EPA-650/2-75-057-g September 1975 Environmental Protection Technology Series OF FLUE GAS DESULFURIZATION SYSTEMS DICKERSON STATION, POTOMAC ELECTRIC POWER CO. ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- STACK BOILER SCRUBBER FAN Figure 2.1 FGD gas flow schematic Dickerson No. 3 - PEPCO. 2-2 ------- 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 ------- 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 ------- 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. ------- 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 ------- 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 ------- 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 ------- 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. ------- 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. ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 8 DISTRIBUTION STATEMENT Unlimited 19 SECURITY CLASS (This Report) Unclassified 21. I OF PAGES 20 SECURITY CLASS (This page) Unclassified 22 PRICE EPA Form 2220-1 (9-73) A-17 ------- |