Survey of Flue Gas Desulfurization Systems: Eddystone Station, Philadelphia Electric Co.

EPA-650/2-75-057-f
September 1975 Environmental Protection Technology Series
ULFURIZ
nur
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EPA-650/2-75-057-f
SURVEY
OF FLUE GAS
DESULFURIZATION SYSTEMS
EDDYSTONi STATION, PHILADELPHIA ELECTRIC CO.
by

Gerald A. Isaacs

PEDCo-Environmenlal Specialists, Inc.
Suite 13
Atkinson Square
Cincinnati, Ohio 45246
Contract No 68-02-1321 . Task 6f
ROAP No. 21ACX-130
Program Element No. 1AB013
EPA Project Officer: Norman Kaplan

Industrial Environmental Research Laboratory
Office of Energy , Minerals, and Industry
Research Triangle Park, North Carolina 27711
Prepared for

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

September 1975
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EPA REVIEW NOTICE

This report has been reviewed by the U.S. Environmental Protection
Agency and approved for publication. Approval does not signify that
the contents necessarily reflect the views and policies of the Environ-
mental Protection Agency, nor does mention of trade names or commer-
cial products constitute endorsement or recommendation for use.
RESEARCH REPORTING SERIES

Research reports of the Office of Research and Development, U.S. Environ-
mental Protection Agency, have been grouped into series. These broad
categories were established to facilitate further development and applica-
tion of environmental technology. Elimination of traditional grouping was
consciously planned to foster technology transfer and maximum interface
in related fields. These 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

9. MISCELLANEOUS

This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to
develop and demonstrate instrumentation, equipment and methodology
to repair or prevent environmental degradation from point and non-
point sources of pollution. This work provides the new or improved
technology required for the control and treatment of pollution sources
to meet environmental quality standards.
This document is available to the public for sale through the National
Technical Information Service, Springfield, Virginia 22161.
Publication No. EPA-650/2-75~057-f
11
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ACKNOWLEDGMENT

This report was prepared under the direction of Mr.

Timothy W. Devitt. The principal author was Dr. Gerald A.

Isaacs. Mr. Charles D. Fleming was responsible for editorial

review and preparation of graphic materials.

Mr. Wade H. Ponder, former EPA Project Officer, had

primary responsibility within EPA for this project report.

Information and data on the plant operation were supplied by

Mr. George Kotnick, Philadelphia Electric Company, and by

Dr. J. T. Pinkston, United Engineers and Constructors, Inc.,

during and subsequent to the plant survey visit.

The author appreciates the efforts and cooperation of

everyone who participated in the preparation of this report.
111
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TABLE OF CONTENTS

Page

ACKNOWLEDGMENT ill

LIST OF FIGURES vi

LIST OF TABLES vi

SUMMARY vii

1.0 INTRODUCTION 1-1

2.0 FACILITY DESCRIPTION 2-1

2.1 Plant Location 2-1

2.2 Boiler Data 2-1

2.3 Pollution Controls 2-1

3.0 FLUE GAS DESULFURIZATION SYSTEM 3-1

3.1 Process Description 3-1

3.2 Design Parameters 3-3

3.3 Installation Schedule 3-5

3.4 Cost Data 3-5

APPENDIX A PLANT SURVEY FORM A-l

APPENDIX B PLANT PHOTOGRAPHS B-l
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LIST OF FIGURES
Figure Page

3.1 General Flow Diagram of the FGD System 3-2
on Eddystone No. 1 - PECO
LIST OF TABLES

Tables

2.1 Pertinent Data on Plant Design, Operation
and Atmospheric Emissions
VI
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SUMMARY

The magnesium oxide based flue gas desulfurization

(FGD) system on Boiler No. 1 at the Eddystone Station of

Philadelphia Electric Company (PECO) was designed and installed

by United Engineers and Constructors, Inc. The system

consists of three first-stage scrubber modules in parallel

for particulate control (two are Environeering Ventri-Rod

Units; one is a Peabody-Lurgi Venturi Unit) and a second-

stage Environeering absorber module with two ventri-rod beds

for SO~ removal.

The three first-stage scrubbers together are sized to

handle all the exhaust gas from Unit 1 which has a net

electric generating capacity of 316 MW. The second-stage

absorber is sized to handle one-third of the gas flow,

equivalent to about 105 MW (net). The system is designed to

remove 90 percent of the SO2 from boiler stack gas.

As of April 1, 1975 the second-stage module had not yet

been operated. This report therefore necessarily emphasizes

design parameters rather than operating parameters and

experience.

Pertinent data on the facility and the FGD system are

presented in the following table.
via.
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SUMMARY OF FGD DATA, GENERATING UNIT NO. 1

EDDYSTONE STATION
Generator rating, MW (net)

Fuel:

Gross heating value, BTU/lb

Ash, percent

Sulfur, percent

FGD vendor:

Process :

New or retrofit:

Start-up date:

FGD modules:

Efficiency, percent overall:

Particulates

so2

Make-up water, gpm/MW

Unit cost: $/KW (net)
308*

Coal

12,100

2.3

United Engineers

Magnesium oxide scrubbing

Retrofit

1975

1 (105 MW)

99.9

1.1

193b
316 MW net rating minus 8 MW auxiliary power for this
FGD System.

This cost is not representative since it includes the installed
cost of three first-stage particulate scrubbers to handle the
exhaust gases from the complete 308 MW unit. The FGD module
size of 105 MW is the basis for this calculation.
Vlll
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1.0 INTRODUCTION

The Industrial Environmental Research Laboratory

(formerly Control Systems Laboratory) of the U.S. Environ-

mental Protection Agency (EPA) has initiated a study to

evaluate the performance characteristics and degree of

reliability of flue gas desulfurization (FGD) systems on

coal-fired utility boilers in the United States. This

report on the Eddystone Station of Philadelphia Electric

Company (PECO) is one of a series of reports on such systems.

It presents values of key process design and operating

parameters and describes the major system problems encoun-

tered at the facility. The report also discusses the mea-

sures taken to alleviate such problems and identifies avail-

able capital and operating costs.

This report is based upon information obtained during a

plant inspection on February 11, 1975, and on subsequent

data provided by PECO and United Engineers and Constructors,

Inc. (UE) personnel.

Section 2.0 presents pertinent data on facility design

and operation, including actual and allowable particulate

and SO- emission rates. Section 3.0 describes the flue gas

desulfurization system. Appendices present details of plant

and system operation and photos of the installation.
1-1
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2.0 FACILITY DESCRIPTION

2.1 PLANT LOCATION

The Eddystone Station of PECO is located on the

Delaware River in Eddystone, Pennsylvania, about 11 miles

southwest of the center of Philadelphia. The plant is about

five miles west of one of the main runways of Philadelphia

International Airport.

2.2 BOILER DATA

The station has four generators with a total net capacity

of 1370 MW. Units 1 and 2 burn coal with an average gross

heating value of 12,100 BTU/lb and ash and sulfur contents

of 12 percent and 2.3 percent, respectively. Steam con-

ditions are 5000 psi and 1150°F. These are the highest

utility plant operating pressure and temperature condi-

tions in the United States. Units 1 and 2, base-load units,

operated at 68 percent capacity in 1974. Units 3 and 4,

peak-load generators, burn No. 6 oil.

2.3 POLLUTION CONTROLS

At the present time an FGD system has been installed

to handle about one-third of the exhaust gas from Unit 1. The
2-1
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unit will have an estimated net generating capacity of about

308 MW with the three particulate scrubbers and the S02

absorber operating.

There are two furnaces on the Unit 1 boiler. Each

furnace was installed with particulate controls consisting

of mechanical collectors and an electrostatic precipitator.

The wet particulate and SO- system, designed and installed

by UE, consists of three, first-stage water scrubbers for

particulate control and a single, 105 MW second-stage

magnesium oxide absorber for SO2 removal. The particulate

scrubber system was started up for initial shakedown purposes

in February 1975. Table 2.1 gives pertinent data on plant

design parameters.
2-2
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Table 2.1 PERTINENT DATA ON PLANT DESIGN,

OPERATION AND ATMOSPHERIC EMISSIONS
Boiler data - Eddystone No. 1 - PECO

Maximum generating capacity, MW (net)

Average capacity factor (1974) , %

Boiler manufacturer

Year placed in service

Unit heat rate, BTU/KWH

Maximum coal consumption, ton/hr

Maximum heat input, MM BTU/hr

Stack height above grade, ft

Flue gas rate - maximum, acfm

Flue gas temperature, °F

Emission controls:

Particulate
Particulate emission rates:

Allowable, Ib/MM BTU

Design, Ib/MM BTU

S02 emission rates:

Allowable, Ib/MM BTU

Design, Ib/MM BTU
308°

C-E Sulzer

1959

9455

120

2912

249

927,000

294
Mechanical and ESP
and ventri-rod scrubber

Ventri-rod magnesium
oxide absorber on
one-third of the gas
flow
0.1

0.04

0.6

0.3
Existing particulate scrubbers and FGD absorber in operation.
2-3
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3.0 FLUE GAS DESULFURIZATION SYSTEM

3.1 PROCESS DESCRIPTION3

Figure 3.1 is a schematic flow diagram for this magnesium

oxide scrubbing system installed to handle approximately

one-third (309,000 acfm at 294°F) of the exhaust gas from

Unit 1. The maximum continuous net generating capacity for

the unit was 316 MW before the scrubbing system was installed.

The particulate scrubbers and the SO- absorber consume about

8 MW to derate the unit to about 308 MW. If additional

second-stage SO- absorber capacity is installed on the rest

of the unit it will derate the unit by an additional 2 MW.

Two of the three first-stage particulate scrubbers were

manufactured by Environeering, Inc., and are ventri-rod

units. The third unit is a Peabody-Lurgi venturi scrubber.

A portion of the particulate scrubber liquid circulating

stream is diverted to on-site ash ponds. Make-up water from

the river is pumped into the surge tanks for the three

particulate scrubbers at the rate of 351 gpm (total).

Exhaust gas is drawn from the two boiler furnaces by

four induced-draft fans. It then passes through the particulate
a Adapted from "Design and Installation of a Prototype Magnesia
Scrubbing Installation", B. M. Anz et al, United Engineers
and Constructors Inc., May 15, 1973, and supplemented with data
from field visit.

3-1
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\
\
_ J
2S4°F
rw.c.
/
\
-
^ s
! L

\ \
ISTACKJEjaSTjNG^
TANKSCRUMER MISJ
14 \ / ELIMINATORS TRAIN
-TOWASTEWATER
M|0 PNEUMATIC TRANSFER SYSTEM
MfO MAKE UP PUMP
PARTICULATE SCRUBBER
CIRC WATER PUMP
STKEA" NO.
DRY GAS ID/mm.
H20 VAPOR Ib/min.
S02 Ib/min.
HjO LIQUID Ib/min.
ASH Ib/min.
MgO Ib/min.
MgS03 Ib/min.
HgSOj-oHjO Ib/min.
AIR Ib/min.
FUEL OIL Ib/min.
HgSOj Ib/min.
M9(HS03].* Ib/min.
Ib/min.
Ib/min.
TOTAL Ib/min.
9P«F OR acfm
SPECIFIC GRAVITY OR
MOLECULAR WEIGHT
DESIGN FLOW OS or 355MW!
MAX. FLOW acfm
1
15,560
947
55.3

3.33

16.565.6
309,000
39.4
321,000
345,000
2
15.560
1,657
55.3

0.67

17,273
268,000
28.7
280,000
301.000
3
15,560
1,620
5.5

0.67

17,186
276,000
20.7
287,000
311,000
4
23.119
1,255
83

24,462
475.000
29.4
492,000
535.000
5
16,162
1.658
5.5

0.67

17,826
339.000
28.7
351 .000
330,000
6

2,922

2,922
351
1.0

186

186
22.3
1.0

974

974
117
1.0

9
24,243
2.421
8.25

26.733
468,000
28.7
487.000
530.000
10

10.811
109

10,920
1.300
1.01

1.600
11

,93.9

93.9

122

2>,2

31 3
6*

41-
3. :•

35. li
1.25
46.5

' i

512. C
14

264
2.66

66.67
32
1.01

00
15

3,476

72.2-
131.2

613*
47.4*

4,339.8
445
1.17

16
I

351,000
•OISSOLVEO SOLIDS.
BASIS: AVERAGE CONDITION OF 2.3'. S COAL.
Figure 3.1. General flow diagram of the FGD system
on Eddystone No. 1 - PECO.
3-2
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I 1J7°F
«H
•\
w.c.
\
1
>

3 t.WW.C. «* f

^
(

-j I
1.0. FANS
(?) EXISTING
]
217 F .
HjSOj SLURRY
TRANSFER PUMP
MOTHER LIQUOR
PUMP
WASTEWATEfl \ /
TREATMENT SYSTEM ~ " TO Mad
FOHSUIFATE AND -—REGENERATION
MISC. ION REMOVAL
If REQUIRED
MAX. 24 gpm
!7

100.800

2, HO*
11,200

18, 100*
1,400'

133,340
13,384
1.20

1,156

25-
195.3

210-
16'

1,902.3
179
1.28
232

1,486

3^*
165.1

270*
21-

1,974.1
197
1.20
256

0.54*
247.6

4.55*
0.35*

278

256

845

17.5*

147*
11.4*

1,021
106
1.16
133

'•>

3,749

77.5*

653*
50.6*

4,530
469
1.16
612

3,302

71*

600*
47*

4 .ore
415
1.16
540

1,897

39.5*
71.8

335*
25.9*

2.369.2
243
1.17

553

12*

100*
7.6*

672.6
70
1.16
90

4,594

95*

800*
62*

5,551
575
1.16
750

122

4.55

126.55

14.85

14.85
1.96
0.91
2.55

2.7

206

208./
2,730
29
3,550

30
1.105
59
4

!,!63
21,500
29.5
28,000

31
1,505
388
4

1,897
47,000
b26.6
11.000

32 33 34

7.85

! 4,726

! , OR*
1 '
503
29.0 ;
! 830.5*
64.3*

29.0 610.85 5, ',50
3.82 I 3.000 600
0.91 29 . 1.17

\
Figure 3.1 (continued). General flow diagram of the
FGD system on Eddystone No. 1 - PECO.
3-3
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scrubber and through the S02 absorber. From there it is

reheated and drawn through a booster fan before it is discharged

through the stack. Dampers in the system permit gas to

bypass the SO2 absorber or any of the particulate scrubbers.

The second-stage SO2 absorber was designed by Enviro-

neering, Inc. The ventri-rod unit contains two absorber

sections in series, each consisting of an adjustable set of

cylindrical rods that are sprayed underneath with magnesium

sulfite slurry. A louvered, continuous-waterwash demister

is installed at the scrubber exit. Slurry flows through the

unit and into an agitated absorber surge tank. Slurry make-

up is also added to this tank from an MgO slaking tank. The

slurry is recirculated to the scrubber from the surge tank.

A portion of the recirculating slurry is bled from the

scrubber circulation pump discharge to the thickener.

Thickener underflow is pumped to a centrifuge. Solid MgSO_

from the centrifuge is then dried in a direct-fired, cocur-

rent rotary dryer.

Thickener tank overflow and mother liquor from the

centrifuge flow into a mother liquor tank. The liquid is

then pumped back to the MgO slaking tank and a mist elimin-

ator spray tank. A portion of the liquid stream can be bled

into the wastewater treatment system, so that the possible

buildup of iron or other impurities can be purged. Make-up

water is added to the first stage demister system from the

mother liquor tank.
3-4
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3.2 DESIGN PARAMETERS

Each of the three particulate scrubbers is designed to

cool 309,000 acfm of exhaust gas from 294°F to 127°F and

to remove about 150 pounds of ash per hour from the exhaust

gas stream. The design water recirculation rate through

each particulate scrubber is 1300 gpm. The liquid-to-gas

ratio (L/G) through each scrubber is therefore calculated to

be about 5.4 gallons of water per 1000 actual cubic feet of

air at 127°F. Approximately 32 gpm are bled from the recir-

culation pump discharge to the wastewater treatment system.

The particulate scrubber recirculation stream carries about

one percent solids by weight. River water make-up to each

scrubber, about- 117 gallons per minute, is supplied to the

scrubber surge tank.

The SO2 absorber is designed to receive 268,000 acfm of

essentially particulate-free exhaust gas at 127°F. Design

pressure drop through the absorber is 12 inches of H20.

Evaporative heat transfer through the scrubber is negligible.

Slurry is circulated from the SO2 scrubber surge tank at

13,400 gpm. L/G is 50 gallons per 1000 actual cubic feet of

gas at 127°F for this stage. The design SO2 removal efficiency

for the absorber is 90 percent. It is reported that magnesium

sulfite is precipitated in the absorber surge tank per the

following equations:

Mg(HS03)2 + Mg(OH)2 + 10 H20 *• 2

Mg(HS03)2 + Mg(OH)2 + 4 H2
-------
Slurry pH is controlled at 6 by regulating the rate of

addition of slaked Mg(OH)_ slurry. The scrubber surge tank

with a capacity of 60,000 gallons, provides a slurry residence

time of about four minutes in order to minimize plugging

problems in the recirculating pipes and scrubber.

The thickener receives 197 gpm of slurry recirculation

bleed. With an approximate capacity of 120,000 gallons,

residence time is close to ten hours. Underflow from the

thickener contains about 25 percent solids (MgSO •6 H_O and

MgS03-3 H2O).

Wet solids from the stainless steel, solid bowl centri-

fuge are conveyed directly into a rotary-kiln, oil-fired,

direct-heat, concurrent-flow dryer. MgSO^ crystals are

conveyed from the dryer to storage silos.

The MgSO3 will be trucked to a sulfuric acid plant

about twenty miles away. There it will be decomposed in an

oil-fired, fluidized-bed reactor to form MgO and SO2. The

SO- will be converted to sulfuric acid, and the regenerated

MgO will be trucked back to the Eddystone Station.

3.3 INSTALLATION SCHEDULE

On-site construction for this plant began in April

1972. Construction was essentially completed in late 1974,

and the particulate scrubber was started up in December of

that year. As of June 1, 1975 the S0_ absorber had not been

put on line, mainly because of corrosion problems encountered

in the particulate system. These problems are now being
3-6
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ameliorated by neutralization, increased blowdown of scrubber

fluid and start-up procedure revisions. Defective polyurethane-

coated tanks will be repaired before operation of the SO~

system will be attempted.

3.4 COST DATA

The particulate and FGD system, consisting of three

first-stage particulate scrubbers and one second-stage SO2

absorber, was installed at a total cost of $20,273,000 or

$193/KW (net). About two-thirds of this amount is for the

particulate scrubbers and the S02 absorption and recovery

equipment with the remaining one-third for site improvements,

land, access roads, engineering and contractor's fees and

interest on capital during construction. The figure does

not include magnesium oxide regenerating facilities. A

considerably lower figure would be realized if the costs for

two-thirds of the 308 MW particulate scrubbing system were

separated out. Since the FGD system has not yet been operated,

actual operating costs cannot be reported at the present

time.
3-7
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APPENDIX A

PLANT SURVEY FORM
A-l
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Revision date 6/10/74
PLANT SURVEY FORM3

RFGEHERABLE FGD PROCESSES

A. COMPANY AMU PLANT INFORMATION

1. COMPANY NAME Philadelphia Electric Company

2. MAIN OFFICE 2301 Market Street. Phila.. Pa. 19101

3 . PLANT SUPERINTENDENT Henry J. Wylie. Jr.
4 . PLANT NAME Eddystone Station
5 . PLANT LOCATION //I Industrial Highway, Chester. Pa. 19013

6. PERSON '10 CONTACT FOR FURTHER INFORMATION George Kotnick

7 . POS ITI ON Supervising Engineer

8. TELEPHONE NUMBER 215/841-4540

9. DATE INFORMATION GATHERED February 11, 1975
Supplemented - February 28, 1975, March 18, 1975
10. PARTICIPANTS IN MEETING AFFILIATION

Wade H. Ponder EPA - Research Triangle Park

John Busik EPA - Washington. D. C.

Gerald A. Isaacs PEDCo
Larry Yerino PEDCo
Bertrand M. Anz United Engineers & Const., Inc.
Henry F. Scheck Philadelphia Electric Co.
Matthew M. Troyan Philadelphia Electric Co.
James A. Gille Philadelphia Electric Co.
a These data were obtained on February 11, 1975. Some of the
data have been updated in the text of the report.

A-2
5/17/74
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B. PLANT DATA. (APPLIES TO ALL BOILERS AT THE PLANT).
CAPACITY, MW (net)
SERVICE (BASE, PE7.:.;
FGD SYSTEM USED
BOILER NO.
1
316
base
MgO
2
334
base
none
3
360
peak
none
4
360
under
:onstructi
none

C. BOILER DATA. COMPLETE SECTIONS (C) THROUGH (R) FOR EACH
1.
2.
3.
4.
5.
6.
7 .
8.
9 .
10.
11.
*
BOILER HAVING AN FGD SYSTEM.
BOILER IDENTIFICATION NO. 1
MAXIMUM CONTINUOUS HEAT INPUT 2912
MAXIMUM CONTINUOUS GENERATING CAPACITY

MM BTU/HR
316 MW (net)
MAXIMUM CONTINUOUS FLUE GAS RATE. 927,000 ACFM @ 294 °F
BOILER MANUFACTURER Combustion
YEAR BOILER PLACED IN SERVICE 1959
BOILER SERVICE (BASE LOAD, PEAK, ETC.)
STACK HEIGHT
BOILER OPERATION HOURS/YEAR (197 )
BOILER CAPACITY FACTOR *
RATIO OF FLY ASH/BOTTOM ASH
DEFINED AS: Kw" GENERATED IN YEAR 1>8?2
Engineer ing-Sulzer

base load
249 ft.
6549 hours
67.65%
80/20
.648 (net)
MAX. CONT. GENERATED CAPACITY IN KW x 8760 HR/YR
316 MW (net)
A-3
5/17/74
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D. FUEL DATA

1. COAL ANALYSIS (as received)

GUV (BTU/LD.)

S %

ASH %
MAX .
12,490
3.49
21.54
MIN.
Ilr444
1.14
7.79
AVG.
12.131
2.34
11.83
2. FUEL OIL ANALYSIS (exclude start-up fuel) (not applicable)

GRADE

S %

ASH %
E. ATMOSPHERIC EMISSIONS

1. APPLICABLE EMISSION REGULATIONS

a) CURRENT REQUIREMENTS
Metro Phila. Ill 6/8/73 FR
AQCR PRIORITY CLASSIFICATION

REGULATION & SECTION NO.Pa.DER

MAX. ALLOWABLE EMISSIONS
LDS/MM BTU

b) FUTURE REQUIREMENTS,
COMPLIANCE DATE

REGULATION & SECTION NO.

MAXIMUM ALLOWABLE EMISSIONS
LBS/MM BTU
PARTICULATES
—
Ill
Title 25 Part 1
Chapt. 123.11
0.1
so2
—
Ill
Article II
Chapf. 123
0.6
PLANT PROGRAM FOR PARTICULATES COMPLIANCE
Program is presented in consent orders signed with EPA and PER
3. PLANT PROGRAM FOR S02 COMPLIANCE
Program is prepared in consent orders signed with EPA and DER

on September 25, 1974.
A-4
5/17/74
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F. PARTICULATE REMOVAL
TYPE

MANUFACTURER

EFFICIENCY: DESIGN/ACTUAL

MAX. EMISSION RATE* LB/I1R

GR/SCF

LB/MMBTU
MECH.
American
Standard
72/70
7500

E.S.P.
Western
Precipitatior
95/92
600

FGD
1 - Peabody
1 - Environeering
90/not avail.
60

DESIGN BASIS, SULFUR CONTENT
2.:
by wt.
G. DESULFURIZATION SYSTEM DATA

1. PROCESS NAME

2. LICENSOR/DESIGNER NAME:

ADDRESS:

PERSON TO CONTACT:

TELEPHONE NO.:
Magnesium Base Wet Scrubbing

United Engineers & Constructors, Inc.

1401 Arch Street

J. T. Pinkston

215/422-4812
3. ARCHITECTURAL/ENGINEERS, NAME: United Engineers & Constructors, Inc.

ADDRESS: 1^01 Arch Street, Phila. 19105

PERSON TO CONTACT: J. T. Pinkston

TELEPHONE NO.: 215/422-4812

DATE
PROJECT CONSTRUCTION SCHEDULE:

a) DATE OF PREPARATION OF BIDS SPECS.

b) DATE OF REQUEST FOR BIDS

C) DATE OF CONTRACT AWARD

d) DATE ON SITE CONSTRUCTION BEGAN

e) DATE ON SITE CONSTRUCTION COMPLETED

f) DATE OF INITIAL STARTUP

q) DATE OF COMPLETION OF SHAKEDOWN Not Available
Not Applicable

Not Applicable

4/72

11/74

12/74
*At Max. Continuous Capacity

A-5
5/17/74
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5. LIST MAJOR DELAYS IN CONSTRUCTION SCHEDULE AND CAUSES:
6.

8.
NUMBER OF SO2 SCRUBBER TRAINS USED

DESIGN THROUGHPUT PER TRAIN, ACFM @ 127°F
Three
300.OOP
DRAWINGS: 1) PROCESS FLOW DIAGRAM AND MATERIAL BALANCE

2) EQUIPMENT LAYOUT
H.
SO2 SCRUBBING AGENT
1,

3
TYPE

SOURCES OF SUPPLY
Magnesium Oxide
Basic Chemical,
Martin Marietta Chemicals
CHEMICAL COMPOSITION (for each source) 97.5% MgO
4. EXCESS SCRUBBING AGENT USED ABOVE
STOICHIOMETRIC REQUIREMENTS

5. MAKE-UP WATER POINT OF ADDITION

6. MAKE-UP ALKALI POINT OF ADDITION
None
Mother Liquor Tank
Scrubber Surge Tanks
A-6
5/17/74
-------
QIHNCH
FIVE OS FROM BOILER
TO OISPOSII SHE

R*™ Ib/min
ACFM
CPM
PARTICULATES Ib/hr
so3. Ib/min
H2S. Ib/hr
SULFUR Ib/min
SULFATES Ib/min
TEMPERATURE of
~uT~1
16,600
309.000

CO
2.922

351
1
r~sr~i
265

165 2.66

(

294 80

127
rcn ft

268. OOC

127

268 r 000

127
ft

276,000

127
CO

CO
133.890

13.384

N.A.
127
IV)

~E)
133.840

13,384

N.A.
127
Q2)

^3)
131.916

n,iR7

dO
1974

1Q7

N.A.
127

RATE Ib/hr
SCFM
CPM
PARTICULATES. Ib/hr
SOz, Ib/hr
H2S. Ib/hr
SULFUR. Ib/hr
SULFATES. Ib/hr
TEMPERATURE. °F
00

fcfl
1788

214

127
(10

(J8)

C'o)

(70

C«3

C"J
T1 .3

100
C't)
85

400
C«3

C26)

C")

(28J

Rftoresentati^e flow rates basec11 on ooe^atir.a data at maxi-num continuous * oad
-------
J . SCRUBBER TRAIN SPECIFICATIONS
1. SCRUBBER NO. 1

TYPE (TOWER/VENTURI) Ventri-Rod

LIQUID/GAS RATIO, G/MCF @ °F _ 4^5 _
GAS VELOCITY THROUGH SCRUBBER, FT/SEC Not Applicable

MATERIAL OF CONSTRUCTION 316L S/S

TYPE OF LINING

INTERNALS:

TYPE (FLOATING BED, MARBLE BED, ETC.) Adjustable ventri-rod

NUMBER OF STAGES One

TYPE AND SIZE OF PACKING MATERIAL Not Applicable

PACKING THICKNESS PER STAGE(b)

MATERIAL OF CONSTRUCTION, PACKING: Not Applicable

SUPPORTS: Not Applicable

SCRUBBER NO. 2 (a)

TYPE (TOWER/VENTURI) Ventri-Rod

LIQUID/GAS RATIO, G/MCF @ °F 40-50
GAS VELOCITY THROUGH SCRUBBER, FT/SEC Not Applicable

MATERIAL OF CONSTRUCTION Lined Carbon Steel

TYPE OF LINING Polyurethane

INTERNALS:

TYPE (FLOATING BED, MARBLE BED, ETC.) Adjustable Ventri-rod

NUMBER OF STAGES Two

TYPE AND SIZE OF PACKING MATERIAL Not Applicable

a) Scrubber No. J is the scrubber that the flue gases first
enter. Scrubber 2 (if applicable) follows Scrubber No. 1.
b) For floating bed, packing thickness at rest.

A-8 5/17/74
-------
PACKING THICKNESS PER STAGED Not Applicable

MATERIAL OF CONSTRUCTION, PACKING: Not Applicable

SUPPORTS: Not Applicable

CLEAR WATER TRAY (AT TOP OF SCRUBBER)

TYPE Not Applicable

L/G RATIO Not Applicable

SOURCE OF WATER
Not Applicable
DEMJSTCK

TYPE (CHEVRON, ETC.)

NUMBER OF PASSES (STAGES)

SPACE BETWEEN VANES

ANGLE OF VANES

TOTAL DEPTH OF DEMISTER

DIAMLTER OF DEMISTER

DISTANCE BETWEEN TOP OF PACKING
AND BOTTOM OF DEMISTER

POSITION (HORIZONTAL, VERTICAL)

MATERIAL OF CONSTRUCTION

METHOD OF CLEANING

SOURCE OF WATER AND PRESSURE

FLOW RATE DURING CLEANINGS, GPM

FREQUENCY AND DURATION OF CLEANI.,

REMARKS
Chevron
Two
Proprietary Vendor
Information
Proprietary Vendor
Information
Proprietary Vendor
Information
Proprietary Vendor
Information

Proprietary Vendor
Information

Vertical

FRP

Clean liquor and water sprays

River. 50 PSIG
1st stage - 600 GPM Liquor
2nd stage - 400 GPM Water
1st stage - Continuous
G 2nd stage - As Required
5. REilEATER

TYPE (DJRL1CT, INDIRECT)
Direct
b) For floating bed, packing thickness at rest.
A-9
5/17/74
-------
DUTY, MMBTU/HR 40 MM BTU/hr. Max.

HEAT TRANSFER SURFACE AREA SO. FT Not Applicable

TEMPERATURE OF GAS: IN 127°F QUT 230°F Max.

HEATING MEDIUM SOURCE Fuel oil
TEMPERATURE & PRESSURE 200°F & 75 PSIG

FLOW RATE 180° LB/HR

REIIEATER TUBES, TYPE AND
MATERIAL OF CONSTRUCTION Not Applicable

REIIEATER LOCATION WITH RESPECT TO DEMISTER
75* downstream of S02 Scrubber Demister
40' downstream of Particulate Scrubber Demister

METHOD OF CLEANING Not Applicable
FREQUENCY AND DURATION OF CLEANING Not Applicable

FLOW RATE OF CLEANING MEDIUM Not Applicable LB/IIR

REMARKS
SCRUBBER TRAIN PRESSURE DROP DATA INCHES OF WATER

PARTICULATE SCRUBBER 12" - 17" W.C.

S02 SCRUBBER 12" W.C.

CLEAR WATER TRAY Not Applicable

DEMISTER i" w-c-

REIIEATER None

DUCTWORK *-2" w-c-
TOTAL FGD SYSTEM 29.2 - 34.2" W.C.
A-10 5/17/74
-------
7 .
8.
FRESH WATER MAKE UP FLOW RATES AND POINTS OF ADDITION

TO: DEMISTER Water added separated from SO System

QUENCH CHAMBER Not Applicable
ALKALI SLDRRYING Not Applicable

PUMP SEALS 25 - 30 GPM
OTHER Water input based on liquor inventory control
TOTAL Not Available

FRESH WATER ADDED PER MOLE OF SULFUR REMOVED

BYPASS SYSTEM

CAN FLUE GAS BE BYPASSED AROUND FGD SYSTEMS Yes
Available
GAS LEAKAGE THROUGH BYPASS VALVE, ACFM Essentially Zero
K. TANK DATA
ALKALI SLURRY MAKEUP TANK

PARTICULATE SCRUBBER EFFLUENT
HOLD TANK (a)

S02 SCRUBBER EFFLUENT HOLD
TANK (a)
PH
10
1-3
6-7
%
Solids
-S-.1Q-.
1
8-10
Capacity
(gal)
12rOOO
4,000
60,000
Hold up
time
5 Hrs.
Phase
2.5 Min.
4 Min.
L. S0? RECOVERY
NAMF OF PROCESS

LICENSOR/DESIGNER

SYSTEM'S CAPACITY

RAW MATERIAL REQUIRED
MgSO- Roasting
Copeland Systems, Inc.
3.5 Solids
Not Applicable
. T/HR
A-ll
5/17/74
-------
M. DISPOSAL OF CONTAMINANTS

PURGE STREAM, gpm

AMOUNT OF CONTAMINANTS IN STREAM

DESCRIBE METHOD OF CONCENTRATION
AND DISPOSAL OF CONTAMINANTS
Not Available
Not Available
Not Available
N. COST DATA

1. TOTAL INSTALLED CAPITAL COST

2. ANNUALIZED OPERATING COST
$20.273.000
Not Available
A-12
-------
3.
COST BREAKDOWN
COST ELEMENTS
INCLUDED IN
ABOVE COST
ESTIMATE "
ESTIMATED AMOUNT
OR % OF TOTAL
INSTALLED CAPITAL
COST
YES
A. CAPITAL COSTS

SO- ABSORPTION/DESORPTION
SYSTEM

SOj RECOVERY SYSTEM IN-
CLUDING HnS GENERATOR
2
GAS QUENCHING &
CLEANING

SITE IMPROVEMENTS

LAND, ROADS, TRACKS,
SUBSTATION

ENGINEERING COSTS

CONTRACTORS FEE

INTEREST ON CAPITAL
DURING CONSTRUCTION

B. ANNUALIZED OPERATING COST
CZI
FIXED COSTS

INTEREST ON CAPITAL

DEPRECIATION

INSURANCE & TAXES

LABOR COST
INCLUDING OVERHEAD

VARIABLE COSTS

RAW MATERIAL

UTILITIES

MAINTENANCE
n
o
n
NO
a
a
a a
a a
a
n
a
a
a
r.i
50%
10%
12%
10%
Not for Publication
Not for Publication
Not for Publication
Not for Publication
Not Available
Not Available

Not Available
A-13
5/17/74
-------
4. COST FACTORS

a. ELECTRICITY Not for Publication

b. WATER Not Available
c. STEAM (OR FUEL FOR REHEATING) Not Available
Not for
d. SULFUR/SULFURIC ACID SELLING COST Publication S/TON
Not for
e. RAW MATERIAL PURCHASING COST Publication/TON OF DRY SLUDGE
Not for Not for Publi-
f. LABOR: SUPERVISOR PnhlicatlonHOURS/WEEK cation WAGE
Not for
OPERATOR Publication
Not for
OPERATOR HELPER Publication
Not for
MAINTENANCE Publication

O. MAJOR PROBLEM AREAS: (CORROSION, PLUGGING, ETC.)

1. S02 SCRUBBER, CIRCULATION TANK AND PUMPS.

a. PROBLEM/SOLUTION Not available at this time.
2. DEMISTER

PROBLEM/SOLUTION Not available at this.time.
3. REHEATER

PROBLEM/SOLUTION Not available at this time.
5/17/74
A-14
-------
4. VENTURT SCRUBBER, CIRCULATION TANKS AND PUMPS

PROBLEM/SOLUTION Not applicable .
5. I.D. BOOSTER FAN AND DUCT WORK

PROBLEM/SOLUTION Not available at this time.
6. SO2 RECOVERY AND CONVERSION

PROBLEM/SOLUTION Not available at this time.
7. GAS QUENCHING AND CLEANING

PROBLEM/SOLUTION Nat^aii.aileikle_aJL_this. time. ...
5/17/74
A-15
-------
8. MISCELLANEOUS AREA INCLUDING BYPASS AND
PURGE STREAM SYSTEM

PROBLEM/SOLUTION Nnt- available at this time.
P. DESCRIBE FACTORS WHICH MAY NOT MAKE THIS A REPRESENTATIVE
INSTALLATION
1. Cost fig_ures misleading, since full scale particulate removal

installed but only 1/3 S09 scrubbing.
"~~~ • ~~ " "•*•£ •" • — ~ • • *~ ------ — .
Q. DESCRIBE METHODS OF SCRUBBER CONTROL UNDER FLUCTUATING
LOAD. IDENTIFY PROBLEMS WITH THIS METHOD AND SOLUTIONS.
IDENTIFY METHOD OF pH CONTROL AND LOCATION OF pH PROBES.
1. Scrubber Control Under Fluctuating Load
a. Scrubber liquor flow rate is held constant. _
b. Adjustable rod deck is automatically controlled to maintain
a_Constant P£es_sur_e_dro_p_at_ varying gas fl°^*_rate.
2. pH Control
The pH of the S00 scrubber surge tank is maintained by the
automatic addition of magnesium hydroxide slurry from the
slaking tank. __Eithejr of two pH probe locations may be
selected for _cqntrol_. One in the surge tank and one _in slurry
recirculating line to the scrubber.
5/17/74
A-16
-------
R.
COMPUTATION OF FGD SYSTEM AVAILABILITY FACTOR
BOILER RATING OR MAXIMUM CONTINUOUS CAPACITY, MW
I
M
~J
PF.RIOn
MONTH/YEAR

FLUE GAS DESULFURIZATION MODULES
MODULE A
DOWN DUE TO
BOILER
(HRS)

MODULE
(HRS)

MODULE B
DOWN DUL TO
BOILER
'HRS)

MODULE
(HRS)

MODULE C
DOWN DUE TO
BOILER
(HRS)

MODULE
(HRS)

MODULE D
DOWN DUE TO
BOILER
(HRS)

MODULE
(HRS)

Availability factor computation: 1,
Divide boiler capacity by the number of modules
and obtain MW/module = x
Multiply boiler capacity by number of hours
during period = a
Add all down times due to module trouble for all modules
during period = b
Add all down times due to boiler trouble or reduction
in electricity demand for all modules during period = c
- X (b + c)]100 = %
a - Y c
5. Availabilitv factor =
5/17/74
-------
APPENDIX B

PLANT PHOTOGRAPHS
B-l
-------
Photo No. 1 Construction photo showing installation of
MgO silo at Eddystone. Boiler house appears in background.
(Courtesy Philadelphia Electric Co.)
B-2
-------
ft it
Photo No. 2 General view of Eddystone scrubber area. Supply
ducts to three particulate scrubbers are visible, but scrubbers
are obscured by strutural steel. FGD module is in foreground
at left. Boiler 1 stack and boiler house are behind scrubbers.
(Courtesy Philadelphia Electric Co.)
B-3
-------
Photo No. 3 View of thickener tank, centrifuge foundations
and MgSCU dryer. Overhead pipe rack carries coal to bunkers
from coal handling building in background. Note empty coal
cars behind thickener.
(Courtesy Philadelphia Electric Co.)
B-4
-------
Photo No. 4 Construction photo showing installation of duct-
work to Peabody scrubber from supply duct in foreground. Coal
conveyor, FGD module, and coal pile are visible in background.

(Courtesy Philadelphia Electric Co.)

B-5
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing}
1 REPORT NO
EPA-650/2-75-057-f
3. RECIPIENT'S ACCESSION NO.
4 TITLE AND SUBTITLE
Survey of Flue Gas Desulfurization Systems
Eddystone Station, Philadelphia Electric Company
5 REPORT DATE
September 1975
6 PERFORMING ORGANIZATION CODE
7 AUTHOR(S)

Gerald A. Isaacs
8 PERFORMING ORGANIZATION REPORT NO.
9 PERFORMING ORdANIZATION NAME AND ADDRESS
PEDCo-Environmental Specialists, Inc.
Suite 13, Atkinson Square
Cincinnati, Ohio 45246
10 PROGRAM ELEMENT NO.
1AB013; 21ACX-130
11 CONTRACT/GRANT NO

68-02-1321, Task 6f
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
Subtask Final: 2/71-9/75
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16 ABSTRACT Tne repOrt gjves results of B. survey of the magnesium-oxide-based flue gas
desulfurization system on boiler 1 at Philadelphia Electric Co. 's Eddystone Station.
The system, designed and installed by United Engineers and Constructors, Inc. ,
consists of three first stage scrubber modules in parallel for particulate control (two
are Environeering ventri-rod units; the third is a Peabody-Lurgi venturi unit) and a
second stage Environeering absorber module with two ventri-rod beds for SO2
removal. The three first stage scrubbers, combined, are sized to handle all the
exhaust gas from unit 1 which has a net electric generating capacity of 314 MW. The
second stage absorber is sized to handle one-third of the gas flow, equivalent to
about 105 MW (net). As of April 1, 1975, the second stage module had not yet been
operated; therefore, this report necessarily emphasizes design, rather than oper-
ating, parameters and experience. The system is designed to remove 90 percent of
the SO2 from boiler stack gas.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c COSATI Field/Group
Air Pollution
Flue Gases
Desulfurization
Sulfur Dioxide
Magnesium Oxides
Scrubbers
Coal
Combustion
Air Pollution Control
Stationary Sources
Particulates
Ventri-Rod Units
Venturi Units
21D
13B
21B
07A, 07D
07B
18 DISTRIBUTION STATEMENT

Unlimited
19. SECURITY CLA!
Unclassified
19. SECURITY CLASS (Tha Report)
21 NO. OF PAGES
42
20 SECURITY CLASS (This page)
Unclassified
22 PRICE
EPA Form 2220-1 (9-73)
B-6
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