EPA-650/2-75-057-g

September 1975
Environmental  Protection  Technology Series
                                     OF FLUE GAS
                    DESULFURIZATION  SYSTEMS
              DICKERSON STATION, POTOMAC ELECTRIC POWER CO.




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                                      EPA-650/2-75-057-g
                    SURVEY
                OF  FLUE  GAS
     DESULFURIZATION  SYSTEMS
DICKERSON  STATION, POTOMAC ELECTRIC POWER CO.
                        by

                   Gerald A. Isaacs

           PEDCo-Environmental Specialists, Inc.
                       Suite 13
                   Atkinson Square
                 Cincinnati, Ohio 45246
             Contract No. 68-02-1321, Task 6g
                  ROAP No. 21ACX-130
               Program Element No. LAB013
            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, D. 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-g
                                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 edi-



torial 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 operations were supplied



by Mr. D. A. Erdman, Potomac Electric Power Company, and by



Mr. John D. Lagakos, Chemico Air Pollution Control Company



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                                              iii

LIST OF FIGURES                                             V

LIST OF TABLES                                              V

SUMMARY                                                     vi

1.0  INTRODUCTION                                           1-1

2.0  FACILITY DESCRIPTION                                   2-1

3.0  FLUE GAS DESULFURIZATION SYSTEM                        3-1

     3.1  Process Description                               3-1

          3.1.1  Ash Removal                                3-1
          3.1.2  SO2 Absorption                             3-3
          3.1.3  Solids Concentration                       3-4
          3.1.4  Drying                                     3-4
          3.1.5  Dry Solids Storage                         3-5
          3.1.6  Calcination                                3-5

     3.2  Process Control                                   3-8

     3.3  Installation Schedule                             3-9

     3.4  Cost Data                                         3-9

4.0  FGD SYSTEM PERFORMANCE                                 4-1

     4.1  Start-up Problems and Solutions                   4-1

     4.2  Performance Test Run                              4-5

     4.3  Performance Parameters                            4-6

     4.4  Process Modifications and Economics for           4-6
          Future Installations

APPENDIX A  PLANT SURVEY FORM                               A-l

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                       LIST OF FIGURES
Figure

 2.1


 3.1


 3.2


 3.3
FGD Gas Flow Schematic - Dickerson No. 3 -
PEPCO

General Flow Diagram of the FGD System on
Dickerson No. 3 - PEPCO

Calcining System Process Flow Diagram at
Essex Chemical Co. - Rumford, R.I.

Sulfuric Acid Plant - Process Flow Diagram
at Essex Chemical Co. - Rumford, R.I.
Page

2-2


3-2


3-6


3-7
Table

 2.1


 4.1
                       LIST OF TABLES
Pertinent Data On Plant Design, Operation
and Atmospheric Emissions

Availability Calculations - Dickerson No. 3
FGD System - PEPCO - 1974
Page

2-3


4-7
                              VI

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                             SUMMARY





     A flue gas desulfurization (FGD) system utilizing the



Chemico-Basic MgO-SO2 removal/recovery process has been



retrofitted to handle approximately one-half the exhaust gas



from the 190 MW Unit 3 at the Dickerson Station of Potomac



Electric Power Company.  The dry-bottom, pulverized-coal-



fired boiler, designed and installed by Combustion Engi-



neering in 1962, is equipped with a Research-Cottrell



electrostatic precipitator that operates with an estimated



particulate collection efficiency of 94 percent. Coal burned



at the station has an average gross heating value of 11,700



BTU/lb, an ash content of 14 percent, and a sulfur content



of 2 percent.



     A single, two-stage scrubber/absorber is used.  The



first stage  (scrubber) incorporates an adjustable venturi



for particulate removal, and the second stage (absorber)



uses a fixed venturi configuration to remove sulfur dioxide.



The liquor streams for the two stages are separate and



independent.  Both streams are operated in a closed-loop



mode.  Magnesium oxide  (MgO) is regenerated using an EPA



financed facility at the Essex Chemical Company sulfuric
                              VII

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acid manufacturing plant in Rumford, Rhode Island, where by-



product SO2 from the regeneration process is converted to a



sulfuric acid.  Excessive transportation costs for this



particular prototype demonstration project are incurred in



shipping magnesium compounds back and forth between Maryland



and Rhode Island.  The Rhode Island acid plant was used



because it was available and was of proper size for the



demonstration program.



     The system was started up in September 1973 and was



operated intermittently for shakedown purposes until January



1974.  The system was then shut down because the Rumford



facility was at that time still being used for a desul-



furization project with Boston Edison.  The longest con-



tinuous run during the first phase of operation was 271



hours.  The system was restarted in July 1974 and operated



until January 1975.  The boiler was shut down for a major



turbine overhaul from January 28, 1975 through August 11,



1975.  The FGD system started up on August 11, 1975, and is



anticipated to run for 3 to 4 weeks.  Operation is limited



by the MgO on hand at Dickerson, since the Essex facility



has been shut down.  Particulate and SO2 removal efficiency



guarantees have been demonstrated.  Pipe and pump corrosion



problems have frequently caused FGD unit outages.  This is



attributed mainly to improper material selection  (mild



steel) for the second stage recirculation system.  Rubber-



lined pumps and piping have been suggested to minimize these



problems.
                              Vlll

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     The FGD system was installed at a cost of $6.5 million.



This cost does not include substantial engineering and



development costs incurred by Chemico and Potomac Electric



Power Company, nor does it include the cost of MgO regen-



erating facilities.  A station transformer spare was used to



power the FGD system in order to avoid an additional ex-



penditure of $200,000 to $500,000 for a separate substation.



     The Dickerson Station is presently operating under a



variance from the State of Maryland.  Additional installa-



tion of desulfurization equipment at this station is con-



tingent on further evaluation of the system to be initiated



around mid-1975.  Operation of the FGD system will be in-



definitely terminated at the conclusion of this evaluation



since the Essex facility has been permanently shut down.



     Pertinent operational data are summarized in the



following table.
                              IX

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                  SUMMARY OF PERTINENT FGD DATA
FGD unit rating



Fuel characteristics



FGD system supplier



Process



New or retrofit



Start-up date



FGD modules



Efficiency,



  Particulate



  so2



Make-up water



Unit cost
95 MW (net)



Coal; 11,700 BTU/lb, 14% ash, 2% S



Chemico



Magnesium oxide



Retrofit



September 1973



One








99.3%



90%



3.2 gpm/MW



Capital estimate:  $6.5 million

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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 FGD systems on coal-fired utility boilers in



the United States.  This report on the Dickerson Station of



Potomac Electric Power Company (PEPCO) is one of a series of



reports on such systems.  It presents values of key process



design and operating parameters,  describes the major start-



up and operational problems encountered at the facility and



the measures taken to alleviate such problems, and identifies



the total installed and annualized operating costs.



     This report is based upon information obtained during



a plant inspection on February 11, 1975 and on data provided



by PEPCO and Chemico 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 FGD system,



and Section 4.0 analyzes FGD system performance.
                              1-1

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                    2.0  FACILITY DESCRIPTION




     The Dickerson Station of PEPCO is located on the Potomac



River outside the town of Dickerson, Maryland.  The plant is



situated in a rural, nonindustrialized area about 30 miles



northwest of Washington, D. C.  Coal is delivered to the



plant by rail.



     The station has three electric generators each rated at



190 MW.  A fourth generator, rated at 800 MW is scheduled



for installation nearby by 1982.  The installed 95 MW FGD



system is sized to handle approximately one-half the exhaust



gas flow from Unit No. 3.



     Unit No. 3 has a dry-bottom coal-fired boiler that was



designed by Combustion Engineering and installed in 1962.



     The coal presently burned has an average gross heating



value of 11,700 BTU/lb.  Average ash and sulfur contents are



14 percent and 2 percent, respectively.



     The boiler is fitted with an electrostatic precipitator



(ESP) designed and installed by Research-Cottrell in 1962.



Particulate collection efficiency is estimated to be 94



percent.  The FGD system is installed so that it can receive



exhaust gas either from the outlet or from the breeching



ahead of the ESP.  Figure 2.1 is a gas-flow schematic for



this installation.  Table 2.1 gives pertinent data on plant



design, operation and atmospheric emissions.




                               2-1

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                                           STACK
BOILER
                                                  SCRUBBER
                                                  FAN
          Figure 2.1  FGD gas flow schematic
               Dickerson No.  3 - PEPCO.
                            2-2

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      Table 2.1  PERTINENT DATA ON PLANT DESIGN, OPERATION

                    AND ATMOSPHERIC EMISSIONS


 Boiler data - Dickerson No. 3 - PEPCO
Rated generating capacity, MW

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



     S02



Particulate emission rates:

     Allowable, gr/scf

     Actual, gr/scf

SO- emission rates:

     Allowable, Ib/MM BTU

     Actual, Ib/MM BTU
      190

       81

Combustion Engineering

     1962

     9180

       74.5

     1744

      400

  590,000

      259
ESP and venturi
 scrubber

Venturi - absorber
 on half of the
 gas flow
     0.03

     0.02



     1.6a

     0.3b
a 1% sulfur coal equivalent.
  Based on 2 percent sulfur in coal, 95 percent conversion of
  sulfur to SO2 and 90 percent FGD efficiency.
                               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 the Chemico-

Basic FGD system installed to handle approximately one-half

(295,00 acfm at 259°F) of the exhaust gas from Unit 3 of the

Dickerson Station of PEPCO.  The maximum gross continuous

generating capacity for the unit is 190 MW.  The boiler was

manufactured by Combustion Engineering, Inc., and was placed

in service in 1962.  The generator, a base load unit, operated

with an 81 percent capacity factor in 1974.  The FGD system

incorporates six major processing steps, i.e., 1) ash re-

moval, 2) SO- absorption, 3) solids concentration, 4) dry-

ing, 5) dry solids storage, and 6) calcination.  Only the

first five steps are accomplished on-site at the Dickerson

facility.

3.1.1  Ash Removal

     A two-stage scrubber/absorber is used at this plant.

The first stage is an adjustable throat venturi where the

gas is cooled from 250°F to 120°F and saturated.  This stage

is used for fly ash (particulate) control only, and recir-
a Adapted from "Chemico-Basic Magnesium Based SO2 Recovery
  Scrubbing Systems," by P.M. Wechselblatt and Robert H.
  Quig - Presented at AIChE 71st National Meeting, Dallas,
  Texas, February 20-23, 1972, and supplemented with data
  from field visit.

                              3-1

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                                      TW STAGE

                                         SCRUBBER
UJ
I
to
                       FLUE GASES
                                                                                HOTHER  XORIER FEED CONVEYOR
                                                                               LIQUOR TANK
                                                                                                               NgSOj CONVEYOR
&=» Ngso, Kim ftaa
                              Figure 3.1   General  flow diagram of the FGD system

                                              on Dickerson No.  3  - PEPCO.

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culating streams for the two stages are separate and in-



dependent.  Ash-laden water is circulated at a two percent



solids concentration.  The adjustable venturi automatically



controls the first stage pressure drop at 11 in. H^O.



Overall design system particulate collection efficiency is



99 percent.  Actual efficiency was measured to be 99.3



percent when the ESP was bypassed.  The ESP was designed to



attain 97.5 percent efficiency, but it attains only about 94



percent efficiency, burning coal containing 2 percent sulfur.



     A 980 gpm bleed stream from the recycle line carries



ash to the thickeners.  A flocculant is used to aid settling



in the thickeners.  Thickener underflow, 20 gpm at 40 per-



cent solids, is discharged to a dilution tank where water is



added, and the mixture is pumped to a settling pond,  The



overflow cascades through a total of four ponds in series,



and the water from the lowest pond is then pumped back to



the dilution tank.  The thickener overflow is pumped back



into the first stage of the scrubber so that closed-loop



operation is maintained.



3.1.2  SO^ Absorption



     The flue gas leaves the first stage passing upward



through an annular mist eliminator and then downward through



the second stage of the scrubber which is designed to remove



90 percent of the S02 from the flue gas stream.  The S02 gas



diffuses into the surface of the water droplets and chemically



reacts with the MgO forming hydrated magnesium sulfites.



Some MgSO4 is also formed as a result of the reaction of SO.





                              3-3

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with MgO and as a result of the oxidation of MgSO-.  The



slurry solids have a relative composition of 89.6 percent



MgSO3-6 H2O and MgS03 • 3 H2O (MgSO.j-6 H2O predominantly), 5.0



percent MgS04«7 H20, and 5.4 percent MgO.



     MgO + S02 + 6 H20   - -   MgSO.j-6 H2O
     MgO + S02 + 3 H20   - -   MgSO.j-3



Other reactions that occur are:



     MgO + SO  + 7 HO   - -   MgSO • 7
     MgS03 + 1/2 02 + 7 H2O - -  MgSO4 - 7 H2O



The flue gas and entrained liquor then enter the separator



portion of the absorber through a central downcomer.  The



liquor falls to the lower section of the separator which



serves as an integral storage reservoir while the gas



containing less than 150 ppm SO2 passes upward through the



second stage mist eliminators and is exhausted through the



stack to the atmosphere.



3.1.3  Solids Concentration



     A 170 gpm bleed from the absorption system enters a 36



in. x 72 in. solid-bowl centrifuge where the crystals of



MgSO_-6 H2O, MgSO_-3 H20 and MgSO^-7 H2O and unreacted MgO



are separated from the mother liquor.  The mother liquor is



returned to the absorption system and the centrifuged wet



cake enters the dryer.



3.1.4  Drying



     The wet cake containing MgSO_-6 H2O,  MgSO_-3 H2O,



MgSO.-7 H2O, MgO and surface moisture is dried by direct-



firing to remove surface and bound moisture.  Dry solids
                              3-4

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total about 100 Ib/min.   The drying reactions are as fol-



lows :



     MgS03-6 H20         Heat^     MgS03 + 6 H2O  (g)



     MgS03-3 H20         Heat^     MgSO3 + 3 H2O  (g)



     MgS04-7 H2O         Heatr     MgSO4 + 3 H2O  (g)



     H2O (1)             Heat^     H20  (g)



Exhaust gas from the dryer passes through a cyclone dust



collector and back into the second stage of the scrubber.



3.1.5  Dry Solids Storage



     The anhydrous MgS03 and MgSO. material is conveyed from



the dryer to a storage silo where it is kept until it  is



transported by covered trucks, barges or rail cars to  the



sulfuric acid manufacturing plant.  Regenerated MgO is



returned (with make-up) and stored in an MgO silo at the



power plant.  The MgO slurry is prepared using regenerated



MgO, make-up MgO and mother liquor.  The MgO slurry is added



as make-up to the absorption recycle liquid system.  The



MgS03 storage silo has a design capacity of 200 tons  (7



days).  The MgO storage silo has a design capacity of  100



tons (7 days).



3.1.6  Calcination



     Figures 3.2 and 3.3 show the schematic process flow



sheets of the calciner plant and sulfuric acid plant.  Both



processes are external to the Dickerson Station.  The  dry



crystals of MgS03, MgS04 and MgO are received, weighed, and



conveyed to the MgS03 silo.  The crystals are fed from there



to the direct-fired rotary calciner at a metered  rate  and



                           3-5

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co
I
                   n
              CONVEYER
                                                                                       TO SULFURIC
                                                                                        ACID PLANT
                   CONVEYER

                       CONVEYER^ |

                             ELEVATOR
              Figure 3.2   Calcining system process flow diagram at Essex Chemical  Company

                                              Rumford, Rhode Island.

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      so? IK FLii^cAS

      FROM CALCINER
UJ
            COLU HEAT
            EXCHANGER
                                                                               981.
                                                                              PUMP
                                                                              TANK
      COdlERS
  i ACIO
CIRCULATING
  PUMP
 98~.
PUMP
TALK
         98Z
      CIRCULATING
        PUMP
  981 PRODI.'.'!
   ACIO TO
   STORAGE

 NO FLOW WHFN
MARKING 93i ACIO
                               Figure  3.3  Sulfuric acid plant -  process flow  diagram

                                    At  Essex  Chemical Company,  Rumford,  Rhode Island.

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calcined to generate SO2 gas and regenerate MgO.  Coke is



added to reduce the residual MgSO4 to MgO and SO2.  The



reactions are:



     MgSO3               Heatr     MgO + SO2



     MgS04 + 1/2 C       Heatr     MgO + SO2 + 1/2 CO2



The calciner effluent gas containing 7 - in percent SO_ and



the MgO dust enter a hot cyclone where essentially all of



the dust is collected and returned to the calciner.  The gas



then enters a venturi scrubber, where final dust cleaning is



accomplished and the gas is adiabatically saturated.  The



saturated gas is cooled to 100°F in a direct contact cooler.



The cleaned, cooled gas enters the drying tower and the



sulfuric acid plant for production of 98 percent sulfuric



acid.  Alternately, the gas can be reduced to elemental



sulfur.  The regenerated MgO is cooled, conveyed to the MgO



storage silo, and recycled back to the power plant site for



reuse.



3.2  PROCESS CONTROL



     The control process for this FGD system is relatively



simple.  Basically, the liquid flow rates through the scrubber



are constant and independent of gas load.  The first stage



of the venturi is automatically adjusted to maintain an 11



in. H20 pressure drop across the venturi.  MgO additive feed



rate is varied to maintain the slurry pH at a preset point,



about 7.  The pH is measured at the discharge of the second



stage recirculation pump.  A downward pH movement triggers
                              3-8

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the addition of MgO to the system from the MgO make-up tank.



The control system has been found to be reliable and relatively



trouble-free.



3.3  INSTALLATION SCHEDULE



     This system was designed by Chemico who also performed



the architectural and engineering work.  Construction work



was performed by Brown & Root, Inc.  On-site construction



began July 1972, and was completed in September 1973.  Plant



start-up occurred in September 1973, but shakedown tests



were not completed until July 1974.  The long interval



between start-up and shakedown occurred because the calcina-



tion facility at Rumford, Rhode Island was unavailable



during that period.  This was the only major delay in the



demonstration schedule.  Start-up was originally scheduled



for June 30, 1973.  Some design modifications based on



ongoing experience at the Mystic Station of Boston Edison



caused slight construction delays.  Dryer delivery was



delayed about one month beyond scheduled delivery.  Structural



steel reinforcement in the boiler room required more time



than construction schedules had allotted.



3.4  COST DATA



     In 1969 PEPCO estimated that the capital cost of a



scrubber system was 12 to $20/KW.  In the January 1974 EPA



report on the October 1973 scrubber hearings the capital



cost was given as 50 to $65/KW.  PEPCO1s current in-house



estimate in 1974 dollars is in excess of $100/KW.  This



installation has cost *>EPCO about $6.5 million  ($68/KW) .





                               3-9

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     Operating costs are incomplete because MgO make-up



costs and maintenance cost estimates have not been reported



by PEPCO.  Their experience indicates that two additional



operators per shift will be required.  Maintenance require-



ments for the present system average 50-60 man-hours/week.



Operation and maintenance costs were estimated to be $500,000



in 1974.  This figure does not include fixed charges on the



total capital costs to account for interest, depreciation,



insurance and taxes.  The figure also does not include FGD



system fuel costs, project management, engineering, air,



electricity, or water costs.  Freight charges and operation



charges by the Rumford acid plant cost PEPCO an additional



$440,000.  If the FGD plant had operated at capacity in



1974, freight costs alone would have been approximately $1.7



million.



     The power consumption for the existing FGD system is



about 3.5 MW.  The estimated increase in power cost for the



Dickerson Station if it were to be fully equipped with FGD



facilities, operating at an 85 percent capacity factor,



would be about 5 mills per kilowatt hour.  Over 3 mills of



that amount would be the fixed charge on investment.  These



costs assume an on-site MgO regeneration system.  The assump-



tion is also made that the sale of elemental sulfur or



sulfuric acid will cover all fixed and operating costs



associated with an on-site sulfur or acid plant.
                              3-10

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                  4.0  FGD SYSTEM PERFORMANCE


 4.1 START-UP PROBLEMS AND SOLUTIONS9

     The FGD system was placed in operation on September 13,

1973.  Operation since that time can be divided into the

following phases:

     Phase I    September 13, 1973 to January 14, 1974 -
                Initial operation and debugging.

     Phase II   January 14 to April 15, 1974 - Maintenance
                and modification.

     Phase III  April 15 to July 1, 1974 - Modification
                verification.

     Phase IV   July 1 to January 28, 1975 - Performance
                testing, optimization and reliability.

     Phase V    January 28, 1975 to August 11, 1975 -
                Maintenance and modification

     Phase VI   August 11, 1975 to about early
                September 1975 - Modification verifica-
                tion

Phase I

     Initial start-up and operation was reasonably smooth.

There were two shutdowns caused by failures of stainless

steel expansion bellows which allowed first stage slurry to

leak into the second stage.  Examination verified that the

bellows were not made of the specified 316 stainless.
a
  Adapted from "Mag-Ox Scrubbing Experience at the Coal-Fired
  Dickerson Station - Potomac Electric Power Company," by
  Donald A. Erdman, Project Engineer, PEPCO.

                            4-1

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     The major problem was with the MgO feed system.  Continual



plugging occurred in the MgO mix tank and suction lines to



the MgO make-up pumps.  The problem was remedied by the



installation of a premix tank ahead of the mix tank to



ensure that scale-forming reactions would occur before the



fresh slurry entered the piping system.  Steam sparging



lines were also added to heat the MgO slurry to about 160°F.



This preheat was found to be necessary to ensure MgO disso-



lution and slurry homogeneity.



     The longest continuous run during this phase was 271



hours.  Approximately midway through this run the boiler was



forced out for 24 hours with a tube leak.  All liquid flows



and levels were maintained and flue gas was returned to the



scrubber as soon as the boiler returned to service.  Phase I



concluded when the boiler shut down January 14 for annual



maintenance.



Phase II



     Inspection of the scrubber system was made after about



700 hours operation.  The system was basically in good



condition with absolutely no sign of scaling or buildup.



However, in the first stage where the operating pH is less



than two, there was corrosion of nuts, bolts, hanger rods,



spray nozzles, bellows and the vessel itself.  Examination



determined that many corroded parts were not constructed of



specified material.  There was some very minor corrosion on



316 stainless.  The corrosion of the vessel occurred only in
                             4-2

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a few places where the protective flake glass lining had



cracked.  The problem here was partly due to improper appli-



cation and partly due to construction damage after the



lining was installed.



Phase III



     Operation resumed with start-up on April 15, 1974.  The



intent was to operate to verify the modifications and then



to shut down to prepare the unit for performance testing.



The premix tank improved slaking but not to an acceptable



standard for long-term operation.  It was decided that at



the end of April the system could be operated for performance



testing.  However, further checks revealed that the inventory



of MgO was insufficient for such a test and that the remaining



storage space for sulfite was also insufficient.  At that



time 130 tons of sulfite were at Rumford waiting to be



calcined.  Boston Edison was using the calciner and it



appeared there was no chance of PEPCO's material being



calcined before July.  Additional virgin MgO had not been



ordered as PEPCO had been expecting to be able to conduct



the test using recycled MgO.  A short operation in May



emptied the MgO silo.



     Chemico decided to replace the premix tank with a



"solids liquid mixing eductor" to improve slaking.



Phase IV



     PEPCO received permission to use the calciner at Rumford,



Rhode Island July 1, 1974.  Virgin MgO, ordered to supple-






                              4-3

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ment the expected recycled MgO, arrived near the end of



July.  The first start-up was August 1.  The mixing eductor



proved totally unsatisfactory, plugging continually.  After



10 hours the FGD system was shut down, and the premix tank



was modified and reinstalled.  Preliminary tests operating



on virgin MgO indicated an SO- removal in the 70 percent



range.  When the pressure drop across the absorber throat



was increased to the design specification, a removal efficiency



in excess of 90 percent was demonstrated, using virgin MgO.



     Recycled MgO was first received and introduced into the



system on August 16.  The dryer feed material became sticky



and caused caking in the dryer.  This was believed to be



caused by unreacted MgO in the centrifuge cake.  During the



next run steam sparging was used to raise the temperature in



the MgO mix tank to correct this problem.  It was also



necessary to change the dryer operating temperature on



recycled MgO.  Slaking with the modified premix tank was



satisfactory on both virgin and recycled MgO.



     In conjunction with Chemico, Basic, Essex and EPA, from



July to December 1974, PEPCO conducted a 6-month program to



test the FGD system, optimize operating conditions, improve



reliability and gain operating experience.  There have been



no problems to rule out the technical feasibility of this



process for S02 removal.  There are still some problems in



the sulfite handling equipment which is somewhat undersized



for actual operating conditions.  The centrifuge hopper and





                            4-4

-------
the dryer tend to hold up material and then release it in a



slug that overloads the sulfite conveyors.



     Several minor problems continue to cause shutdowns.



Examples include corrosion leaks in damaged rubber-lined



pipes, erosion leaks in second stage piping, pump seal



problems, and bearing failure in sulfite bucket elevator.



     Present plans call for repairing the FGD system during



a current outage for a turbine overhaul.  The system is to



be subjected to an approximate three-month test-and-demon-



stration program, beginning around July 1975.



Phase V



     Pipe linings and some materials of construction were



changed.  Corroded equipment was repaired.  Other modifica-



tions included changing the hopper feed to the centrifuge.



Phase VI



     Length of this phase of operation is limited by the



existing supply of MgO, about 3-4 weeks.  The purpose of



this phase is to verify the modifications and repairs that



were made.  At the conclusion of this phase a complete site



inspection will be performed by PEPCO.



4.2  PERFORMANCE TEST RUN



     A performance test program has been completed by York



Research and while formal results are not available, the



indicated S02 removal efficiency is in the 88 to 96 percent



range as gas flow varies from 150,000 to 300,000 acfm.



Overall particulate removal efficiency exceeds 99 percent



whether or not the existing ESP is used.
                              4-5

-------
4.3  PERFORMANCE PARAMETERS

     The FGD system at the Dickerson Power Station operated

intermittently throughout 1974.  Availability figures appear

in Table 4.1.  The boiler capacity factor was 81 percent in

1974.  PEPCO has defined availability as the length of time

the FGD system was operating or ready for operation divided

by the total number of hours in the period.  This definition

differs slightly from the more usual definition of availability,

i.e., FGD operating hours divided by boiler operating hours.

4.4  PROCESS MODIFICATIONS AND ECONOMICS FOR FUTURE
     INSTALLATION

     This installation is not entirely suitable for the

determination of economic parameters, mainly because it is

tied to the operation of an outdated, undersized acid manu-

facturing plant located approximately 400 miles away.

Future installation will probably be predicated on on-site

calcination and across-the-fence transfer of materials to

and from a modern, economically sized acid plant.  All the

Dickerson units together, including Unit 4, an 800 MW gener-

ator to be in service by 1982, would supply enough MgSO., to

operate a 1000 ton/day sulfuric acid plant; this is about

the minimum economical size for a modern plant.  It is

estimated that at best the revenue from the sale of sulfuric

acid would pay operation and maintenance costs associated

with the acid plant.
                            4-6

-------
Future installation will probably be predicated on on-site



calcination and across-the-fence transfer of materials to



and from a modern, economically sized acid plant.  All the



Dickerson units together, including Unit 4, an 800 MW gener-



ator to be in service by 1982, would supply enough MgSO3 to



operate a 1000 ton/day sulfuric acid plant; this is about



the minimum economical size for a modern plant.  It is



estimated that at best the revenue from the sale of sulfuric



acid would pay operation and maintenance costs associated



with the acid plant.



     Corrosion and erosion problems have been encountered in



the existing scrubber, especially in the first stage where



pH is low.  Corrosion and erosion of mild steel piping and



pumps for the second stage absorber indicate that these



items should have been rubber-lined.



     The plant does not have a spare centrifuge or dryer,



which makes the FGD system quite vulnerable.  A full-scale



system would likely employ more redundant critical equipment



items in several areas.  All pumps are spared in this installa-



tion.



     Demister deposits have not occurred.  The principal



problems with the demisters have been in the form of physical



abuse from being walked on by maintenance personnel during



scrubber inspections.  Although it has not been necessary to



replace the demisters it is probable that a sturdier design



will be specified for replacement units or for additional



installations.





                              4-7

-------
     Corrosion and erosion problems have been encountered in



the existing scrubber, especially in the first stage where



pH is low.  Corrosion and erosion of mild steel piping and



pumps for the second stage absorber indicate that these



items should have been rubber-lined.



     The plant does not have a spare centrifuge or dryer,



which makes the FGD system quite vulnerable.  A full-scale



system would likely employ more redundant critical equipment



items in several areas.  All pumps are spared in this installa-



tion.



     Demister deposits have not occurred.  The principal



problems with the demisters have been in the form of physical



abuse from being walked on by maintenance personnel during



scrubber inspections.  Although it has not been necessary to



replace the demisters it is probable that a sturdier design



will be specified for replacement units or for additional



installations.



     The wet scrubber I.D. fan has not caused any problems.



The wheel is constructed of Inconel 625, and the housing is



rubber-lined.



     The centrifuge tends to freeze when it is shut down



unless it is carefully and thoroughly cleaned.



     Bypass dampers tend to bind and do not seal completely,



but operation has not been seriously affected and major



design modifications have not been suggested.



     It was mentioned earlier that the original MgO slurry



mixing system was ineffective and that a premix tank had to





                             4-8

-------
be installed.  The mix tank temperature must be closely



controlled in order to obtain proper dissolution of the



recycled MgO.



     The bucket elevator to the MgSO, silo cannot handle the



surges that normally occur when the dryer is running at



capacity.  Either a surge bin between the dryer and the



elevator or a larger elevator should be installed.  The



present system will only accommodate a flow equivalent to 70



percent of dryer design capacity.
                             4-9

-------
   APPENDIX A




PLANT SURVEY FORM
       A-l

-------
                                      Revision date  6/10/74
                    PLANT SURVEY FORM

                REGEHERABLE FC-D PROCESSES




A.  COMPANY AMD PLANT INFORMATION

    1.  COMPANY NAME         Potomac Electric Power Company	

    2.  MAIN OFFICE          1900 Pennsylvania, Washington,  D.C.

    3.  PLANT MANAGER        W. C. Jensen, Jr.	 	  	
    4.   PLANT NAME           Dickerson Station
    5.   PLANT LOCATION       Dickerson, Maryland	

    6.   PERSON TO CONTACT FOR FURTHER INFORMATION Don  Erdman

    7.   POSITION                            Project Engineer

    8.   TELEPHONE NUMBER                     (202) 872-2441

    9.   DATE INFORMATION GATHERED           February 10,  1975

   10.   PARTICIPANTS IN MEETING                 AFFILIATION

        T. Devitt, L. Yerino                PEDCo	
        G. Isaacs	             PEDCo
        J. Busik/ F. Biros	             EPA Washington,  D.C.
                                            EPA Research  Triangle  Park,
        W. Ponder, R. Atherton              North,  Carolina	

        D. Erdman                           PEPCO
        J. Harvey	             PEPCO	

       "G. Koehler                          Chemico
                               A-2                5/17/74

-------
B.  PLANT DATA.   (APPLIES TO ALL  BOILERS AT THE PLANT).
CAPACITY, MW (Gross)
SERVICE (BASE, PEAK)
FGD SYSTEM USED
BOILER NO.
1
190
B

2
190
B

3
190**
B
95 MW
4***
800
B





C.  BOILER DATA.  COMPLETE  SECTIONS  (C)  THROUGH (R) FOR EACH
1.
2.
3.
4 .
5.
6.
7 .
8.
9 .
10.
11.
*
BOILER
MAXIMUM
MAXIMUM
MAXIMUM
BOILER
BOILER HAVING AN FGD SYSTEM.
IDENTIFICATION NO. 3
CONTINUOUS HEAT INPUT 1456.4 MM BTU/IIR
CONTINUOUS GENERATING CAPACITY 190 MW
CONTINUOUS FLUE GAS RATE. 590.000 ACFM @ 259 °F
MANUFACTURER C-E
YEAR BOILER PLACED IN SERVICE 1962
BOILER
SERVICE (BASE LOAD. PEAK. ETC.) Base
STACK HEIGHT 400'
BOILER
BOILER
RATIO O
DEFINED
OPERATION HOURS/YEAR (1974) 7992.7
CAPACITY FACTOR * 81
F FLY ASH/BOTTOM ASH 9 (Est.)
AS: Kv/H GENERATED IN YEAR
                      MAX.  CONT.  GENERATED CAPACITY  LN KW x 8760 HR/YR

     **  182 MW  (NET)  when  scrubber is not operating.
         178.5 MW  (NET)  when  scrubber is operating.
    ***
        To be  in  service  by  1983.
                                A-3
                                                   5/17/74

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D.  FUEL DATA

    1.  COAL ANALYSIS  (as  received)

             GHV  (BTU/LB.)

             S %

             ASH  %
MAX .

2.2

MIN .

1.7

AVG.
11,737
2.2
14.06
    2.  FUEL OIL ANALYSIS  (exclude  start-up fuel)

             GRADE                       	

             S  %       N/A               	

             ASH %
E.  ATMOSPHERIC  EMISSIONS

    1.  APPLICABLE  EMISSION REGULATIONS

        a)  CURRENT REQUIREMENTS

            AQCR PRIORITY  CLASSIFICATION

            REGULATION  & SECTION NO.

            MAX.  ALLOWABLE EMISSIONS
            LBS/MM  BTU

        b)  FUTURE  REQUIREMENTS,
            COMPLIANCE  DATE

            REGULATION  & SECTION NO.

            MAXIMUM ALLOWABLE EMISSIONS
            LBS/MM  BTU
    3.
PARTICULATES




so2
2.25% S (



                                      Currently under review
                                      Currently under review
        PLANT PROGRAM  FOR PARTICULATES COMPLIANCE
 Particulate and SO2 compliance tied together.	

 Mitre Corp.  Recommended Study underway -	

 Report due in April.	

PLANT PROGRAM FOR SO2 COMPLIANCE   Awaiting Mitre  Report.

 Retrofit est. to take 44 months from contract  to  start-up,
                                A-4
                                            5/17/74

-------
]•'.  PARTICULATK REMOVAL
    1.  TYPE
        MANUFACTURER
         EFFICIENCY: DESIGN/ACTUAL  99/99.3
         MAX.  EMISSION RATE*   LIB/MR
                           LB/i-LMBTU
         DESIGN BASIS, SULFUR CONTENT
MECII .
Chemico
99/99.3

0.02

E.S.P.
R-C
97.5/94
est .



FGD





G.  DESUJ.FURIZATION SYSTEM  DATA

    1.   PROCESS NAME

    2.   LICENSOR/DESIGNER NAME:

                        ADDRESS:

              PL'RSON TO CONTACT:

                  TELEPHONE  NO.:
Chemico-Basic
Chemico
1 Penn  Plaza - NYC
J. Laaakos 	
 (212)  239-5345
     3.   ARCHITECTURAL/ENGINEERS, NAME:  Chemico

                        /ADDRESS:    	

              PERSON TO CONTACT:    	

                  TELEPHONE  NO.:
                 N/A
         PROJECT CONSTRUCTION SCHEDULE:
         a)   DATE OF PREPARATION OF BIDS  SPECS.
         b)   DATE OF REQUEST FOR BIDS             __ !/.7_l
         c)   DATE OF CONTRACT AWARD               __ ZZ7_!
         d)   DATE ON SITE  CONSTRUCTION  BEGAN     _ IZZ2
         e)   DATE ON SITE  CONSTRUCTION  COMPLETED _ 8/7 3_
         f)   DATE OF INITIAL STARTUP                 9/73
         cj)   DATE OF COMPLETION OF SHAKEDOWN
     *At Max. Continuous  Capacity

                                 A-5
                 7/74
               5/17/7-1.

-------
        LIST MAJOR DELAYS IN CONSTRUCTION SCHKDULL 7\MD  C'\USCS:

        Minor  delays  only.   Original  start-up scheduled for	

        June 30,  1973.   Some design mod,  based on ongoing	

        experience  -  Boston.	Dryer delay approximately 1	
        month;  Brown &  Root underestimated time to install

        steel  in  building.   Rumford facility unavailable	

        until  July  1974.	

    6.  NUMBER OF S02 SCRUBBER TRAINS USED         	1	
    7.  DESIGN THROUGHPUT PER TRAIN, ACFM @259 °F    295.000
    8.  DRAWINGS:  1)  PROCESS FLOW DIAGRAM AND MATERIAL BALANCE

                   2)  EQUIPMENT LAYOUT
H.  SO2 SCRUBBING AGENT

    1.   TYPE                                     MqQ
    2.   SOURCES OF SUPPLY                        Sea Water or Calcined
                                            	magnesite

    3.   CHEMICAL COMPOSITION  (for each  source)	90% Purity

    4.   EXCESS SCRUBBING AGENT USED ABOVE    3.5% XS in C'fuqe Cake*
        STOICHIOMETRIC REQUIREMENTS
                                             100 gpm 1st stage
    5.   MAKE-UP WATER POINT OF ADDITION     12  gpm 2nd stage	

    6.   MAKE-UP ALKALI POINT  OF ADDITION     2nd Stage	
  *  In addition to 2-3% unavoidable MgO loss.
                               A-6                5/17/74

-------
J .   SCRUBBER TRAIN  SPECIFICATIONS
    1.  SCRUBBER NO.  1

        T Y P E  ( VENTUR I )                    2-Staqe
        LIQUID/GAS RATIO,  G/MCF @ 117 °r  20  (First)  40 (Second)^

        GAS VELOCITY  THROUGH SCRUBBER, FT/SLC   	
        MATERIAL OF CONSTRUCTION-Shell           Carbon Steel
        TYPL OF LINING                            FRP - Dudick

        INTERNALS:

           TYPE  (FLOATING  BED,  MARBLE BED, ETC . ) Venturi	

           NUMBER OF  STAGES
           TYPE AND  SIZE  OF PACKING MATERIAL    	

           PACKING THICKNESS PER STAGE(b)


           MATERIAL  OP  CONSTRUCTION,  PACKING:   	

                                     SUPPORTS:   	

        SCRUBBER NO.  2  (a^

        TYPE  (TOWER/VENTURI)                     	

        LIQUID/GAS RATIO. G/MCF @    °F          	

        GAS VELOCITY  THROUGH SCRUBBER, FT/SEC   	

        MATERIAL OF  CONSTRUCTION'                	

           TYPE OF LINING                       	

        INTERNALS:

           TYPE  (FLOATING BED, MARBLE BED, ETC.)	

           NUMBER OF  STAGES                     	

           TYPE AND  SIZE  OF PACKING MATERIAL
 a)  Scrubber Ho. 1 is  the  scrubber  that the flue crises  first
    enter.  Scrubber 2  (if applicable)  [follows Scrubber No. 1.
 b)  For floating bed,  packing  thickness at rest.


                             A-7                  5/17/7/1

-------
       PACKING THICKNESS PUR STAGED      	

       MATERIAL OF CONSTRUCTION, PACKING:	.

                                 SUPPORTS:	

    CLEAR WATER TRAY  (AT TOP OF  SCRUBBER)

    TYPE                                 	

    L/G RATIO                            	

    SOURCE OF WATER                      	
DEMISTER - Identical each stage

   TYPE   (CHEVRON,  ETC.)

   NUMBER OF PASSES  (STAGES)

   SPACE BETWEEN VANES

   ANGLE OF VANES

   TOTAL DEPTH OF DEMISTER

   DIAMETER 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
                                          Baffle
                                          3 Stage Impingement

                                          2 inch
                                          45
                                          12 inch
                                          annular - 10 ft/sec
                                          Centrate Up-Spray
       FLOW RATE  DURING  CLEANINGS,  GPM  	
       FREQUENCY AND  DURATION OF CLEANING Once/Day:	

       REMARKS   Demister wash velocity 10 ft/sec. Washed  once
        per shift   2  gal/ft2   12 sections at 5 to 10 min. each,
5.   REHEATF.R  N/A

       TYPE  (DIRECT,  INDIRECT)
b) For floating  bed,  packing thickness at rest.
                         A-8
                                              5/L7/74

-------
       DUTY, MMBTU/HR                    	

       HEAT TRANSFER SURFACE AREA SQ.FT	

       TEMPERATURE OF GAS:  IN	OUT

       HEATING MEDIUM SOURCE             	
            TEMPERATURE & PRESSURE

            FLOW  RATE

       RCIIEATER TUBES, TYPE AND
       MATERIAL OF CONSTRUCTION
      _LB/hR
       REHEATER LOCATION WITH  RESPECT  TO DEMISTER
       METHOD  OF CLEANING
       FREQUENCY AND DURATION  OF CLEANING

       FLOW  RATE OF CLEANING MEDIUM 	

       REMARKS  	
      LB/HR
6.  SCRUBBER TRAIN PRESSURE  DROP DATA

       PART1CULATE SCRUBBER

       S02  SCRUBBER

       CLEAR VJATER TRAY

       DEMISTER

       REIiEATER

       DUCTWORK



       TOTAL FGD SYSTEM
INCHES  OF  WATER
	6-12	
     10
     35
                          A-9
                                                 5/17/74

-------
    7.  FRLSH  WATER HAKE UP FLOV7  RATES AND POINTS OF  ADDITION

            TO:   DEMISTER     	
                 QUENCH CHAMBER
                 ALKALI SLURRY liJG

                 PUMP SEALS 	

                 OTHER 	
                 TOTAL
            FRESH WATER ADDED  PER  MOLE OF SULFUR REMOVED

    8.   BYPASS SYSTEM

         CAN FLUE GAS BE BYPASSED  AROUND FGD SYSTEMS 	

         GAS LEAKAGE THROUGH BYPASS VALVE, ACFM 	
K.  TANK DATA
    ALKALI  SLURRY MAKEUP TANK

    PAKTICULATE SCRUBBER EFFLUENT
    HOLD  TANK (a)

    S02 SCRUBBER EFFLUENT  HOLD
    TANK  (a)
                                         pll
  %    I Capacity
Solids    (era] )
Hold up
 tlPlCJ
5-10
L.  S02 RECOVERY
        NA.MF  OF PROCESS

        LICFNSOR/DESIGMER

        SYSTEM'S CAPACITY

        RAW MATERIAL REOUIRED
                       T/HK
                              A-10
                                                    5/11/74

-------
M.  DISPOSAL OF CONTAMINANTS

    PURGE STREAM, gpm

    AMOUNT OF CONTAMINANTS IN STREAM
    DESCRIBE METHOD OF CONCENTRATION
    AND DISPOSAL OF CONTAMINANTS       Purge requirement does not

      exceed 5% and is accomplished through natural losses.	

      Present MgO  loss is  10%.                	
N.  COST DATA

    1.  TOTAL INSTALLED CAPITAL  COST  (95  MW)  $6.5 x 1Q6 (PEPCO)

    2.  ANNUALIZED OPERATING COST
                             A-ll

-------
3.
COST BREAKDOWN
           COST ELEMENTS
                                INCLUDED  IN
                                ABOVE COST
                                 ESTIMATE
ESTIMATED AMOUNT
OR "; OF TOTAL
INSTALLED CAPITAL
    COST
                                     YES
                                         NO
           CAPITAL COSTS
           SO, ABSORPTION/DESORPTION
           SYSTEM

           SO. RECOVERY SYSTEM  IN-
           CLUDING H2S GENERATOR

           GAS QUENCHING &
           CLEANING
           SITE IMPROVEMENTS

           LAND, ROADS, TRACKS,


           ENGINEERING COSTS

           CONTRACTORS FEE
           SUBSTATION  ($500 K)

           INTEREST ON CAPITAL
           DURING CONSTRUCTION

           ANNUALIZED OPERATING COST
           FIXED COSTS

            INTEREST ON CAPITAL

            DEPRECIATION

            INSURANCE & TAXES

            LABOR COST
            INCLUDING OVERHEAD

           VARIABLE COSTS

            RAW MATERIAL

            UTILITIES
                                        a
                                         X
                                              Work in progress is
                                              capitalized.
                                                  15-1/2%
                               A-12
                                                       5/17/74

-------
     4.   COST FACTORS
         a.  ELECTRICITY
         b.  WATER
         c.  STEAM  (OR FUEL FOR REHEATING)
         d.  SULFUR/SULFURIC ACID SELLING COST      	 $/TON
         e.  RAW MATERIAL PURCHASING COST 	 $/TON OF DRY SLUDGE
         f.  LABOR:  SUPERVISOR       	HOURS/WEEK	WAGE
                     OPERATOR           168              	
                     OPERATOR HELPER    168              	
                     MAINTENANCE       50-60             	
O.   MAJOR PROBLEM AREAS:   (CORROSION, PLUGGING,  ETC.)
     1.   SO2 SCRUBBER, CIRCULATION TANK AND  PUMPS.
          a.   PROBLEM/SOLUTION Corrosion and erosion of 2nd  stage
                 piping and pumps .  Two-year ..pipe, life.  Six-month
                 impeller life.  Rubber lining  is  suggested.   All	
                 pumps are spared.  Centrifuge  and dryer are  not	
                 spared.	


     2.   DEMISTER
               PROBLEM/SOLUTION  Broken by physical abuse.	
                (People walking on demister) .	  	
     3.   REHEATER
          PROBLEM/SOLUTION.
                                A-13               5/17/74

-------
4.    VENTURI SCRUBBER, CIRCULATION TANKS  AND  PUMPS
     PROBLEM/SOLUTION	Rut>ber^lined_fan_ with Inconel_wheel
     	is satisfactory.      	
5 .    I.D.  BOOSTER FAN AND DUCT WORK
     PROBLEM/SOLUTION	
6.
     PROBLEM/SOLUTION Occasional plow breakage  in centrifuge.
     Occasional freeze-up d uring centri fjuge_ .5 hut down indicates
     that a more thorough cleanout procedure _is_ necessary.	
7-   GAS QUENCHING AND CLEANING
     PROBLEM/SOLUTION	
                                              5/17/74
                           A-14

-------
     8.   MISCELLANEOUS AREA INCLUDING BYPASS AND
          PURGE STREAM SYSTEM
          PROBLEM/SOLUTION  Bypass dampers  bind and leak.   Piping
          leaks force shutdowns.	MgO mixing problem  forced	
          installation of premix tank.  Heat to 160°F.  Boiling
          gels slurry.  Bucket elevator to MgSOi silo limits	
          drying to 70% design capacity.  Larger buckets  to be
          installed.
P.   DESCRIBE FACTORS WHICH MAY NOT MAKE THIS A  REPRESENTATIVE
     INS TALLATION  No economical regen. facility.   No  surge 	
     provisions.       	   	    	       	
Q.   DESCRIBE METHODS OF SCRUBBER CONTROL UNDER  FLUCTUATING
     LOAD.  IDENTIFY PROBLEMS WITH THIS METHOD AND  SOLUTIONS.
     IDENTIFY METHOD OF pH CONTROL AND LOCATION  OF  pll  PROBES.
     pH Control.  Measure pH in second stage system.   Downward
     pH triggers MgO addition.  Liquid flows are constant.	
                              A-15                 5/17/74

-------
S.   ADDITIONAL NOTES



      Actual  inlet  gas  at 259°F.   Recycle  liquor  at  125-130°F.







      Pennwalt  acid cement in  stack.








      90%  S02 efficiency  at 270,000 acfm.	



      4:1  turndown  capability








      Breaker should be installed  at MgSO^ storage silo  discharge,








      Dryer fuel  design 2 gpm.   87.3 Ib/min dry MgSO,.








      Virgin MgO  $150/ton FOB  Florida








      Compliance  decision due  June 1975.  Also considering  low



      sulfur fuel.








      Purchased 100 coal  cars  @  $80 K - 1 year delivery
                            A-16

-------
                                 TECHNICAL REPORT DATA
                          (Please read Instructions on the reverse before completing)
 1 REPORT NO.
 EPA-650/2-75-057-g
                            2.
                                                       3. RECIPIENT'S ACCESSION NO.
 4 TITLE AND SUBTITLE
 Survey of Flue Gas Desulfurization Systems
   Dickerson Station,  Potomac Electric Power Company
                                  5. REPORT DATE
                                  September 1975
                                  6. PERFORMING ORGANIZATION CODE
 7 AUTHOR(S)
                                                       8 PERFORMING ORGANIZATION REPORT NO.
 Gerald A. Isaacs
9 PERFORMING OR8ANIZATION NAME AND ADDRESS
 PEDCo-Environmental Specialists, Inc.
 Suite 13,  Atkinson Square
 Cincinnati, Ohio  45246
                                  10. PROGRAM ELEMENT NO.

                                  1AB013; ROAP 21ACX-130
                                  11. CONTRACT/GRANT NO.

                                  68-02-1321, Task 6g
 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:  2/75-8/75
                                  14. SPONSORING AGENCY CODE
 IS SUPPLEMENTARY NOTES
 16 ABSTRACT
 The report gives results of a survey of a flue gas desulfurization system,  utilizing
 the Chemico/Basic MgO-SO2 removal/recovery process, that has been retrofitted
 to handle approximately half of the exhaust gas from the 190 MW unit 3 at Potomac
 E;ectric Power Company's Dickerson Station.   The system was installed at a cost of
 $0. 5 million.  The boiler burns 2 percent sulfur coal and is equipped with a 94 per-
 cent efficient electrostatic precipitator.  A single two-stage scrubber/absorber is
 used.   The liquor streams for the two stages are separate, both operating in  a
 closed-loop mode.  Magnesium oxide (MgO) is regenerated off-site.
 7.
                             KEY WORDS AND DOCUMENT ANALYSIS
                DESCRIPTORS
                                           b IDENTIFIERS/OPEN ENDED TERMS
                                               c  COSATI Field/Group
 Air Pollution
 Flue Gases
 Desulfurization
 Sulfur Dioxide
 Magnesium Oxides
 Coal
Combustion
Electrostatic Precip-
  itators
Scrubbers
Absorbers
Air Pollution Control
Stationary Sources
Chemico/Basic Process
Scrubber/Absorber
13B
2 IB
07A,07D
07B

2 ID
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                                           Unclassified
                                                                    22 PRICE
EPA Form 2220-1 (9-73)
                                        A-17

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