 72o ?CO
•• PROBLEMS/SOLUTIONS/CGMMENTS
ThE FGD PKOCESS FACILITIES, CONSISTING OF THE ABSORBER, EVAPORATOR, S03 RE
OUCTION AND PURGE TREATMENT UNITS, WERE AVAILABLE FOR OPERATION FOR ESSEN-
TIALLY THE ENTIRE PERIOD.
OPERATION OF THE FGD SYSTEM WAS LIMITED BY FAILURE OF THE BOOSTER BLOWER
DRIVE TUPLINE.
OPERATION OF THE FGD SYSTEM WAS LIMITED DUE, IN PART, TO THE INABILITY OF
The ISOLATION DAMPER TO OPERATE
7/78 SYSTEM 6.0 4.0 2.0 744 170
•* PRObLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE FGD SYSTEM WAS LIMITED BY IMBALANCE OF THE BOOSTER BLOWER
DUE TO INABILITY OF THE ISOLATION DAMPER TO OPERATE. THIS CONDITION COULD
NOT fiE CORRECTED UNTIL POWER DEMANDS PERMITTED A SHUT DOWN OF UNIT 11
BOILER. FLUE GAS BOOSTER BLOWER PROBLEMS INCLUDED LOta OIL PRESSURE,
LEAKING BEARING OIL SEALS AND DRIVE TURBINE GOVERNOR MALFUNCTION.
RECURRING FLUCTUATIONS IN THE PRESSURE or THE MAIN STEAM SUPPLY TO THE FGD
SYSTEM LIKITED FGD OPERATICNS.
THE FGD PROCESS FACILITIES WERE AVAILABLE FOR OPERATION FOR THE ENTIRE
PER10 D .
8/78 SYSTEM 98.0 105.C 98.0 98.0 744 7C7
•* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT 11 BOILER OPERATED CONTINUOUSLY ON HIGH SULFUR COAL THROUGHOUT
THE PERIOD. THE FGD SYSTEM ACHIEVED FULL OPERATION ON THE FIRST DAY OF
THE PERIOD. AFTER PROBLEMS WITH THE BOOSTER BLOWER WERE CORRECTED, IT
REMAINED IN FULL OPERATION FOR THE BALANCE OF THE PERIOD WITH THE E»CEP-
TION OF ONE TWO-HOUR INTERRUPTION DUE TO AN ELECTRICAL MOTOR MALFUNCTION.
MINOR BOOSTER BLOWER PROBLEMS OCCURRED OVER THE PERIOD.
9/78 SYSTEM 44.0 99.0 44.0 720 319
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (COM.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•* PROfaLEMS/SOLUTIONS/CCMMENTS
THE UNIT 11 POILER OPERATED on HIGH SULFUR COAL UNTIL SEPTEMBER 12 WHEN IT
WAS SHUT IOWN FOR AN ANNUAL OVERHAUL. THE BOILER REMAINED DOWN THROUGH TM
END OF THE PERIOD. THE FGD SYSTEM CONTINUED IN FULL OPERATION UNTIL SEP-
TEMBER 1?, WITH THE EXCEPTION OF ONE TaO-HOUR INTERRUPTION DUE TO A GOVER-
NOR MALFUNCTION ON THE S02 COMPRESSOR DRIVE TURBINE. AND WAS THEN SHUT DOW
CONCURRENTLY WITH THE UNIT 11 BOILER.
A GOVERNOR MALFUNCTION OCCURRED ON THE so? COMPRESSOR DRIVE TURBINE CAUS-
ING A TWO-HOUR OUTAGE ON THE FGD OPERATIONS.
10/78 SYSTEM 44.0 73.0 44.? 74* 369
** PROBLEMS/SOLUTIONS/COMMENTS
THIS PERIOD COVERS SEPTEMBER 29 THROUGH NOVEMBER 2. FOLLOWING THE ANNUAL
TURNAROUND, THE UNIT 11 BOILER RESTARTED ON OCTOBER 6. A NEW BASELINE
TEST MAS RUN ON THE BOILER OCTOBER 7 THROUGH 12. BALANCING OF THE FLUE
GAS bOOSTER BLOWER WAS THEN COMPLETED AFTER WHICH THE FGD SYSTEM WAS
STARTED ON OCTOBER 18.
11/78 SYSTEM 99.0 99.0 98.0 720 709
** PRObLEMS/SOLUTIONS/COMMENTS
PROBLEMS WEFE ENCOUNTERED WITH THE SODIUM SULFATE PURGE DRYER WHICH
NECESSITATED DISPOSING OF PART OF THE SULFATE PURGE TO THE BOTTOM ASH
POND FOR A PORTION OF THE PERIOD.
THE UNIT 11 BOILER OPERATED CONTINUOUSLY ON HI6H SULFUR COAL EXCEPT FOR
ONE THREE-HOUR OUTAGE FOR REPAIR OF A STEAM CONTROL VALVE. VARIATIONS IN
THE PRESSLRt OF THE STEAM SUPPLY TO FGD OCCURRED DUE TO HIGH SILICA IN
THE MAKE-UP WATER ON UNIT 11.
12/78 SYSTEM 64.3 72.0 64.0 744 462
** PRObLEMS/SOLUTIONS/CCMMENTS
THE bOILEfi WAS SHUT DOWN FROM DEC. 14 TO DEC. 17 TO CLEAN THE AIR
PREHE ATERS.
THE F-OILEt OPERATED ON HIGH SULFUR COAL DURING DECEMBER.
AN INSTRUMENT MALFUNCTION DUE TO FREEZING RESULTED IN THE PLUGGING OF A
HEAT EXCHANGER IN THE S02 REGENERATION UNIT. THE FGD SYSTEM WAS DOWN FOR
THREE DAYS WHILE THE EXCHANGER WAS CLEANED.
1/79 SYSTEM 90.0 9C.O 28.0 744 198
•* PRObLEMS/SOLUTIONS/COMMENTS
THE BOILEt OPERATED ON HIGH SULFUR COAL FROM JANUARY 2-14 AND LOW SULFUR
COAL FROM JANUARY 15-31.
INTIGRtTED OPERATION OF THE FGD SYSTEM CONTINUED TO JANUARY 10 WHEN THE
S02 REDUCTION UNIT WAS SHUT DOWN FOR REPAIR OF A SULFUR CONDENSER INCLU-
DING CORRECTIVE MEASURES TO AVOID FUTURE PROBLEMS WITH THE CONDENSER. THE
ABSORPTION AND REGENERATION UNITS CONTINUED IN OPERATION TO JANUARY 29
WITH RECYCLE OF S02 TO THE ABSORBER INLET. THE FGD SYSTEM REMAINED DOWN
THROUGH JANUARY 31.
2/79 SYSTEM 7.0 1.0 1.0 672 5
•* PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER OPERATED ON LOW SULFUR COAL FEBRUARY 1-12 AND HIGH SULFUR COAL
FEBRUARY 13-MARCH 2. THE FG C SYSTEM REMAINED DOWN THROUGH FEBRUARY 22
FOR COMPLETION OF SULFUR COIDENSER REPAIRS FOLLOWED BY REPAIR OF EXPANSION
255
-------
EPA UTILITY FOD SURVEY: FOURTH QUARTER 1979
NORTHERN INDIANA PUB SERVICE: DEAN h. MITCHELL 11
-------
•IPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
NORTHERN INDIANA PUfa SERVICE: D E IN t. . MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEKAfelLITY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGD CAP.
S02 PART. HOLRS HOURS HOURS FACTOR
•• PROBLEMS/SOLUTIONj/COMMENIS
DURING THE KCNTH OF SEPTEMBER THE UNIT 11 BOILER OPERATED ON HIGH SULFUR
COAL. OUTAGES OCCURRED DUE TO AN ELECTRICAL SYSTEM MALFUNCTION AND A STEAM
L E Ak.
THt FCD OUTAGES DURING SEPTEMBER RESULTED FROM INSTRUMENT AND DRIVE TURBINE
GOVERNOR PtiOKLEMS WITH THE BOOSTER BLOWER, A LEAK IN THE SO? SUPERHEATER
AND AN INTERRUPTION IN THE INSTRUMENT AIR SUPPLY TO THE SYSTEM.
10/79 SYSTEM 81.0 72.0 71." 744 428
*• PROULEMS/SOLUTIONS/CGMMENTS
THE bCILER OPERATED ON HIGH SULFUR COAL UNTIL OCTOBER il WHEN THE UNIT
SHUTDCwN OLE TO A TURBINE BLADE FAILURE. IT WAS DECIDED TO START THE
ANNUAL TURNAROUND AT THAT TIME.
THE FCD SYSTEM OUTAGES WERE RE<.UI»ED FOR REPAIR OF THE BOOSTER BLOaER
DRIVE GOVEF.NOR, AN O&FICE CONTACTOR CONTROL VALVE AND A GAS LEAK IN THE
SOi REDUCTION UNIT.
11/79 SYSTEM .0 .; .- 720 C
** PROuLEMS/SOLUTlONS/COMMENTS
THE BOILER AND FGD SYSTEM ANNUAL TURNAROUND WAS IN PROGRESS THROUGHOUT
THE PENIOD.
257
-------
EP* UTILITY FoD SURVEY: FOUKTH QUARTER 1979
DESIGN AND PERFORMANCE DATA
SECTION J
FOR OPERATIONAL
DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAPE
UNI T Muf'bE*
CITY
STATt
REGULATORY CLASSIFICATION
PARTICULATE ^MISSION LIMITATION - KG/J
SO? EMISSION LIMITATION - NG/J
NET PLANT GE'.ERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - f k
NET UNIT GENERATING CAPACITY W/FGD - rw
NET UNIT GENERATING CAPACITY WO/FGl - MW
EQUIVALENT SCRUBBED CAPACITY - PW
NORTHERN STATtS PO»E&
SHERFURNE
1
BECKER
MINNESOTA
0
37.
3?3C.D
7<.C .0
.Jf7 LF'/MMBTU)
.96o LF/MMDTU)
I'UlLER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DUTc.
MAXIXUh LOILER FLUE GAS FLOW - CU.K/S
fLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP OIAME TER - f»
FUEL DATA
FUEL TYPt
FUEL GRADE
AVERAGE HEAT CONTENT - J/C
RANGE HEAT CONTENT - fTU/lt
AVERAGE ASH CON TENT - *
RANGE ASh CONTE NT - 1
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - '-.
RANGE SULFUR CONTENT - %
AVERAGE CHLORIDE CoNTFf^T - "i
KANCE CHLORIDE CONTENT - '
PARTICULATE SCRUbtER
NUMEUR
TYPF
SUPPLIER
NUMH ER OF STAGE S
SHELL MATERIAL
LINING MATERIAL
INTE RNAL MATERI AL
NUMHER OF NOZZLES
TYPE OF NO/7LES
bOlLER LOAD/SCRUBBER - *
FLUE GAS CAPACITY - CU.M/S
fLUE GAS TEMPERATURE - C
LI8U1D RtCIRCUL ATI ON RATE - LITER/S
L/0 RATIO - LIT ER/CU.H
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
FbD SYSTEM
SALEABLE PRODUC T/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIKM
DEVELOPMENT LEVEL
NEtf/RETROFIT
PARTICULATE DES IGN
S02 DESIGN REMOVAL
COMMERCIAL DATE
INITIAL START-UP
ABSORBER SPARE CAPACITY IKOEX - Z
ABSORBER SPARE COMPONENT INDEX
REMOVAL EFFICIENCY
EFFICIENCY - X
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
3/76
1*4r-.1t (>£59CJO ACFM)
154.4 ( 113 F)
19C . < t5G FT)
S .<) ( 32.6 FT)
COAL
SolbI
1"7 71.
BTU/LP)
12
VENTUBI
CO^bUSTION ENGINEERING
C
CARbON STEEL INLET, 316L SS SKIRT, 316L VENTURI
NONE
3UL SS RODS (2 ROhS OF 2.5 IN. DIA. RODS), CERA
CERAKIC
154.4
223.0
24.4
259900 ACF«)
310 F)
3540 GP"*
17.0 6AL/1000ACF)
***** IN-H20)
80.0 FT/S)
THROWAUAY PRODUCT
WET SCRUBBING
LIMESTONE/ALKALINE FLYASH
NONE
COMBUSTION ENGINEERING
BLACK £ VEATCH
FULL SCALE
NEW
99.00
50.00
5/76
3/76
8.0
.9
258
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
NORTHERN STAUS POWER: SHtRbURNE 1 (CCNT.)
AoSO SfaE k
NUM« t =
TYP F
iM T JAL START
U P
- X
NUMI'iR Of STAGES
Dl MC NS 10.JS - FT
SHilL fA TES1AL
SHELL L1«ER MAT EhlAL
INTE HNAL MATER1 AL
NUMBER Of NOZZLES
NOZZLE TYPE
bOlLtR LuAl/ABS ORfiL S
GAS FLCU - CU.M/S
GAS TEKPcRATURE - C
LIGU1D (UCIRCUL ATION RATE - LITES/S
L/G BA Tlo - L/C U.M
PRLSSU> PASSES
FREEtlOARD DISTANCE - M
VANE SPACING - CM
MASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
*• PUMPS
SERVICE
POND RETURN
THICKENER UNDERFLOW
MAKE-UP WATER
REHEAT WATER
ABSORBER RECIRCULATION
11
MOBILE PACKED TOUER
3/7".
COMBUSTION ENGINEERING
1
18 X 26.5 X 60
CARBON STEEL < 1 / 4 1N>
CEILCOTE FLAKEGLASS
316L ss PERFORATED PLATE, FRP SPRAY HEADERS, GLA
54
CESAMC
9.C
94.36 ( 200000 ACFM)
54.4 13C F)
19CO GPM)
10.0 GAL/1CQCACF)
.5
°.4
6.9
.1
31.0 FT/S)
3.300 GR/SCF)
.336 GR/SC F )
32"
55 .3
SPRAY TOWER
COMBUSTION ENGINEERING
26 X 18 X 60
CARBON STEEL
316L SS PLATES, CERAMIC NOZZLES
*4.38 C 203030 ACFM)
54.4 I 130 F)
1 .3 ( K.O &AL/100CACF)
.5 < 2.G IN-H20)
SCPUbbER ID
CARBON STEEL
DRY
94.38
( 203000 ACFM)
12
CHEVRON
FRP
HORIZONTAL
2
3
4.27 (14.0 FT)
10.2 ( 4.30 IN)
1ST STAGE, VERTICALLY UPWARD 18C DEG. ROTATABLE,
9.4 (31.0 fT/S)
.1 I .5 IN-H20)
SLURRY PH, SLURRY SOLIDS, TANK LEVELS, PRESSURE
PRESSURE DROP 12 IN H20t 101 SOLIDS, PH*5-5.5
AUTOMATIC
FEEDBACK
NUMBER
259
-------
EPA UTILITY FbO SURVEY: FOURTH QUARTER 1979
NORTHERN STATcS POWER: SHERUU3NE 1 (CONT.)
•* TANK?
SERVICt
REACTION
MAKE-UP »ATER
SLURRY MAKE-UP
* RtHEATEK
NUMBER
TYPE
HEATING KEOIUM
TEMPERATURE BOOST - C
ENERGY RcOuIRED
NUMBER
1
1
1
11
IN-LINE
280 f HOT WATtR
22.2 < 40 F)
132 MM bTU/H
NUMPER
TYPE
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SoLlDS - 1
•• WATf LOOP
TYP?
*• REAGENT PREPARATION EQUIPMENT
NUMBER OF bALL MILLS
bALL MILL CAPACITY- « T/H
REAGENT PRODUCT - X SLuRRY SOLIDS
•* TREATMENT
TYPE
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
1
CENTER RA*E DRIVE
CONCRETE JITH CARBON STEEL SIDES
48.8 (16C FT)
2S.O
CLOS ED
21.8
63.3
< 24.0 TPH>
FORCED OXIDATION
FINAL
LINED POND
ON-SITE
PUMPED
500.0
30575000
< 25000.0 ACRE-FT)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPtRABILITY RELIABILITY UTILIZATION X REMOVAL P£R BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/76 SYSTEM
•* PfcObLEMS/SOLUTIONS/COMMENTS
5/76
720
102
1C3
104
105
106
107
1C8
10?
110
111
112
SYSTEM
A PRELIMINARY SYSTEM CHECKOUT WAS SUCCESFULLY COMPLETED BY PASSING A]R AND
WATER THROUGH THE SYSTEM.
62.1
83. n
81.0
59. C
72.0
93.0
57. C
69.0
63.3
75.0
67.0
66.0
88.3
74k
657
6C.O
** PRObLEMS/SOLUTIONS/COMMENTS
FIRST COMMERCIAL OPERATION COMMENCED HAY 1, 1976. THIS IS AN INTERMEDIATE
LC«D UNIT OPERATING NEAR FULL CAPACITY DURING THE DAY AND 35 PERCENT
CAPACITY AT NIGHT.
6/76 SYSTtM
84.0
1::.:
95.6
72C 688
688 73.0
260
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
STATUS POWER: SHtRbllRME 1 (CONT.)
PERFORMANCE DATA
PeRliO MODULE AVAILABILITY OPERAE1L1TY RELIAHILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*• PhOi'LtMS/SOLUTlONS/CCNMENTS
MODIFICATIONS ARt CONTINUING ON THE SPRAY SYSTEM, SPRAY NOZZLES AND
STRAINER SYSTEM.
7/7t
6/76
9/76
1C1
1 ~2
1 ?3
1:«.
1-5
1 ~6
1C?
1 ~c
1 C5
11C
m
112
S Y S T i K
71. r
6". 3
81.T
75.C
91.:
69.0
b4.o
68,
744
512 51.0
•* PRObLEMS/SOLUTlONS/COMMENTS
1C1
102
1 D3
104
105
136
1D7
108
10S
11C
111
112
SYSTEM
131
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
94.0
THE SLURRY NOZZLES ARE FREQUENTLY PLUGGED BY PARTICLES ABOVE QUARTER INCH
SIZE. STRAINER MOO IFICATIONS ARE PLANNED TO ALLEVIATE THIS PROBLEM.
HARD SCALE GYPSUM FORMATION ON THE VESSEL WALLS HAS LEVELED OFF. THE
CLEANING FRGCESS CALLS FOR 3-4 MODULES TO BE TAKEN OUT OF SERVICE EACH
NIGHT. THUS, EACH MODULE IS CLEANED ONCE EVERY 3 DAYS.
A CREW OF 71 PEOPLE IS REQUIRED TO MAINTAIN SCRUBBER OPERATIONS.
ATHE DEPOSITION OF SOFT SOLIDS IS STILL CONTINUING IN THE REHEATERS.
SOFT SOLIDS IN THE MIST ELIMINATORS ARE STILL CAUSING PROBLEMS.
46.j
93.0
51.0
84.T
83.0
76.0
71.3
84.0
81.0
76.D
87.0
91.0
100.0
94.8
744 70S
705 8C.O
95.0
87.0
90.0
93.0
76.0
76.0
79.0
85. 0
79.0
8S.O
80.0
92. 0
96.0
1CO.O
78.6
72C 566
566 68.0
*« PROBLEMS/SOLUTIONS/COMMENTS
THE STRAINER SYSTEM IS BEING MODIFIED. THE DUPLEX UNITS ARE TO BE
REPLACED BY IN-TANK SCREENS AND SOOT BLOWERS. BOTH ARE LOCATED AT THE
SUCTION SIDE OF THE SPRAT WATER PUMP.
CARBON STEEL FIN TUBE REHE IT BUNDLES ARE AN AREA OF CONCERN. MULTIPLE
261
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN STATtS POWER: iHERt-URNE 1
76.0
91.0
81.0
i::.o
87.0
9?. 9 K3.0 b1.5 744 606 cC6
83.-
»:.o
87.-!
79.:
92.0
ac.D
95.1
89.?
6<5.'
73.C
73.:
93.0
93.0 i;:.o 100.0 ?au 720 720 93 r
1/77
•• PROoLEMS/SOLUTIONS/COMMENTS
12/76 1C1
105
106
1C7
1Ce
1D9
11C
111
112
SYSTEM
9 5.0
APPROXIMATELY ONE-THIRD OF THt STRAINER MODIFICATIONS ON MODULE 1C1 ARE
COMPLETED.
THE UNIT IS CURRENTLY HAVING DIFFICULTY COMPLYING WITH THE 20 PERCENT
OPACITY REGULATION DUE TO THE EXTREMELY FINE FLY ASH BEING EMITTED
(7CX LESS THAN 1 MICRON).
67.C
s:.:
71.:
97.0
91.C
95.r
94.1
ss.:-
73.0
75.?
13C.3
97.0
744
722
722 91
** PhObLEMS/SOLUTIONS/COMMENTS
101
1C2
103
1C4
105
1C6
1C1?
106
109
11C
111
THE UTILITY IS NOW CONDUCTING A FULL-LOAD EVALUATION STUDY, ANALYZING
SYSTEM OPERATION ON 13 MODULES VS. THE DESIGNED 11 MODULES.
54.;
75.3
99.3
76.0
96."1
77.D
?•:.3
92.:
31.0
4;.3
75.0
262
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN STATES POWER: SHERbURKc 1 (CGNT.)
PERIOD MODULE AVAILABILITY
1 1 1
SYSTEM 93.0
2/77 101
1 72
103
104
105
1 " t
107
10S
1 "«9
1 1C
111
112
SYST£W 91.0
3/77 101
1-2
102
104
105
1 06
1 "7
10*
1C*
11C
111
112
SYSTEM 95.0
-PERFORMANCE DATA
OPEKA6ILITY RELIABILITY UTILIZATION
95. -1
1CO.C 81.6
85.:
99.0
64.0
96.0
64.0
99.0
81.0
62. C
98.0
93.0
98.0
61.0
i::.o 90.6
47.-
92.0
95. C
93.0
93.0
95.C
83.0
93.3
95.0
63.0
7S.O
7?."
1:0.0 99.9
x REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 6P7 fC7 73. C
67i 609 t09 83. C
744 743 743 97. C
A/77
»* PfcObLEMS/SOLUTIONS/COMWENTS
101
102
1C3
10*
105
1C7
1C 5
11C
111
112
SYSTtM
95.0
ALL MODULES ARE NOW FITTED WITH IN-TANK STRAINERS.
84.0
65.0
92.0
95.3
94.0
62.0
73.0
91.?
5?.:
93.0
90.0
88."
IC'3.0
99.7
7ZO 718
718 90.0
5/77 1v1
103
13*
135
ICt
106
109
11C
111
SYSTEM
96.0
4S.O
92.0
87.0
95.C
81.6
98.0
96.1
7C.3
35.0
67.:
i:3.0
41.9
744 31?
312 37.0
** PROuLtMS/SOLUTIONS/COMMENTS
6/7? 101
102
A SCHEDULED TURBINE OVERHAUL LASTED FROM MAY 14 TO JUNE 18.
76.0
77.0
263
-------
EP* UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHER* STATts POWER: SHERbURNE 1 ICONT.)
PERIOD MODULE AVAILABILITY
103
1?4
1v*5
i:t
107
138
10V
11C
111
112
SYSTEM 92.0
7/77 1CM
102
103
104
105
1C6
1C7
108
109
11C
111
112
SYSTEM 97.0
'PERFORMANCE DATA --
OPERAR1L1TY RELIABILITY UTILIZATION
75.?
75.r
3 j.C
87.:)
58. C
44. C
61.0
a o.o
83.?
103.: 34.4
93.0
66.0
92. C
90.0
92.0
94.0
91.0
17.3
94.0
83.0
78.0
63.0
100.3 98.9
X REMOVAL PER BOILER FGD CAP.
SOa PART. HOURS HOURS HOURS FACTOR
72C 248 248 25. C
744 736 736 9C.C
8/77
«* PHOt
-------
£PA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN STATES POWER: iMERbURNE 1
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN STATES POWER: SHEPbURf.E 1 (CCNT.)
PERIOD
2/7»
3/78
4/78
MODULE
1 C
11
YSTcM
03
04
rs
~t
07
08
OS*
1C
11
12
SVSTtM
•• PROb
101
1C2
103
1C4
1C5
107
1^8
109
111
112
SYSTEM
1n1
1C2
105
106
107
111
112
SYSTir
• • PROD
1C1
1:2
~ J
*"• *«
05
07
Oa
1C
AVAILABILITY OPERAdlLiTY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGO
S02 PART. HOURS HOURS HOURS
91.0
3".0
88.0
62.0
92.0 1CC.O 87.1 74*. 64b £<,£
85.0
88.0
76.0
d6.u
as."
67.0
92.0 103.0 94. t b?t 6T6 f36
LEMS/S OLUTIONS/COMHENTS
MODULES WHICH ARE SHOWING AVAILABILITY OF LESS THAN £,. PERCENT, ARE
THOSE IN WHICH THE STRAINER MODIFICATIONS WERE PERFOMEO.
A BULK ENTRAINMENT SEPARATOR WAS INSTALLED ALONG WITH A KOCH WASH TN
71.0
83.0
64."
89.0
9:.c
83. C
62.0
81.C
47. C
7"!o
9C.O
92.0 KO.0 9C.9 74* 676 676
ss!:
36.0
^7.:
52.T
*5.0 1M.: 99." 72; 713 "• 1 3
STRAif.tt. MODIFICATIONS «ER£ PEOFOSfED ON MODULES 1 C 4 AND 112.
61."
" - • .
c " . :
e •."
t :.:
3 •
;:.:
'1.-
CAP.
FACTOR
71. C
77. C
8 C . 0
91. C
266
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN STATcS POWLR: SHLRUURNE 1 CCONT.)
PERIOD MODULE AVAILABILITY
111
11?
SYSTtM 95.0
6/7f 1n1
1:2
1'3
1:4
105
1?t
1:7
108
179
11C
111
112
SYSTtM 93.0
7/7g 101
1C 2
1C- Z
1C4
1-5
1't
1"7
1,11:
i:<;
11:
111
112
SYSTLX 5 5 . C
PERFORMANCE DATA
OPERAB1L1TY RELIABILITY UTILIZATION
87.-
7<3.0
103.0 85.3
s:."
84.0
85.1
85. 0
62.?
7S.O
55. 0
83.0
SB.:
62.0
72."
?5.C
1C3.3 99.6
82.:
76.0
71.0
74.0
75.:
52.0
75.0
63.1
62.0
72.0
66.0
73.0
100.0 93.3
x REMOVAL PER BOILER FCD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 635 635 72.0
72; 717 717 81.0
744 694 694 75.0
.. PhOuLiMS/SOLUTIONS/COMMENTS
1C1
102
103
104
105
106
107
1?8
109
11C
111
112
SYSTEM
91.0
THE CCCURMNCE OF PLUGGING PROBLEMS IN THE MIST ELIMINATOR HAS BEEN MORE
FREQUENT THAN NORMAL.
THE STRAINER MODIFICATIONS CONTINUED IN JULY.
THE UTILITY IS EVALUATING NEW RUBBER LINED PUMPS (8000 GPH) TO HELP
CORRECT THE REHEATER AND MIST ELIMINATOR PLUGGING PROBLEMS.
THE OCCURANCE OF PLUGGING PROBLEMS IN THE REHEATED HAS BEEN MORE
FREQUENT THAN NORMAL
THE UTILITY IS PREPARING FOR THE STATE COMPLIANCE DEADLINE ON NOV. 1,
1978. CURRENTLY TESTING HAS BEEN PROCEEDING ON DIFFERENT MODULES IN AN
EFFORT TO FINE TUNE THE SYSTEM.
THE FGO SYSTEM HAS BEEN EXPERIENCING PRIMARY CONTACTOR WALL AND MARBLE BED
HEAR.
THE UTILITY IS EVALUATING NEW STAINLESS STEEL MIST ELIMINATOR WASH
LANCES (TC REPLACE THE ORIGINAL FIBERGLASS LANCES) TO HELP CORRECT IHE
REHEATER AND MIST ELIMINATOR PLUGGING PROBLEMS.
64.0
65.0
73.C
63.0
65.0
8C.O
S1.0
73.0
63.0
73.0
64.0
83.0
130.0 99.7 744 7*2 742 79.C
267
-------
EPA UTILITY FGD SURVEY: FOURTH QUAFTEf 1979
NORTHERN STATLJ, POWER: SHERbURNi 1 (CONT.)
PERFORMANCE DATA
PERIOD MCDULt AVAILABILITY CPEPADILITY RELIABILITY UTILIZATION
X REMOVAL PER bOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/78
101
1:2
135
13t
1C7
138
109
11C
111
112
SYSTEM
97.0
62.1
77.:
77.3
58.0
82.0
6S.O
63.0
s:.3
8-1.0
55.?
75.3
i::.o
49. t
720 J57
357 36. C
** PRObLEMS/SOLUTIONS/COMMENTS
10/78
11/78
12/78
102
103
1C*
1:5
1?6
137
13b
1?9
11C
111
112
SYSTEM
92.0
DIFFERENT MIST ELIMINATOR SPRAY PATTERNS ARE BEING TESTED AS POSSIBLE
SOLUTION TO THE MIST ELIMINATOR PLUGGING PROBLEM REFERRED TO IN JULY.
The bOILEk WAS TAKEN OFF LINE ON SEPTEMBER 15, 1978 FOR A SCHEDULED
ANNUAL BOILER AND TURBINE INSPECTION. THE BOILER CAME BACK ON LINE IN
THE PIDDLE OF OCTOBER.
THE RUbBEd LINED PUMPS THAT THE UTILITY WAS INVESTIGATING IN JULY,
HAVE BEEN ORDERED. FOUR 01 THE PUMPS HAVE bEEN RECEIVED AND ONE IS
INSTALLED. THE OTHERS WILL BE INSTALLED AS THEY ARE RECEIVED.
95.?
65.0
8?.?
en:
71.0
7R.O
77.3
63.3
35.0
61.3
84.3
7:.o
1CO.O 53.4
7*4 375
375 37.0
** PROELEKS/SOLUTIONS/COHMENTS
101
1C 2
1C3
1?4
105
1C6
1?7
ice
109
1U
111
112
SYSTEM
1C1
102
103
13*
105
136
1C7
THE Z IN. D1A. SS RODS IN THE PRIMARY CONTACTOR WERE REPLACED WITH t(518)
DIA. CERAMIC COATED C.S. RODS. THE CERAMIC SLEEVES ARE 9/16 IN. THICK.
ThE MODULI IS BEING PREPARED FOR FURTHER TESTING.
42. C
51.0
88. 0
81.1
71.0
78. r
77. C
63.3
85. p
61.0
92.0
73.0
1C3.3
77.0
73. -^
77.3
73.0
86.3
a?.:
93.3
99.2
72; 714
714 79.0
263
-------
EPA UTILITY fCO SURVEY: FOURTH QUARTER 1979
NORTHERN STATiS POWER: SHERbUHf.E 1 (CONT.)
PED1CD MODULE AVAILABILITY CPEKAKIL1TY RELIA01LITY
It
39
1C
11
12
SYSTEM
•* PfcOuL
85."
9 3 . ;•
at .?
9 ;.o
ds.i
94.0 i::.o
EMS/SOLUTIONS/ COMMENTS
THE PROBLEMS ENCOUNTERED
THE TESTING ON MODULE 101
AVAIL AttLE .
THERE .EKE PROBLEMS WITH
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
98.5 744 733 733 76.5
WERE MAINLY HEATHER RELATED.
tAS BEEN COMPLETED BUT NO RESULTS ARE YET
THE COAL FEEDER BELTS RESULTING IN MOVING COAL
Ff-OM COAL STOCKPILES TO THE BOILER.
1/79 1"1
1C2
103
1C 5
106
107
1C£
i:s
11C
111
112
SYSTEM
2/79 101
1C2
102
104
105
It
?7
Ct
C9
1C
11
u
SYSTEM
3/79 171
1 ?2
103
1 04
1 ?5
1 "t
1C7
136
109
11C
111
112
SYSTEM
72.".
39."
?*'~
7 i !:
95."
31.:
&<;.-•
96 .r'
92.:
63.'
52.0
94.0 1;:.:.
7 « . ;
7 ? .-1
7 :.:
7i .-'
5 :.r
4 1 . j
»2."
y 2 •""'
75.;-
77.7
66. C
93.:
89.o ic:.c
61.J
58.0
45. C
86. C
94."
71.:
91.3
73.0
41 ."
8 C . TI
69. ^
a:.:
92.0 i:i.O
92.5 744 683 688 65.8
78.:
73.-
7D.C
76.-
5C.C
91.'
92. r
92.:
75.'
77. -^
66.:
93.'
UO.C 6""2 672 672 67.9
6-.1
06. f
44.4
34 •£
92.7
73.:
S9.S
72. :
b9.«
7e.9
c?.?
7f .9
98.7 744 734 734 59.4
• • PRObLEHS/SOLUTIONS/COMMENTS
THE ONL» MAJOR PROBLEM REPORTED BY THE UTILITY WAS BOILER RELATED -
SPECIFICALLY PROBLEMS WITH WET COAL.
4/79 SYSTEM
5/79 SYSTEM
CURRENTLY THE UTILITY IS
LING 8CCO GPM WORTHINGTON
BEEN INSTALLED ON MODULES
93.0 1SC.O
98.0 1CC.O
INCREASING THE RECYCLE PUMP CAPACITY BY INSTAL-
RECYCLE PUMPS. DURING THIS PERIOD THEY HAVE
1C1.103.104.105.107. AND 110.
86.4 72C 622 622
91.1 744 678 678
269
-------
EP» UTILITY FuD SURVEY: FOURTH OUARTEf. 1979
NORTHERN STATES POWER: SHERbURNc 1 (CCNT.)
------------------------------------------ PEfifORMANC I DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION
% REMOVAL PER BOILER FGD CAP.
SOJ PART. HOURS HOURS HOURS FACTOR
•* PfcOL-LEMS/SOLUTIONS/COMMENTS
THE UTILITY fcILL NO* REPORT THt TOTAL SYSTEM AVAILABILITY ONLY.
THE UTILITY HAD NO OPERATIONAL DIFFICULTIES TO REPORT.
6/79 SYSTEM 93. D 1:C.O 97.4 72 C 701 7^1
•• PNOt 72 C
C95 695
744 744
166 1tt
*• PRObLEMS/SOLUTIONS/CONHENTS
10/77
11/79
12/79
SYSUM
SYSUM
SYSTEM
77. j
97.0
95.0
ON SEPUMMR fi THE
AND IS EXPLCTED TO
UNIT riENT DOWN FOR THE ANNUAL 60 I LE R / TURB I N E INSPECTION
I'E OFF LINE UNTIL THE LAST UEEK OF OCTObER.
744
72.
744
9
522
744
THc UNIT WAI SUPPOSED TO PE bACK CN LINE IN OCTObER AFTER THE ANNUAL
(•GILLS/TUPlINE INSPECTION; HUT, CONTAMINATES IN THE MAIN TURBINE OIL MADE
IT NECcS&AM TO CONTINUE THE OUTAGE UNTIL THE SECOND WEEK OF NOVEMBER.
PRESENTLY THE UTILITY IS SELECTIVELY REMOVING MAHBLE BEDS FROM SERVICE
TO TEST THI FEASIBILITY OF CONVERTING THE FGD MODULES TO SPRAY TOUERS.
ALL PIPINf, HAS UEEN CONVERTED FRO* CARbON STEEL TO FIBERGLASS.
270
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOP OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT tjAKE
UNI T NULL'S*
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOi cMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GtNERATlNG CAPACITY -Mk
NET UNIT GENERATING CAPACITY W/FGD - My
NET UNIT GENERATING CAPACITY fcO/FGt - MW
EQUIVALENT SCRUBBED CAPACITY - HW
•• bOIL?R DATA
SUPPLItR
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATb
MA XI l-Uf. bOlLER FLUE GAS FLOW - CU.fl/S
FLUE GAS TEMPER ATURE - C
STACK HEIGHT - M
STACK TOP DIAME TtR - M
** FUEL DATA
FUEL TYPt
FUcL GKAdE
AVERAGE HEAT CONTENT - J/G
RANGE hEAT CONTENT - bTU/Lb
AVLRA^E ASM CONTENT - 1
RANGE ASH CONTE NT - %
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - *
AVERAGE iULFUfi CONTENT - 7.
RANGE SULFUR CONTENT - *
AVERAGE CHLORIDE CONTENT - *
RANGE CHLORIDE CONTENT - \
** PARTICIPATE SCRUfibEK
NUMBE"
TYPE
SUPPLIER
NUMflER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
TYPE OF NOZZLES
bOlLER LOAD/SCRUbBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID REC1RCULAT10N RATE - LITER/5
L/G HATIJ - LIT ER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
*• FGD SYSTEM
SALEABLE PfcODUCT/THROWAWAY PROLUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMtNT LEVEL
NEM/RETROFIT
PARTKULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
NORTHERN STATES POWER
SHERfcURNE
2
.087 LB/MMBTU)
.960 LB/MMBTU)
MINNESOTA
D
J7.
413.
32DC.O
74C.O
70C.Q
72 :.o
74?.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/77
13A !.16 12859000 ACFH)
154.4 t 310 F)
19P. ( 650 FT>
">.<3 ( 32.6 FT>
COAL
SUPBITUMINOUS
1<)7i 1. < 8500 BTU/LB)
******
9.0C
25.CO
******
.03
12
VENTUR1
COMBUSTION ENGINEERING
C
CARBON STEEL INLET, 316L SS SKIRT, 316L VCNTURI
NONE
316L SS RODS 12 ROWS OF 2.5 IN. DIA. RODS), CERA
CERAMIC
9.0
122.6
15*. 4
22!. 0
( 259900 ACFN)
t 310 F)
( 3540 GPM>
M7.0 GAL/1COOACF)
(«.«.* IN-H20)
( 8%0 FT/S)
THROUAWAY PRODUCT
WET SCRUBBING
LIMESTONE/ALKALINE FLYASH
NONE
COMBUSTION ENGINEERING
BLACK & VEATCH
FULL SCALE
NEW
99.00
5C.OO
4/77
4/77
8.0
.9
271
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN STATES POWER: SHERUURNE 2 (CONT.)
ABSORfaER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
HUMPED OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATER1H
KUMHER Of NOZ7LHS
NOZZLE TYPE
bOlLER LOAD/ABSORbtR - *
(.AS FLOW - CU.M/S
6AS TEMPiRATURE - C
LIQUID RcClRCULAT10N RATE - LITER/S
L/G RATIO - L/C U.M
PRESSURE DROP - HP*
SUPERF1C4L GAS VELOCITY - M/SEC
PARTICIPATE INLET LOAD - G/CU.K
PARTICIPATE OUTLET LOAD-G/CU.H
PARTICIPATE REMOVAL EFFICIENCY - *
SOi INLET CONCENTRATION - PPH
SOi CUTL£T CONTRATION - PPM
$02 DESIGN REMOVAL EFFICIENCY - I
12
MOBILE PACKED TOWER
4/77
COMBUSTION ENGINEERING
18 X 26.5 X 60
CARBON STEEL (1/4 IN)
CEILCOTE FLAKEGLASS
316L ss PERFORATED PLATE, FRP SPRAY HEADERS, OLA
54
CERA IK
94.s
54.4
12:.
1.3
.5
9.4
6.9
.1
99.0
70 (
325
55.0
( 200000 ACFn)
< 130 F)
1900 GPM)
1C.O GAL/100CACF)
31. C FT/S)
3.000 GR/SCF)
.036 GR/SCF)
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - y£T/DRY
CAPACITY - CU.M/S
•• MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMHE" OF PASSES
FREEBOARD DISTANCE - K
VANE SPACING - CK
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
•• PUMPS
SERVICE
POND RETURN
THICKENER UNDERFLOW
MAKE-UP HATER
REHEAT WATER
SCHUtiB£R RECIRCULATION
ABSORBER RECIRCULATION
TANKS
SERVICE
REACTION
MAK.E-UP HATER
SLURRY MAKE-UP
REHEATED
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
SCRUBBER ID
CARBON STEEL
DRV
94.38
CHEVRON
FRP
HORIZONTAL
?
3
4.27
1C.2
( 20QOOO ACFM)
(14.3 FT)
( 4.00 IN)
1ST STAGE, VERTICALLY UPWARD 180 DEC. ROTATABLE;
9.4
.1
( 31.0 FT/S)
( .5 IN-H20)
SLURRY PH. SLURRY SOLIDS. TANK LEVELS, PRESSURE
PRESSURE DROP U IN H20. 1uX SOLIDS, PH»5-5.5
AUTOMATIC
FEEDBACK
NUMBER
1
1
1
2
2
12
NUMBER
1
1
1
11
IN-LINE
280 F HOT WATER
22.2 (
132 MM BTU/H
40 F)
272
-------
NORTHERN STATcS POWER: SHCRhURNE i (CCNT.)
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
** THICKENER
NUMPtR
TYPF
DIAMETER - "I
OUTLET SuLlDS - 5-
** WATER LOOP
TYPE
•* REAGENT PREPARATION EQUIPMENT
hUMPE" Or dALL MILLS
bALL MILL CAPAC ITY- M T/H
r.EAGtNT PRODUCT - i SLtRRY SOLIDS
•* TREATMENT
TYPE
** DISPOSAL
I,ATU(<£
TYPf
LOC« TICN
TRANSPORTATION
ARt* - ACRES
CAPACITY - CU.K
RAKE DRIVE
4P.8 <16~ FT)
2f.C
OPEN
11 .8
60 • u
fQRCEO OX10AT10H
f I HAL
LINED POND
ON-SITE
PUMPrD
s: c.c
TPH)
ACRE-FT)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPEPAf< 1LITY RELIABILITY UTILIZATION
REMOVAL PER BOILER FGD CAP.
O; PART. HOURS HOURS HOURS FACTOR
4/77
5/77
6/77
2"1
i :2
2C3
2 :4
205
2C6
2~ 7
iOB
2* fc
209
21C
211
212
SYSTEM 92.0
211
212
2^9
2CU
iOt
203
204
201
202
SYSTEM 91.0
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM 96.0
55.:
93.D
87.3
83. D
84.;
94.:
S8.C
74.;
91 .3
87. o
85.:
86.:
liC.a 96.8 72u 697 697 78. C
91.0
98.0
94. C
98. C
ICC. 3
44.3
95 .:
33.0
1CC.O
TCC.O 86.6 744 64* 444 75.0
92.3
76.:
78.0
79. C
89.0
74.:
67.:
88.C
88.0
7 j ,1
45.3
85.C
13C. 0 100.0 72; 720 720 83. 0
273
-------
EPA UTILITY FiiD SURVEY: FOURTH QUARTER 1979
NORTHERN STATtS POWER: SHERbURNE 2
S02 PART. HOURS HOURS HOURS FACTOR
PROBLEMS/SOLUTIONS/COMMENTS
7/77
8/77
9/77
tO/77
2?2
205
2C7
238
210
211
212
SYSTEM
2:1
2 D2
203
275
2C6
207
2:3
CRACKING AND BUBBLING OF THE CEILCOTE LINING HAS BEEN ObSEBVEO APOVE THE
LIQUID LEVEL CF THE INTERNAL RECYCLE TANK.
96.?
37. D
86.?
V7.a
96.:
38.-)
88.-)
95.7
57. J
97.0
21u
211
212
SYSTEM
94.3
87.?
8 S.I
75.0
67.7
82.0
84.0
35.1
81.:
B:.J
56.:
79.0
71.:
33.:
74*
602
72.C
90.7
744
675
675 69.0
*• PROBLEMS/SOLUTIONS/COMMENTS
THE SP»AY PUMPS WERE OVERHAULED DURING AUGUST.
Tht SPRAY NC7ZLES REQUIRED EXTENSIVE CLEANING.
2-1 a'.:
2C2 61.0
203 52.:
2-4 ?:.0
2C7 52.-
2?9 St.:
211 7J.?
212 i6.0
SYSTEM 94.? 1::.} 99.6
•» PfcOuLtMS/SOLUTIONS/CCMMENTS
72;
717
83.0
202
213
204
205
207
2?e
20S
2?9
21C
THE STRAINERS IN TH; REACTION TANKS HAVE STARTED ERODING.
ANTICIPATES REPLACING THEM VERY SOON.
56.?
62.'
91.:
96. I
NSP
274
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
NORTHERN STATcS POWE H : SHdRUURNE I (CONT.)
PERFORMANCE DATA —
PtRIOD MOJULE AVAILABILITY CPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/77
212 a 1.0
brSTEM 9 5.0 1C3.0
** pdOtLEWS/SOLUTIONS/COMMENTS
91.9
744 684
684 85.C
THE LOW OFERAfalLlTIES ARE DUE TO SPRAY WATER PUMP OVERHAULS. 24 PUMPS
ARE BEING OVERHAULED.
STRAINER/kASHER SCREEN EROSION HAS BEEN A PROBLEM. 316 SS MATERIAL WILL
be USED IN THE FUTURE. REPLACEMENT MATERIAL IS EXPECTED TO ARRIVE IN
DECEMBER AND WORK is EXPECTED TO LAST FOR THREE MONTHS.
12/77
1/78
2/78
2:5
2-1
i ' ")fc
t->»;
2 1 C
211
212
SYSTEM 91.0
£•"1
I'.-'i
203
204
2C5
2" t
207
2 " fc
2:9
21C
211
212
SYSTEM 93.0
201
2C2
2^3
234
205
2?t
207
208
209
21C
211
212
SYSTEM 92.Q
93."
75.3
66."
94.C-
77. r
91.3
65.0
1 03.0
53.-
93.3
94.1
81.3
8S.3
95.?
93. C
83.3
62. T
8? .:
5 : .0
92.3
1C3.0
91.:
75.:
64. 0
72.C-
74.:
67.:
91.:
as.:
77.:
72.:
73.3
84.0
1C3.0
•* PRObLEMS/SOLUTIONS/COMMENTS
99.3
7ZC 715
85.0
98.5
744 733
733 84.0
91.7
744 68Z
682 73.0
2C2
2C3
234
205
-------
EP* UTILITY FoO SURVEY: FOURTH OUARTFR 1979
NORTHERN STATES POWER: SHERbURNE <.
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
NORTHERN STATES POWER: SMERbURNE Z (CONT.)
. PfcRFORNANCE DATA
PERIOD MODULE AVAILABILITY OPEFABILITY RELIABILITY UTILIZATION * REMOVAL PER bOlLER FGD CAF.
S02 PART. HOURS HOURS HOURS FACTOR
** PkOULEMS/SOLUTIONS/CONMENTS
6/73 2M
202
233
205
THERE WERE LINER FAILURES IN MOST OF THE MODULES DURING I»»Y.
ThE LINERS fcERE REPAIRED K THE CtlLCOTE COMPANY AT THEIR OUN EXPENSE.
ThE UNIT hENT DOWN ON MAT 6 FOR THE FIRST YEAR BOILER AND TURBINE INSPEC
TION AND fc«S DOWN THE REMAINDER OF MAY.
77.7
46. j
41.0
67.3
62.1
62. j
78.0
211
212
SVSUM
7/78 201
204
205
206
o c -
y ..»•.
76. C
75.:
89. C
62.?
93.?
53.3
64.0
79.4
572 64.C
2C9
21C
211
212
SYSTEK
64. 0
ui.?
73.:
71.:
95.: i::.o
• * P|«Oi:LE«S/S OLUTIONi/COMIENTS
92.3
744 697
667 75.0
8/78 201
202
203
204
205
206
207
208
ThE UTILITY IS EVALUATING NEW RUBBER LINED PUMPS (8000 GPM) AS POSSIBLE
SOLUTIONS TO THE MIST ELIMINATOR AND REHEATER PLUGGING PROBLEMS.
THE UTILITY IS EVALUATING NEW STAINLESS STEEL MIST ELIMINATOR WASH LANCES
(TO REPLACE ORIGINAL FIBERGLASS LANCES).
ThE FGD SYSTEM HAS bEEN EXPERIENCING PRIMARY CONTACTOR WALL AND MARBLE
CID WEAR.
THE UTILITY IS PREPARING FOR THE STATE COMPLIANCE DEADLINE ON NOVEMBER 1.
CtRRENTLY TESTING HAS BEEN PROCEEDING ON DIFFERENT MODULES IN AN EFFORT
TO FINE TLKE THE SYSTEM.
PLUGGING FROBLEMS IN THE REHEATER HAVE BEEN MORE FREQUENT THAN NORMAL*
THE UTILITY IS IN THE PROCESS OF REPLACING THE ORIGINAL 7URN DUPLEX
STRAINERS THEM WITH 316 SS STRAINERS.
THE INLET SEAL STRIPS WERE REPAIRED.
PLUGGING FROBLEHS IN THE MIST ELIMINATOR HAVE BEEN MORE FREQUENT THAN
NORMAL.
88.0
1C3.0
48.0
79.?
81.3
72.0
64.0
87.0
277
-------
EPA UTILITY FGD SURVEY: FOURTH QUAPTES 1979
NORTHERN STATES POWER: SHERbURNE 2 (CONT.)
PERFORMANCE DATA ---._
PERIOD NODULE AVAILABILITY CPERABILITY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
54.3
76.";
21C
211
212
SYSTEM
71.C
1 •::.?
53.0
*• PfcOtLclS/SOLUTIONS/COMMENTS
93.4
744 695
695 73.0
NC FCD RELATED OUTAGES WERE REPORTED BY THE UTILITY FOR THE AUGUST-
PcPORT PERIOD.
9/7? 2C1
2?2
2^3
2*4
i " 5
216
72."
82.0
77.D
61.?
74. j
64. ^
2 1C
it 1
212
SYSUP
75. 1
63.
96.0
100.?
72:
PSObLtMS/SOLUTION^/COMMENTS
THE Rut:bEh LINED PUKPS THAT THE UTILITY WAS INVESTIGATING HAVE BEEN
ORDERED. FOUR OF THE PUMPlS HAVE BEEN RECEIVED AND ON i IS INSTALLED. THE
OTHERS fclLL BE INSTALLED A< THEY ARE RECEIVED.
DIFFERENT MIST ELIMINATOR JPRAY PATTERNS ARE bEING TESTED.
10/7? 2C1
202
i-03
205
206
2?7
2D£
£09
21C
211
212
SYSTEM
79."
5
-------
£PA UTILITY FGO SURVEY: FOURTH OUARTER 1979
NORTHERN STATtS POWER: SHERbURNE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE *VAILA HILITY GPERAPIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
«« PROuLEMS/bOLUTIOMS/CCMHENTS
THE LOw NOVEMBER BOILER HOURS RESULTED FROM A TURBINE INSPECTION.
NOSMAL OVERHAUL MAINTENANCE WAS PERFORMED ON THE SPRAY PUMPS OF MODLLES
2^.2 A',0 ?12.
12/7?
2 ''4
92. ?
1/79
2/79
3/79
21:
96. ?
39.0
7H.C
9Z.T
61. j
94.0
K:.J
SYSTtM 94.Q
• • PROl-LtMS/SOLUTIONS/CONMENTS
98.
744
7-<3
733 77.2
201
2C2
ZCS
204
205
206
217
208
2?9
210
211
212
SYSTEM
231
2:2
208
209
21C
211
212
SYSTcM
231
2C2
203
204
205
206
207
2C8
209
21C
211
212
SYSTEM
94.Q
THE F-RObLtNS ENCOUNTERED WERE MAINLY WEATHER RELATED.
THERE WERt PROBLEMS WITH THE COAL FEEDER BELTS RESULTING IN MOVING COAL
FROM COAL STOCKPILES TO TH I BOILER.
57.0
89.0
91.0
35.0
92.0
32.0
75.0
97.9
74.0
88.0
100.0
90.0
1QC.O 92.5 74* 688
93.0
91.0
86.0
84.0
89.0
59.0
76.0
72.C
68.0
63.0
75.0
92.0
65.0
1CC.O
85.0
69.0
78.0
47.0
71.0
76.0
90.0
78.0
50.0
dS.O
57.D
36.C
1CO.O
688 69.8
99.9
672 671
671
100.0
744 744
744
279
-------
EPA UTILITY FbO SURVEY: FOURTH QUARTER 1979
NORTHERN STATES POWER: SHERbURME I (CCNT.)
... ..—. .. ...... PERFORMANCE DATA— ..... . .....—......
PERIOb MODULE AVAILABILITY OPERA81L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
•• PROuLEMS/SOLUTIONS/COMMENTS
THE ONLY REAL PROBLEMS ENCOUNTERED DURING THIS PERIOD WERE PROBLEMS WITH
WET COAL.
THE RECYCLE PUMPS ARE BEING REPLACED WITH LARGER BCOC bPM UORTHINGTON
PUMPS. DURING THIS PERIOD THE PUMPS WERE INSTALLED ON MODULES 20* AND
206.
4/79 SYSTEM 99.0 1CC.C 99.6 72C 717 717
5/79 SYSTEM 95.C 1:3.0 35.3 744 263 26?
•* PSObLENS/SOLUTIONS/COMMENTS
THE LOU BOILER HOURS IN MAY WERE DUE TO COMMENCEMENT OF THE ANNUAL BOILER
AND TURBINE INSPECTION.
ALL PIPING HAS BEEN CHANGED TO FIBERGLASS.
THE UTILITY WILL NOW REPORT THE AVAILABILITY Of THE TOTAL SYSTEM ONLY.
6/79 SYSTEM 93.0 1CC.3 63.1 720 454 454
•• PKOtiLtnS/SOLUIlONS/COMMENTS
THE ONLY PROBLEM REPORTED BY THE UTILITY WAS THE LOSS OF A BOILER SURGE
PUMP AFTER THE UNIT RESTARTED.
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
95
96
95
.0
.0
.3
1CC
ic:
10:
.0
.3
.0
99
99
91
.6
.5
.3
744
744
720
7*1
740
657
741
740
657
** PRObLEMS/SOLUTIONS/COMMENTS
10/79
11/79
t2/79
SYSTEM
SYSTEM
SYSTEM
94
97
97
.0
.0
.0
NO MAJOR
IT CAME
OPERATIONAL
BACK ON LINE
PROBLEMS HAVE BEEN ENCOUNTERED
AFTER THE ANNUAL BOILER/TURBINE
WITH THIS
OVERHAUL,
744
720
744
732
719
662
UNIT SINCE
I
>* PROULEMS/SOLUTIONS/CONMENTS
NO MAJOR BOILER OR FGD OPERATIONAL PROBLEMS WERE ENCOUNTERED DURING
THIS PERIOD.
280
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA fOK OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NU»bE(<
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - MG/J
NET PLANT GENERATIKG CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - Mw
NET UNIT GENtRATlNfi CAPACITY UO/FGt - MW
EOUIVALEM SCRUBBED CAPACITY - MM
** BOlLfH DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATt
MAXIMUM bOlLER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP D1AME TER - M
• * FUEL DATA
fUEL TYPi.
FUtL GRADE
AVERAGE MEAT CONTENT - J/G
RANGE HEAT CONTENT - t'TU/LB
AVERAGE ASH CONTENT - i
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
PACIFIC POWER 8 LIGHT
JIM PRIOGER
4
ROCK SPRINGS
WYOMING
D
43. t
86. (
.1CC LB/MMBTU)
.200 LB/MMBTU)
55 '.0
507.?
509. C
550. 0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
* * / * *
1283.57 J2720000 ACFM)
***•**• (**** f)
152. < SCO FT)
..*.... (....* FT)
COAL
SUBBITUNINOUS
21632.
< 9300 BTU/LB)
9.CO
1 I.Cj
.56
******
.01
** ESP
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY
** PARTICULATE SCRUBbER
TYPE
FGD SYSTEM
SALEABLE PRODUCT/THROWAyAY PRODUCT
faENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-t fIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
so2 DESIGN REMOVAL EFFICIENCY - i
COMMERCIAL DATE
INITIAL START-UP
CONTRACT AUARDE 0
ABSORBER
NUMBER
TYPE
INITIAL START UP
NUMBER OF STAGE S
SHELL MATERIAL
SHELL LINER HAT ER1AL
INTERNAL MATERIAL
COLD SIDE
CARBORUNDUM
X 99.?
NONE
THRObAUAV PRODUCT
WET SCRUBBING
SODIUM CARBONATE
AIR CORRECTION DIVISION, UOP
BECHTEL
LACKENFJY (UOP SUBCONTRACTOR)
FULL SCALE
NEW
99.00
91.00
2/8C
9/79
10/76
TRAY TOWER
9/79
i
CARBON STEEL
RUBBER
SIEVE TRAYS 317L ss
281
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1S7V
PACIFIC PCWER i LIGHT: JIM IR1DGER 4 (CONT.)
•• P1ST ELIMINATOR
VANE ANGLES
•• PUMPS
SERVICE
ABSORBtff REC1RCULATION
•* THICKENER
OUTLET SOLIDS ' *
•• WATER (.OOP
TYPE
»• DISPOSAL
NATURE
TYPE
TRANSPORTATION
ARtA - ACRES
45 DEG.
NU!"!BE R
If.P
CLOSED
FINAL
POND
PUMPE D
8C.C
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERA&ILITY RELlAPlLITY UTILIZATION * KcMOVAL PER BOILER fGD CAP.
SO: PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM
11/79 SYSTtM
12/79 SYSTEM
744
744
•« PkObLtMS/SOLUTIONS/CCMMENTS
THE UNIT STARTED OPERATIONS AS SCHEDULED IN SEPTEMBER 1979. PRESENTLY
THEY ARE IN THE START UP PHASE WITH COMMERCIAL OPERATION SCHEDULED FCP
Y.
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOB OPERATIONAL DOhESTIC f&D SYSTEMS
COMPANY
PLANT
UNIT
CITY
STATt
REGULATORY CLAiSIFlCATl0\
PARTICULAR LdSSION LIMITATION - SG/J
SO* EMISSION LIMITATION - UG/J
NET PLANT GENERATING CAPACITY - MiJ
GROSS UNIT Gt.NtRATING CAPACITY - Mk
NET UNIT &£Nt.RATING CAPACITY h/FGD - MW
NET UNIT &t.N£RATING CAPACITY WO/FGl - 14 W
EQUIVALENT SCRUBBED CAPACITY - l».n
** TOILER DATA
SUPPLIER
TYP?
SEhVKL LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER HUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIA*£ TfcR - I"
** FuEL DATA
FUEL TYPi.
FUEL GRADE
AVtRAGt HEAT CONTENT - J/G
RANGE HEAT CONTENT - bTU/LB
AVERAGE ASH CONTENT - X
RANGE ASh CONTENT - X
AVERAGE HOlSTUfcE CONTENT - *
hANGE MOISTURE CONTENT - %
AVIRAGt SULFUR CONTENT - T
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - S
RANGE CHLORIDE CONTENT - "!
PENNSYLVANIA
BRUC • MANSFIELD
1
SHIPP1NGPORT
PENN SYLVANIA
D
15. (
?5S. (
2751.0
917.0
?a5.o
fSC.C
917.0
FOSTER WHEELER
PULVERIZED COAL
BASE
0/76
158". 86
UC.6
29C.
5.8
•035 LP/MMBTU)
,6?C LB/MMBTU)
COAL
BITUMINOUS
36749.
12.90
11.5 -13.5
7.00
5.5-f .5
!.Cu
1.75-3.75
( 950
F)
FT)
( 19.0 FT)
I 115QG BTU/LB)
11000-11050
PAOTICULATE SCRUBbER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGE S
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATcRlAL
TYPF OF NOZZLES
bOILER LOAD/SCR UlBtR - 51
fLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
LIQUID RtCIRCULATION RATE - LITER/S
L/6 RATIO - L1TER/CU.W
PRESSURE DROP - KPA
SUPERFICIAL &AS VELOCITY - M/S
PART1CULAU INLET LOAD - G/CI.C,
PAHTKULATt OUTLET LOAD - (,/CU.W
PART1CULATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
S02 CUTLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
F&D SYSTEM
SALEABLE PROOUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-t fIS«
DEVELOPMtNT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - i
COMMERCIAL DATE
6
VENTURI
CHEMICO
I
CARBON STEEL
POLYESTER FLAKEGLASS
PLUMR BOB AND 2 SETS OF SPRAYSi 317 SS AND 3U S
TANGENTIAL FEED M SET AT THROAT,1 AT BOTTOM]
17.0
263.5 ( 558333 ACFM)
UO.6 ( 285 F)
1386.0 (22000 GPM>
5.3 UC.O bAL/1000ACF>
••*••*• (.«*.* IN-H20>
61.0 < £00.0 FT/S)
17.7 t 7.75 GR/SCF)
.0 i .016 SB/SCO
- X 99.8
309C.OOO
"30.000
7C.C
THROUAUAY PRODUCT
WET SCRUBBING
LIME
MG (Z-6X)
CHEMICO
GILBERT/COMMONWEALTH ASSOCIATES
FULL SCALE
NEW
- X 99.80
92.10
6/76
283
-------
cPA UTILITY FljD SUUVFY; FOOfcTH QUARTER 1979
PENNSYLV'MA PO«ER: BRUCE MANSFIELD 1 (CONT.)
INITIAL iTART-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORStR SPARE COMPONENT INDEX
** AbSO'bEd
NUMPtB
TYPE
INITIAL START OP
SUPPLIER
NUMBER Of STAGeS
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NOZ:LE TYPE
bOILEI LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEKPtRATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/C U.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
PARTKULATt OUTLET LOAD- G/CU.K
S02 INLET CONCENTRATION - PPM
S02 CUTLET CONTRATION - PPM
S02 DESIbN REMOVAL EFFICIENCY - i
*• FANS
MUMPER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
•* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MA TERIAL
CONFIGURATION
NUMEER OF STAGE S
MUMPER OF PASSES
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
•* MIST ELIMINATOR
NUMBE"
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
•• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
SENSOR LOCATION
•• PUMPS
SERVICE
12/75
.0
.0
6
VENTURI
12/75
CHEM1CO
I '
34 DIA X 51.5 HIGH
CARBON STEEL
POLYESTER FLAKEGLASS
CARBON STEEL, FLAKEGLSASS LINING (? SETS OF SPAR
TANGENTIAL FEED
17.0
( 4Z66GC ACFM)
( 127 F)
(19400 GPM)
t 45.2 GAL/100CACF)
< 8.3 IN-H20)
(100.0 FT/S)
( .016 GR/SCF)
201.31
5?.6
122*.
6.0
2.0
3?.5
.0
930
24C
92.1
12
BOILER ID
INCOLOV 825 ON HOUSINGS; INCONEL 625 SCROLLS AND
WET
363.32 ( 558000 ACFM)
6
CHEVRON
FRP
HORIZONTAL
1
4
7.6 ( 3.00 IN>
90 DEG.
OVERSPRAV (ONCE PER SHIFT), UNDERSPRAY (CONTINUO
T.O ( 10.0 FT/S)
.1 ( .6 IN-H20)
6
CHEVRON
FRP
HORIZONTAL
1
I
7.6 < 3.00 IN)
90 OEG.
OVERSPRAY (ONCE PER SHIFT), UNDERSPRAY CCONTINUO
3.0 t 10.0 FT/S)
.1 ( .6 IN-H20)
PH SLURRY SOLIDS, LIQUID LEVEL, LIOUID FLOW
PH 6.8-7.i
AUTOMATIC
FEEDBACK
PH-RECIRCULATIN6 LINES AND THICKENER
NUMBER
VENTURI RECIRCULATION
SLURRY FtED
LIKE SLURRY RECIRCULATION
ABSORBER RECIRCULATION
THICKENER UNDERFLOW
THICKENER TRANSFER
24
4
4
Z4
4
4
284
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
PENNSYLVANIA HOwER: BRUCE MANSFIELD 1 CCONT.)
•* TANKS
SERVICE
THICKENED UNDERFLOW
MIXING TANK [CALCILOX (, THCKNR USDRF
SLUDGE TRANSFER
WIXING TANK tSPENT SLURRY & FLYASHJ
RECYCLE ISCRUl'BER)
RECYCLE. (AbSORBER)
*• THICKENER
NUMBER
TYPE
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
«• WATER LOOP
TYPE
*« REAGENT PREPARATION EQUIPMENT
NUMPf OF SLAKE RS
iLAKfR CAPACITY - M T/H
** TREATMENT
TYPE
CONTRACTOR
PRODUCT CHARACTERISTICS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
ARE* - ACRES
CAPACITY - CU.M
NUMBER
2
* * * *
*** *
6
6
1
RAKE DRIVE
CARBON STEEL
61.0 12CO FT)
OPEN
2C.O
22.P TPH)
CALCILOX
DRAVO
CONSISTENCY OF GRANULAR SOIL
FINAL
LANDFILL
OFF-SITE
PUMPED
U3(.0
5992700J t 49000.D ACRE-FT)
._ PeRFORMANCF DATA
PERIOD MODULE AVAILABILITY OPEBABIL1TY RELIABILITY UTILIZATION
1 REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/75 A
b
c
D
£
SYSTt«
•* PROuLcHS/SOLUTIONS/COMMEN1S
74 A
INITIAL OPERATION (SHAKEDOWN AND DEBUGGING) FO" PART OF THE SYSTEM COM-
MENCED IN DECEMBER 1975.
0/76 SYSTEM
*« PRObLEMS/SOLUllONS/COMNENTS
1/76 SYSTEM
SINCE THE UNIT COMMENCED COMMERCIAL OPERATIC IN APRIL 1976, A NUMBER OF
PROBLEM AREAS HAVE BEEN ENCOUNTERED. MAJOR AREAS Of CONCERN ARE SPECIFIED
BtLOb:
1. EXCESSIVE MAINTENANCE PROBLEMS WITH THE WET i.o. JAN HOUSINGS.
2. EXCESSIVE WATER ENTRAINMENT AND CARRY OVER OUT OF THE STACK CAUSING A
STACK RAIN PROBLEM.
3. REHEAT BURNER PROBLEMS.
4. STACK FLUE LINER FAILURES.
744
285
-------
EP* UTILITY FGO SURVEY: FOURTH OUARTER 1979
PENNSYLVANIA POwER: BRUCE "ANSF1ELD 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY UPEFAHILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
*• PKObLEMS/SOLUTIONS/COMMENTS
TME UNIT SHUT DOUN FOR ONE WEEK DUE TO PLUGGED MIST ELIMINATORS.
AN I.D. FAN HOUSING VIBRATION CAUSED PART OF THE ONE bEEK OUTAGE, ALONG
«ITH THE HST ELIMINATORS.
2/76 SYST£M t9e>
•• pRObLEMs/sOLUTIONS/COMMENTE
FIRST ATTEMPTS AT STARTING UP THE REHEAT BURNERS WERE MADE THIS MONTH. S
PROE-LEMS WEWE ENCOUNTERED THAT THE VENDOR IS GOING TO REDESIGN NEW
5/76
6/76
7/76
3/76 SYSTEM
4/76 SYSTEM 100.C 1C:.T
** PROuLEMS/SOLUTIONS/CONMENTS
UO.O
744
720 5C6
5G6
TOTAL OPERATING HOURS ACCUMULATLD TO DATE ARE AS FOLLOWS; c, 210, <)>:<.,
C147, 2631, AND 2427 FOR MODULES A THROUGH F RESPECTIVELY. THE SCRUPblNG
SYSTEM is CURRENTLY HANDLING FLUE GAS AT A TOTAL EQUIVALENT CAPACITY OF
APPROXIMATELY 64C Ml, (GROSS).
A
b
C
0
t
f
SYSTEM
35.1
i;:.?
?9.5
32.'
ICO.-1
o2.9
t c.o
100.0
23.1
61 .?
79.6
66.1
o3.6
66.3
6" n
i. . -
744
5<55
5VS
** PRObLEMS/SOLUTIONS/COM1ENTS
A
b
C
D
E
F
SYSTtM
THE LAST iCRUbtER TRAIN WAS PLACED IN SERVICE DURING THE MONTH. CURING OK
PEAK H2URS ON THE WEEKENDS WHEN THE UNIT IS OPERATING AT REDUCED LOADS,
MAINTENANCE IS PERFORMED ON THE SHUT DOWN FGD MODULES SO THAT THEY hlLL BE
IN OPERATING CONDITION FOR FULL LOAD OPERATION DURING THE HIGH DEMAND
HOURS•
99.2
94.4
97.4
93.6
97.9
79.6
13:.: 103.0 103.0 72C 720 720
•* PROULEMS/SOLUTIONS/COMMEN1S
THE UNIT WAS DECLARED COMMERCIALLY AVAILABLE FOR FULL LOAD OPERATION AT
?2S ** (NET) ON JUNE 1, 19 '16. OVER THE PERIOD A REVISED SCRUBBER BAFFLE
SYSTEM WAS INSTALLED IN AN EFFORT TO CORR6C1 THE SCRUbBER RECYCLE PUMP C»-
VITATION PROBLEMS.
A
b
C
D
E
F
SYSTEM
75.8
o7.7
»j.D
94. f
9S.4
9R.2
9C..O
100.0
72.2
99.2
81.2
85.3
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
PENNSYLVANIA PO.ER: BRUCE MANSFIELD '• (CONT.)
PERIOD
8/7t
9/76
10/76
11/76
MODULE
** P«0t
A
b
C
D
£
F
SYSTEM
«. PfiOl
A
b
C
b
E
F
SYSTEM
A
b
C
I,
E
F
SYSTEM
A
b
C
D
i.
F
SVSTt*
AVAILABILITY OPEPAUIL1TY RELIABILITY UTILIZATION J REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
LEWS/SOLUTIONS/ COMMENTS
THE SYSTEM SUPPLIED IS STILL TRYING TO SOLVE THE REHEAT BURNER PROBLEMS.
TESTS CONfcUCTED THIS MONTH SHOWED THAT THE FGD SYSTEM MIST ELIMINATORS ARE
NOT P E3FOMING TO DESIGN AND THAT THERE IS EXCESSIVE WATER ENTRAINED IN
THE CLEANED FLUE GASSES CAUSING A STACK RAIN PROBLEM. CHEMICO IS WORKING
ON THE DEilCN OF ADDITIONAL MIST ELIMINATORS THAT WILL REMOVE THIS EXCESS
MATE* .
95.3 90.3
S 7. 9 8?.?
92.6 67.8
75. 0 71.9
7:. 9 67.2
94.3 89. f
95.0 1::.J 1D3.0 95.7 744 7Q5 7C5
>LE.MS/S OLUT IONS /COMMENTS
SECONDARY VERTICAL MIST ELIMINATORS WERE INSTALLED IN THE ABSORBER 01S-
CHARCE DUCT IN AN ATTEMPT TO REDUCE THE EXCESSIVE ENTRAINED WATER. THEY
DID NOT UCFK bECAUSE THE FLUE GAS BLEW THEM APART IN A FEy MINUTES CF OP -
ERATI ON.
93.3 98. ••
S5.7 S5.7
96.* 96.3
96.5 96.5
Hi. a 62. R
64.4 64.4
100.0 1::.: ij;.o uo.? 720 720 720
96.1 95.4
74.? 7?.*
b 5 .4 fc4 .8
3J.S o3.2
VI. 5 92.9
97.5 92.9
99.0 ic:.: 10:. o 99.0 744 739 739
97.5 37.5
1C:.3 38.6
1::.: 39.2
4C.8 15.7
57.4 22.1
6K.? 34.?
3g.o ic:.: ioc.o 33. r 72^ 277 277
*• PfiOuL£MS/S OLUTlONs/CCMMENTS
12/76
A
b
C
D
E
A THREE WLEK OUTAGE OCCURRED DUE TO A FURNACE IMPLOSION.
DURING THE OUTAGE SCALE THROUGHOUT THE FGD SYSTEM WAS REMOVED.
DURING THE THREE WEEK OUTAGE THE UNIT 1 CHIMNEY FLUES WERE INSPECTED. THE
A-SIOE FLLE POLYESTER LINING MATERIAL WAS FLAKING OFF AND ACID ATTACK WAS
STARTING TO CORRODE THE CARBON STEEL FLUE. THE LINING SUPPLIER IS INVESTI-
GATING Tht PROBLEM.
DURING THE OUTAGE THE PLUGGED MIST ELIMINATORS WERE CLEANED.
a:. 9 7?. 5
1;:.: 97.5
94.7 91.9
6!.D 58.2
86.1 63.6
287
-------
EPA UTILITY fGD SURVEY: FOURTH QUARTER 1979
PENNSYLVANIA POWER: BRUCE MANSFIELD i (CONT.)
. PERFORMANCE DATA
PERlOb MCDULE AVAILABILITY OPE (ABILITY RELIABILITY UTILIZATION
2 REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/77
F
SYSTtM
A
b
C
0
c
F
SYSTEM
100.0
95.0
92.0
77.0
95.0
S>2.3
9 1.0
90.3
86.7
1;:.")
98. •>
91.:>
74.'
98.:
93.?
91.5
ic:.r
100.3
84. I
97."
89.C
82.?
68. C
89.C
84.0
82.:
90.7
744
722
722
744 675
675
•* PfcO^LEMS/SOLUTIONS/COMMENTS
SEVERE WINTER WEATHER HADE OPERATION OF THE OUTDOOR FGD SYSTEM VERY CIFF1-
FiCULT AMI AFFECTED THE RELIABILITY OF THE UNIT.
2/77
3/77
A
D
C
0
E
F
SYSUW
77.u
69.C
77. C
86.0
92.D
el.3
8C.3
THt FIRST PART OF THE MONTH THE THICKENER RAKE MECHANISM JAPNED AND
COULD NOT BE REPAIRED. THE THICKENER WAS OPERATED FOR APPROXIMATELY THREE
WEEKS WITH THE RAKE STOPPED UNTIL THE UNIT 2 THICKEKEN COULD BE PUT
EfERGENCY SERVICE.
fci.? 65.:
7C.C 56.^
di.: 65.-
94.0 77.r
1CC."1 81.3
84..- 67. C
1C3.0 30.4 672 540 540
•« PhObLtMS/SOLUTlONS/COMMENTS
A SECOND LET OF VERTICAL SECONDARY MIST ELIMINATORS MAS INSTALLED IN THE
ABSORBER UiCHARGE DUCT BUT THE FLUE GAS BLEU THEM OUT BEFORE THEIR EFFI-
CIENCY FOf REMOVING ENTRAINED WATER IN THE FLUE GAS COULD BE TESTED.
A
b
C
D
t
F
SYSTEM
99.0
103.0
58.3
95.0
97.0
80.0
88.2
9?..:
1::.:
5«.:
95.:
9'.^
77.-
34. P
35.5
£0.4
33.9
34.5
27.2
35.5
744
264
264
•• PROuLEMS/SOLUTIONS/CUMMENTE
AT ;c;: MARCH 12, THE UNIT WAS SHUT DOWN FOR A IO-WEEK TURBINE OVERHAUL
OUTAGE.
DUR1KG THl MARCH OUTAGE REPAIRS WERt STARTED ON THE A-SIDE CHIMNEY FLUE
WHICH WILL NOT BE COHPLETE I UNTIL THE END OF AUGUST. AN INSPECTION OF THE
P-SlDc CHIMNEY FLUE SHOWED THE SAME TYPE OF REPAIRS WOULD BE NEEDED, BUT
WORK WILL NOT START ON THE O-&IDE UNTIL THE A-SIDE FLUE HAS BEEN REPAIRED
BECAUSE OF THESE REPAIRS THE UNIT WILL BE OPERATING AT APPROXIMATELY HALF*
LOAD FOR tOUGHLY ONE YEAR.
BECAUSE OF THE EXCESSIVE MAINTENANCE REQUIRED ON THE RUBBER LINED CARBON
STEEL 1.0. FAN HOUSINGS FROM PIECES OF SCRUBBER SCALE DAMAGING THE LIMNR
AND COSMO'ION OF THE CARBON STEEL, INCONEL PLATE WILL BE INSTALLED CM ThF
SCROLL AR(A OF EACH Of THE SIX FANS DURING THE OUTAGE.
A NEWLY DESIGNED SECONDARY VERTICAL MIST ELIMINATOR WILL bE INSTALLED IN
THE ABSORfcEft DISCHARGE DUCT OF ONc OF THE SCRUBBER MODULES DURING THE OUT
AfcE.
DURING THt OUTAGE ALL SCRUBBING VtSSELS, DUCTS, PIPING AND MIST ELII-1NATOB
WILL 8E CLEANED AND ALL THE SCALE REMOVED. "
DURING OPERATION OF THE FCC SYSTEM THE PH CONTROL COULD NOT BE AUTOMATED
BECAUSE OF POOR DESIGN AND OPERATIONAL PROBLEMS WITH THE PROVIDED CCNTROl
SYSTEM. FH CONTROL WAS MANUALLY SAMPLED AND CONTROLLED OVER APPROXIMATELY
288
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
PENNSYLVANIA PO«ER: BRUCE MANSFIELD 1 (CONT.)
.... PER FOR "I*NC E DATA
PERIOD HOOULE AvAILAtULITY OPERARILITY RELlAblLITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOt PART. HOURS HOURS HOURS FACTOR
ONE YEAR OF OPERATION. THE PH CONTROL AND MONITORING SYSTEM ARE BEING RE-
VISED i-Y LPLRATING PERSONNFL DURING THE OUTAGE IN AN EFFORT TO IMPROVE THE
THE PH CONUOL SYSTEM.
THl LIME ADDITION PIPING IS BEING REVISED IN EACH OF THE SCRUBBER VESSELS
Out TO THt SEVERE SCALING OCCURRING WITH THE CURRENT LIME ADDITION SYSTEM.
THE SYSTEM SUPPLIER IS RE Ot SI (,N lN(j THE EXISTING MIST ELIMINATOR SPRAY PIP-
ING IN AN EFFORT TO CORRECT THE EXCESSIVE SCALING AND PLUGGING OF TcE «IST
ELIM1N»TOkS.
CHANGES IN FLUSH WATER AND SEAL WAT£R PIPING ARE BEING MADE IN AN EFFORT
TC CLOSE THE MATER LOOP.
4/77 SYSTEM
5/77 A
u
C
D
NEWLY MODIFIED REHEAT BURNERS WILL BE INSTALLED DURING THE OUTAGE AND
TcSTLD ON ThE b-SlDE REHEATER WHEN THE UNIT STARTS UP IN MAY.
ThE UiMlT • THICKENER WAS CLEANED OUT AND THE JAMMED RAKE DRIVE MECHANISM
lAb PcPAUEC DURING THE OUTAGE.
.r 720 3 C
6/77
7/77
.0
.0
.3
1CC.O
100.0
47.0
41.2
84.0
41*.7
i;:.:
SYSTEM
•* PRObLtMS/SOLUTIONS/COMMENTS
47.:
48.r
23.?
55.9
744
131
121
THE UNIT k»S STARTED UP ON MAY 23 USING Dt E. AND F MODULES DUE TO REPAIRS
BEING MADt TO THE A-SIDE CHIMNEY FLUE.
THERE HERE PROBLEMS SLAKING LIME AND GETTING MAGNESIUM LEVELS BUILT UP IN
ThE SCRUBLEK RECYCLE LOOPS AFTER STARTUP.
A
b
C
D
E
F
SYSTEM
.0
.0
.0
94.0
95.0
93.0
.0
ic:.o
97^0
10C.O
. j
.r
94.0
95.1
90.0
92.9
722 669
669
«• PRObLcMS/SOLUTIONS/COMMENTS
A
B
C
P
E
f
SYSTEM
.0
.0
.0
99.0
99.0
100.0
49.7
.P
.3
.0
100. D
1 CC.O
IOC.!
10C.O
ON AUGUST 16 THE 1A CHIMNEY FLUE LINER REPAIRS WERE COMPLETED AND THE A, ft
AND C TRAINS WERE STARTED UP.
SEVERAL REPAIRS WERE MADE TO THE ID FAN HOUSING THIS MONTH.
THE AVERAGE 502 REMOVAL EFFICIENCY FOR THC MONTH HAS 06.7X BASED ON THREE
GRAB SAMPLES.
YORK RESEARCH BEGAN SETTING UP EQUIPMENT TO CONTINUOUSLY MONITOR THE 502
REMOVAL EFFICIENCIES AS PART OF AN EPA RESEARCH PROJECT TO DETERMINE FEA-
SIBLE NSP& FOR FGD.
EXTENSIVE MODIFICATIONS ARE BEING HADE IN THE PH CONTROL SYSTEMS IN AN EF-
FORT TO DEVISE A WORKABLE PH CONTROL SYSTEM.
.0
.0
.0
66.0
66 . C
65.:
63.6 744 473 473
289
-------
EP* UTILITY FGD SURVEY: FOURTH QUARTER 1979
PENNSYLVANIA POWER: BRUCE KASSFIELD i (CONT.)
.. . . PtPFORMANC E DATA
PERIOD MCDULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOORS HOURS HOURS FACTOR
•• PRObLEMS/SOLUTIOMS/COMMENTS
a/77
9/77
A
6
C
D
t
F
SYSTEM
58.0
54.0
31.0
96.0
95.:
88.0
7 :.3
57. C
5*.:
31.:
ic:.o
99.?
95.?
1 ::.?
UNIT 1 UAC DOWN FROM JULY 1 THROUGH JULY 12 TO MAKE SOME MODIFICATIONS TO
THE GENERATOR COOLING SYSTEM. ON JULY 19 AND 20 PENNSYLVANIA'S DEPARTMENT
OF ENVIRONMENTAL RESOURCES TESTED THE S02 AND PARTICULAR EMISSIONS FROM
THE UNIT 1 FGD SYSTEM. SO? EMISSIONS WERE 0.44 LB/MM BTU AND 1.26 LP/C.M
BTU FOR THE TWO TESTS RESPECTIVELY. FGD S02 REMOVAL EFFICIENCY VARIED
FROM 7?X TO 89% FOR THE MONTH.
52.:
50.0
28.0
93.C
93.0
85.r-
93.C 744 692 692
*• PROdLEMS/SOLUTIONS/COMMtNTS
UNIT 1 WAS DOWN FROM AUGUST 13 TO 15 BECAUSE OF BOILER TUBE LEAKS.
A
B
C
D
c
F
SYSTEM
E 7.0
fc 2.0
e 1."
53.C
5%0
43.0
66.0
97.:
95.C
44.0
75.0
73. 0
76. C
46.C
44.?
34.C
77.5
81.0J
720
558
558
•* PROL-LEMS/SOLUT10NS/CCMMENTS
FROM SEPTEMBER 17 TO 22 THE UNIT WAS DOWN TO INSTALL RIGGING IN THE 1B
CHIMNEY FLUE TO BEGIN FLUE LINER REPAIRS.
0, i. AND F TRAINS *ERE OFF THE REMAINDER OF THE MONTH. THE AVERAGE SOJ
REMOVAL EFFICIENCIES FOR TH£ MONTH WERE 93.2X BASED ON FOUR GRAB SAKPLE
TESTS .
A BOILER TUbE LEAK CAUSED THE UNIT TO BE DOWN SEPTEMBER 10 TO 12.
10/77 A
b
C
D
E
9 3.0
98.0
87.0
.0
.0
-.
• J
SYSTEM
96.j
1CC.O
9:.:
1::.
93.?
98.:
87.:
96.S
77.50
744
720
720
•• PRObLtMS/SOLUTIONS/CCMMENTS
THE C-KODILE MIST ELIMINATOR SPRAY NOZZLES AND MIST ELIMINATOR ITSELF WERE
CLEAttED.
11/77
A
U
C
D
t
F
SYSTEM
95.0
99.0
91.0
AuS STACK REPAIRS ON UNIT i NECESSITATED TAKING UNIT 1 DOWN FOR 2 DAYS.
(A PROTECTIVE CAP HAD TO BE PUT OVER THE 2B FLUE BY HELICOPTER. PREVAILING
WINDS NECtSSITATED TAKING LNIT 1 OFF IN ORDER TO DO THIS.)
95.?
99.0
91.0
95.C
99. C
91 .?
1uO.O
65.00
72;
720
720
-------
EPA UTILITt FCO SURVEY: FOURTH QUARTER 1979
PENNSYLVANIA F-0 n E R : BRUCE MANSFIELD 1 (CCNT.)
PERFORMANCE DATA ------------------------------------------
MODULE AVAILABILITY CPE^ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•• PhOi-LtMS/S OLUTION S/CCMMENTS
REMOVAL OF THE OLD COATING AND PRIMING OF THE FLUE LINING IN FLUE 1t IS
PROCEEDING SLOWER THAN ANTICIPATED. IT IS EXPECTED THAT TOTAL WORK ON THE
fLUt »ILL NCT EsE COMPLETED UNTIL FEBRUARY OR MARCH 1978.
9i.:
79. C
12/77
A
b
C
u
E
F
SYSTLM
10 : . o
93. D
99.0
i;:.c
94.-;
u:.:
1 ;:.?
64.1 744 626 626
*• PROt LENS/SOLUTIONS/COMMENTS
SAN 01' LASTING OF UNIT 1B FLUc IS NtARING COMPLETION. THE FLUE HILL BE RE-
LINED ylTh CXL-2003.
C/7 = SYST£M
** PhOuLEMS/SOLUTIONb/COMMENTE
NOTE: AN ATTEMPT IS ALWAYS MADE TO bEblN OPERATION OF THE BOILER AND FGO
SYSTEI" SIMULTANEOUSLY AT bRUCt MANSFIELD. OCCASIONALLY PROBLEMS DE-
LAY BOILER STARTUP MAKING IT POSSIBLE FOP MONTHLY FGO MODULE HOURS
TO EXCEED ACTUAL BOILER HOURS.
1/7& A 103.0 1;:.: 53.:
A 103.0
b
C ICiO.O
0
t
F
SYSTEI"
1::.:
1 CT.D
1CC.C
44.5 744 331 731
• * PkOtjLtMS/SOLUTlONi/CCMMENIS
THE UNIT TPIPPED SEVERAL TIMES DUE TO DIFFICULTIES IN BURNING WET STOCK-
PILE COAL.
THERE WERE PROBLEMS WITH THE 1B FAN WHICH NECESSITATED EXTENSIVE REPAIRS.
LINING AEUASION AND DISBONDMENT IN FAN CAUSED CORROSION OF UNDERLYING SUP-
PORT METAl .
2i7s A 79.0 ic:.o 79.:
b 61.0
C B2.0
D
t
F
SYSTEM 1CC.? 61.6 672 414 414
** PROL-LEMS/SOLUTIONS/CCMMENTS
EXTENSIVE REPMRS TC THE 1 [J ID FAN AND THE EMERGENCY NEED FOR LOAD FROM
THE PLANT DURING THE COAL STRIKE TEMPORARILY OVERLOADED THE 1A AND U
TRAINS .
EXTENSIVE REPAIRS TO THE 1p ID FAN WERE NECESSARY.
THE PIST ELIMINATOR WILL BE REPLACED ON THE 1C TRAIN AS A RESULT OF THE
TEMPORARY OVERLOAD THAT OCCURRED ON THE 1A AND 1C TRAIN DURING THE FtRIOtii
THE 1B FLUE RELINING CONTINUED.
3/7" A 43.0 47.t 43.0
a 91.0 98.G 91.C
291
-------
EPA UTILITY FOD SURVEY: FOURTH QUARTEfc 1979
PENNSYLVANIA PO.ER: BfcUC^ MANSFIELD 1 (CONT.)
PERIOD MODULE AVAILABILITY OPEIAHIL1TY RELIABILITY UTILIZATION Z REMOVAL PER BOILER rGO CAP.
502 PART. HOURS HOURS HOURS FACTOR
C
D
i
f
SYSTEM
9 :.o
65. C
50.0
63. C
66. 5
97."
?:.:
54.1
65.:
u:.c
90.0
65. C
50. C
60. C
92. 6 744 689 669
•* PRObLEMS/SOLUTIONS/CONMENTS
4/78
A
0
C
D
E
F
SYSTEM
74.0
ta.o
49.:
67.0
97.:
94.J
81.5
REPLACEMENT OF THE LINING
REPAIRS WERE MtDt ON TH£ A
74.?
so.:
49.:
67."
97. C:
94.0
10:.:
IN THE 16 CHIMNEY WITH CXL 2000 WAS COMPLETED.
, B AND C FAN HOUSINGS.
74. C
88.0
49.0.
87.0
97.0
94. C
100. C 72C 720 720
** PROeLEMS/SOLUTlONS/CCMMENTS
FAN HOUSINGS HAD LEAK REPAIRS DONE DURING APRIL.
S/78
A
B
C
D
c.
F
SYSTEM
98.0
98.:
91.:
92. C
92.0
rl SCE LLAHtOuS LEAK REPAIRS
9?.;
97.3
is.:
tA.:
St."
1::.?
WERE MADE TO DUCTS.
59."
59.?
52.:
52.?
53."
61.4 744 457 457
•* PROlLtNS/SOLUTIONS/COMMENTS
THE ANNUAL BOILER INSPECT!)
N OUT ACE BEGAN ON NAY 20.
EXTENSIVE REPAIRS WERE HADE ON THE IB FAN.
6/7?
A
i)
C
D
E
F
SYSTEM
100. C
1uC.O
103.0
100.0
72 1
•* PfcOcLEWS/SOLUTlONS/COMMENTS
THE 60IL£f< INSPECTION AND GENERATOR STATOR COOLER REPAIRS REQUIRED SONE
OUTAGE TI*E.
ALL OUTAGES EXPERIENCED ev
THE UNIT THIS MONTH WERE F GD-R ELAT ED .
HORIZONTAL HIST ELIMINATOR PRESSURE DROPS INCREASED TO THE POINT THAT NEW
"1ST ELIMINATOR MODULES WERE INSTALLED ON Dt E AND F SCRUBBERS A«ID D A NC £
AtSOPbCRS.
7/78
8/78
9/78
10/78
11/78
12/78
SYSTeM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
96.3
KC.3
744
744
720
90.2 744 671 671
72 C
744
292
-------
EPA UTILITY FGO SURVEY: FOUPTH GUAHTER 1979
PENNSYLVANIA PO«ER: BRUCE MANSFIELD 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPESAPILITY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•• PfOLLEMS/SOLUTIONi/CCMMENTS
NC INFORMATION WAS AVAILABLE FOR THIS REPORT PERIOD.
SYSTEM 74*
SYSTtN 67i
SYSTEM. 744
SYST-M 72G
SYSTEM 74*
• • Pl-Ot'LEMS/SOLUTIUN-S/CCMMENTS
UNIT 1 IS CURRENTLY DOWN FOR A nOILEH OUTAGE.
1/79
2/79
3/79
4/79
5/79
SIX OF THE T*ELVE FAN HQOSI*GS HAVE bEEN CHANGED FROM CARBON STEEL TC
1NCOLLOY 8i5.
6/79 SYSTEM 92.0
*• P^OLLEMS/SOLUTIONS/COMMENTJ
4344
The ABOVE AVAILABILITY IS T»c AVAILABILITY FROM JANUARY 1, 1979 THROUGH
MAY 31, 107$.
THE UTILITY REPORTED THAT FAN HOTOd FAILURES WE«E A MAJOR PROBLEM AREA
DURING THE FIRST HALF OF 1979.
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
•• PRObLEMS/SOLUTIONS/CCMMENTS
744
744
72 C
10/7?
11/79
12/79
SYSTEM
SYSTEM
SYSTEM
96.1
93.8
99.8
FAN HOoSINC kORK (CHANGING = ROM LINED CARBON STEEL TO INCOLLOY 825) IS
CONTINUING.
NEu PH MONITOR MODIFICATION) HAVE YIELDED PROMISING RESULTS UITH RESPECT
TO MONITOR AVAILABILITY.
THE FED SYSTEM ATTRIBUTED 17.AX OF THE TOTAL UNIT UNAVAILABILITY FOR 1979
TO DATE. THE BREAKDOWN IS : ,S FOLLOWS:
7.6X SCRUBBER ID FAN WORK/PROBLEMS
8.1% ICkEKAL SCPUdBER PROBLEMS AND MAINTENANCE
1.3X REAGENT HANDLING PROBLEMS CLIME SLAKE" AND PIPING)
G.SX KIST ELIMINATOR PLUGGING
744
72;
744
** PROBLEHS/SOLUTIONS/COMMENTS
DURING THE PERIOD AN ADDITIONAL FAN HOUSING UAS REPLACED WITH THE NEW
INCOLLOY 825. BY THE END OF 1980 ALL THE FAN HOUSINGS WILL BE REPLACED
UITH THE NEW MATERIAL.
WHERE THE NEW PH MONITORS HAVE BEEN INSTALLED THE PRObE MAINTENANCE
HAS BEEN CUT ?OX, AND THE MIST ELIMINATORS HAVE BEEN LESS OF A PROBLEM
TO MAINTAIN.
THE SLUDGE PUMPS HAVE BEEN !. PROBLEM. THE PUMPS REQUIRE AN OVERHAUL
293
-------
EPA UTILITY FuD SURVEY: FOURTH QUARTER 1979
PENNSYLVANIA POWER: BRUCE MANSFIELD 1
-------
EPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNi T NUMbER
CITY
STATE.
REGULATORY CLASSIFICATION
PARTJCULATE thlSSION LIMITATION - NG/J
SOZ EMISSION LIMITATION - NG/J
NET PLANT LE.ERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENtRATING CAPACITY W/FGD - MW
NET UNIT GtNtRATING CAPACITY WO/FGt - MW
COUIVALENT SCRUDbED CAPACITY - »»
PENNSYLVANIA POWER
BRUCE MANSFIELD
2
SHIPPINGPORT
PENNSYLVANIA
D
15. < .035
258. I .600
2751.C
917.0
825.0
887.0
917.0
LB/MMBTU)
LB/MMBTU)
DATA
SUPPLIER
TYPE
SERVlCc LOAD
COMMERCIAL SERV ICE DATE
MAXIMUM bCILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAKE TER - M
•* FUEL DATA
FUEL TVP£
FUEL GkAuE
AVcRAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - PTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTE NT - X
AVERAGE K01STURE CONTENT - 3!
RANGE MOISTURE CONTENT - !
AVEPAGc SULFUR CONTENT - X
*AUGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - S
FOSTER wHtELER
PULVERIZED COAL
BASE
0/77
1580.86
U".6
290.
5.8
COAL
BITUMINOUS
26749.
1i .9u
11.5-13.5
• .00
5.5-?.5
2.0u
1.75-3.75
(3350COO ACFM)
( 285 F)
< 950 FT>
{ 19.0 FT>
( 11500 BTU/LB)
11000-1195C
** PARTICULATE SCRUBBER
NUMPER
TYPE
SUPPLIER
NUMHER OF STAGE S
SHELL MATERIAL
LINING MATERIAL
INTERNAL KATERIAL
TYPE OF NOZZLES
bOILER LOAD/SCRUbBtR - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD -5/CU.K
PARTICULATE OUTLET LOAD - G/CU.M
PARTICULAR DESIGN REMOVAL EFFICIENCY - X
S02 INLET CONCENTRATION - PPM
S02 CUTLiT CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
•• FGO SYSTEM
SALEABLE PRODUCT/THROyAUAY PROLUCT
OENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEI SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PAftTICULATE DESIGN REMOVAL EFFICIENCY - X
SOe. DtSUN REMOVAL EFFICIENCY - X
6
VENTURI
CHEMICO
2
CAPBCN STEEL
POLYESTER FLAKE GLASS
PLUM UOb AND i SETS OF SPRAYSt 317 SS AND 716 SS
TANGENTIAL FEED (1 SET AT THRGAT, 1 SET AT BOTTO
1i .0
263.5 ( 558353 ACFM)
14C.6 < 255 F)
1386.C (22COC GP«)
5.3 UC.O GAL/1000ACF)
******* (•••** IN-H20)
61.0 ( 200.0 FT/S)
17.7 ( 7.75 GR/SCF)
.0 ( .016 GR/SCF)
99.8
3099.000
930.000
70.0
THROUAUAY PRODUCT
WET SCRUBBING
LIME
MG (2-61)
CHEMICO
GILBERT/COMMONWEALTH ASSOCIATES
FULL SCALE
NEW
99.80
92.10
295
-------
EPA UT1LI1T FiiD SURVEY: FOUKTH QUARTER 1979
PENNSYLVANIA PO«ER: BRUCE I*ANSF1ELD I (CONT.)
INITIAL START-UP
ABSORBER SPARE CAPACITY IND£X - X
ABSORBER SPARE COMPONENT INDEX
7/77
TYPE
INITIAL iTART UP
SUPPLIER
NUMt-ER OF STAGE S
DIMENSIONS - FT
SHELL MATERIAL
SHELL LI!
90 DEG.
OVERSPRAV (ONCE PER SHIFT), UNDERSPRAV (CONTIMJO
3.0 ( 1G.CI FT/S)
.1 ( .6 IN-H20)
6
CHEVRON
fRP
HORIZONTAL
1
4
7.6 ( 3.30 IN>
90 DEG.
OVERSPRAY (ONCE PER SHIFT), UNOERSPRAY (CONTIMJO
3.0 ( 10.0 FT/S)
.1 ( .6 IN-H20)
PH SLURRY SOLIDS, LIQUID LEVEL* LI8UID FLOW
PH 6.8-7.*
AUTOMATIC
FEEDFACK
PH-RECIRCULATING LINES AND THICKENER
NUMBER
12
4
4
24
4
4
2 "6
-------
EPA UTILITY FCD SURVEY: FOURTH QUARTER 1979
PENNSYLVANIA POwEK: BhUCE MANSFIELD ? (CONT.)
TANKS
SERVlCt
TH1CKENE* UNDER FLO*
MIXING TANK CCALCILOX c, THCKNR UNDRF
iLUCLE TRANSFER
MIXING TANK CSPENT SLURRY & FLYASHD
KECYCLi (SCRUBbEfi)
HECYCLt (AbSORbFR)
NUMBE R
* * * *
6
6
•• THlCKENtR
MUMP ER
TYPE
CONSTRUCTION MATERIAL
OUTLET SOLIDS - %
«» iJATE" LOOP
TYPE
•* REAGENT PREPARATION EQUIPMENT
NUMBER Of SLAKERS
SLAKcR CAPACITY - « T/h
•* TREATMENT
TYPE
CONTRACTuR
PRODUCT CHARACTERISTICS
** &ISPCSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
1
RAKE DRIVE
CARBON STEEL
61.0 (2CC
3-.C
OPEN
FT)
TpH)
CALClLOX
DRAV.
CONSISTENCY OF GRANULAR SOIL
FINAL
LAND FILL
OFF-SITE
PUMPED
uo:.o
599370030 (490030.3 ACRE-FT)
. P£9FOHMANC) DATA
PERIOD MODULE AVAILABILITY CPERADIL1TY RELIAblLITY UTILIZATION
* REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/77
it
ze
2C
20
2E
2F
SYSTEM
94.0
97.0
98.;
63.0
66.0
61. C
79.3
i;:.c
1 ::.:
1 ;:.c
6i.:
57.1
51.0
1::.?
83."
fc8."
«7.-
*S.O
47. r
41.:
m.:
744 595 595
*• PRObLEMS/SOLUTIONS/COMWENTS
11/77 2* 100.0
2B 96.0
2C £8.0
2D 47.0
2E 55.C
2F 47.0
SYSTEM 72.2
UMT 2 WAS DECLARED AVAILABLE FO' COMMERCIAL OPERATION AT ?25 MN ON
OCTOIER 1, 1977.
THE SPRAYi IN THE If FAN WERE CuEANtO.
REPAIRS UEPE MADE TO THE 2U FLUE STACK BECAUSE OF THE PREMATURE FAILURE Of
SEVERAL TEST PATCHES.
THE UNIT TRIPPED DUE TO FAULTY GENERATOR CONTROL TRANSFOBMERS.
1 C v .7
i;:.o
92.0
57.0
52.:
42.3
100.0
83.0
81.0
74.C
46.0
42.C
34.C
80.7
72(
581
581
297
-------
EP* UTILITY F6D SURVEY: FOUfcTH QUARTER 1979
PENNSYLVANIA POWER: BRUCE MANSFIELD z (CONT.)
PERFORMANCE DATA ...
PERJOD MODULE AVAILABILITY OPE 1 At3 IL IT Y RELlAblLITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
•• PROBLEMS/SOLUTIONS/COMMENTS
PfcObLE"S ASSOCIATED hITH THE STATION POWER TRANSFORMERS CAUS£0 LIMITATION
IN LOAD OK UNIT 2. THREE OF THE SIX STATION POWER TRANSFORMERS FOR LMT 2
WcRE OESTdCYED.
63.0
06. :•
t:
66
69
76
12/77
2<
2 1'
2C
C. t>
i E
2F
SYSTEM
74.3
99.:
»&.?
10:. o
8«.c
59.:
93.2
77.7
1 . :.o
1 ; 2 . :
1 ::.o
05.:
93."
ic:.3
ti
74*
607
6C7
•« PhObLEMS/S OLUT10NS/CGMMENTS
CuLD «£ATKER CAUSED SOME P90PLEMS IM PROCESS PIPKvG.
31. C
74.;
29.C
73. c
2«
211
iC
20
2E
2F
SYSTt*
vs.:
io:.o
96.0
94.0
V 9. C
99.0
97.2
5°. C
1 ;o.o
56.:
1 ::.:
1 C ^ . j
94. ^
1 : : . .
53. C
52.6
744
J<51
391
THE UNIT TRIPPED SEVERAL TIMES DUE TO DIFFICULTIES IN BUfNING WET STOCK-
PILE COAL. kHEN THE UNIT WAS ON LINE DURING THIS MONTH, THE WET COAL ALSO
FULL LOAD OPERATION OF COAL MILLS.
bCILER CONTROL VALVE ("w" VALVE) PROBLEMS COMPOUNDED START-UP
DI FFI CULT1ES .
2/7«
20
2E
2F
SYSTtM
fc 4.0
c7.3
97.0
99.3
7S.O
89.u
46.0
as.:
71.:
9?.:
4?.C
68. C
68.r
71.:
99. r
73. 0
100.0
4/7<;
672 672
•• PhObLEMS/SOLUTIONj/COMMENTS
MANY PBCHLEMS OCCURRED WITH I.D. FAN COOLERS DUE TO INCLEMENT WEATHER.
A bOlLfR TUuE LcAK CAUSED SEVERAL DAYS OUTAGE.
67.:
60.C
13."
63.n
64 . j
65.r
66.4 744 494 494
phOuLt MS/SOLUTION;,/COMMENTS
EXTENSIVE I.D. FAN HOUSING REPAIRS w?»E PERFORMED 01. THE iC FAN.
Cl ."
15."
14.'
15."
3/7S
2<
iv
2C
20
\\
SYSTEM
KO.O
9 3 . 0
13. S
V5.0
V7.3
k2.2
1 ;:.o
91.0
i:.~>
1 ; ~. . :
9?!:
i c : . "
2A
iv
2C
i 0
a
-t F
1 o : . o
10C.O
59. j
15.0
14.:
1 :.:
3 I
S2
5g
15
14
1?
290
-------
EPA UTILITY FGD SURVEY: fOURTH QUARTER 1979
PENNSYLVANIA f'OWER: BRUCE MANSFIELD I CCONT.)
PERFORMANCE DATA
PER1CO MODJLE AVA1LAH1L1TY CPEKAtULITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO C AF .
SOI PART. HOURS HOURS HOURS FACTOR
*« PROkLEMS/SOLUTIONS/COMMENTS
DURING APUL THE CHIMNEY FLUE LINING ON Z6 NEEDED REPAIRS.
EXTENSIVE REPAIRS WERE MADE ON THE iC I.D. FAN, CAUSING IT TO BE OQ.N FROM
MARCH * THROUGH APRIL 13.
2L STACK LINING REPAIRS CONTINUED
5/7* 2«
2C
(. D
iE
ic:.3
10 3.0
100.0
1 •;:.?
1::.?
13!.3
P*OL>LEMS/S OLUTIONS/COMMENTS
J7. :
37. C
37."
57.5
74 4
270
270
6/7P
21?
2C
iE
cF
SYSTEM
THE UNIT kAS OFF-LINE FOR 3 WEEKS FOR REPAIRS TO THE it I.D. FAN, INCLUD-
ING COVERING THE HOUSING WITH INCOLOY 825.
?:.o 11:.: ?:.c
69.; ic:.: 69.c
t6.G 1C2.j 66.7
57.9 72C 417 417
It STACK LINING REPAIRS CONTINUED.
-NOTE: AN ATTEMPT is ALWAYS MADE TO BEGIN OPERATION OF THE BOILED AND FGD
SYSTEM SIMULTANEOUSLY AT FRUCE MANSFIELD. OCCASIONALLY PROBLEMS
DELAY bOILE" START-UP, MAKING IT POSSIBLE FOR MONTHLY FGD MODULE
HdLRS TO EXCEED ACTUAL BOILER HOURS.
7/7? SYST£M 744
8/7S SYSTLK 744
9/7? SYSTtM 72o
10/78 SYSTt-N 99.1 1;:.C 19.4 744 144 144
11/78 SYSTEM 72G
12/78 SYSTEM 744
*• PROLLEMS/SOLUTIONj/COMMENTS
NC INFORMATION WAS AVAILABLE FOR THIS PERIOD.
1/79 SYSTEM 744
2/79 SYSTEM 67£
3/79 SYSTEM 74«.
*/7<; jYSTtM 720
«« PROLLEMS/SOLUTIONS/CCMMENTS
NO INFORMATION WAS REPORTED FOR THIS PERIOD BY THE UTILITY.
5/79 SYSTEM 744
6/79 SYSTEM fcS.fc ICC.D 4344
299
-------
EPA UTILITY FbD SURVEY: FOURTH UUARTER 1979
PENNSYLVANIA PO*ER: BRUCE MANSFIELD I (CONT.)
....... PERFORMANCE DATA ...
PERIOD MODULE AVAILAU1L1TY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•• PhOfLEMS/SOLUTIONS/COMMENTS
THi AI-OVE AVAILABILITY IS THE AVAILABILITY FOR JANUARY 1, 1979 THROUGH
H»Y 31, 1979.
THE UTILITY REPORTED THAT SOME FAN PROBLEMS WERE RECENTLY ENCOUNTERED.
7/79 SYSTEM 744
6/79 SYSTcM 744
9/79 SYSTtM 720
*• PRO*. LtM$/s OLUTIONS/CCMMENTS
CHIMNEY LINING WORK (APPLICATION OF CXL 20DO) WAS COMPLETED IN EARLY 1979.
FAN HCUSINL WORK (CHANGING FROH LINED CARBON STEEL TO INCOLLOY 625> IS
CONTINUING.
NEW Ph MONITOR MODIFICATIONS HAVE YIELDED PROMISING RESULTS WITH RESPECT
TO MONITOR AVAILABILITY.
THE FGD SYSTEM ATTRIBUTED 1T.SX OF THE TOTAL UNIT UNAVAILABILITY FOR 1979
TO DATE. THE BREAKDOWN IS AS FOLLOWS:
5.:X CHIMNEY (FINISHED CXL £000 APPLICATION)
1.3X CENERAL SCRUBBER PROBLEMS AND MAINTENANCE
1 .5X It FAN WORK/PROBLEMS
3.:X MST ELIMINATOR PIUGbING
1.CX EMISSION VIOLATION (CUT BACK OF BOILEP LOAD BECAUSE OF LOW S02
PtMOVAL EFFICIENCY J
10/79 SYSTEM 97.5 744
11/79 SYSTEM 100.0 720
12/79 SYSTEM 96.5 744
•* PROuLEMS/SOLUTIONS/CCMMENTS
DURING THE PERIOD AN ADDITIONAL FAN HOUSING WAS REPLACED WITH THE NE»
INCOLLOY ?.'<.'.. BY THE END OF 19£u ALL THE FAN HOUSINGS WILL BE REPLACED
WITH THE NEW MATERIAL.
WHERE THE NEh PH MONITORS HAVE BEEN INSTALLED* THE PROeE MAINTENANCE
HAS BEEN CUT SOX, AND THE H.IST ELIMINATORS HAVE BEEN LcSS OF A PROBLEM
TO MAINTAIN.
THE SLUDGE PUMPS HAVE BEEN A PROBLEM. THE PUMPS REQUIRE AN OVERHAUL
EVERY nCj HOURS AND HAVE FREQUENT VALVE FAILURES. NEW VALVE MANIFOLDS HAT
DRASTICALLY IMPROVE PUMP SERVICE BY ALLOWING ACCESS TO INDIVIDUAL BALL
VALVES .
300
-------
FPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
i>ESiG'i A;.D PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY
PLANT N«I«E
UNI T NUWcER
CITY
STATE
REOULATORY CLASSIFICATION
PARTICULATE cKlSSION LIMITATION - NG/J
SOi EMISSION LIMITATION - NG/J
NET PLANT C.L..LRATINC CAPACITY - MM
GROSS UNIT GENERATING CAPACITY -MW
NET UNIT GENERATING CAPACITY h/FGD - Wy
NET UNIT GENERATING CAPACITY UG/FGl - My
tOUIVALFNT SCRUBBED CAPACITY - "!h
•• BOILC:< I'ATA
SUPPLIER
TYPE
SERVICE LOAD
COM«t«CIAL SERVICE DATE
MAXIKUK uOlLER fLUt G A i FLOn - CU.K/S
FLUE GAS UMPERATUKE - C
STACK HEIGHT - P
STACK TOP HIAME HR - M
•• FUEL DATA
FUEL TYPi
FUEL GfcAiiE
AVERAGE HEAT CONTENT - J/G
fcANGc HEAT CONTENT - 1MU/LB
AVERAGE ASH CONTENT - i
RANtt ASH CONTENT - *
AVERAGE W01STURE CONTENT - ?
RANGE KOISTURE CONTENT - ',
AVERAGE bULFUR CONTENT - I
RANGE SULFUR CONTENT - 1
AVERAGE CHLORIDE CONTEST - X
RANGE CHLORIDE CONTENT - I
PHILADELPHIA ELECTRIC
EDDVSTONE
1A
EDDYSTONE
PENNSYLVANIA
D
****** (***»** LB/MMBTU)
**••** (*•**•* LB/MMBTU)
1395.0
12C.O
120*0
*******
120.0
COMBUSTION ENGINEERING
BASE
0/5<>
437.45
15'. 2
76.
5.6
COAL
BITUMINOUS
31634.
9.40
5.90
2.60
( 927000 ACFH)
I 315 F)
( 249 FT>
( 16.5 FT)
( 136TO BTU/LB)
** ESP
NUMBER
** MECHANICAL COLLECTOR
NUMBER
•* PARTICULATE SCRUBtER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
BOILER LUAD/SCNUBBER - I
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
•• F6D SYSTEM
SALEABLE PRODUCT/THROUAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
MEM/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - I
COMMERCIAL DATE
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
VENTURI
ENVIRONEERING
1
316L SS
25.0
145.8
157.2
.6
*******
( 309000 ACFN)
C 315 F)
< 4.8 (.AL/1C03ACF)
(**•** IN-H20)
SALEABLE PRODUCT
WET SCRUBBING
MAGNESIUM OXIDE
NONE
UNITED ENGINEERS
UNITFD ENGINEERS t CONSTRUCTORS
DEMONSTRATION
RETROFIT
99.00
90.00
9/75
9/7 !
.0
.0
301
-------
EPA UTILITY FuD SURVEY: FOUfcTH UUARTEF. 1979
PHILADELPHIA tLECTRlC: tDDYSTONE 1A (COM.)
AbSORbEf.
NUMUcR
TYPE
INITIAL bTART UP
SUPPLIER
NUMPE* OF STAGES
DIMENSIONS - FT
SHELL MATEKIAL
SHELL LINER MATEUAL
bOILc* LuAD/ABSORbcR
uAS FLCw - CU.«/S
bAS TEhPcRATURE - C
LIHUID RcCIRCULATION
L/U R*TU - L/C U.M
PRESSURE DROP - KPA
RATd - LITEK/S
1
GRID TOWER
9/75
RILEY STOKER/ENVIRONEERING
I
14 X 25 x 53
COR-TEN STEEL
POLYURETHANE
3 :.3
126.47
5 '.7
?43.
6.5
2.5
I 268-00 ACFM)
( 125 F)
(13384 GPC)
( 4S.5 GAL/100CACF)
<1j.C IN-H20)
CENTRIFUGt
NUMB EG
FANS
NUMHER
TYPf
CONSTRUCTION MATERIALS
SERVKc - »ET/D RY
CAPACITY - CU.M/S
"1ST ELIMINATOR
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEbOARD DISTANCE - M
HASH SYSTEM
PUMPS
SERVICE
ABSORBER RECIRCULATION
BtHt* TEf<
NUMBER
TYPE
TEMPERATURE BOOST - C
THICKEN£N
NUMBER
DIAMETfcR - M
OUTLET SOLIDS - *
WATER LOOP
TYPE
FRESH KAKEUP WATER ADDITION - LITERS/S
BYPRODUCTS
BYPRODUCT NATURE
SCRUBBER ID
216L SS WITH CARPENTER 20 HUB
DRY
126.47 ( 266CuO ACFM)
CHEVRON
FIBERGLASS
VERTICAL
I
2
2.4*. ( 8.0 FT)
LOWER M E IS WASHED ONCE PER SHIFT (3 TIMES/DAY)
NUMBER
2
1
DIRECT COMBUSTION
57.2 ( 103 F)
25.C
OPEN
f. 3
SULFURIC ACID
< 4Q FT)
( 132 GPM)
.. . PERFOR1ANC f DATA
PERIOD MODULE AVAILABILITY OPERAH1L1TY RELIABILITY UTILIZATION
% REMOVAL PER BOILER FED CAP
SOZ PART. HOURS HOURS HOURS FACTOR
0/74 StSUM
* PhOl)LtMS/S OLUTION j/CCC.MtNTS
THE EtDYSTCNE STATION OF THE PHILADELPHIA ELECTRIC CO. (PECO) IS LOC*
TtD t.N THl DELAWARE RIVER IN EDDYSTONE, PENNSYLVANIA, A80UT 11 MILES
SOUTHn£ST Cf THE CENTER OF PHILADELPHIA. THE PLANT IS ABOUT 5 MILES
WLST OF CKE OF THt MAIN RUNWAYS OF THE PHILADELPHIA INTERNATIONAL AIRPORT
TH: STATION HAS FOUR GENERATORS WITH A TOTAL NET GENERATING CAPACITY
CF 1?*? I*U. UNITi 1 AND 2 BURN COAL -1TH AN AVERAGE GROSS HEATjNG VALUE
OF 1?,".;: F'TU/LD AND ASM AND SULFUR CONTENTS OF 9.4X AND 2.6X,
302
-------
LPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
PHILADELPHIA tLtCTRIC: LDDYSTONE 1A (CONT.)
.. PERFORMANCE DATA . — --
PERIOD MODULE AVAILABILITY OPERAUILITY RELIABILITY UTILIZATION X hEMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
"tSPECT1VELY. STEAM CONDITIONS ARE 5,000 PSI AND 1150 F. THESE ARE THE
HIGHEST UTILITY PLANT OPERATING PRESSURE AND TEMPERATURE CONDITIONS IN THE
UNITED STATES. UNITS / AND 2 ARE BASE-LOAD UNITS. UNITS 3 AND * ARE PEAK-
LOAD GENERATORS WHICH BuRN NO. 6 OIL.
THERE AF.E TWO FURNACES ON THE NO. 1 BOILER. EACH FURNACE WAS INSTALLED
WITH PSRTICUlATE CONTROLS IONSISTING OF MECHANICAL COLLECTORS AND AN
ELECTROSTATIC PRECIPITATOR.
THE MAGNESIUM OXIDE-BASED FLUE GAS DESULFURI 2ATION (FGD) SYSTEM ON
bOUEH NO. 1 AT THE EDDYSTONE STATION OF PHILADELPHIA ELECTRIC CO. IPECO)
WAS tESlGKEt AND INSTALLED BY UNITED ENGINEERS AND CONSTRUCTORS, INC., IN
CC-OPERAT1CN WITH PHILADELPHIA ELECTRIC. THE SYSTEM CONSISTS OF THREE
FIRST-STACE SCRUBBER MODULES IN PARALLEL FOR PART1CULATE CONTROL
-------
EPA UTILITY FoD SURVEY: FOURTH QUARTER 1979
PHILADELPHIA tLECTmc: EDDYSTONE u
....... .. — ............. . ...—PERFORMANCE DATA ..
PERIOD MODULE AVAILABILITY OPEKABILITY RELIABILITY UTILIZATION
4/75
5/75
6/75
7/75
8/75
9/75
10/75
11/75
12/75
X REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
THESE CONDITIONS COUPLED WITH THE THERMAL SHOCK OF A HOT START PROCEDURE
CAUSED THE CORROSION* THIS PROBLEM WAS AMELIORATED faY CAUSTIC ADDITION
HIGHER SLOWDOWN AND EMPLOYING A COLD START PROCEDURE. AT APPROXIPATELY*
THIS TIME, A CHECKOUT OF S32 SYSTEM WAS CONDUCTED. BLISTERING AND PEELINGM
OF THE POLYURETHANE COATINGS WERE DETECTED AND CORRECTED bY RECOATING
WITH FLAKtGLASS.
12/74 SYSTEM
1/75 SYSTfcM
2/75 SYSTtK
3/75 SYSTtM
SYSTEM
SYSTfcM
SYSTEM
SYSTEM
•• PPOeLEMS/SOLUTIONS/COMMENTS
744
744
72 C
744
72 C
744
SYSTEM
SYSTtM
SYSTEM
SYSTtM
SYSTEM
THE C-SIDE PARTICULATE SCRUBBER RESTARTED ON JULY 23, 1975. THE TxO
OTHER TRAINS, B-SIDE AND A-SIOE, WERE PUT INTO OPERATION ON AUGUST 15 AND
OCTOBER 2, RESPECTIVELY. THE S02 ABSORBER MODULE IN THE C-SIDE SCRUbBING
TRAIN WAS INITIALLY PLACED IN SERVICE OCTOBER 2', 1975. THE OLIN CHEMICAL
MGO REGENERATION FACILITY FIRST PROCESSED MAGNESIUM SULFITE FROM THE EDDY
STONE SCRliBbER ON OCTOBER 26, 1975. THE C-SIDE PARTICULATE SCRUBBER OPERA.
T£D A TOTAL OF 2831 HOURS THROUGH JANUARY 31. 1976, FOR AN AVAILAblLTV Q»
7C PERCENT. THE B-SIDE TRAIN HAS OPERATED A TOTAL OF 1933 HOURS THROUGH
JANUARY 21, 1976 FOR AN AVAILABILITY OF 5SZ. THE SIDE TRAIN OPERA-
TED A TOTAL OF 626 HOURS THROUGH JANUARY 31, 1976. FOR AN AVAILABILITY Of
24*. THE C-SIDE S02 ABSORBER WAS IN SERVICE A TOTAL OF 556 HOURS
THROUGH DECEMBER 31, 1975. WITH AN AVAILABILITY OF 33X SINCE START
UP. PROBLEMS ENCOUNTERED IN THE OPERATION OF THE THREE SCRUBBING TRAIMS
INCLUDED: UNDER-DESIGNED RECIRCULATION PUMPS, MALFUNCTION OF THE FLOE GAS
BY-PASS DAMPER DRIVE UNITS AND FAILURE OF THE DOUBLE-bRICK REFRACTORY
LINING IN THE REHEAT COMBUSTION CHAMBER.
744
720
74*
72 u
744
1/76 SYSTEM
2/76 SYSTEM
• * PROuLlHS/SOLUTIONS/COMMENTS
744
696
J/76 SYSTEM
4/76 SYSTEM
5/76 SYSTEM
OPERATION OF THE SO? SCRUBBING SYSTEM AT EDDYSTONE WAS TEMPORARILY HALTEb
BECAUSE THE ACID PLANT REGENERATION FACILITY AT THE OLIN CHEMICAL SOLFUBIr
ACID PLANT IN PAULSHORO, NEW JERSEY PERMANENTLY CEASED OPERATIONS. THE
UTILITY IS NOW INVESTIGATING ALTERNATIVE REGENERATION SITES. A MINIMUM Pro
IOD OF SIX MONTHS WILL bE REQUIRED FOR RELOCATION ONCE A CHOICE IS CADE
THE UTILITY ANNOUNCED PLANS FOR RELOCATION OF THE REGENERATION FACILITY***
THE ESSEX CHEMICAL PLANT IN NEWARK, NEW JERSEY.
744
720
744
304
-------
EPA UTILITY FGO SUhVEY: FOURTH QUARTER 1*79
PHILADELPHIA tLECTfilC: tDDYSTOKE U (CONT.)
..,. PERFORMANCE DATA
PERIOD MODULE A VA1 LA Ul L 1 TY CPERAPIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/76 SYSTt* 721
• * PnOi-LEMS/SOLUTIONS/COMMENIS
RESUMPTIOk OF S3i SCRUBBING OPERATIONS IS PRESENTLY SCHEDULED FOR DtCEMbER
iv?6. THE RELOCATION OF THE REGENERATION FACILITY is NOy IN PROGRESS. THE
PAPTICULA1E SCRUtbERS ARE OPERATIONAL. THE C-SIDE BOOSTER FAN HAS
DEVELOPED A MATERIALS FAILURE BETnEEN THE HUB AND SHAFT (IDENTICAL TO THE1
L--SIDE UNIT MENTIONED EARLIER).
7/76 SYSTEM 744
8/76 SYSTEM 744
9/76 SYSTEM 721
*• PSOl'LcMS/SOLUTIONS/COMMENTS
»LL THREE BOOSTER FANS HAVE NOW DEVELOPED THE MATERIALS FAILURE PET*EEN
THE nun AKD SHAFT (AS IDENTIFIED IN THE AbOVE FOR THE B-SIDE UNIT). THESET
UMTl HAVt bEEN RETURNED TO THE MANUFACTURER FOR MODIFICATIONS AND
BtpAiRS. CURRENTLY, ONE OF THE PARTICULATE SCRUBBERS is IN THE FLUE GAS
STREAM. TO DATE, ALL THREl OF THE WET PARTICULATE SCRUBBERS HAVE NUT
SUN ANY APPRECIABLE SIMULTANEOUS SERVICE TIME.
10/76 SYSTEM 744
11/76 SYSTcM 726
«• P*Oi.:LtMS/SOLUTIONS/CC MM£NTS
MOO SCRUfrtlNG OPERATIONS ARE NOto SCHEDULED TO RESTART IN MAY 1977. rtEGEN-R
REGENERATION FACILITY RELOCATION IS BEING COMPLETED, AND MODIFICATIONS TOD
THE ID UOCSTER FANS CURRENTLY BEING EFFECTED CONSIST OF CONVERSION FROM A
SHRINK FIT TO A SLIP FIT. THESE MODIFICATIONS ARE EXPECTED TO ELIMINATE
RECUFRING VIBRATION PROBLEMS.
12/76 SYSTEM •? 744 Z C
1/77 SYSTEM 744
•* PRObLEMS/SOLUUONS/COMMENTS
Tht MGO SCRUBBING SYSTEM AT EOOYSTONE NO. 1A IS STILL SCHEDULED FOR
RESTART IK MAY 1977. THE START-UP OF THE NEu MAGNESIUM SULFITE REGENER-
ATION FACILITY AT THE ESSEX CHEMICAL PLANT AT NEWARK, N.J. IS ALSO SCHED-
ULED FOR MAY 1977. THE THREE PARALLEL VENTURI SCRUBBERS CONTROLLING PAR- C
TUUIATE EMISSIONS ON EDDYSTONE 1 WENT BACK INTO SERVICE IN MARCH T.77.
2/77 SYSTEM 672
J/77 SYSTEM 744
4/77 SYSTEM 720
** PRObLEMS/SOLUTIONS/COMMENTS
RESUMPTION OF MAGNESIUM OXIDE SCRUBBING OPERATIONS OCCURRED DURING THE
REPORT PERIOD. THE UTILITY REPORTED THAT S02 SCRUBBING OPERATIONS WERE
NOT CONTINUOUS THROUGHOUT THE PERIOD. THE AbSOPBER bAS IN SERVICE APPROXI-
MATELY 23t HOURS DURING MAY. REOENEHATION OPERATIONS AT THE ESSEX FACILITY
WERE NOT CONDUCTED DURING THE PERIOD. PECO PLANS TO INITIATE S02 RECOVERY
AMD MAGOX REGENERATION OPERATIONS DURING THE MONTH OF JUNE. THE S02 MODULE
CONTAINS TWO ABSORBER SECTIONS IN SERIES (EACH SECTION CONSISTING OF AN
ADJUSTABLE hOD DECK WITH UNDERSPRAYS). ONLY ONE OF THE ABSORBER SECTIONS
IS BEING USED FOR SC2 REMOVAL. S3i REMOVAL EFFICIENCY HAS NOT BEEN
MEASURED. MAGNESIUM OXIDE LOSSES IN THE SYSTEM (ABSORPTION AND
REGENERATION) ARE ESTIMATED AT 1?l.
5/77 S»STEH 744
305
-------
EPA UTILITY FbD SURVEY: FOURTH QUARTER
PHILADELPHIA cLECTRIC: EDDYSTONE 1A (CONT.)
PtTORwANCC DATA
PERIOD MODULE AVAILABILITY CPEf-Af> IL IT Y R EL I At' ILIT Y UTILIZATION X REMOVAL P tR bOILER FGD CAP.
S02 PART. HOuRi HOURS HOURS FACTOR
6/77 SYSTtM 72*
•* PkOoLEMS/SOLUTIONS/CCMMENTr
FAZLI'RE Of V.INOR ANCILLIARY EUU1PMENT CAUSED SOME SHUTDOWNS. LATER, THE
F)t,ILFK ITSELF WENT COW\. OV£R THIS PERIOD THE ROTARY VALVt ON THE MAG.
SULFITF DHIR DISCHARGE PLUGGED REPEATEDLY. ALSO THc BELTS ON THE
AGITATOR tF THE MAG-OX PRESLAKER FAILED.
7/77 SYSTtM 744
8/77 iYSTtl* 74<.
*• PRObLEMS/SOLUTIONS/COMMENTS
THE ROTAFY VALVE PROBLEM APPEARS TO BE SOLVED. CUMULATIVE AVA1LAPILITY
S;NCr MAY IS ESTIMATED TO BE ROUGHLY J3X. PECO REPORTED 131 HOURS OF
CONTINUOUS OPERATION FOB THE SCHUbbtR AND THICKENER CENTRIFUGE DRYING
LOOP. DUPING THE REPORT PERIOD THERE HAVE FEEN CONTINUAL PROBLEMS WITH
THE GLAND PACKING OH THE Ft,t> SYSTEM CIRCULATION PUMPS (STUFFING BOX).
PECO HAS SINCE CHANCED THE GLAND CONFIGURATION. THERE ALSO WAS A PROBLEM
WITH HIGH SOLIDS FORMATION IN THE THICKENER. DURING THE OCTOBER-NOVEMBER
PcPICD THERE taAS ONE RUN WHICH LASTED APPROXIMATELY FIVE DAYS.
GLAND PACKING PROBLEMS PERSISTED AND MECHANICAL SEALS ARE BEING CONSIDERED
AS PCSSir-LE ALTERNATIVES. EVEN WITH HcAT TRACING THE SEAL WATER FR02E-UP
CAUSING 9CTAMETERS TO BURST. HIGH SOLIDS PROBLEM IN THE THICKENER IS STILL
A PROBLEM AREA.
9/77 SYSTtM 72C
10/77 SYSTtM 744
11/77 SYSU? 72C
12/77 SYSTEM 41.0 744
•• PfcOL'LEMS/SOLUTIONS/CCM^ENTS
THE UNIT fcENT DOWN DECEMBER 22 FOR A TURblNE OVERHAUL. DURING THE OUTAGE
MAINTENANCE AND MINOR MODIFICATIONS WILL bE MADE ON THE SCRUBBERS. THE UNI
IS EXPECTED TO BE bACK ON LINE THE FIRST WEEK IN MARCH. THE AVAILABILITY
FACTCk FOR THE OCT. NOV. AND DEC QUARTER WAS 41X. DURING THIS PERIOD SOME
OF THc HEAT TRACING FAILED AND OTHER PROBLEMS OCCURRED WHEN LINES FROZE AT
THE ACID FLANT CAUSING THE FACILITY TO BE RUN INTERMITTENTLY. THE GLAND
PACKING PkCbLEMS HAVE NOT YET BEEN SOLVED ANO MECHANICAL SEALS ARE ST ILL
F.E1NG CONSIDERED.
1/7" SYSTtM .? 744 r
2/7? SYSTEM .<" 672 0
•* pRCuLEMS/sOLUTIONS/COMMEMTS
THE TURBINE OVERHAUL CONTINUED DURING THE REPORT PERIOD. DURING THE SHUT-
DOWN PERICD IT WAS FOUND ThAT SOME HIGH PRESSURE STEAM TUBES WERE CRACKED
sc UNIT MAINTENANCE HAS TAKEN LONGER THAN EXPECTED. SOME MINOR FGD SYSTEM
MODIFICATIONS HAVE I-EEN INCORPORATED IN THE COURSE OF THE SHUTDOWN FERIOO.
START UP iS EXPECTED IN MID-APRIL 1976.
3/7' iYSU* .0 744 C
4/7t SYSTcM 720
*• P-OuLt«S/SOLUTIONi/CCMIENTS
THE UNIT CAME liACK ON LINE JUNE 1 AFTER AN EXTENSIVE SYSTEM MODIFICATION
OLTACt WHICH bEGAN DECEMPES 22. THE UNIT WAS EXPECTED PACK ON LINE IN
AK.IL, bUT THERE WAS A PROHLEH WITH A SUPER PRESSURE STEAM TURBINE.
5/7« SYSTtX 744
3D6
-------
EPA UTILITY FGu SURVEY: FOURTH OUARTEf 1979
PHILADELPHIA dLECTRIC: EDDYSTONE U UONT.)
PERFORMANCE DATA
PERIOD MODULE AVAUAUILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER fcOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/78 SYSTEM (.9.0
*• PfcOi'LEMS/bOLUTIONS/COMMENTS
72C
DURING JUNE THE FGD SYSTEM ACHIEVED A <,9X OPERAUILITY. OPERABILITY FOR
JULY ^4S M*. PfcOl'LEMS OCCURRED IN LATE JUNE WITH THE MGS03 SLURRY
ClRcliLATICN PUMP .HEN THE UTlLlT* DISCOVERED THE RUBBER LINER WAS TCRN
AkAY. THEhE HAVE bEEN SOME PROBLEMS WITH THE MGO SECTION -HERE THE I"GO
"1XES wITh THE SYSTEM LIQUOR. FIRE BRICK WAS REMOVED FROM THE FLUID PED
RtACTOB CHAMBER TO REPLACE THE ACID BARRIER PLATES WHICH WERE FAILING.
THE FISE IfiICK WAS THEN RtPLACEC. THE SLOW PIECE BY PIECE PROCEDURE WAS
TIME cot»SL«!iNG AND ACCOUNTED FOR MOST OF THE REGENERATE FACILTY OO«N
TIME (MOST CF JUNt AND JULY). MAJOR PROBLEMS WERE SOLVED ON THE REGENER-
ATIVE FACILITY OVER THE PERIOD RESULTING IN IMPROVED AVAILABILITY OF THE
F ACIl ITY.
7/7S
8/78
SYSTtf, 3'?.:,
• * phOt^Lt MS/S OLUTIOMS/CCMMENTS
744
611
10/7*
11/7E
MIT?.
1/79
i/75
3/79
4/79
5/79
6/79
BUYING THL f^ONTH OF AUGUST SCHUBPtR CIRCULATING PIPING PROBLEMS UtRE
ENCOL'NTERLD. A BUTTERFLY CONTROL VALVE WAS NOT FULLY OPEN AND A SECTION
JF PIPE DOWNSTREAM AT A 90 DEGREE BEND ERODED AWAY. TO CORRECT THE PROBLEM
Th£ LLTTEkFLY VALVE WAS TAKEN OUT AND REPLACED WITH A RESTRICTION OUFACE.
THE CIRCULATION PUMPING RATE wAS ALSO REDUCED.
9/78 SYSTEM 7'".?
• • PROlrLtMS/SOLUTIONS/COMMENTS
56."
516
402
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS WE"E ENCOUNTERED DURING THE
KUNTH OF SEPTEMBER. CERTAIN MECHANICAL PROBLEMS WERE RESOLVED WHICH CAUSED
AN IMPROVEMENT IN THE OPERABILITY FIGURE.
SYSTLM 23. "3
•* PRObLENS/S OLUTIONi/COMMENTS
744
THE FGD SYSTEM WAb SHUT DOWN FOR AN APPRECIABLE TIME DURING THE LAST
QUARTER OF 1978 DUE TO MODIFICATIONS TO THE MG "• SLAKING E8UIPMENT.
SYSTEM 72C
SYSTLM 744
SYSUtf 744
iYSTtM 67i
SYSTEM 744
• • PI-ObLtMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS REPORTED FOR THIS REPORT PERIOD.
SYSTEM 72C
SYSTEM 744
SYSTEM 72:
«* PSOLLcMS/SOLUTIONS/COMMENTS
NO INFORMATION IS AVAILABLE FOR THIS PERIOD BUT SHOULD BE FOR THE NExT
REPORT PERIOD.
7/79 SYSTEM
744
307
-------
EPA UTILITY FoD SURVEY: FOURTH QUARTER 1979
PHILADELPHIA LUCTPiC: tooYSTOf<£ u (COM.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEI-AHKITY RELIABILITY UTILIZATION % REMOVAL PER BOUER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/79 SYSTEM 744
9/79 SYSTtM 72C
•• P&OoLtMS/S OLUTIONSKCMMENTS
NO DATA HAS AVAILABLE FOR THE UNIT DURING THE THIRD UUARTER 1979.
10/79 SYSTtM 744
11/79 SYSTtM 72;
1Z/79 SYSTtM 744
•• PKObLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THIS PERIOD.
-------
EPA UTILITY FGtl SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F60 SYSTEMS
COMPANY SAKE
PLANT MAKE
UNIT NUMbER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE ..MISSION LIMITATION - NG/J
SOi EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - PU
GROSS UNIT GENERATING CAPACITY - I"W
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY V.O/FGL - My
EQUIVALENT SCRUBBED CAPACITY - M*
** bOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUI*. bOlLER FLUE. GAS FL 0 u - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP UIAME TER - M
•* FUEL DATA
FUEL TYPc
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
SANGt HEAT CONTENT - UTU/Lb
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE KOISTURE CONTENT - X
AVtRAGt iULFUR CONTENT - %
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RAN6E CHLORIDE CCNUNT - »
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
1
WATERFLOW
NEW MEXICO
C
21 . ( .050 LP/MMBTU)
He. ( .340 LB/MMBTU)
361 .0
314.0
33?.0
361 .0
PULVERI2ED COAL
BASE
622: .44
122.?
COAL
******
20931..
1 4.82
.80
(1319000 ACFM)
( 253 F)
(*»«* FT)
(•*»•• ft)
t VOOO BTU/LB)
855C
*« ESP
TYPE
PARTICULAR DESIGN REMOVAL EFFICIENCY
• * PARTICULAR SCRUUtE*
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TtMPERATUhE - C
UUUID REC1RCUL ATION RATE - LIUR/S
PRESSURE DROP - KPA
PRODUCT
FtD
SALEABLE PRODUC T/TnROk'
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIR!"
CONSTRUCTION FIRK
OEVELOPM£NT LEVEL
NEW/RETROFIT
PARTlCULATt DESIGN
S02 DESIGN REMOVAL
INITIAL START-UP
CONSTRUCTION INITIATION
ABSORFER SPARE CAPACITY INDEX -
ABSOHDEP SPARE COMPONENT INDEX
REMOVAL EFFICIENCY
EFFICIENCY - i
HOT SIDE
99.8
VeNTURI
DAVY POwERGAS
CAOQON STEEL
ACID QRICK
257.2
136.1
224.9
( 5450GO ACFM)
( 277 F)
< 3570 6PM>
(«*««* IN-H20)
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
NONE
DAVY POU'EKGAS
STEARNS-ROGER
STEARNS-ROGER
FULL SCALE
RETROFIT
99.50
65.00
4/7"
1/76
33.0
1.0
309
-------
EP» UTILITY F&D SURVEY: FOURTH UUAfcTER 1979
PUBLIC SERVICE OF NtW MEXICO: SAN JLAN 1 P»>
SUPfRFICAL GAS VELOCITY - M/SEl
PARTICIPATE. INLET LOAD - t/CU.K
PARTICoLATt REMOVAL EFFICIENCY - X
SOi INLET CONCENTRATION - PPM
S02 CUTLtT CONTRATION - PF' M
S02 DESIGN REMOVAL EFFICIENCY - i
•• FANS
NUMPER
TYPE
SERVICE - hET/DRY
CAPACITY - CU.M/b
** PUMPS
SESVICt
SLURRY TRANSFER
SCRUkHtR RtCIRCULATION
ABSORH£R RECIRCULATION
StHEATER
NUMHER
TYPE
HEATING MEOIU*
TEMPERAToRt BOOST - C
WATER LOOP
TYPF
PURGE .ATER LOSS - LITcR/S
FRESH KAHEUP WATtR ADDITION - LITERS/S
bYPRODUCTS
bYPRCDUCT NATURE
LYPROOuCT QUANTITY - f T/H
DISPOSITION
TRAY TOWER
A/7?
DAVY POWERGAS
5
CONCRETE AND 316 SS
NONE
316L SS TRAYS
33.0
337.16
4.°. 9
47.
4.0
3.3
.1
75.0
700
7:
90.C
SCRUBBER FD
DRY
155.73
NUMBER
( 4390CO ACFM)
< 12C F>
( 750 GPP)
416.3 1N-H20)
C 10.8 FT/S)
t .C53 GR/SCF)
( 33COOO ACFM)
1
HOT AIR INJECTION
STEAM
2i'.8 (
50 F)
CLOSED
.C
3C.2
( 0 6PM)
( 480 GPM)
ELEMENTAL SULFUR
.85 (
MARKETED
.94 TPH)
PE&FORMANCI DATA
PERIOD MODULE AVAILAUILITY OPEUAPILITY RELIABILITY UTILIZATION x REMOVAL PER BOILED FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
4/78 SYSTtM
•* PRObLEMS/SOLUTIONS/CCMMENTS
720
SG2 AdSORFTION BEGAN ON APF1L 8, 1978 USING TWO OF THE FOUR CELLS. ONE
THIMD OF THt FLUE GAS IS BEING BYPASSED.
THE AtiSORtERS WERE DOWN FOR 28 HOURS.
5/76 SYSTEM
6/7g SYSTtM
•• PROLLEMS/SOLUTIONS/COM«ENTS
744
72 C
7/78 SYSTEM
« HIGH PBLSSURE DROP ACROSS THE VENTURIS PREVENTED FULL FLUE GAS THROUGH
THE FCO SYSTEM.
744
310
-------
cPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE Of NEW MEXICO: SAN JUAN 1
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE OF NEW MEXICO: SAN JLAN 1 CCONT.)
.. PEPFORMANC I DATA .
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
C
D
SYSTEM
1CC
30
56
.0
.0
.0
.0
67
5
38
.4
.0
.f
.0
20
1
11
.3
.0
.?
.0
744
224
85
PRObLEMS/SOLUTIONS/COMMENTS
A REHEATER PROBLEM HAS LIMITED SCRUBBING OPERATIONS TO 2 OF THE 4 ABSORBER
MODULES.
312
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION J
DESIGN AND PtRFORPANCf DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAPE
UNIT NUMbSR
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE ^MISSION LIMITATION - NG/J
SOi EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - KW
NET UNIT GENERATING CAPACITY W/FGO - Mg
NET UNIT GENtRATING CAPACITY WO/FGC, - MW
EOUIVALEKT SCRUBBED CAPACITY - Mw
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
2
NEW MEXICO
C
21 .
U6.
35C .2
306.0
32?.0
3SC.O
.350 LP/MMBTU)
.340 LP/MMBTU)
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM oOlLER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPER ATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - »
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HcftT CONTENT - l'TU/LB
AVERAGE ASH CONUNT - X
RANGE ASM CONTENT - X
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - \
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - 1!
RANGE CHLORIDE CONTENT - X
PULVERIZED COAL
BASE
* * / * •
«2c .44
12?.8
COtL
2C934.
22.45
14.Pi
(1319000 ACFM)
( 253 f)
<**•• FT)
(**«** FT)
( 9300 BTU/LB)
S550
ESP
NUMfER
TYPE
SUPPLIER
PARTICIPATE
DESIGN REMOVAL EFFICIENCY -
•* PARTICIPATE SCRUQCEfl
NUMfER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
L1UUID RECIRCULATION "ATE - LITER/S
PRESSURE DKOP - KPA
** FGD SYSTEIS
SALFAHLE PROOUCT/TnRO«AyAY PROLUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FlhM
CONSTRUCTION FlRM
DEVELOPMENT LEVEL
NEd/RETROFIT
PARTICOLATt DESIGN
S02 DESIGN DEMO VAL
INITIAL START-UP
CONSTRUCTION INITIATION
ABSORBER SPARE CAPACITY INDEX -
ABSORBER SPARE COMPONENT INDEX
REMCVAL EFFICIENCY
EFFICIENCY - X
1
HOT SIDE
WEST IRN PRECIPITATION
99.5
VENTURI
DAVY POtaERGAS
CABBON ST£EL
ACID BRICK
257.2
136.1
224.9
< 545000 ACFM)
( 277 F)
< 357C GPM)
<*««** IN-HeO)
SALEABLE PRODUCT
y£T SCRUBBING
w£LLMAN L0»i)
NONE
DAVY POyERGAS
STEARNS-ROGER
STEARNS -ROGER
FULL SCALE
RETROFIT
9C.50
£5.00
1/7fc
37.0
1 .0
313
-------
EPA UTILITY FliD SURVEY: FOUfcTH QUARtEK 1979
PUBLIC SERviCt or ME <* Mexico: SAN JLAN 2 (COM.)
NUMBLR
TYPc
INITIAL START UP
SUPPLIER
NUMBt" OF STAGtS
SHtLL MATERIAL
SHLLL LI..ER MATERIAL
INTERNAL MATERIAL
bOUtR LCiAO/ABbORBtR - X
GAS FLCW - CU.M/S
GAS TEMPcRATURE - C
LIUL'IO RtCIRCUL ATION RATE - LlTEfc/S
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEl
PARTICuLATfc OUTLET LOAD- C/CU.h
S02 INIET CONCENTRATION - PPM
SOZ OUTLET CONTRATION - PrM
SOi DESIGN REMOVAL EFFICIENCY - X
FANS
NUMBER
TYPE
SERVlCt - wET/DRV
CAPACITY - CU.M/S
PUMPS
SERVICE
SLURRY TRANSFER
SCHUbBER RECIRCULATION
ABSORBER RECIRCULAT ION
•• RtHEATEi)
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
*• WATtR LOOP
TYPE
PURGE WATER LOSS - LITtR/S
•• BYPRODUCT:,
BYPRODUCT NATURE
BYPRODUCT QUANTITY - M T/H
DISPOSITION
TRAY TOWER
8/7?
DAVY POWERGAS
5
CONCRETE AM, 316 SS
NONE
316L SS TRAYS
37. D
ZC7.16 ( 4J9000 ACFM)
48.9 ( 120 F)
47. ^ ?5C GP»>
4.C (16.C IN-HiO)
7.3 ( 1C.* FT/S)
.2 ( .C79 GR/SCF)
120?
85
85.0
SCRUBBER FD
DRY
155.73
NUMBER
( 333000 ACFM)
1
HOT AIR INJECTION
STEA"
2.'.8 < 50 F)
CLOSED
ELEMENTAL SULFUR
2.C4 (
MARKETED
C GPU)
TPH)
. PERFORMANCE DATA ...
PERIOD MODULE AVAILABILITY OP£SABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
8/78 SYSTEM
•• PROuLEMS/SOLUTIONS/COMMENTS
744
INITIAL OPERATIONS BEGAN IN LATE AUGUST. ALL THREE MODULES RAN TOGETHER
FOR THE FIRST TIME IN EARLY SEPTEMBER.
PROBLEMS WERE ENCOUNTERED WITH THE BOOSTER FAN CONTROL DAMPER.
9/78 SYSTEM 72C,
«• PROtoLEMS/SOLUTIONS/COMMENTS
10/78 SYSTtM
A TwO UEEK BOILER OUTAGE WAS CAUSED BY A FIRE IN THE START-UP TRANSFORMER
DUCT BANK.
744
314
-------
tPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE. OF NEW MEXICO: SAN JLAK. 2 (CONT.)
—PERFORMANCE DATA —-—— ———
PtRICD MODULE AVAILABILITY C Pt* Al'IL IT Y RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•* PfcOuLEMS/SOLUTIONi/COMMENTS
HEAT TRACING FAILURES ALLOWED LINE FREEZING TO OCCUR.
A TEMPORARY HIGH FLYASH LOADING WAS THE RESULT OF AN ESP MALFUNCTION.
11/78
12/78
SYSTIH
«• PROoLENS/SOLUTlONS/CONMENTS
744
THE SYSTEM HAS BEEN RUNNING, HOWEVER; HEATHER RELATED PROBLEMS LIMITED
OPERATIONS TO 2 MODULES.
1/79
2/79
3/79
4/79
5/79
SYSTEM
SYSTEM
SYSTEM
SVSTcM
SYSTEM
• * PkObLEMS/SOLUTIONS/COMMENTS
744
672
744
72 C
744
HOURS ARE NOT VET AVAILABLE BECAUSE THE UTILITY IS CONCENTRATING EFFORTS
ON OPERATION OF THIS NEW UNIT. THE UTILITY REPORTED THAT THE SCRUBBING
MODULES THEMSELVES ARE OPERATING FINE. ALSO THE CHEMICAL PLANT IS READY
AND THERE IS NO SYSTEM PLUGGING WHATSOEVER.
THE MAJOR PROBLEM ENCOUNTERED WAS GYRATING FANS.
7/79
a/79
9/79
SYSTEM
SYSTEM
SYSTtM
•• PRObLEMS/SOLUTIONS/COHMENTS
744
744
720
10/79
11/79
12/79
SYSTEM
SYSTEM
E
F
G
H
SYSTtM
100.0
1JO.O
.0
.3
50.0
DURING THE THIRD QUARTER TWO OF THE FOUR ABSORBERS WERE DOWN DUE TO
BOOSTER BLOWER VIBRATION PROBLEMS.
744
720
73.3
66.9
61.3
.0
.r
32.0
744
622
239
38.0
• • PAOcUMS/SOLUTIONS/COMMtNIS
DUfclhG DECEMBER TyO MODULES WERE DOWN COMPLETELY.
CURRENTLY GNl OF THE TWO OPERATING MODULES IS ALSO DOWN AS A RESULT OF
A BOILER-RELATED POWER FAILURE. THERE WAS NOT ENOUGH GAS TO CALL FOR
TWO MODULES.
315
-------
EPA UTILITY FGD SURVEV: FOU&TH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA fOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAPE
UNIT NUMfcEfc
CITY
STATE
REGULATORY CLASSIFICATION
PARTKULATE tMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mfc
NET UNIT GENERATING CAPACITY Ut/FGD - MW
NET UNIT GENERATING CAPACITY U'O/FGl - MW
EQUIVALENT SCRUBBED CAPACITY - Mb
PUBLIC SERVICE OF NEU MEXICO
SAN JUAN
3
WATERFLOW
NEW MEXICO
c
21 . ( .050 LB/MMBTU)
146. < .340 LB/MMBTU)
534.0
468.0
534.0
BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME T£R - M
FUEL DATA
FUEL TYPE
FUcL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LU
AVERAGE ASH CON TENT - *
RANGE ASH CONTE NT - Z
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
PARTICULATE SCRUBbER
NUMBER
TYPE
SUPPLIER
UOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
PRESSURE DROP - *PA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - G/CU.K
PARTICULATE OUTLET LOAD - G/CU.M
S02 INLET CONCENTRATION - PPM
$02 CUTLET CONCENTRATION - PPM
FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEy/RETROFIT
PARTICULATE DESIGN
S02 DESIGN REMOVAL
INITIAL START-UP
CONSTRUCTION INITIATION
ABSORBER SPARE CAPACITY INDEX - I
ABSORBER SPARE COMPONENT INDEX
ABSORBER
NUMBER
TYPE
INIT1AL START UP
SUPPLIER
REMOVAL EFFICIENCY
EFFICIENCY - i
PULVERIZED COAL
BASE
# * / * *
967.05
12C.6
COAL
18841.
22.45
(2040830 ACFM)
( 249 F)
(.... FT)
t«..,. FT)
( 8100 BTU/LB)
.80
******
VENTURI
DAVY POHERGAS
33.0
257.2
136.1
3.3
.2
.1
700.000
700.000
545000 ACFM)
277 F)
*•»** IN-H20)
10.8 FT/S)
.09 GR/SCF)
.056 GR/SCF)
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
DAVY POHER GAS
BROyf g ROOT
FULL SCALE
NEU
99.50
9^.00
12/79
1/79
2.5
1.0
TRAY TOWER
1/82
DAVY POHERGAS
316
-------
EPA UTILITY FGO SURVEY: fOURTH QUARTER 1979
PUBLIC SERVICE. OF NEW MEXICO: SAN JUAN 3 (CONT.)
bAS FLOW - CU.M/S 24C.67
GAS TEMPERATURE - C 4f .9
PRESSURE DROP - KPA 4.2
SUPERF1CAL GAS VLLOCITY - M/SEl 3.3
PARTICULATE INLET LOAD - G/CU.K .1
PARTICIPATE OUTLET LOAD- G/CU.K .1
S02 INLET CONCENTRATION - PPM 700
S02 CUTLLT CONTRATION - PPM 70
«• FANS
NUMBER
TYPE
*• *1ST ELIMINATOR
** (THEATER
TYPE
** BYPRODUCTS
BYPRODUCT NATURE
( 510000 ACFM)
< 120 F>
(17.0 IN-M20)
( 10.8 FT/S)
( .056 GR/SCF)
( .356 GR/SCF)
1
FD
HOT AIR INJECTION
SULFURIC ACID
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION x REMOVAL PER BOILER FGO CAP.
502 PART. HOURS HOURS HOURS FACTOR
12/79 SYSTEM 74<,
•• PHObLEMS/SOLUTlONS/COMMENTS
THE SAN JUAN 3 UNIT BEGAN COMMERCIAL OPERATION IN DECEMBER 1979. HOfcEVER,
THIS IS FOt ONE MODULE ONLY. THE OTHER THREE MODULES DILL BECOME
OPERATIONAL ONE BY ONE UNTIL ALL ARE ON LINE.
12/79
J
SYSTLM
103.0
11.2
5.9
744
392
«* PRObLEMS/SOLUTIONS/COMMENTS
ONE MODULE BECAME OPERATIONAL DURING DECEMBER. NO SCRUBBER RELATED PROBLEMS
HAVE tEEN REPORTED.
317
-------
EP* UTILITY FoD SURVEY: FOURTH tiUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA (OR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT
UNIT
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - IvG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY b/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGL - MU
EQUIVALENT SCRUBBED CAPACITY - «W
SALT RIVER PROJECT
CORONADO
1
ST. JOHNS
ARIZONA
D
344.
******
35C.O
35:.:
26 C.O
>***• LR/NMBTU)
.SCO LP/MMBTU)
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATi
MAXIMUM bOILER FLUE. CAS FLO* - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - f<
•* FUEL DATA
FUEl TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/0
RANGE HEAT CONTENT - 13TU/LB
AVERAGE ASH CONTENT - i
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - ">.
KANGE SULFUR CONTENT - \
AVERAGE CHLORIDE CONTENT - S
RANGE CHLORIDE CONTENT - %
RILEY STOKER
PULV (RUED COAL
BASE
1/80
21.1
15Z.
5.8
COAL
SUBBITUMINOUS
193C6.
******»•
** * ***
1.00
D.4-1.0
(**«««•• ACFM}
< 70 F)
< 503 FT)
( 19.0 FT)
( 8300 BTU/LB)
8,000-11,000
*• ESP
NUMBER
TYPE
SUPPLIER
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
•« PARTICULATE SCRUBBER
TYPE
•* FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TVPE
PROCESS TVPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - 1
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
•« AbSORBER
NUMBER
T»PE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
HOT SIDE
WESTERN PRECIPITATION
1321 .3 (2800000 ACFM)
404.4 ( 760 F)
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
PULLMAN KELLOOG
BECHTEL
FULL SCALE
NEW
99.70
82.50
1/80
11/79
5/77
6/76
.C
.0
SPRAY TOWER
1/7*
PULLCAN KELLOG
318
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SALT RIVEN PROJECT: CORONADC 1 (CONT.)
SHELL LINER MATERIAL
NOZZLE TYPE
BOILER LOAD/A&SORBE3 - *
LlUUID RECIRCULATIOM RATE - LITER/S
SUPEHflCAL GAS VELOCITY - M/SEC
S02 INLET CONCENTRATION - PPM
S02 CUTLLT CONTRATION - PFM
• * FANS
NUMBER
TYPE
SERVICE - WET/DRY
CAPACITY - CU.H/S
** KIST ELIMINATOR
NUMBER
TYPE
CONF IGURATION
MUMPER Of PASSE S
FREEBOARD DISTANCE - *
SUPERFICIAL GAS VELOCITY - f/S
•* PUMPS
SERVICE
SLURRY RtClRCUL
SLUDGE DISPOSAL
SLURRY PURGE
ALKALI MAKEUP
PROCESS MATER
SEAL UATtR
HIGH PRESSURE SEAL WATER
MIST ELIKIKATOR V.ASH
•* TANKS
SERVICE
REACTION MIX TANK
** RtMEAlEH
TYPE
TEMPERATuRE BOOST - C
** THICKENER
NUMBED
CONSTRUCTION MATERIAL
DIAMETER - H
OUTLET SOLIDS - *
** WATER LOOP
TYPE
• * REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
•• DISPOSAL
NATURE
TYPE
TRANSPORTATION
RIGIFLAKE, ALUMINOUS CEMENT FOR PRESATURATOR
CERAMIC
4D.C
252. ( 4COO GPU)
6.6 ( 21.6 FT/S)
100C
18C
SCRUBBER FD
DRY
304.32
2
CHEVRON
VERTICAL
I
8. 8<.
NUMBER
NUMBER
2
BYPASS
2?.8
( 64488C ACFM)
(29.0 FT)
t 15.0 FT/S)
50 F)
1
CONCRETE FLOOR AND STEEL WALLS COATED WITH PVC
32.0 (1C5 FT)
30.0
OPEN
FINAL
LINED POND
PIPE (8 IN. AbOVE GROUND, EPOXY LINED CEMENT ASB
PERFORMANCE DATA __.-._-__.—........—......
PERIOD MODULE AVAILABILITY OPEBABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/79 SYSTEM
12/79 SYSTEM
** PROoLEMS/SOLUTlONS/COMMENTS
720
744
THc CORONA CO UNIT 1 COMMENCED OPERATIONS IN NOVEMBER 1979. THE UNIT
HAS PASSED THE EPA PERFORMANCE TESTING.
319
-------
EPA UTILITY FoO SURVEY: FOURTH QUARTER 197V
SECTION 3
DESIGN AND PERFORMANCE DATA FOk OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GEkERATING CAPACITY - Mw
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY W/FGD - Mw
NET UNIT GENERATING CAPACITY WO/FGL - MW
EQUIVALENT SCRUBBED CAPACITY - Mb
*• B01LFR DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIKUK bOILER FLUE &AS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DlAME T£H - M
** FUEL DATA
FUEL TYPt
FUEL GRADE
AVERAGE HEAT CONTENT - J/C
RANGE HEAT CONTENT - bTU/Lti
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - %
AVERAGE MOISTURE CONTENT - %
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - 2
RANGE SULFUR CONTENT - *
AVERAGE CHLORIDE CONTENT - X
SANGE CHLORIDE CONTENT - X
** ESP
NUMBER
TYPE
SUPPLIER
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
•• PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
BOILER LOAD/SC«UbB£R - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
L/G RATIO - LITEfc/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
*« FGO SYSTEM
SALEABLE PRODUCT/THROUAWAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEh/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
SOUTH CAROLINA PUBLIC SERVICE
WINYAM
2
GEORGETOWN
SOUTH CAROLINA
B
43 .
516.
< .100 LB/MMBTU)
I 1.200 LB/MMBTU)
28:-.D
25J.O
261.0
HO.O
BABCOCK g U1LCOX
PULVERIZED COAL
bASc
0/77
384.14
132.2
122.
4.9
( 814030 ACFK)
( 270 F)
( 400 FT)
( 16.0 FT)
COAL
BITUMINOUS
26749.
13.50
( 11500 BTU/LB)
*•***•*•*
6.5-7.0
1.70
1.0-1.2
COLD SIDE
RESEARCH COTTRELL
384.1 ( 814030 ACFM)
132.2 ( 270 F>
1
VENTURI
8ABCI CK 8 UILCOX
CARBON STEEL
RUBBER
SPRAY NOZZLES (316 ss)
511.o
192.1
132.2
1.9
27.4
( 4Q7Q15 ACFM)
< 270 F>
(14.4 GAL/1000ACF)
(...*« JN-H20)
( 90.0 FT/S)
THROUAUAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
BABCOCK t UILCOX
BURNS R ROE
FULL SCALE
NEW
99.40
69.00
7/77
.0
320
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
OUTH CAROLINA PUBLIC SERVICE: WINVAH 2 (CONT.)
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
&AS FLOW - CU.H/S
GAS TEMPERATURE - C
L/C RATIO - L/C U.M
PRESSURE DROP - KPA
SUPERF1CAL GAS VELOCITY - M/SEC
SO? INLET CONCENTRATION - PPM
S02 CUTLET CONTRATION - PPM
SO* DES16N REMOVAL EFFICIENCY -
•• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
CAPACITY - CU.M/S
• • IOIST ELIMINATOR
NUNPER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER Of STAGES
NUMBER OF PASSES
HASH SYSTEM
PRESSURE DROP - KPA
** PUMPS
SERVICE
VENTUR1 SECIRCULATION
ABSORBER RECIRCULATION
•* REHEATER
TYPE
** THICKENEP
NUMBER
DIAMETER - M
OUTLET SOLIDS - X
*• WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
** REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
.0
TRAY TOWER
7/77
BABCOCK K UILCOX
CARBON STEEL
RUBBER
316 SS
159.50
52.2
6.3
1.1
3.2
935
294
69.0
SCRUBBER FD
CARBON STEEL
192.06
1
CHEVRON
DERAKANE
HORIZONTAL
1
*
OVERSPRAY
.2
NUMBER
BYPASS
1
15.2
35.0
OPEN
6.3
FINAL
POND
ON-S1TE
PUMPED
338000 ACFM)
126 F)
47.5 6AL/100CACF)
4.5 IN-H20)
10.5 FT/S)
< 407000 ACFH)
C 1.0 IN-H20)
( 50 FT)
( 100 6PM)
.—..... . PERFORMANCE DATA ———
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION I REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/78 SYSTEM
• * PR08LEMS/SOLUTIONS/COMMENTS
744
IN EARLY JANUARY THE SYSTEM WENT DOWN TO FOR TWO DAYS TO CHECK THE INSTRU-
MENTATION.
THE S02 MONITORS HAVE MALFUNCTIONED.
321
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1079
SOUTH CAROLINA PUBLIC SERVICE: WlNYAH 2 (CONT.)
--- ---- - ---------------------------------- PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPtRAHILlTY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S03 PART. HOURS HOURS HOURS FACTOR
ALL THE SAMPLE LINES HAVE, BEEN REPLACED. NEW HEAT TRACINGS HAVE BEEN
INSTALLED AROUND THEP.
2/78 SYSTEM 672
** PR06LcMS>SOLUTIONS/COM«IENTS
THE FGD SYSTEM WAS BYPASSED FOR SERVERAL DAYS TO ALLOV SYSTEM CLEANING IN
PREPARATION FOR TESTING BY dABCOCK AMD WUCOX.
J/78 SYSTEM 744
4/78 SYSTEM 72Cl
** PfcObLEMS/SOLUTIONS/COMMENTS
SOME MINOh SCALING WAS ENCOUNTERED BUT IT DID NOT CAUSE AN OUTAGE.
5/78 SYSTEM 744
6/78 SYSTEM 1C3.3 94.? 720 679 679
7/78 SYSTEM 1CC.? 97.0 744 722 722
8/78 SYSTEM 744
** PROBLEMS/SOLUTIONb/COMMENTS
THE UTILITY REPORTED NO FORCED FCO OUTAGE.
9/78 SYSTEM 7Zv
•* PHOfaLEMS/SOLUTIONS/CCMMENTS
THE S02 ANALYZERS PERFORMED WELL DURING A CERTIFICATION TEST.
10/78 SYSTEM 744
11/78 SYSTEM 720
12/78 SYSTEM 84.8 82.6 82.6 82.1 744 740 611
•* PROBLEMS/SOLUTIONS/COMMENTS
SC2 MON1TCP PROBLEMS CONTINUE.
AN OUTAGE WAS NECESSARY FOR ABSORBER PUMP BELT RENEWAL.
FtED SLURRY FLOWMETER PROBLEMS WERE ENCOUNTERED.
THE OIL PLMP FOR LIMESTONE MILL EXPERIENCED TRIPS.
A MINOR OLTAGE WAS CAUSED BY PLUGGING OF THE SLURRY DELIVERY LINE.
QUENCHEH FROpLEMS bERE EXPERIENCED DURING DECEMBER.
1/79 SYSTEM 99.6 99.6 99.6 99.6 744 744 742
2/79 SYSTEM 672 1361
3/79 SYSTEM 96.6 96.4 96.4 92.7 1416 1313
•• PROfcLEMS/SOLUTIONS/COMMENTS
AN OUTAGE UAS REQUIRED TO RENEW QUENCHER PUMP BELTS AND FOR REPAIRS TO A
QUENCHER StCTION VALVE.
OUTAGES WEKE REQUIRED TO REPAIR A HOLE IN THE FEED SLURRY LiNEt TO INSPECT
THE MODULE FOR PLUGGAGE , AND BECAUSE OF A BOOSTER FAN TRIP.
322
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SOUTH CAfiCLlNA PUBLIC SdRvlCE: WINYAH 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGD CAP.
$02 PART. HOURS HOURS HOURS FACTOR
THE OPERATING VALUES SHOWN ARE THE FIGURES FOR FEB. AND MARCH COMBINED.
4/79 SYSTtM 99.4 9?.4 99.4 99.4 720 720 716 73.4
•* PtiObLEMS/SOLUTIONS/CCMMENTS
THE UTILITY REPORTED THAT THE S02 MOM TOR HAS PASSED THE STATE CERTIFICA-
TION TEST IUT REQUIRES CONTINUING MAINTENANCE TO KEEP IT OPERATING.
» MALFUNCTION OF THE REC1«CULATION TANK LEVEL INDICATOR RESULTED IN » L0*
LItUlO LEVEL WHICH RESULTED IN A FORCED OUTAGE.
5/79 StSTcM 98.4 98.7 10C.O 95.6 7*4 721 711 82.C
** PKObLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SOS MONITOR SAMPLE PUMP REGUIRES MAINTENANCE
ALMOST EVEM 24 HOURS.
A bOILER OLTAGE ALLOWED TIME FOR CLEANING ABSORBER TRAYS, UNPLUGGING FOUR
NOZZLES, CLEANING THE SUNP POTTOM, AND REPAIRING A SPRAY WASH VALVE.
6/79 SYSTEM 92.4 92.3 92.1 91.6 £3.00 72i 716 66C 86.6
*« PRObLEMS/SOLUTIONS/COWMENTS
FOUR OUTAGES IN JUNE WERE DIE TO PLUGGED ABSORBER N022LES. THE PRIMARY
CAUSE APPEARED TO BE THAT A SCREEN IN THE ABSORBER SIDE OF THE SUMP fcOTTOW
WAS LEFT OtT DURING THE PREVIOUS OUTAGE.
A HEAVY SCALE bUILD-UP IN THE SUMP BELOW THE VENTURI WAS NOTED.
THE UTILITY REPORTED THAT MGO TESTING HAS BEGUN.
7/79 SYSTEM 98.4 98.4 98.4 97.8 84.00 744 740 732
** PRObLEMS/SOLUTIONS/CCMMENTS
THE AfcSORBfcR WENT OFF-LINE DUE TO OUENCHER PUMP PACKING PROBLEMS.
SOME PLUGGING WAS ENCOUNTERED WITH ONE OF THE ABSORBER NOZZLES.
SOME OUTAGE TIME WAS NEEDED TO INSTALL A QUENCHER WALL WASH N02ZLE.
8/79 SYSTEM 99.4 99."> 99.4 98.1 BC.OO 744 738 739
** PRObLEMS/SOLUTIONS/COMMENTS
A 4 HOUR OUTAGE WAS THE RESULT OF bOOSTER FAN CONTROL PROBLEMS.
A NEW PORT FOR THE SCRUBBER OUTLET GAS SAMPLE PROBE HAD TO BE INSTALLED.
THIS TOOK 1 HOUR OF SCHEDULED DOWN TIME.
9/79 SYSTEM 720
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 7*4
•• PRObLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THIS REPORT PERIOD.
323
-------
EPA UTILITY FCD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY MAE
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mfc
NET UNIT GENERATING CAPACITY U/FGO - MU
NET UNIT GENERATING CAPACITY UO/FGC - MU
EQUIVALENT SCRUBBED CAPACITY - MU
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
NAXIMUfc bOILER FLUE GAS FLOU - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP OIAME TER - M
«* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
.100 LB/MMBTU)
1.200 LB/MMBTU)
SOUTH MISSISSIPPI ELEC PUR
R.D. MORROU
1
HATTISBURG
MISSISSIPPI
B
43. <
516. <
40C.O
?OC.O
18C.O
191.0
124.0
RILEV STOKER
PULVERIZED COAL
BASE
0/7P
132.2
124.
COAL
******
27912.
8.00
6.50
6-7
1.30
1 - 1.75
(**«**** ACFM)
( 270 F>
( 408 FT)
C***** FT)
( 12000 BTU/LB)
ESP
NUMBER 1
TYPE HOT SIDE
SUPPLIER BUELL
PARTICULATE DESIGN REMOVAL EFFICIENCY - X 99.6
PARTICULATE SCRUB6EN
TYPE NONE
** FGD SYSTEM
SALEABLE PRODUCT/THROWAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - x
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
• * ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
THROWAWAV PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RILEV STOKER/ENVIRONEEftlNG
BURNS ft MCDONNELL
RILEV STOKER
FULL SCALE
NEW
- X 99.60
85.00
8/78
.0
.0
GRID TOWER
8/78
RILEV STOKER/ENVIRONEERING
7
90 X 40 X 10
CARBON STEEL
HASTELLOY G AND CHLOROBUTYL RUBBER
324
-------
SOUTH MISSISSIPPI ELEC PUR: R .D . MORROW 1
INTERNAL MATERIAL
GAS FLOW - CU.M/S
GAS 1EMPIRATURE - C
PRESSURE DROP - KPA
•* FANS
TYPE
• • VACUUM FILTER
NUMUER
OUTLET S3LIOS - Z
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER 01 STAGE S
•* PUMPS
SERVICE
ABSORBER RECIRCULATION
*• REHEATER
TYPE
** THICKENER
NUMBER
DIAMETER - M
•* MATER LOOP
TYPE
** REAGENT PREPARATION EQUIPMENT
• * TREATMENT
TYPE
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
(CONT.)
316L SS RODS, HASTELLOV G SUPPORTS
192.03 ( 4C6940 ACFH)
13J.2 ( 273 F>
2.C < 8.0 IN-H20)
BOILER I.D.
1
60.0
1
CHEVRON
FRP
VERTICAL
3
NUMBER
3
BYPASS
1
12.2 t 40 FT)
CLOSED
FLYASH STABILIZATION
FINAL
LANDFILL
OFF-SITE
TRUCK
. PERFORMANCE DATA ————
PERIOD MODULE AVAILABILITY CPE'ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/78 SYSTEM
** PHObLcMS/SOLUTIONb/CCMNENTS
A FORCED EOILER OUTAGE OCCURRED DURING THE PERIOD AS A RESULT OF BOILER
TUBE LEAKS.
9/78 SYSTEM
10/78 SYSTEM
** PRObLEHS/SOLUTIONS/COHMENTS
.0
720
744.
11/78 SYSTEM
12/78 SYSTEM
OPERATION OF THE UNIT UAS INTERMITTENT DUE TO CONTINUING BOILER TUBE
PROBLEMS. THE BOILER UAS SHUT DOWN NOVEMBER 1 AS A RESULT OF BOILER TUBE
PROBLEMS. RESUMPTION OF OFERATION IS SCHEDULED FOR MARCH 1979.
THE FGD SYSTEM UAS BYPASSED ENTIRELY IN OCTOBER DUE TO SERIOUS CONTROL
VALVE PLUGGING.
.0
.0
720
744
325
-------
EPA UTILITY FbO SURVEY: FOURTH QUARTER 1979
SOUTH MISSISSIPPI ELEC PUR: R.D. MORROW 1 (CONT.)
PERFORMANCE DATA- -..«
PERIOD MODULE AVAILABILITY CPE&ABILITY RELIABILITY UTILIZATION * REMOVAL PER boiLER FGD CAP."
S02 PART. HOURS HOURS HOURS FACTOR
*• PRObLEMS/SOLUTIONS/COMMENTS
ThE UNIT HAS NOT YET BEEN RESTARTED SINCE ITS NOVEMBER SHUTDOWN.
1/79 SYSTtM .0 744 0 0
2/79 SYSTtM 672
3/79 SYSTEM 744
4/79 SYSTEM 72C 631
*• PHObLEMS/SOLUTIONS/CCMMENTS
THE BOILER RETURNED TO SERVICE ON APRIL 1 AFTER COMPLETION OF REPAIRS
TO THE BOILER TUBES.
NO FGD SYSTEM RELATED PROBLEMS WERE REPORTED BY THE UTILITY FOR APRH.
744
72C
5/79
6/79
8/79
9/79
10/79
11/79
12/79
SYSTEM
SYSTtM
•* PROoLEMS/SOLUTIOMS/COM1ENTS
THE UTILITY REPORTED THAT THE SYSTEM OPERATED MOST OF MAY AND JUNE WITH
NO MAJOD PROBLEMS.
7/79 SYSTtM
*• PRObLEMS/SOLUTIONS/COMMENTS
744
DURING THE FIRST WEEK OF JULY THE UNIT WAS REMOVED FROM SERVICE DUE TO
SEVERE PROtLlMS WITH THE FGD SYSTEM. THE UTILITY NOTED THAT ABOUT HALF
OF THE 10DLLE HEADERS WERE PLUGGED, HOLES WERE NOTED IN THE MODULE SHELL,
THE UPPER 000 BANK CORRODED AWAY FROM THE SHELL, AND EXTENSIVE PLUGGING
OF THE WIST ELIMINATOR OCCURRED. LINER FAILURE AT THE OUTLET DUCTWORK WAS
ALSO EXPERIENCED. THE UTILITY PLANS TO REPLACE THE DUCTWORK WITH
HASTALLOY. THE FGD SYSTEM IS EXPECTED TO BE OFF LINE FOR SEVERAL MOUTHS
FOR REP«1RS TO PE COMPLETED.
SYSTEM
SYSTEM
•* PKOBLEMS/SOLUTIONS/COMMENTS
744
72C
THE UNIT REMAINED OFF LINE DURING THE MONTHS OF AUGUST AND SEPTEMBER AS
MAINTENANCE AND REPAIR WORK CONTINUED.
SYSTEM
SYSTEM
SYSTtM
.0
.0
.0
.0
.3
.0
.0
.0
91.00
744
720
744
282
•* PRObLcMS/SOLUTIONS/COMNENTS
THE SCRUbBtR HAS REMAINED OFF LINE THROUGH THE REPORT PERIOD DUE TO THE
LINING FAILURE. RELININ6 SHOULD BE COMPLETED AND THE UNIT ON LINE In
MARCH.
326
-------
EPA UTILITY FGD SURVEY: FOURTH OUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTKULATt EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - N&/J
NET PLANT GENERATING CAPACITY - MU
GROSS UMT GENERATING CAPACITY - Mfc
NET UNIT GENERATING CAPACITY W/FGD - M*
NET UNIT GENERATING CAPACITY WO/FGt - MU
EQUIVALENT SCRUBBED CAPACITY - Ku
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FL 01, - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP OIAME TER - M
** FUEL DATA
FUEL TYPt
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - B1U/L6
AVERAGE ASH CONTENT - i.
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE K01STURE CONTENT - ?
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
• * ESP
NUMBER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY
** PARTICULATE SCRUBBER
TYPE
*• FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FI RM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
** ABSORBER
NUMPER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
GAS FLOW - CU.M/S
SOUTH MISSISSIPPI ELEC PwR
R.D. MORROW
2
HATTISBUR&
MISS 1SSIPPI
B
****** (***
43.0
200.0
18'".0
191.0
124.0
RILEY STOKER
PULV [RIZED COAL
BASE
**/**
LB/MMBTU)
LB/MMBTU)
(.**.**
( 270 F)
( 4C8 FT>
(**•** FT)
( 1iCOO BTU/LB)
122.2
124.
*******
COAL
******
27912.
£.00
-------
EPA UTILITY FfaD SURVEY: FOURTH QUARTER 1979
SOUTH MISSISSIPPI ELEC PWR : R.D. MOfcROW 2 (CONT.)
GAS TEMPERATURE - C
•• FANS
TYPE
•* *1ST ELIMINATOR
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMKER OF STAGES
HASH SYSTEM
•* REHEATER
TYPE
•• THICKENER
NUMRER
DIAMETER - M
** WATER LOOP
TYPE
** TREATMENT
TYPE
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
132.2
BOILER ID
CHEVRON
FRP
VERTICAL
3
CONT JNUOUS I. ASH
BYPASS
( 270 F)
1 2.2
( 40 FT)
CLOSED
FLYASH STABILIZATION
FINAL
LANDFILL
ON-S ITE
TRUCK
........ .__.. . .. . PERFORMANCE DATA — — .............. .......___.._.-<._
PERIOD MODULE AVAILABILITY CPEF. ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
72 u
R.D. MORROW UNIT »2 bEGAN OPERATION IN THE LATTER PART OF JUNE. OPEHA-
TICNAL DATA ARE NOT YET AVAILAbLt.
7/79 SYSTEM 74*
8/79 SYSTEM 7*4
•• PfcOfaLENS/SOLUTlONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE JULY-AUGUST 1979 PERIOD.
9/79 SYSTEM 4.7 5.? 5.0 4.7 723 3* 58
*• PRObLEMS/SOLUTIONS/COMMENTS
DUfcING SEPTEMBER THE UNIT WAS TAKEN OFF LINE DUE TO FAILURE OF LINERS AND
PLUGGING IN THE MIST ELIMINITOR SECTIONS.
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
.0
.0
.0
.0
.0
.0
.0
.3
.0
.0
.00 86.00
7*4
720
744
477
•* PKOuLtMS/SOLUTIONS/COMMENTS
THE SCRUbBLR HAS REMAINED OFF LINE THROUGH THE REPORT PERIOD DUE TO THE
LIKING FAILURES. RELININ6 SHOULD BE COMPLETED AND THE UNIT ON LINE IN
MAY.
328
-------
tPA UTILITY fGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAPE
PLANT NAME
UNIT NUMUEK
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE LM1SSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GcNERATlNfc CAPACITY - KW
NET UNIT GENtRATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGl - MW
EQUIVALENT SCRUROEO CAPACITY - Mw
** BOlLfR OATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPER ATURE - C
STACK HEIGHT - M
STACK TOP OIAME TER - M
** FUEL DATA
FUEL TYPL
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - VTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTE NT - %
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - x
RANGt CHLORIDE CONTENT - S
SOUTHERN ILLINOIS POWER COOP
MARION
4
MARION
ILLINOIS
LP/MMBTU)
LB/MMBTU)
270.0
184.0
160.0
>«» *««
164.0
BABCCCK 8 WlLCOX
CYCLONE
BA SE
9/78
******** (.*.*.*• ACFM)
..*„*„. («*•* F)
****** (**** FT)
******* (***** FT)
COAL/SEFUSE
20934.
U.OC
0. CO
3.50
******
.10
( 9DCO BTU/LB)
QABCOCK & WlLCOX
99.6
** ESP
NUMBER
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
FLUE GAS CAPACITY - CU.M/S 326.3
FLUE GAS TEMPERATURE - C 143.3
PRESSURE DROP - KPA **** i**
PARTICULATE OUTLET LOAD - G/CU.K .CO
*« PARTICULATE SCRUBBER
TYPE NONE
< 691500 ACFM)
( 290 F)
(***** JN-H20)
< .CO GR/SCF)
FCD SYSTEM
SALEABLE PRODUC T/THROtlAWAY PROLUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FlRK
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
S02 DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
AbSORfecM
NUMBER
TYPE
INITIAL START UP
SUPPLIER
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
BABCOCK g WlLCOX
BURNS & MCDONNELL
BABCOCK & WlLCOX
FULL SCALE
NEW
99.60
89.40
5/79
5/79
SPRAY TOWER
10/7.?
BABCOCK & WlLCOX
329
-------
EPA UTILITY FoD SURVrY: FOUhTH UUAETFfc 1979
SOUTHERN ILLINOIS POWER COOF: PARION «. (CONT.)
UAS FLOW - CU.M/S
&A» TEPPtRATURE - C
PRESSURE DROP • *PA
S02 OtSIuN REMOVAL EFflCIEtCV - X
«* CENTRIFUGc.
NUMBER
1YPE
CAPACITY - &PM
** FANS
NUMPER
TYPE
SERVlCt - I.ET/ORY
CAPACITY - CU.M/S
** I"IST ELIMINATOR
CONTROL CHEMISTRY
L VARIADLES
CONTROL RANGE
PUMPS
SERVICE
ABSORhlR RECIRCULATION
ULIENCHER R£ CIPCDLATION
MIST ELIMINATOR *ASH
WASTE SLURRY
AECLAIhEi/ MATED
MILL PhOuUCT
LIMESTCM; SLURRY
SLUDGE TRANSFER
TANKS
SERVICE
MIST ELIMINATOR WASH TANK
AOSORbiR/CiUENCHER RECYCLE
NECLAIi'
NUMBER
1
2
1
1
1
NONE
(125 FT)
OPEN
FLYASH STAtlLlZATlON
SIPC
FINAL
LANDFILL
PE»f ORJIANCc DATA
PERIOD MODULE AVAILABILITY CP£RAB1L1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER fGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/79 SYSTEM
6/79 SYSTEM
«• PfcOuLfcNS/SOLUTION i/CO Mi«U»< T S
744
720
THt UTILITY REPORTED THAT THE UNIT BEGAN OPERATION IN MAY. HOWEVER THE
DMT IS NU lOkM AND SUFFERED TWO PREVIOUS OUTAGES. ThE PREVIOUS OUT-
AULS WERE tUi TO CENTRIFUGE AND THICKENED PROBLEMS. THE PRESENT OUTACE
JJO
-------
EPA UTILITY FGO SURVEY: fOURTH QUARTER 1979
SOUTHERN ILLINOIS POWiR COOP: PAIION <. (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPiRABILITY RELIABILITY UTILIZATION I REMOVAL PER BOILER FGD CAP.
SOi PART. HOURS HOURS HOURS FACTOR
IS OUt TO tEARING FAILURES IN THE PU6 HILL AND IMPROPER FIT OF THE SLUDGE
CONVEYING LELT.
7/79 SYSTEM 744
8/79 SYSTtK 74*
9/79 SYSTtM 72J
*• pROuLcws/sOLUTIONS/CCMIENTS
UUfiING THE THIRD QUARTER A ROUTINE INSPECTION OF THE SCRUBBER INTERNALS
SHOwc.0 MO SCALE FORMATION.
THE UTILITY F-EPORTED THAT THE FGD SYSTEM HAS ACHIEVED A 0.7 LB/MMBTU OF
SOi EKISSItN LtVEL. THE UNIT IS SUBJECT TO THE 1.2 LB/WMBTU S02 EMISSION
STANDARD.
THc CONTINUOUS MONITORS HAVE NOT BcEN OPERATING ACCEPTABLY.
A TURBINE CVtRHAUL/INSPECTION IS SCHEDULED FOR OCTOBER 1, 1979.
10/79 SYSTtM 744
11/79 SYSTtM 720
12/79 SYSTEM 744
** PKObLEMS/SOLUTIONS/CCMMENTS
NO INFORMATION WAS AVAILABLE FOR THE FOURTH QUARTER 1979.
331
-------
EPA UTILITY FOD SURVEY: FOURTH OUARTEh 1979
SECTION 3
OESIGN AND PERFORMANCE DATA FO& OPESATIONAL DOMESTIC FGD SYSTEMS
COMPANY MAKE
PLANT N»I"E
UNI T NU«BE<<
CITY
STATE
REGULATORY CLASSIFICATION
PAHT1CULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GcNERATING CAPACITY - Mb,
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY wo/FGt - MM
EQUIVALENT SCRUBBED CAPACITY - My
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP OIAMfc TER - M
** FUEL DATA
FUEL TYPE.
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
«ANGt HEAT CONTENT - frTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - %
AVERAGE MOISTUKE CONTENT - X
RANGE MOISTURE CONTENT - X
AVEIAGt SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - 1
RANGE CHLORIDE CONTENT - 7
** ESP
NUMBER
TYPE
SUPPLIER
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
PARTICIPATE OUTLtT LOAD - G/CU.M
** PARTICULATE SCRUBbER
TYPE
** FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PROtUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FI RM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
soz DESIGN REMOVAL EFFICIENCY - i
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AWARDE 0
STARTED REQUESTING BIDS
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
** ABSORBER
NUMBER
TYPE
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
SOUTHERN INDIANA GAS & ELEC
A.B. BROUN
1
WEST FRANKLIN
INDIANA
B
43.
516.
25C.O
265.0
25C.C
252.0
265.0
BABCCCK 8 WILCOX
PULVF.R12ED COAL
BASE
0/79
372.82
143.3
152.
4.4
( 790036 ACFM)
( 290 F)
( 498 FT)
( 14.5 FT)
COAL
3C261.
{•.SO
11.40
( 13010 BTU/LB)
4.5J
* * * * **
.05
••««»*
COLD SIDE
BUELL
372.8
145.0
64.29
NONE
THROUAWAY PRODUCT
WET SCRUBBING
DUAL ALKALI
NONE
FMC CORPORATION
BROUN £ ROOT
MID IALLEY
FULL SCALE
NEW
9P.50
85.00
3/7"
3/79
10/77
12/76
4/76
20.0
.3
2
VENTURI
( 790036 ACFM)
C 293 F)
( 26.10 GR/SCf)
332
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SOUTHERN INDIANA GAS fc ELEC: A.B. BROWN 1 (CONT.)
INITIAL START UP
SUPPLIER
NUMBER OF STAGE S
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
NOZZLE TYPE
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
SO2 INLET CONCENTRATION - PPH
S02 OUTLET CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - I
• * CENTRIFUGE
TYPE
*• FANS
NUMBER
TYPE
SERVICE - WET/DRY
CAPACITY - CU.H/S
** VACUUM FILTER
NUMBER
TYPE
CONSTRUCTION MATERIAL
CAPACITY - M TlD
OUTLET SOLIDS - X
** MIST ELIMINATOR
NUMBER
TYPE
CONFIGURATION
NUMBER OF STAGES
MASH SYSTEM
•* PROCESS CONTROL CHEMISTRY
•* PUMPS
SERVICE
ABSORBER RECIRCULATION
THICKENER UNDERFLOW
•* TANKS
SERVICE
REACTION
SURGE TANK
•• REHEATER
TYPE
** THICKENER
NUMBER
DIAMETER - M
•• WATER LOOP
TYPE
** REAGEKT PREPARATION EQUIPMENT
NUMBER OF SLAKERS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
3/79
FMC CORPORATION
62 HIGH X 32
CARBON STEEL
FLAKEGLASS
HASTELLOY
1
SINGLE PIPE
60.0
237.84
145.0
281C
520
85.0
( 504000 ACFN)
( 293 F)
NONE
SCRUBBER FD
DRV
117.97
ROTARY DRUM
NYLON BELT
174.1
60.0
CHEVRON
HORIZONTAL
2
OCCASIONAL
NUMBER
4
**• *
NUMBER
( 250000 ACFM)
192 T/D>
*** *
****
NONE
1
3T.5
CLOSED
3
FINAL
LANDFILL
ON-SITE
TRUCK
11CO FT>
333
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SOUTHERN INDIANA GAS 8 ELEC: A.B. BKOviN 1 (CONT.)
.............—..... ..... . .....—PERFORMANCE DATA ....... ....... ...
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/79
4/79
SYSTEM
SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM BEGAN OPERATIONS ON MARCH 18t 1979.
ARE YET AVAILABLE.
5/79
6/79
7/79
8/79
10/79
11/79
12/79
SYSTEM
SYSTEM
** PROfaLEMS/SOLUTIONS/COMMENTS
744
720
NO OPERATIONAL DATA
744
72 C
OPERATING HOURS ARE NOT YET AVAILABLE. HOWEVER THE UNIT HAS BEEN RUNNING
INTERMITTENTLY AS A RESULT OF PUMP LINER AND FRP PIPING DESIGN PROBLEMS.
SYSTEM 63.C
SYSTEM 94.3
** PRObLEMS/SOLUTIONS/COMMENTS
55.3
94.C
744
744
65C
743
408
7C1
IN AUGUST THE FGD SYSTEM WAS FORCED OFF LINE FOR 43 HOURS DUE TO PROBLEMS
WITH THE RECYCLE PUMP IMPELLERS.
9/79 SYSTEM 75.0
•* PROuLEMS/SOLUTlONS/COMMENTS
74.:*
72C 716
534
THE ONLY FCRCEO OUTAGE DURING THE MONTH BEGAN ON SEPTEMBER 28 AND LASTED
THROUGH THE END OF THE MONTH. THIS OUTAGE WAS DUE TO PROBLEMS WITH THE
VACUUM FILTERS AS WELL AS CHEMICAL PROBLEMS.
IN SEPTEMBER 52 HOURS OF SCHEDULED OUTAGE WERE USED TO INSTALL A WATER
FILTER. THE SCRUBBER WAS ALSO TAKEN OFF LINE FOR ?2 HOURS FOR PRECIPITATOR
TESTING. THE ONLY FORCED OUTAGE DURING THE MONTH BEGAN ON SEPTEMBER 28 AND
LASTED THROUGH THE END OF TK MONTH AS A RESULT OF POOR FILTER CAKE
QUALITY. THIS HAS RESULTED FROM PROBLEMS WITH THE VACUUM FILTERS AS WELL
AS CHEMICAL PROBLEMS.
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
8 5.8
88.6
100.0
89.3
86.8
97.0
8C.8
81.2
81.0
96.9
98.6
93. C>
97.1
94.4
96.0
80.9
81.3
81.0
9S.O
97.0
61.0
84.5
86. C
85.r
89.4
86.9
68.0
80.?
81.2
E1.C
74 A
649
72C 663
744
743
634
635
6C3
*« PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER PROBLEMS WERE ENCOUNTERED WITH THE LIME SLAKER
FEED.
THE THICKENER RAKE FROZE CAUSING 9 DAYS OUTAGE TIME.
THL ISOLATION DAMPER HAS CAUSED SOME PROBLEMS THIS OUARTER. THE UTILITY
HAS NOT YET SOLVED THIS PROfLEM.
334
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DAT* FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY SAME
PLANT NAKE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
RARTICULATt EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY b./FGD - MU
NET UNIT GENERATING CAPACITY WO/FGC - MW
EOUIVALEST SCRUBBED CAPACITY - HH
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
fLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME T£R - M
.* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
SPRINGFIELD CITY UTILITIES
SOUT I-UEST
SPRINGFIELD
MISSOURI
8
43.
516.
177.0
194.0
173.0
182.0
194.0
( .103 LB/MMBTU)
( 1.200 LB/MMBTU)
R1LEY STOKED
PULVERIZED COAL
BASE
0/76
148.9
117.
*******
COAL
BITUMINOUS
29075.
13.00
(******* ACFM)
< 300 F)
( 384 FT)
(.**** FT)
( 12500 BTU/LB)
******
6-12
3.50
2.5 - 4.5
.30
• • ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY
FLUE GAS TEMPERATURE - C
.* PARTICULATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
«* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
COLD SIDE
AIR CORRECTION DIVISION, OOP
- X 99.7
U8.9 < 300 F)
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
AIR CORRECTION DIVISION. UOP
BURNS £ MCDONNELL
FULL SCALE
NEW
- X 99.70
80.00
4/77
.0
.0
MOBILE PACKED TOWER
4/77
AIR CORRECTION DIVISION* UOP
3
16 X 30 X 54.5 HI6H
A-36 CARBON STEEL
NEOPSENE RUBBER
6> .0
335
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
GAS FLOW - CU.N/S
GAS TEMPERATURE - C
LIQUID RECIDCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SOi DESIGN REMOVAL EFFICIENCY - X
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
CAPACITY - CU.N/S
•• VACUUH FILTER
NUMBER
TYPE
OUTLET SOLIDS - X
•• KIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
NUMBER OF STAGES
MASH SYSTEM
•• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
»• PUMPS
SERVICE
ABSORBcR RECIRCULATION
HIST ELIMINATOR WASH
THICKENER FEED
SLURRY FEED
SLURRY TRANSFER
•• TANKS
SERVICE
LIMESTONE SLURRY STORAGE TANK
SLURRY HOLD TANK
DEMISTER WASH TANK
PRESATURATOR SUPPLY TANK
•* THICKENER
NUMBER
*• WATER LOOP
TYPE
EVAPORATOR WATER LOSS - LITER/S
SLUDGE WATER LOSS - LITER/S
FRESH MAKEUP WATER ADDITION - LITERS/S
*• REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
•* TREATMENT
PRODUCT CHARACTERISTICS
•« DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
( 332500 ACFM1
( 300 F)
(13000 6PM)
( 4.1 CAI/100CACF)
(12.0 IN-H20)
407000 ACFM>
156.91
148.9
756.
.5
3.0
91.7
2
BOILER 1.6.
CARBON STEEL
192.06
ROTARY DRUM
60.0
CHEVRON
FRP
2
CONTINUOUS ON BOTTOM LEVEL
PHt 8AS FLOM
NUMBER
NUMBER
1
2
1
1
CLOSED
<.9
1.8
19.8
( 157 GPM>
( 29 6PM)
( 315 6PM)
DRY LIME AND FLVASM STABILIZED
FINAL
LANDFILL
ON SITE
TRUCK
10.0
DATA- —« — ———.-——..-.._..,_._.,-
PERIOD NODULE AVAILABILITY OPEBABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAp~~
S02 PART. HOURS HOURS HOURS FACTOR
0/77 SYSTEM
336
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
-. —— PERFORMANCE DATA — — ..... —
PERIOD HODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•« PROBLEMS/SOLUTIONS/COMMENTS
INSTALLATION OF THE LIMESTONE FGD SYSTEM WAS COMPLETED DURING THE FIRST
QUARTER OF 1977 (BEHIND SCHEDULE, PRIMARILY BECAUSE OF DELAYS IN ELECTRIC-
AL WORK). FOLLOWING AIR/WATER TESTS AND CHECKOUT OF LIMESTONE PREPARATION
FACILITIES, THE FGD PLANT UAS STARTED UP IN EARLY APRIL 1977 FOR MECHANIC-
AL SHAKEDOWN/DEBUGGING OPERATIONS WHICH CONTINUED THROUGHOUT THE SUMMER.
COMPLIANCE TESTING AND CERTIFICATION OF COMMERCIAL AVAILABILITY WERE SUC-
CESSFULLY COMPLETED IN SEPTEMBER, JUST BEFORE A SCHEDULED 3-MONTH FALL
SHUTDOWN. OPERATION OF THE SYSTEM HAS BEEN HAMPERED 6Y A NUMBER OF PROB-
LEMS: MIST ELIMINATOR PLUGGING (PIPING TO M.E. SPRAY SYSTEM HAS BEEN MOD-
IFIED), CORROSION IN THE PRESATURATOR (WAS RELINED WITH PRECRETE),
CORROSION OF THE INLET/OUTLET GAS DAMPERS (REPLACED WITH 316 SS DAMPERS),
AND FAILURE OF PRECRETE LINING IN THE SCRUBBER AND CEILCOTE IN THE STACK
(faOTH FAILURES IDENTIFIED AS APPLICATION PROBLEMS). THE UTILITY ALSO
FOUND IT KECESSARV TO CHANGE THE SYSTEM'S PH CONTROL FROM 5.9 TO 5.6 TO
INCREASE LIMESTONE UTILIZATION AND DECREASE PLUGGING WITHIN THE SYSTEM.
«/77 SYSTtM 72C
5/77 SYSTEM 744
7/77 SYSTEM 744
8/77 SYSTEM 744
** PRObLEHS/SOLUTIONS/COMHENTS
THE FGD SYSTEM WAS OPERATED ROUGHLY 6CX OF THE AUGUST-SEPTEMBER
PERIOD. A NEW SOURCE PERFORMANCE TEST WAS RUN DURING THE SECOND WEEK OF
SEPTEMBER. LATER, THE UNIT WAS SHUT DOWN FOR THE FIRST TURBINE IN-
SPECTION.
9/77 SYSTEM 720
10/77 SYSTtM 744
*• PRObLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE OUTLET DAMPERS W£RE MODIFIED (REPLACED WITH 316L SS). .
A SCHEDULED OCTOBER-NOVEMBER OUTAGE HAS INITIATED. THE UNIT IS SCHEDULED
TO START tP AGAIN IN JANUARY.
THE PRESATURATOR WAS RELINED WITH HI-MO (HIGH MOLYBDENUM) STEEL.
OUTLET DUCTWORK WAS RELINED WITH CEILCOTE.
HOLLOW PACKING BALLS WERE REPLACED WITH HEAVIER WALLED PLASTIC BALLS.
LEAKING AROUND OUTLET DAMPERS WAS MINIMIZED BY SEAL-AIR FANS.
11/77 SYSTEM 72C
12/77 SYSTtM 744
*• PRObLEMS/SOLUTIONS/COMMENTS
THE PLANT SHUTDOWN CONTINUED UNTIL JANUARY 28 WHEN THE BOILER RESTARTED.
Tht FGD SYSTEM WAS EXPECTED TO BE PUT BACK ON LINE IN FEBRUARY 1978.
DURING THE OUTAGE ALL REMAINING MODIFICATIONS TO THE FGD SYSTEM WERE COM-
PLETED.
1/78 SYSTEM 744
2/78 SYSTtM 672
337
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PEfiFORMANC E DATA
PERIOD MODULE AVAILABILITY OPePABIHTY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGO CAP.
502 PART. HOURS HOURS HOURS FACTOfi
** PRObLEMS/SOLUTIONS/COMMENTS
THE ABSORBERS DID NOT OPERATE DUE TO AN EXPANSION JOINT FAILURE BETWEEN
THE ID FAN AND THE ABSORBERS.
THE ABSORLERS ARE CURRENTLY BEING BY-PASSED. THE FGD SYSTEM IS EXPECTED
TC BE BAC*. ON LINE fit THE END OF APRIL.
3/78
4/78
5/78
6/78
SYSTEM
SYSTEM
** PROfaLEMS/SOLUTIONS/COMMENTS
744
720
ONLY ONE SCRUBbtR-AfcSORBER MODULE IS CURRENTLY OPERATING. THE EXPANSION
JOINT FAILURE MENTIONED PREVIOUSLY WAS DIRECTLY RELATED TO THE DAMPER
FAILURE WhICH ALLOWED THE POILER TO CONTINUE PUMPING GAS TO THE SEALED OFF
FGD S YSTf K.
THE UNIT EXPERIENCED AN FRP LINEP FAILURE OVER THE PERIOD.
A PUKP FAILURE OCCURRED DURING THE PERIOD.
SYSTEM 744
SYSTEM 72C
*• PRObLtMS/SOLUTIONS/CCMMENTS
THE A-i»ODLLE RAN STEADILY FOR OVER 11 DAYS. B-MODULE HAS STILL DOWN WITH
EXPANSION JOINT PROBLEMS.
7/78
s-1
S-2
SYSTEM
16.7
.0
8.0
THE MONTH THE MIST ELIMINATOR WASH SYSTEM WAS ALTERED FROM A SEPAR-
ATE CLOSEL LOOP FOR EACH MODULE TO A COMMON SYSTEM FOR BOTH NODULES. THE
NEW SYSTEM TAKES SUPERNATAIT FROM THE TOP OF THE THICKENER FOR MIST ELIM-
INATOR SPRAY.
INSTRUMENTATION PROBLEMS WERE ENCOUNTERED DURING THE MONTH. PH PR06ES
wtRE LOST, 1HE MAb-FLOW METER FOR LIMESTONE SLURRY FAILED, AND THE AUTO-
MATIC GAS ANALYZERS DID NOT OPERATE PROPERLY.
SOME PIPES PLUGGED DUE TO NEOPRENt PEELING FROM VALVES.
THE SLUDGE SYSTEM EXPERIENCED SOME FILTER BELT PROBLEMS DURING THE MONTH
PUT THESE WERE REPAIRED.
16.7
1b.7
«j
fe.O
16.7
• '
8.T
744
744
62 68.C
PRObLEMS/SOLUTIONS/CO MMENTS
8/78
S-1
S-2
SY STEM
59.0
.0
30.0
PROBLEMS ^ERE ENCOUNTERED WITH THE MOOULE-A TRANSFER PUMPS.
WERE REQUlRtO TO TRACE THE EL ECTRICAL-RELATED PROBLEM.
NINE DAYS
A 17-QAY OUTAGE WAS CAUSED BY PROBLEMS WITH THE BALL MILL AIR SUPPLY WHICH
RESULTED IN THE UNAVAILABILITY OF SLURRY.
P-MOOULE WAS STILL DOWN IN JULY WHILE THE UTILITY WAITED FOR THE REPLACE-
MENT EXPANSION JOINT.
WORK WAS LONE DURING THE MONTH TO IMPROVE THE INSTRUMENTATION. IT *AS
D1SCCVEREI THAT MANY OF THE PRObLcMS WERE DUE TO SCALE ACCUMULATION ON TH£
PROBES.
59.0
.0
30.0
59.0
-)
• -
3D.C
744
744
220 54.9
338
-------
EPA UTILITY rGD SURVEY: FOURTH OUARTER 1979
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PLRFOHMANCE DATA — —
PERIOD MODULE AVA1LAML1TY OPEPAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
«* PfcObLEMS/SOLUTlONS/CGMMENTS
10/78
THE 1--KIOOILE. REMAINED DOWN THROUGHOUT AUGUST BECAUSE THE REPLACEMENT EX-
PANSION JOINT HAD NOT YET ARRIVED. EXPANSION JOINT REPAIR WAS REQUIRED ON
THE A-MODLLL.
PROBLEMS WITH THE THICKENED AND PLUGGED LINES CAUSED THE A-HODULE OUTAGE
TOTALING ill HOURS.
9/78 S-1
S-2
SY STEM
22.1
.0
1 1.0
28.6
.3
14.0
28.6
.0
U.O
22.1
.0
11.0
720 557
8C 47.6
*• PROBLEMS/SOLUTIONS/COMMENTS
CONTINUATION OF THE EXPANSION JOINT PROBLEM RESULTED IN THE B-MODULE RE-
MAINING DCWN THROUGHOUT THE MONTH.
A-MODULE DOWN TIME UAS DUE TO PLUGGING OF THE THICKENER SLURRY MAKEUP
LINES AND FAILURE OF THE BALLS WITHIN THE MODULE.
A-MODULE EALLS FAILED OVER THE PERIOD. THE HE AVIER-UALLED PING PONG BALLS
THAT WERE INSTALLED DURING THE DECEMBER 1977-jANUARY 1978 PERIOD WERE RE-
PLA3ED WITH 1.25 INCH DIAMETER SOLID RUBBER BALLS DURING SEPTEMBER 1978.
S-1
S-2
SYSTEM
• w
.0
.1
.3
.C
.3
.0
.0
.0
.0
744 26 Q
** PNObLEMS/SOLUTIONS/COMMENTS
THE BOILEIi WAS DOWN FOR A SCHEDULED OUTAGE DURING THE MONTH.
CONSIDERABLE CLEANING OF T»E A-MODULE MAS DONE AS THE LOWER TWO LEVELS OF
THE MODULE HAD BEGUN TO PLUG WHEN THE BALLS FAILED (SEE SEPTEMBER 1S7B).
A THOROUGH CLEANING OF THE ENTIRE FGD SYSTEM OCCURRED DURING THIS PERIOD.
A BEARING WAS REPLACED ON THE SLURRY DRAW OFF PUMP.
THE OUTLET DUCT WAS CLEANED AND PLASITE INSTALLED. REPAIR WAS HADE TO
THE BYPASS DUCT TOGGLE DUE TO METAL DETERIORATION.
THE RUBBER COATING ON HOLD TANK AGITATORS AND SLURRY STORAGE TANK
AGITATORS WERE REPAIRED.
11/78 S-1
S-2
SYSTEM
75.7
26.3
51.0
64.7
22.5
43.5
64.7
22.5
43.6
64.3
22.4
43.3
720 716
** PRObLEMS/SOLUTIONS/COMMENTS
THE tOILEK OUTAGE LASTED INTO THE FIRST PART OF NOVEMBER.
AN FGD OUTAGE WAS CAUSED BY A FAN BEARING FAILURE ON MODULE B.
ALL DAMPEkS WERE SERVICED, REPAIRED AND EXERCISED.
312 50.5
12/78 S-1
S-2
SYSTbM
45.2
81.7
63.4
32.9
76.2
54.6
32.9
76.2
54.6
29.7
68.7
49.2
744 671 366
»* PHObLENS/SOLUTIONS/CCNMENTS
ONCE THE SPRAY NOZZLES WERE REPLACED FROZEN LINES PREVENTED MODULE STARTUP
SC.VERAL LINES BROKE OR DEVELOPED LEAKS.
ALL THE MAJOR OUTAGES CAN BE ATTRIBUTED TO THE COLD HEATHER. THE SYSTEM
339
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
__„_.— PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPES ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/79 S-1 55.0 53.1 54.2 53.9
S-2 .0 .0 .0 .0
SYSTEM 27.5 26.5 27.1 26.5 72C 719 191
•« PROhLEMS/SOLUTIONS/COMNENTS
THE BROKEN AGITATOR SHAFT WAS REPLACED AND LINED DURING JUNE.
THE S-2 MODULE WAS OUT OF SERVICE. ON THREE OCCASIONS DUE TO PLUGGAGE OF
THE FIRST AND SECOND STAGES. THE UTILITY REPORTED THAT WITH THE EXCEPTION
OF THE PLUGGING PROBLEM ONU A FEW MINOR SHORT DURATION TRIPS WERE NOTED.
7/79 S-1 59.2 34.1 34.1 34.1
S-2 55.3 47.4 47.4 47.3
SYSTEM 57.3 4C.8 40.8 40.' 744 743 111
•* PROBLEMS/SOLUTIONS/CCMMENTS
THE S-1 MODULE WAS NOT OPERATED DURING THE FIRST PART OF THE PERIOD DUE TO
THt PLUGGAGE IN THE FIRST AND SECOND STAGES. TWO OTHER OUTAGES OCCURRED.
ONE DUE TO A BROKEN LINE AND THE OTHER TIME IT WAS P.C. TROUBLE.
THc S-2 HOtULE WAS NOT OPERATED FOR TWO PERIODS. ONCE WHEN THE TANK WAS
BEING REFILLED AFTER AN AGITATOR WAS INSTALLED AND ONCE TO CLEAN THE FIRST
AND SECOND STAGES.
6/79 S-1 74.5 53.8 50.7
S-2 94.6 7C.9 66.8
SYSTEM 84.7 62.4 62.4 58.8 744 701 A3?
PROBLEMS/SOLUTIONS/COMMENTS
THE S-1 MODULE WAS DOWN FOR TWO PERIODS DUE TO PLUGGING IN THE ABSORBER
SECTION. THE MODULE ALSO TRIPPED OFF DUE TO LOSS OF SUPERNATE PUMPS.
APART FROM THIS BOTH MODULES WERE EITHER AVAILABLE OR IN OPERATION.
9/79 S-1 48.6 58.3 58.3 45.8
S-2 68.8 6:.2 78.8 47.4
SYSTEM 71.3 59.3 65.7 46.6 72C 566 336
•* PRObLEMS/SOLUTIONS/CONMENTS
THE S-1 MODULE WAS OFF LINE DUE TO PLUGGING IN THE ABSORBER SECTION FOR
TWO PERIODS AND IT ALSO TRIPPED DUE TO LOSS OF SUPERNATE PUMPS. APART FROM
THIS IT WAS EITHER OPERATING OR AVAILABLE.
THE S-2 MODULE WAS OFF LINE ONCE DUE TO BROKEN SUPERNATE LINE, AND ONCE
DUE TO BAD .PH PROBES IN SEPTEMBER. IT WAS ALSO OFF LINE FOR SEVERAL SHORT
PEfUOOS DUE TO NUISANCE TRIPS; HOWEVER, IT WAS EITHER ON LINE OR AVAILABLE
THE REST OF THE PERIOD.
10/79 SYSTEM 7*4
11/79 S-1
S-2
SYSTEM 20.9 2C.6 20.9 20.3 720 708 146
• * PRObLtMS/SOLUTIONS/CONMENTS
FOR THE FIRST WEEK OF NOVEMBER NEITHER MODULE WAS AVAILABLE DUE TO AN
OVERRUN ON SCHEDULED OUTAGE CAUSED BY A LACK OF MANPOWER.
THE S-1 MODULE WAS NOT AVAILABLE FOR THE REST OF THE MONTH BECAUSE OF THE
LACK OF MANPOWER TO FINISH THE ABSORBER SECTION AND HOLD TANK CLEANOUT.
PROBLEMS WITH THE S-2 MODULI RECYCLE PUMPS WERE ENCOUNTERED. THE MODULE
WAS REMOVED FROM SERVICE SO THAT THE REPAIRS COULD BE MADE AND THE S-1
CLEANING COULD BE FINISHED.
341
-------
EP* UTILITY FCO SURVEY: FOURTH QUARTEh 1979
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PERFQRMANCF DATA __
PERIOD MODULE AVAILABILITY OPERARILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SO; PART. HOURS HOURS HOURS FACTOR
SEVERAL ATTEMPTS TO RETURN THE MODULE TO SERVICE WERE ABORTED DUE TO
VARIOUS PIUNG PROBLEMS.
12/79 S-1
S-2
SYSTEM 59.3 32.1 32.1 2S.7 744 664 ?13
•* PBOoLEMS/SOLUTIONi/COMMENTS
THt 5-1 APSOhBtR SECTION AND HOLD TANK CLtANOUT WAS COMPLETED DURING
DECEMLER. THE MODULE WAS RETURNED TO SERVICE.
THt PRESATtRATlON N02ZLES CAUSED SOME PROBLEMS AND HAD TO BE REMOVED
ANl/ CLEANEC.
AT THE END OF THE MONTH THE ID FAN EXPANSION JOINT BROKE AND HAD TO BE
fi EPLAC ED.
THt DENSITY METER ON THE RECYCLE LINE NEEDED REPAIR.
THE DRAINS ON THE DE1ISTER PUMPS HAD TO BE REPLACED.
THE WEIGH FEEDER WEIGH BELT AND CALIbRATED FEEDER WERE REPLACED AND
THt C»L IbRATlON FEEDER WAS CHECKED.
343
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION J
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
6:.o
60.0
COMPANY SAFE ST. JOE ZINC
PLANT NAPE G.F. WEATON
UNIT NUPttER 1
CITY MONACA
STATE PENNSYLVANIA
REGULATORY CLASSIFICATION! 6
PARTICULATi EMISSION LIMITATION - NG/J 43.
S0
-------
EPA UTILITr F&D SURVEY: FOURTH QUARTER 1979
ST. JOE ZINC: G.F. WEATON 1 (CONT.)
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID ReCIRCULATION RATE - LlTER/S
S02 INLET CONCENTRATION - PPM
S02 CUTLET CONTHATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - I
73.62
48.9
283.
2000C
200
90.0
( 156000 ACFM)
( 120 F)
( 4500 GPH>
•* FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
*• MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
** PUMPS
SERVICE
SULFUR SLURRY
LEAN SOLUTION
**•*•«
SULFUR TRANSFER
SCRUBBER RECIRCULATION
SULFUR LOADING
RICH CITRATE SOLUTION
FLUE GAS. DOUBLE INLET MECHANICAL OR
CARBON STEEL
2
CHEVRON
CHLORINATE PVC
NUMBER
2
2
1
1
4
1
2
•» TANKS
SERVICE
SULFUR FLOTATION
SULFUR SLURRY
CITRATE SOLUTION STORAGE TANK
MAKE-UP MATER
SULFlR STORAGE
•* REHEATER
NUMBER
TYPE
NUMBER
1
1
1
1
1
HOT AIR INJECTION
•* REHEATER
NUMBER
TtPE
•* UATER LOOP
TYPE
•• BYPRODUCTS
BYPRODUCT NATUR E
BYPRODUCT QUALITY - X
1
DIRECT COMBUSTION
CLOSED
ELEMENTAL SULFUR
99.5
PERFORMANCE DATA ——. .«.
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION x REMOVAL PER BOILER FCD CAP.
S02 PART. HOURS HOURS HOURS FACTO*
11/79 SYSTEM
12/79 SYSTEM
•• PRObLEMS/SOLUTlONS/COMNENTS
720
744
SINCE START-UP IN NOVEMBER THE UNIT HAS BEEN DOWN FOR A MONTH AND A HALF
DUE TO SOME MECHANICAL PROBLEMS.
THE ELECTRIC MOTOR IN THE SCRUBBER LIQUOR RECYCLE UNIT HAS BEEN A PRCBLEH
SINCE START-UP.
LEAKS HAVE BEEN ENCOUNTERED IN THE PIPING OF THE ABSORBER SOLUTION. SOMt
OF THE LEAKAGE WAS DUE TO FREEZE UP.
BECAUSE oi THE SMELTER SHUT DOWN AT ST. JOE ZINC, THE UNIT HAS BEEN
OPERATING AT 2C-3Q MU.
344
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
ST. JOE ZINC: G.F. UEATON 1 (CONT.)
PERFORMANCE DATA ........ .....
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
INITIAL SC.2 REMOVAL EFFICIENCY HAS BEEN APPROXIMATELY 80-90X.
345
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTES 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY SAME
PLANT NAPE
UNIT NUMBER
CITY
STATt
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY y/FGD - Mw
NET UNIT GENERATING CAPACITY UO/FGt - MW
EQUIVALENT SCRUBBED CAPACITY - »U
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.n/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP OIAME TER - W
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE MEAT CONTENT - .»/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - »
RANGE SULFUR CONTENT - Z
AVERAGE CHLORIDE CONTENT - H
RANGE CHLORIDE CONTENT - *
•* PARTICULATE SCRUBBER
TYPE
•• FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PROIUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
INITIAL START-UP
•* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
GAS FLOW - CU.N/S
GAS TEMPERATURE - C
PARTICULATE INLET LOAD - G/CU.M
$02 INLET CONCENTRATION - PPM
•« CENTRIFUGE
NUMBER
TYPE
•* MIST ELIMINATOR
NUMBER
TYPE
kASH SYSTEM
TENNESSEE VALLEY AUTHORITY
SHAWNEE
10A
PADUCAH
KENTUCKY
E
4?. ( .100 LB/MMBTU)
516. ( 1.200 LB/MMBTU)
1750.0
1C.O
10.0
10.0
COAL
BITUMINOUS
I******* ACFM)
(**** F)
(**** FT)
(***** ft)
(****** BTU/LB)
******
2.9Q
***** *
MOBILE PACKED TOWER
THROWAWAY PRODUCT
WET SCRUBBING
LIME/LIMESTONE
VARIABLE - TEST FACILITY
AIR CORRECTION DIVISION, UOP
BECHTEL
TVA
PROTOTYPE
RETROFIT
4/72
1
MOBILE PACKED TgUER
4/72
AIR CORRECTION DIVISION, UOP
( 3SOOO ACFH)
( 300 F)
( 3.300 GR/SCF)
16.52
148.9
6.9
2900
1
SOLID BOWL
CHEVRON
INTERMITTENT WASHING WITH AVAILABLE RAW WATER
346
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAnNEE IDA (CONT.)
** TANK.S
SERVICE NUMBER
EFFLUENT HOLD TANK *»**
«• REHEATER
TYPE DIRECT COMBUSTION
** THICKENER
NUMBER 1
TYPE CLARIFUR
** yATER LOOP
TYPE CLOSED
PERFORMANCE DATA «
PERIOD MODULE AVAILABILITY CPERABILITY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/79 StSTcM
•* PROfaLEMS/SOLUTIONS/COMMENTS
REFER TO THE PERFORMANCE UPDATE INFORMATION FOR SHAUNEE 10B.
347
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOi EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mh
NET UNIT GENERATING CAPACITY b/FGD - MU
NET UNIT GENERATING CAPACITY WO/FGt - MU
EQUIVALENT SCRUBBED CAPACITY - HW
»• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPER ATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - I
RANGE ASH CONTENT - Z
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - Z
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - Z
•* PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
•* FGD SYSTEM
SALEABLE PRODUCT/THROUAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEU/RETROFIT
INITIAL START-UP
** ABSORBER
NUMBER
TVPE
INITIAL START UP
SUPPLIER
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
• • MIST ELIMINATOR
NUMBER
TENNESSEE VALLEY AUTHORITY
SHAWNEE
10B
PADUCAH
KENTUCKY
E
43. C .100 LB/MMBTU)
516. ( 1.200 LB/MMBTU)
1750.0
10.0
ir.o
13.0
**** **
**/**
COAL
BITUMINOUS
****• **
******
2.90
******
1
VENTURI
CHEMKCO
1.7
US.9
(****•** ACFM.)
(**** F)
(*.** FT)
<*»*** FT>
(*****• BTU/LB)
3500 ACFM)
300 F>
THROUAUAY PRODUCT
UET SCRUBBING
LIME/LIMESTONE
VARIABLE - TEST FACILITY
CHEN ICO
BECH "EL
TVA
PROTOTYPE
RETROFIT
4/72
SPRAY TOWER
4/72
CHEHIcO
16.52 < 35000 ACFM)
148.9 ( 300 F)
348
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EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAWNEE 1CB (CONT.)
** TANKS
SERVICE NUMBER
SPRAY TOtfER EFFLUENT HOLD TANK «•**
OXIDATION TANK ••**
OESUPERSATURATIOH TANK • *»•
•* REHEATER
TYPE DIRECT COMBUSTION
•* WATER LOOP
TYPE CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/72 SYSTEM
»* PRObLENS/SOLUTIONS/COMMENTS
IN JUNE 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE LIME AND
LIMESTONE SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND PARTICULATE FROM COAL-
FIRED BOILER FLUE GASES. THE PROGRAM WAS CARRIED OUT IN A TEST FACILITY
INCORPORATED INTO THE FLUE GAS DUCTWORK OF UNIT NO. 10, A COAL-FIRED BOIL-
ER AT THE TVA SHAUNEE POWER STATION, PADUCAH, KENTUCKY. TVA IS THE CON-
STRUCTION AND FACILITY OPERATOR AND BECHTEL CORP. IS CONTRACTOR, TEST
DIRECTOR AND REPORT WRITER.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PRO-
TOTYPE SUE, TREATING PART OF THE FLUE GAS FROM THE BOILER. EACH SCRUBBER
TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30.000 ACFM OR THE EQUIVALENT
OF APPROXIMATELY 10 MW OF POWER PLANT GENERATING CAPACITY.
THREE PARALLEL wET SCRUBBER SYSTEMS WERE SELECTED FOP THE TEST PRO-
JECT: 1) A VENTURI WITH A SPRAY TOWER AFTER ABSORBER, 2) A TURBULENT CON-
TACT ABSOhBtR CTCA), AND 3) A MARbLt-BED ABSORBER. THE VENTURI SYSTEM,
MANUFACTURED BY CHEMICAL CONSTRUCTION to., CONTAINS AN ADJUSTABLE THROAT
THAT PERMITS CONTROL AND VARIATION OF PRESSURE DROP OVER A WIDE RANGE OF
FLOW CONDITIONS. THE TCA UNIT, MANUFACTURED BY UNIVERSAL OIL PRODUCTS.
INCORPORATES A FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT ARE FREE
TO MOVE BETWEEN RETAINING GRIDS. THE MARBLE BED ABSORBER, SUPPLIED BY
COMBUSTION ENGINEERING CO., USES A PACKING OF 3-4-INCH GLASS MARBLE
SPHERES AND A TURBULENT LAYER OF LIQUID AND GAS ABOVE THE MARBLE LAYER TO
ENHANCE MASS TRANSFER.
IN JUNE 1974, THE EPA BEGAN A 3-YEAR ADVANCED TEST PROGRAM AT THE
SHAWNEE FACILITY WITH THESE MAJOR GOALS: C1> CONTINUATION OF LONG-TERM
TESTING, WITH EMPHASIS PLACED UPON THE RELIABLE OPERATION OF MIST ELIMINA-
TION SYSTEMS AT INCREASED GAS VELOCITY, (2) INVESTIGATION OF ADVANCED PRO-
CESS AND EQUIPMENT DESIGN VARIATIONS FOR IMPROVING EQUIPMENT RELIABILITY
AND PROCESS ECONOMICS. AND <3> LONG-TERM RELIABILITY TESTING ON PROMISING
PROCESS AND EQUIPMENT DESIGN VARIATIONS.
THE TWO PARALLEL SCRUBBING SYSTEMS OPERATING DURING THE ADVANCED PRO-
GRAM ARE THE VENTURI/SPRAY TOWER SYSTEM AND THE TCA UNIT. GENERAL PROCESS
FLOW DIAGRAMS OF THE TWO PROTOTYPE UNITS ARE PROVIDED IN APPENDIX B. OPER-
ATION OF THE MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
EACH OF THE SCRUBBING SYSTEMS CONTAINS ITS OWN SLURRY HANDLING FACIL-
ITIES AND CAN TREAT APPROXIMATELY 30.000 ACFM OF GAS AT 300 F CONTAINING
1800 TO 4COC PPM OF SULFUR DIOXIDE AND 2 TO * 6RAINS/SCF OF PARTICULATE.
BOILER NO. 1 NORMALLY BURNS A HIGH-SULFUR BITUMINOUS COAL.
FROM JUNE 1974 TO JANUARY 1976, HIST ELIMINATION AND LIMESTONE UTILI-
ZATION TESTS WERE CONDUCTED AT THE SHAWNEE FACILITY. DURING THIS TEST PER-
IOD THE VENTURI/SPRAY TOWER SYSTEM WAS OPERATED ON BOTH LINE AND LIMESTONE
AND THE TCA SYSTEM WITH LIMESTONE. TESTING HAS PERFORMED UNDER A CLOSED-
WATER OPERATION MODE. DURING THIS PERIOD THE SLURRY SOLIDS CONTAINED AP-
PROXIMATELY 40 TO 50 PERCENT-BV-WEI6HT FLY ASH BECAUSE OF RELATIVELY HIGH
GAS INLET PARTICULATE LOADING. THIS TESTING PROGRAM IS SCHEDULED TO RUN
THROUGH TC FEBRUARY 1978.
ADDITIONAL INFORMATION AND DATA CONCERNING THE DETAILS OF THE ADVANCED
TEST PROGRAM ARE PRESENTED IN THE PERFORMANCE HISTORY THAT FOLLOWS.
9/75 SYSTEM 720
349
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAHMEE 1GB (CONT.)
PERFORMANCE DATA ._.
PERIOD NODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•• PROULEMS/SOLUT10NS/COMMENTS
ThIS EXPEMMENTAL EPA-FUNDED OPERATION IS PROCEEDING HTH THE TEST PROGRAM
TLO ABSORtER MODULES ARE CURRENTLY OPERATIONAL (10 MW EACH). THE MARBLE-BE
AbSOPBER IS STILL INOPERATIVE (SINCE JULY 1973). CURRENT EXPERIMENTS ARE
RELATED TO MIST ELIMINATOR SECTION.
10/75 SYSTEM 744
11/75 SYSTEM 730
*• PRObLeMS/SOLUTIONS/COMMENTS
RECENT TESTING AT SHAWNEE H»S SHOWN THAT THE CHEVRON MIST ELIMINATORS IN
BOTH THE SPRAY TOWER AND THE TCA CAN BE KEPT FREE OF SOLIDS BUILDUP AT
HIGH ALKALI UTILIZATION (GREATER THAN 90X), USING ONLY INTERNITTANT
WASHING WITH AVAILABLE RAW WATER. THIS HIGH UTILIZATION IS NORMALLY
ACHIEVED kITH LIME. IT HAS BEEN ACHIEVED WITH LIMESTONE AT REDUCED SCRUB-
BER INLET SLURRY PH (ABOUT 5.2> AND WITH THREE EFFLUENT TANKS IN SERIES
TO SIMULATE A PLUG-FLOW REACTOR. TESTING IS CONTINUING TO DETERMINE THE
EFFECTS Of PROCESS VARIABLES ON MIST ELIMINATOR PERFORMANCE AND ON LIME-
STONE UTILIZATION. FUTURE PLANS INCLUDE: (1) FACTORIAL TESTING WITH LIME
AND LIMESTONE TO DETERMINE THE EFFECTS OF PROCESS VARIABLES ON SC2 RE-
MOVAL AND (i> TESTING THE OXIDATION Of SLUDGE TO GYPSUM IN THE VENTURI/
SPRAY TOWtR SYSTEM USING AIR SPARGING OF AN ACIDIFIED SLURRY BLEED STREAM
12/75 SYSTEM 744
1/76 SYSTEM 744
•• PROBLEMS/SOLUTIONS/COMMENTS
THE ADVANCED TEST PROGRAM IS CONTINUING. HIGHLIGHTS OF THE PROGRAM ARE AS
FOLLOWS:
EVALUATE SCRUBBER OPERABILITV DURING VARIABLE LOAD OPERATION.
CONTINUE LONG-TERM RELIABILITY TESTING.
INVESTIGATE METHODS FOR IMPROVING WASTE SOLIDS SEPARATION.
CONTINUE SLUDGE OXIDATION AND SLUDGE FIXATION STUDY PROGRAMS.
EVALUATE SYSTEM PERFORMANCE AT REDUCED FLY ASH LOADING.
DETERMINE THE PRACTICAL UPPER LIMITS OF SG2 REMOVAL EFFICIENCY.
EVALUATE ADDITION OF MAGNESIUM ION TO THE SCRUBBING SLURRY.
CHARACTERIZE ALL STACK GAS EMISSION COMPONENTS.
EVALUATE MATERIALS OF CONSTRUCTION OF ALL SCRUBBER AND PLANT-RELATED
COMPCNENTS.
DEVELOPE A COMPUTER PROGRAM FOR DESIGN AND COST ANALYSIS OF FULL-SCALE
LIME/LIMESTONE SYSTEM.
2/76 SYSTEM 696
3/76 SYSTEM 744
** PRObLEMS/SOLUTIONS/COMMENTS
BECHTEL REPORTED THAT THE FACTORIAL TEST PROGRAM, EVALUATING THE PERFOR-
MANCE OF THE LIME/LIMESTONE SCRUBBING SYSTEMS WITH AND WITHOUT MAGNESIUM
ADDITION HAS BEEN COMPLETED. CURRENTLY TESTING IS PROCEEDING ON THE
EVALUATION OF SYSTEM PERFORMANCE AS A FUNCTION OF LOU RESIDENCE TI»ES
C1.5 TO 5.0) MINUTES) IN THE RECYCLE TANKS. IN ADDITION, A FLY ASH-FREE
DUCT IS BEING INSTALLED AT THE TEST FACILITY. THUS ENABLING EVALUATION OF-
SYSTEM PERFORMANCE IN THE ABSENCE OF FLY ASH.
4/76 SYSTEM 720
5/76 SYSTEM 744
350
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fcPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLET AUTHORITY: SHAwNEE KE (COM.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPEPAB1L1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROL-LtMS/SOLUTIONS/COMMENTS
THE TEST tIRECTOR, CECHTEL, PROVIDED THE FOLLOWING INPUT CONCERNING THE
OPERATION OF THE EXPERIMENTAL SCRUBBING SYSTEMS DURING THE REPORT PERIOD.
THE EFFECT OF *GO ADDITION WAS EXPLORED IN BOTH SCRUBBER SYSTEMS. RESULTS
INDICATE KAGNESIUM ION IN THE SCRUBBER SLURRY LIQUOR ENHANCES SCZ REMOVAL
AND CAN DEPRESS SULFATE SUPER SATURATION. IT WAS FOUND THAT THE MAGNESIUM
ION CONCENTRATION HAD TO E>CEED THE EQUIVALENT CHLORIDE ION CONCENTRATION
TO HAVE AN EFFECT ON S32 RIMOVAL.
IN THE TCA UNIT, WITH LIMESTONE SLURRY, S02 REMOVAL WAS INCREASED FROM 75
TO 95X BY INCREASING THE MAGNESIUM ION CONCENTRATION TO 9,000 PPM
IN EXCESS 01 EQUIVALENT EQUAL TO 62 BY WEIGHT OF THE LIMESTONE AD-
DITION RATE. IN THE VENTUR IISPR AY TOMER SYSTEM, WITH LIME SLURRY, SCZ RE-
MOVAL WAS INCREASED FROM 75 TO 90X BY INCREASING THE MAGNESIUM ION
CONCENTRATION TO 2,COO PPM IN EXCESS OF EQUIVALENT CHLORIDE ION. THE MAG-
NESlUM OXIDE ADDITION RATE WAS 2X BY WEIGHT OF THE LIME ADDITION
HATE. BOTH SCRUBBING SYSTEMS OPERATED IN THE SUBSATURATED SULFATE MODE
WHEN MAGNESIUM OXIDE WAS ADDED. INLET SC2 CONCENTRATIONS DURING THE TESTS
AVERAGE Af-PROXIMATELY 3,000 PPM DURING THESE TESTS.
FOLLOWING THE TEST BLOCKS MENTIONED ABOVE, BOTH SCRUBBERS ARE OPERATING
WITH LIME SLURRY SCRUBBING SOLUTIONS, THE TCA SYSTEM ON FLUE GAS CONTAIN-
ING FLY ASH AND THE VENTURI/SPRAY TOWER SYSTEM ON FLY ASH-FREE FLUE GAS.
6/76 SYSTEM 730
7/76 SYSTEM 744
«* PRObLEMS/SOLUTIONS/COMMENTS
EXPERIMENTAL OPERATION OF THE EPA/TVA ALKALI SCRUBBING TEST FACILITY CON-
TINUED DURING THE REPORT PERIOD. BECHTEL, THE TEST DIRECTOR, PROVIDED THE
FOLLOWING INPUT CONCERNING THE OPERATION OF THE PROTOTYPE TEST UNITS.
VEKTURI/SFRAY TOWER SYSTEM: THIS SYSTEM RAN OFF FLY ASM-FREE FLUE GAS
USING A LIME SLURRY SCRUBBING SOLUTION. NO SIGNIFICANT DIFFERENCES IN S02-
REMOVAL, GYPSUM SATURATION AND SULFITE OXIDATION WERE DETECTED (VERSUS
FLY ASH-LADEN FLUE GAS). ONE DIFFERENCE NOTED WAS THE FILTER CAKE SCLIDS
CONTENT WHICH WAS APPROXIMATELY 10* LOWER FOR THE FLY ASH-FREE SLUDGE ">0
TO SOX SOLIDS) VERSUS THE FLY ASH-LADEN SLUDGE 50 TO 60X SOLIDS
IN ADDITION OPERATION IN A LOW RESIDENCE TIME MODE <3 MINUTES) WAS
EXPLORED. SCALE-FREE OPERATION WAS ACHIEVED IN THIS MODE UNDER THE FOLLOW-
ING CONDITIONS: 8X SOLIDS INO FLY ASH) IN THE REC1RCULATED SLURRY,
PH OF THE SCRUBBER LIQUID INLET WAS 8.0, SUPERFICIAL GAS VELOCITY OF 9.4
FT/SEC., AND A TOTAL LIQUID-TO-GAS RATIO (L-G) OF 7.1 GAL/MCF. SOME SCALE
FORMATION OCCURRED WHEN THE SOLIDS CONTENT OF THE REC1RCULATED SLURRY
DROPPED BELOW THE AX LEVEL.
TCA SYSTEM: THIS SYSTEM OPERATED ON FLY ASH-LADEN FLUE GAS USING A LIME
SLURRY SCRUBBING SOLUTION INNOCULATED WITH MAGNESIUM OXIDE. GYPSUM SUBSAT-
URATION OPERATION WAS ACHIEVED UNDER THE FOLLOWING CONDITIONS: MAGNESIUM
ION CONCENTRATION EXCEEDED THE CHLORIDE ION CONCENTRATION BY 2000 FFM,
SUPERFICIAL GAS VELOCITY WAS 12.5 FT/SEC., L/G WAS 5C. THE SCRUBBING SO-
LUTION INLET PH WAS 7.Of AND RESIDENCE TINE WAS 4 MINUTES. THE SO 2 REMOV-
AL EFFICIENCY WAS APPROXIMATELY 90S. WHEN L/G WAS REDUCED TO 37, WHILE
ALL OTHER CONDITIONS REMAINED CONSTANT, SEVERE GYPSUM SCALE FORMATION RE-
SULTED. INCREASING THE EFFECTIVE MAGNESIUM CONCENTRATION TO 430C fff AND
THE SCRUBbER LIQUID INLET PH TO 8.0 DID NOT AMELIORATE THE SCALE PRCBLEH.
PRESENTLY THE VENTURII SPRAY TOWER SYSTEM IS OPERATING ON FLY »SH-fR£E FLUE
GAS WITH MAGNESIUM OXIDE-INNOCULATED LIME SCRUBBING SLURRY.
8/76 SYSTEM 7*4
9/76 SYSTEM 720
*« PRObLEMS/SOLUTIONS/COMMENTS
IN SEPTEMBER AND OCTOBER 1976 THE VENTURI/SPRAY SYSTEM WAS OPERATED WITH
FLY ASH-FREE FLUE GAS USING LIME SLURRY WITH ADDED NGO TYPICAL
TEST CONDITIONS WERE 9.4 FT/SEC SPRAY TOwER 6AS VELOCITY, 21 6AL/MCF
VENTURI L/G, 53 GAL/MCF SPRY TOWER L/G, 8X SLURRY SOLIDS (FLY ASH FREE).
351
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EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAWNEE IOB E ELECTROSTATIC PRECIPITATOR (0.1 TO 0.4
GR/DSCF TO THE SCRUBBER). THE SCRUBBER OUTLET LOADING AVERAGED 0.005
GR/DSCF. THUS, ENTRAINED SLURRY FROM THE N.E. MUST HAVE BEEN LESS TM»N
0.005 GR/DSCF. SIZE DISTRIBUTION DATA ARE STILL BEING ANALYZED. SULFURIC
ACID MIST VALUES MERE APPRCXIHATELY 2 TO 25 PPM AT THE SCRUBBER INLET AND
REMOVALS HAVE BEEN ABOUT 50 TO 75X.
THE REMAIkOlR OF DECEMBER THE VENTURI/SPRAY TOWER SYSTEM WAS DOWN FOR MOD-
IFICATIONS FOR TWO-STAGE OXIDATION TESTING. SEE APPENDIX B FOR A PROCESS
FLOW DIAGRAM.
DURING NOVEMBER THE TCA WAlS OPERATING WITH FLY ASH-CONTAINING FLUE GAS US-
ING LIME SLURRY WITHOUT ADDED MAGNESIUM OXIDE. OPERATING CONDITIONS WERE
12.5 FT/SEC GAS VELOCITY, 50 6AL/NCF L/G, 8.0 SCRUBBER INLET PH, AND 8 TO
15X SLURRY SOLIDS. AT THE !E CONDITIONS THE S02 REMOVAL WAS ABOUT
ecx.
FLY ASH-FREE LIMESTONE TESTS WITHOUT MAGNESIUM OXIDE ADDITION BEGAN ON
THE TCA SYSTEM IN LATE NOVEMBER. TYPICAL OPERATING CONDITIONS WERE 12.5
FT/SEC 6AS VELOCITY, SC GAL/NCF L/G. AND 1.1 TO 1.2 STOICHIOMETRlC RATIO.
AT THE SAME STOICHIOMETRY, THE PH OF TNE FLY ASH-FREE SLURRY WAS C.i TO
0.3 UNITS HIGHER THAN OBSERVED IN PREVIOUS RUNS WITH FLY ASH.
12/76 SYSTEM 744
1/77 SYSTEM 744
** PRObLEMS/SOLUTIONS/COMMENTS
THE VENTURI/SPRAV TOWER SYSTEM HAS BEEN OPERATED IN A TWO-SERIES-SCRUBBER
MODE WITH FORCED OXIDATION SINCE EARLY JANUARY 1977 AFTER SYSTEM MODIFICA-
TIONS TO ALLOW OPERATION OF THE VENTURI AND SPRAY TOWER WITH INDEPENDENT
SLURRY RECIRCULATION LOOPS. SULFITE OXIDATION HAS CARRIED OUT IN AN 8 FT
DIAMETER VENTURI (PRE-SCRUBBER) EFFLUENT HOLD TANK WHICH HAD AN AIR
SPARGER WITH 130-1/8 INCH HOLES IMMERSED IN 18 FT OF SLURRY. THE SPRAY
TOWER (AFTER SCRUBBER) FUNCTIONED AS A PRIMARY S02 ABSORBER.
TYPICAL OPERATION CONDITIONS, USING LIMESTONE SLURRY. WERE 6.7 FT/SEC
352
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EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAUNEE UB (CONT.)
._—. . . PERFORMANCE DATA — - — ...........— —
PERIOD NODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SPRAY TOWtP GAS VELOCITY, 20-30 GAL/MCF VENTURI L/G, 70 GAL/NCF SPR»Y
TOWER L/G 15* SOLIDS (WITH FLY ASH) IN VENTURI REClRCulATED SLURRY. 4.5-5
VENTURI INLET (OXIDATION TANK) PN, AND 11.3 MINUTES OXIDATION TANK RESI-
DENCE TIME (BASED ON 600 GPM SLURRY FLOW TO VENTURI). DURING THESE
TESTS. AVERAGE OVERALL SULIITE OXIDATION RANGED FROM 93 TO 99* AT AIR
STOlCHlOWiTRIC RATIO OF 1.0 TO 4.7 LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED.
CORRESPONtING AVERAGE OXIDATION IN THE SPRAY TOWER RANGED FROM 10 TO 1«
AVERAGE OVERALL LIMESTONE UTILIZATION RANGED FROM 83 TO 961. NO
SCALING WAS EXPERIENCED IN EITHER SCRUBBER. AVERAGE FILTER CAKE SOLIDS
WERE 79 TC 86X BY WEIGHT COMPARED WITH 55 TO 651 WITHOUT FORCED OXIDA-
TION. SuU(,RY SOLIDS SETTLING RATE RANGED 0.5 TO 1.4 CM/MIN, 5 TO 1C TIMES
FASTER THAN THAT FOR UNOXIoiZED SLURRY. FINAL SETTLED DENSITY RANGED
65 TO 8C* SOLIDS COMPARED WITH <> 5 TO 60X FOR SLURRY WITHOUT FORCED OXI-
DATION.
FLY ASH-FREE LIMESTONE TESTING ON THE TCA SYSTEM WAS COMPLETED IN EARLY
FEBRUARY. THE PH OF THE FLY ASH-FREE SLURRY WAS 0.2 TO Q.3 UNITS HIGHER
THAN OBSERVED IN PREVIOUS RUNS WITH FLY ASH. IN ADDITION THE FLY ASH-FREE
SLURRY APPEARED TO HAVE INFERIOR SOLIDS DEWATERING CHARACTERISTICS. FOR
EXAMPLE THE CENTRIFUGE CAKE SOLIDS AVERAGED ABOUT 5CZ COMPARED WITH
ABOUT 6CX FOR SLUDGE CONTAINING FLY ASH.
INTENSIVE FLUE GAS CHARACTERIZATION TESTING WITH LIMESTONE SLURRY ON THE
TCA SYSTEK BEGAN IN EARLY FEBRUARY AND ENDED IN EARLY MAf>CH 1977. PRELIM-
INARY ANALYSIS OF THE DATA SNOWED AN OUTLET MASS LOADING OF 0.4-C.8
6R/DSCF FLY ASH AND 0.02-0.03 GR/DSCF FOR FLUE GAS WITHDRAWN DOWNSTREAM OF
THE ESP. IT WAS ESTIMATED THAT THESE OUTLET MASS LOADINGS CONTAINED ABOUT
3.03 GR/DSCF FLY ASH, 0.02 &R/OSCF RESTRAINED SLURRY SOLIDS AND O.C15
ENTRAINED DISSOLVED SOLIDS (WHEN A CONTINUOUS MIST ELIMINATOR UNDER WASH
WAS USED). THESE VALUES VARY DEPENDING ON THE MIST ELIMINATOR WASH SCHEME
AND GAS FLOW RATE.
2/77 SYSTEM 672
3/77 SYSTEM 7*4
** PRObLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE VENTURI/SPRAY TOWER WAS TESTED WITH LIME SLURRY AND FLY
ASH LADEN FLUE GAS IN A TWO-STAGE SCRUBBER NODE WITH FORCED OXIDATION.
OPERATION WITH LINE WAS SI IILAR TO THE PREVIOUSLY REPORTED LIMESTONE
OPERATION WITH GREATER THAN 951 OXIDATION AT AN AIR STOICHIOMETRIC RATIO
OF 1.S LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED WITH A SIMPLE AIR SPARGED IN
VENTURI HOLD TANK. SLURRY SOLIDS SETTLING RATE VARIED FROM 0.6 TO 1.9 CM/
MIN (A 5 TO 10-FOLD ENHANCEMENT OVER UNOXIDIZED SLURRY) AND FILTER CAKE
SOLIDS RANGED FROM 74 TO 88* (COMPARED TO 4$ TO 60S WITH UN-
OXIDIZED SLURRY).
TWO MAJOR DIFFERENCES BETWEEN LIME AND LIMESTONE WERE OBSERVED IN A TWO-
STAGE FORCED OXIDATION SYSTEM. TO MAINTAIN PH CONTROL IT WAS NECESSARY TO
FEED LIME TO BOTH STAGES. WITH LIMESTONE, FEED ONLY TO THE SECOND STAGE
WAS ADEQUATE. TO MAINTAIN 80* SO? REMOVAL, IT WAS NECESSARY TO OPERATE
WITH A HIGH SLURRY SOLIDS CONCENTRATION IN THE SPRAY TOWER LOOP WITH LINE-
STONE (15X) THAN WITH LIME <6X>, RESULTING IN A TIGHTER WATER
BALANCE WITH LIMESTONE AND INADEQUATE WATER TO FLUSH THE HIST ELIMINATOR.
PRELIMINARY LIMESTONE TYPE AND GRIND TESTS MADE ON THE TCA SYSTEM DURING
MARCH INDICATED THAT $02 REMOVAL IS IMPROVED BY THE USE OF FINER GROUND
LIMESTONE. S02 REMOVAL WITt EOUIVALENTLY GROUND FREDONIA WHITE AND LONG-
VIEW, ALAbAMA LIMSTONES WAS THE SAME. BLtEDSTREAM FORCED OXIDATION TESTS
ARE BEING CONDUCTED WITH A PfNBERTHY ELL-3 INJECTOR IN A CLOSED LOOP
AROUND A faLtED STREAM HOLD TANK. INITIAL TESTS HERE UNSUCESSFUL DUE TO
HIGH PN OF 7 TO 8 IN THE FOLD TANK. BY LOWERING THE HOLD TANK PH TO 5 OR
6, SULFITE OXIDATION UP TO 98Z WAS ACHIEVED.
*/77 SYSTEM 720
** PRObLEMS/SOLUTIONS/COMMENTS
UNIT 10 BCILER WAS SHUT DOWN FOR A SCHEDULED TWO-MONTH MAINTENANCE OUTAGE.
BECAUSE OF THE BOILER OUTAGE. THE SHAWNEE SCRUBBERS DID NOT OPERATE DURING
APRIL AND MAY.
5/77 SYSTEM 744
353
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAUNEE KB (COM.)
------------------------------------------ PERFORMANCE DATA -------------------------- - ------------ ___
PERIOD MODULE AVAILABILITY OPERABILJTY RELIABILITY UTILIZATION t REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
6/77 SYSTEM 720
«* PRObLEMS/SOLUTIONS/COMMENTS
SCRUPBER OPERATION RESUMED ON JUNE 15 AFTER A 1Q-WEEK SCHEDULED MAINTEN-
ANCE OUTALE ON THE BOILER.
THE VENTUfc/SPRAY TOWER SYSTEM CONTINUED TO OPERATED WITH TWO SCRUBBED
STAGES AND FORCED OXIDATION BY MEANS OF AN AIR SPARGING RING IN THE VEN-
TURI HOLD TANK. IN JUNE AND JULY, OPERATION WAS WITH LIME SLURRY AND FLY
ASH-FREE FLUE GAS. THE SYSTEM PERFORMED WELL WITH LITTLE DIFFERENCE FROM
THE PREVIOUS LIME SLURRY TEST BLOCK WHEN THERE WAS FLY ASH IN THE FLUE
GAS. TYPICAL RESULTS WERE ABOUT <97X SULFITE OXIDATION AT AN AIR STC1CHO-
METRY OF 1.6 LB-ATOMS OX YGEN/LB -MOLE SO? ABSORBED AN OXIDATION TANK f>H
OF 5.5. TYPICAL SOLIDS SETTLING RATE WAS ABOUT 2 CM/MIN (AN ORDER OF MAG-
NITUDE BETTER THAN WITH UNOXIDUED SLURRY) AND FILTER CAKE SOLIDS AVER-
AGED ABOUT £02 (COMPARE WITH 45 TO 692 WITH UNOXIDIDED SLURRY).
THE TCA SYSTEM OPERATED WITH FORCED OXIDATION IN THE HOLD TANK ACHIEVED BY
CIRCULATING SLURRY THROUGH AN AIR EDUCTOR. IN JUNE AND JULY, OPERATION WAS
WITH LIMESTONE SLURRY AND FLY ASH IN THE FLUE GAS. SULFITE OXIDATION WAS
POOR IN THE INITIAL TEST (LESS THAN 90X) MAINLY BECAUSE OF INADE-
QUATE AIR/SLURRY CONTACT IN THE HOLD TANK. BY INCREASING AGITATOR SPEED(TO
6k RPM), HOLD TANK SLURRY LEVEL (TO 12 FT) AND DECREASING PH (TO LESS THAN
5.5) IN THE SLURRY TO THE tOUCTOR, SULFITE OXIDATION OF 9GX WAS
CONSISTENTLY ACHIEVED AT A l> AIR S TOIC H I OME TR Y OF ABOUT 4.5 LB-ATOMS
OXYtEN/LB-MOLE S02 ABSORBED. WASTE SOLIDS PROPERTIES WERE ENHANCED -ITU
OXIDATION TO ABOUT THE SAME EXTENT AS OBSERVED IN THE VENTUR I /SPR A V TOWER
SYSTEM. ADDITIONAL TESTING WILL BE DIRECTED TOWARD ACHIEVING 9ox OR BETTER
SOLFITE OXIDATION AT A REDUCED AIR STOICHI OMETRV .
7/77 SYSTEM 744
8/77 SYSTtM 7«4
• • PRObLEMS/SOLUTIONS/CCMMENTS
THE VENTUR1/SPRAY TOWER SYSTEM CONTINUED TO OPERATE UITH TWO SCRUBBER
STAGES AND FORCED OXIDATION USING AN AIR SPARGER IN THE VENTURI HOLD TANK.
OPERATION DURING AUGUST AND SEPTEMBER WAS WITH LIMESTONE SLURRY AND FLUE
GAS UITH LOfc FLY ASH LOADING (FLUE GAS FROM DOWNSTREAM OF THE ESP). THE
SYSTEM PESFORMED WELL AT 4.5 TO 5.0 OXIDATION PH , WITH LITTLE DIFFERENCE
FROM THE PREVIOUS LIMESTONE TESTS WHEN THE FLUE GAS HAD FLY ASH LOADING.
(THE PREVIOUS TESTS HAD BEEN MADE ONLY AT OXIDATION PH OF 4.5 AND 5.0).*
FOR THE AUGUST AND SEPTEMBER TESTS. THE OXIDATION PH WAS FURTHER INCREASED
TO 5.5, APPROACHING THE PH IN THE SPRAY TOWER. THIS CAUSED SOME DIFFICUL-
TIES IN THE OXIDATION PH CONTROL AND WIDER FLUCTUATIONS IN VENTURI AND
SPRAY TOWER LIMSTONE STOI C HOMETR 1C RATIOS. HOWEVER NEAR COMPLETE OXIDA-
TION WAS STILL ACHIEVED AT THE HIGHER PH. TYPICAL RESULTS W£R E BETTER THAN
97* SULFITE OXIDATION AT AN AIR STOICHIOMETRV OF 1.7 ATOMS OXYGEN/
MOLE SC2 ABSORBED AND AN OXIDATION PH OF 5.5. THE FILTER CAKE SOLIDS CON-
TENT AVERAGED BETTER THAN 85X. TESTS WERE ALSO CONDUCTED WITHOUT
THE DESUPERSATURATION TANK IN THE VENTURI SLURRY LOOP AND UITH THE OXIDA-
TION TANK LEVEL DROPPED FROM 18 TO 14 FT WITHOUT ADVERSE EFFECTS.
DURING AUGUST AND SEPTEMBER THE TCA SYSTEM WAS OPERATED MOSTLY IN A TWO-
TANK FORCE OXIDATION NODE USING AN AIR EOUCTOR. THE TCA EFFLUENT (LIME-
STONE SLURRY WITH A HIGH FLY ASH LOADING) WAS COLLECTED IN A SHALL LOW-PH
SLURRY HOLD TANK WHERE LIMESTONE WAS ADDED THUS TAKING ADVANTAGE OF THE
LOW PH SLURRY THROUGH THE AIR EDUCTOR FOR IMPROVED SULFITE OXIDATION AND
HIGH PH SLURRY TO TCA FOR BETTER S02 REMOVAL.
TESTS WERE MADE BOTH WITH THE AIR EDUCTOR MOUNTED ON TOP OF THE EFFLUENT
HOLD TANK WITH DOWNWARD SLURRY DISCHARGE TO THE BOTTOM OF THE TANK. AVER-
AGE SULFITE OXIDATION RANGE FROM 93 TO 98X AT ABOUT 2.5 AIR STOICHICMETRYY
AND 5.2 EI/UCTOR INLET PH. DURING TWO OF THE RUNS MADE IN AUGUST WHEN
THE ROTARY DRUM FILTER WAS USED THE FILTER CAKE SOLIDS CONTENT AVERAGED
85 AND 88 X.
A TEN-DAY RUN WAS MADE IN SEPTEMBER ON THE TCA SYSTEM WITH AUTOMATIC LIME-
STONE FEEt CONTROL BASED ON S TOI CHIOME TR Y. THE LIMESTONE SLURRY FEED RATE
WAS CONTROLLED BY THE FLUE GAS FLOW RATE AND THE INLET SOi CONCENTRATION
THE CONTROL SYSTEM WORKED WELL ACCORDING TO THE SPECIFICATIONS.
354
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAWNEE KB (CONT.)
__. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/77 SYSTEM 744
*« PRObLEMS/SOLUTIOSS/COMMENTS
THE VENTUH/SPRAY TOWER SYSTEM CONTINUED TO OPERATE WITH TWO SCRUBBER
STAGES AMI FORCED OXIDATION IN THE VENTUR1 HOLD TANK. IN OCTOBER, THE FOL-
LOWING IMPROVEMENTS WERE MADE WITH NO SIGNIFICANT DROP IN OXIDATION EF-
FICIENCY HTH SATISFACTORY $02 REMOVAL EFFICIENCY.
THE SPRAY TOWER GAS VELOCITY WAS INCREASED FROM 6.7 TO 9.4 FT/SEC.
THE OXIDATION TANK LEVEL WAS DROPPED FROM 18 TO U FT.
THE AIR SPARGER RING CONTAINING 40 14-INCH DlAM£TtR HOLES, WAS RE-
PLACED WITH A SINGLE 3-INCH DIAMETER PIPE DISCHARGING DOWNWARD AT THE
CENTER OF THE OXIDATION TANK 3 INCHES FROM THE BOTTOM.
WITH AIR DISCHARGED FROM AN OPEN-ENDED PIPE IT MAS APPARENT THAT THE AIR
DISPERSIOK IN THE OXIDATION TANK WAS ACCOMPLISHED MAINLY bV THE TURBINE
AGITATOR FATHER THAN THE STARGER. IN NOVEMBER, A ONE-MONTH RELIABILITY
TEST nAS STARTED ON THE VENTURI/SPRAY TOuER SYSTEM USING FORCED OXIDATION
WITH TWO SCRUBBER STAGES AND LIMESTONE SLURRY WITH HIGH FLY ASH LOADING.
THE FLUE GAS RATE TO THE SCRUBBER SYSTEM yAS VARIED ACCORDING TO THE BOIL-
ER LOAD WHICH RANGED BETWEEN 100 AND 155 HW. TEST CONDITIONS WERE SELECTED
TC MEET THE EPA NEU SOURCE PERFORMANCE STANDARDS OF 1.2 LBS 502 AND 0.1
Lb PARTICLLATE PER MILLION BTU. THIS RUN WAS STILL IN PROGRESS AT THE END
OF NOVEMBER. ON THE TCA SYSTEM, FORCED OXIDATION WITH A SINGLE SCRUHBER
STAGE US1KG AN AIR EDUCTOR yAS DISCONTINUED IN EARLY OCTOBER AFTER A HOLE
ERODED THkOUGH THE EDUCTOR BODY. FORCED OXIDATION TESTING WILL BE RESUMED
IN EARLY DECEMBER AFTER AN AIR SPARGER IS INSTALLED.
IN OCTOBEK-NOVEMBER, A ONE-MONTH RELIABILITY TEST WITHOUT FORCED OXIDATION
WAS CONDUCTED ON THE TCA SYSTEM WITH LIMESTONE SLURRY, FLUE GAS WITH HIGH
FLY ASH LOADING, THREE HOLD TANKS IN SERIES, AND 7.5 INCHES STATIC HEIGHT
OF NIT RILE FOAM SPHERES IN EACH OF 3 BEDS IN THE TCA. GAS RATE TO THE
SCRUBBER WAS VARIED WITH BOILER LOAD AND STOICHIOMETR1C RATIO WAS CON-
TROLLED BY AN AUTOMATIC LIMESTONE FEED SYSTEM. CONDITIONS WERE SELECTED TO
MLET THE EPA NEW SOURCE PERFORMANCE STANDARDS AT A LOW STOICHIOMTRIC RATIO
OF 1.2 MOLES CA/MOLE S02 ABSORBED. THE AVERAGE S02 REMOVAL FOR THE ENTIRE
RUN WAS 3t* AT 2800 PPM WHICH WAS BETTER THAN THE 8 3X RE-
QUIRED TO MLET THE EMISSIONS STANDARD. HOWEVER, THE STANDARD WAS FREQUENT-
LY EXCEEDED FOR PERIODS GREATER THAN THE 3 HOURS ALLOWED BV THE EPA REGU-
LATIONS. AVERAGE OUTLET PARTICULATE MASS LOADING WAS 0.043 GRAIN/SCF DRV
WHICH MAS BETTER THAN THE 7.052 GRAIN/SCF DRV (AT JCX EXCESS AIR) RE-
QUIRED TO MEET THE STANDARI. THE RANGE OF THE OUTLET MASS LOADING WAS
C.C26 TO C.D69 GRAIN/SCF DRV.
11/77 SYSTEM 723
12/77 SYSTEM 744
** PBObLEMS/SOLUTIONS/COHMENTS
A LIMESTONE RELIABILITY TEST ON THE VENTURI/SPRAV TOWER SYSTEM WAS
COMPLETED IN MID-DECEMBER, 1977 AFTER 965 OPERATING HOURS. THE TEST WAS
CONDUCTED WITH TWO SCRUBBER LOOPS WITH FORCED OXIDATION IN THE FIRST
(VENTURI) LOOP. THE FLUE GAS FLOW RATE WAS VARIED ACCORDING TO THE BOILERD
LOAD WHICH RANGED BETWEEN 100 AND 155 MW.
TEST CONDITIONS WERE SELECTED TO MEET THE EPA NEW SOURCE PERFORMANCE STAN-
DARDS OF 1.2 LB S02 AND 0.1 Lb PARTICULATE PER MILLION BTU. THE OPERATING
RELIABILITY OF THE SYSTEM WAS DEMONSTRATED. HOWEVER, DUE TO WIDE VARIATION
IN THE INLET S02 CONCENTRATION (2500-3400 PPM) AND THE SLOW SYSTEM RE-
SPONSE TIME THE SOZ EMISSION STANDARD WAS FREQUENTLY EXCEEDED FOR PERIODS
GREATER THAN THE THREE HOURS ALLOWED bY EPA REGULATIONS. AVERAGE S02 RE-
MOVAL FOR THE ENTIRE RUN *.S 86X AT 29SC PPM AVERAGE INLET SOZ WHICH WAS
HIGHER THAN THE 84X REQUIRED TO MEET THE STANDARD FOR 28CO PPM INLET
S02. THE OUTLET PARTICULATE LOADING RANGED FROM 0.021 TO 0.063 GRAIN/DRV
SCF, WITH A RUN AVERAGE OF 0.042 GRAIN/DRY SCF. THESE VALUES COMPARE WITH
LOADING OF C.052 GR/DRY SCF OR LESS REQUIRED TO MEET THE EPA PARTICULATE
STANDARD, ASSUMING 30X TOTAL BOILER EXCESS AIR.
ANOTHER RELIABILITY RUN ON THE VENTURI/SPRAY TOWER SYSTEM WAS STARTED IN
MID DECEMBER USING LIME SCRUBBING. THE RUN WAS COMPLETED IN JANUARY 1978.
WITH THE EXCEPTION OF HIGHER SPRAY TOwER INLET PH AND HIGHER ALKALI UTIL1-
355
-------
EPA UTILITY FGD SURVEY: FOURTH OUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAMNEE KB (CONT.)
........ . . . -PERFORMANCE DATA--- — - — -______
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
ZATION INHERENT WITH THE LIME SYSTEM, THE OPERATING CONDITIONS AND THE
TEST RESULTS WERE SIMILAR TO THOSE OF THE LIMESTONE RELIABILITY RUN.
Oh THE TCA SYSTEM, TWO RUNS WERE MADE WITH THE NIT RILE FOAM SPHERES RE-
Pi.ACED BY A 46 INCH HEIGHT (23 LAYERS) OF CEILCOTE PACKING SUPPORT PLATES
AT FULL GAS FLOW RATE OF 3C.COO ACFM, THE S02 REMOVAL FOR THE CEItCCTE *
PLATES WAS SLIGHTLY LESS THAN THAT OF A 3-BED, 4-GR1D TCA WITH FIVE INCHES
Of STATIC SPHERE HEIGHT PER BED. HOWEVER, AT 1P.OOO ACFM THE S02 REMOVAL
FCR THE CEILCOTE PLATES WAS A FEW PERCENTAGE POINTS HIGHER THAN THAT EX-
PERIENCED WITH THE TCA BEDS.
FORCED OXIDATION TESTS WERE CONDUCTED ON THE TCA SYSTEM WITH AN AIR SPARG-
ER USING LIMESTONE SLURRY WITH HIGH FLY ASH LOADING. BOTH ONE-TANK CAUSING PRO-
BLEMS IN SYSTEM CONTROL.
TCA WAS OPERATED HITH BOTH LIME AND LIMESTONE AND WITH MEGNESIUM OXIDE AD-
DITION. FLUE GAS WITH HIGH FLY ASH LOADING WAS USED. THESE TESTS HERE CON-
DUCTED PRIMARILY TO RESOLVE SOME OF THE INCONSISTENT RESULTS OBTAINED
DURING EARLIER LIME/MGO AND LIMESTONE/M&O TEST MADE IN APRIL NOVEMBER
1976. AIR LEAKAGE THROUGH THE SCRUBBER DOWNCONER WAS SUSPECTED IN SOME
OF THOSE EARLIER RUNS, RESULTING IN HIGHER-THAN-NORMAL SULFITE OXIDATION
AND GYPSUM SATURATION. TEST RESULTS SO FAR HERE INCONCLUSIVE BECAUSE OF
THE FLUTUATION IN INLET S02 AND CONTROL PROBLEMS MENTIONED ABOVE.
3/78 SYSTEM 744
4/78 SYSTEM 720
*• PRObLEMS/SOLUTIONS/COMMENTS
THE VENTURI/SPRAY TOWER SYSTEM CONTINUED TO OPERATE THROUGH EARLY MAY UITU
MGO ADDITION AND WITH TWO SCRUBBER LOOPS. THE SYSTEM WAS OPERATED WITH
LIMESTONE SLURRY AND WITH HIGH FLY ASH LOADING. MGO WAS ADDED TO THE SPRA*
TOWER SLURRY LOOP TO MAINTAIN AN EFFECTIVE M6++ ION CONCENTRATION OF SOOn
PPM (ABOUT 8000 PPM IN THE VENTUR1 SLURRY LOOP) TO IMPROVE THE S02 RENOWAi
EFFICIENCY IN THE SPRAY TOWER. OXIDATION WAS FORCED IN THE VENTURI SLURRY
HOLD TANK. UNDER TYPICAL OPERATING CONDITONS, THE OVERALL S02 REMOVAL u«
96* AT 23CO PPM INLET S02 CONCETRATION, COMPARED TO 86*
REMOVAL AT 1600 PPM INLET S02 WITHOUT MGO ADDITION. S02 REMOVAL BY VENTUII
ALONE MAS JOX, ABOUT THE SAME AS THE CASE WITHOUT MGO ADDITION.
356
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: SHAWNEE KB (CONT.)
_._ . PERFORMANCE DATA — ——-— — •"
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
NEAR COMPLETE SULFITE OXIDATION COULD BE ACHIEVED AT AN
AIR STOICHIOMETRIC RATIO AS LOW AS 1.3 ATOMS OXYGEN/MOLE OF S02 ABSORBED,
IN THE SAhE ORDER AS THE CASE WITHOUT MGO ADDITION.
FORCED OXbATION WAS ALSO CONDUCTED ON THE LIMESTONE SLURRY BLEED STREAM
FROM THE VENTUH1/SPRAY TOWER SYSTEM. A SINGLE EFFLUENT HOLD TANK WAS USED
FOR eOTH VEkTURI AND SPRAY TOWER. MGO WAS ADDED TO THE EFFLUENT HOLD TANK
TO MAINTAIN AN EFFECTIVE MG + + ION CONCENTRATION OF 5000 PPM. A SLURRY
STREAM WAS TAKEN FROM THE SCRUBBER DOWNCOMER AND SENT TO AN OXIDATION TANK
INTO WHICH AIR WAS SPARGED- A RECYCLE STREAM OF ABOUT 30 GPM WAS SENT BACK
FROM THE CXIDAT10N TANK TO THE EFFLUENT HOLD TANK TO CONTROL PH IN THE
OXIDATION TANK AND TO PROVIDE GYPSUM SEEDS IN THE SCRUBBER SLURRY FINAL
SYSTEM BLEED WAS WITHDRAWN FROM THE OXIDATION TANK. AT AVERAGE OXIDATION
TANK PH OF 6, SULFITE OXIDATION AVERAGED 982. FILTER CAKE SOLIDS
CONTENT WAS 85Z, SIMILAR TO THAT OBTAINED WITH TWO SCRUBBER 1001
OPERATIONS. HOWEVER. THE SLURRY SOLIDS SETTLING RATE *AS ONLY ABOUT 0.4
CH/M1N, COMPARED TO ABOUT '(.8 CM/MIN FOR THE TWO LOOP OPERATION. SETTLING
RATE FOR LNOXIDIZED SLURRY CONTAINING MAGNESIUM ION NORMALLY DID NOT EX-
CiEO C.1 CH/M1N WITH 50 TO 60Z FILTER CAKE SOLIDS.
TCA CONTINUED TO OPERATE WITH MGO ADDITION WITH BOTH LIME AND LIMESTONE
SCRUFblNG. FLUE GAS WITH HIGH FLY ASH LOADING WAS USED. THE INTENT OF THEE
TESTS -*S TO CLARIFY SOME OF THE INCONSISTANT RESULTS OBTAINED DURING
EARLIER RLNS MADE IN APRIL-NOVEMBER 1976, DURING WHICH SCRUBBER DOWNCOMER
AIR LEAKAGE WAS SUSPECTED IN SOME OF THE TESTS. IN GENERAL, TEST RUNS MADE
Ik 1976 HAD HIGHER S02 CONCENTRATION, MOSTLY GREATER THAN 3000 PPM. WHILE
THE RECENT RUNS HAD ONLY ABOUT 2500 PPM. AT THE HIGHER INLET SO 2 AND THE
HIGHER RESULTANT S02 MAKE-PER-PASS, THE 1976 TESTS OPERATED EITHER UNSATU-
RATED OR SUPERSATURATED WITH RESPECT TO GYPSUM, DEPENDING ON THE SULFITE
OXIDATION LEVEL. SEVERE GYPSUM SCALING OCCURRED WHEN THE OPERATION »AS
UNDER GYPSUM-SATURATED MODE. IN THE RECENT RUNS, OPERATION WAS MOSTLY
UNDER GYPSUM-SATURATED MODE. HOWEVER, BECAUSE OF THE LOWER INLET SOi AND
LOWER S02 MAKE-PER-PASS, THE GYPSUM SATURATION LEVELS WERE NOT HIGH ENOUGH
TO CAUSE ANY SIGNIFICANT SCALING.
5/78 SYSTEM 744
6/78 SYSTEM 72C
*• PfiOULEMS/SOLUTIONS/COMMENTS
FORCED OXIDATION FEED STREAM FROM THE VENTURI/SPRAY TOWER SYSTEM
CONTINUED THROUGH MID-JUNE. TWO TEST RUNS WERE HADE IN WHICH M60 WAS
AUDED TO MAINTAIN AN EFFECi IVE MG«« CONCENTRATION OF 5000 PPM IN THE
SCRUL-BER SLURRY AND NO RECYCLE STREAM WAS SENT BACK FROM THE OXIDATION
TANK (8 FT DIAMTER AND 18 FT TANK LEVEL) TO THE EFFLUENT HOLD TANK. AV-
EHAGE SULFITE OXIDATION WAS ?6% OR HIGHER AT AN AIR STOICHIOMETRIC RATIO
OF 1.6 ATCMS OXYGtN/MOLE S02 ABSORBED. THE OXIDATION TANK PH WAS 5.* TO
5.6 ONLY L.i UNITS HIGHER THAN THE EFFLUENT HOLD TANK PH. THE FILTER CAKE
SCLIDS bAS £5Z AND THE SOLIDS SETTLING RATE WAS C.4 TQ 0.5 CM/MIN.
BOTH SCRUlBtP SYSTEI-S WERE SHUT DOWN FOR TWO WEEKS FROM JUNE 19 DUE TO A
BOILER OUTAGE SCHEDULED FOR RE-ROUTING THE FLUF GAS DUCT FROM THE 8
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 19?9
TENNESSEE VALLEY AUTHORITY: SHAWNEE He
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEfiABILlTY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROdLEMS/SOLUTIONS/COMMENTS
TESTING WITH ADIPIC ACID AS ADDITIVE FOR IMPROVING SOi REMOVAL EFFICIENCY
CONTINUED THROUGH AUGUST AND SEPTEMBER. BOTH VENTUR1/SPRAY TOMER AND TCA
SYSTEMS WIRE OPERATED ON LIMESTONE SLURRY WITH HIGH FLY ASH LOADING DURING
THIS PERICD. THE TCA WAS OPERATED WITHOUT FORCED OXIDATION AND THE vENTURI
SFRAY TOWER WITH TwO-SCRUBEER-LOOP FORCED OXIDATION. AS IN THE LIME TESTS
WITH ADIPIC ACID ADDITION CONDUCTED IN JULY SIGNIFICANT IMPROVEMENT IN SO?
REMOVAL EFFICIENCY MAS ALSO OBSERVED IN THE LIMSTONE TESTS. UNDER TYPICAL
OPERATION, S02 REMOVAL HIGHER THAN 90i COULD BE ACHIEVED BY THE
VENTUR I/SPRAY TOWER WITH i bOUT 2100 PPI« AND 15JO PPM ADIFIC ACID IN THE
VENTURI AKD SPRAY TOWER RESPECTIVELY. UNDER THE SHOE. OPERATING CONOITONS
bUT WITHOLT ADIPIC ACID, T FE SOZ REMOVAL WAS ONLY 57X. THE SULFlTE
OXIDATION EFFICIENCY AND WASTE SLUDGE DEWATERING PROPERTIES DID NOT APPEAR
TC BE AFFECTED BY THE PRESENCE OF ADIPIC ACID.
IN THE TCA, HIGHER THAN 9} I S02 REMOVALS WERE OBTAINED UITH 750 TO
15C3 PPM ADIPIC ACID COMPARED TO 7U REMOVAL FOR A BASE CASE RUN
WITHCU T ADIPIC ACID.
IK BCTH SCRUBBER SYSTEMS THE PH IN THt SCRUBBER SLURRY NEEDS TO PE H1GHEPR
THAN ABOUT 5.j, THE UPPER PH BUFFER POINT OF ADIPIC ACID, FOR THIS
ADDITIVE TO BE FULLY EFFECTIVE.
DETERIORATION OR DECOMPOSITION OF ADIPIC ACID APPARENTLY TAKES PL ACt IN
THE SCRUDIER. ACTUAL FEED RATES OF ADIPIC ACID WERE 2 TO 3 TIMES HIGHER
THAN COULt E:E ACCOUNTED FOR IN THt SYSTEM DISCHARGE SLUDGE.
9/78 SYSTEM 720
10/78 SYSTEM 74*
•• PRObLEMS/SOLUTIONS/CCMMENTS
A ONE MONTH LONG-TERM RELIABILITY RUN WAS CONDUCTED ON E-OTH THE VENTURI/
SPRAY TOWtR AND TCA SYSTEMS USING LIMESTONE SLURRY WITH AOIPIC ACID AS AN
ADDITIVE FCh ENHANCING S^i REMOVAL EFFICIENCY. STEADY-STATE S02 REMOVAL
IN BOTH RLNS WAS CONSISTANTLY HIGH IN THE RANGE OF 96 TO 90* UNDER
TYPICAL OPERATING CONDITIONS. THE VENTURI/SPRAY TOWER SYSTEM WAS OPERATED
WITH TwO-SCRUbBER-LOOP FORCED OXIDATION. ADIPIC ACID CONCENTRATIONS WERE
15CO PPM IN THE TCA AND THE SPRAY TOWER, AND 2400 PPM IN THE VENTURI. BOTH
SCRUEdER SYSTEMS OPERATED -FREE OF SCALING AND PLUGGING.
LONG-TERM TESTS BEGAN IN MID-NOVEMBER TO COMPARE CONVENTIONAL LIME SCRUB-
BING «ITH ADVANCED LIMSTONE SCRUBBING USING CHEMICAL ADDITIVES AND FORCED
OXIDATION. EACH TEST WILL LAST ONE MONTH OR LONGER. THE VENTURI/SPR AY TOW-
ER SYSTEM is BEING OPERATED WITH TWO-SCRUBBER-LOOP FORCED OXIDATION AND
LIMESTONE SLURRY AND ADIPIC ACID ADDITION. THE TCA SYSTEM IS BEING CPERAT
ED WITH L1«E SLURRY (NO ADDITIVES) AND WITHOUT FORCED OXIDATION. DURING
THESE TESTS CONTINUOUS 502 EMISSIONS MONITORING PROCEDURES WILL EE
ASSESSED.
11/78 SYSTEM 720
12/78 SYSTEM 744
•* PRObLEMS/SOLUTIONS/CCM*ENTS
LONG-TERM TESTS ON IOTH SCRUBBER SYSTEMS. WHICH BEGAN IN MID-NOVEMBER 1V7£
WERE COMPLETED NEAR THE END OF JANUARY 1979. THESE TESTS WERE CONDUCTED
TO COMPARE CONVENTIONAL LIME SCRUBBING WITH ADVANCED LIMESTONE SCRUBBING
USING CHEMCAL ADDITIVES AND FORCED OXIDATION. THE V EN TURI/S PR AY TOWER
WAS OPERATED WITH Tk. 0-SC RUBBE R-LOOP FORCED OXIDATION AND WITH LIMESTONE
SLURRY ANI ADIPIC ACID ADDITION. THE TCA SYSTEM WAS OPERATED WITH LIME
SLURRY (Nt AD&ITIVE) AND WITHOUT FOKCED OXIDATION. DURING THESE TESTS
CONTINUOUS S02 EMISSIONS MONITORING PROCEDURES WERE ASSESSED.
1/79 SYSTLM 74<(
2/79 SYSTEM 67i
3/79 SYSTEf 744
353
-------
tPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
TENNESScE VALLEY AUTHORITY: SnAwNEE KB (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROuLcMS/SOLUTIONS/COMMENTS
ONE TEST RUN WAS CONDUCTED ON EACH OF THE TWO SCRUBBER SYSTEMS IN
EAkLY FE6PLAKY TO PROVIDE SAMPLES FOR LEVEL 1 BIOASSY TESTING BY LITTON
niCNETICS CORPORATION UNDER CONTRACT UI1TH EPA. ACTUAL SAMPLING OF SLUR-
RIES AND CONDENSATES FROM THE SCRUBBER AND OXIDATION TANK OFF-GASES WAS
PERFORMED LY BATTELLE COLUMBUS LABORATORY. fOR THIS PURPOSEt THE TCA WAS
OPERATED WITH LiNESTONE/FLY ASH SLURRY AS A BASE CASE, AND THE VENTURI/
SPRAY TOwEF. WAS OPERATED WITH LIME STONE If LYASH SLURRY AND WITH ADIPIC
AClb ADDITIVE AMD TWO-SCHUBbER-LOOP FORCED OXIDATION.
A SERIES OF TESTS WAS CONDUCTED ON THE VENTURI/SPRAY TOWER SYSTEM FROM
MID-FEBRUAfcY THROUGH THE END OF MARCH TO SIMULATE THE PLANNED TV A WIDOWS
CRtEK INIT 8 FULL-SCALE, TUO-SCRUPBER-LOOP FORCED-OXIDATION SCHEME.
SPECIAL WIDOWS CREEK LIMESTONE (STONEMAN) AND COAL (PITTSBURGH MIDWAY)
WERE USED AT SHAWNEE DURING THESE TESTS. NEAR COMPLETE SULFITE OXIDATION
WAS ACHIEVED AT OXIDATION TANK PH UP TO 6.0 AND AN AIR STOICHIOMETRY AS
LO. AS 1.5 ATOMS OXYGEN/ MOLE S0< ABSORBED. EXPECTED SLURRY CARRY-OVER
F"CM THE FIRST TO THE SECOND SCRUBBER LOOP AT WIDOWS CREEK WAS SIMULATED
(,Y AN ARTIFICIAL BACKM1X STREAM OF UP TO 65 GPM.
A NEW LIWt/ADIPIC ACID TEST BLOCK WITH AND WITHOUT FORCED OXIDATION
[j£l>AN IN EARLY FEBRUARY ON THE SINGLE-LOOP TCA SYSTEM USING FLUE GAS WITH
HIGH FLYASh LOADINGS. AT TCA INLET PH OF 7.0, 24QO TO 2900 PPM INLET SC2,
L/0 OF 5C GAL/ MCF, AND 15 INCHES TOTAL STATIC BED HEIGHT OF 1-7/8 INCH
HITRILE FOAW SPHERES, S02 REMOVALS WERE 63, 93, AND 97 PERCENT WITH ZERO,
£?C. AND 1iOO PPM ADIPIC ACID, RESPECTIVELY, WITHOUT FORCED OXIDATION.
Sri REMOVAL REMAINED HIGH AT 91 PERCENT WITH 1200 PPM ADIPIC ACID WHEN L/G
•AS REDUCED FROM 50 TO 37 GAL/MCF. WHEN OXIDATION WAS FORCED WITH AfaOUT
1.c AIR STCICHIOMETRY, NEAR COMPLETE SULFITE OXIDATION WAS ACHIEVED AT
OXIDATION TANK PH (TCA INLET PH) UP TO ABOUT 5.5, AND 1200 PPM ADIPIC
ACID. SC; REMOVAL ABOVE 90 PERCENT WAS OBTAINED AT TCA INLET PH AS LOW
AS 5.C WITH FORCED OXIDATION.
4/79 SYSTEM 720
5/79 SYSTEM 744
** PROuLEMS/SOLUTIONS/CCMNENTS
A SERIES OF BLEED STREAM OXIDATION TESTS USING LIMESTONE AND ADIPIC
ACID WAS CCNDUCTED ON THE VENTURI/SPRAY TOWER DURING THE MONTH OF APRIL.
NEAP COMPLETE SULFITE OXIDATION WAS ACHIEVED UNDER CONDITIONS OF EITHER
LO. FLUE GAS THROUGHPUT, WHICH RESULTED IN LOW BLEED RATES AND SUBSEQUENT-
LY HIGHER RESIDENCE TIMES IN THE OXIDATION TANK, OR RECIRCULAT ION AT
LlwUOR HACK TO THE EFFLUENT HOLD TANK WHICH ARTIFICIALLY MAINTAINED A LOW
PH IN THE OXIDATION TANK.
DURING THE MONTH OF APRIL, THE TCA WAS OPERATED WITH LIMESTONE, ADIPIC
ACID AND FORCED OXIDATION USING A SINGLE TANK. AT AIR STOICHIOMETRIC
RATIOS OF 1.7-2.3 ATOMS OXYGEN/MOLE S02 ABSORBED, AN UNUSUAL SET OF CON-
DITIONS WAS ENCOUNTERED DURING WHICH THE LIQUID SULFITE ION LEVEL IN-
CREASED TO A RANGE OF 800 TO 1700 PPM AND THE DEMAND FOR LIMESTONE TC
MAINTAIN THE SCRUBBER INLET PH AT 5.1 INCREASED TO A RANGE OF 1.8 TO 4.C
MOLES LIMESTONE/MOLE S02 ABSORBED. THt CAUSE HAS NOT YET BEEN DETERMINED
ALTHOUGH IT WAS FOUND THAT THE SITUATION COULD BE ALLEVIATED BY EITHER
INCREASING THE AIR STOICHIOMETRY TO GREATER THAN 2.2, OR BY MOVING THE
LIMESTONE FEED TO A SECOND TANK DOWNSTREAM OF THE OXIDATION TANK.
BOILER NO. 10 WENT DOWN ON MAY 5TH FOR A SCHEDULED 6 WEEK BOILER CUT-
AGE. DURING THIS PERIOD, THE VENTURI/SPRAY TOWER WILL BE DOWN BUT THE
TCA IS BEING OPERATED ON FLUE GAS FROM BOILER NO. 9 THROUGH THE NEWLY IN-
STALLED DUCT. DURING THIS PERIOD, THE TCA WILL COMPLETE A SERIES OF
LIMESTONE/ADIPIC ACID FACTORIAL TESTS WITH AND WITHOUT FORCED OXIDATION.
6/79 SYSTEM 720
7/79 SYSTEM 744
3/79 SYSTEM 744
9/79 SYSTEM 720
359
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENMSSEE VALLEY AUTHORITY: SHAhNEE 1CB (CONT.)
PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERARILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
** PfiOcLEMS/SOLUTIONS/COMMENTS
BOILER NO. 1C MAS RESTARTED ON JULY 6, 1979 AFTER NINE WEEKS OF SCHEDULED
MAINTENANCE OUTAGE.
LIMESTONE FACTORIAL TESTING WITH ADIPIC ACID ADDITION ON THE VENTUR1/SPRAY
TObER SYSTEM CONTINUED THROUGHOUT THE THIRD QUARTER. THESE TESTS MERE
MADE WITH TWO-LOOP OPERATION WITH FORCED OXIDATION AND SPRAY TOWER ONLY
OPERATION blTHOUT FORCED OXIDATION, bOTH UNDER CLOSED-LOOP CONDITIONS.
OPEN-L1QUOR-LOOP TESTS WITH TWO-LOOP OPERATION AND WITHOUT FORCED OXIDATION
WERE ALSO CONDUCTED TO COMPARE THE RESULTS WITH "FRESH" ADIPIC ACID
AGAINST THOSE WITH "AGED" ACID OBTAINED UNDER CLOSED-LIOUOR-LOOP
CONDITIONS.
DURING THE THIRD QUARTER, ADDITIONAL LIMESTONE FACTORIAL TESTS WITH
ADIPIC ACID bERE CONDUCTED ON THE TOA SYSTEM TO SUPPLEMENT THOSE MADE IN
MAY AND JUKE. IN ADDITION. A SERIES OF LIMESTONE TESTS WITHOUT ADIPIC
ACID WERE FERFORMED USING A SINGLE TANK TO INVESTIGATE THE EFFECT OF AIR
STGICHIOMETRY AND OXIDATION TANK AGITATOR SPEED ON SULFITE OXIDATION. IN
A SIMILAR SERIES OF TESTS CONDUCTED IN APRIL BUT WITH ADIPIC ACID, AN
UNUSUAL SET OF CONDITIONS W 13 ENCOUNTERED WHICH GAVE HIGH LIQUOR SULFITE
CONCENTRATION (800-1700 PPM) AND DEMANDED HIGH LIMESTONE STOICHIOMETRV
(1.8-4.C MCLES CA/HOLE S02 /BSORBED) TO MAINTAIN A SCRUBBER INLET PH OF
5.1. THESE PHENOMENA HERE ALSO OBSERVED DURING TESTS WITHOUT ADIPIC ACID
INSUFFICIENT SULFITE OXIDATION RATE (CAUSED BY REDUCED AIR STOHMIOMETRY *
AND/OR REDUCED AGITATION IN THE OXIDATION TANK) AND DECREASED AMOUNT Of
SOLID CASC3 SEEDS WERE BELIEVED TO CAUSE HIGH SULFITE SUPERSATURAT ION
(HIGH SULFITE CONCENTRATIONS) AND THE RESULTANT BLINDING OF LIMESTONE BY
SULFITE (HIGH LIMESTONE STOICHIOMETRY).
10/79 SYSTEM 744
11/79 SYSTEM 72C
12/79 SYSTEM 7**
•• PRObLEMS/SOLUTIONS/COMMENTS
THE TRAP-OUT FUNNEL, WHICH HAD BEEN INSTALLED EARLIER IN THE SPRAY TOWER
TO SEPARATE VESTURI AND SPRAY TOWER SLURRIES FOR TWO-SCRUBBER-LOOP OPERA
TION. HAS REMOVED IN EARLY OCTOBER.
THE SYSTEM WAS OPERATED THRCUGHOUT THE FOURTH QUARTER IN A CONVENTIONAL
MODE IN WHICH THE VENTURI AND SPRAY TOWER USED A COMMON HOLD TANK. ADDI-
TIONAL FACTORIAL TESTS WERE CONDUCTED IN THIS NODE OF OPERATION THROUGH
MID-DECEMBER USING LIMESTONE/ADIPIC ACID SLURRY WITHOUT FORCED OXIDATION
A NEW TEST BLOCK WAS INITIATED IN MID-DECEMBER TO OPTIMIZE THE LEVELS Or*
PH AND ADIPIC ACID CONCENTRATION AT A DESIRED DEGREE OF S02 REMOVAL bITH
LIMESTONE SCRUBBING AND WITHOUT FORCED OXIDATION. IT HAS BEEN OBSERVED
THAT THE DECOMPOSITION RATE OF ADIPIC ACID IS DECREASED WITH REDUCING PH.
THE TESTlNb ON THE EFFECTS OF AIR STOICHlOHETRt AND OXIDATION TANK AGITATA.
SPEED ON SULFITE OXIDATION WAS CONCLUDED ON THE TCA SYSTEM IN "ID-OCTOBM
THE TCA SYSTEM WAS TEMPORARILY TRANSFERRED TO TVA/UOP EPRI IN MID-OCTOBEI
FOR THE DEMONSTRATION OF THE DOWA BASIC ALUMINUM SULFATE SCRUBBING PROCESS
360
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PL AM NAKc
UNI T NUI'cEB
CITY
STATE
REGULATORY CLASSIFICATION
PAKTUULAU EMISSION LIMITATION - NG/J
SOi EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY -Ml,
NET UNIT GENERATING CAPACITY b/FGD - MU
NET UNIT GENtRATING CAPACITY WO/FG& - MW
EQUIVALENT SCRUBBED CAPACITY - KW
•* BOILEH DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
NAXIKUI-i U01 LED FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - c
STACK HEIGHT - «
STACK TOP DIAME TER - "
• * FUEL DATA
FUEL TYPc
FUEL GKAuE
AVERAGE HEAT CONTENT - j/t
RANGE HEAT CONTENT - I TU/LB
AVERAGE ASH CONTENT - i
RANGE ASn CONTENT - ''.
AVERAGE MOISTURE: CONTENT - *
RANGE MOISTURE CONTENT - %
AVERAGE SULFUR CONTENT - X
MANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - ?.
** ESP
NUMBER
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY
• * PARTICIPATE SCRUBI-.EH
NUMBER
TVPE
SUPPLIER
NUMBER OF STAGE S
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERI AL
BOILER LOAD/SCRULBtR - X
FLUE GAS CAPACITY - cu.n/s
FLUE GAS TEMPERATURE - c
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
PAHTICULATE INLET LOAD - G/CU.>
PARTICIPATE OUTLET LOAD - G/CU.r
PAHTICULATE DESIGN REMCVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - Z
** FGD SYSTErt
SALEABLE PRODUCT/THROWAUAY PROCUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK
BRIDGEPORT
ALABAMA
E
5?.
516.
( .120 LB/MMBTU)
( 1.200 LB/MMBTU)
550.0
516.0
5*2.0
550.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/63
755.04 41600000 ACFM)
137.8 { 280 F)
****** (««•• fj)
******* (**«** Ft)
COAL
******
23263.
25.00
< 1GOOO BTU/LB)
******
1C.00
** * ** *
3.70
******
KOPPfRS
5C.O
4
VENTURI
TVA/POLYCON
1
J16L SS
NONE
NONE
25.C
18 (.8
137.8
1.3
*******
12.6
.1
99.5
344C.OOO
ir.o
< 4COOOO ACFn)
( 28C F>
MC.O GAL/1COOACF)
(***** IN-H20)
( 5.5Q GR/SCF)
( .030 GR/SCF)
THROUAUAV PRODUCT
WET SCRUBBING
LIMESTONE
NONE
TENNESSEE VALLEY AUTHORITY
NONE
TENNESSEE VALLEY AUTHORITY
FULL SCALE
RETROFIT
361
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: ulDOUS CRiEK 3 (CCNT.)
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - 1
COMMERCIAL DATE
INI TIAL STAHT-U P
CONSTRUCTION INITIATION
CONTRACT AuAKDE D
ABSORBER SPARE CAPACITY INDEX - *
ABSORBER SPARE COMPONENT INDEX
AbSORbER
NUMPER
TYPE
INITIAL START U P
SUPPLIER
NUMBER OF STAGE S
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
faOlLEC L^AD/ARSORBEH - X
L/6 RATIO - L/C U.M
PRESSURE DROP - KPA
SUPEHFKAL GAS VELOCITY - M/SEC
PARTICULATE OUTLET LOAD - N6/J
S02 CUTLET CONTRATION - PFM
S02 DESIGN REMOVAL EFFICIENCY - X
AbSORBEh
NUMB ER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
BOILER LOAD/ABSORBER - X
GAS TEMPERATURE - C
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
PARTICULATE OUTLET LOAD- G/CU.K
S02 CUTLtT CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
1/7;.
5/77
2/7'
2/72
'.OO
.C
1
GRID/MOblLr PACKED TOwER
5/77
POLYCON
c
30 WIDE X 1o DEEP X 3*. HIGH
CA"BON STEEL, 316L SS ON SLOPING SECTION
RUBBER, EXCEPT ON SLOPING SECTION
316L SS GRIDS CTOP Zl ; FRP [BOTTOM
3]
25.:
8.0
.5
3.7
( 60.0 GAL/KOtACF)
( 2.0 lN-H2o)
( 1 2 . <"• F T / S )
( .020 LP/KMBTU)
GRID TOWER
5/77
POLYCON
c
30 WIDE X 16 DEtP X 3<. HIGH
CARBON STEEL, 316L SS ON SLOPING SECTION
RUBBER, EXCEPT ON SLOPING SECTION
316L 35 GRIDS [TOP 23; FRP [BOTTOM i3
25.0
5 1.7
.5
7.7
.:•
65"
7C.O
( 125 F)
( 6C.C1 GAL/100CACF)
( 2.j IN-HiO)
( 12.? FT/S)
( .020 GR/SC F >
FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.M/S
MIST ELIMINATOR
NUMB ED
TYPE
CONSTRUCTION MATERIAL
CONF IGURATION
NUMPER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
WASH SYSTEM
SUPERFICIAL GAS VELOCITY -
PRESSURE DROP - KPA
PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
SENSOR LOCATION
"I/S
•* PUMPS
ICE
YENTLR1 KECIRCULATION
PONP RLTjRN
RIVER k-ATEfc TRANSFER
BOILED l.D.
CARBCN STEEL
DRY
1S8.76
CHEVRON
316L SS
VERTICAL
4.27
.30
7.8
CONT 1NUOUS
7.8
.2
I 4:3000 ACFIT)
CU.C FT)
( 1.0 FT)
( 1.5? IN)
< 12.5 FT/S)
< -1.0 IN-H20)
PH, PRESSURE CHANGE, OUTLET SC2
PH-ATSORDLR RECYCLE LINE
NUMBER
3t2
-------
•:PA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENNESSEF. VALLEY AUTHORITY: .ai'O.S (.HE* C tCONT.)
ABSORBtR RtClflC ULATIOf. 12
*« TANKS
SERVICE
AdSORBtR RECYCLE 4
VENTtiRl RECYCLE 4
LlMESTONC SLURRY 1
RECIRC TNK UNDRFLU SURGE TANK 1
** REHEATEh
NUMBER 4
TYPE HOT AIR INJECTION
HEATING MEDIUM STEAM, 650 F AT 500 PS1G
TEMPERATURE bOOSI - C 27.8 t 50 f>
»* REAGENT PREPARATION EQUIPMENT
NUMBER OF IsALL WILLS 1
BALL *1LL CAPACITY- M T/H 36.3 < 4C.O TPH)
** DISPOSAL
NATURE FINAL
TYPE POND
DIMENSIONS 110 ACRES X 30 FT DEEP
AREA - ACRES 110.0
CAPACITY - CU.M 473590: < 3300.D ACRE-FT)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEF-AP1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/77
8A
6R
ae
80
SYSTEM
20.
43.
36.
8.
26.
0
1
7
3
C
22,
45,
41,
9,
3:
,7
.4
.6
.4
.0
20
40
36
8
30.0 26
.0
.1
.7
.3
.0
744 657 196
*• PnOcLEMS/SOLUTIONS/COMMENTS
TVA HAS HAD EXTENSIVE PROBLEMS WITH START-UP OF ITS SCRUBBER FACILITY.
THERE HAVL BEEN EROSION PROBLEMS WITH THE I.D. FAN BLADES.
THE FAN DUVE MOTORS HAVE ALSO BEEN TROUBLESOME.
THE GUILLOTINE DAMPERS ARE INOPERABLE DUE TO JAMMED CEAR BOXES.
THE SEALS AROUND THE DAMPERS HAVE CORRODED, CAUSING LEAKAGE OF THE FLUE
GAS AND PARTICULATE.
THE RUBBEF, LINING IN THE ABSORBER SECTION OF ALL FOUR TRAINS HAS DETACHED
IN VARIOUS PLACES. THE VENDOR HAS REPAIRED THE DEFECTIVE SECTIONS.
INSTRUMENTATION HAS BEEN A SERIOUS PROBLEM AREA.
THE BALL MILL IS ONLY ABLE TO PRODUCE 35 TPH OF LIMESTONE SLURRY OUT OF
IT'S 5C TPH CAPACITY.
9/77 8A 33.3 21.0 17. f
SB 72.7 68.3 57.8
6C 97.4 97.r 82.1
80 98.4 98.2 83.1
SYSTEM 75.0 71.0 71.0 60.0 72G 609 433
** PRObLEMS/SOLOTIONS/COMMENTS
DURING THIS MONTH THE BOILER WAS OPERATED AT A REDUCED LOAD OF ABOUT
3C3 MW. AT THIS REDUCED LOAD, ONLY 3 TRAINS WERE REGUIRED TO HANDLE
ALL OF THE bOILER FLUE GAS.
SOME SCALING WAS DISCOVERED IN THE ABSORBER COLUMN AND ENTRAINMENT
SEPARATOR OUTLET OF ONE TRAIN.
SERIOUS EHOSION PROBLEMS CONTINUE WITH THE I.D. FAN ROTORS.
363
-------
EPA UTILITY FGD SURVEY: fOUHTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK a
— . PERFORHANC i DATA —... .—-.__. --_._
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP."
SO? PART. HOURS HOURS HOURS FACTOR
THE UNIT UENT OFF LINE SEPTEMBER 33 FOR A SCHEDULED OUTAGE TO REPAIR BOIL-
ER TUBES.DURING THE OUTAGE, AN ATTEMPT UILL BE HADE TO CORRECT MANY OF THE
MECHANICAL PROBLEMS.
10/77 SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
11/77
12/77
1/78
.0
744
UNIT 8 WAS OFF-LINE FOR THE ENTIRE MONTH DURING SCHEDULED OUTAGE FCR
REPAIR OF BOILER TUBES, DURING THIS PERIOD, MANY MECHANICAL AND INSTRUMfcN
TAL SCRUBtEfi PROBLEMS WERE CORRECTED.
8«
on
8C
8D
SYSTEM
85.5
8".8
99.8
75.8
83."
66.3
• PhOoLEMS/SOLUTIONS/COMMENTS
88.0
49.:
51.5
57.2
43.5
50.0
72C 413
362
8*
8B
6C
80
SYSTEM
59.3
55.9
58.7
57.7
56.0
98.1
97.9
97. 2
95.3
97.^
THE UNIT hAS BROUGHT BACK IN SERVICE ON NOVEMBER 11 FOLLOWING THE SCHED-
ULED BOILER OUTAGE (AVAILABILITY MAS CALCUATED FROM NOVEMBER 11 THRCUGH
NOVEMBER 3D.
ALL I.D. MNS HAVE BEEN REBUILT IN AN ATTEMPT TO CORRECT THE CORROSION AND
DRIVE MOTOR PROBLEMS.
GAS LEAKAGE FROM THE DAMPERS WAS CORRECTED BY WELDING A COVER PLATE OVER
THE SEAL DOORS. THE VENDOR IS CURRENTLY WORKING ON A NEW DESIGN FOR THE
DAMPE RS.
ALMOST ALL INSTRUMENTATION PROBLEMS CONTINUE TO HAMPER PROPER SCRUBBER
OPERATION.
56.2
56. 0
55.6
54.6
59.0 56.0 744 426 414
PNOULEMS/SOLUTIONS/COMMENTS
THE UNIT kAS OFF-LINE FROM DECEMBER 20 TO DECEMBER 31 FOR REPAIRS OF A
BOILER TUtE LEAK.
DtRiNG THIS OUTAGE, AN INSPECTION WAS MADE OF THE SCRUBBER MODULES.
THE RUBBEft LINER WAS FOUND TO BE HISSING IN SEVERAL AREAS OF ALL FOUR
MODULES AND WAS REPAIRED DURING THE OUTAGE.
6A
8P
8C
8D
SYSTEM
9C.2
86.7
84.6
88.8
88.0
99.3
95.3
92.7
97.9
96.?
96.3
81.9
78.5
76.3
60.6
79.0
744
618
590
*• PROBLEMS/SOLUTIONS/COMMENTS
ALL FOUR SCRUBBER MODULES RETURNED TO SERVICE THIS MONTH FOLLOWING KEPA1A
WCRK ON ThE RUBBER LINER.
THERE HAVE BEEN MINOR PROBLEMS WITH COOLING LINES FREEZING AND BURSTING.
FEED HOPPERS AT THE LIMESTONE STORAGE AREA HAVE BEEN PLUGGING DUE TO FBf»-
EN GRAVEL. "
THE BALL KILL SUMP PUMP LINERS HAVE BEEN WEARING OUT.
SOME PLUGGING OF THE VENTUU SPRAT NOZZLES WAS ENCOUNTERED.
364
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: WIDOWS C*fcEK 8 (CONT.)
PERFORMANCE DATA-— —-— —
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGO CAP.
SO? PART. HOURS HOURS HOURS FACTOR
INSTRUMENTATION CONTINUES TO BE A MAJOR PROblEM WITH OPERATION OF ThE
SCRUbBER.
2/7" 2fc 69.4 68.5 59.7
SC 67.8 63.1 55.0
dO 56.5 53.6 46.?
8A 35.5 3?.3 Z5.5
SYSTiM 55.0 54.D 61.3 47.f c7? 586 314
*• PKOtLEMS/SOLUTIONS/CONKENTS
THE UTILITY COMPANY REPORTED THAT THEY COULD NOT ACCURATELY DETERMINE
RELIABILITY BECAUSE OF THEIR INABILITY TO CALCULATE UNIT LOAD DEMAND ON A
DAILY BASIS. GENERALLY, IT IS ASSUMED THAT SYSTEM FCRCED OUTAGE HOURS PLUS
THE HOURS THE FGD SYSTEM w«s OPERATED WILL GIVE ROUGLY THE HOURS THE SYS-
TLM MAS CALLED UPON TO OPERATE, IN THIS WAV, RELIABILITY CAN BE CALCULATED
INDIRECTLY, HOWEVER, IN THIS CASE, TWO TRAINS AT A TIME HAVE BEEN DOWN ONA
SCHEDULED OUTAGE FOF NECESSARY MODIFICATIONS. PART OF THIS OUTAGE TIME
LIMITED BCILEK OPERATION SO THAT THE UNIT COULD NOT RUN AT FULL LOAD WHEN
THERE 4AS DEMAND FOR A FULL LOAD. FOR THIS CALCULATION IT WAS ASSUPit THAT
THERE WAS A DEMAND FOR FULL LOAD DURING THE ENTIRE OUTAGE SO THAT ALL OF
THE TRAINS hOULD HAVE BEEN CALLED THE ENTIRE SCHEDULED OUTAGE. THE RESULT
WAS A VERY CONSERVATIVE ESTIMATE OF RELIABILITY WHERE HOURS CALLED=SYST£M
FCRCED OUTACE TIME + SYSTEM SCHEDULED OUTAGE TIME * HOURS THE FGD SYSTEM
OPERATED.
NCTt - THIS IS A PEDCO ESTIMATE.
THE OUTAGE TIME FOR TRAINS A AND & WAS REQUIRED TO REPLACE THE RUBBER
LINERS IN THE DOwNCOMER AREA WITH STAINLESS STEEL. THE OTHER TWO TRAINS
WILL RECEIVE SIMILAR TREATMENT.
3/7S 8A 61.9 9:.8 78.6
8P 48.4 53.4 46.2
8C 26.8 33.? 26.7
£0 81.6 9:.5 7S.4
SYSTEM 63.0 66.0 5?.0 58.C 744 644 428
** PRObLEMS/SOLUTIONS/COMMENTS
TRAIN B WAS OUT OF SERVICE MARCH 1 - MARCH 13 TO INSTALL STAINLESS STEEL
IN THE ABSORBER AND VENTURI DOWNCOMER AREAS.
STAINLESS STEEL COVERS WERE INSTALLED AROUND TWO EXPANSION JOINTS ON TRAIN
C IN ORDER TO PREVENT FLUE GAS LEAKAGE.
A STAINLESS STEEL PLATE WAS WELDED OVER THE ENTRY DOOR OPENINGS TO TRAIN C
OUTLET AN I bYPASS GUILLOTINE DAMPERS FOR THE PURPOSE OF ELIMINATING GAS
LEAKAGE.
TRAIN C WAS OUT OF SERVICE MARCH 14 - NARiCH 29 TQ INSTALL STAINLESS STEELE
AbSORDER AND VENTURI DOWNCOMER AREAS.
SEVERAL LIFTER BARS ON THE FEED AND DISCHARGE ENDS OF THE PALL MILL WERE
IN THE FOLND TO BE BADLY WORN.
THE UTILITY HAS HAD WEAR PROBLEMS WITH THE SLURRY SUMP PUMP LINERS AT THE
BALL MILL.
4/78 8A &j.O 88.9 66.6
8B 67.7 85.9 64.4
8C 93.0 1C3.0 83.0
SD 38.1 5C.P 38.1
SYSTEM 69.0 83.C 67.0 62.0 720 540 448
• * PRObLEMS/SOLUTIONS/COMMENTS
DURIFG A b&IEF INSPECTION OF THE SCRUBBING SYSTEM IN EARLY APRIL. SCLIDS
DEPOSITION WAS NOTICED IN THE MIST ELIMINATOR SECTION OF ALL TRAINS DUE TO
PLUGGING THAT HAD OCCURRED IN SEVERAL OF THE HIST ELIMINATOR SPRAY NOZZLES
365
-------
EPA UTILITY FGD SURVEY: FOURTH OUARTEK 1979
TENNESSEE VALLEY AUTHORITY: WlDOtaS IPLEK 8 (CONT.)
PtRFORMANC? DATA
PERIOD MODULE AVAILABILITY GPERAHILiTY RELIABILITY UTILIZATION
X REMOVAL PER bOILER FGD CAp.
SOZ PART. HOURS HOURS HOURS FACTOR
TKAIf. D WAS NOT IN OPERATION FOR 17 DAYS WHILE THE MIST ELIMINATOR *A$
DISASSEMBLED AMD CLEANED.
A STAINLESS STEEL LINER WAS INSTALLED CN THE SLOPING SECTIONS OF THE
AbSOPbER AND VENTURI.
STAINLESS STEEL PLATES WERE INSTALLED OVER TH£ ENTRY DOOR OPENINGS TC
TRAIN D IKLET, OUTLET AND BYPASS GUILLOTINE DAMPERS TO REDUCE GAS LEAKAGE
STAINLESS STEEL COVERS WERE INSTALLED AROUND THE FIVE EXPANSION JOINTS ON
TMIN D, TWO EXPANSION JOINTS ON TRAIN A, AND ONE EXPANSION JOINT ON TRAIfc
!•' TO REDUCE GAS LEAKAGE.
THERE CONTINUES TO L't A WEAR PROt'LEM WITH PUMP LINERS AT THE BALL MILL. NO
CAUSE OR SOLUTION OF THE PROBLEM HAS bEEN ASCERTAINED AS YET.
74*
72 i,
744
744
72 u
744
OLUTIONi/CONMENIS
THE l-OILEF uENT OFF LINE IN EARLY OCTOBER FOR BOILER OVERHAUL. THE UNIT
RESTARTED FOR A FEw DAYS IN DtCEfbEh UNTIL A TURblNE ROTOR PROBLEM
*AS DISCOVERED. THE PROOLEM FORCED THE UNIT OFF LINE THROUGH JANUARY.
721 0 0
744
744 C 0
67i
744
OLUTIONS/COMMENT?
CONSTRUCTUN OF THE FORCED OXIDATION TEST WAS COMPLETED AND THE TESTING
HAS l-EGUN ALTHOUGH t,C RESULTS ARE YET AVAILABLE (THIS TESTING IS BEING
DONE CN ONI OF THE FOUR MODULES).
THt UNIT OITAGE WHICH BEGAN IN OCTOBER AND WAS SCHEDULED TO END IN FEB-
RUARY CONTINUED THROUGH MARCH BECAUSE THERE WERE BOILER AND TURBINE
FAILURES AFTER A FEW START UPS.
72C
5/78
6/7?
7/7S
8/7E
9/7fi
10/78
11/7?
12/78
1/79
2/79
3/79
SYSTtM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
iYSTEM
•• PKOuLEMS/S
SYSTEM
SYSTtM
SYSTEM
SYSTEM
SYSTEM
•• PROuLtMS/S
4/75 SYSTEM
5/79 A
t)
C
D
55.:
10
13
i« PhOiLEMS/SOLUTIONi/CfMMENTS
51.5
£9.'
67.9
78. C
fcO.t-j
744 638
58C
THE VFNTURI HEADERS AND NOZ7LES HAVE PLUGGED WITH SCALE AND SOLIDS. A NEW
VENTURI HEADER HAS KEEN INSTALLED AND IS faEING TESTED ON TRAIN B. THE
'JEk HEADER CONSISTS OF SIX ?-IUCH FULL-CONE NOZZLES WITH A 3-INCH DISCHARGE
ORIFICE. THE HEADER IS INSTALLED OVER THE VENTURI THROAT TO PROVIDE GOOD
THROAT COVERAGE. IF THE NEW HEADER PROVES SUCCESSFUL, NEW HEADERS WILL BE
INSTALLED IN ALL VENTURIS.
366
-------
FPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TENNESSEE VALLEY AUTHORITY: WIDOWS (.RiEK 8 (CONT.)
PERIOD MODULE AVAILABILITY
6/75 A
b
C
D
SYSTi*
10:.:
133.0
103.3
99. t
99.9
PERFORMANCE DATA
CiPERAI-lLlTY RELIABILITY UTILIZATION X REMOVAL PER BOILER
92. L
d 3.9
91.1
93.8
92.1
S02 PART. HOURS HOURS
75.7
72.6
73.6
75.8
74.4 84.23 99.50 72 C 582
FGO CAP.
HOURS FACTOR
536
tMS/SOLUTION 5/COMMENTS
THl NE. HEADER IN TRAIN B PROVED SATISFACTORY SO NEW HEADERS ARE TO bE
INSTALLED CN ALL VENTURIS.
OPTIMIZATION TESTS ON UNIT 8 SCRUPBER HAVE BEGUN AND WILL BE COMPLETED Bt
THE END OF OCTOBER. THE TE5TS WILL INCLUDE TESTING THE ADDITIONAL FIBER-
GLASS REINFORCED PLASTIC GRIDSi NEW ABSORBER FULL-CONE SPRAY NOZZLES,
POLYPCOPYLtNfc GRID-TYPE PACKING. AND TURBULENT CONTACT ABSORBER SPHERES.
7/79
A
b
C
D
SYSTEM
9/79
100.0
100.0
100.0
103.0
103.G
1 .0.3
1C 0.7,
1G3.?
89.3
1 C C' . 3
44.i
41.8
42.5
34.P
41. 0
66.40 99.?
744 291
305
** PROuLEMS/SOLUTIONS/COMMENTS
CORROSION UAS FOUND IN THE "EHtAT TUBES IN TRAIN A. THE CORROSION WAS
CAUSED BY FLY ASH AND FERROUS CORROSION PRODUCTS. CHLORIDE AND SLURRY
SOLIDS WERE ALSO DETECTED. A DETAILED ANALYSIS OF THE TUBE CORROSION IS
BEING PERFORMED.
8/79 A
tt
C
D
SYSTtM
99.2
100.0
96.2
96.1
97.9
icr.c
94.9
ic:.3
1 c. .c
74.3
60.fc
70.2
74.9
75. j
87.90 99.CO
744
550
558
** PROULEMS/SOLUT10NS/COMMENTS
A
B
C
D
SYSTtM
100.0
100.0
94.4
94.2
97.4
1C3.0
100.0
96.7
1C 3. 3
icr.o
THt BALL MILL WAS OUT OF SERVICE FECAUSE OF BROKEN BOLTS WHICH SECURE THE
INBOARD BEARING JOURNAL TO 'HE BALL HILL. THE BOLTS WERE REPLACED AND TH
DISCHARGE END OF THE MILL WAS CLEANED.
THE SCRUBBER OPTIMIZATION TEST CONTINUED DURING AUGUST.
71.7
75. C
65.5
72.8
71.3
(53.00 99.10 720
488
513
** PRObLEMS/SOLUTIONS/COMMENTS
THE L1MESTCNE BUCKET ELEVATOR, WHICH FEEDS LIMESTONE INTO THE BALL MILL
SURGE HOPPER, FAILED ON SEPTEMBER 28. THE FAILURE, WHICH HAS OCCURRED
BEFORE, WAS CAUSED BY LIMESTONE PARTICLE BUILDUP ON THE BUCKETS AND IN THE
BOTTOM OF THE HOUSING, RESULTING IN THE ELEVATOR JAMMING AND BREAKAGE OF
THE bUCKET GUIDE CHAINS. THE ELEVATOR WILL BE REPLACED WITH BELT CONVEYORS
IN THE SUMKER OF 1980.
10/79 A
D
C
D
SYSTEM
74.2
103.0
103.0
93.4
87,9
72.7
95.8
95.2
7C.?
9C.9
51.1
67.3
66.9
100.0
63.9
744 523
476
** PROLLEMS/SOLUTIONS/COMMENTS
THE REPAIR OF THE BUCKET ELEVATOR CONSISTED OF THE REPLACEMENT OF 25
BUCKETS, REPLACEMENT OF 50 FEET OF DRIVE CHAIN ON EACH SIDE Of THE BUCKETS,
AND REMOVAL OF LIMESTONE ACCUMULATIONS ON ALL SURFACES WITH HIGH-PRESSURE
367
-------
EPA UTILITY FliD SURVEY: FOURTH QUARTER 1979
TENNESStE VALLEV AUTHOR1TY : WIDOWS CREEK 8 CCONT.)
PERFORMANCE DATA — — —-.
PERIOD MODULE AVAILABILITY CPcRABILITY RELIABILITY UTILIZATION Z REMOVAL PER BOILED FOD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
WATER. THE BUCKET ELEVATOR WAS RETURNED TO SERVICE ON OCTOBER 6, 1979.
11/79 A
b
C
0
SYSTtM
9 1.8
92.6
67.7
720 526
487
** PfiObLEMS/SOLUTIONS/CCMMENTS
CONSTRUCTION OF AN ON-SITE AREA I" WHICH TO STACK GYpSUM WAS COMPLETED
DURING EAPLY NOVEMbEK AND STACKING (LANDFILL) OPERATIONS BEGAN ON
15. THE TRAIN D SCRUl'BER SLUDGE IS OXIDIZED BY AIR SPARGING, DEUATEReD, AND
TRANSPORTEt TO THE SITE IN TRUCKS. THE GYPSUM PILE IS FORMED KITH A 8ULL-
D02ER,
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATc EMISSION LIMITATION - KG/J
$02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY UO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLO* - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - »l
*• FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - bTU/LU
AVERAGE ASH CONTENT - X
RANGE ASH CONTE NT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
ESP
NUMPER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
EFFICIENCY - X
*• PARTICULATE SCRUBBER
TYPE
** F6D SYSTEM
SALEABLE PRODUCT/THROWAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
•* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
- X
( .TOO LB/MMBTU)
( 1.200 LB/MMBTU)
TEXAS UTILITIES
MARTIN LAKE
1
TATUM
TEXAS
B
43.
516.
300 C.O
793.0
750.0
760.0
595.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/77
1494.51 (3167000 ACFM)
168.3 « 335 F)
****** (**** FT)
***• .«* (*•*•* FT)
COAL
LIGNITE
17166.
s.oo
5.6-13.2
33.00
29.0-37.9
.9o
0.5-1.5
********
( 7380 BTU/LB)
6972-7894
1
COLD SIDE
RESEARCH COTTRELL
99.4
1494.5 (3167000 ACFM)
168.3 ( 335 F)
******* (**••* IN-H20)
NONE
THROWAUAY PRODUCT
MET SCRUBBING
LIMESTONE
NONE
RESEARCH COTTRELL
C.T. MAIN
C.T. MAIN
FULL SCALE
NEW
99.40
71.00
10/78
4/77
.0
.0
GRID/SPRAY TONER
4/77
RESEARCH COTTRELL
369
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MARTIN LAKE 1 (CONT.)
NUMBER OF STAGES
DIMENSIONS - FT
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
PRESSURE DROP - fcPA
i02 DESIGN REMOVAL EFFICIENCY - X
** CENTRIFUGt
NUMBER
INLfT SOLIDS - X
OUTLET SOLIDS - 1
** FANS
NUMBER
TTPE
SERVKt - *ET/DR»
CAP«CITY - CU.M/S
26 DIA. X 100 TALL
1Z.5
177.13 « 375350 ACF«>
162.8 ( 325 F)
1.1 < 4.5 1N-M20)
3C, .0
60.0
BOILER 1.0.
DRY
375.4
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MARTIN LAKt 1 (CONT.)
PERFORMANCE DATA —
PERIOD MODULE AVAILA 01LITY OPEPABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/77
9/77
10/77
11/77
12/77
1/78
2/78
3/78
4/78
5/78
6/78
7/78
8/78
SYSTEM
SYSTEM
SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
74*
720
744
SYSTEM
SYSTEM
SYSTEM
SYSTEM
INSTALLATION OF THE LIMESTONE SCRUBBING SYSTEM AND THE ESP HAS COMPLETED
BY OCTOBER 1977. THE INITIAL OPERATING PHASE IS EXPECTED TO CONTINUE
THROUGH THE FIRST QUARTER OF 1978. COMPLIANCE TESTING WAS CONDUCTED IN
LATE 1^77 AND CERTIFICATION OF COMMERCIAL AVAILABILITY IS AWAITED.
THE UTILITY EXPERIENCED SOCE DIFFICULTIES IN THE SLURRY HANDLING SYSTEM.
720
744
744
672
*« PROuLEMS/SOLUTIONS/COMMENTS
CERTIFICATION WAS RECEIVED FROM THE EPA DURING THE PERIOD. THE BOILER AND
FfcD SYSTEK OPERATED THROUGHOUT THE PERIOD.
THE UTILITY IS STILL HAVING SOME PROBLEMS WITH THE SLURRY HANDLING SYSTEM.
SOME FORCED OUTAGE TIME OCCURRED.
SYSTEM 744
SYSTEM 720
*« PKObLEMS/SOLUTIONS/COMMENTS
THE UNIT UAS TAKEN OFF LINE IN APRIL FOR AN ANNUAL TWO WEEK OUTAGE.
GENERATOR PROBLEMS WERE ENCOUNTERED IN MAY CAUSING THE UNIT TO BE TAKEN
OFF LINE THROUGH THE END OF THE MONTH.
SYSTEM
SYSTEM
«• PKOuLEMS/SOLUTIONS/COMMENTS
744
720
THE DAMPERS FOR EACH ABSORBER MODULE HERE NOT FUNCTIONING PROPERLY. IT
HAS BEEN IMPOSSIBLE TO ISOLATE INDIVIDUAL MODULES FOR REPAIRS (THE ENTIRE
SYSTEM WOULD HAVE TO BE SHUT DOWN IF REPAIRS WERE REQUIRED ON ONLY ONE
MODULE).
THE UNIT IS OPERATING COMMERCIALLY.
THERE HAVE BEEN PROBLEMS WITH THE PH METERS.
PROPERLY FOR SOME TIME NOW.
SYSTEM
SYSTEM
•* PRObLEMS/SOLUTIONS/CONMENTS
ISOLATION DAMPER PROBLEMS CONTINUED.
THE UNIT CONTINUES TO REQUIRE EXCESSIVE MAINTENANCE. FGD SYSTEM ACCEPT-
ANCE TEST WERE PERFORMED B* THE UTILITY DURING AUGUST. RESULTS ARE NOT
YET AVAILABLE.
THE METERS HAVE NOT OPERATED
744
744
371
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MARTIN LAKE 1 (CONT.)
....... ............. ..... .....—PERFORMANCE DATA ..........—... . „—_—__
PERIOD NODULE AVAILABILITY OPERABILlTY RELIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
FLOU MEASUREMENT INSTRUMENTATION HAS BEEN FAILING.
OPACITY HAS BEEN HIGHER THAN EXPECTED (20-25X) RESULTING FROM ESP PROB-
LEMS.
9/78
10/78
11/78
12/78
SYSTEM
SYSTEM
** PROULENS/SOLUTIONS/COMMENTS
NO PROBLEMS HAVE BEEN REPOFTEO.
SYSTEM
SYSTEM
•• PRObLEMS/SOLUTIONS/COMMENTS
720
744
720
74 <•
1/79
2/79
3/79
4/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
THE FGO SYSTEM WAS SHUT DOWN WHILE THE BOTTOM ASH POND WAS CLEANED OUT.
THE UTILITY HAS BEEN DUMPING SLUDGE INTO THE POND WHICH WAS DESIGNED FOR
BOTTOM ASH ONLY. ALSO SLUDGE IS PRODUCED FASTER THAN IT IS REMOVED BY
RAIL CAR. THE UTILITY IS NOT GETTING RAIL CARS FAST ENOUGH. THE ACTUAL
PROBLEM IS REPORTEDLY IN THE DEwATERING SYSTEM.
SOME MIST ELIMINATOR WASH PROBLEMS WERE ENCOUNTERED.
THE FGD SYSTEM HAS REPORTEDLY RAN WELL DURING DECEMBER AND JANUARY.
COAL HANDLING WAS A SERIOUS PROBLEM DUE TO FREEZING OF THE COAL IN THE
HOPPERS. THIS PROBLEM EFFECTED ALL UNITS AT MARTIN LAKE FORCING THE GAS
AND OIL UMTS TO CARRY THE LOAD.
THE SCRUBBING SYSTEM WAS SHUT DOWN FOR A TIME DURING THE REPORT PERIOD.
744
672
744
720
PROBLEMS/SOLUTIONS/COMMENTS
UNIT 1 IS kOW IN FULL OPERATION ALTHOUGH A SLUDGE DISPOSAL PROBLEM STILL
EXISTS.
THE UTILITY HAS REPLACED THE LOUVER DAMPERS WITH GUILLOTINE DAMPERS uHICH
SEEM TO WOKK BETTER. HOWEVER, THEY STILL HAVE PROBLEMS WITH THE GUIL-
LOTINE DAMPERS FAILING TO S IAL WHEN THEY BECOME SCALED.
THERE HAVE BEEN REPORTS OF TOWER LEAKS FROM LINER FAILURE BUT IT DOESN'T
SEEM TO BE SERIOUS.
5/79
6/79
SYSTEM
SYSTEM
•• PRObLEHS/SOLUTIONS/COMMENTS
744
720
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
THE SLUDGE DISPOSAL SYSTEM IS STILL CAUSING SOME OPERATING PROBLEMS. THE
PROBLEMS REPORTED LAST QUARTER WERE CAUSED BY HEAVY RAINS WHICH KNOCKED
OUT THE THICKENERS.
744
744
72 C
372
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MAO TIN LAKE 1 (CONT.)
_ PERFORMANCE DATA — — — --
PERIOD MODULE AVAILABILITY OPERAFHLITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
«• PRObLEMS/SOLUTIONS/COMMENTS
DURING THE THIRD QUARTER TH I UTILITY REPORTED THE SYSTEM IS OPERATING WELL.
THE SLUDGE DISPOSAL SYSTEM PROBLEMS PLAGUING THE UNIT HAVE BEEN SOLVED.
10/79 SYSTEM 7*4
11/79 SYSTEM 7ZC
1Z/T9 SYSTEM 744
** PROULE.MS/SOLUTIONS/COMNENTS
PLUGGING PfcObLEMS HAVE BEEN ENCOUNTERED DURING THE FOURTH QUARTER REQUIRING
HEAVY MAINTENANCE.
373
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F&D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLAKT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Kfc
NET UNIT GENERATING CAPACITY W/FGD - Mb
NET UNIT GENERATING CAPACITY WO/FGt - MU
EQUIVALENT SCRUBBED CAPACITY - Kh
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
*• FUEL DATA
FUEL TYPc
FUEL GRADE
AVERAGE HEAT CONTENT - J/b
RANGE HEAT CONTENT - ETU/Ld
AVERAGE ASM CONTENT - i
RANGE ASH CONTE NT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*• ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - %
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
** PARTICULATE SCRUBBER
TYPE
•• FGO SYSTEM
SALEABLE PROOUCT/THROWAWAY PROtUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULAR DESIGN REMOVAL EFFICIENCY - X
S02 DESIGN REMOVAL EFFICIENCY - i
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - 1
ABSORBER SPARE COMPONENT INDEX
•• AbSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS - FT
TEXAS UTILITIES
MARTIN LAKE
2
TATU*
TEXAS
516.
30CC.O
793.0
75C.O
76C.C
59?. 0
COMBUSTION ENGINEERING
PULVERISED COAL
BASE
0/7*
1494.51
16F.3
( .100 LB/MMBTU)
( 1.2CO LB/MMBTU)
C3167COO ACFM)
( 335 F>
(•*«* FT)
(..«.« FT)
COAL
LIGNITE
17166.
P. 00
5.6-13.Z
33.00
29.0-37.9
.90
0.5-1.5
( 7380 BTU/LB)
6972-7894
1
COLD SIDE
RESEARCH COTTRELL
9P.A
U94.5
16£.3
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH COTTRELL
C.T. MAIN
FULL SCALE
NEW
99.4C
71.00
5/7S
.0
GRID/SPRAY TOWER
5/76
RESEARCH COTTRELL
4
26 DIA. X 203 TALL
(3167000 ACFM)
< 335 F)
(..... I
374
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MARTIN LAKE 2 (CONT.)
U01LER LCAD/ABSORBcR - 1
GAS FLOW - CU.M /S
GAS TEMPERATURE - C
PRESSURE DROP - KPA
S02 DESIGN REMOVAL EFFICIENCY - *
** CENTRIFUGE
NUMBER
INLET SOLIDS - X
OUTLET SOLIDS - X
•* FANS
NUMBE"
TYPE
SERVICE - WET/DRY
CAPACITY - CU.M/S
•* MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSE S
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
•• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
** PUMPS
SERVICE
QUENCHER FEED PUMP
SLURRY FiEO
ABSORBER RECIRCULATION
TANKS
SERVICE
ABSORBER FEED
QUENCHER SUMP
** REHEATER
TVPE
TEMPERATURE BOOST - C
** THICKENER
NUMBER
TYPE
DIAMETER - M
OUTLET SOLIDS - I
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
** TREATMENT
TYPE
PRODUCT CHARACTERISTICS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
« 375350 ACFM)
( 3Z5 F)
t 4.5 JN-H20)
< 795680 ACFM)
13.5
177.13
162.8
1.1
95.0
35.0
69.0
BOILER I.D.
DRY
375.48
12
CHEVRON
POLPFOPYLENE
HORIZONTAL
TOP AND BOTTOM WASH
?.4 ( 8.C FT/S)
.2 ( 1.0 IN-H20)
PH, LIQUID LEVEL, LIQUID AND GAS FLOW
NUMB ER
54
NUMBER
3
6
BYPASS
4C.O
1
GRAVITY
43.7
35.0
CLOSED
34.6
7Z F>
C140 FT)
( SSO 6PM)
FLVASH STABILIZATION
CENTRIFUGE SOLIDS MIXED WITH FLY ASH
FINAL
LANDFILL
ON-SITE
RAIL
375
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
TEXAS UTJLITItS: MARTIN LAKE 2 (CONT.)
PERfORWANC f DATA —— ..........—_____
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
5/78
6/78
7/78
8/78
9/78
10/78
11/78
12/78
1/79
2/79
3/79
4/79
SYSTEM
SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
744
720
SYSTEM
SYSTEM
THE UNIT fcEGAN OPERATIONS IN MAY 1978. THE COMPLIANCE TESTING IS SCHEDUL-
ED FOR AUGUST.
744
744
•* PRObLEMS/SOLUTIONS/COMMENTS
SYSTEM
SYSTEM
THE FGD SYSTEM WAS TESTED FOR COMPLIANCE WITH ALL SIX MODULES IN THE GAS
STREAM DURING THE FIRST PART OF AUGUST. TEST RESULTS HAVE NOT VET BEEN
PUBLISHED. NO NAJOR FGD-RELATED PROBLEMS HERE REPORTED.
720
744
«* PRObLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TEST RESULTS ARE BEING REVIEWED.
SYSTEM
SYSTEM
*• PROBLEMS/SOLUTIONS/COMNENTS
720
744
5/79
6/79
COAL HANDLING WAS A SERIOUS PROBLEM DUE TO FREEZING OF THE COAL IN THE
HOPPERS. THIS PROBLEM EFFECTED ALL UNITS AT MARTIN LAKE FORCING THE GAS
AND OIL UNITS TO CARRY THE LOAD.
THE F6D UNIT REPORTEDLV RAN WELL DURING DECEMBER AND JANUARY.
THE FGD SYSTEM HAS SHUT DOWN WHILE THE BOTTOM ASH POND WAS CLEANED OUT.
THE UTILITY HAS BEEN DUMPING SLUDGE INTO THE POND WHICH WAS DESIGNED FOR
BOTTOM ASH ONLY. ALSO SLUDGE IS PRODUCED FASTER THAN IT IS REMOVED BV R «i
CAR. THE UTILITY IS NOT GETTING RAIL CARS FAST ENOUGH. THE ACTUAL
PROBLEM IS REPORTEDLV IN THE DEWATERING SYSTEM.
SOME MIST ELIMINATOR PROBLEMS WERE ENCOUNTERED.
SYSTEM 744
SYSTEM 672
SYSTEM 744
SYSTEM 720
• • PROBLEMS/SOLUTIONS/COMNENTS
THE UTILITY REPORTS THAT OPERATIONAL PROBLEMS HAVE INCLUDED ABSORBER
LINER FAILURES AND TOWER LEWS.
UNIT 2 IS NOW IN FULL OPERATION ALTHOUGH A SLUDGE DISPOSAL PROBLEM STILL
EXISTS.
THE UTILITY HAS REPLACED THE LOUVER DAMPERS WITH GUILLOTINE DAMPERS WHICH
SEEM TO WORK BETTER. HOWEVER, THEY STILL HAVE PROBLEMS WITH THE GUIL-
LOTINE DAMPERS FAILING TO SEAL WHEN TNET BECOME SCALED.
S»STEM 744
SYSTEM 720
376
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MARTIN LAKE 2 (CONT.)
. - PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•• PROBLEMS/SOLUTIONS/COMMENTS
THE SLUDGE DISPOSAL SYSTEM IS STILL CAUSING SOME OPERATING PROBLEMS. THE
PROBLEMS REPORTED LAST QUARTER WERE CAUSED BY HEAVY RAINS WHICH KNOCKED
OUT THE THICKENERS.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLENS/SOLUTIONS/COHMENTS
DURING THE THIRD QUARTER THE UTILITY REPORTED THE SYSTEM HAS OPERATING
WELL. THE SLUDGE DISPOSAL SYSTEM PROBLEMS PLAGUINC THE UNIT WERE SOLVED.
10/79 SYSTEM 744
11/79 SYSTEM 720
1Z/79 SYSTEM 744
*• PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING PROBLEMS HAVE BEEN ENCOUNTERED DURING THE FOURTH QUARTER REQUIRING
HEAVY MAINTENANCE.
377
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NARE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - hG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/FGD - My
NET UNIT GENERATING CAPACITY WO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM EOILER FLUE GAS FLOU - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•* ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
•* PARTICULATE SCRUBBER
TYPE
*• FGD SYSTEM
SALEABLE PRODUCT/THROUAUAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - X
ABSORBER SPARE COMPONENT INDEX
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER Of STAGES
TEXAS UTILITIES
MARTIN LAKE
3
TATUM
TEXAS
B
43. (
516. <
3000.0
793.0
750.0
760.0
595. 0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
**/**
1494.51
168.3
.100 LB/MMBTU)
1.200 LB/MMBTU)
(3167000 ACFM)
C 335 F)
(•**. FT)
<****• FT)
COAL
LIGNITE
171. .6.
8.00
5.6-13.2
33.00
29.0-37.9
.90
0.5-1.5
« 7380 BTU/LB)
6972-789*
COLD SIDE
RESEARCH COTTRELL
X 99.4
1494.5 C3167000 ACFM)
168.3 ( 335 F)
****..*« <**»** IN-H20)
NONE
THROUAUAV PRODUCT
UET SCRUBBING
LIMESTONE
NONE
RESEARCH COTTRELL
C.T. MAIN
H.B. ZACHARV
FULL SCALE
NEW
- X 99.40
71.00
2/79
.0
.0
GRID/SPRAY TOMER
2/79
RESEARCH COTTRELL
4
378
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MARTIN LAKE 3 (CONT.)
BOILER LOAD/ABSORBER - X
GAS FLOU - CU.M/S
GAS TEMPERATURE - C
PRESSURE DROP - KPA
SO2 DESIGN REMOVAL EFFICIENCY - X
** CENTRIFUGE
NUMBER
INLET SOLIDS - X
OUTLET SOLIDS - X
«* FANS
NUMBER
TYPE
SERVICE - UET/D RV
CAPACITY - CU.M/S
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
HASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
** PUMPS
SERVICE
QUENCHER FEED PUMP
SLURRY FEED
ABSORBER RECIRCULATION
>• TANKS
SERVICE
ABSORBER FEED
QUENCHER SUMP
** REHEATED
TYPE
** THICKENER
NUMBER
TYPE
DIAMETER - M
OUTLET SOLIDS - X
.* TREATMENT
TYPE
•• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
( 375350 ACFM)
C 325 F>
C 4.5 IN-H20)
( 795680 ACFMl
12.5
177.13
162.8
1.1
95.0
35.0
69.0
BOILER I.D.
DRV
375.48
12
CHEVRON
POLPROPVLENE
HORIZONTAL
TOP AND BOTTOM WASH
2.4 < 8.0 FT/S)
.2 ( 1.0 IN-H20)
PH. LIQUID LEVEL, LIQUID AND GAS FLOU
NUMBER
*»**
*»»•
54
NUMBER
3
6
BYPASS
GRAVITY
42.7
35.0
1140 FT)
FLYASH STABILIZATION
FINAL
LANDFILL
ON-SITE
RAIL
___-—— —— —... ---PERFORMANCE DATA——
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
3/79 SYSTEM
4/79 SYSTEM
744
120
379
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MARTIN LAKE 3
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAHE
PLANT NAME
UNIT NUMBER
cirv
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - MG/J
$02 EMISSION LIMITATION - N6/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - Mw
NET UNIT GENERATING CAPACITY UO/F6D - MU
EQUIVALENT SCRUBBED CAPACITY - My
*• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - N
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 2
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
FLUE GAS CAPACITY - CU.N/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICULATE OUTLET LOAD - G/CU.H
•• PARTICULATE SCRUBBER
TYPE
•* F6D SYSTEM
SALEABLE PROOUCT/THROWAVAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
soz DESIGN REMOVAL EFFICIENCY - x
COMMERCIAL DATE
INITIAL START-UP
ABSORBER-SPARE CAPACITY 1NDEI - X
ABSORBER SPARE COMPONENT INDEX
•* ABSORBER
NUMBER
TTPE
INITIAL START UP
SUPPLIER
.100 LB/MMBTU)
1.200 LB/MHBTU>
TEXAS UTILITIES
MONTICELLO
3
MT. PLEASANT
TEXAS
B
43. (
516. <
1900.0
800.0
750.0
*******
800.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/78
1650.71 (3498000 ACFH)
168.3 ( 335 F)
******
*******
COAL
LIGNITE
*******
18.90
******
31.90
******
1.50
******
.04
******
COLD SIDE
C.E. WALTHER
99.5
1650.7
168.3
***• •••
.09
NONE
(**** FT>
(***** FT)
(•«**** BTU/LB)
6500-7500
(3498000 ACFM>
( 335 F>
(***** IN-H20>
< .04 6R/SCF>
THROWAUAV PRODUCT
WET SCRUBBING
LIMESTONE
NONE
CHENICO
C.T. MAIN
FULL SCALE
NEW
99.50
74.00
10/78
5/78
.0
.0
SPRAY TOMER
5/78
CNEM1CO
381
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: NONTICELbO 3 (CONT.)
NUMBER OF STAGE S
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.H/S
GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - G/CU.M
PARTICULATE OUTLET LOAD-G/CU.H
SO2 INLET CONCENTRATION - PPM
SO2 OUTLET CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
4
33.0
425.01
6C.6
400C.
9.4
1.2
.1
.1
1353
496
74.0
907000 ACFM)
141 F)
63490 CPM>
70.0 GAL/1000ACF)
5.0 IN-H20)
.050 GR/SCF)
.050 GR/SCF)
•* FANS
NUMBER
TYPE
SERVICE - WET/DRY
CAPACITY - CU.H/S
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MA TERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - H/S
*• PUMPS
SERVICE
ABSORBER RE CIRC ULAT ION
SLURRY FEED
TANKS
SERVICE
LIMESTONE SLURRY
RECYCLE
REHEATED
TYPE
MEATIN6 MEDIUM
TEMPERATURE BOOST - C
WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
TREATMENT
TYPE
DISPOSAL
NATURE
TYPE
LOCATION
3
BOILER
DRV
539.38
I.D.
(1143000 ACFN)
3
CHEVRON
POLYPROPYLENE
HORIZONTAL
1
4
CONTINUOUS VERTICAL UPWARD; INTERMITTENT VERTICA
;.0 < 10.0 FT/S)
NUMBER
3
*»»»
NUMBER
• *»»
«**»
HOT AIR INJECTION
STEAM, 650 f AT 125 PSI6
10.0 C 18 F)
CLOSED
34.4
( 546 6PM)
FLVASH STABILIZATION
FINAL
LANDFILL
ON-SITE
.......... ..............—... .—-PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPE LABILITY RELIABILITY UTILIZATION
I REMOVAL PER BOILER F6D CAP
S02 PART. HOURS HOURS HOURS FACTOR
4/78 SYSTEM
*• PROBLEMS/SOLUTIONS/COMMENTS
72 C
5/78 SYSTEM
6/78 SYSTEM
THE TEXAS AIR CONTROL BOARD REPORTED THAT THE TEXAS UTILITIES 750 Hh
MONTI CELLO UNIT 3 BEGAN FGD OPERATIONS DURING THE REPORT PERIOD. IS OF
VET THE UNIT HAS NOT RUN Al FULL LOAD BUT IS EXPECTED TO BY THE END OF
AUGUST.
744
720
382
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: HONTICELLO 3 (CQNT.)
__ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERA8IL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS NOT AT FULL LOAD VET. ONE OF THE THREE FGD MODULES IS FULLY
OPERATIONAL. ANOTHER ONE IS PARTIALLY OPERATIONAL, WHILE THE THIRD IS NOT
OPERATING AT ALL.
7/78 SYSTEM 7*4
8/78 SYSTEM 744
*« PROBLEMS/SOLUTIONS/COMMENTS
THE COMPLIANCE TEST HAS NOT YET TAKEN PLACE. THE FGD SYSTEM IS OPERATION-
AL. INSTRUMENTATION INDICATES THAT THE UNIT IS IN COMPLIANCE.
9/78 SYSTEM 720
10/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
CONTINUOUS NOX, 02, AND S02 MONITORS ARE A PROBLEM AREA.
THE SLUDGE IS CURRENTLY NOT FIXATED. IT IS BEING PUMPED DIRECTLY TO THE
POND.
11/78 SYSTEM 720
12/78 SYSTEM 744
** PROBLEMS/SOLUT10NS/CONMENTS
THE FGD SYSTEM IS FULLY OPERATIONAL. A PRELIMINARY TEST WAS PERFORMED ON
DECEMBER 14. RESULTS OF THE TEST ARE NOT VET AVAILABLE.
THE FGD SYSTEM REPORTEDLY HAS BEEN PERFORMING WELL.
THE ESP IS NOT OPERATING VELL. COLLECTION EFFICIENCY IS NOT AS HIGH AS IT
SHOULD BE. AMMONIA INJECTION HAS BEEN TRIED TO IMPROVE ITS EFFICIENCY.
REPORTEDLY THE PROBLEM IS THE RESULT OF STRUCTURAL DAMAGE.
1/79 SYSTEM 744
2/79 SYSTEM 672
3/79 SYSTEM 744
4/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS CURRENTLY DOWN FOR A SCHEDULED OVERHAUL. THE TOWERS HAVE
BEEN INSPECTED AND NO SCALING WAS FOUND.
SOME MINOR RECYCLE PUMP LINER PROBLEMS HAVE BEEN REPORTED.
DUE TO HIGH ASH LEVELS SOME PLATES IN THE ESP HERE KNOCKED OUT OF
ALIGNMENT CAUSING AN OPACITY PROBLEM.
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS IN OPERATION DURING THIS PERIOD ALTHOUGH OPERATIONAL DATA
WERE NOT AVAILABLE.
7/79 SYSTEM 744
383
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
TEXAS UTILITIES: MONTICELLO 3 CCONT.)
DATA— — — ---—•——-—-—.._,_„
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X RENOVAL PER BOILER F6D CMP
S02 PART. HOURS HOURS HOURS fACTOR
8/79 SYSTEM
9/79 SYSTEM
*• PROBLEMS/SOLUTIONS/COMMENTS
744
120
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
THE ESP WAS REBUILT AND SINCE THE INITIATION OF 6AS CONDITIONING WITH
AMMONIA THE OPACITY PROBLEM HAS BEEN MINIMIZED.
DURING THE THIRD QUARTER THE UNIT OPERATED WITHOUT ANY MAJOR PROBLEMS.
SOME MINOR ABSORBER RECYCLE PUMP LIN£R FAILURES HAVE BEEN ENCOUNTERED.
744
•720
744
PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS HAVE BEEN ENCOUNTERED DUDIN6 THE FOURTH QUARTER. SINCE GAS
CONDITIONING WITH AMMONIA BEGAN, THE OPACITY HAS BEEN ACCEPTABLE.
384
-------
EPA UTILITY F60 SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
CROSS UNIT GENERATING CAPACITY - Nb
NET UNIT GENERATING CAPACITY W/FGD - My
NET UNIT GENERATING CAPACITY WO/F66 - NU
EQUIVALENT SCRUBBED CAPACITY - NU
*• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
*« FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONUNT - X
• * ESP
NUMBER
SUPPLIER
•* PARTICULATE SCRUBBER
TYPE
•• FGD SYSTEM
SALEABLE PRODUC T/THROUAWAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
SO 2 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
•* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
GAS fLOW - CU.M/S
GAS TEMPERATURE - c
L/6 RATIO - L/CU.M
PRESSURE DROP - KPA
UTAH POWER t LIGHT
HUNTER
1
CASTLE DALE
UTAH
B
43.
516.
f .100 LB/MNBTU)
< 1.ZOO LB/HHBTU)
400.0
400.0
*******
360.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
**/**
822.05 <1742000 ACFM)
130.0 < 266 F)
183. < 600 FT}
7.3 ( 24.0 FT)
COAL
BITUMINOUS
29075.
10.00
9 - 12
6.50
******
.55
******
********
**** »*
1
BUELL
NONE
THROUAVAV PRODUCT
WET SCRUBBING
LIME
NONE
CHEMICO
STEARNS-ROGER
FULL SCALE
NEW
99.50
8C.OO
5/79
SPRAY TOWER
5/79
CHEMICO
t
CARBON STEEL
POLYESTER FLAKEGLASS
205.51
130.0
< 12500 BTU/LB)
12*200 - 12t700
5.7
.6
< 435500 ACFM>
C 266 F)
( 43.0 GAL/1000ACF)
< 2.5 IN-H2O
385
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
UTAH POWER I LIGHT: HUNTER 1 CCONT.)
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
CAPACITY - CU.H/S
** HIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGE S
NUMBER OF PASSES
FREEBOARD DISTANCE - M
MASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
** PUMPS
SERVICE
ABSORBER RECIRCULATION
•* REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
** REHEATER
TYPE
TEMPERATURE BOOST - C
SCRUBBER FD
CARBON STEEL
DRY
411.02 i 871000 ACFM)
CHEVRON
POLYPROPYLENE
HORIZONTAL
1
4
3.66 (12.0 FT)
CONTINUOUS SPRAY OPERATED ON EACH OF THE 12 SECT
.3 t 1.0 FT/S)
NUMBER
16
HOT AIR INJECTION
STEAW
26.7 ( 48 F)
BYPASS
26.7 ( 48 F)
•* HATER LOOP
TYPE
** TREATMENT
TYPE
*• DISPOSAL
NATURE
TYPE
LOCATION
PERIOD MODULE AVAILABILITY
5/79 SYSTEM
6/79 SYSTEM
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM
OPEN
FLVASH STABILIZATION
FINAL
POND
ON-SITE
OPERABILITY RELIABILITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
78.6 32.8 744 311 244
97.9 96.9 720 713 698
100.0 99.2 744 738 738
100.0 100.0 744 744 744
100.0 100.0 720 720 720
•• PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OPERATIONAL PROBLEMS WERE REPORTED BY THE UTILITY FOR THIS UNIT
DURIN6 THE THIRD QUARTER 19>9.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
•* PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLI FOR THE FOURTH QUARTER 1979.
386
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGO - MU
NET UNIT GENERATING CAPACITY WO/FGO - MU
EQUIVALENT SCRUBBED CAPACITY - «W
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOU - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - H
STACK TOP DIAMETER - M
«* FUEL DATA
FUEL TYP£
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - Z
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
UTAH POWER & LIGHT
HUNTINGTON
1
PRICE
UTAH
B
.100 LB/HHBTU)
1.200 LB/MMBTU)
43. (
516. C
81C.O
430.0
400.0
407.0
36 i.O
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/78
822.05 (1742000 ACFM)
13C.O < 266 F)
183. ( 600 FT)
7.3 < 24.0 FT>
COAL
BITUMINOUS
29075.
10. 00
9-12
6.SO
******
.55
******
********
( 12500 BTU/LB)
12200-12700
** ESP
NUMBER
TYPE
SUPPLIER
*• PARTICULATE SCRUBBER
TYPE
** FGO SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
ABSORBER SPARE CAPACITY INDEX - I
ABSORBER SPARE COMPONENT INDEX
•* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
GAS FLOU - CU.M/S
GAS TEMPERATURE - c
L/6 RATIO - L/CU.M
COLD SIDE
BUELL
NONE
THROUAUAV PRODUCT
WET SCRUBBING
LIME
NONE
CHEMICO
STEARNS-ROGER
FULL SCALE
NEW
- X 99.50
80.00
5/78
2.5
.0
SPRAY TOWER
5/7*
CHEMICO
4
CARBON STEEL
POLYESTER FLAK.EGLASS
205.51 < 435500 ACFH)
130.0 ( 266 F)
5.7 ( 43.0 CAL/1000ACF)
387
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
UTAH POWER t LIGHT: HUNTINGTON 1 (CCNT.)
PRESSURE DROP - KPA
•• FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SERVICE - MET/DRY
CAPACITY - CU.M/S
•• VACUUM FILTER
NUMBER
OUTLET SOLIDS - X
•• HIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER Of STAGES
NUMBER Of PASSES
FREEBOARD DISTANCE - H
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
** PUMPS
SERVICE
ABSORBER RECIRCULATION
•• TANKS
SERVICE
RECYCLE
*• REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
•* REHEATER
TYPE
TEMPERATURE BOOST - C
•* THICKENER
NUMBER
TYPE
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
•• WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
•* TREATMENT
TYPE
•* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
( 2.5 IN-H20)
( 871000 ACFM)
.6
SCRUBBER FD
CARBON STEEL
DRV
411.02
60.0
4
CHEVRON
POLYPROPYLENE
HORIZONTAL
1
4
3.66 (12.0 FT)
CONTINUOUS SPRAY OPERATES ON EACH OF THE 12 SECT
.3 ( 1.0 FT/S)
NUMBER
16
NUMBER
HOT AIR INJECTION
STEAM
26.7 (
BYPASS
26.7
48 F)
48 F)
1
CYLINDRICAL WITH DORR OLIVER RAKE
CARBON STEEL WITH FLAKEGLASS LINING
1 1.3 < 60 FT)
27.5
CLOSED
18.9
( 300 6PH)
FLYASH STABILIZATION
FINAL
LAND IILL
ON-SITE
TRUCK
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP
S02 PART. HOURS HOURS HOURS FACTOR
5/78 SYSTEM
.. PROBLEMS/SOLUTIONS/COHNENTS
INITIAL OPERATIONS BEGAN ON MAY 10. 1978.
6/78 SYSTEM 65.3 65.3
744
720 720
470
388
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
UTAH POWER & LIGHT: HUNTINGTON 1 CCONT.)
PERFORMANCE DATA — —
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
«* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT 10-201 OF THE FLUE 6AS WAS BYPASSED.
7/78 SYSTEM 97.7 95.9 744 731 714
8/78 SYSTEM 100.0 73.1 744 544 544
** PRQbLEMS/SOLUTIONS/COMHENTS
AN EXPLOSION CAUSED A THREE WEEK BOILER OUTAGE.
THE UTILITY REPORTED THAT THERE WERE NO FORCED FGD OUTAGES.
9/78 SYSTEM 1CO.O 68.9 720 496 496
10/78 SYSTEM 100.0 100.0 744 744 744
11/78 SYSTEM 62.4 62.4 72C 720 449
*• PROBLEMS/SOLUTIONS/COMMENTS
THE THICKENER HAD SOLIDS BUILDUP THE LAST OF NOVEMBER AND THE FIRST PART
OF DECEMBER FORCING SYSTEM SHUTDOWN TO ALLOW MANUAL REMOVAL OF THE SOLIDS.
12/78 SYSTEM 34.0 32.7 744 715 243
** PROBLEMS/SOLUTIONS/COMMENTS
FREEZE-UP PROBLEMS CAUSED OUTAGES OF A FEW WEEKS DURATION.
1/79 SYSTEM 76.2 65.7 744 642 489
2/79 SYSTEM 9C.1 58.2 672 434 391
3/79 SYSTEM 100.3 86.5 744 644 644
4/79 SYSTEM 100.0 76.8 720 553 553
•* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE PROBLEMS ENCOUNTERED DURING FEBRUARY-APRIL
INCLUDED LINING FAILURE, PU*P PROBLEMS AND DAMPER PROBLEMS.
PROBLEMS HAVE BEEN EXPERIENCED WITH DAMPER MECHANISMS CLOGGING.
5/79
6/79
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
100.0
62.5
79.7
30.0
54.9
92.6
54.9
79.5
27.0
54.3
744
720
744
744
720
689
632
742
669
712
689
395
591
201
391
• « PROBLENS/SOLUTIONS/COMMENTS
THE PROBLEMS ENCOUNTERED DURING THE THIRD QUARTER
OF CONTROL VALVES AND SOME AGITATOR PROBLEMS.
10/79
11/79
12/79
SYSTEM
SYSTEM
SYSTEM
1979
744
720
744
INCLUDED
FAILURE
389
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
UTAH POMER & LIGHT: HUNTINGTON 1 (CCNT.)
PERFORMANCE DATA ——.___
PERIOD MODULE AVAILABILITY OPEMBIL1TT RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
•• PRObLEHS/SOLUTIONS/COMMENTS
MULTIPLE PROBLEMS OCCURRED DURING THE PERIOD CAUSING THE UNIT TO SHUT
DOWN TO GET THE SYSTEM UNDER CONTROL.
390
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 4
SUHWARY OF FGD SYSTEMS BY COMPANY
TOTAL OPERATIONAL
COMPANY NAME NO.
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTEM
ARIZONA ELECTRIC POWER COOP
ARIZONA PUBLIC SERVICE
ASSOCIATED ELECTRIC COOP
bASIN ELECTRIC POWER COOP
BIG RIVERS ELECTRIC
CENTRAL ILLINOIS LIGHT
CENTRAL ILLINOIS PUBLIC SERV
CENTRAL MAINE POWER
CINCINNATI GAS & ELECTRIC
COLORADO UTE ELECTRIC ASSN.
COLUMBUS & SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
COOPERATIVE POWER ASSOCIATION
DELMAkVA POWER & LIGHT
DUUUESNE LIGHT
EAST KENTUCKY POWER COOP
GENERAL PUBLIC UTILITIES
HOOSIER ENERGY
HOUSTON LIGHTING K POWER CO.
INDIANAPOLIS POWER & LIGHT
KANSAS CITY POWER & LIGHT
KANSAS POWER & LIGHT
KENTUCKY UTILITIES
LAKELAND UTILITIE S
LOUISVILLE GAS 8 ELECTRIC
MIDDLE SOUTH UTILITIES
MINNESOTA POWER t LIGHT
MINNKOTA POWER COOPERATIVE
MONTANA POWER
MUSCATINE POWER 8, WATER
NEVADA POWER
NEW YORK STATE ELEC k. GAS
NIAGARA MOHAWK POWER COOP
NORTHERN INDIANA PUB SERVICE
NORTHERN STATES POWER
OTTER TAIL POWER
PACIFIC GAS & ELECTRIC
PACIFIC POnER & LIGHT
PENNSYLVANIA POWER
PHILADELPHIA ELECTRIC
POTOMAC ELECTRIC POWER
POWER AUTHORITY OF NEW YORK
PUBLIC SERVICE OF INDIANA
PUBLIC SERVICE OF NEW MEXICO
SALT RIVER PROJECT
SAN MIGUEL ELECTRIC COOP
SEHINOLE ELECTRIC
SIKESTON BOARD OF MUNIC. UTIL.
SOUTH CAROLINA PUBLIC SERVICE
SOUTH MISSISSIPPI ELEC PWR
SOUTHERN ILLINOIS POWER COOP
SOUTHERN INDIANA GAS g ELEC
SOUTHWESTERN ELECTRIC POWER
SPRINGFIELD CITY UTILITIES
SPRINGFIELD WATER t LIGHT g PwR
ST. JOE ZINC
TAMPA ELECTRIC
TENNESSEE VALLEY AUTHORITY
TEXAS MUNICIPAL POWER AGENCY
TEXAS POWER I LIGHT
TEXAS UTILITIES
TUCSON GAS i ELECTRIC
UTAH POWER t LIGHT
2
3
2
8
1
c
4
2
1
1
1
J
4
1
2
2
2
3
5
2
1
5
T
4
1
1
10
6
1
1
4
1
10
1
1
3
4
1
2
1
3
4
1
1
1
4
3
1
2
1
3
2
2
1
1
1
1
1
1
7
1
3
8
2
5
MW
358.
1338.
39C.
2684.
670.
2680.
1364.
794.
617.
60u.
650.
1341.
1572.
450.
654.
730.
92C.
1800.
3475.
882.
512.
3012.
1054.
1575.
64.
364.
3543.
5340.
475.
405.
2120.
160.
3125.
870.
100.
957.
2450.
440.
1600.
550.
2751.
844.
80C.
703.
650.
1779.
84C.
400.
1240.
235.
700.
248.
484.
265.
720.
194.
205.
60.
475.
3153.
400.
1882.
5585.
740.
1886.
NOTE - PLANNED STATUS INCLUDES LETTER OF
AND CONSIDERING ONLY FGD SYSTEMS
NO.
2
1
2
2
0
0
1
1
1
0
0
1
2
0
1
0
2
0
0
0
0
1
3
3
1
0
5
0
0
1
2
0
3
0
0
1
2
0
0
1
2
1
0
0
0
3
1
0
0
0
1
2
1
1
0
1
0
1
0
3
0
0
4
0
2
MW
358.
519.
390.
469.
0.
0.
242.
378.
617.
0.
0.
447.
822.
0.
327.
0.
920.
0.
0.
0.
0.
532.
1054.
1085.
64.
0.
1190.
0.
0.
405.
720.
0.
375.
0.
C.
115.
1480.
0.
0.
550.
1834.
120.
0.
0.
0.
1245.
280.
u.
0.
0.
140.
248.
184.
265.
0.
194.
0.
60.
0.
570.
0.
0.
2585.
0.
726.
INTENT SIG
CONSTRUCTION CONTRACT
AWARDED
NO.
0
1
0
4
1
3
1
0
0
0
1
1
0
1
1
1
0
1
0
1
0
1
0
1
0
1
3
0
1
0
2
0
0
0
1
0
1
1
0
0
1
0
0
0
0
1
1
1
0
1
1
0
0
0
0
0
1
0
0
1
0
1
0
0
1
NED
MW
0.
519.
0.
705.
670.
1640.
242.
0.
0.
0.
650.
447.
0.
450.
327.
180.
0.
500.
0.
441.
0.
530.
0.
493.
0.
364.
1203.
0.
475.
P.
1400.
0.
0.
0.
100.
0.
110.
440.
0.
0.
917.
0.
0.
0.
0.
534.
280.
400.
0.
235.
280.
0.
0.
0.
0.
0.
205.
0.
0.
575.
0.
382.
0.
0.
360.
NO.
0
1
0
2
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
o
0
0
0
0
0
3
0
0
1
0
0
0
0
0
1
0
0
0
1
0
0
0
0
2
1
2
1
2
2
, REQUESTING
MW
0.
300.
0.
1510.
0.
600.
0.
0.
c.
0.
0.
0.
c.
0.
0.
0.
0.
0.
0.
441.
512.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
c.
c.
0.
0.
0.
0.
0.
724.
Q.
0.
650
U J \J •
0.
0.
0.
0.
0.
280.
0.
0.
0.
720.
0.
0.
0.
c.
1408.
400.
1500.
750.
740.
800.
/EVALUT1N6
PLANNED
NO.
0
0
0
0
0
1
2
1
o
1
o
1
2
0
o
1
o
2
5
o
o
3
0
o
o
o
2
6
o
o
o
1
7
1
o
2
1
o
2
o
^
1
o
1
2
Q
o
1
Q
o
o
0
1
1
o
0
3
0
0
BIDS
MW
0.
0.
0.
0.
0.
440.
880.
416.
0.
6CO.
0.
447.
75Q.
C.
0.
550.
0.
13CO.
3475.
0.
0.
1950.
0.
0.
0.
0.
1150.
5340.
0.
0.
0.
160.
275C.
870.
0.
842.
86C«
0.
16CO.
P.
V .
0.
0.
.
a rn
° LU .
7rn.
• L V •
.
C.
2tO.
C.
1 2*0.
0.
.
n.
V .
Q*
1 rn.
-* L u •
•
•
0_
•
r..
v •
0.
•
475,
6QO»
0«
C.
2250.
C.
0*
t
391
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION <•
SUMMARY OF FGD SYSTEMS BY COMPANY
STATUS ...
TOTAL OPERATIONAL CONSTRUCTION CONTRACT PLANNED
AWARDED
COMPANY NAME NC. MU NO. NW NO. HW NO* HU NO. MM
WISCONSIN POWER fc LIGHT 1 316. 0 0. 0 0. 1 316. 0 0.
TOTALS 176 80237. 62 20510. 39 16051. 23 11651. 52 31025.
NOTE - PLANNED STATUS INCLUDES LETTER Of INTENT SI6 NED. REQUESTING/EVALUTIN6 BIDS.
AND CONSIDERING ONLY FGD SYSTEMS
392
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 5
SUMMARY OF FGD SYSTEMS BY SYSTEM SUPPLIER
TOTAL
SYSTEM SUPPLIER/PROCESS
ADL/COMbUSTl ON EQUIP ASSOCIATE
DUAL ALKALI
LIME
LIME/ALKALINE FLYASH
SODIUM CARBONATE
TOTAL -
AIR CORRECTION DIVISION, UOF>
LIME
LIMESTONE
LIME/LIMESTONE
SODIUM CARBONATE
TOTAL -
AMERICAN AIR FILTER
LIME
LIMESTONE
TOTAL -
BABCOCK t WILCOX
LIME
LIMESTONE
LIME/SPRAY DRYING
TCTAL -
BUELL/ENVIROTECH
DUAL ALKALI
TOTAL -
BUREAU OF MINES
CITRATE
TOTAL -
CHEMICO
LIME
LIMESTONE
LIME/ALKALINE FLYASH
LIME/LIMESTONE
TOTAL -
COMBUSTION ENGINEERING
LIME
LIMESTONE
LIMESTONE/ALKALINE FLYASH
LIME/ALKALINE FLYASH
LIME^LIME STONE
TOTAL -
DAVY POWERGAS
UELLMAN LOR D
TOTAL -
FMC CORPORATION
DUAL ALKALI
TOTAL -
JOY MFG/NIRO ATOMIZER
LIME/SPRAY DRYING
TCTAL -
MITSUBISHI HEAVY INDUSTRIES
LIMESTONE
TOTAL -
NO.
1
1
5
3
10
2
4
1
1
8
6
1
7
3
7
1
11
1
1
1
1
8
7
4
1
20
4
7
2
2
2
17
6
6
1
1
4
4
2
2
MW
238.
500.
2525.
375.
3688.
822.
1896.
10.
5SO.
3278.
1673.
280.
1953.
1688.
2477.
600.
4765.
617.
617.
60.
60.
4140.
4508.
895.
10.
9553.
452.
2932.
U80.
654.
708.
6226.
2074.
2074.
265.
265.
1290.
1290.
882.
882.
OPERATIONAL
NO.
1
0
3
3
7
2
2
1
1
6
4
0
4
1
3
0
4
1
1
1
1
6
1
0
1
8
4
3
2
1
0
10
4
4
1
1
0
0
0
0
My
288.
0.
1125.
375.
1788.
822.
726.
10.
550.
2108.
936.
0.
936.
519.
1198.
0.
1717.
617.
617.
60.
60.
3480.
800.
0.
10.
4290.
452.
1085.
1480.
327.
0.
3344.
1360.
1360.
265.
265.
0.
0.
0.
0.
CONSTRUCTION
NO.
0
1
2
0
3
0
1
0
0
1
2
0
2
2
4
0
6
0
0
0
0
1
0
3
0
4
0
3
0
1
2
6
2
2
0
0
2
2
1
1
My
0.
500.
1400.
0.
1900.
0.
450.
0.
0.
450.
737.
0.
737.
1169.
1279.
0.
2448.
0.
0.
0.
0.
360.
0.
579.
0.
939.
0.
1447.
0.
327.
708.
2482.
714.
714.
0.
0.
550.
550.
441.
441.
CONTRACT
AWARDED
NO.
0
0
0
0
0
0
1
0
0
1
0
1
1
0
0
1
1
0
c
p
0
1
6
1
0
8
0
1
0
0
0
1
e
0
0
0
2
2
1
1
My
0.
0.
0.
0.
0.
o.
720.
0.
0.
720.
o.
280.
280.
0.
0.
600.
600.
0.
0.
0.
0.
300.
3708.
316.
0.
4324.
0.
400.
0.
0.
0.
400.
o.
0.
0.
0.
740.
740.
441.
441.
393
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 5
SUMMARY OF F60 SYSTEMS EY SYSTEM SUPPLIER
TOTAL
SYSTEM SUPPLIER/PROCESS
PEABODY PROCESS SYSTEMS
LIMESTONE
LIME/ALKALINE FLYASH
TCTAL -
PULLMAN KELLOGG
LIME
LIMESTONE
TOTAL -
RESEARCH COTTRELL
LIMESTONE
TOTAL -
RILEV STOKER /ENVIRONEERING
LIMESTONE
TOTAL -
ROCKWELL INTERNATIONAL
AQUEOUS CARBONATE
TOTAL -
TENNESSEE VALLEY AUTHORITY
LIMESTONE
TOTAL -
UNITED ENGINEERS
LIME
MAGNtSIUM OXIDE
TOTAL -
VENDOR NOT SELECTED
LIMESTONE
TOTAL -
WHEELABRATOR -F RYE/ R.I.
AQUEOUS CARBONATE/SPRAY DRYING
TOTAL -
NO.
4
1
5
1
4
5
13
13
3
3
1
1
1
1
2
4
6
1
1
1
1
NU
1252.
475.
1727.
917.
1880.
2797.
5455.
5455.
626.
626.
100.
100.
550.
550.
1510.
844.
2354.
512.
512.
440.
440.
OPERATIONAL
NO.
3
0
3
0
1
1
7
7
3
3
0
0
1
1
0
1
1
0
0
0
0
My
805.
0.
805.
0.
280.
280.
2644.
2644.
626.
626.
0.
0.
550.
550.
0.
120.
120.
0.
0.
0.
0.
CONSTRUCTION
NO*
1
1
2
1
2
3
5
5
0
0
1
1
0
0
0
0
0
0
a
1
1
MU
447.
475.
922.
917.
950.
1867.
2061.
2061.
0.
0.
100.
100.
0.
0.
0.
0.
0.
0.
0.
440.
440.
CONTRACT
AWARDED
NO.
0
0
0
0
1
1
1
1
0
0
0
0
0
0
2
3
5
1
1
0
0
MU
0.
0.
0.
0.
650.
650.
750.
750.
0.
0.
0.
0.
0.
0.
1510.
724.
2234.
512.
512.
0.
0.
TOTAL -
124 49212.
62 21510.
39 16051,
23 11651,
394
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION <
SUMMARY OF F6D SYSTEMS BY PROCESS
TOTAL
OPERATIONAL
STATUS
CONSTRUCTION CONTRACT
AWARDED
PLANNED
PROCESS
Hi.
MW
NO.
NW
NO
MW
NO.
MW
NO.
MW
AQUEOUS CARBONATE
CITRATE
MAGNESIUM OXIDE
WELLMAN LOhD
SUBTOTAL - SALEABLE PRODUCT
AQUEOUS CARBONATE /SPRAY DRYING
DUAL ALKALI
LIME
LIMESTONE
LIMESTONE/ALKALINE FLYASH
LIME/ALKALINE FLYASH
LI ME /LIME STONE
LIME/SFRAt DRYING
PROCESS NOT SELECTED
SODIUP CARBONATE
1
1
5
fc
13
1
5
27
t6
2
12
5
6
35
4
100.
60.
1 444 .
2074.
3678.
440.
2012.
11732.
31016.
1480.
4549.
1328.
2337.
20770.
925.
0
1
1
4
6
0
3
17
2-4
2
4
2
0
0
4
0.
60.
120.
•1360.
1540.
0.
1170.
6209.
8714.
1480.
1452.
20.
0.
0.
925.
1
0
0
2
3
1
0
7
17
0
7
2
2
0
0
100.
0.
3.
714.
814.
440.
0.
3683.
7075.
0.
2781.
708.
550.
0.
0.
0
0
3
0
3
0
0
3
13
0
1
0
3
0
0
0.
0.
724.
0.
724.
0.
0.
1810.
7461.
0.
316.
0.
1340.
0.
0.
0
0
1
0
1
0
2
0
12
0
0
1
1
35
0
0.
0.
tro.
0.
600.
0.
842.
0.
7766.
0.
C.
6CO.
447.
20770.
0.
SUBTOTAL - THROWAUAY PRODUCT 163 76559.
56 19970.
36 15237.
20 10927.
51 3Q425.
TOTALS
SALEABLE X OF TOTAL MW
176 8C237.
5
62 21510.
7
39 16051.
5
23 11651.
6
52 31025.
2
395
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 7
SUMMARY OF OPERATIONAL FGO SYSTEMS BY PROCESS AND UNIT
PROCES S/
UNIT NAME
CITRATE
6.F. WEAT3N
DUAL ALKALI
A.B. BROUN
CANE RUN
NEWT ON
LINE
6RUC E MANSFIELD
BRUC E MANSFIELD
CANE RUN
CANE RUN
CONE SVILLE
CONE SVILLE
ELRAMA
GREEN
GREEN RIVER
HAWTHORN
HAWTHORN
HUNTER
HUNTJNGTON
MILL CREEK
PADDY'S RUN
PHILLIPS
PLEASANTS
LIMESTONE
APAC HE
APACHE
CHOLLA
CHOLLA
CORONADO
CRAIG
DUCK CREEK
JEFF REY
LA C VGNE
LAWRENCE
LAWRENCE
MARI ON
MARTIN LAKE
MARTIN LAKE
MARTIN LAKE
MONTICELLO
PETERSBURG
R.D. MORROW
R.D. MORROW
SOUTHWEST
TOMBIGBEE
TOMBIGBEE
WIDOWS CREEK
WINVAH
LIMESTONE/ALKALINE
SHERBURNE
SHERBURNE
UNIT NO.
1
1
6
1
1
2
4
5
5
6
1-4
1
1-3
3
4
1
1
3
6
1-6
1
2
3
1
2
1
2
1
1
1
4
5
4
1
2
3
3
3
1
2
1
2
3
8
2
FLVASH
1
2
CAPACITY
MW
60.
60.
265.
288.
617.
1170.
917.
917.
188.
200.
411.
411.
510.
242.
64.
90.
90.
360.
366.
442.
72.
410.
519.
6209.
195.
195.
119.
350.
280.
447.
378.
540.
874.
125.
420.
184.
595.
595.
595.
800.
532.
124.
124.
194.
179.
179.
550.
140.
8714.
740.
740.
INITIAL
STARTUP
11/79
3/79
4/79
9/79
12/75
7/77
8/76
12/77
1/77
6/78
10/75
12/79
9/75
11/72
8/72
5/79
5/78
8/78
4/73
7/73
3/79
8/78
6/79
1C/73
4/78
11/79
8/79
9/76
8/78
2/73
1/76
11/71
5/79
4/77
5/78
2/79
5/78
12/77
8/78
6/79
4/77
9/78
6/79
5/77
7/77
3/76
4/77
COMMERCIAL
STARTUP
1/80
O/ 0
o/ c
12/79
6/76
01 0
9/77
7/78
2/77
O/ 0
10/75
12/79
6/76
O/ 0
o/ c
O/ 0
o/ c
3/79
O/ 0
O/ 0
O/ o
1/79
4/79
12/73
O/ 0
1/80
11/79
8/78
01 0
6/73
O/ 0
O/ 0
5/79
10/78
01 0
o/ c
10/78
01 0
01 0
01 0
01 0
9/78
01 0
1/78
C/ 0
5/76
4/77
1480.
396
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 7
SUMMARY Of OPERATIONAL FGD SYSTEMS BY PROCESS AND UNIT
PROCESS/
UNIT NAME
UNIT NO.
CAPACITY
MW
INITIAL
STARTUP
COMMERCIAL
STARTUP
LIME/ALKALINE FLYASH
COAL CREEK 1
COLS TRIP 1
COLSTRIP 2
MILTON R. YOUNG 2
327.
360.
360.
405.
1452.
8/79
9/75
5/76
9/77
O/ 0
11/75
10/76
6/78
LIME/LIMESTONE
SHAVNEE
SHAH NEE
MAGNESIUM OXIDE
EDDY STONE
SODIUM CARBONATE
JIM BRIDGER
REID GARDNER
REID GARDNER
REID GARDNER
HELLMAN LORD
DEAN H. MITCHELL
SAN JUAN
SAN JUAN
SAN JUAN
IDA
10B
1A
11
1
2
3
10.
10.
20.
120.
120.
550.
125.
125.
125.
925.
115.
361.
350.
534.
1J60.
4/72
4/72
9/75
9/79
4/74
4/74
6/76
7/76
4/78
8/78
12/79
O/ u
O/ 0
9/75
2/80
O/ 0
O/ C
7/76
6/77
O/ C
O/ 0
O/ 0
TOTAL
21510.
397
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
PROCESS/
UNIT NAME
SECTION e
SUMMARY OF END-PRODUCT DISPOSAL PRACTICES FOR OPERATIONAL FGp SYSTEMS
THROWAWAY
UNIT NO STABILIZED UNSTAB1LIZED
-BYPRODUCT-
TYPE
DISPOSITION
CITRATE
G.F. WEATCN
DUAL ALKALI
A.B. BROWN
CANE RUN
NEWTON
LIME
ELEMENTAL SULFUR
BRUCE MANSFIELD
BRUCE MANSFIELD
CANE RUN
CANE RUN
CONESVILLE
CONESVILLE
ELRAMA
GREEN
GREEN RIVER
HAWTHORN
HAWTHORN
HUNTER
HUNTINGTOK
MILL CREEK
PADDY'S RUN
PHILLIPS
PLEASANTS
LIMESTONE
APACHE
APACHE
CHOLLA
CHOLLA
CORONADO
CRAIG
DUCK CREEK
JEFFREY
LA CVGNE
LAURENCE
LAWRENCE
MARION
MARTIN LAKE
MARTIN LAKE
MARTIN LAKE
HONTICELLC
PETERSBURG
R.D. MORRCW
R.D. MORROW
SOUTHWEST
TOMBI6BEE
TOMBIGBEE
WIDOWS CREEK
WINYAH
LIMESTONE/ALKALINE F
SHE A BUR NE
SHERBURNE
LIME/ALKALINE FLYASH
COAL CREEK
COLSTRIP
COLSTRIP
MILTON R. YOUNG
1
2
4
5
5
6
1-4
1
1-3
3
4
1
1
3
6
1-6
1
2
3
1
2
1
2
1
1
1
4
5
4
1
2
3
3
3
1
2
1
2
3
8
2
LYASH
1
2
1
1
2
2
LINED POND
LANDFILL
LANDFILL
LINED POND
LINED POND
LANDFILL
LANDFILL
LANDFILL
POND
POND
POND
LANDFILL
POND
POND
LANDFILL
POND
POND
POND
LANDFILL
LANDFILL
LANDFILL
LANDFILL
LANDFILL
POND
LANDFILL
LANDFILL
LANDFILL
LINED POND
LINEb POND
LINED POND
LINEb POND
LINED POND
LANDFILL
LINED POND
POND
POND
POND
POND
LINED POND
MINEFILI
LINED POND
UNLINED POND
POND
POND
POND
POND
MINEFILL
398
-------
EPA UTILITY F60 SURVEY: FOURTH 8UARTER 1979
SECTION !
SUMMARY Of END-PRODUCT DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS
PROCESS/
UNIT NAME
THROWAyAY
UNIT NO STAblLlZEO UNSTABIiIZED
-BYPRODUCT-
TYPE
DISPOSITION
LIME/LIMESTONE
SHAWNEE 10A
SHAUNEE 136
MAGNESIU* OXIDE
EDDYSTONE 1A
SODIUM CARBONATE
JIM BIUDGER <•
REID faARDMER 1
REID GARDNER 2
REID GARDNER 3
WELLMAN LORD
DEAN H. MITCHELL 11
SAN JUAN 1
SAN JUAN 2
SAN JUAN 3
SULFURIC ACID
POND
LINED POND
LINED PCND
LINED POND
ELEMENTAL SULFUR
ELEMENTAL SULFUR
ELEMENTAL SULFUR
SULFURIC ACID
MARKETED
MARKETED
399
-------
SECTION 9
SUMMARY OF FGD SYSTEMS IN OPERATION
COMPANY NAME/
UNIT NAME UNIT NO.
ALABAMA ELECTRIC COOP
TOMBIGBEE 2
ALABAKA ELECTRIC COOP
TOMBItBEE 3
ALLEGHENY POWER SYSTEM
PLEASANTS 1
ARIZ OHH ELECTRIC POWER COOP
APACHE 2
ARIZONA ELECTRIC POWER COOP
APACHE 3
ARIZONA PUBLIC SERVICE
CHOLLA 1
ARIZONA PUBLIC SERVICE
CHOLLA e.
BIG RIVERS ELECTRIC
GREEN 1
CENTRAL ILLINOIS LIGHT
BUCK CREEK 1
CENTRAL ILLINOIS PUBLIC SERV
NEWTON 1
COLORADO UTE ELECTRIC ASSN.
CRAIG 2
COLUMBUS 4 SOUTHERN OHIO EL EC.
CONESVILLE 5
COLUMBUS i. SOUTHERN OHIO EL E C .
CONESVILLE 6
COOPERATIVE POWER ASSOCIATION
COAL CREEK 1
DUOUESNE LIGHT
ELRAMA 1-4
OUQUESNE LIGHT
PHILLIPS 1-6
INDIANAPOLIS POWER I LIGHT
PETERSBURG 3
KANSAS CITY POWER I LIGHT
HAWTHORN 3
KANSAS CITY POWER t LIGHT
HAWTHORN *
KANSAS CITY POWER I LIGHT
LA CVGNE 1
KANSAS POWER I LIGHT
JEFFREY 1
KANSAS POWER & LIGHT
LAWRENCE 4
KANSAS POWER K LIGHT
LAWRENCE 5
KENTUCKY UTILITIES
GREEN RIVER 1-3
NEW OR
RETROFIT
NEW
NEW
NEW
NEW
NEW
RETROFIT
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
RETROFIT
RETROFIT
NEW
RETROFIT
RETROFIT
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
CAPACITY
MW
179. C
179. C
519.0
195. C
195. D
119. C
350.0
242. 0
378. C
617. C
447.0
411.?
411.0
327.0
510.0
410.0
532.0
90.0
90.0
874. C
540.0
125.0
420.0
64.0
PROCESS/
SYSTEM SUPPLIER
LIMESTONE
PEABODV PROCESS SYSTEMS
LIMESTONE
PEABODV PROCESS SYSTEMS
LIME
BABCOCK g WILCOX
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTHELL
LIME
AMERICAN AIR FILTER
LIMESTONE
RILE' STOKER/ENVIRONEERING
DUAL ALKALI
BUELL/ENV1ROTECH
LIMESTONE
PEABODV PROCESS SYSTEMS
LIME
AIR CORRECTION DIVISION, UOP
LIME
AIR CORRECTION DIVISION, UOP
LIME/ALKALINE FLVASH
COMBUSTION ENGINEERING
LIME
CHEMICO
LIME
CHEMICO
LIMESTONE
AIR CORRECTION DIVISION, UOP
LIME
COMBUSTION ENGINEERING
LIME
COMBUSTION ENGINEERING
LIMESTONE
BABCOCK ( WILCOX
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
COMBUSTION ENGINEERING
LIME
AMERICAN AIR FILTER
START-UP
DATE
9/78
6/79
3/79
8/78
6/79
10/73
4/78
12/79
9/76
9/79
8/79
1/77
6/78
8/79
10/75
7/73
12/77
11/72
8/72
2/73
8/78
1/76
11/71
9/75
400
-------
EPA UTILITY FGD SURVEY; FOURTH QUARTER 1979
SECTION 9
SUMKARY OF FGD SYSTEMS IN OPERATION
COMPANY NAME/
UNIT NAME UNIT NO.
LOUISVILLE GAS & ELECTRIC
CANE DUN <•
LOUISVILLE GAS & ELECTRIC
CANE RUN 5
LOUISVILLE GAS K ELECTRIC
CANE RUN 6
LOUISVILLE GAS & ELECTRIC
MILL CREEK 3
LOUISVILLE GAS & ELECTRIC
PADDY'S RUN 6
MINNKOTA POkER COOPERATIVE
MILTON f>. YOUNG i
MONTANA POWER
COLSTRIP 1
MONTANA POWER
COLSTRIP i
NEVADA POuER
REID GARDNER 1
NEVADA POWER
REID GARDNER I
NEVADA P04ER
REID GARDNER 2
NORTHERN INDIANA PUB SERVICE
DEAN H. MITCHELL 11
NORTHERN STATES POWER
SHERBURNE i
NORTHERN STATES POWER
SHERBURNE 2
PACIFIC POWER 8 LIGHT
JIM BRIDGcR 4
PENNSYLVANIA POWER
BRUCE MANSFIELD 1
PENNSYLVANIA POWER
BRUCE MANSFIELD t
PHILADELPHIA ELECTRIC
EDDYSTOME 1A
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 1
PUBLIC SERVICE OF MEW MEXICO
SAN JUAN i
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 3
SALT RIVER PROJECT
CORONADO 1
SOUTH CAROLINA PUbLIC SERVICE
WINVAH 2
SOUTH MISSISSIPPI ELEC PWR
NEW OR C
RETROFIT
RETROFIT
RETROFIT
RETROFIT
NEW
RETROFIT
NEW
NEW
NEW
RETROFIT
RETROFIT
NEW
RETROFIT
NEW
NEW
NEW
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
;APACITY
MW
138.0
200.3
288.0
442.?
72.0
405.0
360. C
360.0
125. C
125. C
125.0
115. C
740.0
740.0
550.0
917.0
917.0
120.0
361.0
350.0
534.0
280.0
140.0
124. C
PROCESS/ !
SYSTEM SUPPLIER
LIME
AMERICAN AIR FILTER
LIME
COMBUSTION ENGINEERING
DUAL ALKALI
ADL/COMbUSTION EOUlP ASSOCIATE
LIME
AMERICAN AIR FILTER
LINE
COMBUSTION ENGINEERING
LIME/ALKALINE FLVASH
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH
ADL/CONBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLVASH
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE
ADL/COMBUSTION EQUIP ASSOCIATE
WELLMAN LORD
DAVY POHER6AS
LIMESTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLVASH
COMBUSTION ENGINEERING
SODIUM CARBONATE
AIR CORRECTION DIVISION, UOP
LIME
CHEMICO
LIME
CHEMICO
MAGNESIUM OXIDE
UNITED ENGINEERS
WELLHAN LORD
DAW POWER6AS
WELLMAN LORD
DAVY POWER6AS
WELLMAN LORD
DAVY POUERGAS
LIMESTONE
PULLMAN KELLOGG
LIMESTONE
BABCOCK t WILCOX
LIMESTONE
START-UP
DATE
8/76
12/77
4/79
8/78
4/73
9/77
9/75
5/76
4/74
4/74
6/76
7/76
3/76
4/77
9/79
12/75
7/77
9/75
4/78
8/78
12/79
11/79
7/77
8/78
RILEV STOKER/ENVIRONEERIN6
401
-------
EPA UTILITY fGD SURVEY; FOURTH QUARTER 1979
SECTION 9
SUMMARY OF FGD SYSTEMS IN OPERATION
COMPANY NAME/
UNIT NAME
UNIT NO.
SOUTH MISSISSIPPI ELEC PUR
R.D. BORROW 2
SOUTHERN 1LL1NOI
MARION
SOUTHERN INDIANA
A.B. BROWN
SPRINGFIELD CITY
SOUTHfcEST
ST. JCE ZINC
G.F. kEATON
TENNESSEE VALLEY
SHAWNEE
TENNESSEE VALLEY
SHAyNEE
TENNESSEE VALLEY
WIDOWS CREEK
TEXAS UTILITIES
MARTIN LAKE
TEXAS UTILITIES
MARTIN LAKE
TEXAS UTILITIES
MARTIN LAKE
TEXAS UTILITIES
MONT I CELLO
S POWE R COOP
4
GAS & ELEC
1
UTILITIES
1
1
AUTHORITY
10A
AUTHORITY
ice
AUTHORITY
6
1
i
3
3
UTAH POWER & LIGHT
HUNTER 1
UTAH POWER i LIGHT
HUN TING TON 1
NEW OR
RETROFIT
NEW
NEW
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
NEW
NEW
CAPACITY
MW
124.0
184.0
265.0
194. P
60.0
10.0
10.0
550.0
595.0
595.0
595.0
800.0
360.0
366. C
PROCESS/
SYSTEM SUPPLIER
LIMESTONE
RILEV STOKER/ENVIRONEERING
LIMESTONE
BABCOCK g wILCOX
DUAL ALKALI
FMC CORPORATION
LIMESTONE
AIR CORRECTION DIVISION, UOP
CITRATE
BUREAU OF MINES
LIME/LIMESTONE
AIR CORRECTION DIVISION, UOP
LIME/LIMESTONE
CHEMICO
LIMESTONE
TENNESSEE VALLEY AUTHORITY
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
CHEMICO
LINE
CHEMICO
LIME
CHEMICO
START-UP
DATE
6/79
5/79
3/79
4/77
11/79
4/72
4/72
5/77
4/77
5/78
2/79
5/78
5/79
5/78
402
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 10
SUMMARY OF FGD SYSTEMS UNDER CONSTRUCTION
COMPANY NAME/
UNIT NAME UNIT NO.
ALLEGHENY POWER SYSTEM
PLEASANTS 2
ARIZONA PUBLIC SERVICE
CMOLLA 4
ARIZONA PUBLIC SERVICE
FOUR CORNERS 1
ARIZONA PUBLIC S ERVICE
FOUR CORNERS i
ARIZONA PUBLIC SERVICE
FOUR CORNERS I
ASSOCIATED ELECTRIC COOP
THOMAS HILL 3
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY 1
BASIN ELECTRIC POWER COCP
LARAMIE RIVER 1
BASIN ELECTRIC P OWE R COOP
LARAMIE RIVER <
BIG RIVERS ELECTRIC
GREEN i
CINCINNATI GAS K ELECTRIC
EAST BEND 2
COLORADO UTE ELECTRIC ASSN.
CRAIG 1
COMMONWEALTH EDI SON
POWERTON 51
COOPERATIVE POWER ASSOCIATION
COAL CREEK 2
OELHARVA POWER K LIGHT
DELAWARE CITY 1-3
EAST KENTUCKY POWER COOP
SPURLOCK 2
HOOSIER ENERGY
MfcROM 2
INDIANAPOLIS POWER & LIGHT
PETERSBURG '•
KANSAS POWER & LIGHT
JEFFREY 2
LAKELAND UTILITI ES
MCINTCSH 3
LOUISVILLE GAS & ELECTRIC
MILL CREEK 1
LOUISVILLE GAS t ELECTRIC
MILL CREEK 2
LOUISVILLE GAS K ELECTRIC
MILL CREEK 4
MINNESOTA POWER 8 LIGHT
NEW OR (
RETROFIT
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
NEW
NEW
NEW
RETROFIT
NEW
RETROFIT
NEW
NEW
NEW
NEW
NEW
RETROFIT
RETROFIT
NEW
NEW
OPACITY
MW
519.0
136. C
175. C
175.0
229. C
670.0
440.0
600.0
630.0
242. 0
650. C
447. C
450.0
327.0
180.0
500.0
441. c
530.0
490.0
364.0
358.0
350.0
495.0
475.0
PROCESS/ !
SYSTEM SUPPLIER
LIME
BABCOCK g WILCOX
LIMESTONE
RESEARCH COTTRELL
LIME/ALKALINE FLVASH
CHEMICO
LIME/ALKALINE FLYASH
CHEMICO
LIME/ALKALINE FLYASH
CHEMICO
LIMESTONE
PULLMAN KELLOGG
LIME/SPRAY DRYING
JOY MFG/NIRO ATOMIZER
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIME
AMERICAN AIR FILTER
LIME
BABCOCK g WILCOX
LIMESTONE
PEABODY PROCESS SYSTEMS
LIMESTONE
AIR CORRECTION DIVISION, UOP
LIME/ALKALINE FLYASH
COMBUSTION ENGINEERING
WELLMAN LORD
DAVY POUERGAS
LIME
ADL/COMBUSTION EQUIP ASSOCIATE
LIMESTONE
MITSUBISHI HEAVY INDUSTRIES
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
BABCOCK C WILCOX
L1ME/LIHEST0NE
COMBUSTION ENGINEERING
LIME/LIMESTONE
COMBUSTION ENGINEERING
LIME
AMERICAN AH) FILTER
LIMt/ALKALIME FLYASM
»TART-UP
DATE
9/80
6/80
11/79
11/79
11/79
1/82
11/61
4/80
10/80
11/8C
9/80
4/80
4/80
10/80
4/80
10/80
7/81
10/83
6/80
10/81
4/81
4/82
7/81
2/80
PEABODY PROCESS SYSTEMS
403
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 10
SUMMARY OF FGD SYSTEMS UNDER CONSTRUCTION
COMPANY NAME/
UNIT NAME UNIT NO.
MONTANA POWER
COLSTfilp 3
MONTANA POWER
COLSTRIP 4
NIAGARA MOHAWK POWER COOP
CHARLES R. HUNTLEY c6
NORTHERN STATES POWER
RIVERSIDE 6,7
OTTER TAIL POWER
COYOTE 1
PENNSYLVANIA POWER
BRUCE MANSFIELD 3
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 4
SALT RIVER PROJECT
CORONADO 2
SAN HI6UEL ELECTRIC COOP
SAN MIGUEL 1
SIKESTON BOARD OF MUNJC. UTIL.
SIKESTON 1
SOUTH CAROLINA PUBLIC SERVICE
W1NYAH 3
SPRINGFIELD WATER, LIGHT & PUR
OALLMAN 3
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK 7
TEXAS POWER C II 6HT
SANOOW 4
UTAH POWER * LIGHT
HUNTER 2
NEW OR
RETROFIT
NEW
NEW
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
RETROFIT
NEW
NEW
CAPACITY
MW
700.0
700.0
100.0
110.0
440.0
917.0
534.0
280.0
400.0
235.0
280.0
205.0
575.0
382. C
360.0
PROCESS/
SYSTEM SUPPLIER
LIME/ALKALINE FLYASH
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH
AOL/COMBUSTION EQUIP ASSOCIATE
AQUEOUS CARBONATE
ROCKWELL INTERNATIONAL
LIME/SPRAY DRYING
JOY MFG/NIHO ATOMIZER
AQUEOUS CARBONATE/SPRAY DRYING
WHEELABRATOR-FRYE/R.I .
LIME
PULLMAN KELLOGG
WELLMAN LORD
DAVY POWERGAS
LIMESTONE
PULLMAN KELLOGG
LIMESTONE
BABCOCK 8 WILCOX
LIMESTONE
BABCOCK 8 WILCOX
LIMESTONE
BABCOCK 8 WILCOX
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
COMBUSTION ENGINEERING
LIME
CHEMICO
START-UP
DATE
1/64
0/84
4/82
7/80
3/81
5/80
1/82
10/8C
9/80
1/81
5/8C
9/8C
10/8C
7/fiQ
6/80
404
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 11
SUMMARY OF CONTRACT AWARDED FGD SYSTEMS
COMPANY NAME/
UNIT NAME UNIT NO.
ALLEGHENY POWER SYSTEM
MITCHELL 23
ARIZONA PUBLIC SERVICE
FOUR CORNIRS *
ARIZONA PUBLIC SERVICE
FOUR CORNERS 5
BASIN ELEtTRIC POWER COOP
LARAMIE RIVER 3
HOOS1ER ENERGY
MEROM 1
HOUSTON LIGHTING & POWER CO.
W.A. PARISH C
PHILADELPHIA ELECTRIC
CROMfiY
PHILADELPHIA ELECTRIC
EDOYSTONE 1B
PHILADELPHIA ELECTRIC
EDOYSTONE 2
PUBLIC SERVICE OF INDIANA
GIBSON 5
SOUTH CAROLINA PUbLIC SERVICE
WlNYAH 4
SOUTHWESTERN ELECTRIC POWER
HENRY W. PERKEY 1
TENNESSEE VALLEY AUTHORITY
PARADISE 1
TENNESSEE VALLEY AUTHORITY
PARADISE i
TEXAS MUNICIPAL POWER AGENCY
GIBBONS CREEK 1
TEXAS POWER & LIGHT
TWIN OAKS 1
TEXAS POWER & LIGHT
THIN OAKS <
TEXAS UTILITIES
MARTIN LAKE 4
TUCSON GAS & ELE CTRIC
SPRIN6ERV1LLE 1
TUCSON GAS i. ELECTRIC
SPRINGERV1LLE 2
UTAH POWER t LIGHT
HUNTER 3
UTAH POWER & LIGHT
HUNTER 4
WISCONSIN POWER C LIGHT
NEW OR C
RETROFIT
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
RETROFIT
:APACITY
MW
300.0
755.0
755. C
600.0
441.0
512. 3
150.0
240.0
334.0
650. C
280.0
720.0
704.0
704.0
400.0
750.?
750.0
753.0
370.0
370.0
400.0
400. 0
316.0
PROCESS/
SYSTEM SUPPLIER
LIME
CHEH1CO
LIME
UNITED ENGINEERS
LIME
UNITED ENGINEERS
LIME/SPRAY DRYING
BABCOCK & WILCOX
LIMESTONE
MITSUBISHI HEAVY INDUSTRIES
LIMESTONE
VENDOR NOT SELECTED
MAGNESIUM OXIDE
UNITED ENGINEERS
MAGNESIUM OXIDE
UNITED ENGINEERS
MAGNESIUM OXIDE
UNITED ENGINEERS
LIMESTONE
PULLMAN KELLOGG
LIMESTONE
AMERICAN AIR FILTER
LIMESTONE
AIR CORRECTION DIVISION, UOP
LIMESTONE
CHEMICO
LIMESTONE
CHEMICO
LIMF.STONE
COMBUSTION ENGINEERING
LIMESTONE
CHFM1CO
LIMESTONE
CHEMICO
LIMESTONE
RESEARCH COTTRELL
LIME/SPRAY DRYING
JOY MFG/NIRO ATOMIZER
LIME/SPRAY DRYING
JOY MFG/NIRO ATOMIZER
LIMESTONE
CHEMICO
LIMESTONE
CHEMICO
LIME/ALKALINE FLYASH
START-UP
DATE
fJ&i
C/8t
0/?i
7/81
5/5 :
11/8i
6/s:
*/?:
t/s :
0/8;
7/81
12/84
6/S2
3/82
1/82
8/84
8/8S
0/85
0/85
0/87
0/83
0/85
1/82
COLUMBIA 2
CHEMICO
405
-------
EPA UTILITY Fl-D SURVEY: FOUnTH JUARTER 1579
SECTION 12
SLV>,ABY OF PLANNED FGD SYSTEMS
COMPANY Nnh.t/ \'Lt, os
u;«lT t.AI-.L Ui.IT MO. F.--TROF1T
Lt-TTES ... F I:;TL\T S I IA' i t
•vGRTHtTv INHA'.A F Uo -> : n V 1 f L ktU
\l/F>THEPI\ GUIANA F U o i ; K Y I C L K' L W
HHAH f C i- 1
» t :.U£S T; NO/i VALUA TINfi [IDS
IAS1N =Lf_LTi,lC H31-ER ClOf' NEW
UNTPAL ILLINOIS LIGHT NEW
DUCK C1?:: if
•"UDOLE SOuTH UTILITIES MW
«RKA\SAb LOAL 5
MIDDLE SOUTH UTILITIES MW
ARKANSAS COAL (,
MIDDLE SOuTH UTILITIES NEW
LOUISIANA COAL 1
MIDDLE SOUTH UTILITIES NEW
LOUISIANA COAL i
KIDDLE SOUTH UTILITIES NEW
MISSISSIPPI COAL 1
MIDDLE SOUTH UTILITIES NEW
MISSISSIPPI COAL t
MUSCATINE POWER & WATER NEW
MUSCATINE 9
NORTHERN STATES POWER NEW
SHERBURNE 3
SEMINOLE tLECTRlC NEW
StMlNCLE 1
SEMINCLE ELECTRIC NEW
SEMlNCLt 'i
TAMP* ELECTRIC NEW
BIG EJENU 4
TENNESSEE VALLEY AUTHORITY RETROFIT
JOHNSONVILLE 1-1C
TEXAS UTILITIES NEW
FOREST GROVE 1
CONSIDERING FGD SYSTEMS
BIG RIVERS ELECTRIC NEW
D. ti. WILSON 1
BIG RIVERS ELECTRIC NEW
D. B. WILSON i
CENTRAL MAINE POWER NEW
SEARS ISLAND 1
COLORADO UTE ELECTRIC ASSN. NEW
CRAIG 3
COLUMBUS i SOUTHERN OHIC EL E C . NtU
CAPACI -Y
nu
421.7
4,1.-
44-.:
416.-
8^.-
890.:
890. C
89C.O
890.0
890. C
160.0
860.0
620.0
620.0
475. r
600. C
750. T
440.0
44C.O
600.0
447.0
375."
PROCESS/
SYSTEM SUPPLIER
DUAL ALKALI
FI1C CORPORATION
DUAL ALKALI
FMC CORPORATION
PROCESS NOT SELECTED
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
LIMESTONE
COMbUSTjON ENGINEERING
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
MAGNESIUM OxIDE
TVA/UNITED ENGINEERS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
LIME/LIMESTONE
VENDOR NOT SELECTED
LIME/SPRAY DRYING
VENDOR NOT SELECTED
PROCESS NOT SELECTED
START-UP
DATE
6/81
6/85
11/83
1/86
1/86
1/81!
0/86
T/8a
0/8S
0/87
-------
EPA UTILITY FGO SUKVEY: FOURTH OuARTtB ^579
SECTION 12
SUMMARY Of PLANNED FGO SYSTEMS
COMPANY NAME/
UNIT NAPlt UMT NO.
COLO^bUS t. SOUTHERN OHIO EL t C .
POSTON t
DELMARVA HO*ER & LIGHT
VIENNA hAHYLAND 9
EAST KENTUCKY POWER COOP
J. K. SMITH 1
EAST KENTUCKY POWER COOP
J. k. ShlTH i
GtNE'AL POC.LIC UTILITIES
COhO 1
GENERAL PUBLIC UTILITIES
GILBERT 1
GENERAL PUBLIC UTILITIES
SCOTTSVILLE 1
GENERAL PUBLIC UTILITIES
SfcwARD 7
GENERAL PUBLIC UTILITIES
tatHRUf 1
INDIANAPOLIS POWER fc LIGHT
PATRIOT 1
INDl»lsAPOLJS POWER 6 LIGHT
PATRIOT ^
INDIANAPOLIS POWER i. LIGHT
PATRIOT 3
LOUISVILLE GAS & ELECTRIC
TRIMtUE COUNT* 1
LOUISVILLE GAS K ELECTRIC
TRIMBLE COUNTY i
NEVADA POtaER
HARRY ALLEN 1
NEVADA POWER
HARRY ALLEN i
NEVADA PO^ER
HARRY ALLEN 3
NEVADA POWER
HARRY ALLtN <•
NEVADA POWER
REID GARDNER <•
NEVADA POKED
WARNER VALLEY 1
NEVADA POWER
WARNER VALLEY 2
NEW YCRK STATE ELEC 8 GAS
SOMERSET 1
PACIFIC GAS & ELECTRIC
HONTEZUKA 1
PACIFIC GAS ft ELECTRIC
NEW OR
RETROFIT
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEU
CAPACITY
CIW
375.?
550.0
o5".:
6s:.c
»jo.-
625. r
6Z5.0
800. C
625. C
650. C
650.0
650.0
575.0
575.0
500.0
500.0
500.0
500.0
25C.O
250.0
250.0
870. C
800.3
830. 0
PhOCESS /
SYSTEM SUPPLIER
PROCESS NOT ScL£CT£D
VtNUOR NOT SELECTED
Ll"cSTONE
VENOOS NOT SEeECTiD
PhOCfSS SOT StLtCTEO
WLNuOK NOT STLECTtD
PROCESS NOT SELECTED
vtNuon NOT ^ELECTED
PROCESS NOT ScL£CTtD
VdMjOh NOT SELECTED
PROCESS NOT StLECTED
VE«JfcC« NOT SELECT=DC
PROCESS NOT SELECTED
VENDOR NOT SELECTtDD
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTtDD
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
START -UP
DAU
r /?•.
:/*•?
1/-',
i/°t
1 ? t <• .-
: / r-
:/9i
12/ C7
:/<55
c /??
0/97
0/87
7/84
7/84
6/86
6/e?
6/88
6/8$
4/83
6/85
6/8t>
6/8t
6/86
6/87
VENDOR NOT SELECTED
-------
EPA UTILITY FID SURVEY; FOURTH QUARTER 1979
SECTION 12
SbKHARY OF PLANNED FGO SYSTEMS
COMPANY NAME/
UNIT NAME
UNIT NO.
NEW OR
RETROFIT
CAPACITY
nu
PROCESS/
SYSTEH SUPPLIER
START-UP
DATE
POTOMAC ELECTRIC POWER
OKKERSCN 4
POWLR AUTHORITY of NEW YORK
ARTHUR KILL
SALT Riven PROJECT
CORONADO 3
N ILLINOIS POWER COOP
MARION 5
TEXAS UTILITIES
MILL C"EEK 1
TEXAS UTILITIES
CRtEK 2
NEW
NEW
NEW
MW
NEW
NEW
800.C PROCESS NOT SELECTED
VENDOR NOT SELECTED
709.C PROCESS NOT SELECTED
VENDOR NOT SELECTED
280.0 LIMESTONE
VENDOR NOT SELECTED
300.C PROCESS NOT SELECT6D
VENDOR NOT SELECTED
750.0 PROCESS NOT SELECTED
VENDOR NOT SELECTED
750.0 PROCESS NOT SELECTED
VENDOR NOT SELECTED
C/87
11/87
O/ 0
0/84
0/86
403
-------
EPA UTILITY F6D SURVEY: FOURTH OUARTER 1979
SECTION 13
TOTAL FGD UNITS AND CAPACITY (HU) INSTALLED BY YEAR
YEAR
1968
1969
1971
1972
1973
1974
1975
197t
1977
1978
1979
198C
1981
1982
1983
1984
1985
1986
1987
1988
1989
199C
1991
1995
UNDEFINED
NEW ON LINE
NO. MU
1
0
4
t
b
3
t
b
11
12
2C
25
11
16
7
9
12
9
12
4
2
1
1
1
12
140.
0.
702.
518.
1938.
606.
2018.
2786.
4684.
4736.
6345.
9839.
5003.
7798.
3036.
5915.
6766.
5721.
7960.
3080.
875.
625.
625.
625.
2242.
TERMINATED
NO. HW
0
1
0
0
1
3
3
3
1
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0.
140.
0.
0.
175.
340.
1637.
850.
47.
0.
23.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
TOTAL
NO.
1
0
4
12
19
19
22
27
37
50
69
94
105
121
128
137
149
158
170
174
176
177
178
179
ON LINE
nu
140.
0.
702.
1220.
2983.
32SO.
3631.
5567.
10204.
14940.
21262.
31101.
36104.
43902.
46938.
52853.
59619.
6534Q.
73300.
76380.
77255.
77880.
78505.
79130.
409
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL
PARTICLE
SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NC/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY V/FGO - My
NET UNIT GENERATING CAPACITY UO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMi TER - M
•• FUEL DATA
FUEL TYPE
FUEL GdADE
AVERAGE HEAT CONTENT - J/G
RANGE MEAT CONTENT - 6TU/LFJ
AVERAGE ASH CONTENT - X
RANGE ASH CONT INT - Z
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
COMMONWEALTH EDISON
VILL COUNTY
1
ROMEOVILLE
ILLINOIS
»***> •*
86.
774.
1147.0
165. 0
137.0
i .ZOO LB/MHBTU)
< 1.8DO LB/MMBTU)
*•**•**
BABCtCK 8 WILCOX
CYCL'INE
CYCLIC
0/51
363.36
179.*
107.
3.8
< 770000 ACfM)
( 355 F)
C 350 FT)
( 12.4 FT)
COAL
22260.
7.40
3-16
****:«*
1.50
0.3 - 4.5
******
< 9570 BTU/LB)
9,100 - 10.500
** ESP
NUMBER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY
FLUE GAS TEMPERATURE - C
•• PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
TYPE OF N02ZLEI
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID RECIRCUtATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - C/CU.M
PARTICULATE DESIGN REMOVAL EFFICIENCY
COLD SIDE
WESTERN PRECIPITATION
X 79.0
179.4 ( 355 F)
VENTURI
BABCI CK t WILCOX
CARBON STEEL
PLASITE AND KAOCRETE
STAINLESS STEEL
- X
181.7
179.4
365.4
36.6
.4
91.0
385000 ACFM)
3)5 F)
5800 6PM>
18.0 6AL/1000ACF)
••• IN-H20)
120.0 FT/SI
.16 6R/SCF)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPENABILITV RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/75
A
B
SYSTEM
94.0
.0
99.2
.0
81.2
.0
744 609
410
-------
EPA UT1KITT FGD SURVEY: FOURTH QUARTER 1979
COMMONWEALTH EDISON: WILL COUNTY 1 (CONT.)
.__.—-.- 1 —PERFORMANCE 6ATA
PERIOD NODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION
Z REMOVAL PER BOILER
S02 PART. HOURS HOURS
FED CAP.
HOURS FACTOR
.* PROBLEMS/«OLUTIONS/CO«MENTS
A MENTURI HOSE LEAK FORCED MODULE A OUT ONCE.
MODULE B HAS OUT OF SERVICE TWICE FOR NO DEMAND AND ONCE AS A RESULT OF AN
ACCIDENTAL 50 MINUTE TRIP.
COAL BURNED THIS MONTH AVERAGED LESS THAN ONE PERCENT SULFUR.
4/75
A
B
SYSTEM
37.0
.0
39.5
.0
35.0
.0
720 638
PROBLEMS/SOLUTIONS/COMMENTS
CHICAGO FLY ASH IS TREATING MATERIAL FROM THE SCRUBBER WITH LIKE AND FLY
ASH AND DUMPING IT INTO THE HOLDING BASIN.
A BOILER OUTAGE FORCED MODULE A OUT OF SERVICE ONCE THIS MONTH (MODULE B
MAS ALREADY OUT OF SERVICE).
COAL BURNED THIS MONTH WAS RECLAIM COAL ANO VARIED IN SULFUR CONTENT.
5/75
A
B
SYSTEM
84.5
37.1
84.5
37.1
84.5
37.1
744
744
PROBLEMS/SOLUTIONS/COMMENTS
MODULE B UAS IN SERVICE ON HAY 20 FOR THE FIRST TIME SINCE APRIL 13, 1973.
RECIRCULAT10N TANK MIXERS.
MODULE A (WHICH UAS THE ONLY ONE OPERATING) UAS FORCED OUT TUICE IN APRIL
TO AVOID POND OVERBOARDING INTO THE DES PLAI HES RIVER. THE SECOND OUTAGE
LASTED UNTIL MAY 5. DURING THE PAST SEVERAL MONTHS OF GENERALLY CONTINUOUS
OPERATION OF MODULE A. IT HAS BECOME APPARENT THAT THE PRESENT LIQUID
CIRCULATING SYSTEM CANNOT BE OPERATED IN A CONTINUOUSLY CLOSED CYCLE. THE
HATER IMBALANCE POSES A HIGH RISK OF OVERBOARDING FROM THE SLUDGE POND
DURING LONG PERIODS OF SUST IINED OPERATON. THE FOLLOWING REVISIONS HAVE
BEEN MADE TO REDUCE THE UATER IMBALANCE:
1. THE PUMP GLAND UATE I FLOUS HAVE BEEN CUT FROM 10 GPM TO 5 GPP>.
2. THE SCRUBBER HOUSE SERVICE UATER FILTER BACKWASH HAS BEEN ROUTED
OUT OF THE SYSTEM.
3. THE CONTINUOUS UNOERSPRAY HAS BEEN CHANGED TO AN INTERMITTENT
SPRAY 5 MINUTES ON. 5 MINUTES OFF.
THE THICKENER HAS BEEN DOUN SINCE APRIL 21 DUE TO A BROKEN GEAR AND A STUCK
SWEEP ARM. THE THICKENER HAS BEEN BYPASSED AND THE SLUDGE IS GOING TC THE
POND.
DURING MAY. MODULE A WAS OUT FOR 45 MINUTES DUE TO A DAMPER TRIP.
MODULE A UAS OUT ONCE FOR SPRAY NOZZLE CLEANING.
MODULE B UAS OUT TUICE AFTEf START UP, ONCE FOR A VENTURI PUMP TRIP AND
ONCE FOR A RECIRCULATION TANK LEVEL TRIP.
CHICAGO FLY ASH IS TREATING THE MATERIAL FROM THE SCRUBBER UITH LIME AND
FLY ASM AND DUMPING IT INTO THE HOLDING BASIN. A MIXER HAS BEEN INSTALLED
AT THE THICKENER, WHICH ENABLES THEM TO SUBSTITUTE SEALED DUMP TRUCKS FOR
THE CEMENT TRUCKS UHICH UERE USED IN THE PAST FOR MIXING AND TRANSPORTING
THE UASTE MATERIAL TO THE HOLDING BASIN.
COAL BURNED THIS MONTH VARIED GREATLY IN SULFUR CONTENT. RANGING FRO* LOW
SULFUR WESTERN COAL TO HIGH SULFUR ILLINOIS COAL.
6/75
A
B
SYSTEM
85.5
60.6
84.6
54.1
75.4
73 C 642
.. PROBLEMS/iOLUTIONS/COMMENTS
A REHEATER PLUG6AGE INSPECTION FORCED ONE MODULE A OUTAGE.
A LOW LEVEL TRIP CAUSED A 35 MINUTE OUTAGE. AND NO DEMAND ACCOUNTED FOR TUO
MORE MODULE A OUTAGES.
MODULE B UAS OUT FOR 95 HOURS TO CLEAN THE BOOSTER FAN AND DEMISTER.
HIGH BOOSTER FAN VIBRATIONS CAUSED MODULE B TO SHUT DOWN ON JUNE 30.
DURING THIS MONTH HIGH SULFUR COAL WAS BURNED IN A TUO WEEK TEST, AND LOU
SULFUR COAL WAS BURNED THE REST OF THE MONTH.
7/75
A
B
SYSTEM
.0
79.2
.0
79.4
.0
73.5
744 689
411
-------
EPA UTILITY F6D SURVEY: FOURTH BUARTER 1979
COMMONWEALTH EDISON! WILL COUNTY 1
.....—.......—....—.___._.— ....... .PERFORMANCI DATA--—
PERIOD MODULE AVAILABILITY OPERABILITT RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
CHICAGO FLY ASH IS TREATIN6 THE SCRUBBER WASTE MATERIAL WITH LIME AND FLY
ASH AND DUMPING IT INTO THE ON SITE HOLDING BASIN. THE MATERIAL FROM THE
HOLDIR6 BASIN IS BEING TRUCKED TO AN OFF SITE DUMP.
MODULE B WAS OUT ONCE (30 MINUTES) TO REPAIR A MINOR STEAM HEADER LEAK
MODULE B WAS OUT ONCE DUE T'C NO DEMAND.
LOW SULFUR COAL WAS BURNED HOST OF THIS MONT. WITH HIGH SULFUR COAL BE INK
BURNED DURING THE LAST WEEK OF THE MONTH.
8/75
A
B
SYSTEM
.0
93.5
.0
100.0
.0
76.4
7*4 565
** PROBLEHS/tOLUTIONS/COMMENTS
IN JUNE, MODULE A ENCOUNTERED PLU6GA«F IN THE OEftlSTER, WHICH REQUIRED IT*
REPLACEMENT. THE WORK WAS COMPLETED IN AUGUST. *
MODULE A WENT OUT OF SERVICE ON JUNE 20 AND REMAINED OUT THROUGH AUGUST Bur
TO MASSIVE REHEATER LEAKS. THERE IS PRESENTLY A HOLD ON THE NEW REHEATEB
ORDER BECAUSE OF MATERIAL FAILURES EXPERIENCED IN MODULE B'S CARBON STEEL
REHEATER.
MODULE B SUFFERED TWO OUTAGES IN JULY AND ONE IN AUGUST BECAUSE OF REHEATPB
TUBE LEAKS. THE FAILURES WERE DUF TO VIBRATION FATIGUE. THE REHEATER. WHiru
WAS INSTALLED IN MAY, HAS LIST SIX OF ITS TWELVE TUBE BUNDLES SO FAR THF
LENGTH OF TINE THAT THE TUBES HAVE LASTED WOULD SEEM TO INDICATE THAT TMFBc
IS A IIESIGN RELATED MATERIAL DEFICIENCY. THREE OF THE TUBE BUNDLES WERE
REPLACED WITH MARGINAL BUNDLES LEFT OVER FROM MODULE A.
A SMALL STEAM HEADER LEAK CAUSED ONE MODULE B OUTAGE.
MODULE B WAS OUT FOUR TINES FOR NO DEMAND AND ONCE FOR A LOW FLOW TRIP
HIGH SULFUR COAL WAS BURNED ALL MONTH, CAUSING AN INCREASE IN SLUDGE *
PRODUCTION WHICH HAS FORCED A MINIMUM SIX DAV A WEEK, TEN HOUR A DAY
SLUDGE DISPOSAL OPERATION. THE SLUDGE IS BEING TREATED WITH LINE AMD
FLY ASH AND BEING DUMPED INTO THE ON SITE HOLDING POND. STABILIZED
MATERIAL IS BEING TRUCKED FROM THE POND TO AN OFF SITE DISPOSAL AREA.
9/75
10/75
A
B
SYSTEM
A
B
SYSTEM
.0
32.3
.0
100.0
.0
26.6
720
744
194
** PROBLEMS/SOLUTIONS/COHMENTS
NODULE A WAS OFF THE ENTIRE 11 OATS THE BOILER OPERATED THIS MONTH. HAITI*..
FOR IIS NEW REHEATER, WHICH HAS NOW BEEN RELEASED FOR MANUFACTURING BY
SHED.
MODULI B HAD TWO OUTAGES, O IE FOR NO ftEMANk AND ONE MINOR 15 MINUTE TRIP
HIGH SULFUR COAL WAS BURNED THIS MONTH WHEN THE SCRUBBER WAS IN SERVICE
THE SLUDGE IS BEING TREATED WITH LIME AND FLV ASH AND HAULED TO AN OFF *
DISPOSAL AREA.
11/75 A
B
SYSTEM
12/75 A
B
SYSTEM
1/76
A
B
SYSTEM
2/76 A
B
SYSTEM
3/76 A
.0
.0
.0
.0
.0
.0
.0
.0
30.1
45.2
.0
.0
.0
.0
.0
.0
.0
.0
18.8
720
744
744
696
412
-------
EPA UTIIITT FCD SURVEY: FOURTH QUARTER 1979
COMMONWEALTH EDISON: HILL COUNTY 1 (CONT.)
_—_———— —~—— -__.__—_ -PERFORMANCE DAT* ————
PERIOD MOBULE AVAILABILITY OPERABIL1TV RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B 8.8 20.4 8.5
SYSTEM 744 309
** PROBLEMS/BOLUT10NS/COMHENTS
UNIT 1 WAS DOWN FROM OCTOBER 11 THROUGH MARCH 19 FOR ITS BOILER TURBINE
AND SCRUBBER OVERHAUL. THE MAJOR ITEMS TO BE ACCOMPLISHED DURING THE
OUTAGE WERE:
1. SIMPLIFICATION OF THE MILLING SYSTEM CONTROL.
2. PULLING AND CLEANINC OF THE MODULE B REHEATER AND RETURNING IT
REPLACED WITH MAR6I>AL BUNDLES LEFT OVER FROM MODULE A.
3. CLEANING OF THE PONt PUMP BAY.
4. REMOVAL OF THE «ENTURI AND ABSORBED PUMP CHECK VALVES (ONE OF THEM
FAILED LAST SPRING AND DESTROYED A PUMP LINER AND IMPELLER).
5. CLEANING AND REPAIR OF THE VENTURI NOZZLES AND SUPPORTS.
6. REPAIR OF CORRODED REHEATER SUPPORTS.
7. RESETTING AND ADJUSTMENT OF ALL DAMPERS.
8. REVISION OF SCRUBBER CONTROLS BY RCNOVING THE CONTROLS NO LONGER
USED OR NEEDED.
9. INSPECTION AND CLEA IIN6 OF THE ENTIRE SCRUBBER AND RELATED
EQUIPMENT.
MODULE A MAS PUT INTO THE ft.S PATH ON MARCH 22 AND REMAINED AVAILABLE FOR
SERVICE THE REST OF THE MONTH.
NODULE B HAD TO REMAIN OUT OF SERVICE UNTIL MARCH 29 WHILE ITS REPAIRED
REHEA1ER WAS INSTALLED.
4/76 A 13.0 20.0 19.2
B 49.3 47.3
SYSTEM 720 691
•• PROBLEMS/*OLUTIONS/COMHENTS
UNIT 1 RETURNED TO SERVICE APRIL 2 AFTER A SHORT TURBINE CONTROL OUTAGE.
BOTH MODULES CAME ON LINE JUST BEFORE THE BOILER.
A FIVE DAY OUTAGE OF MODULE B HAS DUE TO REHEATER TUBE BUNDLE LEAKS.
SEVERAL MODULE B OUTAGES WERE DUE TO PLUGGED ABSORBER TANK SCREENS CAUSED
BY MILL AND CLASSIFIER FAILURES WHICH ALLOWED ROCK TO GET INTO THE SYSTEM.
MODULE B HAS THOROUGHLY CLEANED.
ONLY ONE ABSORBER PUMP IS BEING USED IN MODULE B, SINCE THE 182 PUMP LINER
FAILED AS A RESULT OF A BROKEN DISCHARGE VALVE. A REPLACEMENT LINER IS
BEING INSTALLED.
A SCRUBBER TESTING AND EVALUATING PROGRAM MAS STARTED THIS MONTH. MUCH OF
THE LATTER TWO WEEKS OF THE MONTH HERE SPENT TRAINING THE TESTING PERSON- .
NEL. THE PROGRAM WILL PROVI IE CHEMISTRY DATA AND OPERATING CHARACTERISTICS
5/76 A .0 .0 .0
SYSTEM 744 665
** PROBLEMS/IOLUTIONS/CONNENTS
A VENTRUI HOSE LEAK FORCED NODULE B OFF ONCE THIS MONTH.
MODULE B HAS TAKEN OUT OF SERVICE ONCE BECAUSE OF A PLUGGED ABSORBER TANK
SCREEN.
MODULE B MAS OFF ONCE DUE TO A FOULED I.D. FAN.
MODULE B MAS OUT OF THE GAS PATH ONCE DUE TO NO DEMAND.
6/76 A S2.0 **.2 37.6
8 16.2 84.5 71.9
SYSTEM 720 612
«• PROBLfcNS/tOLUTIONS/CONMENTS
NODULE A SUFFERED VENTURI PUMP LINER FAILURES ON APRIL 78 WHEN AN INLET 16
INCH SUTTERFLV ISOLATION VAftVE BROKE APART AND FELL INTO THE VENTURI PUMP.
BOTH THE A AND BACKUP AB VEiTURI PUMP LINERS MERE DESTROYED. NODULE A
REMAINED OUT SERVICE UNITL JUNE 9, WHEN THE LINERS MERE REPLACED.
MODULE A WAS OFF ONCE FOR SHEARED BYPASS DAMPER PINS.
I.D. BOOSTER FAN FOULING FORCED MODULE A OIF ONCE THIS MONTH FOR ABOUT
164 HOURS.
BOTH MODULES MERE OFF TWICE DUE TO NO DEMAND. DURING THESE OUTAGES. THE
DEMISTERS MERE MASHED AND ABSORBER TRAY SCALE. IF ANY. MAS KNOCKED Off.
MODULE B MAS OUT OF THE GAS PATH FOR SEVERAL SHORT VENTURI LOW FLOW TRIP
OUTAGES DUE TO A PLUGGED, SCALED VENTURI TANK SCREEN. AT THE END OF THE
MONTH. THE MODULE WAS TAKEN OUT TO CLEAN THE SCREEN.
413
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
COMMONWEALTH EDISON: HILL COUNTY 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
THE MODULE B I.D. BOOSTER FAN REQUIRED CLEANING DURING THE MONTH.
THE RENEATER TUBES ARE SCALING, WHICH RESULTS IN A LOWER HEAT TRANSFER RATE
RATE, AND THEREFORE INCREASfS I.D. BOOSTER FAN FOULING. THE ONLY WAV TO
CLEAN THE RENEATERS EFFECTIfELY IS TO REMOVE THEM, WHICH DEMANDS A SUBSTAN-
TIAL OUTAGE.
7776
A
B
SYSTEM
19.9
86.2
.0
90.0
.0
72.3
7*4
598
•* PROBLEMS/IOLUUONS/COMMENTS
MODULE A WAS OFF THE FIRST PART OF THE MONTH DURING REPAIRS TO THE ABSORBER
THE LATTER PART OF THE MONTH THE MODULE WAS READY FOR SERVICE BUT MAS NOT
OPERATED BECAUSE OF THICKENER-POND SLUDGE OVERLOADING.
MODULE B WAS FORCED OFF ONCE TO BALANCE THE I.D. BOOSTER FAN, AND ONCE TO
WASH THE FAN.
MODULE B WAS OUT Of THE CAS PATH TWICE DUE TO NO DEMAND.
8/76
A
B
SYSTEM
98.2
65.4
57.6
61.4
38.3
40.9
744 495
*• PROBLEMS/BOLUTIONS/COMMENTS
MODULE A WAS OUT OF THE GAS PATH THE FIRST HALF OF THE MONTH T AVOID
THICKENER-POND OVERLOADING.
DURING THE LATTER HALF OF THE MONTH. MODULE A WAS USED WITH THREE MINOR
FORCED OUTAGES AND ONE FOUR DAY NO DEMAND OUTAGE.
MODUL6 B WAS OUT OF THE GAS PATH THREE TIMES DUE TO NO DEMAND.
LOSS OF CHEMICAL CONTROL CAUSED TWO MODULE A OUTAGES.
MODULE B WAS OFF FOR NINE DAYS DUE TO FOULING.
SPENT SLURRY VALVE REPAIRS FORCED A MODULE B OUTAGE.
ON AUGUST 12 THE OPERATING PH CONTROL SET POINT WAS REDUCED FROM 5.4 TO
5.1. IT IS BELIEVED THAT THIS LOWER PH IS THE CAUSE OF THE FOULING OUTACE
OF MODULE B ON AUGUST 21. M0DULE A WAS ALSO OPERATED FOR THREE DAYS, AND
IT, TOO. EXPERIENCED INCREASED SACLE FOULING. THE PH SET POINT WAS THEN
INCREASED BACK TO 5.4.
9/76
A
B
SYSTEM
42.3
79.4
28.7
22.6
59.9
720 566
PBOBLEMS/SOLUTIONS/COMMENTS
MODULE A WENT OFF ONCE DUE TO A LOW FLOW TRIP.
MODULE A WAS TAKEN OFF ONCE FOR CLEANING Of THE RECIRCULATION TANK AND
PUMPS* AND INSPECTION Of PUBP ISOLATION VALVES.
A LINER LEAK IN 1A2 ABOSORBER PUMP ALSO FORCED MODULE A OFF.
MODULE A WAS OUT OF TN CAS PATH TWICE DUE TO NO DEMAND.
MODULE A WAS TAKEN OFF ONCE TO AVOID THICKENER-POND OVERLOADING.
SPENT SLURRY VALVE TROUBLE CAUSED TWO MODULE B OUTAGES.
10/76
A
B
SYSTEM
17.9
76.4
28.9
56.2
37.9
54.8
744 726
*• PROBLEMS/SOLUTIONS/COMMENTS
HIGH SULFUR ILLINOIS COAL WIS BURNED IN THE BOILER FROM MARCH THROUGH
OC TOBE R.
TNE SCRUBBER WASTE MATERIAL WAS TREATED WITH LIME ANC FLY ASH AND HAULED TO
AN OFC SITE DISPOSAL AREA.
MODULI A OPERATED ON ONE ABSORBER PUMP. ALLOWING TESTING ON A LOWER
ABSORBER FAN.
MODUL6 A WAS OUT OF THE GAS PATH ONCE FOR AN I.D. BOBOOSTER FAN TRIP.
WORK ON RECIRCULATION TANK LEVEL CONTROLS CAUSED A MODULE A OUTAGE.
MODULE B WAS FORCED OFF ONCi TO REPAIR A REHEATER HEADER LEAK.
ONE MODULE B OUTAGE WAS FOR VENTURI NOZZLE CLEANING.
MODULE B WENT OFF FOR A VENTURI LOW FLOW TRIP.
MODULE B REMAINED OUT OF SERVICE WHILE MODULE A WAS BEING TESTED TO AVOID
THICK! NER-F'OND OVERLOADING.
A VACUUM FILTER WAS TIED IN AT THE THICKENER.
414
-------
EPA UTIhITY FGO SURVEY: FOURTH QUARTER 1979
COMMONWEALTH EDI SONS WILL COUNTY 1 (CONT.)
_ PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPERAB1LITV RELIABILITY UTILIZATION t REMOVAL PER BOILER F6D CAP.
502 PART. HOURS HOURS HOURS FACTOR
11/76 A 20.1 25.6 20.1
B 72.2 69.6 4.7
SYSTEM 720 566
•* PROBLEHS/80LUTIONS/COMMENTS
MODULE A OPERATED ON ONE ABSORBER PUMP DURING MODULE B OUTA6E.
MODULE B WAS FORCED OUT OF THE CAS PATH ONCE FOR A MILLING SYSTEM FAILURE.
MODULE B ENCOUNTERED A VENTURI HEADER LEAK.
THE VENTURI NOZZLES REQUIRED CLEANING CURIMG THE MONTH.
REPLACEMENT OF THE SPENT SLURRY VALVE NECESSITATED A MODULE OUTAGE.
MODULE B WAS OFF ONCE DUE TO A CHEMICAL SYSTEM UPSET.
MODULE B WAS OUT OF THE GAS PATH TWICE DUE TO NO DEMAND (MODULE A WAS NOT
IN SERVICE AT THE TINE OF THE OUTAGE).
12/76 A *4.9 48.5 44.9
B 53.4 S1.7 48.0
SYSTEM 744 692
*» r>ROBLENS/«OLUTIONS/COMNENTS
DURING THE LAST WEEK OF NOViHBER, THE 1A2 ABSORBER PUMP WAS TAKEN OUT OF
SERVICE FOR OVERHAUL. THE REPAIRS HERE COMPLETED ON DECEMBER 6. WHEN THE
MODULE ASSUMED A ONE ABSORBER PUMP STANDBY CAPABILITY UNTIL THE 1A1 ABSOR-
BER PUMP CAN BE REPAIRED.
DURING THE LAST HALF OF THE MONTH, MOOUELE A OPERATED WHILE MODULE 6 MAS
BEING REPAIRED.
MODULE B PERFORMED SATISFACTORILY DURING THE FIRST HALF OF THE MONTH,
EXPERIENCING ONLY ONE NO DEMAND OUTAGE. ON THE 17TH, HOWEVER, THE SPENT
SLURRY VALVE FAILED AND THE MODULE HAS REMAINED OUT OF SERVICE.
1/77 A »8.2 98.7 95.8
B 13.5 1.1 1.1
SYSTEM 744 722
• • PROBLENS/SOLUTlONSyCOMNENTS
THE 1A1 ABSORBER PUMP WENT OUT IN LATE SEPTEMBER WITH BURNED OUT BEARINGS
AND REMAINED OUT THROUGH JANUARY WAITING FOR PARTS.
LOU SULFUR COAL WAS BURNED IN THE BOILER FROM NOVEMBER THROUGH JANUARY.
DUE TO THE LOW VOLUME OF SLUDGE PRODUCED WHILE BURNING LOW SULFUR COAL,
MUCH OF THE SLUDGE HANDLING TIME WAS SPENT DISCING OUT THE ACCUMULATED
SLUDC6 IN THE RECIRCULATION PONDS. THIS MATERIAL. ALONG WITH SCRUBBER
WASTE MATERIAL. WAS TREATED WITH LIME AND FLYASH AND HAULED TO AN OFF
SITE DISPOSAL AREA.
MODULE A WAS FORCED OUT ONCI BY A FAILED SPENT SLURRY VALVE.
PLUGGED DEHISTER UNDERSPRAVS CAUSED ANOTHER MODULE » OUTAGE.
NODULE A WENT OUT ONCE BECAUSE OF NO DEMAND AND ONCE DUE TO A BOILER OUTAGE
(MODULE B WAS ALREADY OUT 0* SERVICE FOR REPAIRS).
MODULE B BECAME AVAILABLE FOR SERVICE ON JANUARY 27, AFTER REPAIRS TO THE
SPENT SLURRY VALVE WERE COMRLETED. DUE TO SEVERE WEATHER CONDITIONS. THE
MODULE WAS PLACED IN THE CAS PATH JANUARY 31.
2/77 A 38.8 42.6 38.8
B 72.0 45.7 41.7
STSTEM 672 613
*« PROBLEMS/SOLUTIONS/COMMENTS
THERE HAS VERY LITTLE DISCING IN THE RECIRCULATION PONDS. CHICAGO FLYASM
SPENT MOST OF THEIR TIME ON CLEANING AND MAINTENANCE.
3/77 A »6.9 66.7 64.2
B 80.9 75.5 73.9
SYSTEM 744 728
•• PSOflLEMS/SOLUTIONS/COMMENTS
AN ERT $02 ANALYZER WAS INSTALLED ON THE D-ISCMARGC SIDE OF MODULE B I.D.
BOOSTIR FAN. THIS IS AN "IN SHU* ON-DISPERSIVE ANALYZER THAT CONTINUALLY
MEASURES AND READS OUT CONCXNTRATIONS OF S02, CO, C02. AND NO.
AN ABSORBER SUCTION HEADER LEAK FORCED MODULE B FROM THE GAS PATH.
MODULE B WAS FORCED OUT DUE TO A SLU8RY VALVE GASKET LEAK.
415
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
COMMONWEALTH ED1SONS HILL COUNTY 1 (CONT.)
—-.—.-...-——-.—-.---—-—.——-PERFORMANCf DATA--—
PERIOD NODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION
X REMOVAL PER BOILE* FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
A PLUGGED FEED SLURRY RECIRCULATION LINE HAS ENCOUNTERED IN NODULE B.
HI6H SULFUR COAL WAS BURNED FOR SEVEN DAYS THIS MONTH TO PROVIDE H16M
SULFUR SLU06E FOR THE UOP SLUDGE TtST.
CHICACO FLVASH SPENT 75X OF THEIR TIM DIGGING IN THE POND. THE REST MAS
SPENT ON THE THICKENER AND VACUUM FILTER ITERATION. THE SCRUBBER WASTE
MATERIAL HAS TREATED WITH LIME FLVASH AND HAULED OFF SITE.
DISPOSAL AREA.
4/77
A
B
SYSTEM
86.1
45.5
67.7
30.2
61.2
27.3
720 650
•• PROBLENS/KOLUTIONS/COMNENTS
THE PERFORMANCE OF THE ERT 302 ANALYZER TO DATE HAS BEEN. At BEST. UNRELIA-
BLE AND INCONSISTENT. THE ERT TECHNICIANS ARE OUT TO SERVICE THE ANALYZER
ALMOST EVERY OTHER DAY. THE PROBLEM. ACCORDING TO ERT TECHNICIANS. IS Of A
"THERMAL NATURE". WHEN THE ANALYZER REACHES A CERTAIH TEMPERATURE. A CHIP
SHORTS OUT. THEY HAVE NOT BIEN ABLE TO LOCATE THE FAULTY INTEGRATED CIRCUIT
YET.
A BOILER TUBE LEAK REPAIR FORCED NODULE A OUT OF THE GAS PATH ONCE THIS
MONTH (MODULE B WAS ALREADY DOWN FOR REPAIRS).
MODULE B WAS FORCED OUT OF THE GAS PATH TWICE FOR AN ABSORBER SUCTION
HEADER LEAK REPAIR.
NODULE B WAS OUT OF SERVICE ONCE TO WASH THE I. D. BOOSTER FAN.
CHICAGO ADMIXTURES SPENT MOST OF THEIR TIME DIGGING IN THE SMALL POND.
GETTING READY FOR THE N60 AUDITION AND FOROED OXIDATION TEST. THE SCRUBBER
HASTE MATERIAL HAS TREATED WITH LIME AND FLVASH AND HAULED TO AN OFF SITE
DISPOSAL AREA.
5/77 A
B
SYSTEM
89.4
98.0
2.2
S0.9
2.0
47.3
744 691
• • PROBLEHS/SOLUTIONS/CONHENTS
THE ERT $02 ANALYZER HAS BERN REMOVED FROM SERVICE DUE TO A POOR PERFORM-
ANCE RECORD OVER THE LAST THREE MONTHS. ERT IS IN THE PROCESS OF RE-
ENGIMIERIN6 THEIR ANALYZER.
THE MGO ADDITION TEST WENT WELL. ALTHOUGH HUT MGO INCREASED S02 REMOVAL
EFFICIENCY ABOUT 10S. IT DIB PRACTICALLY NOTHING FOR THE TWO MORE SERIOUS
PROBLEMS, SINCE THICKENER AND SLUDGE PRODUCTION AND LIMESTONE CONSUMPTION
RATE WERE ABOUT THE SAME.
MODULE A WAS FORCED OUT OF THE GAS PATH ONCE THIS MONTH WHEN THE INLET
VALVE ON 1A2 ABSORBER PUMP FAILED.
MODULE B WAS TAKEN OFF TO CLEAN AND INSPECT THE REHEATCR TUBES.
BOTH MODULES HERE FORCED OF
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
COMMONWEALTH EDISON: VILL COUNTY 1 SPRAYER.
NODULE A WAS FORCED OFF WHEN A STEAM REGULATING VALVE BLEW ITS PACKING.
ON THE 23RD, BOTH NODULES WERE TAKEN OFF AND DRAINED TO ALLOW THE SHOP TO
INSTALL NEW ISOLATION VALVES IN THE ABSORBER AND VENTURI PUMPS.
TOWARD THE END OF THE MONTH, SOME PROBLEMS WERE ENCOUNTERED WITH THE POND
RETURN PUMPS FREEZING.
2/78 A -0>9 56.5 34.4
B -9.5 92.9 56.5
SYSTEM 672 409
417
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
COMMONWEALTH EDISON: WILL COUNTY 1 (CONT.)
f PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION
Z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PROBLENS/SOLUTIONS/CCMMENTS
MODULE A RAN INTO DIFFICULT OPERATIONG CONDITIONS THIS MONTH DUE TO RAPID
PLUGGING OF THE REHEAT COIUS.
INSPECTION AND SUBSEQUENT CLEANING OF MODULE A UNCOVERED PLUGGED SPRAT
N01ZLES AND DEMISTER TRAVS BUE TO NOZZLE INEFFICIENCY.
MOCULE B OPERATED VERY HELL AND AN INSPECTION SHOWED THE MODULE TO BE VERY
CLEAN.
3/78
A
B
SYSTEM
t3.5
88. 5
100.0
84.7
90.6
76.0
26.2
744 230
• • PROBLEMS/SOLUTIONS/COMMENTS
THIS MONTH, DUE TO COAL CONSERVATION* UNIT 1 HAS ON THE SYSTEM VERY LITTLE
MODULE B HAD DIFFICULTY FOR SEVERAL DAYS BECAUSE OF A CRACKED SHEAVE ON THE
VENTURI PUMP.
HIGH PRESSURE CLEANING ON BOTH MODULES DURING THE COAL CONSERVATION ALONG
WITH REMOVING THE VENTURI THROAT RESTRICTOR BLOCKS PROVED BENEFICIAL IN
MAINTAINING BETTER CONTROL OF THE DRAFT CONDITIONS IN THE SCRUBBER.
4/78 A
B
SYSTEM
§9.9
100.0
99.7
99.9
92.0
92.2
720 665
** PROBLENS/SOLUTIONS/COMMENTS
TNE PRESSURE DIFFERENTIAL ACROSS THE VENTURIS HAS BEEN REDUCED BY APPROXI-
MATELY 401 AT 140 MM BY REMOVING THE VENTURI RESTRICTOR BLOCKS. PARTICULATE
REMOVAL AND SOLIDS CARRYOVE I COULD BE ADVERSELY AFFECTED BY THIS ACTION.
SINCE PARTICULATE REMOVAL AM THE VENTURI 19 A FUNCTION OF HATER DROPLET
SIZE, WHICH IN TURN IS A FUNCTION OF PRESSURE DROP. INCREASED SOLIDS CARRY-
OVER COULD POSSIBLY COMPUND REHEATED PLUGGING PROBLEMS. THE UTILITY IS
KEEPING A CLOSE WATCH FOR PkUGGING. BUT HAS NOT YET FOUND ANYTHING UNUSUAL
MODULE A WAS FORCED OUT OF THE GAS PATH ONCE THIS MONTH FOR A VENTURI PIPE*
LEAK.
5/78
A
B
SYSTEM
9.5
19.2
99.4
100.0
55.2
56.1
744 413
PROBLEMS/SOLUTIONS/COMMENTS
DURING THE LAST PART OF THE MONTH BOTH MODULES WERE FORCED OUT OF THE GAS
PATH DUE TO REHEATER LEAKS. IT REQUIRED A TWO DAY OUTAGE TO REMOVE THE
LEAKING REHEATER BUNDLES. ADDITIONAL REHATERS ARE ON ORDER AND ARE EXPECT-
ED TO ARRIVE IN JUNE.
6/78
A
B
SYSTEM
87.1
85.6
94.1
100.0
23.7
25.1
720 181
•* PROBLEMS/SOLUTIONi/CtMMENTS
DURIN6 A SCRUBBER INSPECTION, 2SZ DIEMISTER AND 75Z ABSORBER SPRAY PLUGGAGE
WAS DISCOVERED IN MODULE A. MODULE B WAS NOT AS BAD.
HIGH VIBRATION WAS ENCOUNTERED IN THE TURBINE BEARINGS DURING BOILER START
UP. CAUSING THE BOILER TO S MIT BACK DOWN.
THE PUG MILL FOR CHICAGO ADMIXTURES HAS BEEN APPROVED. AND THE NEW SLUDGE
TREATMENT SYSTEM SHOULD BE OPERATING BY FALL.
THE SCRUBBER WAS FORCED OUT OF THE GAS PATH ONCE THIS MONTH WHEN THE IB 1
ABSORBER DISCHARGE VALVE FAILED TO OPEN.
THE BftlLER WAS FORCED OFF THE LAST FOUR DAYS OF THE MONTH FOR CYCLONE
LEAKS. DURING THIS OUTAGE, THE A AND B MODULE SPENT SLURRY VALVES
WERE REPLACED.
7/78 A
• 7.0
• 9.2
100.0
1CO.O
11.6
11.6
SYSTEM
744
77
418
-------
EPA UTILITY F60 SURVEY: FOURTH QUARTER 1979
COMMONWEALTH £01 SONS WILL COUNTY 1
———-r—..—- PERFORMANCE DATA—— —
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER fGO CAP.
SO2 PART. HOURS HOURS HOURS FACTOR
*« PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS PLAGUED ALL MONTH BY CYCLONE CASING LEAKS. BECAUSE OF THE
CYCLONE PROBLEMS AND THE COAL CONSERVATION PROGRAM. THE BOILER WAS ONLY
OPERATED SEVENTY-SEVEN HOURS FOR THE MONTH.
THE BOILER DOUN TIME WAS USED FOR PREVENTAT1VE MAINTENANCE ON THE SCRUBBER.
SIX NEV REHEATERS WERE INSTALLED AND A DRAIN VALVE ON THE SPENT SLURRY LINE
HAS REPAIRED.
A VALVE FAILURE ON THE 1A1 ABSORBER PUMP FORCED THE SCRUBBER FROM THE GAS
PATH ONCE DURING THE MONTH.
MODULE B EXPERIENCED A LEAKING VENTURI HEADER.
8/78
A
B
SYSTEM
97.8
99.6
100.0
100.0
59.1
59.1
7*4 440
** PROBLEMS/tOLUTIONS/CONMENTS
CHICAGO ADMIXTURES SPENT HOST OF THEIR TIME OPERATING OUT OF THE THICKENER.
THE SCRUBBER WASTE MATERIAL WAS TREATED WITH LIME AND FLY ASH AND HAULED
OFF Tl AN OFF SITE DISPOSAL AREA.
REPAIRS TO THE VENTURI EMERGENCY SPRAY VALVE CAUSED ONE BOILER OUTAGE
DURING THE MONTH.
A REHEATER FLANGE LEAK WAS RESPONSIBLE FOR FORCING THE UNIT OFF.
MODULE A WAS FORCED OFF ONCE DUE TO HIGH VCBRATION OF THE I.D. BOOSTER FAN.
THE PROBLEM WAS CORRECTED BV REPACKING THE COUPLING ON THE FAN.
9/78
A
B
SYSTEM
»7.7
?7.7
95.9
96.0
55.*
55.5
720 416
*• PROBLEMS/SOLUTIONS/COMMENTS
CHICAGO ADMIXTURES SPENT MOST OF THEIR TIME OPERATING OUT OF THE THICKENER.
THE SCRUBBER WASTE MATERIAL HAS TREATED WITH LIME AND FLY ASH AND HAULED TO
AN OF I SITE DISPOSAL AREA.
REHEATER TUBE LEAKS. ONE IN MODULE A AND FOUR IN MODULE B, CAUSED ONE
BOILER OUTAGE AND CAUSED THE FGO SYSTEM TO BE UNAVAILABLE FOR A TOTAL
OF NINETY HOURS. SAMPLES OF THE TUBES HAVE BEEN SUBMITTED TO O.A.D. FOR
METALLURGICAL EXAMINATION.
A RUPTURED AIR LINE ON A VENTURI PUMP ISOLATION VALVE WOULD NOT ALLOW THE E
VALVE TO GO COMPLETELY CLOSED.
WHEN THE A VENTURI PUMP WAS STARTED. A VENTURI SPRAY HOSE RUPTURED.
IT WAS DISCOVERED THAT THE MODULE A VENTURI TANK LEVEL PRESSURE SWITCH WAS
NOT WORKING PROPERLY.
THE PUGHILL ORDERED FOR CHICAGO ADMIXTURES HAS ARRIVED ON SITE. IN OCTOBER.
THEY WILL FINISH THE CONVERSION. WHICH WILL ALLOW THE MATERIAL SERVICE
MIXER TRUCKS TO BE ELIMINATED.
IN OCTOBER. THE THICKENER WILL HAVE TO BE BYPASSED WHILE THE UTILITY DOES
MAINTENANCE ON THE RAKE AND REPLACES SOME LEAKING VALVES.
10/78
A
B
SYSTEM
1BO.O
100.0
100.0
100.0
35.0
35.0
744
261
** PROBLEHSrtOLUTIONS/COMHENTS
LOU BOILER HOURS WERE DUE TO FOUR OUTAGES CAUSED BY HIGH BEARING METAL
TEMPERATURES AND EXCESSIVE VIBRATION IN THE 1-B FORCED DRAFT FAN.
THE BOILER DOWN TIME WAS UTILIZED FOR CLEANING AND REPAIR OF THE VENTURI
THROAT. SUMP AND SUMP SCRCERS. AND INLET BLOCK DAMPERS OF MODULE A. AS
WELL «S THE VENTURI AND ABSORBER TANKS AND SCREENS AND ALL ABSORBER SPRAY
NOZZLES OF BOTH MODULES.
ON INSPECTION. IT WAS DISCOVERED THAT THE B MODULE ABSORBER DEPARTMENTAL
DAMPER HAD SLIPPED 50X CLOSID. THE DAMPERS WERE JACKED OPEN AND WELDED
IN PLACE.
TO CORRECT A HIGH PRESSURE DROP ACROSS THE MODULE B REHEATER. A NEW METHOD
WAS EMPLOYED WHEREBY ONLY THE MIDDLE TUBES WERE REMOVED. ALLOWING THE TOP
AND BOTTOM TUBES TO BE SEEN AND CLEANED. ELIMINATING THE REMOVAL OF ALL THE
TUBES. THIS PROCEDURE CUT OUTAGE TIME FROM ONE OR TWO WEEKS TO TWO DAYS.
11/78 A
96.2
100.0
48.3
419
-------
EPA UTILI1T FGD SURMET: FOURTH QUARTER 1979
COMMONWEALTH EDISON: ylLL CCUNTV 1 /COMHENT$
UNIT 1 HAS 6UT OF SERVICE TO REPLACE THE AIR HEATER TUBES. TUBE SHEET AND
HOPPERS. DURING THIS OUTAGE. THE WORN VENTURI SPRAY NOZZLES AND DEMISTERS
WERE REPLACED. WELDING LEAKS AND GENERAL CLEANING OF THE S02 INTERNALS
WAS ALSO DONE AT THIS TIME.
420
-------
EPA UTILITY FCO SURVEY: FOURTH QUARTER 1979
COMMONWEALTH EDISON? MILL COUNTY 1 (CONT.)
____ — —-—PERFORMANCE DATA — — —————
PERIOD NODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
THE BOILER AND THE SCRUBBER ARE SCHEDULED TO RETURN TO SERVICE OCTOBER 1.
1979.
720 0
744 0
9/79
10/79
11/79
SYSTEM
SYSTEM
A
a
SYSTEM
(3.3
(3.3
53.3
100.0
100.0
100.0
65.*
85. 4
85.4
7ZO 336 336
•* PBOBLEMS/SOLUTIONS/COHMENTS
ON NOVEMBER 5. UNIT 1 RETURNED TO SERVICE AFTER A SIX MONTH OUTAGE TO
REPLACE THE AIR HEATER TUBES, TUBE SHEET AND HOPPERS.
DURINE THE OUTAGE. SEVERAL IEN6THS Of VENTURI PIPING HAD TO BE REPLACED
UITH NEW RUBBER LINED PIPE.
THE SOZ UNIT DID NOT FORCE THE BOILER OFF A.T ANY TIME DURING NOVEMBER.
421
-------
EPA UTILITY F60 SURVEY: FOURTH QUARTER 1979
SECTION 14
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL
PARTICLE SCRUBBERS
COMPANY MHE
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - N6/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FCD - My
NET UNIT GENERA TINS CAPACITY WO/FGD - MU
EQUIVALENT SCRUBBEO CAPACITY - MU
** BOILED DATA
SUPPLIER
UPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - H
STACK TOP DIANETER - M
•* FUEL DATA
(UEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - 2
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** ESP
*• MECHANICAL COLLECTOR
•• PARTICULATE SCRUBBER
NUMBER
TYPE
DETROIT EDISON
ST. CLAIR
6
BELLE RIVER
MICHIGAN
C
**•« f*
1376.
1771.0
260.0
(*•**** LB/MMBTU)
C 3.200 LB/MMBTU)
*******
COMBUSTION ENGINEERING
******
BASE
0/61
46J.77
132. 2
< 987000
< 270 F)
«•*** FT»
(***** ff
ACFH>
COAL
SUBBITUHINOUS
4.00
******
22 - 2*
.35
0.3 - 0.4
I****** BTU/LB)
9,500 - 9.600
2
VENTURI
... .—..—.....— — PERFORMANCE OAT*——— .—.
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/7* SYSTEM
12/7* SYSTEM
1/75 SYSTEM
720
744
744
** PROBLENS/SOLUTIONS/COMMENTS
INSTALLATION OF THE F6D SYSTEM HAS ESSENTIALLY COMPLETED BY THE NOVEMBER
1974 THROUGH JANUARY 1975 P>RIOD.
A FAULTY INSTRUMENT PANEL WHICH WAS INCORRECTLY HIRED HAS BEEN RETURNED TO
THE MANUFACTURER FOR REPAIR.
TO DATE. THE UTILITY HAS WATER TESTED ALL THE AUXILIARY EQUIPMENT. THE ID
FAN HAS BEEN TESTED AND AIR BALANCE HAS BEEN CHECKED.
2/75 SYSTEM
J/75 SYSTEM
4/75 SYSTEM
672
744
720
422
-------
EPA UTHITV FGO SURVEY: FOURTH QUARTER 1979
DETROIT EDISON: ST. CLAIR 6 (CONT.)
___....._._._. ........ PERFORNANCI DATA—— ——— —
PERIOD MODULE AVAILABILITY OPERABIL1TV RELIABILITY UTILIZATION X REMOVAL PER BOlLtK FED CAP.
S02 PART. HOURS HOWS HOURS FACTOR
** PROBLEMS/SOLUTIONS/CONBENTS
A COLD FLUE GAS RUN MAS SUCCESSFULLY CONDUCTED MARCH 22 AND 23. CURING
THIS PERIOD THE RUBBER-LINED PUMPS HERE REPAIRED AND THE LIMESTONE PREARA-
TION SYSTEM HAS CALIBRATED.
5/75 SYSTEM 744
5/75 SYSTEM 720
7/75 SYSTEM 744
• * PROBLEMS/1OLUTIONS/COMKENTS
THE FIRST HOT FLUE GAS RUN WAS CONDUCTED ON JUNE 22. 1975. THE RUN LASTED
FOR A PERIOD OF 22 HOURS. DURING THIS RUN. THE SCRUBBER HAS PURPOSELY
TRIPPED OFF AT LOADS OF 40 AND 80 PERCENT. THIS WAS PERFORMED TO OBSERVE
IF ANY DETRIMENTAL EFFECTS TO THE STEAM GENERATION OPERATIONS RESULTED.
NONE HERE DETECTED. THE SYSTEM HAS TAKEN OUT OF SERVICE FOLLOWING THIS
«AS RUN TO CORRECT THE FOLLOWING MAJOR OPERATION AREAS:
GAS CIRCUIT: LUGI THROAT POSITIONAL FAILURE; DETERIORATION OF THE
DAMPER SEALS; SEVERE VIBRATIONS; S02 ANALYZERS INOPERATIVE.
LIQUID CIRCUIT: FAILURE OF PH CONTROL SYSTEM; TARGET FLOW METER
TARGETS HAVE BEEN BROKEN OFF; PUMP SEAL WATER LOW FLOW ALARM TRIPS.
8/75 SYSTEM 744
9/75 SYSTEM 720
• • PR06LENS/COLUTIONS/CONMENTS
A SECOND HOT FLUE 6AS RUN WAS INITIATED ON AUGUST 6 AND LASTED 27 HOURS.
THE RUN WAS TERMINATED BECAUSE OF A REHEATC* THERMOCOUPLE IAILURE. A
SUBSEQUENT INSPECTION OF THE SCRUBBING SYSTEM REVEALED NO APPARENT
ABNORMALITIES OR MALFUNCTIONS.
A THIRD HOT FLUE GAS RUN OF 41 HOURS DURATION WAS COMPLETED OCTOBER S. THE
MAIN OBJECTIVE OF THIS RUN WAS TO EVALUATE VARIOUS COMPONENTS OF THE FRESH
WATER SPRAY SYSTEM AND EFFEfTS ON SYSTEM OPERATION. THE TEST RUN WAS
PREMATURELY TERMINATED BECAUSE OF A BOILER FEED PUMP MALFUNCTION, RESULTING
IN A REDUCED BOILER LOAD CAUSING SUBSEQUENT WEEPING OF THE HASH TRAY.
10/75 SYSTEM 744
11/7S SYSTEM 720
T2/75 SYSTEM 744
•« PBOBLEMSMOLUTIONS/COMMENTS
A FOURTH FLUE GAS RUN OF 23 DAYS DURATION WAS TERMINATED DUE TO EXCESSIVE
VIBRATION IN THE I.D. t BOOSTER FAN. ONE OTMEA SCRUBBER-RELATED OUTACE
OCCURRED WHEN THE PACKING 0>F ONE OF THE SCRUBBER RECIRCULATION PUMPS NEEDED
MAINTENANCE. S02 REMOVAL DURING THIS PERIOD WAS 90 PERCENT AND PARTICULATE
OUTLE LOADING WAS 0.1 LB/1000 LBS OF FLUE GAS FOR 1-3 PERCENT SULFUR COAL.
1/76 SYSTEM 744
2/76 SYSTEM 696
3/76 SYSTEM 744
4/76 SYSTEM 100.0 100.0 720
*• PROBLEMS/SOLUTIONS/COHMENTS
THE 50-DAY VENDOR QUALIFICATION RUN AND FINAL ACCEPTANCE TEST WERE
COMPLETED BY HAY 29. THE QUALIFICATION RUN WAS CONDUCTED ON A "HANDS OFF"
BASIS USING PLANT PERSONNEL EXCLUSIVELY. THE SYSTEM HAS IN SERVICE 100
PERCENT OF THE TIME THE BOIHER HAS OPERATIONAL. THE FINAL ACCEPTANCE TEST
CONSISTED OF SIX 4-HR. TEST RUNS CONDUCTED IN THE SPACE OF ONE WEEK. TME
S02 REMOVAL EFFICIENCY FOR NIGH SULFUR COAJ. WAS 90.9 PERCENT. PARTICULATE
REMOVAL ALSO EXCEEDED DESIGN LEVELS. NO MAJOR CHEMICAL OR MECHANICAL-
RELATED PROBLEMS WERE ENCOUNTERED.
5/76 SYSTEM 744
423
-------
EPA UTILITY FGO SURVEY: FOURTH ttUARTER 1979
DETROIT EDISON: ST. CLA1R 6 CCONT.)
___,„_,—— — — -PERFORMANCE OAT*— —————————— ———.._
PERIOD NODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP
S02 PART. HOURS HOURS HOURS FACTO*
6/76 SYSTEM 720
7/76 SYSTEM 7*4
8/76 SYSTEM 744
•• PROBLEMS/SOLUTIONS/COHHENTS
THE UTILITY IS NOW PREPARING TO CONDUCT A 2 MONTH MINIMUM INTERNAL SCRUBBER
DEMONSTRATION PR06RAM TO ACQUIRE OPERATING DATA AND INFORMATION. FOLLOWING
THE COMPLETION OF THIS PROGRAM THE BOILERS HILL FIRE LOW SULFUR DECKER
COAL tO.3 TO 4.0 PERCENT) TO MEET S02 EMISSION REGULATIONS. THE SCRUBBERS
WILL CONTINUE TO OPERATE IN THE PARTICULATE REMOVAL MODE.
9/76 SYSTEM 720
10/76 SYSTEM 7**
• • PROBLEMS/SOLUTIONS/COMMENTS
THE INTERNAL S02 SCRUBBING DEMONSTRATION PROGRAM COMMENCED ON OCTOBER 14.
THE SCRUBBERS OPERATED CONTINUOUSLY FOR 10 DAYS..
OPERATION ON THE DEMONSTRATION PROGRAM MAS INTERRUPTED BY A FORCED SCRUBBER
OUTAGE RESULTING FROM SCALE AND SOLIDS CARRYOVER FROM THE HASH TRAY AND
MIST ELIMINATOR TO THE SCRUBBER I.D. BOOSTER FAN ASSEMBLY. CAUSING VIBRA-
TION AND BALANCE PROBLEMS. IT HAS DECIDED TO SANDBLAST THE FAN TO REMOVE
SOLID' BUILDUP ON THE FAN ASSEMBLY.
THE UTILITY PLANS TO MODIFY THE COMPONENT'S HASH SYSTEM FOR GREATER FLOH
CAPABILITY AFTER COMPLETION OF THE S02 SCRUBBING PROGRAM. DECO ALSO PLANS
TO CONTINUE PARTICULATE SCRUBBING FOLLOWING THE TERMINATION OF THE S02
PROGRAM BY UNCOUPLING THE SPRAY TOHERS AND MAINTAINING THE PEABODV-LURCI
VENTURI SCRUBBERS IN THE FLUE GAS STREAM. SOME LIMESTONE MAY HAVE TO BE
ADDED TO THE PARTICULATE SCRUBBING SOLUTION IN ORDER TO PREVENT LOW PH
SWINGS AND MINIMIZE THE POSSIBILITY OF ACID CORROSION DAMAGE TO THE
INTERNAL COMPONENTS.
11/76 SYSTEM 80.0 7ZO
•• PROBLEHS/«OLUTIO«S/CONHENTS
FOLLOWING THE COMPLETION OF SAND BLASTING OPERATIONS TO SCRUBBER'S I.D.
BOOSTBR FAN FOR REMOVAL OF (SOLIDS BUILD UP. OPERATIONS RESUMED ON NOVEMBER
7 AND CONTINUED THROUGHOUT 1HE MONTH. THE SYSTEM'S AVAILABILITY INDEX FOR
THE MONTH MS 80 PERCENT. THE MAJORITY OF THE OUTAGE TINE HAS CONSUMED
PROCURING SAND BLASTING SERVICES. THE OPERATION ITSELF REQUIRED ONLY 8
HOURS.
12/76 SYSTEM 51.0 744
•* PROBLEMS/SOLUTIONS/COMMENTS
THE $02 DEMONSTRATION PROGRAM CONTINUED THROUGHOUT DECEMBER. THE SYSTEM'Ss
AVAILABILITY INDEX FOR THE PERIOD HAS 51 PERCENT.
SCRUBBER OUTAGES RESULTED F'lON LIMESTONE FEEDER PROBLEMS.
SCRUBBER OUTAGES RESULTED Ft ION DENSE SLURRY TRAVERSE PUMP PROBLEMS.
SCRUBBER OUTAGES RESULTED FROM DENSE SLURRY TANK AGITATOR MALFUNCTIONS.
PH SAMPLING LINE PLUGGING » SULTED IN SOME OUTAGE TINE.
1/77 SYSTEM .0 744
2/77 SYSTEM .0 672
• • PROBLEMS/I OLUIIONS/CetMMENTS
THE SO2 DEMONSTRATION PROGRAM HAS OFFICIALLY TERMINATED ON DEC. 31, 1974
THE SCRUBBER PLANT HAS SHUT DOHN AT THIS POINT AND FLUE GAS HAS BY-PASSED
AROUNB THE SYSTEM.
3/77 STSTEN .0 744
424
-------
EPA UTILITY F€D SURVEY: FOURTH QUARTER 1979
DETROIT EDISON: ST. CLAIR 6 CCONT.)
_»«——————».—— — —-PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION
I REMOVAL PER BOILER
S02 PART. HOURS HOURS
F6D CAP.
HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER REMAINS IN SERVICE, FIRING LOW SULFUR C0.3X) WESTERN COAL.
CURRENT PLANS CALL FOR THE SCRUBBER PLANT TO REMAIN OUT OF SERVICE UNTIL
MID-JUNE FOR DESIGN AND OPEIATING MODIFICATIONS. RESUMPTION OF SCRUBBER
OPERATIONS HILL OCCUR IN THI PRIMARY PARTICULATE-REMOVAL MODE. THE
PEABODY-LURfil VENTURI SCRUBBERS AND SPRAY TOWER ABSORBERS WILL REMAIN IN
THE GAS STREAM. SOLUTION WILL BE CIRCULATED THROUGH THE VENTURI'S NASH
TRAYS. AND HIST ELIMINATORS'. NO SOLUTION WILL BE CIRCULATED THROUGH THE
SPRAY IONE OF THE ABSORBER TOWERS. LIMESTONE REAGENT HILL BE ADDED TO THE
SCRUBBING SOLUTION IN ORDER TO PREVENT LOW PH SWINGS AND SUBSEQUENT
MATERIALS DAMAGE TO THE SCRUBBER'S INTERNALS. S02 REMOVAL SHOULD RESIDE
IN THE 35 TO SOX RANGE IN THIS MODE OF OPERATION BECAUSE OF THE SOLUTION'S
ALKALINITY DUE TO THE FLY ASH AND LIMESTONE. ALSO DECO PLANS TO MAINTAIN
A HIGHER L/G RATIO IN THE SCRUBBER NODULES. THIS MODE OF OPERATION IS
PROJECTED TO CONTINUE FOR A ONE TO THREE YEAR PERIOD FOLLOWING THE
MID-JUNE RESTART.
4/77 SYSTEM .0
5/77 SYSTEM .0
6/77 SYSTEM .0
7/77 SYSTEM .0
8/77 SYSTEM .0
9/77 SYSTEM .0
10/77 SYSTEM
720
744
720
744
744
720
744
• * PROBLEMS/SOLUTIONS/CONMENTS
THE UNIT WAS PULLED OFF LINE IN DECEMBER 1976 AND DID NOT RESTART UNTIL
OCTOBER 1977. WHILE THE UNIT WAS DOWN THE UTILITY INSTALLED BUILD1N6S
AROUND PUMPS THAT WERE EXPOMED TO SEVERE WEATHER CONDITIONS.
11/77 SYSTEM
12/77 SYSTEM
1/78 SYSTEM
2/78 SYSTEM »6.0
3/78 SYSTEM B5.6
4/78 SYSTEM 90.0
5/78 SYSTEM ff4.6
720
744
744
672
744
720
744
•* PROBLEMS/SOLUTIONS/CttMNENTS
THE UNIT EXPERIENCED SPRAY NEAOER PROBLEMS IN THE ABSORBER TOMER. SOME
BROKEN NOZZLES WERE DISCOVERED.
THERE WERE SOME I.o. BOOSTER FAN PROBLEMS. THE UTILITY MUST SAND BLAST THE
FAN EVER* * TO S WEEKS WHEN THE MAGNITUDE OF VIBRATION OF THE FAN BECOMES
EXCESSIVE FROM SCALE FORMATION; HOWEVER, IN THIS INSTANCE THE PROBLEM WAS
A RESULT OF A LOW FAN OIL LEVEL.
TH| UTILITY NOW OPERATES 3 RECYCLE TANK AGITATORS. PREVIOUSLY ONLY 2 HERE
OPERATE). IT WAS FELT THAT PART OF THE TANK PLUGGING WAS A RESULT OF
INSUFFICIENT AGITATION.
THE SLURRY SPRAY SURGE TANK ENCOUNTERED CONTINUAL OVERFLOW PROBLEMS WHEN
THE ABSORBER SUMP PUMP WAS OPERATING. THW WAS BELIEVED TO BE A RESULT OF
A BROKEN SECTION IN THE SPRAY NOZZLE LINES. SPRAY WAS BEING DIRECTED
UPWARD TO THE BOTTOM OF A TRAY INSTEAD Of DOWN, COUNTERCURRENT TO THE
GAS FLOW AS INTENDED.
REHEATER PROBLEMS OCCURRED WITH THE FORMATION OF OIL CLINKERS IN THE
BURNER AREA. IT y*s DISCOVERED THAT THE AIR SUPPLY TO THE BURNER WAS
INSUFFICIENT.
425
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
DETROIT EDISON: ST. CLAIR 6 fCONT.)
__ ... ________..__.___.. —-PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGo CAP.
S02 PART. HOURS HOURS HOURS FACTO*
SOME SPRAY HEADER PROBLEMS WERE ENCOUNTERED. THE FRP PIPING WAS RUPTURINC
IT WAS SUSPECTED THAT THE RUPTUMtS WCRfe A RESUL> OF "WATER HAMMER* I.E. *
THE SURGE THAT OCCURRS IN THE PIPE WITH A SUDDEN FLOW RATE CHANGE.
THE SPRAY HEADERS WERE PLUGGING. WHEN THE HEADERS ARE DRAINED (E.G.
SYSTEMS SHUTDOWN) SOME SLURRY SETTLES IN THE HEADER LINES ETC. RINSE LINES
ARE NOU BEING INSTALLED TO FLUSH OUT HEADERS DURING FUTURE SHUTDOWNS.
6/78 SYSTEM
87.9
720
PROBLEMS/SOLUTIONS/COMMENTS
ONE OF THE BLADES CAME LOOSE FROM AN I.D. BOOSTER FAN AND PASSED THROUGH
THE HOUSING. REPAIRS WERE MADE WITHOUT SERIOUS COMPLICATIONS.
7/78 SYSTEM
16.0
744
•* PROBLEMS/SOLUTIONS/COMMENTS
THE INSTALLATION OF RINSE LINES HAS NOT VET BEEN COMPLETED.
PROBLEMS WITH RUPTURED SPRAY HEADER PIPING CONTINUED. IT HAS BEEN POSSIBLE
TO OPERATE THE SCRUBBER WITN THE RUPTURED LINES WITHOUT SERIOUS
CONSEQUENCES. IT IS NOT CRUCIAL THAT REPAIRS BE MADE IMMEDIATELY.
8/78 SYSTEM »0.4
9/78 SYSTEM B9.0
10/78 SYSTEM .0
11/78 SYSTEM .0
12/78 SYSTEM .0
1/79 SYSTEM
744
720
744
720
744
744
•• PROBLEMS/SOLUTIONS/COMMENTS
DURING THIS PERIOD RECYCLE TANK AGITATORS WERE BREAKING LOOSE AND SIMILAR
PROBLEMS WERE ENCOUNTERED WITH THE SLURRY STORAGE TANK AGITATORS. THE
SCRUBBING SYSTEM WAS REMOVE! FROM SERVICE FROM SEPTEMBER THROUGH JANUARY
STEADY BEARINGS WERE INSTALLED AT THE BOTTOM OF THE RECYCLE TANK SOLVING*
THE RtCVCLE TANK AGITATOR PROBLEM. THE SLURRY STORAGE TANK SYSTEM ALREADY
HAD STEADY BEARINGS. THESE WERE REWORKED TO IMPROVE OPERATIONS.
2/79 SYSTEM
3/79 SYSTEM
*• PROBLEMS/SOLUTIONS/COMMENTS
SOME BEHEATER PROBLEMS OCCURRED.
4/79 SYSTEM
5/79 SYSTEM
6/79 SYSTEM
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM
10/79 SYSTEM
672
744
720
744
720
744
744
720
744
PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM IS CURRENTLY DOWN BUT IS EXPECTED TO BE BACK ON LINE SOON. TMF
SCRUBBING SYSTEM HAS OPERATID ONLY 1 WEEK SINCC MAY 18. 1979 BECAUSE OF
SUMP PROBLEMS.
THE ACITATOR BEARING SYSTEM WAS POORLY DESIGNED. TMl BEARING SYSTEM HAS
NOW BfEN COMPLETELY REDESIGRED. THE AGITATORS HAVE NOW OPERATED 200C HOURS
ON THE NEW BEARINGS. THE UTILITY WILL PROBABLY DRAIN THE TANK AFTER ABOUT
500 MORE HOURS TO INSPECT AND READJUST THE BEARINGS. THE NEW BEARING
426
-------
EPA UTILITY F60 SURVEY: FOURTH QUARTER 1979
DETROIT EDISON: ST. CLAIR 6 * PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT CANE BACK ON LINE AROUND MID-NOVEMBER.
NEW DENVER PUMPS WITH £JECTOHS HERE INSTALLED TO ASSIST THE SUMP PUMPS
UNTIL TME ESP'S COME ON LINI.
THE ABSORBER PUMPS NAVE BEER A PROBLEM RESULTING IN A CAPACITY TURNDOVN
TO 225 MW (FROM 230 «W>.
ONE OF THE COAL MILLS HAS BBEN DOWN CAUSING LIMITED OPERATIONS.
427
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 14
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICLE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NG/U
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY U/FGO - MW
NET UNIT GENERATING CAPACITY WO/F6D - MU
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
•• FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE NEAT CONTENT - J/G
RANCE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTINT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CMLORIIE CONTENT - X
RANGE CHLORIDE CONTENT - X
•• FABRIC FILTER
NUMBER
TYPE
•• ESP
NUMBER
TYPE
•* MECHANICAL COLLECTOR
NUMBER
TYPE
•* PARTICULATE SCUDBBER
NUMBER
TYPt
SUPPLIER
SHEL.L MATERIAL
LINING MATERIAL
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE CAS TENPEIATURE - C
L/C RATIO - LITER/CU.N
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - C/CU.M
PARTICULATE OUTLET LOAD - NG/J
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCINTRATION - PPM
S02 OUTLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
MINNISOTA
AUROIA
1
AURORA
NINKISOTA
POWER ( LIGHT
< .600 LB/MMBTU)
<**•**» LB/MMBTU)
258.
>**•«•
11 (.0
5.8.0
57.3
58.0
58.0
COMBUSTION ENGINEERING
PULVERIZED COAL
*•»«**
0/53
14T.57 < 300000 ACFM)
17*1.1 C 340 F>
**««*« <*••* rr*
***•**• (»**•* fi)
C 8800 BTU/LB)
COAL
SUBBITUMINOUS
204«9.
9.00
******
26.70
24.0-26.7
1.37
0.8-1.37
.01
0.00-0.07
0
NONE
0
NONE
0
NONE
SPRAY IMPINGEMENT TOMER
KREBS ENGINEERS
316 ELC SS
FLAKf-POLYESTER
100.0
151.4
17-1.1
1.1
***••••
2.1
4.7
34.
98.0
800.000
501.000
37.0
291160 ACFM>
340 F>
8.3 tAL'IOOOACf)
••••* IH^IffOI
7.0 FT/S>
2.06 GR/SCF)
.078 LB/MMBTU)
428
-------
EPA UT1LITT F6B SURVEY: FOURTH QUARTER 1979
MINNESOTA POWER S UGMTt AURORA 1
„__.. — — • PERFORMANCE OATA
PERIOO MOMLE AVAILABILITY OPC4 ABILITY BELIABKITV UTILIZATION I REMOVAL PER BOILER F«B CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SVSTEN 744
11/79 STSTEM 7ZO
12/79 SVSTEM 744
** PROBLEMS/SOLUTIONS/CONHENTS
NO INFORMATION HAS AVAILABLI FOR THE FOURTH QUARTER 1979.
429
-------
EPA UTILITY reO SURVEY: FOURTH QUARTER 1979
SECTION 14
DESI6N AND PERFORMANCE DATA FOR OPERATIONAL PARTICLE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT 6ENEIIATffl6 CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY W/F60 - MU
NET UNIT GENERATING CAPACITY UO/FGD - HW
EQUIVALENT SCRUBBED CAPACITY - MU
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE 6AS FLOW - CU.H/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE NEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASM CONTENT - X
NANCE ASM CONTENT - X
AVERAGE HOISTUBE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
MANGE CHLORIDE CONTENT - X
•• FABRIC FILTER
NUMBER
TYPE
•• ESP
NUMBER
TYPE
•• MECHANICAL COLLBCTOK
NUMBER
TYPE
•• PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
L/C RATIO - LlIEfl/CU.M
PRESSURE DROP * KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - S/CU.M
PARTICULATE OUSLET LOAD - NC/J
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
S02 INLET CONCENTRATION - PPM
S02 OUTLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
MINNESOTA POWER t LIGHT
AURORA
2
AURORA
MINNESOTA
**** **
258.
•••*•»
116.0
58.0
57.3
58.0
51.0
COMBUSTION ENGINEERING
PULVERIZED COAL
< .600 LB/MMBTU)
C****** LB/MMBTU)
0/53
1*1.57
17H.1
( 300000 ACFB)
( 340 F>
(**** FT;
{***** FT>
( 8800 BTU/LB)
•«••**
*»****•
COAL
SUBBITUHIKOUS
20469.
9.00
******
26.70
2*.0-26.7
1.37
0.8-1.37
.01
0.00-0.07
0
NONE
0
NONE
0
NONE
1
SPRAY IMPINGEMENT TOUER
KREBS ENGINEERS
316 ILC SS
FLAKE-POLYESTER
100.0
137.4 291140 ACFM)
17>1.1 34U H
1.1 8.3 SAL/1000ACf)
«*•*•** •*•** IN-H20)
2.1 7.0 FT/S)
4.7 2.06 GR/SCF)
34. .078 LB/MMBTU)
98.0
800.000
500.000
37.0
430
-------
EPA UTILITY F«D SURVEY: FOURTH QUARTER 1979
MINNESOTA POWER t LIGHT: AURORA 2 (CONT.)
_ r PERFORMANCE BAT*
PERIOD MODULE AVAILABILITY CPEBABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM 7*4
11/79 SYSTEM 720
12/79 SYSTEM 744
** PNOBLEMS/IOLUTIONS/CONMENTS
NO INIORMATION HAS AVAILABLE FOR THE FOURTH QUARTER 1979.
431
-------
EPA UTILITY FCD SURVEY: FOURTH QUARTER 1979
SECTION 1*
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICLE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - kG/J
S02 EMISSION LIMITATION - N6/J
NET PLANT GENERATING CAPACITY - HW
GROSS UNIT GENERATING CAPACITY - My
NET UNIT GENERATING CAPACITY W/F6D - MU
NET UNIT GENERATING CAPACITY UO/F6D - HU
EOUIVALENT SCRUBBED CAPACITY - MW
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE 6AS FLOH - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - H
STACK TOP DIAMITER - M
** FUEL DATA
FUEL TYPE
FUEL GRAPE
AVERAGE HEAT CONTENT - J/6
RANGE NEAT CONVENT - BUI/IB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE NOISTUBE CONTENT - X
RANGE MOISTURE CONTENT - 1
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CDNTENT - X
AVERAGE CHLORIDE CONTENT - X
DANCE CHLORIDE CONTENT - X
•• FABRIC FILTER
NUMBER
TYPE
*• ESP
NUMBER
•* MECHAHICAL COLLSCTOR
NUHBER
•• PARTICIPATE SCROBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAUS
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATER!AL
BOILER LOAD/SCtUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LI«UID RECIRCW.ATION RATE - LITER/S
L/C RATIO - LITER/CO.M
PRESSURE DROP - UFA
SUPERFICIAL CAB VELOCITY - M/S
PARTICIPATE INLET LOAD - fi/CU.M
PARTICIPATE OUTLET LOAD - NC/J
PARTICULATE 8E81CN REMOVAL EFFICIENCY
SO2 INLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
<****** LB/MNBTU)
C****** LB/MMBTU)
MINNESOTA POWER I LIGHT
CLAY BOSUELL
3
COHASSET
MINNESOTA
******
****•*
******
***• **
350.0
347.1
350.0
350.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/79
613~.47 C1300000 ACFM}
123.3 I 254 F)
»*•*:** (**«» FT*
******* (***•* ft)
COAL
SUBBITUMINOUS
19538.
9.00
******
26.00
24.ai26.0
.92
0.8-8.92
.01
< 6*00 BTU/LB)
8400-8800
0
NONE
SPRAY IMPINGEMENT TOWER
KREBS ENGINEERS
316LC SS
NONE
316L SS
118.0
613.5
123.3
714.4
1.1
*•*•«•*
2.4
6.9
34.
X 99.0
808.000
28.0
mooooo ACFM>
i 254 F>
(11340 GPMJ
t 8«3 6AL/1000ACF)
<••*•« IN-N20>
C 8.0 FT/S>
I 3.00 GR/SCF)
( .078 LB/HMBTU>
432
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
MINNESOTA POWER > LIGHT: CLAY BOSWELL 3 CCONT.>
- . .* PERFORMANCE DATA ——
PERIOD MODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION 1 REMOVAL PER BOILER F6» CAP.
S02 PART. HOURS HOURS HOURS FACTOR
w*** •• • *•««•• »™**"*^ ••«•«• »«• «••«••*<•« *•«••»*« «•*••••«•*• BVH« ^^^^^ ^^ «>^ M ^^^«*^«B «B^^ ^v* ^^^^^ v
10/79 SYSTEM 7*4
11/79 SYSTEM 720
12/79 SYSTEM 744
•* PROBLEMS/tOLUTIONS/COMMENTS
NO INFORMATION HAS AVAILABL ( FOR THE FOURTH QUARTER 1979.
433
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 14
DESIGN AND PERFORMANCE DATA FOR OPERITIONAL
PARTICLE SCRUBBERS
COMPANY NAME
PLANT MAKE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - NG/J
SOI EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY -Mb
NET UNIT GENERATING CAPACITY WF60 - My
NET UNIT GENERATING CAPACITY UO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MW
•• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
*• FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/lB
AVERAGE ASH CONTENT - X
RANGE ASH CONTf NT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
NAN6E CHLORIDE CONTENT - X
•• MECHANICAL COLLfCTOR
NUMBER
TYPE
SUPPLIER
PART1CULATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPEBATUBE - C
PRESSURE DROP - KPA
PAHT1CULATE OUTLET LOAD - 6/CU.M
*• PARTICULATE SCRUBBER
TYPE
SUPPLIER
NUMBER OF STAGIS
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERi AL
NUMBER OF NOZZLES
BOILER LOAO/SCiUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - L1TER/S
L/6 RATIO - LISER/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - 6/CU.M
PARTICULATE OUTLET LOAD - 6/CU.M
SO? INLET CONCINTRATION - NG/J
MONTANA-DAKOTA UTILITIES co.
LEWIS t CLARK
1
SIDNEY
MONTANA
86.
430.
50.3
55.1
5C.3
5'1.5
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
10/58
153.37
215.6
76.
( .200 LB/MMBTU)
( 1.000 LB/MMBTU)
< 325000 ACFM)
< 420 F)
< 250 FT)
t 14.5 FT)
COAL
LIGNITE
15003.
7.80
7.2-9.3
3«.20
34.25-38.16
.61
.32-1.43
.03
< 6450 BTU/LB)
6200-6700
1
MULTICLONE
WESTERN PRECIPITATION
- X 85.7
106.2 t 225000 ACFM)
176.7 ( 350 F>
•*•**•• (.«..« IN-H20)
?.93 ( 1.28 GR/SCF)
VENTURI
RESEARCH COTTRELL
1
CARBON STEEL
CEILCOTE FLAKEL1NE 103
CARBON STEEL WITH 1" NORTON CA-308
0
100.0
148.0 < 313730 ACFM)
?15.6 ( 420 F)
212.6 < 3374 GPM)
•1.7 <13.0 6At/1000ACf>
****••• (••*•• IN-H20)
327.2 (143.00 GR/SCF)
.1 ( .030 GR/SCF)
88134. (•*•••• LB/HHBTU)
434
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
MONTANA-DAKOTA UTILITIES CO.: LEWIS t CLARK 1 (CONT.l
r PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM 72C
*« PROBLEHS/SOLUTIONS/COMMENTS
DURINC A SCHEDULED BOILER OUTAGE GENERAL SCRUBBER MAINTENANCE WAS
PERFORMED.
11/79 SYSTEM 720
** PROBLEMS/*OLU1IONS/COHNEN7S
DURINf NOVEMBER THE SCRUBBER WAS TEMPORARILY BYPASSED TO ALLOW FOR REPAIRS
NECESSITATED BY A LEAK IN THE FLOODED DISC SCRUBBER.
12/79 STSTEH 7*4
** PROBLEMS/COLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THERE WERE NO PROBLEMS DURING THIS MONTH.
435
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL
PARTICLE SCRUBBERS
COMPANY DAME
PLANT NAflE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - hG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - HW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/FGD - MU
NET UNIT GENERATIN8 CAPACITY WO/FGH - HU
EQUIVALENT SCRUBBED CAPACITY - MU
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIANfTER - M
•• FUEL 6ATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTiNT - X
AVERAGE MOISTURE CONTENT - i
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•• PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
BOILER LOAD/SCIU6BER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPE IATURE - C
LIQUID RECIRCUtATION RATE - LITER/S
L/6 RATIO - LITER/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - G/CU.M
PARTICULATE OUTLET LOAD - G/CU.M
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
S02 INLET CONCENTRATION - PPM
SO2 tESIGN REMOVAL EFFICIENCY - X
PACIFIC POWER t LIGHT
DAVE JOHNSTON
4
GLENROCK
WYOMING
•*»•**
90. (
215. <
.210 LB/MMBTU)
.500 LB/MMBTU)
33C.O
326.5
330.0
33.0
COMBUSTION ENGINEERING
PULVERIZED COAL
** **A*
707.85
132.2
76.
COAL
sueaiTUMiNOus
17292.
12.00
******
24.00
*•** ««
.50
(1500000 ACFM)
« 270 F)
t 250 FT>
(***** FT)
( 7430 BTU/LB)
5,000-9,000
.04
3
VENTURI
CHEHICO
CARBON STEEL, 3/8" AT VENTURI THROAT
POLYESTER-LINED STEEL
J3.3
327.5 694000 ACFM)
135.0 275 F)
409.5 6500 6PM)
1.7 13.0 6AL/1000ACF)
•***•** «*•** IN-H20)
9.2 4.00 GR/SCF)
.1 .040 GR/SCF)
99.7
5QC.OOO
»C.O
...—..........—-—......—. — . PERFORMANCE DATA—
PERIOD MODULE AVAILABILITY OPEfiABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
744
720
744
436
-------
EPA UTILITY FGO SURVEY: FOURTH BUARTER 1979
PACIFIC POUER K LIGHT: DAVE JOHNSTON 4 (CONT.)
PERFORNANC I DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER (GO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•* PROBLENS/SOLUTIONS/COHHENTS
NO INFORMATION WAS AVAILABLE FOR THE FOURTH QUARTER 1979.
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERIT10NAL PARTICLE SCRUBBERS
COMPANY NAME POTOMAC ELECTRIC POWER
PLANT NAME D1CKIRSON
UNIT NUMBER 1
CITY DICKINSON
STATE MARYLAND
REGULATORY CLASSIFICATION ******
PART1CULATE EMISSION LIMITATION - NG/J ****** (**«*** LB/MMBTU)
S02 EMISSION LIMITATION - NG/J *»•*** <•«•••* LB/MMBTU)
NET PLANT GENERATING CAPACITY - MU 1348.0
GROSS UNIT GENERATING CAPACITY - MU 19C.O
NET UNIT GENERATING CAPACITY y/FGO - MW 183.0
NET UNIT GENERATING CAPACITY hO/FGO - MW **•*«*«
EQUIVALENT SCRUBBED CAPACITY - MW **«••**
«* BOILER DATA
SUPPLIER *•**«*
TYPE PULViRXZED COAL
SERVICE LOAD **••«*
COMMERCIAL SERVICE DATE **/•«
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S **•*«•** <******* ACFM)
FLUE GAS TEMPERATURE - C «•**«*• <**.* f)
STACK HEIGHT - M »*«•** (*.** FT)
STACK TOP OIAMITER - M ******* <*..** FT)
•• FUEL DATA
FUEL TYPE COAL
FUEL GRADE ••»•••
AVERAGE HEAT CONTENT - J/6 272U. ( 11700 BTU/LB)
RANGE HEAT CONTENT - BTU/18 ******
AVERAGE ASH CONTENT - X U.OO
RANGE ASH CONTiNT - X •***.,*
AVERAGE MOISTURE CONTENT - * .*».*•*.
RANGE MOISTURE CONTENT - X «*»•••
AVERAGE SULFUR CONTENT - Z 2.00
RANGE SULFUR CONTENT - X •***«•
AVERAGE CHLORItE CONTENT - * *•»*««..
RANGE CHLORIDE CONTENT - X ******
** PARTICULATE SCRUBBER
TYPE
NUMBER OF STAGE S
VENTURI
........... — ................ — .—...—---PERFORMANCE DATA —•-- ._
PERIOD MODULE AVAILABILITY CPERABIL1TY RELIABILITY UTILIZATION t REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SVSTEM
11/79 STSTEM
12/79 SYSTEM
1CC.O
96.0
1CO.O
83.6
80.1
87.4
744 622
720 601
744 650
622
577
65C
*• PROBLEHS/SOLUT10NS/COMMENTS
DURING THIS PERIOD ONLY ONE FGD RELATED OUTAGE OCCURRED. THE OUTAGE UAS
FOR AN ID FAN INSPECTION WHICH LASTED ONE DAY.
438
-------
SECTION 1t
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
PARTICLE SCRUBBERS
COMPANY NAME
PLANT NAPE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLAN1 GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/F&D - My
NET UNIT GENERATING CAPACITY WO/F&D - MM
EOUIVALEXT SCRUBBED CAPACITY - Mh
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
HAXIPUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPER ATURE - C
STACK HEIGHT - M
STACK TOP DIAME TER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - Z
AVERAGE MOISTURE CONTENT - I
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
• * PARTICULATE SCRUBBER
TYPE
NUMBER OF STAGE S
POTOMAC ELECTRIC POUER
D1CKERSON
2
D1CKERSON
MARYLAND
******
******
1348.0
191.0
183.0
******
PULVERIZED COAL
******
** /**
(****** LB/MMBTU)
(«•*•** LB/MMBTU)
COAL
******
27214.
14.00
• ***»•*
* ***•«*
2.00
******
VENTURI
I
ACFM)
< 11700 BTU/LB)
******
...... . -PERFORMANCE DATA— — ——........ .
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
1QC.O
96.4
100.0
97.0
88.9
100.0
744
72C
744
722 ?22
664 64C
744 744
** PROBLEMS/SOLUTIONS/COMNENTS
A ONE DAY OUTAGE OCCURRED, DUE TO A FAN LINING PROBLEM. NO OTHER FG6
UNIT PROBLEMS WERE ENCOUNTERED DURING THE PERIOD.
439
-------
EPA UTILITY F60 SURVEY: rOURTH QUARTER 1979
DESIGN AND PERFORMANCE
SECTION 14
DATA FOR OPERATIONAL
PARTICLE SCRUBBERS
COMPANY MME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
SOZ EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mil
NET UNIT GENERATING CAPACITY W/FGD - My
NET UNIT GENERATING CAPACITY UO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
•« BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE 6AS TEMPEIATURE - C
STACK HEIGHT - M
STACK TOP DIAMt TER - M
•• FUEL BATA
FUEL TYPfc
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/L8
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - 1
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*« ESP
NUMBER
SUPPLIER
PARTlCl/LATE DESIGN REMOVAfc EFFICIENCY
«« PARTICIPATE SCRUBBER
NUMBER
TYPE
SUPPLIER
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
L/& RATIO - LITER/CU.M
PRESSURE DROP - KPA
- X
POTOMAC ELECTRIC POUER
OICKERSON
DICKERSON
MARY IAND
***•t*
****4*
688.
5*8.0
190.0
183.0
(*••**• LB/MNBTU)
( 1.600 LB/MNBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/62
278.12 ( 590000 ACFM)
126.1 ( 259 F)
122. ( *00 FT)
****<** (*•*** rt)
COAL
27*14..
14.00
••**«*
2.00
******
I 11700 BTU/LB)
******
RESEARCH COTTRELL
94.0
VENTURI
CHENICO
sc.o
139.2
126.1
2.7
I 295000 ACFM)
( 259 F)
C20.0 &AL/1000ACF)
<*•*** IN-H20)
— —--—, PERFORNANCI DATA » _
PERIOD MODULE AVAILABILITY CPE«ABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F£B ~r»I~~
^ $02 PART. HOURS HOURS HOURS FACTOR
9/73 SYSTEM
10/73 SYSTEM
11/73 SYSTEM
12/73 SYSTEM
1/74 SYSTEM
720
744
720
744
744
440
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
POTOMAC ELECTRIC POMES: DICKERSON 3 (CONT.)
r— —— — .PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPE (ABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PROBLEMS/SOLUTIONS/CONNENTS
PROBLEMS Old ING THIS PERIOD RANGED FROM CORROSION LEAKS IN EXPANSION JOINTS
TO PROBLEMS IN MATERIAL HANDLING EQUIPMENT, FEEDING AND SLAKING OF M60,
PLUGGING IN THE MGO MIX TANK AND SUCTION LINES TO THE NGO MAKE-UP PUMPS.
Z/74 SYSTEM
3/7* SYSTEM
4/74 SYSTEM
672
72 C
PROBLEMS/SOLUTIONS/COMMENTS
MAINTENANCE AND MODIFICATIONS WERE PERFORMED ON THE SYSTEM. THE MAJCR
SYSTEM REVISION MADE DURING THIS PERIOD WAS THE ADDITION OF A PRE-MII TANK
IN THE MGO SYSTEM.
4/74
5/74
6/7*
7/74
SYSTEM
SYSTEM
SYSTEM
SYSTEM
72C
744
72 C
744
*• PROBLEMS/60LUT10NS/CONMENTS
LIMITED OPERATION OCCURRED BECAUSE THE UTILITY DID NOT HAVE ACCESS TC THE
EPA CALCINING FACILITY AT THE ESSEX CHEMICAL COMPANY SULFURIC ACID PLANT.
BY THE END OF JUNE 1974. ALL THE MGO AT DICKERSON HAD BEEN USED AND • SILO
PLUS THREE CARS WERE FULL OF H6S03.
744 o?
72C
744
72C
744
• • PROBLENS/SOLUTIONS/CONMENTS
DURING THIS PERIOD THE SYSTEM GENERALLY OPERATED AT 75 PERCENT OF THE
DESIGN GAS FLOW.
8/74
9/74
10/7*
11/74
12/7*
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
1/75 SYSTEM
744
PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS DEVELOPED IN THE BUCKET ELEVATOR TRANSPORTING THE MGS03 FRCf THE
DRYER TO THE STORAGE SILO.
2/75
3/75
5/75
6/75
7/75
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
672
744
744
720
744
* PRObLEMS/SOLUTIONS/COMMENTS
UNIT NO. 3 WAS TAKEN OUT OF SERVICE FOR AN 8 TO 12 WEEK TURBINE OVERHAUL.
THE SCRUBBER WAS INSPECTED, MAINTENANCE AND MODIFICATIONS WERE MADE.
8/75 SYSTEM
744
441
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
POTOMAC ELECTRIC POKER: DICKERSON 3 (CONT.)
f PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/75
10/75
11/75
12/75
1/76
2/76
3/76
4/76
5/76
6/76
7/76
8/76
9/76
11/76
12/76
1/77
2/77
3/77
4/77
5/77
6/77
7/77
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
•* PHOBL£MS/»OLUTIONS/COMMENTS
THE F6D SYSTEM CONSISTS OF A SINGLE, TyO-STAGE SCRUBBER/ABSORBER, WHICH
INCORPORATES AN ADJUSTABLE- 1HROAT VENTURI SCRUBBER FOR PARTICULATE REMOVAL
AND A SECOND STAGE ABSORBER WITH A FIXED VENTURI TO REMOVE $02. THE LIQUOR
STREAMS FOR BOTH STAGES ARE SEPARATE AND OPERATE IN A CLOSED-LOOP MODE.
UNTIL MID-1975 THE MAGNESlUf SULFITE GENERATED WAS TRANSFERRED TO AN EPA
FINANCED FACILITY AT THE ESSEX CHEMICAL COMPANY SULFUR 1C ACID MANUFACTURING
PLANT IN RUMFORD. RHODE ISLAND WHERE MAGNESIUM OXIDE WAS REGENERATED AND
S02 FROM THE REGENERATION PROCESS WAS CONVERTED TO SULFURIC ACID. THE
RUMFORD FACILITY HAS SINCE EEEN CLOSED DOWN.
CONSTRUCTION WAS COMPLETED IN AUGUST AND THE SYSTEM STARTED UP IN SEPTEMBER
1973. DURING INTERMITTENT OPERATIONS FOR SHAKEDOWN THROUGH JANUARY 1974,
THE SYSTEM'S LONGEST CONTINUOUS RUN WAS 371 HOURS. THE SYSTEM HAS RE-
STARTED FROM JULY THROUGH DECEMBER 1974, AND AGAIN ON AUGUST 11, 1975, FOR
APPROXIMATELY 87 HOURS.
FGD UNIT OUTAGES WERE CAUSED PRIMARILY BY PIPE AND PUMP CORROSION AND
MAJOR TURBINE OVERHAUL OF THE BOILER. PARTICULATE AND SO? REMOVAL
EFFICIENCY GUARANTEES WERE CORRObOR ATE D DURING OPERATIONAL PHASES.
THE FGD SYSTEM WAS RESTARTED IN AUGUST. STEAM WAS LOST TO THE MGO AIX
TANK, RESULTING IN A VERY HOIST PRODUCT FROM THE CENTRIFUGE. CAKING IN THE
DRYER OCCURRED. AT THIS POINT, THE UTILITY DECIDED TO TEST ONLY THE FIRST-
STAGE OF THE SCRUBBING SYSTEM, TAKING GAS AHEAD OF THE PR EC 1PI TA TOR . FGD
OPERATION AT DICKERSON TERMINATED AT THIS POINT.
THE REMAINING SUPPLY OF MAGNESIUM OXIDE, ABOUT 100 TONS (10 DAYS), HAS
BEEN DEPLETED, AND THE DICKERSON UNIT MAS BEEN TERMINATED AS A FGD SYSTEM.
72C
720
744
744
696
744
720
744
720
744
744
720
720
744
744
672
744
720
744
720
744
*42
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
POTOMAC ELECTRIC POWER: OICKERSON 3 (CONT.)
_______ _ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/77
9/77
10/77
11/77
12/77
1/78
2/78
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
38.0
38.0
38. C
744
720
744
72C
744
744
672
672
252
** PROBLEHS/SOLUTIONS/COMMENT5
THERE HAVE BEEN MANY MAINTENANCE PROBLEMS AND PROBLEMS WITH LINER FAILURES.
SINCE SHIFTING FROM S02 TO PARTICULATE SCRUBBING ONLY, PLUGGING PROBLEMS
HAVE NOT OCCURRED. LOW PH HAS CAUSED CORROSION WHICH .AS AGGRAVATED BY
PARTICULATE ERROSION. THE UTILITY WILL PROBABLY RELINE WITH A FLAKE GLASS
TYPE LINER. NO CHEMICALS (E.G. LIME) ARE ADDED TO THE CIRCULATING LIQUOR
FOR PH BALANCE.
OUTAGE TINE WAS CAUSED BY LEAK REPAIRS IN SLURRY PIPING.
3/78 SYSTEM
21.0
22.0
21.0
744
717
156
• * PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME WAS DUE TO RUBBER LINING FAILURE IN THE RECYCLE PUMP DISCHARGE
LINE.
4/78 SYSTEM
80.7
79.8
76.4
720
689
** PROBLEMS/SOLUTIONS/COMMENTS
26 HOURS OF OUTAGE TIME WERE DUE TO SMALL LEAKS IN PIPING.
5/78 SYSTEM
84.5
82.7
74.0
744
666
ssc
551
** PROBLEMS/SOLUTIONS/CONMENTS
A LEAK OCCURRED IN A HIST EIIHINATOR DRAIN.
THERE .AS A LEAK IN A BLEED LINE FOR THE SCRUBBER RECYCLE CIRCUIT.
OUTAGE TIME WAS REQUIRED FOR BLEED LINE REPLACEMENT.
6/78
7/78
SYSTEM
SYSTEM
100.0
100.0
90.1
.0
68.7
.0
720
744
549
16
495
C
• • PROBLEMS/SOLUTIONS/COMMENTS
THE VENTURI SCRUBBER HAD AN AVAILABILITY OF 1001 FOR JUNE AND JULY. THE
ONLY VENTURI OUTAGE TIME WAS IN JUNE. THE OUTAGE TIME WAS REQUIRED TO
TIE IN EQUIPMENT COMMON TO THE NEW UNIT AND UNIT 3.
THE BOILER WAS DOWN IN JULY FOR AN OVERHAUL.
THE REASON VENTURI HOURS CAN BE LOWER THAN BOILER HOURS WHEN THE VENTURI
HAS A 1COI AVAILABILITY IS BECAUSE THE VENTURI IS NOT OPERATED UNDER LOW
LOAD CONDITIONS.
8/78
9/78
10/78
11/78
12/78
1/79
2/79
3/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
744
72C
744
72C
744
744
672
744
443
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
POTOMAC ELECTRIC POUER: DICKERSON 3 (CONT.)
. _ PERFORMANCE DATA _
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION J REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/79
5/79
SYSTEM
SYSTEM
720
744
•* PROBLEMS/SOLUTIONS/COHMENTS
SCRUBBER OUTAGE HOURS SINCE SEPTEMBER 1978 (I.E. SEPTEMBER 1978 THROUGH
MAY 30, 1979) TOTAL 140. THE UTILITY INDICATED THAT IT IS NO LONGER ALLOW-
ABLE TO BYPASS THE SCRUBBER WHEN PROBLEMS OCCUR, CLEANING THE PARTICULAR
MATTER SOLELY WITH THE ESP. THE UTILITY MUST DROP THE BOILER LOAD SO THE
UNIT REMAINS IN COMPLIANCE.
THERE HAVE BEEN NO PROBLEMS REPORTED FOR THE LAST FEU MONTHS. THE UTILITY
IS KEEPING AHEAD OF PROBLEMS WITH A CONSCIENTIOUS INSPECTION AND MAINTEN-
ANCE PROGRAM.
6/79
7/79
8/79
9/79
10/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
98.6
95.4
720
744
744
720
744
720
• * PROBLEMS/tOLUTIONS/COMMENTS
A TEN HOUR OUTAGE OCCURRED 'FOR REPAIRS OF A LEAD LINE LEAK.
11/79 SYSTEM
95.2
88.8
720
672
710
64C
•• PROBLEMS/COLUTIONS/COHMENTS
IN NOVEMBER, 8 HOURS OUTAGE TIME WAS REQUIRED TO REPAIR A LEAK IN A
RECYCLE LINE.
12/79 SYSTEM
96.1
93.5
744
724
696
•* PflOBLEMS/SOLUTIONS/CCNMENTS
AN OUTAGE FOR GENERAL INSPECTION TOOK PLACE DURING DECEMBER.
444
-------
SECTION U
DESIGN AND PERFORMANCE DATA fOR OPERATIONAL
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
PARTICLE SCRUBBERS
COMPANY KAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SO3 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
CROSS UNIT GENERATING CAPACITY - Mh
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY '• NW
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMITER - M
• • FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/IB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - *
RANGE CHLORIDE CONTENT - X
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - Z
RANGE ASH CONTINT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT '• X
RANGE CHLORIDE CONTENT - X
•* FABRIC FILTER
NUMBER
TYPE
• • ESP
NUMBER
** MECHANICAL COLLECTOR
NUMBER
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
PUBLIC SERVICE OF COLORADO
ARAPAHOE
DENVER
COLO IADO
43. (
****** (<
.100 LB/MHBTU)
*** LR/MMBTU)
112.0
109.8
11.2
PULVERIZED COAL
******
0/55
245.39 ( 520000 ACFM)
148.9 t 300 F)
****.* (**** FT')
******* (**•** fT)
COAL
SUBBITUHINOUS
Z3725.
( 10200 BTU/LB)
9.30
****
13.70
.95
0.6-0.95
.01
COAL
BITUMINOUS
23493.
12.50
( 10100 BTU/LB)
11.20
******
.65
.01
0
NONE
MOBILE PACKED TOWER
AIR CORRECTION DIVISION, UOP
3
CARBON STEEL
RUBBER
STAINLESS STEEL GRIDS, PLASTIC SPHERES
100.0
245.4 ( 520000 ACFM)
445
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE OF COLORADO: ARAPAHOE 4
156.0 GAL/1000ACF)
(**»** IN-H20)
« 11.0 FT/S>
( .80 GR/SCF)
C .020 GR/SCF)
r _—-PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION
X RE 3VAL PER BOILER FGD CAP.
SO' PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
744
720
744
*• PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER REHEATED FAILURES OCCURRED.
LEAKAGE IN THE INLINE STEAM TUBES HAS BEEN ENCOUNTERED. CORROSION
IS KNOUN TO OCCUR AFTER LEAKS ARE EXPERIENCED.
THE PRIMARY PROBLEM WITH THE SYSTEM IS THE INABILITY TO ISOLATE MODULES.
IF A PROBLEM OCCURS NO MODULE MAINTENANCE CAN BE PERFORMED UNLESS THE
UNIT IS CUT BACK OR SHUT DOWN.
446
-------
EPA UTILITY fCO SURVEY: FOURTH QUARTER 1979
SECTION 1«
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL
PARTICLE SCRUBBERS
COMPANY NAME
PLANT NAM
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION • NG/J
$02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - RW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/FGD - MM
NET UNIT GENERATINC CAPACITY WO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - nw
*« BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.H/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP D1AMI TER - H
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - 8TU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTf NT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RAN6E SULFUR CtNTENT - Z
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
.• FABRIC FILTER
NUMBER
TYPE
*• ESP
NUMBER
** MECHANICAL COLUCTOR
NUMBER
«* PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGiS
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - GSCU.H
PARTICULATE OUTLET LOAD - G/CU.H
PARTICULATE DESIGN REMOVAL EFFICIENCY
SO2 INLET CONCENTRATION - PPM
SO2 CUTLET CONCENTRATION - PPM
S02 DESIGN REMtVAL EFFICIENCY - X
PUBLIC SERVICE OF COLORADO
CHERCKEE
1
DENVIR
COLORADO
< .100 LB/MMBTU)
<****** LB/NNBTU)
43.
*•**«*
710.0
115.0
100.0
115.0
102.2
BABC
****** (*•** FT)
.....** (•**«* FTJ
COAL
BITUMINOUS
23493.
12.50
9.4-12.5
1't.30
.65
« 10100 BTU/LB)
.01
0
NONE
- X
MOBILE PACKED TOWER
AIR CORRECTION DIVISION. UOP
3
CARBON STEEL
RUBBER
STAINLESS STEEL. 1.5 INCH PLASTIC SPHERES
67.0
164.4 ( 348400 ACFM)
146.1 t 295 F)
7.5 (56.0 GAL/1000ACF)
**«*«** (....* IN-M20)
3.4 ( 11.0 FT/S>
1.8 < .80 6R/Str>
.0 ( .020 GR/SCF>
97.0
500.000
42C.OOO
16.0
447
-------
EPA UTILI1T FGO SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE OF COLORADO: CHEROKEE 1 (CONT.l
f. . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOIIER FED CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM 74*
11/79 SYSTEM 720
12/79 SYSTEM 7*4
•• PROBLEMS/SOLUTIONS/COMMENTS
DURING THE PERIOD ID FAN FAILURES HAVE OCCURRED DUE TO EROSION FROM THE
FLVASH .
THE ISOLATION DAMPER HAS BEEN A PROBLEM DUE TO FREEZE UPS MAKING IT
INOPERATIVE.
REMEATER FAILURES HAVE OCCURRED DUE TO PLUG6IN6 OF THE HOT AIR INJECTION
STEAM COILS.
THE SCRUBBER EXIT DUCTWORK WILL BE REPAIRED TEMPORARILY VITH A SPRAY ON
FIBERGLASS LIKE MATERIAL.
4*8
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 1 '
DESI6N AND PERFORMANCE DATA FOR OPERATIONAL
PARTICLE SCRUBBED*
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SO2 EMISSION LIMITATION - N6/J
NET PLANT 6ENERATIN6 CAPACITY • MU
CROSS UNIT GENERATING CAPACITY - HU
NET UNIT GENERATING CAPACITY U/FGO - MU
NET UNIT GENERATING CAPACITY WO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOU - CU.M/S
ILUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMKTER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CtNTENT - J/G
RANGE HEAT CONTENT - 6TU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTINT - I
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - J
AVERAGE SULFUR CONTENT - 1
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
•* MECHANICAL COLLECTOR
NUMBER
*• PARTICULATE SCRBBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERiAL
L/C RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - G/CU.M
PARTICULATE OUILET LOAD - G/CU.M
PARTICULATE DESIGN REMOVAL EFFICIENCY
SO! INLET CONCENTRATION - PPM
S02 CUTLET CONCENTRATION - PPN
S02 DESIGN REMOVAL EFFICIENCY - X
( .100 LB/MHBTU)
(**•**• LB/MMBTU)
PUBLIC SERVICE OF COLORADO
CHEROKEE
4
DENVER
COLORADO
43.
**•***
710.0
375.0
350.0
375.0
356.4
COMBUSTION ENGINEERING
PULVIR12ED COAL
******
0/68
717.29 (1520000 ACfM)
135.0 ( 275 F>
****** (**•* FT)
******* (***** FT>
( 10100 BTU/LB)
COAL
BITUMINOUS
23493.
12.50
9.4-12.5
11.30
.65
******
.01
******
0
NONE
1
1
MOBILE PACKED TOUER
AIR (ORRECT10N DIVISION, UOP
j
CARBON STEEL
RUBBER
STAINLESS STEEL, 1.5 INCH PLASTIC SPHERES
7.5
*******
3.4
•1.6
.0
97.0
501.000
42 C.OOO
16.0
(56.0 6AL/1000ACF)
<•**•• IN-H20)
( 11.0 FT/S)
( .70 GR/SCF)
( .020 GR/SCF)
449
-------
EPA UTILITY FGD SURIEV: FOURTH QUARTER 1979
PUBLIC SERVICE or COLORADO: CHEROKEE 4
-------
SECTION 14
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL
EPA UTIfclTV F6D SURVEY: FOURTH QUARTER 1979
PARTICLE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLAN! GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY U/FGD - MU
NET UNIT GENERATING CAPACITY UO/FGD - NU
EaUIVALEkT SCRUBBED CAPACITY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOU - CU.M/S
FLUE CAS TEMPEIATURE - C
STACK HEIGHT - H
STACK TOP DIAMITER - M
«* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - Z
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERA6E SULFUR CONTENT - ]
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
• * FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
TYPE
FLUE GAS CAPACITY - CU.M/S
• * MECHANICAL COLLECTOR
NUMBER
FLUE GAS CAPACITY - CU.M/S
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGfS
SHELL MATERIAL
LINING MATERIAL
INTERNAL HATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCIUBBER - X
FLUE CAS CAPACITY - CU.M/S
FLUE 6AS TEMPERATURE - C
L/C RATIO - LIIER/CU.M
PRESSURE DROP r KPA
SUPERFICIAL 6A» VELOCITY - M/S
PARTICULATE INLET LOAD - 6/CU.M
PARTICULATE OUILET LOAD - C/CU.M
S02 INLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
PUBLIC SERVICE OF COLORADO
VALNONT
5
VALMKNT
COLORADO
43.
.100 LB/MMBTU)
>•** LB/MNBTU>
27? .8
164.0
157.0
163.0
166.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/64
436.98 < 926000 ACFM)
126.7 < 260 F)
****** (**** FT)
******* (***** FT)
COAL
SUBBITUMINOUS
25121.
6.00
5.4-7.0
11.00
12.7M8.3
.70
0.68-.73
< 10800 BTU/LB)
0
NONE
COLD SIDE
21«. 5
218.5
C 463000 ACFH)
< 463000 ACFH)
HOBIhE PACKED TOUER
AIR CORRECTION DIVISION. UOP
3
CARBON STEEL
RUBBER
STAINLESS STEEL, 1.5 INCH PLASTIC SPHERES
25.
36.0
109.2 < 231500 ACFH)
271 F)
(58.3 GAL/1000ACF)
(•**•* IN-H20)
11.0 FT/S)
.80 6R/SCF)
.020 6R/SCF)
132.8
7.8
*••*•**
3.4
1.8
.0
500.000
40.0
451
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE OF COLORADO: VALNONT 5 CCONT.)
,. PERFORMANC £ DATA —
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/7* SYSTEM 744
• • PROBLEMS/COLUTIONS/COMMENTS
THE SCRUBBER HAS ORIGINALLY INSTALLED FOR PARTICULATC REMOVAL SINCE THE
PLANT BURNS LOU SULFUR COAL; HOWEVER. 45X OF THE S02 IS REMOVED AS HELL
BECAUSE OF THE ALKALINITY OF THE FLVASH.
11/7* SYSTEM 720
12/74 SYSTEM 744
1/75 SYSTEM 744
2/75 SYSTEM 672
3/75 SYSTEM 7*4
4/75 SYSTEM 720
5/75 SYSTEM 744
6/75 SYSTEM 720
7/75 SYSTEM 744
8/75 SYSTEM 744
9/75 SYSTEM 720
10/75 SYSTEM 744
11/75 SYSTEM 720
12/75 SYSTEM 744
•« PROBLEMS/IOLUTIONS/COMMENTS
DURIN6 THE FIRST YEAR OF OPIRATION PROBLEMS INCLUDED DIFFICULTIES WITH THE
MODULE PACKING GRID SUPPORT» GENERAL VESSEL SCALE FORMATION, FLOW DISTRI-
BUTION PROBLEMS. BALL BREAKAGE, SCALING IN THE MIST ELIMINATOR SECTION.
AND PLUGGING OF THE REHEATER. SCALE FORMATION WAS THE MOST PREDOMINANT
CONT1»UING MAJOR CAUSE OF D (UNTINE IN THE SCRUBBER. SCALE ACCUMULATION D
WAS NOTED ON THE WET-DRY INTERFACE IMMEDIATELY DOWNSTREAM OF THE PRESATU-
RATIOM NOZILES. SCALE ALSO ACCUMULATED HEAVILY ON THE UNDERSIDE OF THE
FIRST LAYER OF GRID BARS.
SCALE ON THE UPPER GRID BARS WAS LESS PREVALENT AS THE ACTION OF THE "PING
PONG" BALLS TENDED TO KEEP THE SCALE OFF OF THESE SECTIONS. SCALE ALSO
COLLECTED ON THE WALLS OF THE VESSEL AND INTERMITTENTLY SLOUGHED OFF AND
FELL INTO THE SUMP IN LARGE PIECES CAUSING BLOCKAGE OF THE RECIRCULATION
PUMP SUCTION SCREENS. SCALING OF THE MIST ELIMINATOR ABATED SOMEWHAT WITH
THE INTRODUCTION OF A CLEAR RINSE WATER WASH. SCALE FORMATION IN THE RE-
HEAT SECTION SOMETIMES REQUIRED SUPPLEMENTAL CLEANING OF THE REHEATER IN
ADDITION TO THE CLEANING OBTAINED BY THE USE OF THE SOOTBLOWERS WHICH WERE
INSTALLED AS A PART OF THE REHEATER EQUIPMENT. UNDER NORMAL OPERATION.
THE SOOTBLOWERS LOCATED IN THIS REHEAT SECTION WERE FAIRLY SUCCESSFUL IN
REMOVING THE ACCUMULATION 0)1 THE SCALE IN THE REHEATER.
ALTHOI6H MANY OF THE INITIAL START-UP PROBLEMS WERE SOLVED OVER A PERIOD
OF TIM, THE CALCIUM SULFATE-FLVASH SCALING CONTINUED TO BE A SIGNIFICANT
OPERATING PROBLEM AT THE VALNONT INSTALLATION. IN ADDITION TO THESE
SCALING RELIABILITY PROBLEMS. A WATER QUALITY CONCERN ALSO SURFACED THAT
WAS A DIRECT RESULT OF THE PARTICULATE SCRUBBER OPERATION. THE RELATIVELY
HIGH CAO CONCENTRATION IN THE VALMONT FLVASH RESULTED IN FAIRLY H16H S02
REMOVAL RATES (45-50 PERCENT) WITHIN THE UNITS. SINCE NO PH CONTROL CAPA-
BILITY FOR EITHER THE RECIRCULATIN6 SLURRY OR THE SYSTEM SLOWDOWN SLURRY
WAS DESIGNED INTO THE SYSTEM, AN ACID CONDITION WAS CREATED IN THE SLURRY
AND THE SLOWDOWN STREAM. PH LEVELS OF THE SLOWDOWN NORMALLY RANGED BETWEEN
1.7 AND 2.C. ALTHOUGH THE STREAM WAS NEUTRALIZED TO A DEGREE BY ALKALINE
FLYASH, PSCC FELT THAT IT W»S IMPORTANT TO INVESTIGATE VARIOUS CONTROL
MEASURES WHICH COULD BE APPLIED TO THIS STREAM. THE CALCIUM SULFATE
SCALING PROBLEM WAS THOUGHT TO BE THE RESULT OF A SUPER-SATURATED CALCIUM
452
-------
EPA UTIHTY F60 SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE OF COLORADO: VALMONT 5 (CONT.l
___.— —— . PERFORMANCE DATA
PERI 06 NODULE AVAILABILITY OPED ABILITY RELIABILITY UTILIZATION
t REMOVAL PER BOILER
S02 PART. HOURS HOURS
F6D CAP.
HOURS FACTOR
SULFATE CONDITION IN THE RE CIRCULATING SLURRY. BECAUSE OF THIS IT WAS FELT
THAT CONTINUOUS PH CONTROL OF THE RECIRCULATING SLURRY, CONVERSION Of THE
SYSTEM TO CLOSED LOOP OPERATION AND ESTABLISHING A HIGHER CONCENTRATION OF
SEEDING SOLIDS IN THE RECIRCULATION SLURRY (THEREBY CONTROLLING THE SCALING
PROBLEMS WITHOUT CHEMICAL ADDITIVES) WOULD BE NECESSARY MEASURES.
FOR PH CONTROL. LIMESTONE U«S TESTED INITIALLY, THEN LIME WAS UTILIZED FOR
THE ALKALI REAGENT. IN THE FIRST TEST, SINCE LIMESTONE UTILIZATION kA$ A
MAJOR CONCERN, A SPECIAL EFFORT WAS HADE TO REDUCE THE POTENTIAL FOR THE
SHORT CIRCUITING OF THE ADD ID LIMESTONE AND TO PROVIDE SUFFICIENT RESIDENCE
TIME IN THE REACTOR SECTION OF THE SYSTEM. BY UTILIZING FOUR REATIOk Mil
TANKS IN SERIES* PLUG FLOW WAS EXPECTED TO BL MORE CLOSELY SIMULATED. TO
MAINTAIN A CLOSED LOOP SYSTEM WHERE THE QUANTITY OF WATER REMOVED FROM THE
SYSTEM WAS HELD TO A MINIMUM, FOUR SYSTEM DESIGN FEATURES WERE UTILIZED.
1. UTILIZATION OF A COMBINATION OF POND SUPERNATANT AND MAKE-UP WATER
FOR RECYCLE WATER.
2. PRESATURATION OF THE INCOMING FLUE GAS WITH RECIRCULATING SLURRY.
3. INTERMITTENT HIST ELIMINATOR WASH.
4. PROPER SELECTION OF MATERIALS OF CONSTRUCTION TO PROTECT AGAINST
ATTACK CAUSED BY HIGH CHLORIDE CONCENTRATIONS.
THE SCRUBBERS R ( D FACILITY WAS NOT EQUIPPED WITH A MECHANICAL THICKENER
FOR CONTROL OF THE SUSPENDED SOLIDS CONCENTRATION OF THE RECIRCULATING
SLURRY (ACL PURGED MATERIAL WAS SENT TO THE SLUDGE POND>. WITH A SCC PPM
$02 CONCENTRATION IN THE FLUE GAS, IT IS E'XPECTED THAT THE «E C IB CULATING
SLURRY SOLIDS COULD BE REALLY CONTROLLED IN THE 5 TO 7 PERCENT RANGE. DUE
TO THE MIXED FUEL FIRED AT THE UNIT DURING THE TEST PERIOD, HOWEVER, THE
S02 CONCENTRATIONS EMITTED FROM THE BOILER AND HENCE PRESENT IN THE FLUE
GAS STREAM VARIED SIGNIFICANTLY AND FINALLY FELL TO SUCH LOW LEVELS (OFTEN
100-200 PPM) THAT SUSPENDED SOLIDS CONCENTRATIONS IN THE SLURRY COULD NOT
BE MAINTAINED. IT IS ALMOST CERTAIN THAT A THICKENER, WITH THE SUBSE-
QUENT RETURN OF SOLIDS TO THE SCRUBBER LIQUOR, COULD HAVE BEEN USED 10
GOOD ADVANTAGE DURING THIS TIME PERIOD. GENERALLY SPEAKING, THE SEVERE
SCALING CONDITIONS PLAGUING THE TEST MODULE WERE INTENSIFIED DURING THESE
PERIODS OF LOW INLET $02 CONDITION.
744
696
744
720
720
744
744
720
744
72 C
744
744
672
744
720
744
720
744
1/76
2/76
3/76
A/76
5/76
6/76
7/76
8/76
9/76
10/76
11/76
12/76
1/77
2/77
3/77
4/77
5/77
6/77
7/77
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
453
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE OF COLORADO: VALMONT 5 (CONT.)
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/77 SYSTEM
9/77 SYSTEM
10/77 SYSTEM
11/77 SYSTEM
12/77 SYSTEM
1/78 SYSTEM
2/76 SYSTEM
3/78 SYSTEM
744
720
744
720
744
744
672
744
•* PROBLEMS/SOLUTIONS/COMMENTS
THERE HAVE BEEN RECURRING PROBLEMS ASSOCIATED WITH BALL MIGRATION IN THE
BALL COMPARTMENT AS WELL AS RE CI RCULAT ION PUMP MOTOR BEARING FAILURE, AND
WEAR IHD FAILURE IN THE BALL COMPARTMENT LINING. THERE HAVE BEEN CONTINUAL
PROBLEMS WITH REHEATER PLUGGING. THERE ALSO HAVE BEEN EXPANSION JOINT
FAILURES AT BOTH THE INLET AND OUTLET OF THE SCRUBBER.
MORE RECENTLY THERE VAS A PINCH BELT FAILURE.
THE SCRUBBING SYSTEM HAS HAD AN AVAILABILITY RANGE OF 50 TO 78Z WITH AN
AVERAGE OF 66Z.
4/78 SYSTEM
5/78 SYSTEM
720
744
•• PROBLEMS/SOLUTIONS/COMMENTS
NO SIGNIFICANT PROBLEMS HERE ENCOUNTERED.
6/78 SYSTEM
7/78 SYSTEM
8/78 SYSTEM
720
744
744
• • PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAD NO COMMENTS FOR THIS PERIOD.
9/78 SYSTEM
10/78 SYSTEM
11/78 SYSTEM
12/78 SYSTEM
1/79 SYSTEM
2/79 SYSTEM
3/79 SYSTEM
4/79 SYSTEM
5/79 SYSTEM
6/79 SYSTEM
72C
744
720
744
744
672
744
720
744
72 C
** PROBLEMS/SOLUTIONS/COMMENTS
AVERA6E SCRUBBER AVAILABILITY FROM START UP THROUGH APRIL 1979 WAS 64.421.
AVERACE SCRUBBER AVAILABILITY FOR 1978 WAS 66.8SX.
AVERAGE SCRUBBER AVAILABILITY FROM JANUARY 1. 1979 THROUGH MAY, 1979 WAS
APPROXIMATELY BOX.
BALL MIGRATION, ALTHOUGH NOT S£RIOUS, IS A CHRONIC PROBLEM FOR VALMONT 5.
454
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
PUBLIC SERVICE OF COLORADO: VALMONT 5 (CONT.)
_ • ---PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
EROSION AND CORROSION HAVE OCCURRED ON THE SCRUBBER GRID BAR AREA (PACKING
SUPPORT).
EROSION/CORROSION IS EVIOEN1 IN THE HIST ELIMINATOR SECTION.
EROSION/CORROSION OCCURRS IN THE REHEATER AREA AND SOOT BLOWER.
THE UTILITY HAD TO REPLACE INLET AND OUTLET EXPANSION JOINTS.
REHEATER PLUGGING HAS BEEN » PROBLEM.
RECYCLE PUMP BEARING FAILURES OCCURRED.
THE JACK SCREW DRIVE HAS BEEN MALFUNCTIONING ON INLET AND OUTLET ISOLATION
DAMPERS.
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM
74*
744
720
PROBLEMS/SOLUTIONS/COMMENTS
DURING THE ANNUAL SHUTDOWN IN SEPTEMBER THE OLD SCRUBBER BALLS WERE
REPLACED WITH A NEW BRAND. DUE TO BALL MOTION THE RUBBER LINER ERODED.
IN THE HIST ELIMINATOR SECTION EROSION AND CORROSION OCCURRED.
10/79 SYSTEM 100.0
11/79 SYSTEM 92.3
12/79 SYSTEH 98.1
744
720
744
• • PROBLEHS/SOLUT10NS/COHMENTS
ONE OF THE MAJOR FGD SYSTEM PROBLEMS IS THE SCRUBBER WALL WEAR WHICH HAS
TO BE PATCHED DURING THE SPRING AND FALL.
REHEATER PLUGGING HAS BEEN A CHRONIC PROBLEM.
THE UTILITY HAS REPORTED THE FOLLOWING ANNUAL AVAILABILITIES FOR THE UNIT,
1972 - 1978: 64.3X
1972 - 1979: 65.9X
1978: 66.8X
1979: 80.5X
45S
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION 14
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL
PARTICLE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
C1T»
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - My
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY V/FGD - My
NET UNIT GENERATING CAPACITY WO/F6B - My
EQUIVALENT SCRUBBEO CAPACITY - MM
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.H/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIANITER - H
•• FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/C
RANGE HEAT CONTENT - BTU/L8
AVERAGE ASH CONTENT - X
RANGE ASH CONTINT - Z
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - Z
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - Z
RANGE CHLORIDE CONTENT - X
SOUTHVESTERN PUBLIC SERVICE
HARRINGTON
AMARILLO
TEXAS
• **•:•
43.
516.
360.0
360.0
< .100 LB/MMBTU)
( 1.200 LB/MMBTU)
*••*:<**
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
8/7.<
77».63
176.7
76.
.8
COAL
SUBBITUMINOUS
19538.
5.00
4.5-d
27.10
25-3 C
.42
.39-,45
(1650000 ACFM>
( 350 F)
C 250 FT)
< 2.7 FT)
< 8400 BTU/LB)
8000-8900
•• ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - Z
FLUE GAS CAPACITY - CU.M/S
fLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICULATE OUTLET LOAD - G/CU.H
*• PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL NATERIAL
NUMBER OF NOZZLES
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TENPEIATUNE - C
LIQUID RECIRCULATION RATE - LITER/S
L/fi RATIO - LITER/CU.M
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - NG/J
PARTICULATE OUTLET LOAD - NG/J
S02 INLET CONCINTRATION - NG/J
SO2 OUTLET CONCENTRATION - NG/J
S02 tESIGN REMOVAL EFFICIENCY - X
1
COLD SIDE
RESEARCH COTTRELL
95.0
778.6 (1650000 ACFH)
168.3 < 335 *)
••»**•• (****. 1N-H20)
'1.83 ( .80 GR/SCF)
MOBILE PACKED TOUER
COMBUSTION ENGINEERING
1
CARBON STEEL
RIGID LINE POLYESTER
316L SS FIBERGLASS ALLOY 20
14.1.6
6C.O
444.1
3.1
2.4
80.
30.
430.
21S.
50.0
300000 ACFM)
140 F)
7050 GPM)
23.0 GAL/1000ACF)
8.0 FT/S)
.185 LB/MMBTU)
.070 LB/MMBTU)
1*000 LB/MMBTU)
.500 LB/MMBTU)
456
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
SOUTHWESTERN PUBLIC SERVICE: HARRINGTON 1 (CONT.)
___...._. . .... -PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FCO CAP.
SQZ PART. HOURS HOURS HOURS (ACTOR
10/79 SYSTEM 744
11/79 SYSTEM 720
1Z/79 SYSTEM 7*4
** PROBLENS/SOLUTIONS/COMHENTS
DURING OCTOBER THROUGH DECEMBER, TWO SPRAY PUMP MOTORS FAILED.
THE FRP MATERIAL IN THE FLUSH PIPING HAS FAILED CAUSING SOME LEAKAGE.
PLUGGING IN ONE MARBLE BED WAS ENCOUNTERED WHEN THE CHEMISTRY CONTROL WAS
TEMPORARILY LOST.
SOME MARBLE CAPS HAVE LOOSENED ALLOWING SOME MARBLE TO FALL INTO
THE RECYCLE TANK. THIS WAS RECTIFIED DURING THE PERIOD.
457
-------
EPA UTILITY F6D SURVEY: FOURTH 8UARTER 1979
SECTION 15
DESIGN AND PERFORMANCE DATA FOR OPERITIONAL FOREIGN FGD SVSTENS
COMPANY NAME CMUGOKU ELECTRIC
PLANT NAME SHIHONOSEKI
UNIT NUMBER 1
CITY **.«*.
STATE ******
REGULATORY CLASSIFICATION *•*•«*
PARTICULATE EMISSION LIMITATION - NG/J ****** {****** LB/MMBTU)
S02 EMISSION LIMITATION - NG/J *••«•« (•****• LB/HMBTU)
NET PLANT GENERATING CAPACITY - HW ***.*«.
GROSS UNIT GENERATING CAPACITY - Mb 175.0
NET UNIT GENERATING CAPACITY U/FGD - MW .......
NET UNIT GENERATING CAPACITY WO/FGD - HU .,..«..
EQUIVALENT SCRUBBED CAPACITY - HU .......
** BOILER DATA
SUPPLIER •*«.««
TYPE ******
SERVICE LOAD .*.**.
COMMERCIAL SERVICE DATE ../..
MAXIMUM BOILER FLUE GAS FLOH - CU.M/S ******** (**..*.* ACfM)
FLUE GAS TEMPEBATUHE - C *•**<«* (**** F)
STACK HEIGHT - M *•*.*. (*••* FT)
STACK TOP DIAMiTER - M •***•*« (***** FT)
•* FUEL DATA
FUEL TYPE COAL
FUEL GRADE ******
AVERAGE HEAT CONTENT - J/6 ******* <*..... BTU/LB)
RANGE HEAT CONTENT - BTU/LB *•*•«•
AVERAGE ASH CONTENT - X .**.«...
RANGE ASH CONTfNT - X ******
AVERAGE MOISTURE CONTENT - X *..*••*»
RANGE MOISTURE CONTENT - X *.*...
AVERAGE SULFUR CONTENT - X 3.00
RANGE SULFUR C*NTENT - X ******
AVERAGE CHLORIDE CONTENT - X *••****•
RANGE CHLORIDE CONTENT - X ******
** FGD SYSTEM
SALEABLE PRODUfiT/THROUAUAT PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEMEL
NEU/RETROfIT
SO2 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DAT!
CONSTRUCTION INITIATION
** REHEATER
TYPE
** BYPRODUCTS
BYPRODUCT NATUtE
SALEABLE PRODUCT
WET SCRUBBING
LIMESTONE
MITSUBISHI HEAVY INDUSTRIES
FULL SCALE
RETROFIT
96.00
0/79
0/78
UASTI HEAT RECOVERY
GYPSUM
458
-------
EPA UTIUTY fGO SURVEY: FOURTH OUARTER 1979
SECTION 15
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FOREIGN F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/4
NET PLANT GENERATING CAPACITY - NW
GROSS UNIT GENERATING CAPACITY - MH
NET UNIT GENERATING CAPACITY U/FGD - MU
NET UNIT GENERATING CAPACITY WO/FGO - My
EQUIVALENT SCRUBBED CAPACITY - flW
»« BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE 6AS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMITER - M
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE NEAT CONTENT - BTU/L8
AVERAGE ASH CONTENT - X
RANGE ASH CONT ENT - X
AVERAGE MOISTUBE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CflNTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
• * ESP
NUMBER
PARTICIPATE OUTLET LOAD - G/CU.M
• * PARTICULATE SCRUBBER
TYPE
.* F60 SYSTEM
SALEABLE PRODUtT/THROUAUAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIEI
DEVELOPMENT LEVEL
NEM/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGIS
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
6AS FLOU - CU.B/S
6AS TEMPERATURE - C
4./G RATIO - L/IU.M
PRESSURE DROP t KPA
SUPERFICAL GAS VELOCITY - H/SEC
PARTICULATE INLET LOAD - fc/CU.ft
PARTICIPATE OUTLET LOAD- G/CU.M
ELECTRIC POWER DEVELOPMENT CO.
ISOGO
1
YOKOHAMA
JAPAN
******
I****** LB/MNBTU)
(****** LB/MHBTU)
26»:.0
265.0
IHI
******
BASE
0/67
405.36
170.0
122.
*******
COAL
25586.
16.00
t 8S9000 ACFM)
< 338 F)
< 400 FT)
(****• FT)
< 11000 BTU/LB)
•.20
******
.60
0.2 - 0.6
.59
VENTURI
< .26 GR/SCF)
SALEABLE PRODUCT
MET (SCRUBBING
LIMESTONE
IHI - CHCMICO
FULL SCALE
RETROFIT
- X 96.70
9C.OO
3/76
1
VENTLRI
3/7«
IHI - CHEMICO
1
MILD STEEL
FLAK I
100.0
405.36
170.0
t.t
1.5
3.0
.6
.1
85AOOO «CFM>
338 F)
70.0 GAL/1000ACF)
5.9 IN-H20)
10.0 FT/S)
.262 GR/SCF)
.022 GR/SCF)
459
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.: ISOGO 1
( 70.0 GAI/1000ACF)
< 5.9 IN-H20)
C 10.0 FT/S)
( .022 GH/SCF)
( .022 GR/SCF)
( 767400 «CFN)
OXIDATION BLOWER
.86 < 1830 ACFM)
CHEVRON
PLASTIC
HORIZONTAL
I
i i
INTERMITTENT FRESH WATER HASH
.5 ( 2.0 IN-H20)
PH
NUMBER
3
10
NUMBER
DIRECT COMBUSTION
83.9 I 151 F)
SEDIMENTATION AND CONCENTRATION TYPE
460
-------
EPA UT111TT F60 SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.* 1SOGO 1 (CONT.)
•* UATER LOOP
TYPE
PURGE WATER LOSS - LITER/S
FRESH MAKEUP UATER ADDITION - LITERS/S
** BYPRODUCTS
BYPRODUCT NATURE
BYPRODUCT QUANTITY - M T/H
DISPOSITION
•• TREATMENT
TYPE
OPEN
2.5
22.3
GYPSUM
«. 53
HARKITED
< 40 6PM)
( 354 GPM)
t 5.00 TPM)
FORCED OXIDATION
461
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 15
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FOREIGN FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
$02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MU
NET UNIT GENERATING CAPACITY WO/FGO - MW
EGUIVALEhT SCRUBBED CAPACITY - MW
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.H/S
FLUE GAS TEMPEIATURE - C
STACK HEIGHT - M
STACK TOP DIAMf TER - M
•• FUEL DATA
FUEL TYPl
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - 61U/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - 1
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - Z
AVERAGE CHLORI IE CONTENT - X
RANGE CHLORIDE CONTENT - X
*• ESP
NUMBER
ELECTRIC POWER DEVELOPMENT CO.
ISOGO
2
YOKOHAMA
JAPAN
******
265.0
265.0
IHI
******
BASE
0/69
405.36
170.0
14C.
COAL
******
25586.
16.00
4.20
•*•*••
.60
0.2 - 0.6
LB/MMBTU)
LB/MMBTU)
C 859000 ACFM)
( 338 F)
( 460 FT)
C***** FT)
C 11000 BTU/LB)
*• PARTICULATE SCRUBBER
TYPE
VENTURI
** F6D SYSTEM
SALEABLE PRODUCT/THROUAUAV PRODUCT
GENERAL PROCES< TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
** ABSORBER
NUMBER
TYPE
INITIAL START IIP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLOV - CU.M/S
GAS TEMPERATURC - C
L/6 RATIO - L/CU.H
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY • M/SEC
PARTICULATE INIET LOAD - 6/CU.M
PARTICULATE OUTLET LOAD- 6/CU.M
S02 INLET CONCENTRATION - PPM
SALEABLE PRODUCT
WET SCRUBBING
LIMESTONE
IHI ' CHEMICO
FULL SCALE
RETROFIT
- X 96.70
90.00
5/76
1
VENTURI
5/76
IHI - CHEMICO
1
MILD STEEL
FLAKE
100.0
405.36
170.0
9.4
1.5
3.0
.6
.1
500
859000 ACFM)
338 F)
70.0 6AL/100CACF)
5.9 IN-H20)
10.0 FT/S)
.262 GR/SCF)
.022 GR/SCF)
462
-------
EPA UTIkITT F60 SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVEtOPRENT CO.: ISO60 2 CCONT.)
S02 CUTLET CONTRATION - PPM
S02 DESIGN REHtVAL EFFICIENCY - X
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MAJERIAL
BOILER LOAD/ABSORBER - X
GAS (LOU - CU.n/S
GAS TEMPERATURC - C
L/G RATIO - L/CU.M
PRESSURE DROP '• KPA
SUPEDFICAL GAS VELOCITY - K/SEC
PARTKULATE INLET LOAD - G/CU.M
PARTICULATE OUILET LOAD- G/CU.M
PARTKULATE REMOVAL EFFICIENCY - X
S02 INLET CONCENTRATION - PPM
S02 OUTLET CONIRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - I
** CENTRIFUGE
NUMBER
OUTLET SOLIDS - X
*« FANS
NUMBER
CAPACITY - CU.N/S
** FANS
NUMBER
TYPE
CAPACITY - CU.M/S
«* HIST ELIMINATOR
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
HASH SYSTEM
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
• • PUMPS
SERVICE
SLURRY MAKEUP
ABSORBER REC IRC ULA 1ION
OXIDATION TOWER SUPPLY TRANSFER
FILTRATE
TANKS
SERVICE
OXIDATION TOUEA FEED TANK
RECYCLE
SLURRY TANK
THICKENER OVERf LOU
FILTRATE TANK
OXIDATION TOUEI
• * REHEATER
TYPE
TEMPERATURE BOtST - C
•• THICKENER
NUMBER
TYPE
160
65.0
VENTURI
5/7 l
IHI • CHEHICO
1
MILD STEEL
FLAKE
100.0
566.28
5!.0
9.4
1.5
3.0
.1
.1
96.7
16C
5I(
8C.O
90.0
362.14
11200000 ACFH)
131 F)
70.0 GAL/1000ACF)
S.9 1N-H20)
10.0 FT/SJ
.022 GR/SCF )
.022 GR/SCF)
( 767400 ACFM>
OXIDATION BLOyER
.86 ( 1830 ACFM)
CHEVRON
PLASTIC
HORIZONTAL
INTERMITTENT FRESH yATER UASH
.5 ( 2.0 IN-H20)
PH
NUMBER
3
10
.*»•
*«*•
NUMBER
DIRECT COMBUSTION
83.9 ( 151 F>
1
SEDIMENTATION AND CONCENTRATION TYPE
463
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.: I SO60 2 CCONT.)
•• WATER LOOP
TYPE OPEN
PURGE WATER LOSS - LITER'S 2.5 ( 40 6PM>
FRESH MAKEUP WATER ADDITION - L1TERS/S 22.3 ( 354 6PM)
•* BYPRODUCTS
BYPRODUCT NATU1E GYPSUM
BYPRODUCT QUANTITY - M T/H 4.53 ( 5.00 TPH)
DISPOSITION MARK[TED
•• TREATMENT
TYPE FORCED OXIDATION
464
-------
EPA UTILITY rCD SURVEY: FOURTH QUARTER 1979
SECTION 11
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FOREIGN F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
SOZ EMISSION LIMITATION - N6/J
NET PLANT GENERATING CAPACITY - HU
CROSS UNIT GENERATING CAPACITY -Mb
NET UNIT GENERATING CAPACITY W/F60 - My
NET UNIT GENERATING CAPACITY WO/FGD - MU
EQUIVALENT SCRUBBED CAPACITY - MU
«• BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIKUM BOILER FLUE GAS FLON - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMBTER - M
• * FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RAN6E MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANCE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
• « ESP
TYPE
PARTICIPATE DEC1GN REMOVAL EFFICIENCY
FLUE GAS CAPACITY • CU.M/S
FLUE GAS TEMPERATURE - C
•* PARTICULATE SCRBBBER
TYPE
*« F6D SYSTEM
SALEABLE PRODUCT/THROUAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
S02 DESIGN REMOVAL EFFICIENCY - k
INITIAL START-UP
• * ABSORBER
NUMBER
INITIAL START DP
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
6AS FLOW - CU.H/S
6AS TEMPERATURf - C
PARTICULATE INLET LOAD - 6/CU.R
S02 INLET CONCENTRATION - PPM
«* ABSORBER
NUMBER
INITIAL START UP
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
ELECTRIC POWER DEVELOPMENT CO.
MATSUSHIMA
1
****•*
JAPAN
****:«*
****** (*•*«•* LB/MMBTU)
«*•*«• (**•*** LB/MMBTU)
*******
500.0
<•*••*** ACFM)
(«••* F)
(***• FT>
C***** FT)
<«•***. BTU/LB)
******
- X
*******
375.0
******
0/8 C
********
***«••*
******
****>•**
COAL
******
*******
********
****• 4*
** ****
1.60
****:••
********
******
HOT 'IDE
99.5
457.7
8S.O
NONE
SALEABLE PRODUCT
WET SCRUBBING
LIMEJITONE
VENDOR NOT SELECTED
FULL SCALE
NEW
9S.OO
1/88
1
1/80
FLAKE6LASS FILLED PLASTIC
100.0
457.74 < 970000 ACFM)
85.0 ( 185 F)
.3 < .130 GR/SCF)
1000
( 970000 ACFH)
( 185 F)
1
1/80
FLAKE6LASS
75.0
FILLED PLASTIC
465
-------
EPA UTILITY FGO SURIEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.: MATSUSH1MA 1 ICONT.)
GAS FLOW - CU.H/S
GAS TEMPERATURE - C
PARTKULATE OUTLET LOAD- G/CU.Pl
S02 OUTLET CONTRATION - PPM
•• FANS
NUMBER
TYPE
•* HIST ELIMINATOR
CONFIGURATION
•• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
** PUMPS
SERVICE
*• AEHEATER
TYPE
•• REHEATER
TYPE
•• WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
** BYPRODUCTS
BYPRODUCT NATURE
*• TREATMENT
TYPE
737.11
55.0
.0
50
BOOSTER
HORIZONTAL
(1562000 ACFM)
< 131 f)
( .013 GR/SCF)
PH BASED CONTROL-TRIMMED BY BOILER LOAD SIGNAL
NUMBER
*»••
BYPASS
WASTE HEAT RECOVERY
OPEN
3C.8
GYPSUM
FORCED OXIDATION
489 GPM)
466
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION 15
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FOREIGN F60 SYSTEMS
COMPANY HAKE ELECTRIC POWER DEVELOPMENT CO.
PLANT NAME BATS ISH1MA
UNIT NUMBER 2
CITY ....••
STATE JAPAN
REGULATORY CLASSIFICATION ......
PARTICULATE EMISSION LIMITATION - NG/J ...... (...*.. LB/MMBTU)
S02 EMISSION LIMITATION - N67J ...... (...... LB/MMBTU)
NET PLANT GENERATING CAPACITY - MW ..*.**«
CROSS UNIT GENERATING CAPACITY - Mb 500.0
NET UNIT GENERATING CAPACITY U/F6D - MW .......
NET UNIT GENERATING CAPACITY UO/FGC - MW .......
EQUIVALENT SCRUBBED CAPACITY - MW 375.0
.. BOILER DATA
SUPPLIER ......
TYPE ......
SERVICE LOAD ......
COMMERCIAL SERVICE DATE 0/8M
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S ........ <•..«... ACFH)
FLUE GAS TEMPERATURE - C ....... <.... f)
STACK HEIGHT - M ...... (..** ft)
STACK TOP D1AM6TER - M ....... (..... fT)
.. FUEL DATA
FUEL TTPE COAL
FUEL GRADE ......
AVERAGE HEAT CONTENT - J/G ....... (*....* BTU/L8)
RANGE MEAT CONTENT - BTU/LB ......
AVERAGE ASH CONTENT - X ........
RANGE ASH CONTENT - X ......
AVERAGE MOISTUBE CONTENT - X ........
RANGE MOISTURE CONTENT - X *...*.
AVERAGE SULFUR CONTENT - X 1.60
RANGE SULFUR CONTENT - X ......
AVERAGE CHLOR1IE CONTENT - X ........
RANGE CHLORIDE CONTENT - X ......
.. ESP
TYPE
PARTICULATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TENPEBATURE - C
.. PARTICULATE SCRUBBER
TYPE
.* FGD SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIEI
DEVELOPMENT LEVEL
NEW/RETROFIT
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
.. ABSORBER
NUMBER
INITIAL START UP
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.B/S
GAS TEMPERATURE - C
PARTICULATE INLET LOAD - S/CU.M
SO2 INLET CONCENTRATION - PPM
.. ABSORBER
NUMBER
INITIAL START UP
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
HOT SIDE
- X 99.5
457.7
85. 0
NONE
( 970000 ACFH)
( 185 F)
SALEABLE PRODUCT
WET SCRUBBING
LIMESTONE
VENDOR NOT SELECTED
FULL SCALE
NEU
9S.OO
7/8C
1
7/80
FLAKCGLASS FILLED PLASTIC
100.0
457.74 ( 970000 ACFM)
85.0 I 185 F)
.3 t .130 GR/SCF)
1000
1
7/80
FLAKEGLASS FILLED PLASTIC
7.'.0
467
-------
EPA UTILITY FGD SURVEY: FOURTH flUARTER 1979
ELECTRIC POKER DEVELOPMENT CO.: HATSUSHIHA 2 (CONT.)
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
PARTICIPATE OUTLET LOAD- G/CU.H
SO2 OUTLET CONTRAT10N - PPM
•• FANS
NUMBER
TYPE
•• HIST ELIMINATOR
CONFIGURATION
*• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
•• PUMPS
SERVICE
737.11
55.0
.0
so
BOOSTER
HORIZONTAL
11562000 ACFH)
< 131 F>
< .013 GR/SCF)
PH BASED CONTROL-TRIMMED BY BOILER LOAD SIGNAL
NUMBER
*•**
•* REHEATER
TYPE
•* REHEATER
TYPE
•• UATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
*• BYPRODUCTS
BYPRODUCT NATME
•* TREATKENT
TYPE
BYPASS
HASTE HEAT RECOVERY
OPEN
30.8
GYPSUM
FORCED OXIDATION
( 489 GPM)
468
-------
EPA imtiTt FGD SURVEY: FOURTH QUARTER 1979
SECTION 15
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FOREIGN FCD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EM1SSI(N LIMITATION - HG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY H/F60 - NW
NET UNIT GENERATING CAPACITY UO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - My
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERtlCE DATE
MAK1HUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIANfTER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - Z
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - Z
RANGE SULFUR CANTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
ELECTRIC POWER DEVELOPMENT CO.
TAKASA60
t
H1MEJI
JAPAN
***•**
******
******
250.0
*******
250. 0
**** **
BASE
0/68
365.25
154.*
******
*******
COAL
******
24656.
******
******
1.80
******
•*•**••*
******
<*«**** LB/HMBTU)
<*.**** L6/MHBTU)
( 774000 ACFNJ
( 310 F)
(*«** fji
C***** FT)
( 10600 BTU/LB)
• * ESP
NUMBER
FLUE GAS TEMPERATURE - C
•* PARTICULATE SCRUBBER
TYPE
•• FGD SYSTEM
SALEABLE PRODUCT/THROUAUAI PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIED
DEVELOPMENT LEVEL
NEH/RETROFIT
INITIAL START-HP
«* ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
BOILER LOAD/ABIORBED - X
GAS FLOW - CU.B/S
GAS TEMPERATURI - C
L/G RATIO - L/CU.N
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - C/CU.M
S02 INLET CONCINTRATION - PPM
.« ABSORBER
NUMBER
TYPE
INITIAL START DP
1
154.4
VENTURI
< 310 F)
SALEABLE PRODUCT
WET SCRUBBING
LIMESTONE
MITSUI - CMEN1CO
FULL SCALE
RETROFIT
2/7J
VENTURI
2/75
MITSUI - CMEM1CO
1
75.0
260.49 < 552000 ACFM)
154.4 < 310 F)
6.5
1.5
.1
1500
VENTURI
2/75
( 48.6 GAL/100QACF)
(5.9 1N-H20)
I .035 GR/SCF)
469
-------
EP* UTILITY FGD SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.: TAKASA60 1 (CONT.)
SUPPLIER
NUMBER Of STACIS
BOILER LOAD/AB !ORB£R - X
GAS TEMPERATURE - C
L/b RATIO - L/CU.M
PRESSURE DROP »• KPA
PARTICIPATE OUTLET LOAD- 6/CU.M
S02 CUTLET CONTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - Z
M1TSOI -
1
100.0
55.0
6.5
1.5
.0
75
93.3
CHEHICO
( 131 f)
< 46.6 GAL/1000ACFJ
( 5.9 IN-H20)
( .009 GR/SCF)
ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAG!S
BOILER LOAO/ABEORBER - X
GAS FLOW - CU.N/S
GAS TEMPERATURE - C
PARTICIPATE INLET LOAD - G/CU.M
S02 INLET CONCENTRATION - PPM
VENTURI
0/7*.
MITSUI - CHEHICO
1
20.0
69.37 <
154.4 (
.1 (
1500
H7000 ACFM)
310 f)
.035 GR/SCF)
•• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGIS
BOILER LOAD/ABSORBER - X
GAS TEMPERATURI - C
PARTICIPATE INLET LOAD - G/CU.K
S02 INLET CONCINTRAT10N - PPM
*• CENTRIFUGE
NUMBER
OUTLET SOLIDS - X
*• FANS
TYPE
SPRAY TOWER
2/75
MITSUI - CMEMICO
1
5.0
1S-.4 < 310 F)
.1 ( .035 GR/SCF)
15DO
90.0
BOOSTER
•* FANS
TYPE
•• MIST ELIMINATOR
TYPE
NUMBER OF STAGIS
NUMBER OF PASSES
WASH SYSTEM
-. PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
«• TANKS
SERVICE
RECYCLE
ABSORBENT MAKEUP
OXIOIZER OVERFLOW
MOTHER LIQUOR JANK
ABSORBER FEED
REHEATER
TYPE
THICKENER
OUTLET SOLIDS r X
WATER LOOP
TYPE
PURGE WATER LOSS - LITER/S
FRESH MAKEUP WATER ADDITION - LITERS/S
BYPRODUCTS
BYPRODUCT NATU*£
BYPRCDUCT QUANTITY - H T/H
OIIBIZER BLOWER
CHEVION
4
4
SEQUENTIAL WASH-PROCESS LIQUOR K FRESH WATER
FLUE GAS VOLUME AND S02 CONCENTRATION
NUMBER
2
* * **
**« •
****
• * * *
DIRECT COMBUSTION
2(.0
OPEN
2.5
GYPSUM
8.69
( 40 6PM)
( 208 GPM)
( 9.58 TPH)
470
-------
EPA UTIklTV F6D SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVEIOPHENT CO.: TAKASAGO 1 ICONT.)
•• TREATMENT
TYPE FORCED OXIDATION
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6b CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/75 SYSTEM 96.9 88.8 672 616 597
• • PROBLEMS/SOLUTIONS/COMHENTS
THE FGD SYSTEM WAS DOWN ONCE DUE TO A PIPING FLANGE LEAK.
3/75 SYSTEM 100.0 48.4 744 360 36C
4/75 SYSTEM 100.0 44.1 720 318 318
** PROBLEMS/tOLUTIONS/COHMENTS
THE BOILER WAS TAKEN OFF-LIRE FOR ANNUAL MAINTENANCE DURING MARCH AND
APRIL'.
5/75 SYSTEM 100.0 96.4 744 717 717
6/75 SYSTEM 97.9 97.9 720 720 705
7/75 SYSTEM 98.0 97.8 744 743 728
8/75 SYSTEM 98.0 98.0 744 744 729
9/75 SYSTEM 95.7 91.7 720 690 66C
• * PROBLENS/tOLUTIONS/COMMENTS
SYSTEM DOUN TIME FROM JUNE THROUGH SEPTEMBER HAS DUE TO MIST ELIMINATOR
SCALING.
10/75 SYSTEM 95.2 95.2 744 744 708
** PROBLEMS/SOLUTIONS/COMMENTS
FAN VIBRATIONS CAUSED A SYSTEM OUTAGE DURING THE MONTH.
11/75 SYSTEM 98.5 98.5 720 720 70«
*• PROBLEMS/SOLUTIONS/COHMENTS
HIST ELIMINATOR SCALING WAS ENCOUNTERED IN NOVEMBER.
12/75 SYSTEM 95.9 92.2 744 715 686
1/76 SYSTEM 1CO.O 100.0 744 744 744
2/76 SYSTEM 95.2 90.8 696 664 632
• * PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY, THE SYSTEM AGAIN ENCOUNTERED MIST ELIMINATOR SCALlNt.
3/76 SYSTEM 1CO.O 92.3 744 687 687
4/76 SYSTEM 100.0 30.4 720 219 219
5/76 SYSTEM 100.0 100.0 744 744 744
6/76 SYSTEM 1CO.O 100.0 720 720 720
7/76 SYSTEM 100.0 100.0 744 744 744
8/76 SYSTEM 744 744
9/76 SYSTEM 100.0 100.0 720 720 72C
10/76 SYSTEM 91.7 91.7 744 744 682
471
-------
EPA UTILITY F60 SUBNET: FOURTH flUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.: TAKASA60 1 (CONT.)
PERFORMANCE DATA- _ ___
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION i REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•• PROBLENS/SOLUTIONS/COHMENTS
THE SYSTEM HAS TAKEN OFF-LINE FOR CLEANING OF THE FIRST STACE SCRUBBER.
11/76 SYSTEM 99.3 99.3 720 720 715
•* PROBLEMS/IOLUTIONS/COMMENTS
REPAIR OF A DUCT FORCED ONE SYSTEM OUTAGE IURIN6 THE MONTH.
12/76 SYSTEM 98.9 98.9 744 744 736
•• PROBLEMS/SOLUTIONS/COMMENTS
THE DECEMBER OUTAGE MAS DUE TO THE REPAIR OF A SPRAY PIPE.
1/77 SYSTEM 99.3 99.3 744 744 739
•* PROBLEMS/COLUTIONS/COHNENTS
THE SYSTEM WAS TAKEN OFF-LINE ONCE FOR CLEANING OF THE FIRST STAGE
SCRUBBER.
2/77 SYSTEM 100.0 100.0 672 672 672
3/77 SYSTEM .0 744 0 0
«• PROBLEMS/SOLUTIONS/COMHENTS
THE SVSTEN HAS OFF DURING MARCH FOR ANNUAL BOILER MAINTENANCE.
4/77 SYSTEM 100.0 71.3 720 513 513
5/77 SYSTEM 98.7 98.7 744 744 734
• • PROBLEMS/COLUTIONS/COHMENTS
FAN VIBRATIONS CAUSED ONE SYSTEM OUTAGE DURING MAY.
6/77 SYSTEM 100.0 100.0 ?2Q 720 720
7/77 SYSTEM 100.0 96.4 744 717 717
•• PROBLEMS/tOLUTIONS/CONMENTS
THE FIRST STAGE ABSORBER MAS CLEANED DURING JULY.
8/77 SYSTEM 100.0 100.0 744 744 744
9/77 SYSTEM 100.0 100.0 720 720 720
10/77 SYSTEM 94.2 94.2 744 744 7Q1
•• PROBLENS/COLUTIONS/COHMENTS
THE S'STEH WAS OFF LINE PART OF THIS MONTH FOR CLEANING OF SCRUBBERS AMI)
REACTORS. "
11/77 SYSTEM 100.0 100.0 720 720 720
12/77 SYSTEM 100.0 100.0 744 744 744
1/7fl SYSTEM 100.0 100.0 744 744 744
•* PROBLEMS/SOLUTIONS/COMMENTS
THE FIRST REACTOR MAS CLEANED THIS MONTH.
472
-------
EPA UTIklTY FGD SURVEY: FOURTH QUARTER 1979
SECTION 15
DESIGN AND PERFORMANCE DATA FOR OPERJT10NAL FOREIGN FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/F6D - NW
NET UNIT GENERATING CAPACITY UO/F6C - MU
EttUIVALEKT SCRUBBEI CAPACITY - MM
** BOILER DAIA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.H/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - H
STACK TOP DIAMITER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - Z
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
** ESP
NUMBER
FLUE GAS TEMPERATURE - C
«* PARTICULATE SCRUBBER
TYPE
** FGD SYSTEM
SALEABLE PRODW T/THROVAWAV PRODUCT
GENERAL PROCESI TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEU/RETROFIT
INITIAL START-HP
** ABSORBER
NUMBER
TYPE
INITIAL START DP
SUPPLIER
NUMBER OF STAGIS
BOILER LOAD/ABSORBEft - X
GAS FLOW - CU.N/S
GAS TEMPERATURE - C
L/C RATIO - L/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - 6/CU.M
S02 INLET CONCENTRATION - PPM
** ABSORBER
NUMBER
TYPE
INITIAL START UP
ELECTRIC POWER DEVELOPMENT CO.
TAKASAGO
2
HIMEJI
JAPAN
******
•***<* <*****. LB/HMBTU)
***••• (*****• LB/MMBTU)
250.0
2»I.O
****•*.*
• •*•» i*
BASE
0/69
365.25
154.*
******
*******
COAL
** **4*
24656.
****• ** ri
**** «*
( 774000 ACFN)
( 310 F)
(**** FT)
(***** FT)
< 10600 BTU/LB)
******
1.80
******
15 '.4
VENTURI
C 310 F)
SALE «LE PRODUCT
VET SCRUBBING
LIMESTONE
MITSUI - CHEMICO
FULL SCALE
RETROFIT
3/7 <
1
VENTURI
3/76
MITSUI - CHEMICO
•1
75.0
260.49
154. 4
6.5
1.5
.1
1500
VENTURI
3/7«
552000 ACFM)
310 F)
48.6 GAL/1000ACF)
5.9 IN-H20)
.035 6R/SCF)
473
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.: TAKASAGO 2 (CONT.)
SUPPLIER
NUMBER OF STA6IS
BOILER LOAD/AB 20RBER - X
GAS TEMPERATURE - C
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
PARTICIPATE OUTLET LOAD- G/CU.M
S02 CUTLET CONTRITION - PPM
S02 DESIGN REMOVAL EFF1CIENCI - X
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGi S
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.H/S
GAS TEMPERATURE - C
PARTICIPATE INLET LOAD - G/CU.H
S02 INLET CONCINTRATJON - PPM
*• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGIS
BOILER LOAD/ABSORBER - X
GAS TEMPERATURf - C
PARTICIPATE IFM.ET LOAD - 6/CU.H
S02 INLET CONCENTRATION - PPM
** CENTRIFUGE
NUMBER
OUTLET SOLIDS - X
•• FANS
TYPE
•• FANS
TYPE
•* MIST ELIMINATOR
TYPE
NUMBER OF STAGIS
NUMBER OF PASSE S
HASH SYSTEM
•• PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
*• TANKS
SERVICE
RECYCLE
ABSORBENT MAKEUP
OX I BUtfl OVERFLOW
MOTHER LIQUOR TANK
ABSORBER f£EO
REMEATER
TYPE
THICKENER
OUTLET SOLIDS - X
WATER LOOP
TYPE
PURGE WATER L0«S - L1TER/S
FRESH MAKEUP WATER ADDITION - LITERS/S
BYPRODUCTS
BYPRODUCT NATUBE
BYPRODUCT QUANTITY - ft T/H
MITSUI - CHEMICO
1
100.0
55.0
1.5
.0
7»
93.3
( 131 F)
« 48.6 6AL/1000ACF)
{ 5.9 IN-H20)
( .009 GR/SCF)
VENTURI
3/76
MITSUI - CHEMICO
1
20.0
6i .37 (
154.4 t
.1 (
1500
1*7000 ACFM)
310 F)
.035 GR/SCF)
SPRAY TOWER
3/76
MITSLI - CHEMICO
1
5.0
15*.* < 310 F)
.1 C .035 GR/SCF)
1500
90.0
BOOSTER
OXIDIZER BLOWER
CHEVION
4
4
SEQUINT1AL WASH-PROCESS LIQUOR t FRESH WATER
FLUE 6AS VOLUME AND S02 CONCENTRATION
NUMBER
2
****
*•«»
DIRECT COMBUSTION
20.0
OPEN
2.5
13.1
GYPSUM
1.69
( 40 6PM>
( 208 6PM)
C 9.58 TPH>
47*
-------
EPA UTILITY FGfi SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.: TAKASA60 2 (CONT.)
*• TREATMENT
TYPE FORCED OXIDATION
„_——— <- PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV RELIABILITY UTILIZATION S REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/76
4/76
5/7«
6/76
SYSTEM
SYSTEM
SYSTEM
SYSTEM
1CO.O
1CO.O
100.0
100.0
100.0
100.0
29.0
87.8
744
720
744
720
744
720
216
632
72C
720
216
632
*• PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM MAS DOWN FOR PART OF MAY AND JUNE FOR ANNUAL BOILER MAlNTENAHCE.
7/76 SYSTEM 100.0 100.0 744 744 744
8/76 SYSTEM 100.0 100.0 744 744 744
9/76 SYSTEM ''00.0 100.0 72C 720 72C
10/76 SYSTEM 94.2 94.2 744 744 701
• • PROBLEMS/tOLUTIONS/COHMENTS
OUTAGE TIME DURIN6 OCTOBER WAS NECESSARY FOR DUCT CLEANING.
11/76 SYSTEM 100.0 100.0 720 720 720
12/76 SYSTEM 99.3 99.3 744 744 739
** PROBLEHS/tOLUTIONS/COMMENTS
THE SYSTEM WAS DOWN BRIEFLY FOR REPAIR OF A GYPSUM CONVEYOR.
1/77 SYSTEM 100.0 100.0 744 744 744
2/77 SYSTEM 88.2 88.2 672 672 593
3/77 SYSTEM 98.7 98.7 744 744 734
** PROBLEMS/COLUTIONS/COMMENTS
OUTAGE TIME IN FEBRUARY AND MARCH WAS NEEDED FOR CLEANING OF PH CONTROLLER.
4/77 SYSTEM 1CO.O 100.0 720 720 72C
5/77 SYSTEM 100.0 51.6 744 384 384
6/77 SYSTEM 100.0 3.3 720 240 24C
7/77 SYSTEM 100.0 100.0 744 744 744
8/77 SYSTEM 100.0 100.0 744 744 744
9/77 SYSTEM 100.0 100.0 720 720 720
10/77 SYSTEM 100.0 100.0 744 744 744
11/77 SYSTEM 89.2 89.2 720 720 642
** PROBLEMS/iOLUTIONS/COMMENTS
CLEANING OF THE PH CONTROLLER CAUSED ONE OUTAGE DURING NOVEMBER.
A REAUOR WAS ALSO CLEANED THIS MONTH.
12/77 SYSTEM 100.0 100.0 744 744 744
1/78 SYSTEM 744, 744
475
-------
EPA UTILITY F6D SURIEV: FOURTH QUARTER 1979
SECTION 15
DESIGN AMD PERFORMANCE OATA fOR OPERAT10NAI FOREIGN F6D SYSTEMS
COMPANY HAKE
PLANT NAPE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NC/J
NET PLANT GENERATING CAPACITY - My
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY U/F6D - My
NET UNIT GENERATING CAPACITY UO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - My
•• BOILER OATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE SAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMITER - M
** FUEL OATA
FUEL TYPE
FUEL GRACE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CO*TENT - 2
RANGE ASH CONTE NT - X
AVERAGE MOISTURE CONTENT - t
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
•• ESP
PARTICULATE DESIGN REMOVAL EFFICIENCY
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
PARTICULATE OUILET LOAO - 6/CU.M
•• PARTICULATE SCRUBBER
TYPE
•• F6D SYSTEM
SALEABLE PRODI* T/THROWAWAY PRODUCT
GENERAL PROCESC TYPE
PROCESS TYPE
SYSTEM SUPPLIEi
DEVELOPMENT LEVEL
NEU/RETROFIT
INITIAL START-UP
*• ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAG!S
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/AB(OR8ER - X
(AS FLOU • CU.H/S
GAS TEHPERATURI - C
L/t RATIO - L/iU.M
PRESSURE DROP - KPA
PARTICULATE INtET LOAD - 6/CU.M
502 INLET CONCINTRATION - PPM
ELECTRIC POWER DEVELOPMENT CO.
TAKEHARA
1
HIHARA
JAPAN
** ** i*
****•• <*»*•** LB/MMBTU)
***•«* «•*•**• LB/MMBTU)
250.0
*******
25 t.O
******
******
BASE
0/67
577.13
140.0
201.
COAL
24656.
23.00
«.40
(1223000 ACFM)
C 284 F>
< 660 FT)
(•**** FT)
( 10600 BTU/LB)
;.oo
•*•*«•
********
- X
98.0
333.2
14C.O
.37
< 706000 ACFM)
< 28* F>
( .16 GR/SCF)
NONE
SALES .81 E PRODUCT
WET SCRUBBING
LIMESTONE
BABCOCK - HITACHI
FULL SCALE
RETROFIT
2/77
2
VENTURI
2/77
BABCOCK - HITACHI
1
ACID RESISTANT CASTftBLE
PLASTIC
50.0
168.00
140.0
'..0
2.3
.4
1600
356000 ACFH)
284 F)
15.0 CAL/1000ACF)
9.1 1N-H20)
.157 GR/SCF)
476
-------
EPA UTILITY F60 SURVEY: FOURTH QUARTER 1979
ELECTRIC POWER DEVELOPMENT CO.: TAKEHARA 1 (CONT.)
•« ABSORBER
NUMB ER
TTPE
INITIAL START DP
SUPPLIER
NUMBER OF STAGiS
SHELL LINER MATERIAL
L/6 RATIO - L/IU.H
PRESSURE DROP r KPA
•• CENTRIFUGE
•* FANS
NUMBER
TYPE
•• HIST ELIMINATOR
NUMBER
TYPE
CONFIGURATION
HASH SYSTEM
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
*• TANKS
SERVICE
PRESCRUBBER RECYCLE
SCRUBBER RECYCLE
FILTER LIQUID SANK
SLURRY TANK
OXIDATION TOWER
•• REMEATER
TYPE
** THICKENER
*« WATER LOOP
TYPE
PURGE WATER LOIS - LITER/S
FRESH MAKEUP WATER ADDITION - LITERS/S
** BYPRODUCTS
BYPRODUCT NATURE
BYPRODUCT 8UANTITT - M T/H
DISPOSITION
** TREATMENT
TYPE
TRAY TOWER
2/77
BABCOCK - HITACHI
5
PLASTIC
7.0 < 52.4 6AL/1000ACF)
3.8 (15.2 IN-H20)
2
I.D.
FINNED TUBE
HORIZONTAL
FRESH WATER WASH
.1 ( .4 1N-H20)
PH. GAS FLOW
PH] PRESCRUBBER - 5.0. SCRUBBER- 6.0
NUMBIR
-__.» ._
***•
***•
*•»«
***•
DIRECT COMBUSTION
OPEN
3.8
U.I
GYPSUM
8.51
MARKETED
< 60 6PM>
< 224 GPM)
( 9.38 TPH)
FORCED OXIDATION
-------
APPENDIX A
FGD SYSTEM COST DATA: OPERATIONAL AND NONOPERATIONAL SYSTEMS
A-l
-------
INTRODUCTION
The cost of flue gas desulfurization (FGD) systems for the
control of sulfur dioxide emissions is an area of intense inter-
est and substantial controversy. As a result, many computer
models have recently been developed to estimate capital and
annual costs. As part of an effort by the U.S. Environmental
Protection Agency to provide meaningful economic data concerning
FGD systems, reported economic data have been incorporated into
the EPA Utility FGD Survey report. This information has appeared
as a separate appendix of the report since October 1976. Until
January 1978, this cost appendix consisted entirely of data
reported by the utilities with little or no interpretation pro-
vided by PEDCo Environmental, Inc. Beginning with the May 1978
report, the format and content of the cost appendix were revised
to include reported and adjusted costs for the operational FGD
systems.
The rationale for including adjusted as well as reported
costs stems primarily from the lack of comparability of the
reported costs. Many of the reported cost figures, both capital
and operating, are largely site-sensitive values that cannot be
accurately compared because they refer to different FGD battery
limits and different years in which the expenditures were made.
As a result, an analysis of the cost data was made for the opera-
tional units since these systems offer the potential of having
complete and accurate economic data. The adjustments were made
to provide comparable, accurate cost data for the sulfur dioxide
portion of the emission control system. This, in effect, will
eliminate much of the confusion that exists concerning the re-
ported data, and it will provide a common basis for the reported
costs.
A-2
-------
In an attempt to promote further comparability of the
figures, the adjustment procedure was carried one step further
and standardized adjusted figures were developed. This was done
by modifying the fixed annual cost rates such that they would be
identical for each unit (i.e. cost of depreciation, interim re-
placement, taxes, insurance and capital costs). The newly ad-
justed total fixed annual cost rate was applied to the total ad-
justed capital cost in each case and a standardized adjusted
annual cost was obtained.
A-3
-------
APPROACH
In March 1978, each utility having at least one operational
FGD system was given a cost form containing all available cost
information then in the PEDCo files. The utility was asked to
verify the data and fill in any missing information called for
on the form. A follow-up visit by the PEDCo Environmental staff
was arranged to assist in data acquisition and to insure com-
pleteness and reliability of information. Results of the cost
analysis were forwarded to each participating utility for final
review and comment.
The cost data were treated solely to establish the accurate
costs for FGD systems, on a common basis, not to critique the
design or reasonableness of the costs reported by any utility.
Adjustments focused primarily on the following items:
0 All capital costs were adjusted to July 1, 1977, dol-
lars using the Chemical Engineering Index. All capital
costs, represented in dollars/kilowatt (S/kW), were
expressed in terms of gross megawatts (MW). Actual
costs were reported by utilities in dollar values for
years 1970 to 1980. These values are represented in
terms of the year of greatest capital expenditures.
0 Gross unit capacity was used to express all FGD capital
expenditures because the capital requirement of an FGD
system is dependent on actual boiler size before de-
rating for auxiliary and air quality control power
requirements.
0 Particulate control costs were deducted. Since the
purpose of the study was to estimate the incremental
cost for sulfur dioxide control, particulate control
costs were deducted using either data contained in the
cost breakdowns or as a percentage of the total direct
cost (capital and annual). The percentage reduction
varied depending upon system design and operation.
A-4
-------
The capital costs associated with the modification or
installation of equipment not part of the FGD system
but needed for its proper functioning, were included
(e.g. - stack lining, modification to existing ductwork
or fans, etc.).
Indirect charges were adjusted to provide adequate
funds for engineering, field expenses, legal expenses,
insurance, interest during construction, allowance for
startup, taxes, and contingency.
All annual costs, represented in mills/kilowatt-hour
(raills/kWh), were expressed in terms of net megawatts
(MW) .
Net unit capacity was used to express all FGD annual
expenditures because the annual cost requirement of an
FGD system is dependent on the actual amount of kilo-
watt-hours (kWh) produced by the unit after derating
for auxiliary and air quality control power require-
ments.
All annual costs were adjusted to a common capacity
factor (65%).
Replacement power costs were not included since only a
few utilities reported such costs and these were pre-
sented using a variety of methods.
Sludge disposal costs were adjusted to reflect the
costs of sulfur dioxide waste disposal only (i.e.,
excluding fly ash disposal) and to provide for disposal
over the anticipated lifetime of the FGD system. This
latter correction was necessary since several utilities
reported costs for sludge disposal capacity that would
last only a fraction of the FGD system life. The
adjustments were based on a land cost of $2000/acre
with a sludge depth of 50 ft in a clay-lined pond (clay
is assumed to be available at the site).
A 30-year life was assumed for all process and economic
considerations for all new systems that were installed
for the life of the unit. A 20-year life was assumed
for all process and economic considerations for retro-
A-5
-------
fit systems that were installed for the remaining por-
tion of the life of the unit.*
0 Regeneration and by-product recovery facility costs
were added for those regenerable systems not reporting
such costs.
To the extent possible, all cost adjustments were made using
the previous assumptions developed by PEDCo Environmental. When
cost data were inadequate, adjustments were made using process
design data in conjunction with the previous cost assumptions.
In some cases, no adjustments were possible because of in-
sufficient data.
The use of a 30-year service life for new units coincides with
the conclusion of the National Power Survey of the Federal
Power Commission which recognized this value as reasonable for
steam-electric plants. A 20-year service life was assumed for
all retrofit units even if the remaining life of the units is
less than this value. Thus, two different rates are used and
should be noted when making comparisons between new and retro-
fit systems.
A-6
-------
DESCRIPTION OF COST ELEMENTS
Capital costs consist of direct costs, indirect costs, con-
tingency costs, and other capital costs. Direct costs include
•the "bought-out" cost of the equipment, the cost of installation,
and site development. Indirect costs include interest during
construction, contractor's fees and expenses, engineering, legal
expenses, taxes, insurance, allowance for start-up and shake-
down, and spares. Contingency costs include those costs result-
ing from malfunctions, equipment alterations, and similar un-
foreseen sources. Other capital costs include the nondepreciable
items of land and working capital.
Annual costs consist of direct costs, fixed costs, and over-
head costs. Direct costs include the cost of raw materials,
utilities, operating labor and supervision, and maintenance and
repairs. Fixed costs include those of depreciation, interim
replacement, insurance, taxes, and interest on borrowed capital.
Overhead costs include those of plant and payroll expenses. The
various capital and annual cost components are discussed and
defined in greater detail in the following paragraphs.
The direct capital costs include the following elements:
0 Equipment required for the FGD system. Table A-l
provides a summary of the major process equipment used
in regenerable and nonregenerable systems.
° installation of equipment, including foundations; steel
work for support, buildings, piping and ducting for
effluents, slurries, sludge, and make-up water, control
panels, instrumentation, insulation of ducting, buildings,
piping, and other equipment, painting and piling.
0 Site development may include clearing and grading,
construction of access roads and walkways, establish-
ment of rail, barge, and/or truck facilities, and
parking facilities.
A-7
-------
TABLE A-l. MAJOR FGD SYSTEM EQUIPMENT SUMMARY
Category
Description
Material handling-
raw materials
Feed preparation-
raw materials
Sulfur dioxide
absorption
Flue gas reheat
Gas handling
Sludge disposal
Utilities
By-product
handling
Equipment for the handling and transfer of
raw materials includes unloading facilities,
conveyors, storage areas and silos, vibrators,
atmospheric emission control associated with
these facilities, and related accessories.
Equipment for the preparation of raw material
to produce a feed slurry consists of feed
weighers, crushers, grinders, classifiers,
ball mills, mixing tanks, pumps, agitators,
and related accessories.
Equipment for treating the flue gas includes
absorbers, mist eliminators, hold tanks,
agitators, circulating pumps, pond water re-
turn pumps, and related accessories.
Equipment required includes air, steam, or
hot water heaters, condensate tanks, pumps,
soot blowers, fans, fuel storage facilities,
gas bypass equipment, and related accessories.
Equipment to handle the boiler flue gas in-
cludes booster fans, ductwork, flue gas by-
pass system, turning vanes, supports, plat-
forms, and related accessories.
Nonregenerable FGD systems require solids/
water separation equipment such as clarifiers,
vacuum filters, centrifuges, sludge fixation
equipment, and related accessories.
Equipment to supply power and water to the
FGD equipment consists of switch-gear, break-
ers, transformers, piping, and related
accessories.
Equipment for processing the by-product of
regenerable FGD systems may include a rotary
kiln, fluid bed dryer, conveyor, storage silo,
vibrator, combustion equipment and oil stor-
age tanks, waste heat boilers, hammer mills,
evaporators, crystallizers, strippers, tanks,
agitators, pumps, compressors, sulfuric acid
absorber and cooling, mist eliminator, pumps,
acid coolers, tanks, etc.
(continued)
A-8
-------
TABLE A-l. (continued)
Category
Description
Regeneration
purge treatment
Auxiliary
Equipment for regeneration of the absorbing
medium of an FGD system may consist of re-
actor vessels, material handling system,
storage, weigh feeder, conveyor, rotary kiln,
fluid bed calciner, dust collector, storage
silo, vibrator, combustion equipment and oil
storage tanks, waste heat boiler, hammer
mill, evaporators, crystallizers, strippers,
tanks, agitators, pumps, compressors, sul-
furic acid absorber and cooling, mist elimi-
nator, pumps, acid coolers, tanks, etc.
Equipment for the removal of purge material
(e.g. sodium sulfate) includes refrigeration,
pumps, tanks, crystallizer, centrifuge,
dryer, dust collector, conveyors, storage,
and related equipment.
Equipment not directly related to the
FGD system, but which may require design or
modification to accommodate an FGD system
may include such items as existing fans,
ducts, or stack. If new fans, ducts, or
stacks are added to improve boiler perfor-
mance and accommodate the FGD system, the
costs are prorated to the boiler and FGD
system.
A-9
-------
Indirect capital costs include the following elements:
0 Interest accrued on borrowed capital during construction,
0 Contractor's fee and expenses, including costs for
field labor payroll; field office supervision; person-
nel; construction offices; temporary roadways; railroad
trackage; maintenance and welding shops; parking lot;
communications; temporary piping and electrical and
sanitary facilities; safety security (fire, material,
medical, etc.); construction tools and rental equip-
ment; unloading and storage of materials; travel ex-
penses; permits; licenses; taxes; insurance; overhead;
legal liabilities; field testing of equipment; start-
up; and labor relations.
0 Engineering costs, including administrative, process,
project, and general; design and related functions for
specifications; bid analysis; special studies; cost
analysis; accounting; reports; consultant fees; pur-
chasing; procurement; travel expenses; living expenses;
expediting; inspection; safety; communications; model-
ing; pilot plant studies (if required because of pro-
cess design or application novelty); royalty payments
during construction; training of plant personnel; field
engineering; safety engineering; and consultant ser-
vices.
0 Legal expenses, including those for securing permits,
rights-of-way, etc.
0 Taxes, including sales, and excise taxes.
0 Insurance covering liability for equipment in transit
and at site; fire, casualty, injury, and death; damage
to property; delay; and noncompliance.
0 Allowance for start-up and shakedown includes the cost
associated with system start-up.
0 Spare parts including pumps, valves, controls, special
piping and fittings, instruments, spray nozzles, and
similar items.
Other capital costs include the following elements:
0 Land required for the FGD process, waste disposal, re-
generation facility, and storage.
0 Working capital, including the total amount of money
invested in raw materials and supplies in stock,
finished products in stock, and unfinished products
A-10
-------
in the process of being manufactured; accounts re-
ceivable; cash kept on hand for payment of operating
expenses such as salaries, wages, and raw materials
purchases; accounts payable; and taxes payable.
Annual cost of an FGD system includes the following direct,
fixed and overhead charges:
o Direct Charges
Raw materials, including those required by the FGD
process for sulfur dioxide control, absorbent regenera-
tion, sludge treatment, sludge fixation, flocculants,
etc.
Utilities, including water for slurries, cooling and
cleaning; electricity for pumps, fans, valves, lighting
controls, conveyors, and mixers; fuel for reheating of
flue gases; and stream for processing.
Operating labor, including supervisory, skilled, and
unskilled labor required to operate, monitor and
control the FGD process.
Maintenance and repairs, consisting of both manpower
and materials to keep the unit operating efficiently.
The function of maintenance is both preventive and
corrective to keep outages to a minimum.
Byproduct Sales; credit from the sale of byproducts
regenerable FGD processes (e.g. sulfur, sulfuric acid)
is a negative charge deducted from the annual direct
cost to obtain the net annual direct cost of the FGD
system.
0 Fixed Charges
Depreciation - the annual charge to recover direct and
indirect costs of physical assets over the life of the
asset.
Interim, replacement - costs expended for temporary or
provisional replacement of equipment that has failed or
malfunctioned prematurely.
Insurance, including the costs of protection from loss
by a specified contingency, peril, or unforeseen event.
Required coverage could include losses due to fire,
personal injury or death, property damage, explosion,
lightning, or other natural phenomena.
A-ll
-------
Taxes, including franchise, excise, and property taxes
levied by a city, county, state, or Federal government.
Interest on borrowed funds.
0 Overhead
Plant and administrative overhead is a business expense
that is not charged directly to a particular part of a
project, but is allocated to it. Overhead costs in-
clude administrative, safety, engineering, legal and
medical services; payroll; employee benefits; recrea-
tion; and public relations.
Table A-2 provides a summary of the means used to determine
the missing cost elements if the costs were not reported or
insufficient information prevented their actual determination.
The assumptions and cost bases for determining the capital and
annual costs of FGD systems were developed by the PEDCo staff
based upon previous economic studies conducted for the U.S. EPA
(Flue Gas Desulfurization Process Cost Assessment, May 1975;
Simplified Procedures for Estimating Flue Gas Desulfurization
System Costs, June 1976, EPA-600/2-76-150; Particulate and Sulfur
Dioxide Emission Control Costs for Large Coal-Fired Boilers,
March 1978, EPA-600/7-78-032).
A-12
-------
TABLE A-2. COST ELEMENT FACTORS
Category
Value
Indirect capital costs:
Interest during
construction
Field overhead
Contractor's fee and
expenses
Engineering
Taxes
Spares
Shakedown allowance
Other capital costs:
Contingency
Direct annual costs:
Raw materials:
Fixation chemicals
Lime
Limestone
Magnesium oxide
Sodium carbonate
Salt cake (credit)
Sulfur (credit)
Sulfuric acid (credit)
Utilities:
Electricity
Water
Steam
Operating labor:
Direct labor
Supervision
10% of total direct capital costs
10% of total direct capital costs
5% of total direct capital costs
10% of total direct capital costs
2% of total direct capital costs
1% of total direct capital costs
5% of total direct capital costs
20% of total direct and indirect
capital costs
$2/ton
$40/ton
$10/ton
$150/ton
$80/ton
$50/ton
$65/ton
$25/ton
25 mills/kWh
$0.20/103 gal
$0.80/106 Btu
$8.50/man-hour
15% of direct labor costs
a Contingency costs are used only when the cost data supplied are
incomplete (such as equipment costs or direct costs only) and a
contingency cost must be factored in to give an accurate estimate
of the total capital cost.
(continued)
A-13
-------
TABLE A-2. (continued)
Category
Value
Maintenance:
Labor and materials
Supplies
Overhead:
Plant
Payroll
Fixed annual costs:
Depreciation
b
Interim replacement
Taxes
Insurance
Capital costs
4% of total direct capital costs
15% of labor and materials costs
50% of operation and maintenance costs
20% of operating labor costs
3.33% or 5% (new or retrofit)
0.7% or 0.35%
4%
0.3%
9%
Some system components have life spans less than the expected
service life of the system. Interim replacement is an allow-
ance factor used in estimating annual revenue requirements to
provide for the replacement of these short-lived items. An
average allowance of 0.35% of the total investment is normally
provided and used for systems with an expected service life of
20 years or less. A higher allowance of 0.70% of the total
investment is provided and used for systems with an expected
service life of 30 years or more.
A-14
-------
DEFINITION OF COST ELEMENTS
The costs displayed in Appendix A are accompanied by a
series of alphabetic characters summarizing data presented for
each FGD system. These relate to the cost elements described
earlier in this section and identify what has been included and
excluded for reported and adjusted capital and annual costs. The
alphabetic characters, along with their titles, are briefly de-
scribed in Table A-3.
A-15
-------
TABLE A-3. DESCRIPTION OF COST
Code
Title
Description
L
M
N
0
Particula.te control (required for FGD pro-
cess) included in capital cost.
Particulate control (included in FGD
process) included in capital cost.
Total direct capital costs included.
Partial direct capital costs included.
Total indirect capital costs included.
Partial indirect costs included.
Chemical fixation of sludge included in
capital cost.
Dry sludge disposal included in capital
cost.
Off-site landfill area included in
capital cost.
Sludge pond included in capital cost.
Additional sludge disposal capacity
added for life of system.
Stack included in capital cost.
Modifications to stack, ducts, and/or
fans included in capital cost.
Total regeneration facility cost included
in capital cost.
Partial regeneration facility cost in-
cluded in capital cost.
R t D costs included in capital cost.
Particulate precollection device (ESP,
fabric filter, venturi) prior to FGD
system required for proper operation of
SO2 control system.
Particulate collection equipment (venturi
scrubber) is included in the FGD system.
Complete cost of all FGD equipment, the
labor and materials required for equip-
ment installation, and interconnecting
the system is included in the total
capital cost.
One or a number of direct cost items, or
the cost associated with one or a number
of direct cost items, are excluded from
the total capital cost.
Complete cost of all the indirect cost
elements, including interest during con-
struction, contractor's fees, engineer-
ing, legal expenses, taxes, insurance,
allowance for start-up, and spares, is
included in total capital cost.
One or a number of indirect cost items,
or the cost associated with one or a
number of indirect cost items, are ex-
cluded from the total capital cost.
The cost of a chemical fixation process
which stabilizes the flue gas cleaning
wastes prior to disposal is included in
the total capital cost.
The cost of a secondary dewatering or
treatment method, such as filtration, cen-
trifugation, or forced oxidation, which
ultimately produces a dry sludge cake
for final disposal, is included in the
total capital cost.
The cost of an off-site area used as a
landfill for flue gas cleaning wastes is
included in the total capital cost.
The cost of an on-site disposal area for
ponding of treated or untreated flue gas
cleaning wastes is included in the total
capital cost.
The cost of additional SO. waste disposal
capacity required for FGD system operation
over the anticipated service life of the
unit is included in the total capital cost.
The cost of the stack is included in the
total capital cost.
Modifications to existing equipment (stack,
fans, ducts, etc.) which are required be-
cause of inclusion of an FGD system.
Complete cost of entire regeneration
facility included in total capital cost.
Part of the cost associated with the re->
generation facility included in the total
capital cost.
Bench scale or pilot plant studies to de-
termine process and design characteristics.
(continued)
A-16
-------
TABLE A-3. (continued)
it
S
Title
osts underwritten by system supplier in-
luded in capital cost.
Ixcess reagent supply costs included in
capital cost.
Total direct annual costs included.
Partial direct annual costs included.
Total fixed annual costs included.
Partial fixed annual costs included.
Overhead cost included in total annual
cost.
Particulate control costs included in
direct annual cost.
Sludge disposal service costs (contract)
included in direct annual cost.
Replacement energy costs included in
total annual costs.
Description
Capital expenditures underwritten by the
system supplier for system repairs or
modifications for optimization of perfor-
mance or R fc D programs.
Capital expenditures for reagent supply
exceeds the amount required for the period
of initial operation.
Complete cost of all raw materials,
utilities, operating labor and maintenance
and repairs is included in the total
annual cost.
One or a number of direct annual cost items,
or the cost associated with one or a number
of direct annual cost items, are excluded
from the total annual cost.
Complete cost of all fixed cost elements,
including depreciation, interim replace-
ment, insurance, taxes, and interest, is
included in the total annual cost.
One or a number of fixed annual cost items,
or the cost associated with one or a
number of fixed annual cost items, are ex-
cluded from the total annual cost.
Plant and payroll overhead costs are in-
cluded in the total annual cost.
The cost of operating particulate collection
equipment included in the FGD system is in-
cluded in the total annual cost.
The treat»»ent and disposal of flu* gas
cleaning wastes that are handled by an
outside firm.
The cost of additional power-generating
capacity required to compensate for power
uced by the FGD system.
A-17
-------
RESULTS OF COST ANALYSIS
The results of the operational FGD system survey are summarized
in Table A-4 and Section A-l. Table A-4 produces a summary of a
categorical analysis of the reported and adjusted capital and
annual costs for the operational FGD systems addressed in the
survey. Included in this categorical analysis are the ranges,
means, and standard deviation for all the various types and
categories of FGD systems examined. Section A-l summarizes the
reported and adjusted capital and annual costs for all the oper-
ational FGD systems that were addressed in the cost study
(Section A-2 summarizes available cost data for nonoperational
FGD systems).
A-18
-------
TABLE A-4. CATEGORICAL RESULTS OF THE REPORTED AND ADJUSTED
CAPITAL AND ANNUAL COSTS FOR OPERATIONAL FGD SYSTEMS
I
M
vo
CATEGORY
ALL
HEM
RETROFIT
TMKOUAUAT MOIUCT
SALEAILE flOIUCT
LIHESIONE
IUAL ALKALI
LINE
UNE/ALKALIM FLTAIM
101 1 UN CARIONATC
VEILNAN LOII
LIMESTONE/ALKALINE FLTAtN
N ACHE SI UN OX HE
RAN6E AV6
29.2-232.3 tO. 3
31. 8-232. 5 94.8
2». 2-134.9 83. »
2T. 2-232. 3 04.3
127.9-134.9 142.3
43.2-IOf.O 94.7
29. 2-120.4 73.4
77.1- IS.f 00.0
42.9-111.4 44.3
I27.T-I34.9 137.4
47. »- 47.9 47. 1
134.7-134.7 134.7
IEV
32.4
58.1
41. »
31.8
14.3
43.5
32.1
4.1
13.1
13.7
.0
.0
RANSE
.3- 14.9
.3- 14.3
2.1- 14.9
.3- 14.3
14.9- 14.9
3.2- 3.2
3.8- 14.3
.3- .3
2.1- ?.l
14.9- 14.9
2.0- 2.0
•(*««- .0
MILLS/KUH- —
AV6 IEV
5.4
4.1
7.3
5.0
14.9
3.2
9.7
.3
2.1
14.9
2.0
.0
4.7
4.3
4.3
4.4
.0
.0
3.4
.0
.0
.0
.0
.0
NP JUS IIP
CAPITAL, «/KM ANNUAL,
RAN6E AVG DEV RANGE
40.9-233.2
44.4-117.4
40. 7-233. Z
40.9-140.6
134.8-233.2
46.4-117.4
•••••- .0
67.3-140.6
77.2- 93.0
40. 9-107. V
134.8-134. I
71.5- 71.5
233.2-233.2
94.2
83.3
103.4
87.0
184. t
93.1
.0
90.1
82.3
76.4
134.1
71.3
233.2
33.2
14.9
43.1
21.2
4».2
21.9
.0
22.2
7.4
22.2
.0
.0
.0
2.7- 12.4
2.7- 12.4
2.7- 8.7
12.4- 12.4
2.9- 6.6
••»••- .0
4.1- 3.2
1.2- 4.4
12.4- 12.4
2.8- 2.8
••«••- .0
HILLS/KVH—
AV6 DEV
3.5
3.1
3.2
12.4
3.0
.0
4.3
3.6
12.4
2.8
.0
2.4
2.6
1.9
.0
1.4
.0
.3
.4
.0
.0
.0
-------
EPA UTILITY FGD SURVEY: FOURTH QUARTER 1979
SECTION A-1
COSTS FOR OPERATIONAI F60 SYSTEMS
UNIT DESCRIPTION
ALABAMA ELECTRIC CO (P
1
179.0 MW (NET)
ARIZONA ELECTRIC POWER ..OOP
195.0 MU (NET)
ARIZONA ELECTRIC POWER COOP
3
195,Q MU
BIG RIVERS ELECTRIC
U2.0 MU (NET)
CENTRAL ILLINOIS LIGHT
DUCK CR E EK
378.0 MU (NET)
CENTRAL ILLINOIS PUBLIC SE R M
NEUTCN
617.0 MW (NET)
COLORADO LIE ELECTRIC ASSN.
CRAIG
447.0 MU (NET)
COST DESCRIPTION
CAPACITY FACTOR. X
COST ELEMENTS
CAPACITY FACTOR, X
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL ANNUAL, NILLS/KMH( YEAR )
COST ELEMENTS
CAPACITY FACTOR, X
COST ELEMENTS
CAPACITY FACTOR. X
COST ELEMENTS
CAPACITY FACTOR. X
TOTAL ANNUAL, MI LLS /KWH( YEA R )
COST ELEMENTS
CAPACITY FACTOR, X
COST ELEMENTS
REPORTED
* * *
C.E.J
44
C.E.H.J.L.S,
U.W.V.Z
44
2.1(1978)
u.u.v.z
***
B.C
* * *
C.E.J.M
* * *
C.E.t
* * *
A.C
ADJUSTED STANDARDIZED
ADJUSTED
65 65
65 65
65 65
******( 0) ******( o>
65 65
65 65
65 65
65 65
COLUMBUS I SOUTHERN OHIO ELEC.
CONESVILLE
5
411 .0 MW (NET)
CAPACITY FACTOR, X
TOTAL CAPITAL. 1/KWfVEAR)
TOTAL ANNUAL, MILLS/KWM(YEAR)
COST ELEMENTS
48 65 65
55.5(1975) 70.7(1977) 7C.7*1977)
5.8(1978) 7.4(1977) 7.4«1977)
B.C.J.M.S.U. C,E,J,M,S,U, C,E,J,M,S,U,
U.X.V W.Y W,Y
COLUftbUS f SOUTHERN OHIO ELEC.
CONESVILLE
6
411.0 MM (NET)
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KW(VfAR>
TOTAL ANNUAL, NILLS/KWH(YEAR)
COST ELEMENTS
48 65
55.5(1978) 70.7(1977)
5.8(1978) •••*•*( 0)
B.C.J.M.S.U, C.E.J.M.S.U.
U,X,Y y.Y
65
0)
C)
DUOUESNE LIGHT
ELRAMA
1-4
510.0 MW (NET)
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KU(YEAR)
TOTAL ANNUAL, MILLS/KWH(YEAR)
COST ELEMENTS
64 65 65
113.4(1976) 127.111977) 127.1(1977)
8.6(1977) 7.8(1977) 7.5(1977)
B,D,F,I,J,M. C,E,I.J,M,S, C,E.I.J,fl,S,
T.V.X.V U.Y U.V
INDICATES COST FIGURES NOT VET AVAILABLE
A- 20
-------
EPA UTILITY F6D SURVEY: FOURTH QUARTER 1979
SECTION A-1
COSTS FOR OPERATIONAL F6D SYSTEMS
IOST
UNIT DESCRIPTION COST DESCRIPTION REPORTED ADJUSTED STAN6MD1JED
AOJLSTEO
DUQUESNE LIGHT CAPACITY FACTOR. X 70 65 «5
PHILLIPS TOTAL CAPITAL, S/KM(VEAR> 106.9(197?) UO.6(1977) 140.4(1977)
1-6 TOTAL ANNUAL. NILLS/KWM(YtAR> 7.8(1977) 8.6(1977) g.i(1977>
410.0 My (NET) COST ELEMENTS B.D.F.I.J.N. C.E.I.J.N.S. C .E . I .J .*. S .
T.V.I.V U.T U,T
INDIANAPOLIS POUER I LIGHT CAPACITY FACTOR. X ••• 65 65
PETERSBURG TOTAL CAPITAL. S/KM(VEAR) 99.5(1976) 100.6(1977) 100.4(1977)
3 TOTAL ANNUAL. NILLS/KUM4YEAR* ••••••( 0) 6.6(1977) 7.4(1977)
532.0 MU (NET) COST ELEMENTS C.F.G.J.* C.E.S.J.H.S. C.E,CtJ.».S .
U,M,» U.W.t
KANSAS CITY POUER 8 LIGHT CAPACITY FACTOR. X U 65 65
HAWTHORN TOTAL CAPITAL. */KUfVEAR> 29.2(1973) 87.2(1977) 87.2(1977)
3 TOTAL ANNUAL. N1LLS'KWM(YEAR> 8.4(1977) 4.3(1977) 4.4(1977)
90.0 MU (NET) COST ELEMENTS 8.0.F.T.I B.C,E,J,«.S. B,C,E.J,«,S,
U.M.I U,W,«
KANSAS CITY POUER t LIGHT CAPACITY FACTOR. X ••« 65 «5
HAWTHORN TOTAL CAPITAL. WKM«YEAR) 29.2(1972) 87.2(1977) 87.2(1977)
4 TOTAL ANNUAL. MILLS/KMH(YEAR) 8.4(1977) 4.3(1977) 4.4(1977)
90.0 *l*t (NET) COST ELEMENTS B.D.F.T.X B.C.E.J.K.S. B.C.E.J.I.S.
U.M.k U.W.I
KANSAS CITY POUER 8 LIGHT CAPACITY FACTOR, X 42 65 65
LA CVGNE TOTAL CAPITAL. S/KU(YEAR) 53.6(1972) 68.0(1977) 68.CM977)
1 TOTAL ANNUAL. MILLS/KMH(YEAR) 1.3(1978) 3.8(1977) 3.9(1977)
874.0 MW (NET) COST ELEMENTS T C.E.J.K.S.U C.E.J.I.S.U
KENTUCKY UTILITIES CAPACITY FACTOR. X 16 65 65
GBEEN RIVER TOTAL CAPITAL. S/KU(YIAR> 70.3(1975) 77.5(1977) 77.5(1977)
1-3 TOTAL ANNUAL. NILL$/KVM(YEAR) 14.3(1977) 2.7(1977) 5.2(1977)
64.0 MM (NET) COST ELEMENTS B.C.E.J.S.U. C.E.J.S.U.W C.E.J.S.U.H
U
LOUISVILLE GAS t ELICTRIC CAPACITY FACTOR, X 55 65 65
CANE RUN TOTAL CAPITAL. SSKM(YEAR) 66.5(1975) 80.6(1977) 8C.6(1977)
4 TOTAL ANNUAL. NILLS/KWN(YEAR) ••....(1977) 5.8(1977) 6.2(1977)
188.0 MW (NET) COST ELEMENTS C.E,M,J.«,T C.t.H.J,K.O. C.E.H.>.K.«.
S.U.W S.U.W
LOUISVILLE GAS C ELECTRIC CAPACITY FACTOR. X ..I65 65
CANE RUN TOTAL CAPITAL. SJKU(YIAft) 62.4(1977) 67.5(1977) 67.5(1977)
S TOTAL ANNUAL, MILLS/KMM(YEAR) ••«...< Q) 5.6(1977) 5.6(1977)
200.0 MM CNET) COST ELEMENTS C.E.H.J C.E.M.J.t.S, C.E.H.J.K.S.
u.w u.w
LOUISVILLE GAS & ELICTRIC CAPACITY FACTOR. X ... 65 65
CANE RUN TOTAL CAPITAL. */KU(YtAR) 57.0(1977) ....«.( 0) ••••••( 0)
6 TOTAL ANNUAL. HILLS/KUN«YEAR) 3.2(1979) ......( 0) ( 0)
288.0 MM (NET) COST ELEMENTS t.E.H.N.S.V,
W
LOUISVILLE GAS & ELECTRIC CAPACITY FACTOR, X *«T" "45 65
PADDY'S RUN TOTAL CAPITAL. S/KN(VCAt> 52.8(1973) 76.4(19771 76.4(1977)
6 TOTAL ANNUAL, M1LLS/KUH(Y(AR) «»....< Q> c.5(1977) 6.4(1977)
72.0 MM (NET) COST ELEMENTS C,E C.E.S.U.W C.E.S.U.t.
•••••• INDICATES COST FIGURES NOT YET AVAILABLE
A- 21
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION A-1
COSTS FOR OPERATIONAL F6D SYSTEMS
...._._.. ..........p._«_... .... . ......»..—.•—..•————-—————..—»——-•—•.•.——.«.-. .....................
— .—. ..._COST _ —
UNIT DESCRIPTION COST DESCRIPTION REPORTED ADJUSTED STANDARD 12 ED
ADJUSTED
M1NNKOTA POWER COOPERATIVE CAPACITY FACTOR* X •*• «5 65
WILTON R. YOUNC TOTAL CAPITAL. $/KU(YEAR) 85.9(1976) 93.0(1977) 93.CO977>
2 TOTAL ANNUAL, HILLS/KUH(YEAR) ••**••« 0) 5.2(1977) 5.^(1977)
405.0 HW (NET) COST ELEMENTS C,E,H,P C,E,H,M.P,S, C.E.H.M.P.S.
U.W U.W
MONTANA POWER CAPACITY FACTOR, X 76 65 65
COLSTRIP TOTAL CAPITAL, S/KU(YEAR) 77.1(1975) 77.2(1977) 77.2(1977)
1 TOTAL ANNUAL, NJLLS7KUH(YEAR) .3(1977) 4.1(1977) 4.CM977)
360.0 HU (NET) COST ELEMENTS B.C.E.J.P.T C.E.J.K.P.S. C.E.J.K.P.S,
U.U U.W
MONTANA POWER CAPACITY FACTOR, X 76 65 65
COLSTRIP TOTAL CAPITAL. SXKU(VEAR) 77.1(1975) 77.2(1977) 77.2(1977)
2 TOTAL ANNUAL, MILLS/KWH(VEAR) .3(1977) 4.1(1977) 4.1(1977)
360.0 MW (NET) COST ELEMENTS B.C.E.J.P.T C.E.J.K.P.S, C.E.J.K.P.S,
U.W U.W
NEVADA POWER CAPACITY FACTOR, X 67 65 65
REID GARDNER TOTAL CAPITAL, SSKU(YEAR) 42.9(1973) 60.9(1977) 60.9(1977)
1 TOTAL ANNUAL, NILLS/KWH(YEAR) 2.1(1977) 3.2(1977) 3.4(1977)
125.0 MW (NET) COST ELEMENTS B,D,E,P,S,U. B.D.E.P.S.U, B.D.E.P.S.U.
w.x u,x u.x
NEVADA POfcER CAPACITY FACTOR, X 67 65 65
REID 6ARDKER TOTAL CAPITAL. */KU(YEAR) 42.9(1973) 60.9(1977) 60.9(1977)
2 TOTAL ANNUAL. HILLS/KUH(VEAR) 2.1(1977) 3.2(1977) 3.4(1977)
125.0 MW (NET) COST ELEMENTS B.D.E.P.S.U, B.D.E.P.S.U, B.D.E.P.S.U,
u.x w.x v.x
NEVADA POKER CAPACITY FACTOR, X 67 65 65
REID GARDNER TOTAL CAPITAL, S/KU(YEAR) 113.6(1975) 107.9(1977) 107.9(1977)
3 TOTAL ANNUAL, MILLS/KUH(VEAR) 2.1(1977) 4.4(1977) 5.C(1977)
125.0 HW (NET) COST ELEMENTS B.C.E.L.S.U, B.C.E.L.S.U, B.C.E,L,S.U,
U.X U.X U.X
— — — — -—— - -•——- — — —-•— y •—— — --—• — — -«•.—•-..—• *-••*•**<•**...•....* «....«..«•..* -._•• ***..•.* ••—»•.•».«••
NORTHERN INDIANA PUB SERVICE CAPACITY FACTOR, X 77 65 65
DEAN H. MITCHELL TOTAL CAPITAL, S/KU(YEAR) 156.4(1976) 134.8(1977) 134.8(1977)
11 TOTAL ANNUAL, MILLS/KUH 47.9(1972) 71.5(1977) 71.5(1977)
1 TOTAL ANNUAL. MILLS/KUH(VEAR> 2.0(1977) 2.8(1977) 3.3(1977)
740.0 MW (NET) COST ELEMENTS B.C.J.S.U.X. C.E.J.K.S.U, C.E.J.K.S.U,
z u u
NORTHERN STATES POUER CAPACITY FACTOR. X 73 65 65
SHERBURNE TOTAL CAPITAL. */KU(»EAR) 47.0(1972) 71.5(1977) 71.5(1977)
2 TOTAL ANNUAL, HILLS/KUH(YEAR) 2.0(1977) 2.8(1977) 3.3(1977)
740.0 MU (NET) COST ELEMENTS B,C,J,S.U,X, C.E.J.K.S.U, C.E.J.K.S.U,
Z U U
PACIFIC POUER t LIGHT . CAPACITY FACTOR. X *** 65 65
JIM BRID6ER TOTAL CAPITAL, $/KH(YIAR) 120.0(1979) *•****( 0) *••*••( 0)
4 TOTAL ANNUAL. HILLS/K«H(YEAR) *•»*••( 0) *•****( 0) *•*«*•( 0)
550.0 MU (NET) COST ELEMENTS C.E.J
****** INDICATES COST FI64IRES NOT YET AVAILABLE
A- 22
-------
EP» UTI.1TV F6D SURVEY: FOURTH QUARTER 1979
SECTION *-1
COSTS FOR OPERATION*!: F6D SYSTEMS
— ---—---------—_r --------------------- -------- -------- ______----_-—-__ ----------- — —-- -------
COST
UNIT DESCRIPTION COST DESCRIPTION REPORTED ADJUSTED STANDARDIZED
ADJUSTED
PENNSYLVANIA POWER CAPACITY FACTOR. X 40 65 65
BRUCE MANSFIELD TOTAL CAPITAL. $/KU(Y£AR) 120.6(1975) 107.1(1977) 102.1(1977)
1 TOTAL ANNUAL. MILLS/KUH(YEAR> U.3U977) 8.7(1977) 10.6(1977)
917.0 HU COST ELEMENTS B.C.E.G.I,L. C.E.G.I,M.S. C.E.G.I.M.S.
s.u.u.x u.w u,u
PENNSYLVANIA POWER CAPACITY FACTOR. X 40 65 65
BRUCE MANSFIELD TOTAL CAPITAL. S/KU(YEAR) 120.6(1975) 102.1(1977) 102.1(1977)
2 TOTAL ANNUAL, HILLS/KUH(YEAR) U.3(1977) 8.7(1977) 10.8(1977)
917.0 HU (NET) COST ELEMENTS B.C.E.G.I.L, C.E.G.I,M.S. C,E,6,1,*,S.
s.u.u.x u.y u.w
_—_______-_—_-_____—_______.__ ______________________________ ____________ ____________ ____________
PHILADELPHIA ELECTRIC CAPACITY FACTOR. X *•* 65 65
EODYSTONE TOTAL CAPITAL, S/-M(YEAR> 156.7(1972) 233.2(1977) 233.2*1977)
1A TOTAL ANNUAL. MILLS/KHH(YEAR) ******(1972) ****«*(1977) •«**««(1977)
120.0 MU (NET) COST ELEMENTS D.F.N.P C.E.N.P C.E.N.P
PUBLIC SERVICE OF NtW MEXICO CAPACITY FACTOR, X *•• 65 65
SAN JUAN TOTAL CAPITAL, J/KW(YEAR) 127.9(1977) ••*••*( 0) ••*••*( 0)
1 TOTAL ANNUAL. HILLS/KUH(YEAR) «•*•*»( 0) •*•***( 0) ••*•••( C)
361.0 MU (NET) COST ELEMENTS A.C.E.N
PUBLIC SERVICE OF NiU MEXICO CAPACITY FACTOR, X • ** 65 65
SAN JUAN TOTAL CAPITAL, SSKU(VEAR) 127.9(1977) *•**•*( 0) •*••«•( 0)
2 TOTAL ANNUAL, MILLS/KMH(YEAR) *••**«( 0) •*•***( 0) ***•*«( 0)
350.0 MW (NET) COST ELEMENTS A.C.E.N
SALT RIVER PROJECT CAPACITY FACTOR. X •** 65 65
CORONADO TOTAL CAPITAL. S/KU(VEAR> 74.0(1978) •*»***( 0) **••••( 0)
1 TOTAL ANNUAL, NILLS/KVH(YEAR) ****•*( 0) •**••*( 0) ••••••( 0)
280.0 MW (NET) COST ELEMENTS C,E
-----—-----—-—- —-r---_______ ______________________________ ____________ ____ — -_«-- ___---_-----
SOUTH CAROLINA PUBLIC SERVICE CAPACITY FACTOR, X 80 65 65
MINYAH TOTAL CAPITAL. S/KU(YEAR) 47.4(1976) 66.4(1977) 6.4(1977)
2 TOTAL ANNUAL. BILLS/KVH(YEAR) 1.6( 0) 2.9(1977) 3.2(1977)
140.0 HU (NET) COST ELEMENTS C.F.J.H.S.V C.E.J.K.M.S. C.E.J.K.N.S,
U.W U.W
______________________________ ______________________________ ____________ ____________ ___•_-______
SOUTH MISSISSIPPI E-EC PUR CAPACITY FACTOR, X «•* 65 65
R.O. MORROW TOTAL CAPITAL. S/KU(riAR> 232.5(1978) «•••••( 0) *•*•••( 0)
1 TOTAL ANNUAL, MILLS/KUH ••••••( 0)
2 TOTAL ANNUAL, MILLS/KMH(YEAR) *•*••*( 0) *••*•*( 0) *•••••( 0)
124.0 NU (NET) COST ELEMENTS D
SOUTHERN INDIANA GAS t ELEC CAPACITY FACTOR, X -** 65 65
A.8. BROUN TOTAL CAPITAL, S/KW(VEAR) 43.2(1979) **•*••( 0) •*•••«( 0)
1 TOTAL ANNUAL, MILLS/ltUHlYEAR) **•*••( 0) ***••*( 0) ••••••( 0)
265.0 NU (NET) COST ELEMENTS C.E.6
****** INDICATES COST FIGURES NOT VET AVAILABLE
A- 23
-------
EPA UTILITY FGO SURVEY: FOURTH QUARTER 1979
SECTION A-1
COSTS fOR OPERATIONAL F6D SYSTEMS
UNIT DESCRIPTION COST DESCRIPTION
REPORTED
ADJUSTED STANDARDISED
ADJUSTED
SPRINGFIELD CITY UTILITIES
SOUTHWEST
1
194.0 HW (NET)
CAPACITY FACTOR. X
TOTAL CAPITAL, S/KU(V(AR)
TOTAL ANNUAL. MILLS/KWH(YEAR)
COST ELEMENTS
... 45 65
77.3(1974) 117.6(1977) 117.6(1977)
*»*.».( 0) 6.2(1977) 6.5(1977)
C.F.H.J.P C,E,H,J,K.P. C.E.H.J.K.P,
s.u.u s.u.w
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK
8
550.0 MU (NET)
CAPACITY FACTOR. X
TOTAL CAPITAL. i/KU(Y8AR)
TOTAL ANNUAL. M J LLS/K'WH < YE AR >
COST ELEMENTS
60
98.1(1976)
3.0(1977)
B.C.E.P.R.T,
U
65
113.1(1977)
5.3(1977)
C.E.J.S.U.W
65
113.1(1977)
5.1(1977)
C.C.J.S.U.U
*•*««» INDICATES COST FIGURES NOT YET AVAILABLE
A- 24
-------
EPA UTIIITY F6D SURVEY: FOURTH QUARTER 1979
SECTION A-2
COSTS FOR NON-OPERATIONAL F60 SYSTEMS
UNIT DESCRIPTION
COST DESCRIPTION
COST
REPORTED ADJUSTED STANDARDIZED
ADJUSTED
BASIN ELECTRIC POWEt COOP
LARAMIE RIVER
1
600.0 HW (NET)
CAPACITY FACTOR. X *** 65
TOTAL CAPITAL, J/KWCTEAR) 56.0<1980> •*«•**<
TOTAL ANNUAL. MILLS/KWH(VEAR) .9(7800) **•*•*<
COST ELEMENTS C,E
65
0) **••«•< 0)
0) ******( 0)
BASIN ELECTRIC POUEI COOP
LARAK1E RIVER
2
600.0 MW (NET>
CAPACITY FACTOR. X
TOTAL CAPITAL, SSKU(VCAR)
TOTAL ANNUAL. HILLS/KMH(YEAR)
COST ELEMENTS
• •• 65
56.0(1980) *•«*••( 0)
.9(7800) ••••••( 0)
C.E
65
0)
0)
BOSTON EDISON
MYSTIC
6
150.0 MW (NET)
CAPACITY FACTOR. X •** 65
TOTAL CAPITAL, S/KV(VEAI) 63.4(1972) •****•(
TOTAL ANNUAL. MILLS/KhH
COST ELEMENTS
49 65
113.0(1972) •••*••(
13.1(1975) ««««««(
B.C.E.6.J.X
65
0) •«••••( 0)
0) *«..««( 0)
DETROIT EDISON
.0 MW (NET)
CAPACITY FACTOR. X
TOTAL CAPITAL, S/KW(YEAR)
TOTAL ANNUAL, MILLS/KWH( YEAR)
COST ELEMENTS
• *• 65
9»6C1976> ******< Q) <
65
ILLINOIS POWER COMPANY
WOOD RIVER
4
110.0 MW (NET)
CAPACITY FACTOR. X •«« fi 65
TOTAL CAPITAL, S/KU(VEAR) 82.5(1972) «••*••( 0) ••••••( 0)
TOTAL ANNUAL. M1LLS/KWH(YEAR) ••****( 0) *•«***( OJ ***»»«( C)
COST ELEMENTS A,C,E,M,N
POTOMAC ELECTRIC POKER
DICKERSON
3
.0 HW (NET)
CAPACITY FACTOR. X •*« 65
TOTAL CAPITAL, S/KW(VEAR) 68.0(1978) •*«**•<
TOTAL ANNUAL, MILLS/KWH(VEAR> •*•••*( 0) •••**•(
COST ELEMENTS A,C,E,M
0)
0)
65
0)
0)
PUBLIC SERVICE OF COLORADO
VALMONT
5
166.0 MW (NET)
CAPACITY FACTOR, X *•• 65 65
TOTAL CAPITAL, S/KW(YCAR) 87.0(1974) •••*••( 0) ••••••(
TOTAL ANNUAL, MILLS/!P1H(YEAR> ••*•*»( 0) *•****( 0) ***•«»(
COST ELEMENTS B,C,E.J
0)
0)
*•**•• INDICATES COST FI61RES NOT YET AVAILABLE
A- 25
-------
EPA UTILITY F&O SURVEY: FOURTH QUARTER 1979
SECTION A-2
COSTS FOR NON-OPERATIONAL FCC SYSTEMS
COST
UNIT DESCRIPTION COST DESCRIPTION REPORTED ADJUSTED STANOARDI1ED
ADJUSTED
SALT RIVER PROJECT CAPACITY FACTOR, X *** 65 65
CORONADO TOTAL CAPITAL, J/KWCYEARJ 74.0C1978> ••••••! 0> ••*•••< 0>
2 TOTAL ANNUAL. MILLS/K/kH(YEAR> *••*««( 0) »*••*•( Q) ***•••( 0)
280.0 MW (NET) COST ELEMENTS C,E
****** INDICATES COST FIGURES NOT VET AVAILABLE
A- 26
-------
APPENDIX B
FGD PROCESS FLOW DIAGRAMS
THIS APPENDIX COMPRISES OPERATING FGD SYSTEMS
ARRANGED ALPHABETICALLY ACCORDING TO UTILITY
-------
f IK CM
TOM HUM
(WIT Z)
DO
I
IV)
MS TO STICK
FW« WIT 3
LIMSTtMC SI WHY *UN>S
(TWO TOTU)
Alabama Electric,
Simplified Process Flow Diagram for Tombigbee 2 and 3
-------
co
i
oo
LINESTOC
STOMtt UN
DOUBU-BLADED
GUILLOTINE
DAMPER
L MILL
WET LIMESTOK
GRINDING SYSTEM
TOTAL PROCESS
HAKE-UP HATER
(COOLING TOWER
BLOHDOHN)
-* TO UNIT NO. 3
FROM UNIT NO. 3
-* TO UNIT NO. 3
ABSORBER REAGENT
FEED PUMPS
Arizona Electric Power Coop, Apache 2 and 3
Process Flow Diagram
-------
-N
w
iLom«
f —
—
$T|MI
f
f
*
4-
1^ | Lfluvrt
1 ^1
r nil S
nm
10 {MrOMTIOH
Arizona Public Service, Cholla 1:
Simplified Process Flow Diagram
-------
i
Ul
mu IT I 1*1
SlUMY I I Ql
TWOS ' ' tV
T«MSF£«
PUHP5
SLUMY
STOMGf TMKSrfP
'«« PW1
«tCI«CWAtlO«
PIPI",
Central Illinois Light,
Simplified Process Flow Diagram of Duck Creek 1
Power Plant and Emission Control System
-------
TO STACK - FLUE GASES
MMEUf MUTER
(POM) MUTER)
IW FROM
STORAGE
W
• OVERFLOW
TO ASH POND
FROM OTHER
' RECYCLE TANK
••TOIMCS
Columbus and Southern Ohio Electric, Conesville 5 and 6:
Simplified Process Flow Diagram for a Riven Module
-------
w
-J
1ST STAGE
ADJUSTABLE VENTURI
FOR FLY ASH/S02
CaS03/S04
FLY ASH SLURRY ,,
TO
STABILIZATION
FACILITIES
S02 ABSORBER SCRUBBER
RECYCLE RETURN SYSTEM
Duquesne Light, F. R. Phillips FGD System:
General Diagram.
-------
STACK
I.D. FAN
COAL
SUPPLY
to
i
CD
STACK GAS
REHEATER
AIR HEATER
DEMISTER
STACK GAS
SCRUBBER
PULVERIZER
RECYCLE
PUMP
Kansas City Power and Light, Hawthorn Units 3 and 4:
Simplified Process Flow Diagram of the Lime Scrubbing Process
LIME
PREPARATION
TANK
CLARIFIER
MAKE UP
WATER
TO ASH DISPOSAL
POND
-------
DO
I
ABSORBER
RECIRCULATION
PUMPS
VENTURI
RECIRCULATION
PUMPS
LIMESTONE
SLURRY
STORAGE
BOILER
160 ACRE
SETTLING POND
WET BALL
MILL
Kansas City Power and Light,
LaCygne 1 FGD System: General Diagram
-------
FURNACE
DAMPERS
TWO PRECIPITATORS
to
i
FOUR I.D. FANS
ONE
STACK
WATER RETURN TO
REACTION TANKS
BLEED PUMP
FOUR,
REACTION
TANKS
SLUDGE DISPOSAL
POND
Kansas Power and Light,
Schematic of Jeffrey Steam Generator and Emission Control Equipment
-------
N0»r>
\
JIUMTIK
V
SML'IK
MOIT1VE
TiAKSft"
W'Sl
OMSHED
inKSTOML
nun
i
OKUTlOi MIC! (fKf
«Cni»( STOMCt HECItCULXTICM T«rl
TM« M SOLIDS
MOITW
oi Lin 10*
? ™"
I Pi L*™-
k>J [Ij^r
-€/ ' >^"TO OTHtH
«BOnl«
XIMBCO
OWE Or TWO NODULES
L_
Kansas Power and Liqht,
Lawrence 4 Operational FGD System:
Simplified Process Flow Diagram
-------
HHIEK FOR
LIMESTONE
imABCB
HUSHED
UNCSTOM
WCKT
ELEVATOR
•^
iwrrt.w
^
\X
«
^
SL WRITING
1
I SCAIPIN6
-^j^SCHEEN
ffi
b
u*5boni«
TMMSfEII
PUMPS
| NILl Pi
•"LiilnC— '
MIEI
0/w
/Tl
c*o
WOITKE S
TMK U Ml IBS
011UT1W MTtR
(FWM ffiCIKCULATlOM TAMC)
SUW
SlUMT PUNK
-+J 1 JL lAOOmVE
-OMMITIIE I Pi ••
00
I
ro
(W^P
LJ! J COLLECTION
^!cT..T:^,TANKl
I!STRAINER
EFFLUENT
BLEED PUMP
JB.
ON
BUED^
n
REACTION
TANK
1 STRAINER
„
f
spr
PU»
SAY
tp
|
1
|J
1
EFFLUENT
BLEED
HEIR
OVERFLOW
L
Y-O^ ^SETTLING
TEENER POND
UHOERFLOU PUMPS
Kansas Power and Light,
Lawrence 5 Operational FGD System:
Simplified Process Flow Diagram
-------
w
I
M
CO
ELECTRICAL
GENERATING
UNIT NO. 1
ELECTRICAL
GENERATING
UNIT NO. 2
SPARE
RECYCLE r-N MIX/HOLD TANK
SPADE
SPARE
Kentucky Utilities,
Green River FGD System: General Process Diagram
-------
QUENCHER
MIST
ELIMINATOR
(CHEVRON)
CONTACTOR
SCRUBBER
MODULE
ELECTROSTATIC
PRECIPITATOR
REACTION
TANK
BOILER
FLUE
GAS
eo
i
CONTACTOR
SCRUBBER
MODULE
MIST
ELIMINATOR
(CHEVRON)
FLOCCULANT
ADDITION
1
— r~\ ' -/""*--
\ SETTLING / POND WATER RETURN
SURGE '
TANK
\ POND /
Louisville Gas and Electric, Cane Run 4
FGD System: Simplified Process Flow Diagram
-------
IN LINE REHEATER (STEAM)
I.D. BOOSTER fi
TO STACK
BYPASS
SPRAY PUMPS
IN-TANK STRAINER
UNER J
•MIST ELIMINATOR
P MIST ELIMINATOR MASH
—eAj — «
-BULK ENTRAINMENT
SEPARATOR
CRUSHER-
DISINTEGRATOR
•-SPRAY TOWER ABSORBERS
ITORJ
D *
FROM LIME
STORAGE TANK
-1*1-
LIMEG-
FEED PUMPS
LIME FEEDTANK
REACTION TANK
TO DISPOSAL-*
PUMPS
) UNDERFLOW PUMPS
ocrvri c~ ' * — M.E.WASH
RPHMP!;E "ECYCLE PUMP
TANK
Louisville Gas and Electric, Cane Run 5
FGD System: Simplified Process Flow Diagram
-------
COMBUSTION AIR
MIST ELIMINATOR
EXISTING BY CEA
II
JL Jl
T
EXISTING
FAN
JWlH)
F-*i
EXISTING |
I PRECIPITATOR i
I ^ 1
EXISTING |
' ot\ii rn i
BOILER i
FEED TANK
A
FROM
1
FROM REH
=£2
BOOSTER
FAN
ABSORBER A-201 1
1
1
FROM ABSORBER A-
IME SLl
BY OTHI
TAHT
LJRRY)
RRY
RS
f.
'/
101
—
I
1
i
RII
0
PR
RE
OF
(RIVER WATER)
EMERGENCY WATER
EATER SUPPLY
TOAABrER^— I r
A-2
WRY REACTOR
F TRAIN 2
SECONDARY -
OF TRAIN
2
**C "
INARY
ACTOR
TRAIN 1
1 .
' m
SECONDARY
REACTOR
OF TRAIN
11
>ORBER
01
ABSORBER
A- 101
hHUM IHKHtrttK MULU IANK
J^
M7*
RECYCLE PUMP '
TYPICAL FOR (2)
RECYCLE PUMPS
I
J
REACTOR
TRANSFER
PUMP
Q
U
Pi-
, OVERFLOW
tn/
THICKENER
\
n^
UNO
P
•
MASH ;
^Tv(
r
^
i
ERFLOW
UMP5
j
I
J
1
HOL
TAN
!
SODA ASH
SOLUTION
PUMPS
^QT
MAKE-UP
D - ,.
SODA ASH
SILD
RIVER WATER
M START UP) <-^— — 7— f
- 9
WEIGH FEEDER
~^^^~^/
SODA ASH
SOLUTION
TANK^?
. .-T^ ! OVERFLOW
'TO THICKENER
RIVER WATER
1 _
K rt-J^OTANK Tn
REACTANT
FEED PW»S
KACTMTMNSFE*
PUMP
PUMPS
. _ .
A'201
Louisville Gas and Electric, Cane Run 6
Dual Alkali FGD System: Simplified Process Flow Diagram
B-16
-------
GAS TO STUCK
I
H
^J
GAS BEHEATEHS
CA(0«)2
•OOl'IVt S»ST[K
Louisville Gas and Electric,
Paddys Run 6 FGD System:
Simplified Process Flow Diagram
-------
w
i
FLUE
GAS
EMERGENCY HATER
oo-
MIST
ELIMINATORS
HASH TRAY
U \J
^^^
STEAM
5 "CLEAN FLUE GAS £^~">
Cxj-SEAL HATER SUPPLY
^UNDERSPRAY „ MAKEUP
WATER
TRAY RECYCLE
FLY ASH POND
Montana Power, Col strip 1 and 2:
Process diagram of a given FGO module.
i
HASH TRAY POND
POND
RETURN
-------
TO CMIMEY
to
I
(-•
vo
NCOMNICM.
OUST
COUECTOH
(NUITICLONCS)
THIN
VCNTURI
THROAT
SCRUSK*
Nevada Power, Reid Gardner 1,2 and 3:
Process diagram of a given FGD system.
-------
DISCHARGE
TO STACK
CONDENSER
PRESCRUBBER
(VARIABLE-THROAT
VENTURI)
ro
o
FLUE GAS FROM
UNIT 111
•
FLY ASH PURGE TO POND-*
TRAY TOMER
ABSORBER
TREATED
PURGE STREAM
SODIUM SULFATE
CAKE
EVAPORATOR/
^CRYSTALLIZE*
J COMPRESSOR
CRYSTALLIZER
«- STEAM
DRIED
SULFATE
PRODUCT
Northern Indiana Public Service,
D. H. Mitchell 11 Wellman. Lord/Allied System:
General Process Diagram.
-------
GO
to
FLUE GAS
TO
SCRUBBER
REHEATER
LIMESTONE —i
MIST
ELIMINATOR
OVERFLOW POTS
AND MARBLE BED
THICKENER
UNDERFLOW
PUMP
ASH POND
RETURN PUMP
Northern States Power, Sherburne 1 and 2 FGD System:
Simplified Process Flow Diagram
-------
w
I
to
to
Pennsylvania Power, Bruce Mansfield FGD System:
Process Flow Diagram for Unit 1 or 2
-------
FRESH
WATER >
INLET
BACKWASH
SPRAYS
STACK GAS
FROM I.D.
FANS
PARTICULATE
SCRUBBER
03
NJ
U>
HUMIDIFIED
GAS STREAM
CLEAN GAS OUTLET
>.
MIST ELIMINATORS
MIST ENTRAPMENT SEPARATOR
VENTURI ROD MODULES
Mg (OH)2 SLURRY
PARTICULATE
SCRUBBER
SURGE TANK
S02 SCRUBBER
SURGE TANK
TO WASTE WATER
TREATMENT SYSTEM
Philadelphia Electric Co.,
Eddystone 1 FGD System:
General Process Diagram.
SCRUBBING SLURRY INLET
TO Mg S03
RECOVERY
-------
FLUE GAS FROM
UPPER ESP
w
to
FLUE GAS FROM
LOWER ESP
\
STACK INLET
DAMPERS (2)
(1 EACH SIDE)
STACK
HOT REHEAT GAS
EXHAUST PLENUM
EXHAUST
ISOLATION
DAMPERS
(4 PER UNIT)
INLET
PLENUM
INLET ISOLATION
DAMPERS (4 PER UNIT)
BOOSTER FAN FLOW
CONTROL DAMPERS
(4 PER UNIT)
ABSORBERS
(4 PER UNIT)
VENTURIS
(4 PER UNIT)
BOOSTER FANS
(4 PER UNIT)
Public Service of New Mexico, San Juan 1, 2, and 3*
FGD System Flue Gas Flow Path
*San Juan 3 is identical except that only one scrubbing
train is operational.
-------
LIME SILO
w
K)
01
FLUE GAS
BY-PASS
FLUE GAS FROM
ELECTROSTATIC
PRECIPITATOR
_^ CLEAN GAS
TO STACK
CaO
HATER
SOLID TO
OH-SITE
LANDFILL
Southern Indiana Gas and Electric, A.B. Brown 1:
Dual Alkali F6D System: Simplified Process Flow Diagram
-------
BOILER
to
to
EXISTING
ELEC.PRECIP. *I»
I — 1 HEATER
\x\y\Ay
LIMESTONE
FEED UN
(ONE IN USE
FOR TO
•OILERS)
MET BALL HILL
(ONE IN USE)
NNKUP HATER
MIST ELIMIMTQ*
HIST
ELININA'
TANK (ONE
USE)
(ONE IN USE
ONE SPARE)
MILL SLURRY
TANK
(CM IN USE) »5| »W) (ONE IN USE)
SLURRY STORAGE
SLURRY
PUMP
(ONE IN USE
ONE SPARE)
MIIER >
(ONE IN USE)
p N
If-
IXER
E IN USE)
T
VENTURI SORBER
SCNUMERlM
(ONE IN USE)
TNI
TO TM1CKBKH
«U*«*^*MV>» ^^*'
RECYCLE TANK
(ONE IN USE)
RECYCLE
MNP
(THO IN OK
ONE SPARE)
THICNBCR
SUPPLY
TANK
(ONE IN USE)
.(ORE IN USE
ONE SPARE)
South Mississippi Electric, R.D. Morrow 1 and 2:
Simplified Process Flow Diagram
-------
SCRUBBER INLET
TEST PORT LOCATION
TOP OF STACK
ELEVATION 1645'
TEST PORT
ELEVATION 1516'
W
I
ro
•B" ABSORBER
I NODULE
L—TOP OF OUTLET BREECHING
ELEVATION 1372'-2 3/8*
I—TOP OF BYPASS BREECHING
ELEVATION 1307'- 8 1/2'
-MADE ELEVATION 1HI'
PRECIPITATOR
INLET TEST
PORT LOCATION
ABSORBER
NODULE
SCRUBBER INLET
TEST PORT LOCATION
HKUTUMIOI
MM OKin.HI
Springfield City Utilities, Southwest 1:
Simplified Process Diagram
-------
N>
00
i AIR
IFUEL OIL>— »|REHEATER}— ,
SCRUBBER
.
-------
_
I FUEL OIL >->) REHEATER- •
IFLUE GAS>-O"®-,
VENTURI
SCRUBBER
I LIME
PROCESS
WATER
HOLD TANK
SCRUBBER
EFFLUENT
HOLD
TANK
SAMPLE POINTS
OGAS COMPOSITION
®PARTICIPATE COMPOSITION & LOADING
©SLURRY OR SOLIDS COMPOSITION
GAS STREAM
LIQUOR STREAM
SETTLING POND
Tennessee Valley Authority, ShawneelOB Prototype Unit:
General Process Diagram.
-------
FLUE GAS
MAKE-UP WATER
w
VENT AIR
A
OXIDATION
TANK
CLARIFIED LIQUOR
WATER
SPRAY TOWER EFFLUENT
HOLD TANK
:=>
=>
*• ,*
t
— J
T
<-
-~>
r^
* I ^ | ^_
DESUPERSATURATION
TANK
BLEED TO
DEWATERIN6
-^ SYSTEM
Tennessee Valley Authority, Shawnee TOB Prototype Test Unit:
Modified Venturi/Spray Tower System for 2-Stage Oxidation Testing.
-------
w
I
u>
VTRAINS
[8,C, AND 0
ENTRAINMENT
SEPARATOR
fc TO ASH 1
:
U DISPOSAL POND
TO STACK PLENUM
FROM ESP
>
[
FAN
y FROM B. C, AND D TRAIN
VENTURI CIRCULATION TAN«1_
>_ TO SETTLING POND
*.
1
VENTURI
CIRCULATION
TANK AND
PUMPS
SLURRY PIMP
SEAL WATER
, HEADER
-DRIVER HATER
"SB* -.——I
RECYCLE PUMPS
FROM LIMESTONE SLURRY
EFFLUENT SLURRY
SURGE TANK AND PUMPS
ABSORBER
CIRCULATION
TANK AND
PUMPS
TO TRAINSv
B,C, AND D]
LIMESTONE SLURRY
STORAGE TANK
LIMESTONE SLURRY
FEED PUMPS
Tennessee Valley Authority, Widows Creek 8 FGD System:
Process Flow Diagram for One of the Four Scrubber Trains
-------
FAN OUTLET HAMPER--
'TOMER tNirr DAMPER
nsx WILER
AIR PREHEATERS
7
UJ
ro
FIT ASM
PIM> SEN. HATER.
BALL MILL COOLIUS
AND HOSE STATIODS
MAKEUP WTER TO
LIMESTONE AREA
UHNND
rruwmAT
(Rtcrac HATED)
Texas Utilities,
Simplified Process Flow Diagram for One of the Three Identical
Martin Lake FGD Systems
-------
FM
tt
I
00
UJ
TO ASH AREA
•YPASS
TO SPRAT TOUCH 101
BYPASS
FROM SPRAT TQUCR 301
TO SPRAT TOUCR 701
FROM SPRAT TOME*
N?ST ELIMINATOR
MASH HATER
TO SPRAT TOUCR Ml
TO SPRAT TOHCR 201
TO SPRAT TOUCR 201
f(K» SPRAT TOMER _30I
FRO* SPRAT TOWR2oT
TO SPRAT TONER 301
TO SPRAT TOWR 201
TO SPRAT TOUCR 301
TO SPRAT TOMER 301
TO SPRAT TOUCR 201
TOUCR DRAIN TO
DISPOSAL
TO SPRAT TOME* 301
: SPRAT TOWER
BCCTCLE PUHP
TOTAL PUMP SEALS AND
INSTRUMENT PURGE HATER
I LIMESTONE CRlWfftC
I STSTEH
LIMESTONE SLURRr
TANK AGITATOR
FROM
LIKESTONC STORAGE
FROM ASH MATCR
RETENTION POND
SO, REMOVAL AREA
SUMP PUMPS
S02 REMOVAL AREA SUMP
Texas Utilities,
Simplified Process Flow Diagram for Monticello 3
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APPENDIX C
DEFINITIONS
C-l
-------
DEFINITIONS
Boiler Commercial Service Date
Byproduct
Commercial Service Date
(FGD System)
Company Name
Disposal
Efficiency:
Particulate Matter
SO,
Date when boiler and auxiliary
equipment (including FGD sys-
tem for new boilers) has met
initial supplier guarantees
and begins to contribute elec-
trical power to the power
grid.
The nature (e.g. elemental
sulfur, sulfuric acid) and
disposition (e.g. stockpile on
site, marketed) of the end
product by systems that gen-
erate a saleable product.
Date when the FGD system suc-
cessfully completes compliance
testing and the utility is
satisfied that the system
meets supplier contractual
guarantees.
Name of corporation as it ap-
pears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - as space permits.
Disposal method for throwaway
product systems producing
sludge including: stabilized
or unstabilized sludge, inter-
im and final disposal sites
and disposal type (minefill,
landfill, etc.) as well as
disposal location.
The actual percentage of par-
ticulate matter removed by the
emission control system (me-
chanical collectors, ESP, or
fabric filter and FGD) from
the untreated flue gas.
The actual percentage of S02
removed from the flue gas by
the FGD system.
C-2
-------
FGD Viability Indexes
Availability Index
Reliability Index
Several parameters have been
developed to quantify the vi-
ability of FGD system technol-
ogy. Various terms such as
"availability," "reliability,"
"operability," and "utiliza-
tion" are used to accurately
represent the operation of any
FGD system during a given per-
iod. The above-mentioned pa-
rameters are defined below and
discussed briefly. The objec-
tives of this discussion are
to make the reader aware that
several different definitions
are being used and to select
appropriate parameters that
can be used for reporting pur-
poses so that reasonably con-
sistent comparisons can be
made.
Hours the FGD system is avail-
able for operation (whether
operated or not) divided by
hours in period, expressed as
a percentage. This parameter
tends to overestimate the vi-
ability of the FGD system be-
cause it does not penalize for
election not to operate the
system when it could have been
operated. Boiler downtime may
tend to increase the magnitude
of the parameter because FGD
failures generally cannot oc-
cur during such periods.
Hours the FGD system wc.3 oper-
ated divided by the hours the
FGD system was called upon to
operate, expressed as a per-
centage. This parameter has
been developed in order not to
penalize the FGD system for
elected outages, e.g., periods
when the FGD system could have
been run but was not run be-
cause of chemical shortages,
lack of manpower, short dura-
tion boiler operations, etc.
The main problem in using this
C-3
-------
FGD Operability Index
FGD Utilization Index
End Product
Saleable
formula is the concise determi-
nation whether or not the sys-
tem was "called upon to oper-
ate" during a given time per-
iod. In addition, an undefined
value can result when the FGD
system is not called upon to
operate for a given period
(e.g., turbine or boiler out-
age when FGD system is avail-
able) .
Hours the FGD system was oper-
ated divided by boiler operat-
ing hours in period, expressed
as a percentage. This param-
eter indicates the degree to
which the FGD system is actu-
ally used, relative to boiler
operating time. The parameter
is penalized when options are
exercised not to use the FGD
system in periods when the
system is operable. In addi-
tion, an undefined value can
result when the FGD system is
not called upon to operate for
a given period (e.g., turbine
or boiler outage when FGD sys-
tem is available).
Hours that the FGD system op-
erated divided by total hours
in period. This parameter is
a relative stress factor for
the FGD system. It is not a
complete measure of FGD system
viability because the parameter
can be strongly influenced by
conditions that are external
to the FGD system (e.g., in-
frequent boiler operation will
lower the value of the parame-
ter although the FGD system
may be highly dependable in
its particular application).
The S02 removed from the flue
gas is recovered in a usable
or marketable form (e.g., sul-
fur, sulfuric acid, gypsum,
C-4
-------
Throwaway
Energy Consumption, %
Equivalent Scrubbed Capacity
(ESC)
FGD Status:
Category 1
Category 2
Category 3
Cateogry 4
Category 5
ammonium sulfate, sodium sul-
fate).
The SC-2 removed from the flue
gas is not recovered in a us-
able or marketable form and
resulting sulfur-bearing waste
products must be disposed in
an environmentally acceptable
fashion.
The percentage of gross unit
electrical generating capacity
consumed by the FGD system, as
defined by the following equa-
tion:
[Net MW w/o FGD - Net MW w/FGD]/
Gross unit rating]
The effective scrubbed flue
gas in equivalent MW based on
the percent of flue gas scrubbed
by the FGD system.
Operational - FGD system is in
service removing S02•
Under construction - ground
has been broken for installa-
tion of FGD system, but FGD
system has not become opera-
tional .
Planned, Contract Awarded -
contract has been signed for
purchase of FGD system but
ground has not been broken for
installation.
Planned, Letter of Intent
Signed - letter of intent has
been signed, but legal con-
tract for purchase has not
been awarded.
Planned, Requesting/Evaluating
Bids - bid requests have been
released but no letter of in-
tent or contract has been is-
sued.
C-5
-------
Category 6
Category 7
Category 8
Fuel Firing Rate - TPH
General Process Type
Initial Start-Up (FGD System)
New
Plant Name
Process Additives
Considering only FGD Systems -
an FGD system is proposed as a
means to meet an S02 regulation,
Considering an FGD system as
well as alternative methods.
Nonoperational - FGD system
has been operated in the past
but has been shut down perma-
nently or for an extended in-
definite period of time.
Boiler fuel firing rate in
terms of tons per hour at max-
imum continuous load.
The manner in which the SC>2
from the flue gas is collected,
e.g., wet scrubbing, spray
drying, dry adsorption.
Date when flue gas first
passes through any component
of the FGD system {or is
scheduled to do so).
FGD unit and boiler were de-
signed at the same time or
space for addition of an FGD
unit was reserved when boiler
was constructed.
Unit identification as it ap-
pears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - or as indicated by
utility representative for in-
stallations in planning stages.
A chemical compound or element
which is added to the process
or normally found with the
main process reagent in small
quantities (e.g., Mg, adipic
acid) to promote improved
process operation (e.g., scale
reduction, increased SC>2
removal efficiency).
C-6
-------
Process Type
Regulatory Class
Retrofit
Spare Capacity Index - %
Spare Component Index
System Supplier
Total Controlled Capacity
(TCC)
Company name if process is
patented. Generic name if
several companies have similar
processes (e.g., Lime, Lime-
stone, Wellman Lord, Thorough-
bred 121) .
A. New boiler constructed
subject to Federal New
Source Performance Stan-
dards (NSPS), 8/17/71.
B. Existing boiler subject
to State Standard that is
more stringent than the
NSPS, 8/17/71.
C. Existing boiler subject
to State Standard that is
equal to or less stringent
than NSPS, 8/17/71.
D. Other (unknown, undeter-
mined) .
FGD unit will be/was added to
an existing boiler not specif-
ically designed to accommodate
FGD unit.
The summation of the individ-
ual component capacities (%)
minus 100%.
The equipment spare capacity
index (%) divided by the indi-
vidual component capacity (%).
A firm that fabricates and
supplies flue gas desulfuriza-
tion systems.
The gross rating (MW) of a
unit brought into compliance
with FGD, regardless of the
percent of flue gas treated at
the facility. In the case of
prototype and demonstration
FGD systems, this figure will
be identical to the Equivalent
Scrubbed Capacity rather than
C-7
-------
Unit Rating
Gross
New w/FGD
Net w/o FGD
the gross unit rating if the
system is not meant to bring
the facility into compliance
with SO2 emission standards.
Operational - Maximum contin-
uous gross generation capacity
in MW; Preoperational - maxi-
mum continuous design genera-
tion capacity in MW.
Gross unit rating less the en-
ergy required to operate
ancillary station equipment/
inclusive of emission control
systems.
Gross unit rating less the en-
ergy required to operate
ancillary station equipment,
exclusive of emission control
systems.
C-8
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APPENDIX D
TABLE OF UNIT NOTATION
D-l
-------
TABLE OF UNIT NOTATION
Classification
Area
Concentration
Flow
Heat Content
Length
L/G Ratio
Mass/Weight
Pressure
Temperature
Volune
English Unit
Acre
Square foot
Grains per standard
cubic foot
Parts per million
Pounds per million
Btu
Actual cubic feet
per minute
Gallons per minute
Pounds per minute
Ton per day
Ton per hour
Btu per pound
Foot
Inch
Mile
Gallons per
thousand actual
cubic feet
Pound
Ton
Inches of water
Degree Fahrenheit
Cubic feet
Ac re- feet
Symbol
acre
ft2
gr/scf
ppm ,
lb/10 Btu
ft3/min
(actual)
gal/min
Ib/min
t/day
t/h
Btu/lb
ft
in
mi
gal/1000
ftJ
(actual)
Ib
t
in. H20
°F
ft3
Acre-f t
Survey Report
Notation
ACRE
SQ.FT
GR/SCF
PPM
LB/MMBTU
ACFM
GPM
LB/MIN
TPD
TPH
BTU/LB
FT
IN
MI
GAL/1000ACF
LB
T
IN. H20
F
CU.F
ACRE-FT
ASTM/SI Unit
Square meter
Square meter
Grams per cubic meter
Parts per million
Nanograros per joule
Cubic meters per
second
Liters per second
Kilogram per second
Metric ton per day
Metric ton per hour
Joules per
gram
Meter
Centimeter
Kilometer
Liters per cubic
meter
Kilogram
Megagram
Kilopascal
Degree Celsius
Cubic meter
Cubic meter
Symbol
M2
M2
g/m3
PPm
ng/J
m3/s
liter/s
kg/s
M t/d
M t/h
J/g
m
cm
km
liter/m3
kg
Mg
kPa
°c
"3
in
Survey Report
Notation
SQ.M
SQ.M
G/CU.M
PPM
NG/J
CU.M/S
LITER/S
KG/S
M T/D
M T/H
J/G
M
CM
KM
LITER/CU.M
KG
HG
KPA
C
CU.N
CU.M
o
10
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TECHNICAL REPORT DATA
(Hour read Instructions an tin /ritrsi be Jon r
1. REPORT NO.
EPA-600/7-80-029a
2.
3 RECIPltNT'S ACCESSION NO
4. TITLE AND SUBTITLE
EPA Utility FGD Survey: October - December 1979
REPORT DATE
January 1980
PERFORMING ORGANIZATION CODE
7 AUTHOR(S)
M. Smith, M. Melia, N. Gregory
8 PERFORMING ORGANIZATION REPORT NO
PN 3470-1-KK
9. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO
EHE624
11. CONTRACT/GRANT NO
68-01-4147, Task 113
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
Quarterly; 10/79 - 12/79
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTES EpA Project officers are N. Kaplan (IERL-RTP, MD-61, 919/541-2556)
and J.C. Herlihy (DSSE, 202/755-8137). Related reports are in the EPA-600/7-78-051
and EPA-600/7-79-022 series.
16. ABSTRACT
This report is the first full compilation (not a supplement) since the December 1978 -
January 1979 report. Because the next three reports are to be supplements, this issue
should be retained for reference throughout the year. The report, which is generated
by a computerized data base system, presents a survey of utility flue gas desulfuriza-
tion (FGD) systems in the U.S. and Japan. It summarizes information contributed by the
utility industry, process suppliers, regulatory agencies, and consulting engineering
firms. Systems are tabulated alphabetically by development status (operational, under
construction, or in planning stages), utility company, process supplier, process and
waste disposal practice. It presents data on boiler design, FGD system design, fuel
characteristics, and actual performance. It includes unit by unit dependability param-
eters and discusses problems and solutions associated with the boilers and FGD systems.
rrocess I.LOW diagrams anu ruu system economic uaLa are appenaea to tne report.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
Pollution Maintenance
Flue Gases
Desulfurization
Electric Utilities
Waste Disposal
Boilers
18. DISTRIBUTION STATEMENT
[Unlimited
b.lDENTIFIERS/OPEN ENDED TERMS
Pollution Control
Stationary Sources
Utility Boilers
19. SECURITY CLASS (This Report)'
Unclassified
20. SECURITY CLASS (ThisfHft)
Unclassified
c. COSATi Field/Group
13B
21B
07A, 07D
15E
13A
21. NO. Of PAGES
570
22. PRICE
EPA Perm 1220-1 (t-73)
D-3
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