QECHNOL
The Bridge Between Research and Use
322
U.S. ENVIRONMENTAL. PROTECTION AGENCY
MAY 1S7S
TECHNICAL CAPSULE REPORT ON FLUE
GAS DESULFURIZATION ANDSULFURIC
ACID PRODUCTION VIA MAGNESIA
SCRUBBING
A technical Capsule Report covering the two-
year operation of a large prototype sulfur
dioxide recovery plant based upon magnesia
slurry scrubbing is presently being printed and
will be available for distribution at the APCA
'75 Exhibition, June 15-19, in Boston, Mass.
This prototype program was jointly funded by
EPA and Boston Edison Company. The S02
absorption plant was installed at Boston Edi-
son's Mystic Station in Everett, Massachusetts,
and the regeneration facility at Essex Chemical's
Rumford, Rhode Island, sulfuric acid plant.
The Capsule Report describes both process
operations at Boston Edison and Essex Chemi-
cal; the problems encountered during the test
RLJEG>S
program, as well as the solutions to these
problems; the economics of MgO scrubbing,
MgO regeneration, and sulfuric acid production;
and areas of application for this process.
During the operational period, the system
demonstrated its ability to regenerate and reuse
magnesium oxide. Over five thousand tons of
commercial grade sulfuric acid were produced
from magnesium sulfite and the scrubbing sys-
tem demonstrated a consistent ability to achieve
S02 removal efficiencies in excess of 90 percent
using regenerated magnesium oxide. During the
last four month period of the recovery system's
operation, the monthly availabilities were 87%,
81%, 57% and 80%. The lowest reported value
was due to the lack of MgO for S02 removal,
caused by problems in the sulfuric acid plant
and an intentional emptying of the MgO silos
during a controlled test.
For your copy of this Capsule Report, use the
order blank at the back of this newsletter.
TECHNOLOGY TRANSFER LAND
TREATMENT SEMINAR SERIES
Technology Transfer recently completed the
first two of a series of design seminars on "Land
Treatment of Municipal Wastewater Effluents".
The first two seminars were held in Atlanta,
Georgia—April 23-24, and San Francisco,
California—May 7-8, 1975. This seminar series is
aimed at providing federal, state and municipal
engineers and the consulting engineering profes-
sion with the latest design information to
properly design and evaluate land treatment as a
viable treatment alternative.
Russell E. Train, USEPA Administrator, ini-
tiated the seminar series and presented the
introduction and purpose to the 330 plus
attendees at the Atlanta Seminar.
Interest has been extremely high at both
seminars due to the timeliness of this subject
area. The latest design factors and cost compari-
Refer to inside last page of this publication for
complete listing of current Technology Transfer
publications.
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sons are covered in detail. Case histories are
presented on successful projects and the up-to-
date status of the Muskegon, Michigan, EPA
demonstration project is discussed. Seminars for
the other EPA Regions are being planned and
detailed information may be obtained from
contacting the respective Regional Technology
Transfer Chairmen. Following is a general out-
line of the seminar format:
• EPA's APPROACH TO LAND TREAT-
MENT AND COST EFFECTIVENESS
• DESIGN FACTORS
Introduction & Pretreatment
Overland Flow
Irrigation
(Nutrient/Water Utilization)
I nfiltration-Percolation
Site Selection
Storage
(Total Water Balance)
Land Availability
Distribution Techniques
Public Health Considerations
Monitoring (Need)
Land Use
Climate, Topography
Surface Runoff Control
Hydraulic Loading
Nutrient Loading
Soil
Water Rights
Crop Selection
(Forest Application-Hardwood/
Softwood)
Heavy Metals
Farming Management
Underdrain Systems
Groundwater Conditions
Monitoring (Location)
• REVIEW OF SIGNIFICANT LAND
TREATMENT PROJECTS
• Overview & EPA-APWA Report
• MISC. CASE HISTORIES
Penn State
Mich. State
Melbourne
Phoenix
Tallahassee
• MUSKEGON, MICHIGAN, PROJECT
• COST OF LAND APPLICATION
SYSTEMS
• EXAMPLE COMPARISON OF LAND
TREATMENT AND AWT
Presentations at the seminars have been given
by Bill Whittington, Office of Water Program
Operations (OWPO), EPA, Washington, D.C.;
Charles Pound, Metcalf & Eddy, Palo Alto,
Calif.; Morgan Powell, CH2M/Hill, Denver, Colo;
Belford Seabrook, OWPO, EPA, Washington,
D.C.; Frank D'ltri, Michigan State University,
Lansing, Michigan; Y. A. Demirjian, Deputy
Director of Public Works, Muskegon County,
Michigan; and Gordon Gulp, Clean Water
Consultants, Eldorado Hills, Calif.
95TH AWWA CONFERENCE
Technology Transfer will provide a manned
exhibit for the 95th Annual American Water
Works Association Conference in Minneapolis,
Minnesota, June 8-13, 1975. Over five thousand
private and municipal water utility personnel are
expected to attend the meeting, which is being
held at the Minneapolis Convention Hall.
The theme of the exhibit will be a Technical
Capsule Report on "Magnesium Carbonate—A
Recycled Coagulant for Water Treatment",
which will be initially distributed at the
Conference.
MONITORING SEMINARS
Technology Transfer held six more Monitor-
ing Industrial Wastewater seminars for industry.
Each of these seminars was well attended by
plant managers and engineers. Dates and loca-
tions of the Monitoring seminars were:
January 9, 1975
February 18, 1975
February 19, 1975
March 11, 1975
March 13, 1975
March 20, 1975
Washington, D.C.
Kansas City, Missouri
Denver, Colorado
Oklahoma City,
Oklahoma
Houston, Texas
Chicago, Illinois
Mr. John Quarles, Deputy Administrator of
EPA gave the welcome address at the Washing-
ton seminar. Mr. Quarles emphasized the devel-
opment of a practical approach to monitoring as
it relates to permit conditions. He also stressed
the need for a cooperative effort by the Federal
Government, the states, and the discharger to
meet their respective monitoring responsibilities
under PL 92-500.
The morning session of these seminars cov-
ered EPA regulatory policy with regard to the
monitoring requirements of PL 92-500. States
within respective EPA regional offices presented
their relationships to the Federal Program with
regard to monitoring policies and requirements.
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. ...
Mr. John Quarles, EPA Deputy Administrator, at the Washing-
ton, D.C. Monitoring Seminar.
The afternoon sessions offered technical
guidance for implementing a monitoring pro-
gram. Gerry Shell of AWARE, Inc. concentrated
on an overview of Monitoring Industrial Waste-
water. Dr. Phillip Shelley of Hydrospace-
Challenger discussed Sampling. The session on
Flow Measurement was presented by Vic Jelen
of the EPA Cincinnati Field Investigation
Center. The session on Analytical Quality Con-
trol was prepared by Robert Booth pf the EPA
Cincinnati Methods Development and Quality
Assurance Research Laboratory. The final ses-
sion on In-Process Monitoring was presented by
Walter Zabban of Chester Engineers.
MUNICIPAL DESIGN SEMINARS
One additional Technology Transfer muni-
cipal design seminar has been conducted since
the January, 1975, newsletter was published. A
special cold climate treatment seminar was held
• in Anchorage, Alaska on April 9-10, 1975.
The Anchorage Seminar included technical
sessions on cold climate biological treatment and
physical-chemical treatment. Ernst Mueller,
Commissioner of the Department of Environ-
mental Conservation for the State of Alaska,
opened the seminar attended by approximately
135 consultants and regulatory personnel. Tech-
nical presentations during the two-day seminar
were given by Lee Reid, Borough of Anchorage;
Jack Grainge, Environmental Protection Service,
Environment Canada; Gene Suhr, CH2M/Hill;
Jack Cleasby, Iowa State University; Gordon
Gulp, Clean Water Consultants; Joe Rizzo,
Calgon Corporation; and Randy Bayliss, State of
Alaska. EPA speakers were Jack Coutts and Jim
Westrick.
TECHNICAL CAPSULE REPORT ON
LIME/LIMESTONE WET-SCRUBBING
A technical Capsule Report covering progress
at the EPA alkali test facility at the TVA
Shawnee Power Station is presently being
printed and will be available for distribution at
the «APCA '75 Exhibition, June 15-19, in
Boston, Massachusetts. The Capsule Report is
the 2nd in a series on the Shawnee project, with
each new capsule report being prepared when
significant test data have been developed.
The Shawnee test facility consists of three
parallel scrubber systems: (1) a venturi followed
by a spray tower; (2) a Turbulent Contact
Absorber (TCA); and (3) a Marble-Bed Ab-
sorber. Each system is capable of treating
approximately 10 Mw equivalent (30,000 acfm
SECOKD PROGRESS RSOn
IME/ir/ESTONE US Oft
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@ 300° F) of flue gas containing 1800-4000
ppm sulfur dioxide and 2 to 5 grains/scf of
particulates.
The limestone and lime reliability testing at
the Shawnee facility has shown that scrubber
internals can be kept relatively free of scale if
the sulfate (gypsum) saturation of the scrubber
slurry is kept below about 135 percent.
For your copy of this Capsule Report, use the
order blank at the back of this newsletter.
TECHNICAL CAPSULE REPORT ON
MAGNESIUM CARBONATE-
A RECYCLED COAGULANT
FOR WATER TREATMENT
A technical Capsule Report describing a new
magnesium recycle coagulation system for water
treatment is presently being printed, and will be
available for distribution at the 95th Annual
Conference of the American Water Works Asso-
ciation (AWWA) in Minneapolis, Minnesota,
June 8-13. The system is based on a combina-
tion of water softening and conventional coagu-
lation techniques which can be applied to all
types of water.
The process development began in 1957 at the
Dayton, Ohio, water treatment plant where a
hard, clear, high magnesium water is softened by
a lime-soda process. The cities of Melbourne,
Florida, and Montgomery, Alabama, have also
provided additional support to the development
of the magnesium carbonate coagulation system.
Approximately 1 million tons per year of dry
solids are produced from an estimated 3,600
water treatment plants practicing coagulation
throughout the country. Of these, less than 5
percent receive treatment of any kind before
return to the water course. Wastes from water
treatment plants are today recognized as a
significant pollution problem. The new process
offers an alternative approach to chemical sludge
handling as well as providing for reuse of the
chemicals.
For your copy of this Capsule Report, use the
order blank at the back of this newsletter.
PROCESS DESIGN MANUAL
FOR SLUDGE TREATMENT & DISPOSAL
The following changes should be made in
the Process Design Manual for Sludge
Treatment and Disposal:
• Figure 8-4, page 8-9: BTU rating
should read-1,000 BTU/CF
• Figure 9-2, page 9-11: Curves were
based on a sludge concentration after
thickening to 3-1/2% solids.
TECHNOLOGY TRANSFER/AICHE
CO-SPONSOR THE 2ND NATIONAL
CONFERENCE ON COMPLETE WATER
REUSE (WATER'S INTERFACE
WITH ENERGY, AIR AND SOLIDS)
Technology Transfer and the American Insti-
tute of Chemical Engineers jointly sponsored the
2nd National Conference on Complete Water
Reuse, held at the Palmer House, May 4-8, 1975,
in Chicago, Illinois.
The Conference brought together govern-
ment, industry, management, and environmental
personnel to consider and evaluate the meaning
and potential for complete water reuse systems
to fulfill the objective of Public Law 92-500 for
Zero Discharge of Pollutants, and Water's Inter-
face with Energy, Air and Solids.
Session topics included: Land Disposal of
Wastewaters and Sludges; Technology Transfer
in Water Reuse; Energy; and Air/Water
Interface.
APCA '75 MEETING AND EXHIBITION
Technology Transfer will exhibit recent air-
related publications at the 68th Annual Air
Pollution Control Association Meeting and Ex-
hibition, to be held June 15-19, 1975, in
Boston, Massachusetts. Technical sessions will be
conducted at the Sheraton Boston, which is
directly connected to the John B. Hynes Civic
Auditorium exhibit hall.
The Conference will bring together govern-
ment, industry, management, air pollution
equipment manufacturers, and environmental
personnel to learn about the latest technical
developments in air pollution effects, measure-
ment and control.
Participants at Technology Transfer Textile Seminar held in
Boston on January 15-16, 1975. In front row (l-r) Mr. Luis
Dichtl Subias of Empresa National Adaro, Spain; Mr. Fernando
Troyano Lobaton of Spain's Ministry of Public Works; and Mr.
Jaime Ruiz Rodriguez of Spain's Ministry of Industry.
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EPA's OFFICE OF
ENERGY RESEARCH
The Office of Energy Research (OER) of
EPA's Office of Research and Development is a
new office operating within a highly dynamic
environment. Not only is the OER responsible
for the design, planning and strategic manage-
ment of a $130-million FY 75 research and
development program, but it is doing so within
an interagency context which is quite unique.
Dr. Stephen J. Gage, Acting Director of OER
and formerly of CEQ, and his staff of eight
professionals have designed a R&D program
based upon two major interagency working
group reports. These reports—Health and Ecol-
ogical Effects of Energy Use and Environmental
Control Technology for Energy Systems-
embody the recommendations of more than a
dozen federal agencies, offices and laboratories.
In developing these recommendations into a
balanced energy/environment R&D program, the
OER has had to work in close coordination with
the EPA research centers and laboratories for
the portion of the work to be performed by
EPA, and with other federal agencies for those
projects which they will be implementing.
In order to assure the success of this massive
and complex planning exercise, the OER evolved
an entirely new and highly simplified planning
system. The guiding philosophy behind this new
planning system is that the proper role for OER
in headquarters is one of strategic planning,
information integration and transfer, and pro-
gram and resource balancing. This more limited
role requires the delegation of the responsibility
for detailed program implementation and man-
agement to the field and to those management
individuals closest to the research efforts. Im-
plementation of this philosophy required a new
set of operating procedures.
The first step in the implementation of the
energy/environment R&D program involved the
identification of key outputs necessary for an
effective program. These outputs range from
"initiate demonstration of regenerate sulfur-
producing flue-gas desulfurization system" to
"produce users manual on cold climate shoreline
protection and restoration". They all have two
things in common, however. First, they are
discrete, identifiable, tangible units, and second,
they are all essential parts of a balanced energy/
environment R&D program.
Once these necessary outputs have been iden-
tified, short descriptions are sent to the appro-
priate EPA operation or other agency. This
other organization reviews the output descrip-
tion and, within the time and resources allotted,
provides OER with an accomplishment plan
designed to provide the necessary outputs. This
process yields several benefits. First, it assures
that both OER and field research manager
understand what is required. Second, it involves
a high level of interaction among all parties
involved in a particular research area, thus
establishing linkages for future research coordi-
nation and information transfer. Third, it re-
duces to an absolute minimum the amount of
paperwork involved.
The program itself is being planned on a five
year basis with approximately $130 million
programmed for expenditures in FY 75. The
purpose of the program is the development of a
sound scientific and technical basis for ensuring
(1) adequate protection of human health, wel-
fare, ecosystem and social goals; (2) environ-
mental protection necessary to facilitate the use
of energy supplies, with particular emphasis on
domestic fuels; (3) implementation of energy
system initiatives without delays caused by
inadequate and insufficient environmental
impact data; (4) development of appropriate
cost-effective control technologies for emerging
energy systems; and (5) assessment of environ-
mental implications of energy conservation
measures in order to maximize the energy
savings and minimize the associated impacts.
The EPA energy-related environmental re-
search and development program is divided
functionally into three activities: (1) the Proc-
esses and Effects program to determine the
environmental effects (and hence the control
requirements) associated with energy extraction,
transmission, conversion and use, (2) the En-
vironmental Control Technology Program to
identify, develop and demonstrate necessary
control techniques based on the source effluent
and ambient pollutant control requirements
specified in (1), and (3) the Policy Implementa-
tion Research Program to evaluate the environ-
mental, economic and social consequences of
alternative control strategies for energy systems
as input to EPA policy formulation. Each of
these three programs is addressed in more detail
below.
The energy-related processes and effects re-
search program is composed of three general
subactivities: pollutant identification, measure-
ment and monitoring; health effects; and fresh-
water, marine and atmospheric/terrestrial ecol-
ogical processes and effects. The program is
designed to determine the environmental effects
associated with energy extraction, transmission,
conversion and use so that measures can be
taken in a timely manner to protect human
health, the ecosystem and social goals. Identifi-
cation of the pollutants released by energy-
related industrial operations and determination
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of their impact on the human and natural
environment will define the environmental con-
trol requirements for the pollution operations.
The environmental control technology pro-
gram is divided into four general subactivities:
extraction and beneficiation, fossil fuel com-
bustion, synthetic fuels, and advanced systems
and conservation. The program is designed to
identify, develop and demonstrate cost-effective
control techniques for energy extraction, trans-
mission, conversion and use. The program neces-
sarily involves assessment of the pollution poten-
tial of source effluent streams and the
technological processes producing those pollut-
ants as well as research and development on
control devices and process modifications to
reduce the impacts of the pollutants on ambient
conditions. The thrust of the program is to
provide adequate environmental protection as
the Nation moves toward expanding use of
domestic fuels.
The policy and implementation research pro-
gram objective is to provide the information
necessary to develop comprehensive environ-
mental protection standards for energy produc-
tion activities while attempting to balance the
environmental and economic costs. The com-
prehensive evaluation of environmental, eco-
nomic and social consequences of energy alter-
natives is intended for use as a basis for EPA
policy formulation.
EPA's CONTROL
SYSTEMS
LABORATORY
As a part of EPA's Office of Research and
Development, the Control Systems Laboratory
(CSL), based in Research Triangle Park, North
Carolina, has unique, wide-ranging responsibility
in stationary source air pollution control and
energy-related programs. CSL, under its director,
Dr. John K. Burchard, is currently funding
approximately 300 projects encompassing a
broad range of research, development and
demonstration programs interrelated by a
common objective. The work of CSL is geared
to answer the challenge of Section 101.(b)(2) of
the Clean Air Act "to initiate and accelerate a
national research and development program to
achieve the prevention and control of air pollu-
tion." Over the last decade, CSL has established
a comprehensive program to determine air pollu-
tion sources, assess the environmental impact of
identified pollutants, and accelerate the develop-
ment and commercial application of air pollu-
tion control processes.
Many of the technologies which show promise
as solutions to environment/energy problems
originated in CSL. In such diverse areas as flue
gas cleaning, clean fuels, combustion modifica-
tion, pollution control for metallurgical and
chemical processes, and particle cleanup. Con-
trol Systems Laboratory has taken the develop-
mental initiative through co-sponsorship of
major research, development, and demonstration
(RD&D) projects, contractual studies, and in-
house efforts.
Subdivided programmatically, CSL consists of
four Branches: Gas Cleaning and Metallurgical
Processes, Clean Fuels and Energy, Particulate
and Chemical Processes, and Engineering Analy-
sis. The Engineering Analysis Branch provides
the staff function of program monitoring and
evaluation support, including project evalua-
tions, program reviews, and industrial processes
catalog development.
The three line branches are engaged in a wide
spectrum of control systems development work,
ranging from small-scale experimental research
to full-scale prototype demonstration and
evaluation.
The Gas Cleaning and Metallurgical Processes
Branch is developing and demonstrating flue gas
cleaning for fossil fuel-fired electric utility
power plants and industrial boilers, and pollu-
tion control systems for metallurgical processes
such as in the iron and steel, and smelting
industries.
Environmental assessment, pollution control
for fuel conversion systems, development of
Research Project—Magnesia Slurry Scrubbing System for SO,
Removal at Boston Edison.
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combustion modification techniques for nitro-
gen oxides control, and physical and chemical
fuel cleaning are the responsibilities of the Clean
Fuels and Energy Branch.
The Particulate and Chemical Processes
Branch is concerned with control of pollutants
from chemical processes, development and
demonstration of fine particulate control, im-
provement of conventional particulate control
equipment, and evaluation and development of
measurement, sampling, and analysis techniques
and equipment.
• FLUE GAS DESULFURIZATION
To date, about 80 percent of CSL's total
expenditures have been related to control of
sulfur oxides (SOX) emissions from fuel com-
bustion and have been concentrated in flue gas
desulfurization (FGD). The efforts of CSL have
accelerated the development of FGD so that it is
now in the process of commercialization in this
country. Over 100 flue gas desulfurization sys-
tems are currently in operation, under construc-
tion, or planned.
CSL has been deeply involved in develop-
ment/demonstration of the following flue gas
desulfurization processes. (See table at bottom
of this page.)
An advanced FGD process producing elemen-
tal sulfur as the major system by-product and a
double alkali FGD system are new full-scale
development/demonstration projects currently
being planned.
In addition CSL has projects underway to
improve FGD performance and reliability, and
to evaluate and broaden the scope of FGD
applications. These projects include determining
chemical and physical properties of throwaway
sludge, development/demonstration of environ-
mentally acceptable disposal technology, the
evaluation of technologies and markets for
sludge utilization, purge reduction/elimination
studies, evaluation of reductant gas technologies
for by-product sulfur production, studies in
overall FGD economics and applicability of
FGD to non-utility combustion sources, and
studies on the marketability of abatement sulfur
and sulfuric acid from utility power plants.
• CLEAN FUELS
A second alternative to control SOX emissions
is to remove the sulfur from fuel prior to
combustion. CSL has developed and improved
methods to physically clean coal of sulfur and
ash, thus reducing the fuel's potential to pollute.
This program is continuing, with emphasis
placed on improving available means of coal
cleaning, and evaluating and sponsoring novel
techniques of physical pollutant removal. The
2-stage froth-flotation technique for separating
pyrite from very fine coal will be demonstrated.
A coal cleaning manual is being prepared which
will aid in implementation of this technology.
Methods are also being developed with CSL's
assistance to chemically clean sulfur from coal.
This project has been demonstrated successfully
at the laboratory scale and a pilot scale opera-
tion is currently under negotiation. Other
methods of pre-combustion cleaning of fuels are
being investigated to determine their potential
for control of sulfur, nitrogen, hazardous ele-
ments and compounds, and particulates. One of
these methods removes vanadium and nickel
from high metals, high sulfur residual oils,
yielding a low polluting fuel oil.
Process
Wet Lime/Limestone
Scrubbing
Wet Lime Scrubbing
Magnesium Oxide
Scrubbing
Magnesium Oxide
Scrubbing
Catalytic Oxidation
Wellman- Lord/Allied
Double Alkali
Waste/By-Product
Throwaway Sludge
Throwaway Sludge
98% Sulfuric Acid
98% Sulfuric Acid
98% Sulfuric Acid
>99% Elemental Sulfur
Throwaway Sludge
Application
30 Mw (prototype)
coal-fired utility
40 Mw (full-scale)
oil-fired utility
155 Mw (full-scale)
oil-fired utility
100 Mw (full-scale)
coal-fired utility
100 Mw (full-scale)
coal-fired utility
1 15 Mw (full-scale)
coal-fired utility
30 Mw (full-scale)
coal-fired industrial
.S02
Removal
Efficiency
75-90%
60-80%
85-90%
85-90%
85-90%
90-95%
85-95%
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Pollutant levels in dirty fuels (coal and oil)
can be decreased by fuel conversion processes
such as gasification or liquefaction. These proc-
esses remove potential pollutants from the raw
fuel to provide clean synthetic fuels. In order to
ensure that these systems do not simply transfer
the environmental problems from the fuel usage
to fuel processing, a significant effort is under-
way to environmentally assess the entire sys-
tems. The assessment is resulting in the identifi-
cation of more environmentally sound and
economic systems and is supplying input to
environmental control technology development.
The converted fuels could be utilized in many
ways. One promising method uses the fuel in
combined cycle power generation. CSL has
performed studies in the past and is currently
performing studies on the best integrated com-
bined cycle approach for achieving both environ-
mentally sound and economic total systems. In
conjunction with this study, CSL is co-
sponsoring the development of a high tempera-
ture fuel gas desulfurization system which could
be utilized as one step of the total system.
There is a potential for developing nonpollut-
ing fuels from wastes. A full-scale system which
utilizes municipal waste as a fuel source is being
demonstrated under CSL leadership. As with
other fuel usage systems, an important aspect is
to ensure that the system is environmentally
sound.
• COMBUSTION MODIFICATION
Absorption of sulfur during combustion is
another approach being studied by CSL to
reduce sulfur oxides emissions. Since 1967, this
Laboratory has been actively developing
fluidized-bed combustion for coal, and fluidized-
bed gasification/desulfurization of residual oil as
a means of economical pollution control in
steam and power generation. Study of the
environmental control potential of the fluidized-
bed coal combustion process has advanced to
the stage where a 630 kW (equivalent) pilot
plant, capable of being operated at up to 10 atm
pressure, has been built. Bench scale testing of
the fluidized-bed coal combustion process has
demonstrated 90-95 percent SO2 removal at low
sorbent addition rates, and up to 80 percent
reduction of NOX emissions. Cost estimates
indicate a potential power cost savings for new
fluidized-bed boiler plants of 10-15 percent
compared to new conventional pulverized-coal
boilers with flue gas desulfurization. The en-
vironmental potential of the Chemically Active
Fluid Bed process for gasifying and desulfurizing
heavy fuel oil has been demonstrated in a CSL
co-sponsored pilot-scale program. The pilot test-
ing of the process has accomplished impressive
reduction of sulfur, vanadium, nickel, sodium.
and nitrogen oxides emissions. Economic studies
indicate that the process appears to have viable
commercial potential. The design of a larger,
demonstration scale project is now underway.
Combustion modification techniques are
being developed as control methods for nitrogen
oxides and other pollutants from existing and
new conventional stationary combustion
sources, and recent studies indicate that this
technological approach is the primary near-term
method of controlling NOX emissions from the
combustion of fossil fuels. CSL supported and
directed efforts have shown that promising
combustion modification techniques include
combustion with low excess air, staged combus-
tion, recirculation of flue gas in the fuel/air
mixture, and burner/combustor systems rede-
sign. The major emphasis to date has been on
combustion control for the electric utility in-
dustry since this industry ranks first among the
stationary sources as a contributor of NOX
emissions and a major user of fossil fuels.
Industrial, commercial and residential combus-
tion sources have also been subjects for signifi-
cant R&D because of their fuel usage and the
potential impact of area source emissions.
Field testing of state-of-the-art combustion
modification for residential and commercial
heating systems, industrial boilers, and utility
boilers is well advanced, and the results are the
basis for design and user manuals to inform and
guide manufacturers and operators in the appli-
cation of the technology. Pilot demonstrations
of staged combustion and other techniques for
coal-fired utility boilers (firing both Eastern and
Western coals) at field sites are underway.
Reports of these investigations will provide
practical operating information on the effects of
the control techniques on NOX and other
emissions and on unit performance. Similar
studies are planned and are being initiated for
other major combustion source categories in an
effort to provide maximum stationary source
technology for NOX control.
• POLLUTION CONTROL FOR METAL-
LURGICAL AND CHEMICAL
PROCESSES
Control Systems Laboratory is also develop-
ing, evaluating, and improving air pollution
control systems for metallurgical industries. Be-
cause of the different nature of each industry
and different technical and economic constraints
confronting it, programs to develop air pollution
control technology have been tailored to each
industry. The most significant advances to date
have been in the control of emissions from
coking operations. A full-scale demonstration by
CSL in the development of coke oven charging
control methods has led to the commercial
installation of smokeless coke charging systems
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by several coke producers. Other promising
demonstration programs in coke pushing and
quenching are nearing completion. Novel coke
oven door sealing techniques are now being
evaluated and will be tested on operating ovens
in the next fiscal year.
Another metallurgical process for which CSL
is developing control techniques is the charging
of basic oxygen furnaces. This development
program, being conducted on a 1 ton pilot
furnace, is concentrated on process modifica-
tions, including development of a prototype
emission collection system and a gas cleaning
system that will allow emissions to be collected.
Recirculation of sinter plant effluent gases is"
being studied as a means to control the large
quantities of particles, hydrocarbons, and other
gaseous emissions which are currently being
emitted from these plants. CSL co-sponsorship
has assisted in the development of a windbox gas
recirculation system which is being installed on a
commercial sinter plant. This process appears to
be a viable solution to the sinter plant emission
problem, with initial results indicating signifi-
cant reduction of both plant emissions and
system energy requirements.
Evaluation and/or developmental control
process work is also being conducted for the iron
foundry cupola, secondary aluminum smelters,
ferro-alloy furnaces, and primary copper, lead,
and zinc smelters.
The control of emissions from chemical and
petroleum processes is also being studied by
CSL. Steam stripping for the control of sulfur
oxides from petroleum catalytic cracker regener-
ators has been tested favorably in a laboratory
program. Available alternatives to control sulfur
emissions from refineries and determination of
the economic impact of various levels of control
on the petroleum industry are currently being
studied. Efforts to control atmospheric emis-
sions from nitric and sulfuric acid plants are
presently concentrated on treatment of tailgases
from these industries. Demonstration programs
are currently underway to evaluate the effi-
ciency of a promising process for cleanup of
these gases. Control of hydrocarbons is being
tested for solvent evaporation operations, ethyl-
ene dichloride manufacture, and other station-
ary sources.
• PARTICLE CONTROL
Much progress has been made in recent years
to control particulate matter emissions. Systems
currently used for particulate removal (i.e.,
scrubbers, electrostatic precipitators, and fabric
filter particle collectors) are receiving continued
development and improvement through research
conducted by Control Systems Laboratory. This
CSL program has led to the development of a
new class of scrubber systems. Called the Flux
Force/Condensation scrubber, this system is
currently being tested at the pilot scale demon-
stration stage. The control of fine particulate
(less than 3 microns) is receiving high priority
because these particles persist in the atmosphere,
comprise a variety of known toxic substances,
and are a major contributor to atmospheric haze
and visibility problems. Activities include evalua-
tion of dust conditioning techniques, modifica-
tion of charging sections and collecting elec-
trodes for electrostatic precipitators, and
evaluation of special operating techniques and
filter fabrics to extend the capability of bag-
houses. In addition, novel concepts of particu-
late collection are being evaluated for per-
formance and cost.
Nearly 70 contractors, grantees and consult-
ants are currently working with CSL to develop
particulate control technology as rapidly as
possible. A systems study of conventional elec-
trostatic precipitators (ESPs) has been published
in an ESP Handbook, and a systems study of
wet ESPs is scheduled for completion this year.
Other documents which have been prepared in
this area under CSL direction include a wet
scrubber handbook and a fabric filter handbook.
A handbook documenting a systems study of
wet scrubber entrainment separators is in
preparation.
• AUXILIARY PROGRAMS
CSL has efforts underway to acquire source
assessment data relating the characteristics of
hazardous, toxic and other pollutant emissions
to their probable impact on receptors in order to
define control technology development needs.
The sources include industrial and utility com-
bustion sources, non-combustion industrial
processes, and open-burning sources. A listing of
source priorities has been established and
sources have been selected for which initial
Source Assessment Documents are now being
developed. These documents will consider the
environmental impact of identified pollutants
and present information necessary to allow
decisions to be made by CSL personnel as to
control development needs for the source types
under consideration.
Evaluation and development of sampling and
analytical procedures supports assessment of
problem areas, evaluation of control technolo-
gies and the development of advanced control
technologies. CSL is involved in detailing cur-
rently available techniques and developing new
methods for sampling, measurement and analy-
sis. The overall program area is balanced be-
tween process stream measurement and analysis,
and specialized air pollution emission measure-
ments. Several handbooks have been completed
detailing manual methods for sampling and
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analyzing gaseous pollutants, reviewing instru-
mental methods for measuring gases, and review
methods for determination of particulate mass
and size. In the area of particle measurement
systems, a stack sampler which increases ac-
curacy, minimizes sampling time, and is espe-
cially applicable to gas streams with low grain
loadings was commercially packaged under con-
tract. Studies are being implemented to develop
an even higher volumetric rate sampler in sup-
port of the development of very high efficiency
control devices.
A significant auxiliary program within the
Laboratory is concerned with disseminating the
large volume of information generated by its
research, development and demonstration proj-
ects. For about 7 years, CSL has sponsored
symposia, conferences, briefings, etc. in key
areas such as flue gas desulfurization, clean fuels,
particulate control, and combustion modifica-
tion techniques for SOX control and for NOX
control. About 25 such information exchanges
have taken place and a number are planned
within the near future. CSL personnel publish
about 60 papers per year for presentation in
EPA sponsored and co-sponsored symposia,
technical and industrial association symposia,
and institutional symposia. In addition, as in-
dicated throughout this article, CSL RD&D has
led to the publication of numerous (nearly 90 in
1974) handbooks, manuals, and technical re-
ports which are available to potential users of
the technologies.
A report containing titles, etc. of contract,
grant, in-house (including symposia proceed-
ings), and interagency reports covering air pollu-
tion RD&D work sponsored by CSL and other
EPA organizations is prepared semi-annually and
includes instructions for obtaining the docu-
ments. Additionally, CSL prepares a monthly
report of abstracts representing CSL reports
which have been issued but not yet included in
the overall EPA report of air pollution technical
publications. These documents are made avail-
able to interested parties. CSL is currently
formulating a program to intensify efforts to
disseminate, to industry and regulatory agencies,
technical and economic information derived
from its RD&D programs in order to accelerate
commercial application of control technology.
Where to Get Further Information
In order to get details on items appearing in this publication, or any other aspects
of the Technology Transfer Program, contact your EPA Regional Technology
Transfer Committee Chairman from the list below:
REGION CHAIRMAN
Lester Sutton
Robert Olson
III Albert Montague
IV
Asa B. Foster, Jr.
Clifford Risley
ADDRESS
Environmental Protection Agency
John F. Kennedy Federal Building
Room 2304
Boston, Massachusetts 02203
617 223-2226
(Maine, N.H., Vt., Mass., R.I., Conn.)
Environmental Protection Agency
26 Federal Plaza
New York, New York 10017
212 264-1867
(N.Y.. N.J., P.R., V.I.)
Environmental Protection Agency
6th & Walnut Streets
Philadelphia, Pennsylvania 19106
215 597-9856
(Pa., W. Va., Md., Del., D.C., Va.)
Environmental Protection Agency
Suite 300
1421 Peach tree Street, N.E.
Atlanta, Georgia 30309
404 526-3454
(N.C., S.C., Ky., Tenn., Ga., Ala.,
Miss., Fla.)
Environmental Protection Agency
230 S. Dearborn St.
Chicago, Illinois 60604
312 353-8880
(Mich., Wis., Minn., III., Ind., Ohio)
REGION CHAIRMAN ADDRESS
VI Mildred Smith
VII John Coakley
VIII Russell Fitch
Environmental Protection Agency
1600 Patterson Street, Suite 1100
Dallas, Texas 75201
214 749-1885
(Texas, Okla., Ark., La., N. Mex.)
Environmental Protection Agency
1735 Baltimore Avenue
Kansas City, Missouri 64108
816 374-5971
(Kansas, Nebr., Iowa, Mo.)
Environmental Protection Agency
1860 Lincoln Street
Denver, Colorado 80203
303 837-3849—837-3691
(Colo., Mont., Wyo., Utah, N.D.,
S.D.)
IX William Bishop Environmental Protection Agency
100 California Street
San Francisco, Calif. 94111
415 556-4806
(Calif., Ariz., Nev., Hawaii)
X John Osborn Environmental Protection Agency
1200 6th Avenue
Seattle, Washington 98101
206442-1296
(Wash., Ore., Idaho, Alaska)
For the following audio-visual material, please contact your Regional Technology Transfer Chairman. (See above)
MOTION PICTURES (16mm sound)
• Richardson Texas Project—Title: "Somebody around here
must be doing something good." (15 min.)
• Phosphorus Removal (5 min.)
• Water Quality Management, Alameda Creek, Calif.—Title:
"The Water Plan." (28% min.)
• The Seattle METRO Story. (28 min.)
VIDEOTAPES
• Carbon Adsorption. (40 min.)
• Upgrading Activated Sludge Treatment Plants.
(40 min.)
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REQUEST FOR TECHNOLOGY TRANSFER MATERIAL
The publications listed on this form are the only ones available through the Office of Technology Transfer.
Please send me the following publications at no charge. (Check appropriate boxes)
PROCESS DESIGN MANUALS
d Phosphorus Removal 1001
D Carbon Adsorption 1002
D Suspended Solids Removal 1003
D Upgrading Existing Wastewater
Treatment Plants 1004
D Sulfide Control in Sanitary Sewerage Systems 1005
D Sludge Treatment and Disposal 1006
TECHNICAL CAPSULE REPORTS
D Recycling Zinc in Viscose Rayon Plants 2001
D Color Removal from Kraft Pulping
Effluent by Lime Addition 2002
D Pollution Abatement in a Copper Wire Mill 2003
D First Interim Report on EPA Alkali SO2
Scrubbing Test Facility 2004
D Dry Caustic Peeling of Peaches 2005
D Pollution Abatement in a Brewing Facility 2006
*D SO, Scrubbing and Sulfuric Acid
Production Via Magnesia Scrubbing 2007
*D Second Interim Report on EPA
Alkali Scrubbing Test Facility 2008
*D Magnesium Carbonate Process for
Water Treatment 2009
INDUSTRIAL SEMINAR PUBLICATIONS
D Upgrading Poultry Processing Facilities
to Reduce Pollution (3 Vols.) 3001
D Upgrading Metal Finishing Facilities
to Reduce Pollution (2 Vols.) 3002
D Upgrading Meat Packing Facilities
to Reduce Pollution (3 Vols.) 3003
O Upgrading Textile Operations
to Reduce Pollution (2 Vols.) 3004
MUNICIPAL SEMINAR PUBLICATIONS
CD Upgrading Lagoons 4001
D Physical-Chemical Treatment 4002
D Oxygen Activated Sludge 4003
D Nitrification/Denitrification 4004
D Upgrading Existing Wastewater Treatment
Facilities-Case Histories 4005
D Flow Equalization 4006
D Wastewater Filtration '. , . . .4007
D Physical-Chemical Nitrogen Removal 4008
BROCHURES
D Physical-Chemical Treatment 5001
D Phosphorus Removal 5002
D Upgrading Existing Wastewater
Treatment Plants 5003
D Carbon Adsorption 5004
D Oxygen Aeration 5005
D Nitrogen Control 5006
D Seattle, Washington METRO 5007
CD Wastewater Purification at Lake Tahoe 5008
CD Indian Creek Reservoir 5009
D Richardson, Texas 5010
HANDBOOKS
D Analytical Quality Control in Water
and Wastewater Laboratories 6001
D Monitoring Industrial Wastewater 6002
CD Methods for Chemical Analysis of Water
and Wastes 6003
'Publication listed for first time
If you are not currently on the mailing list for this Technology Transfer Newsletter, do you want to be added?
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Note: Tear this sheet out and forward to Technology Transfer, U. S. Environmental Protection Agency, Washington, D.C. 20460
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