oEPA
United States
Environmental Protection
Agency
Industrial Environmental Research EPA-600/7-79-067b
Laboratory April 1979
Research Triangle Park NC 2771 1
EPA Industrial Boiler
FGD Survey:
First Quarter 1979
Interagency
Energy/Environment
R&D Program Report
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development. U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of, and development of, control technologies for energy
systems; and integrated assessments of a wide range of energy-related environ-
mental issues.
EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/7-79-067b
April 1979
EPA Industrial Boiler FGD Survey:
First Quarter 1979
by
J. Tuttle, A. Patkar. S. Kothari,
D. Osterhout, M. Heffling, and M. Eckstein
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-2603
Task No. 45
Program Element No. EHE624
EPA Project Officer: R. Michael Me Adams
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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NOTICE
This report (prepared by PEDCo Environmental, Inc.,
Cincinnati, Ohio under EPA Contract No. 68-02-2603, Task No.
45) is provided as an information transfer document. Data
in this report are supplied voluntarily by industrial
representatives; flue gas desulfurization (FGD) system
designers, vendors, and suppliers; regulatory personnel; and
others. Neither EPA nor the designated contractor warrants
the accuracy or completeness of information contained in
this report.
Initial distribution of the report is limited to organi-
zation and individuals indicating a specific interest in the
field of FGD technology. Additional copies of this report
and succeeding issues can be purchased from National Technical
Information Service, Springfield, Virginia 22151.
11
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TABLE OF CONTENTS
SECTION
•»•••••
NOTICE
TAtlLE UF CONTENTS
EXECUTIVE SUMMARY iv
t INTRODUCTION 1
8 STATUS OF INDUSTRIAL bOILtRS WITH FGU SYSTEMS 3
A SUHMAKY UF ALL INSTALLATIONS BY NAME, LOCATION, START-UP DATE*
CURRENT STATUS, AND PAGE LOCATION FUR ADDITIONAL DATA.
3 SUMMARY UF FGU SYSTEMS ON INDUSTRIAL BOILERS 6
A UKIEF SUMMARY OF THE SOURCE CHARACTERISTICS, THE CONTROL PROCESS AND
CONTROL SYSTEM SUPPLIER, ANU INFORMATION ON RECENT SYSTEM PERFORMANCE.
4 SUMMARY BY VENDOR OF FGD SYSTEMS ON INDUSTRIAL BOILERS 16
A LIST UF THE CONTROL SYSTEMS SUPPLIED BY EACH SYSTEM VENDOR OR MANUFACTURER.
5 SUMMARY BY CONTROL PROCESS OF FGO SYSTEMS ON INDUSTRIAL BOILERS 19
6 UPERATIONAL FGO SYSTEMS UN INDUSTRIAL BOILERS 22
7 FUTURE FGU SYSTEMS ON INDUSTRIAL BOILERS 26
8 SUMMARY OF DISPOSAL PRACTICES FOR FGO SYSTEMS ON INDUSTRIAL BOILERS 27
9 PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS 31
AN IN DEPTH DATA PRESENTATION FOR THE OPERATIONAL CONTROL SYSTEMS.
THIS SECTION PRESENTS BACKGROUND INFORMATION, OPERATING EXPERIENCE,
DESIGN DATA, DISPOSAL PRACTICES, AND ANY OTHER RELEVANT INFORMATION
AVAILABLE CONCERNING THE FGD SYSTEMS AT THE VARIOUS INSTALLATIONS.
10 DESIGN INFORMATION FOR UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS 123
SAME AS SECTION 9, FUR CONTROL SYSTEMS UNDER CONSTRUCTION*
u DESIGN INFORMATION FOR PLANNED FGD SYSTEMS ON INDUSTRIAL BOILERS i«6
SAME AS SECTION 9, FOR PLANNED CONTROL SYSTEMS.
12 DESCRIPTION UF INDUSTRIAL BOILER FGO SYSTEMS NOT OPERATING 159
SAME AS SECTION 9, FOR CONTROL SYSTEMS WHERE FOR SOME REASON, THE SYSTEM
IS Mil OPERATING.
IS INDUSTRIAL BOILER FGO COSTS 166
14 PROCESS DIAGRAMS FOR INDUSTRIAL BOILER FGD SYSTEMS 179
IS FUEL SULFUR CONTENT OF INDUSTRIAL BOILER FGD SYSTEMS 223
iii
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EXECUTIVE SUMMARY
THE FIRST FULL-SCALE UNITED STATES APPLICATION OF FLUE GAS OESULFURIZATION IFCO) TECHNOLOGY TO
INDUSTRIAL BOILERS HAS AT THE GENERAL MOTORS PLANT IN ST. LOUIS, MISSOURI WHERE T*0 F6D SYSTEMS MERE
INSTALLED ON THU CUAL-FIHEO BOKbttS IN 1972. IN THIS 1ST QUARTER 1979 REPORT, 126 OPERATIONAL FGD
SYSTEMS ARE DESCRIBED. THESE SYSTEMS ARE CONTROLLING 302 EMISSIONS FROM 232 BOILERS, LOCATED AT 56
PLANT SITES ACROSS THE UNITED STATES. FGD SYSTEMS AT 21 PLANTS ARE KNOWN TO BE UNDER CONSTRUCTION
OK IN SOME STAGE OF PLANNING. IN ADDITION THERE ARE 6 INSTALLATIONS INCLUDED IN THE REPORT HHERE
FGD OPERATIONS HAVE EITHER SEEN TERMINATED, INDEFINITELY SHUT UOMN, UR NEVEN STARTEO-UP. THE TOTAL
COVERAGE OF THIS REPORT IS THEREFORE 65 INSTALLATIONS. TABLE 1 SUMMARIZES THE NUMBER AND SCFM OF
THOSE SYSTEMS OPERATING, UNDER CONSTRUCTION, OK IN SOME PLANNING PHASE.
TABLE I
NUMBER AND SCFM OF INDUSTKIAL BOILER FGD SYSTEMS*
STATUS
OPERATIONAL
UNDER CONSTRUCTION
PLANNING
CONTRACT AriAHDED
LETTER OF INTENT
REQUESTING/EVALUATING BIDS
CONSIDERING USING FGO
TOTAL 57 6,505,970 163 505
•NOTE: THERE ARE PROBABLY SEVERAL FGO SYSTEMS IN ALL CATEGORIES WHICH HAVE NOT BEEN LOCATED BY
THIS SURVEY ANO THEREFORE ARE NOT COVERED IN THIS REPORT.
••CURRENT ISSUE CHANGES**
THIS 1ST QUARTER 1979 ISSUE INCLUDES SEVERAL CHANGES AS FOLLOMSS
1. THERE ARE TWO NED SECTIONS IN THE REPORTS ONE IS A SUMMARY TABLE t)Y FUEL AND FUEL SULFUR
CONTENT (SECTION IS) ANO ONE IS A SUMMARY TABLE BY FGD PROCESS (SECTION 5). THE PREVIOUS
SECTION 5, "OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS," IS NO* SECTION 6. THE PREVIOUS
SECTIONS 6 AND 7, UNDER CONSTRUCTION AND PLANNED FGD SYSTEMS, MERE CONSOLIDATED INTO A NEW
SECTION 7, "FUTURE FGO SYSTEMS ON INDUSTRIAL BOILERS.*
2. TEN UNITS, ORIGINALLY DESIGNED AS PARTICIPATE CONTROL SYSTEMS, HAVE BEEN DELETED FROM
THE REPORT I AMERICAN THREAD, AHMCO, THE SEVEN GREAT ntSTERN SUGAR PLANTS, ANO ST. REGIS.
ALL THESE UNITS DEMONSTRATE SIGNIFICANT S02 CONTROL BECAUSE OF CAUSTIC, LIME, OR AMMONIACAL
CONTENT IN THE SCRUBBING LIQUOR. THESE DELETIONS HAVE BEEN MADE AT THE REQUEST OF
RESPECTIVE PLANT REPRESENTATIVES. IN THE REPORT, THERE ARE A FEW OTHER INSTALLATIONS
MHERE A SIMILAR SITUATION EXISTS, I.E., SIGNIFICANT S02 REMOVAL IN SYSTEMS ORIGINALLY
iv
NO. OF
INSTALLATIONS
36
12
4
0
1
4
CAPACITY
SCFM
5,464,770
1,101,500
195,700
0
140,000
1,604,000
NO. OF SEPARATE
FGD SYSTEMS
126
24
5
0
2
6
NO. OF BOILERS
CONTROLLED
232
49
7
0
2
16
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DESIGNED FUR PARTICIPATE CONTROL CONTINUED. DATA TRANSFER CONCERNIN6 THIS TYPE OF SYSTEM
IS VERY USEFUL TO EVERYONE CONCERNED KITH FGO TECHNOLOGY.
3. THIS ISSUE INCLUDES SEVEN INSTALLATIONS NOT PREVIOUSLY INCLUDED IN THE SURVEY EFFORT.
THREE OF THESE UNITS ARE COVERED IN THE HIGHLIGHTS SECTION JUST BELOW: CELANE8E, INLAND
CONTAINER, AND STRATHMORE. THE OTHER FOUR ARE DOUBLE BARREL OIL* GETTY OIL IN ORCUTT,
CALIFORNIA, PFIZER, AND REICHHOLD CHEMICALS. A DETAILED INDEX TO THESE AND ALL SYSTEMS
MAY BE FOUND IN SECTION 2.
TABLE 2 SUMMARIZES THE PLANTS ACCORDING TO THE YEAR UF FGD STARTUP, AND THE SCFM CAPACITY.
HIGHLIGHTS FROM THE CURRENT INDUSTRIAL BOILER SURVEY ARE GIVEN BELOWs
TA8LE Z
STARTUP YEAR AND SCFM OF INDUSTRIAL BOILER FGO SYSTEMS
YEAR
UNITS
SCFM
1972
1973
1974
1975
1976
1977
1978
1979
1980
1982
1984
1965
YEAR NOT YET
DETERMINED
TOTAL
1
1
5
9
5
4
9
14
4
1
1
1
2
57
64,000
347,000
431,400
1,276,070
959,300
291,000
1,953,000
990,200
450,000
140,000
1,200,000
280,000
124,000
8,505,970
HIGHLIGHTS FROM THE CURRENT INDUSTRIAL BOILER SURVEY ARE GIVEN BELONI
BELRIDGE OIL CO. HAS REPORTED A RELIABILITY INDEX VALUE OF ABOUT 82X FOR THE HEATER TECHNOLOGY UNIT.
ELECTRICAL MALFUNCTIONS, MIST ELIMINATOR DAMAGE, AND ABSORBER LINING DAMAGE MERE THE PRIMARY CAUSES
FOR DONNTIME. THE C-E NATCO FGD SYSTEM STARTED UP ON MARCH 15 AND HAS DEMONSTRATED 802 REMOVAL
EFFICIENCY GREATER THAN REQUIRED.
C.A.M. CCARBI0E-AHOCO-MONSANTO) PLANNERS HAVE DECIDED THAT A DOUBLE ALKALI PROCESS MILL BE USED TO
CONTROL S02 EMISSIONS FROM THE THREE BOILERS TO BE INSTALLED AT THE C06ENERATION FACILITY.
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CELANESE CORPORATION HAS AWARDED A CONTRACT TO WHEELABRATOR-FHYE/ROCKKELL INTERNATIONAL TO INSTALL A
PARTICIPATE AND 302 CONTROL SYSTEM USING THE SPRAY DRYER/FABRIC FILTER CONFIGURATION AT THEIR
CUMBERLAND PLANT IN MARYLAND. START-UP IS SLATED FOR THE END OF 197S.
IN BAKERSFIELOt CALIFORNIA* CHEVRON U.S.A., INC. CONTINUES TO OPERATE THE THREE FSD SYSTEMS AT 10UX
AVAILABILITY. THE SOOA ASH CONSUMPTION IS CLOSE TO THE OPTIMUM STOICHIOMETHIC REUU1REMENT.
CHANSLOR WESTERN HAS CHANGED ITS NAME TO SANTA FE ENERGY CORPORATION. THE FMC DOUBLE ALKALI SYSTEM
IS SCHEDULED TO STARTUP IN MAY 1979.
MHILE REPORTING CANCELLATION OF THE PLANS FOR THE PLANT IN TEXAS, DUPONT HAS DISCLOSED THE SITE
FOR THE PLANT IN GEORGIA TO BE NEAR ATHENS.
GETTY OIL HAS COMMISSIONED THE LAST FOUR OUT OF A TOTAL OF NINE IN-HOUSE DESIGNED SYSTEMS, AT
GETTY'S ENHANCED OIL RECOVERY OPERATION NEAR BAKERSFIELD, CALIFORNIA. HOWEVER, ONLY FOUR SYSTEMS
MERE CONTINUOUSLY OPERATED DURING THIS QUARTER DUE TO THE INTRICACIES IN THE CURRENT OIL PRICING
REGULATIONS.
GREAT SOUTHERN PAPER CO. REPORTED THAT EARLIER PROBLEMS WITH PUMP SEAL FAILURES HAVE BEEN SOLVED BY
LONERING THE RECIRCULATED SOLIDS CONTENT AND INSTALLING SEAL HATER PRESSURE SWITCHES.
AT GRISSOM AIR FORCE BASE NEAR BUNKER HILL, INDIANA, CONSTRUCTION HAS BEGUN ON A 1.6 MILLION DOLLAR
CONCENTRATED DOUBLE ALKALI FGD SYSTEM SUPPLIED BY NEPTUNE AIRPOL. THE SYSTEM MILL CONTROL
EMISSIONS FROM ONE NEW AND TWO EXISTING BOILERS FIRING COAL WITH AN AVERAGE SULFUR CONTENT OF ABOUT
3.5 PERCENT.
AT THE INLAND CONTAINER CORPORATION IN NEW JOHNSONVILLE, TENNESSEE, NEPTUNE AIRPOL IS SUPPLYING AN
FGO SYSTEM USING AMMONIA SCRUBBING TECHNOLOGY. THE SYSTEM IS CURRENTLY UNDER CONSTRUCTION.
ITT RAYONIER, INC. REPORTED THAT THE BOILER AND THE AIRPOL FGD SYSTEMS OPERATED TROUBLE-FREE
THROUGHOUT THE PERIOD. THE SYSTEM HAS NOT BEEN DOWN SINCE THE FAN MAS REPAIRED .LAST QUARTER.
vi
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KERR-MCGEE SODA ASH PLANT, UTILIZING A COMBUSTION EQUIPMENT ASSOCIATES DESIGN FOR 302 HEMOVALf HE-
PORTED THAT BOTH SCRUBBERS DEMONSTRATED 100X RELIABILITY FOR THIS QUARTER.
NEK008A PAPERS, INC. IN ASHDONN, ARKANSAS REPORTED AN AVAILABILITY VALUE OF 100X FOR THEIR NEPTUNE
AIRPOL OE8I6NEO FGO SYSTEMS. THE FGD SYSTEMS MERE SHUTDOWN FOR ABOUT ONE MEEK DUE TO MILL EXPANSION
NORK AND COAL HANDLING PROBLEMS.
PFIZER, AFTER EXTENSIVE TESTING FOR FOUR YEARS, HAS DEMONSTRATED COMPLIANCE AT THE EAST ST. LOUIS,(
ILLINOIS PLANT. THE NLA-LEWIS DESIGN MAS MODIFIED BY PFIZER TO A LIME SCRUBBING SYSTEM WHICH HAS
ALSO ACHIEVED DESIRED PARTICULATE REMOVAL. THE RELIABILITY OF 9SX HAS REPORTED FOR THIS PERIOD.
AT THE ST. JOE ZINC CO. FGD SYSTEM CONSTRUCTION IS NEARING COMPLETION? THE BUREAU OF MINES CITRATE
PROCESS SYSTEM IS NOW SCHEDULED TO START-UP IN APRIL 1979.
3TRATHMORE PAPER CO. A DIVISION OF HAMMERMILL PAPER COMPANY HEPOKTED THAT A DRY SCRUBBING (LIME)
FGD SYSTEM SUPPLIED BY MIKROPUL CORPORATION, A SUBSIDIARY OF U.S. FILTER CORPORATION, IS SCHEDULED
FOR STARTUP IN MAY, 1979 AT ITS NORONOCO PLANT.
SUN PRODUCTION CO. REPORTS THAT TWO FGD SYSTEMS AHE NEARING COMPLETIONI
OILOALE, CALIFORNIA - THE SYSTEM MILL INCLUDE A TWO-STAGE SPRAY TOWER. THE SCRUBBER IS DESIGNED
TO HANDLE 6000 SCFM FROM AN EXISTING 25 MM BTU/HR OIL-FIRED STEAM GENERATOR. START-UP IS
SCHEDULED FOR EARLY APRIL 1979.
FELLOWS* CALIFORNIA - THE SYSTEM, IDENTICAL TO THE ONE AT OILOALE, IS SCHEDULED FOR STARTUP
BY EARLY MAY 1979.
TENNECO OIL CO. IS PLANNING TWO SODIUM CARBONATE FGD SCRUBBING SYSTEMS AT GREEN RIVER, WYOMING.
EACH SYSTEM MILL BE DESIGNED TO HANDLE 70,000 SCFM FROM A NEN 300,000 LB/HR COAL-FIRED BOILER. THE
SYSTEMS ARE SCHEDULED TO START-UP IN EARLY 1982.
TEXASGULF INC. REPORTED 100X RELIABILITY FOR BOTH FGO SYSTEMS AT THEIR GRANGER, WYOMING SODA ASH
PLANT. MAKEUP LIQUOR FLOW WILL NOW BE CONTROLLED BY RECIRCULATION LIQUOR PH AND DENSITY.
vii
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OF THE MORE THAN 170 ACTIVE (OPERATING* UNDER CONSTRUCTION, OR PLANNED) FGD UMTS ADDRESSED IN
THIS REPORT, MORE THAN HALF ARE BEING USED OR SCHEDULED TO BE USED IN ENHANCED OIL RECOVERY (EOR)
SITES IN CALIFORNIA. bECAUSE OF THE FACT THESfc UNITS PREDOMINATE IN THIS REPORT, A BRIEF DISCUSSION
OF THE EOR INDUSTRY FOLLOWS.
IN 1976, THt SAN JOAGIUIN VALLEY AIR BASIN PRODUCED ABOUT U5X OF CALIFORNIA'S CRUDE OIL OUTPUT.
EOR OPERATIONS ACCOUNTED FOR ABOUT SOX OF THAT PRODUCTION. ADDITIONALLY, EOR OPERATIONS IN THE
BASIN ACCOUNTED FOR APPROXIMATELY BOX OF CALIFORNIA'S TOTAL EON OPERATIONS.
THE MOST COMMON MEANS OF PRODUCING CRUDE UIL RELIES ON NATURAL UNDERGROUND PRESSURE TO PUSH THE
OIL TO THE SURFACE OF A WELL. IF NATURAL PRESSURE IS LACKING, PUMPS ARE USED TO PULL THE OIL OUT OF
AN OIL RESERVOIR. THESE METHODS OF PRODUCING CRUDE OIL ARE TERMED PRIMARY RECOVERY. IF MATER IS
PUMPED INTO AN OIL RESERVOIR (SECONDARY RECOVERY), CRUDE RECOVERY CAN BE INCREASED OR "ENHANCED*.
WHEN THE CAPABILITIES UF THE PRIMARY AND THt SECONDARY METHODS ARE EXHAUSTED, ADDITIONAL ENHANCED
RECOVERY (TERTIARY RECOVERY) METHODS ARE CONSIDERED. TERTIARY OIL RECOVERY EMPLOYS THERMAL MEANS TO
MAKE HEAVY, VISCOUS CRUDE OILS MOVE THROUGH SAND AND ROCK STKATA MORE EASILY.
TYPICALLY STEAM IS INJECTED CONTINUOUSLY TO FLOOD THE UNUERGKOUND OIL RESERVOIR WITH STEAM AND
HOT NATER. THERE *KE CURRENTLY ABOUT BOO STEAM GENERATORS (TYPICAL STEAM QUALITY IS 80 PERCENT) IN
THE SAN JOAQUIN BASIN AND MOST OF THESE UNITS HAVE CAPACITIES IN THE RANGE OF IS MM BTU/HR TO
65 MM BTU/HR. STEAM GENERATORS IN THIS SIZE RANGE VARY FROM ABOUT 5,000 TO 30,000 ACFM 9 APPROX-
IMATELY 600 F.
THE CALIFORNIA AIR RESOURCES BOARD (CAR8) HAS PROPOSED REGULATIONS WHICH MOULD REQUIRE THE
FOLLOWING FOR OIL-FIREU STEAM GENERATORS!
SOURCE SU2 EMISSION LIMIT NOX EMISSION LIMIT
NEW GENERATORS 60 PPM 100 PPM
EXISTING GENERATORS 200 PPM 150 PPM
THIS REPORT ADDRESSES IN DETAIL FGD OPERATIONS FOR THOSE EOR PRODUCTION COMPANIES MHO HAVE
GIVEN PERMISSION. THOSE COMPANIES ARE AS FOLLOWS:
BELKIDGb OIL COMPANY
CHEVRON U.S.A., INC.
GETTY OIL COMPANY
MOBIL OIL COMPANY
SANTA FE ENERGY CORPORATION
SHELL OIL COMPANY
SUN PRODUCTION COMPANY
TEXACO, INC.
IN SECTION 2 OF THIS REPORT (BEGINNING ON PAGE 3) THE READER CAN FIND A DETAILED INDEX
TO INFORMATION ON THE ABOVE INSTALLATIONS.
Viii
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SECTION 1
INTRODUCTION
THIS REPORT ADDRESSES THE APPLICATION OF FLUE CAS DESULFURIZATION (FED) TECHNOLOGY TO INDUSTRIAL
BOILERS. AN INDUSTRIAL BOILER WILL BE DEFINED AS A BOILER OK STEAM GENERATOR WHICH IS OPERATING OR
SCHEDULED FOR OPERATION AT AN INDUSTRIAL SITE. THIS IS IN CONTRAST TO A UTILITY BOILER WHEREIN THE
PRIME FUNCTION IS STEAM GENERATION AND SUBSEQUENT CONVERSION TO ELECTRICAL POWER FOR SALE TO THE
PUBLIC. THE NEED FOR SUCH A DOCUMENT HAS ARISEN AS A RESULT OF MORE STRINGENT EMISSION REGULATIONS
DESIGNED TO REDUCE SULFUR DIOXIDE (S02) EMISSIONS. IN VIEW OF THE DEVELOPMENTAL STATUS OF FGO TECH-
NOLOGY, EPA'S INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY IN RESEARCH TRIANGLE PARK, NORTH CARO-
LINA, HAS ESTABLISHED THIS PERIODICALLY UPDATED ENGINEERING APPLICATION/INFORMATION TRANSFER
PROGRAM FOR INDUSTRIAL USE OF 303 CONTROL TECHNOLOGY.
fIRST ISSUED IN DECEMBER 1977 AS A COMPREHENSIVE 900-PAGE REPORT ON S02 CONTROL SYSTEMS ON ALL
NON-UTILITY COMBUSTION AND PROCESS SOURCES, THE CURRENT SERIES, IN THE INTEREST OF ECONOMIZING OPER-
ATIONS, ADDRESSES ONLY INDUSTRIAL BOILER APPLICATIONS OF FGD TECHNOLOGY. THE FIRST ISSUE OF THIS
SERIES, ENTITLED "EPA INDUSTRIAL BOILER FGO SURVEY: FIRST QUARTER 1976," PRESENTED DETAILED TECH-
NICAL INFORMATION ON INDUSTRIAL BOILER FGD INSTALLATIONS. THE INFORMATION MAS OBTAINED BY A
SURVEY OF PLANT PERSONNEL, CONTROL SYSTEM VENDORS, REGULATORY AGENCIES, AND ENGINEERING FIRMS.
THE CURRENT REPORT REPRESENTS AN EXPANSION OVER THE FOURTH QUARTER 1970 ISSUE WITH RESPECT TO
BOTH THE NUMBER OF INSTALLATIONS, AND THE INFORMATION PRESENTED FOR EACH INSTALLATION. THE DATA
ARE GIVEN IN TWO TYPES OF TABLES! ONE GIVES SUMMARY INFORMATION* THE OTHER DETAILED INFORMATION.
SUMMARY TABLES PRESENT INFORMATION AS FUNCTIONS OF TYPE OF CONTROL PROCESS, CONTROL SYSTEM VENDOR,
DISPOSAL TECHNIQUES AND OPERATIONAL STATUS (OPERATIONAL, UNDER CONSTRUCTION, PLANNED, OR NOT OPERAT-
ING). NUMBERS, OPERATIONAL STATUS, AND OVERALL CAPACITY OF THE FGD SYSTEMS ARE SUMMARIZED IN THE
EXECUTIVE SUMMARY. DETAILED INFORMATION INCLUDESI CONTROL SYSTEM DESIGN PARAMETERS, OPERATING EX-
PERIENCE, ECONOMICS, PROBLEMS AND SOLUTIONS, WASTE DISPOSAL TECHNIQUES, AND MAINTENANCE PRACTICES.
THE INFORMATION IN THIS REPORT HILL BE PERIODICALLY UPDATED AND EXPANDED BY MEANS OF TELEPHONE
AND MAIL SURVEYS, AND PUBLISHED EACH QUARTER. IN FUTURE ISSUES, THE DATA BASE ON SELECTED PLANTS
MILL BE EXPANDED BY ON-SITE SURVEYS.
CERTAIN ENGINEERING SYMBOLS AND TERMS ARE USED VERY FREQUENTLY IN THE FIELD OF FGD TECHNOLOGY.
TABULATED BELOW ARE THE DEFINITIONS OF PERTINENT SYMBOLS AND TERMS USED IN THIS REPORT.
SYMBOL/TERM DEFINITION
ACF ACTUAL CUBIC FEET, UNIT OF GAS VOLUME MEASURED AT ITS ACTUAL TEMPERATURE AND
PRESSURE
ACFN ACTUAL CUBIC FEET PER MINUTE, UNIT OF GAS FLOW RATE MEASURED AT ITS ACTUAL
TEMPERATURE AND PRESSURE
AVAILABILITY HOURS THE FGD SYSTEM HAS AVAILABLE (WHETHER OPERATED OR NOT) DIVIDED BY HOURS IN
PERIOD, EXPRESSED AS PERCENTAGE
Cf CARBON STEEL
F DEGREES FARENHEIT, UNIT OF TEMPERATURE
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DEFINITIONS (CONTINUED)
SYMBOL/TERM
DEFINITION
F.D.
FRP
GAL
6PM
1.0.
L/6
MM
MS
MN(COUIVALENT)
OPERABILITY
PSIB
RELIABILITY
8CFM
T
N.B.
FORCED DRAFT
FIBERGLASS-REINFORCED POLYESTER (OR PLASTIC)
GALLONS
GALLONS PER MINUTE
INDUCED DRAFT
LIQUID-TO-GAS RATIO, RECIRCULATING LIQUID FLON DIVIDED BY THE ACTUAL GAS FLOW,
GAL/1000 ACF
MILLION (DOLLARS, GALLONS, BTU, ETC.)
MILD STEEL
2000 SCFM/MH IS THE CONVERSION FACTOR USED FOR THIS REPORT. ALTHOUGH THERE ARE
SEVERAL METHODS IN USE FOR ARRIVING AT EQUIVALENT MN, SUCH AS LB/HR OF STEAM,
MM BTU/HR OF HEAT INPUT, THE FACTOR MOST INFLUENTIAL IN AFFECTING EQUIPMENT
SIZING IS FLON RATE. THIS CONVERSION ALLOWS FOR EASY COMPARISON BETWEEN THESE
INDUSTRIAL FGD SYSTEMS AND THE UTILITY F60 SYSTEMS.
HOURS THE FGO SYSTEM OPERATED DIVIDED BY BOILER OPERATING HOURS IN PERIOD*
EXPRESSED AS PERCENTAGE
POUNDS PER SQUARE INCH, UNIT OF PRESSURE, AS COMPARED TO ATMOSPHERIC PRESSURE
OF 14.7 PSI.
HOURS THE FGD SYSTEM MAS OPERATED DIVIDED BY HOURS IT NA8 CALLED UPON TO OPERATE,
EXPRESSED AS PERCENTAGE
STANDARD CUBIC FEET PER MINUTE, UNIT OF GAS FLON RATE MEASURED AT TO F AND I ATM.
PRESSURE
IF THE PRESSURE IS ASSUMED TO BE ONE ATMOSPHERE, THEN THE FOLLOWING RELATION
EXI8TSI SCFM * ACFM(4fcO * 70)/(4tO *• ACTUAL TEMP)
STAINLESS STEEL
TEMPERATURE
NATER GAUGE, PRESSURE DROP EXPRESSED AS INCHES OF MATER (ATMOSPHERIC • 407 IN.)
0/0
SYMBOL USED WHEN THE .MONTH OF A,STARTUP DATE IS NOT AVAILABLE
SYMBOL USED WHEN NEITHER THE MONTH NOR THE YEAR OF A STARTUP DATE IS AVAILABLE
THE ENGLISH SYSTEM IS USED IN THIS REPORT. SOME OF THE CONVERSION FIGURES BETWEEN THE ENGLISH
AND METRIC SYSTEMS AND ABBREVIATIONS ARE SHONN BELONI
I F (FOOT) • 0.304S MITER
I T (SHORT TON) • 0.91 METRIC TON
1 LI (POUND) • 0.49 KILOGRAM
1 SAL (BALLON) • J.T9 LITER
1 ML (BARREL) • O.lfc KILOLITER
I ICPM • l.SS NORMAL CUBIC METERS PER HOUR
1 BALLON/1000 ACF • 0.115 LITERS/NORMAL CUBIC METER
1 BTU » 0.19 KCAL
ANYONE DESIRING tO RECEIVE THE QUARTERLY UPDATED VERSIONS OP THIS REPORT FREE OF COST, MAY
RIOUEST ADDITION OF HIS/HER NAME TO THE MAILING LIST BY CONTACTIN8 THE IPA PROJECT OFFICER OR
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STATUS TO APRIL 1979
SECTION 2
STATUS OF INDUSTRIAL BOILEHS WITH F6D SYSTEMS
INSTALLATION NAME
ALYESKA PIPELINE SERVICE CO.
ARCO/POLYMER5, INC.
BELRIDGE OIL CO.
BELRIDGE OIL CO.
8ELR106E OIL CO.
»UNGE, INC.
C.A.M.(CARBIDE-AMOCO-MOMSANTO)
CANTON TEXTILES
CARBORUNDUM ABRASIVES
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CELANESE CORPORATION
CHEVRON U.S.A. INC.
CHEVRON U.S.A. INC.
DOUBLE BARREL OIL CO.
OUPONT, INC.
FIRESTONE TIRE AND RUBBER CO.
FMC (SODA ASH PLANT)
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
GEORGIA-PACIFIC PAPER CO.
LOCATION
VALDtZ, ALASKA
MONACA, PENNSYLVANIA
MCKITTRICK, CALIFORNIA
MCKITTRICK, CALIFORNIA
MCKITTRICK, CALIFORNIA
CAIRO, ILLINOIS
HOUSTON, TEXAS
CANTON, GEORGIA
BUFFALO, NEW YORK
EAST PEORIA, ILLINOIS
JOLIET, ILLINOIS
MAPLETON, ILLINOIS
MAPLETON, ILLINOIS
MORTON, ILLINOIS
MOSSVILLE, ILLINOIS
CUMBERLAND, MARYLAND
6AKERSFIELD, CALIFORNIA
8AKERSFIELD, CALIFORNIA
BAKERSFIELD, CALIFORNIA
ATHENS, GEORGIA
POTTSTONN, PENNSYLVANIA
GREEN RIVER, WYOMING
OAVTONi OHIO
PARMA, OHIO
PONTIAC, MICHIGAN
ST. LOUIS, MISSOURI
TONONANDA, NEW YORK
CR08SETT, ARKANSAS
START-UP
DATE STATUS*
6-77
6-60
1-79
6-78
7-78
9-77
0-84
6-74
0-60
4-78
9-74
3-79
1-60
1-76
10-75
12-79
7-78
7-79
6-76
12-65
1-75
5-76
9-74
3-74
4-76
0-72
6-75
7-79
1
2
1
1
1
a
b
1
3
1
1
1
3
1
1
3
1
2
1
6
1
1
1
1
1
1
1
1
PAGE NUMBER*
31( 6,20,22,29,166)
123( 6,19,25,27,166)
34( 6,20,22, 0,166)
36 C 6,21,22,29,166)
381 6,21,22,29,167)
159( 6,20, 0,27,167)
146< 6,19,26,30, 0)
40( 7,19,22,28,167)
148( 7,20,26,29, 0)
421 7,19,22,27,167)
44( 7,19,22,27,168)
47C 7,19,22,27,168)
1501 7,19,26,27* 0)
49( 7,19,22,27,168)
52( 6,19,22,27,168)
15K 8,19,26,30, 0)
55( 6,20,22,29,169)
1251 8,20,25,29,169)
S7( 8,21*22,28,169)
153( 6,19,26,27, 0)
59( 8,19,22,27,1*9)
63C 9,20,23,28,170)
65( 9,21,23,29,170)
68( 9,19,23,27,170)
75( 9,21,23,27,170)
77( 9,21,23,29,170)
79( 9,21,21,29,171)
• 1C 9,19,2J,29,171)
* STATUS cooes
0 - STATUS NOT DEFINED S • PLANNEO-REOUE8TING/EVALUATIN6 BIDS
1 - OPERATIONAL 6 - PLANNED-CONSIDERING 102 CONTROLS
2 * CONSTRUCTIONAL 7 - TERMINATED
3 - PLANNED-CONTRACT AWARDED 6 • INDEFINITELY SHUT DONN
4 - PLANNED-LETTER OF INTENT SIGNED 9 - NEVER STARTED-UP
» FOR COMPLETE INFORMATION ON THE INDICATED FttO SYSTEM REFER TO FIRST PAGE LISTED.
THE INSTALLATION APPEARS IN OTHER SUMMARY SECTIONS ON THE PAGES IN PARENTHESES.
A ZERO INDICATES THAT INFORMATION IS NOT AVAILABLE FOR AN INSTALLATION IN A
PARTICULAR SECTION SEARCHED BY THE COMPUTER SYSTEM. SECTION 14 PROVIDES PROCESS
DIAGRAMS FOR SEVERAL INSTALLATIONS! AN INDEX TO THE FIGURES IS IN SECTION 14.
-------
STATUS TO APRIL 1979
SECTION 2 (CONTINUED)
STATUS OF INDUSTRIAL BOILERS WITH FGD SYSTEMS
INSTALLATION NAME
OCTTV OIL COMPANY
GETTY OIL COMPANY
GETTY OIL COMPANY
GREAT SOUTHERN PAPER CO.
ORI880M AIR FORCE BASE
HARRIS MININO CO.
INLAND CONTAINER CORPORATION
ITT RAVONIER, INC.
KERR-MC8EE CHEMICAL CORP.
MEAD PAPEHBOARO CO.
MINN-OAK FARMER'S CO-OPERATIVE
MOBIL OIL COMPANY
MOBIL OIL COMPANY
NEK008A PAPERS, INC.
NORTHERN OHIO SUGAR COMPANY
NORTHERN OHIO 8U6AR COMPANY
PFIZER, INC.
PHILLIP MORRIS* INC.
RCICHHOLO CHEMICALS, INC.
RICKENBACKER AIR FORCE BASE
SANTA PC ENER6V CORP.
SHELL OIL COMPANY
SHELL OIL COMPANY
SMELLER 8LOBE CORP.
ST. JOE ZINC CO.
STRATHMORE PAPER COMPANY
SUN PRODUCTION COMPANY
SUN PRODUCTION COMPANY
LOCATION
BAKERSFIELD, CALIFORNIA
8AKER8FIELO, CALIFORNIA
ORCUTT, CALIFORNIA
CEDAR SPRINGS, bEOKGIA
BUNKER HILL, INDIANA
SPHUCE PINE, NORTH CAROLINA
NEW JOHN8UNVILLE, TENNESSEE
FERNANDINA BEACH, FLORIDA
TRONA, CALIFORNIA
STEVENSON, ALABAMA
HAHPETUN, NORTH OAKOTA
6UTTONWILLOW, CALIFORNIA
SAN ANOO, CALIFORNIA
ASHDONN, ARKANSAS
FINDLAY* OHIO
FHEEMONT, OHIO
EAST ST. LOUIS, ILLINOIS
CHESTERFIELD, VIRGINIA
PEN8ACOLA, FLORIDA
COLUMBUS, OHIO
BAKEH8FIELD, CALIFORNIA
8AKER8FIELD, CALIFORNIA
TAFT, CALIFORNIA
NORFOLK, VIRGINIA
MONACA, PENNSYLVANIA
NORONOCO, MASSACHUSETTS
FELLOWS, CALIFORNIA
OlLDALfc, CALIFORNIA
START-UP
DATE STATUS*
6-77
12-78
6-77
0-75
11-79
0-73
3-79
0-79
6-78
0-75
6-77
4-79
0-74
2-76
10-74
10-73
9-78
6-79
6-7S
3-76
5-79
0- 0
0- 0
0-79
4-79
3-79
9-79
4-79
1
1
1
1
2
8
2
1
1
1
1
2
1
1
7
1
1
2
1
1
2
6
6
S
2
2
a
2
PAGE NUMBER*
83(10,20,21.28,171)
86(10,20,23,29,171)
86(10,21,23,28,172)
90(10,19,23,28,172)
126(10,19,23,27,172)
160(10,21, 0,JO,172)
128(10,19,25,27,172)
92(11,21,23,29,173)
94(11,20,23,28,173)
97(11,20,24,27,173)
100(11,19,24,30,173)
129(11,20,23,28,174)
102(11,21,24,28,174)
104(11,19,24,27,174)
161(12,20, 0,29,174)
108(12,21,24,29,175)
109(12,20,24,27,173)
131(12,20*25, 0,175)
112(12,20,24,29,173)
113(12,20*24,28,176)
133(12,19,23,27,176)
134(13,20,26,30, 0)
133(13,20,26,30, 0)
162(13,21, 0,30*176)
133(13,19*29,28*176)
138(13,19,23,30,177)
140(13,21,29,28,177)
142(13,21*29*28*177)
* STATUS CODES
0 - STATUS NOT DEFINED
1 - OPERATIONAL
2 - CONSTRUCTIONAL
3 - PLANNED-CONTRACT AWARDED
9 - PLANNEO-REOUE8TIN6/EVALUATING BIDS
6 - PLANNED-CONSIDERING 802 CONTROLS
7 - TERMINATED
6 - INDEFINITELY SHUT DONN
4 - PLANNED-LETTER OF INTENT SIGNED 9 - NEVER STARTED-UP
FOR COMPLETE INFORMATION ON THE INDICATED F6D SYSTEM REFER TO FIRST PAGE LISTED.
THE INSTALLATION APPEARS IN OTHER SUMMARY SECTIONS ON THE PAGES IN PARENTHESES.
A ZERO INDICATES THAT INFORMATION IS NOT AVAILABLE FOR AN INSTALLATION IN A
PARTICULAR SECTION SEARCHED BY THE COMPUTER SYSTEM. SECTION 14 PROVIDES PROCESS
DIAGRAMS FOR SEVERAL INSTALLATIONS! AN INDEX TO THE FIGURES IS IN SECTION 14.
-------
STATUS TO APRIL 1979
SECTION 2 (CONTINUED)
STATUS OF INDUSTRIAL BOILERS WITH FGD SYSTEMS
INSTALLATION NAME
TENNECO OIL CO.
TEXACO INCORPORATED
TEXACO INCORPORATED
TEXAS6ULF
TRAN8CO TEXTILES! INC.
U.S. SYPSUM CORP.
NEITERN CORRECTIONAL INST.
LOCATION
GREEN RIVER, WYOMING
SAN ARDO, CALIFORNIA
SAN AROO, CALIFORNIA
GRANGER, WYOMING
AUGUSTA* GEORGIA
OAKMONT, PENNSYLVANIA
PITTSBURGH, PENNSYLVANIA
START-UP
DATE STATUS* PAGE NUMBER*
1-82 5 156(11,20,26,28, 0)
11*73 1 117(14,21,24,30,177)
3-79 2 144(14,20,23,30,176)
9-76 1 120(14,20,24,30,176)
3-75 6 164(14,20, 0,29,176)
0-0 9 163114,19, 0,26,176)
1-60 3 137(13,21,26,26, 0)
* STATUS COOES
0 - STATUS NOT DEFINED
1 - OPERATIONAL
I - CONSTRUCTIONAL
3. - PLANNED-CONTRACT AWARDED
9 • PLANNED-REBUE8TIN6/EVALUATXNG BIDS
6 • PLANNED-CONSIDERING 802 CONTROLS
7 • TERMINATED
8 - INDEFINITELY SHUT DONN
4 - PLANNED-LETTER OF INTENT SIGNED 9 - NEVER STARTED-UP
t-FOR COMPLETE INFORMATION ON THE INDICATED F6D SYSTEM REFER TO FIRST PAGE LISTED.
THE INSTALLATION APPEARS IN OTHER SUMMARY SECTIONS ON THE PAGES IN PARENTHESES.
A ZERO INDICATES THAT INFORMATION IS NOT AVAILABLE FOR AN INSTALLATION IN A
PARTICULAR SECTION SEARCHED BY THE COMPUTER SYSTEM. 4ECTION 14 PROVIDES PROCESS
DIAGRAMS FOR SEVERAL INSTALLATIONS! AN INDEX TO THE FIGURES IS IN SECTION 14.
-------
STATUS TO APRIL 1979
SECTION 3
SUMMARY OF F60 SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
ALYESKA PIPELINE SERVICE CO.
VALDEZ, ALASKA
FMC ENVIRONMENTAL EQUIPMENT
OIL (0.03X - 0.1X SULFUR)
50,000 SCFM (DESIGN MAXIMUM)
START-UP 6/77
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGDI THE ALEYSKA FGD SYSTEM 18 UNIQUE IN THAT IT
MAS NOT INSTALLED PRIMARILY FOR CONTROL OF EMIS-
SIONS, BUT TO TREAT GAS USED IN THE OIL STORAGE
TANKS.
•1ST OTR 791 SCRUBBER OPERATIONS CONTINUED TO BE
PROBLEM-FREE DURING THIS REPORT PERIOD. PLANS
ARE BEING MADE TO TEST MORE VOLATILE AMINE
CHEMICALS IN PLACE OF THE CYCLOHEXYLAMINE.
ARCO/POLYMERS, INC.
MONACAr PENNSYLVANIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.OX SULFUR)
305,060 SCFM (TOTAL - 3 BOILERS)
START-UP 6/dO
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
*BKGDI ARCO/POLYMERS HAS ANAROEO A CONTRACT TO FMC
ENVIRONMENTAL EQUIPMENT DIVISION FOR A DOUBLE
ALKALI FGO SYSTEM. THE SYSTEM MILL CONSIST OF A
SEPARATE SCRUBBER TRAIN FOR EACH OF THE THREE
IDENTICAL BOILERS. EACH ABSORBER MODULE MILL
HAVE FOUR DISC-AND-OONUT TRAYS AND BE FOLLOWED
BY A CHEVRON MIST ELIMINATOR.
•1ST QTR 79: CONSTRUCTION OF THE FGD SYSTEM STILL
IN EARLY STAGES, CONTINUES AS SCHEDULED.
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
HEATER TECHNOLOGY
OIL (l.IX SULFUR)
12,000 SCFM (1 BOILER)
8TART-UP 6/76
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGDI BELRIOGE IS UTILIZING A HEATER TECHNOLOGY
FGD SYSTEM TO CONTROL SOZ EMISSIONS FROM A SMALL
OIL-FIRED (l.IX SULFUR) STEAM GENERATOR AT AN EN-
HANCED OIL RECOVERY SITE.
•1ST OTR 791 A RELIABILITY INDEX OF 82X MAS
ACHIEVED THIS QUARTER. ELECTRIC MALFUNCTIONS AND
DAMAGE TO THE LINING AND MIST ELIMINATOR MERE THE
MAJOR PROBLEMS IN ADDITION TO CAUSTIC LINE LEAKS
AND GAUGE GLASS REPAIRS.
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
THERMOTICS INC.
CRUDE OIL (l.IX SULFUR)
12,000 SCFM
START-UP 7/78
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGDI BELRIDGE IS UTILIZING A THERMOTICS, INC.
FGO SYSTEM TO CONTROL S02 EMISSIONS FROM A SMALL
OIL-FIRED (l.IX SULFUR) STEAM GENERATOR AT THE
MCKITTRICK ENHANCED OIL RECOVERY SITE.
•1ST QTR 791 THE FGD SYSTEM MAS OONN FOR THE
ENTIRE PERIOD DUE TO FAILURE OF A WELD LINE ON
THE ABSORBER. THE MELDING NAB REPAIRED AND THE
SYSTEM MAS SCHEDULED TO START-UP ON MARCH-»3,
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
C-E NATCO
CRUDE OIL (l.IX SULFUR)
12,000 serM
START-UP 1/79
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGDI C-E NATCO HAS SUPPLIED A CAUSTIC SCRUBBING
FGD SYSTEM TO BELRIDGE OIL FOR ONE 50 MM BTO/HR
STEAM GENERATOR. THE SYSTEM STARTED UP IN
MARCH 1979.
• 1ST QYR'WTME FIRST START-UP DID NOT ACHIEVE
COMPLIANCE (90X 802 REMOVAL) DUE TO INEFFICIENT
SPRAY NOZZLE DESIGN, HIGH BLONDONN RATl, AND LON
CAUSTIC ADDITION. THE SECOND TESTING PERFORMED ON
MARCH IS, APPEARS TO HAVE ACHIEVED HIGH 802
REMOVAL O9SX).
BUNGE, INC.
CAIRO, ILLINOIS
DRAVO CORP./NAT'L LIME ASS'N
COAL (IX SULFUR)
4«,000 SCFM (TOTAL - 2 BOILERS)
START-UP 9/77
LIME SCRUBBING
STATUS - INDEFINITELY SHUT DONN
•BKGDI BUN8E PURCHASED THIS LIME SYSTEM FOR TEST-
ING PURP08IS. THE PLANT REPORTS THAT THE LEMIS
SCRUBBER, A HORIZONTAL ROTARY SCRUBBER KITH
INTERNAL CHAINS, PERFORMED HILL DURIN8 THE TEST,
EFFECTING 94S 802 CONTROL.
•1ST OTR 791 SUNOS IS STILL FIRING LON SULFUR
(0.9X) COAL AND HAS NO PLANS TO REUSE THE SYSTEM.
C.A.M.(CARBIOE-AMOCO-MONSANTO)
HOUSTON, TEXAS
VENDOR NOT VET SELECTED
FU1L NOT YET SELECTED
1,100,000 8CFN (J BOILERS)
START-UP 0/84
DOUBLE ALKALI
STATUS - PLANNED-CONSIDERING 802 CONTROL
•BKGDI UNION CARBIDE, AMOCO, AND MONSANTO HAVE
ENTERED INTO A JOINT VENTURE (C.A.M.) MMICH HILL
PRODUCE 9,500,000 .LS/HR STEAM FOR PROCESS USE AND
16S MN ELECTRICITY TO THE LOCAL UTILITY BRIO.
• 1ST OTR 791 AFTER THE SELECTIONS A VENDOR TNI
CONSTRUCTION MILL START IN 2ND QUARTER WO HITM
COMPLETION SCHEDULED FOR JRO QUARTER 1984.
-------
STATUS TO APRIL 1979
SECTION 3 CCONTINUEO)
SUMMARY OF FGD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
CANTON TEXTILES
CANTONi GEORGIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (0.8X SULFUR)
25,000 SCFM Cl BOILER)
START-UP 6/74
CAUSTIC NASTE STREAM
STATUS » OPERATIONAL
*BKGDI AT CANTON TEXTILES THE CONTROL SYSTEM CON-
SISTS OF AN FMC MEDIUM ENERGY VENTURI SCRUBBER AND
UTILIZES A CAUSTIC NASTE STREAM FOR 802 REMOVAL.
THE UNIT HAS BEEN IN OPERATION SINCE JUNE 1974.
•1ST QTR 79: THE FGO SYSTEM WAS DOWN FOR ABOUT
ONE MEEK WHEN THE FAN MOTOR BURNED OUT. IT MAS
REWIRED AND RETURNED TO SERVICE.
CARBORUNDUM ABRASIVES
BUFFALO, NEW YORK
CARBORUNDUM ENVIR. SYS. LTD.
COAL 12.ax SULFUR)
30,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/80
LIME SCRUBBING
STATUS - PLANNED-CONTRACT AWARDED
•BKGDI THE CARBORUNDUM F9D SYSTEM CONSISTS OF A
VENTURI FOR PARTICULATE CONTROL FOLLOWED BY A SIX-
STAGE SPRAY TONER. IN 1975 THE VENTURI MAS PUT
INTO SERVICE USING MATER ONLY. THE HUH CHLORIDES
CONTENT OF THE FLUE GAS CAUSED SERIOUS CORROSION
PROBLEMS, AND BOTH THE VENTURI AND THE SPRAY TONER
WILL BE REPLACED BEFORE START-UP OF THE COMPLETE
LIME SCRUBBING SYSTEM IN I960. THE NEW VENTURI
AND SPRAY TOMER WILL BE MADE OF HA8TELLOY-C
AND FRPr RESPECTIVELY.
CATERPILLAR TRACTOR CO.
EAST PEORIAi ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.2X SULFUR)
210,000 SCFM (TOTAL - « BOILERS)
START-UP 4/76
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
•BKGDI START-UP OCCURRED IN APRIL 197S. FGD
OPERATIONS PROCEEDED FOR 30 DAYS BEFORE BOILER
PLANT SHUTDOWN FOR THE SUMMER. AN ABNORMALLY HIGH
PRESSURE DROP THROUGH THE SCRUBBERS IS RESTRICTING
THE BOILERS TO ABOUT SOX OF THEIR CAPACITY.
•1ST OTR 791 THE P6D SYSTEMS OPERATED NITHOUT ANY
MAJOR PROBLEMS. UNAVAILABILITY OF 800A ASH CAUSED
THE SHUTDONN OF FGD OPERATIONS FOR MORE THAN ONE
MONTH.
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
ZURN INDUSTRIES
COAL (3.2X SULFUR)
67,000 SCFM (TOTAL - 2 BOILERS)
STAKT-UP 9/74
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
•8K60I THE FGO SYSTEM CONSISTS OF AN INDEPENDENT
SCRUBBING TRAIN ON EACH OP TNO COAL-FIRED BOILERS.
•1ST QTR 79t THE F8D SYSTEMS WERE PLAGUED BY A
SERIES OF PROBLEMS. MAJOR PROBLEMS MERE FAILURE
OF THE THICKENER PUMP, SLUDGE ACCUMULATION AND
PLUGGING AT VARIOUS PLACES IN THE SYSTEMS* AND
FREEZING OF SODA ASH SCREM FEEDER.
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.IX SULFUR)
131,000 SCFM (TOTAL • 3 BOILERS)
START-UP 3/79
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
•BKGDI AT THE CATERPILLAR MAPLETON PLANT, FMC CON"
CENTRATEO MODE DUAL ALKALI TECHNOLOGY MILL !E
UTILIZED TO CONTROL 801 EMISSIONS.
•1ST OTR 791 CONfTRUCTION Of THE THREE F8D SYSTEMS
IS COMPLETE. START-UP OPERATION! BB8AN MARCH 19.
ONE OF THE LARGE BOILERS MILL NOT BE OPERATED
THIS YEAR.
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.21 SULFUR)
105,000 SCFM (TOTAL - i BOILERS)
START-UP 1/60
DOUBLE ALKALI (CONCENTRATED)
STATUS - PLANNED-CONTRACT AWARDED
•BKGDI AT THE MAPLBTON PLANT, AN ADDITIONAL
i NED BOILERS ARE PLANNED FOR START-UP IN THE
EARLY 1960'S. INSTALLATION FOR THESE TNO HAS
STARTED. THEY MILL EACH IE EQUIPPED
WITH FMC DOUBLE ALKALI FGO IV8TEM8. TMEY NHL,
SHARE RE0ENERATION AND SLUOOE HANOLIN8 FACILITIES
NITH THE OTHER THREE PSD SYSTEMS AT THIS SITE.
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
ZURN INDUSTRIES
COAL (3.IX SULFUR)
38,000 8CFM (TOTAL • I BOILERS)
START-UP I/7S
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
•BKGDI THE CATERPILLAR MORTON PLANT UTILIZE! IURN
INDUSTRIES' DILUTE MODE DOUBLE ALKALI TBCHNOL08Y
TO CONTROL EMISSIONS FROM THE STEAM PLANT*
•1ST QTR 791 AN OPERATIN8 PERMIT HAS MEN GRANTED
FOR THE PLANT BY IBPA. OURINB THE REPORT PERIOD
FGD SYSTEMS 1 AND I YIELDED RELIABILITY VALUES
OF 99,TK AND 80.91 RESPECTIVELY. MIST ELIMINATOR
PLU86INO AND FROZEN PIPIN8 MERE MAJOR CAUSE! Of
DOMNTIME.
-------
STATUS TO APRIL 1979
SECTION 3 (CONTINUED)
SUMMARY OF FGO SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
CATERPILLAR TRACTOR CO.
MOSSVILLEt ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.ai SULFUR)
140,000 SCFM (TOTAL - 4 BOILERS)
START-UP 10/75
DOUBLE ALKALI (CONCENTRATED)
STATUS • OPERATIONAL
•BK60: THE CATERPILLAR MOSSVILLE PLANT HAS UTIL-
IZED FMC CONCENTRATED MODE FGO SYSTEM EACH HEATING
SEASON SINCE OCTOBER 1975. THERE ARE FOUR COAL-
FIRED BOILERS, EACH POSSESSING A SEPARATE SCRUB-
BING TRAIN.
•1ST OTR 79: THE OPERATION OF FGD SYSTEM CONTINUES
TO BE FLUCTUATING AND SPORADIC. MIST ELIMINATOR
PLUGGING AND CHEMICALS IMBALANCE ARE THE MAJOR
PROBLEMS.
CELANESE CORPORATION
CUMBERLAND, MARYLAND
MHEELABRATOR-FRYE/ROCKNELL INT
COAL (1.0-2.01 SULFUR)
50,700 SCFM (1 BOILER)
START-UP 12/79
DRY LIME SCRUBBING
STATUS - PLANNED-CONTRACT AWARDED
•BKGD: A SPRAY DRYER/FABRIC FILTER CONFIGURATION
MILL BE USED TO CONTROL PARTICULATE AND 802
EMISSIONS FROM A COAL-FIRED BOILER AT THE
CUMBERLAND PLANT. A DRY HASTE PRODUCT MILL BE
GENERATED. CONSTRUCTION HILL BEGIN IN JUNE 1979
WITH START-UP EXPECTED BY THE END OF 1979.
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
KOCH ENGINEERING
OIL (UU SULFUR)
248,000 SCFM (TOTAL - 16 BOILERS)
START-UP 7/78
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
*8K60: CHEVRON U.S.A. UTILIZES THREE KOCH ENGINE-
ERING ABSORBERS TO REMOVE 802 FROM THE FLUE GAS OF
EIGHTEEN BOILERS. THE SYSTEMS ARE DESIGNED TO
REDUCE S02 EMISSIONS TO LESS THAN 70 PPM.
•1ST OTR 79: THE FGD SYSTEMS OPERATED PROBLEM-FREE
DURING THE QUARTER DEMONSTRATING AN AVAILABILITY
INDEX OF 1001.
CHEVRON U.S.A. INC.
BAKERSFIELO, CALIFORNIA
KOCH ENGINEERING
OIL (1.1* SULFUR)
146,000 SCFM (TOTAL - 12 BOILERS)
START-UP 7/79
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
•1ST QTR 79: CHEVRON U.S.A. IS INSTALLING
TWO MORE FGD SYSTEMS AT THE BAKERSFIELD OIL SITE.
THESE HILL BE ONCE-THROUGH, SODIUM CARBONATE
SCRUBBING SYSTEMS AND ARE SCHEDULED TO GO ON*
STREAM BY JULY 1979. A CONTRACT HAS BEEN AWARDED
TO KOCH ENGINEERING FOR THE DESIGN AND INSTALLA-
TION OF THE TWO SYSTEMS. CONSTRUCTION HAS STARTED
IN JANUARY 1979.
DOUBLE BARREL OIL CO.
BAKERSFIELO, CALIFORNIA
C-E NATCO
OIL (l.U SULFUR)
12,000 SCFM (1 BOILER)
START-UP 6/78
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGOt C-E NATCO SUPPLIED THIS FGD SYSTEM AS A
PROTOTYPE UNIT. EXTENSIVE TESTS MERE PERFORMED
OVER A HIDE RANGE OF SEVERAL PARAMETERS INCLUDING
PH, L/C RATIO AND SPRAY NOZZLE DESIGN.
*1ST QTR 79: THE RECIRCULATION PUMP SEAL NEEDED
REPLACEMENT.
DUPONT, INC.
ATHENS, 6EOR6IA
VENDOR NOT VET SELECTED
COAL (l.SX SULFUR)
280,000 SCFM (TOTAL - 3 BOILERS)
START-UP 12/85
DOUBLE ALKALI
STATUS - PLANNED-CONSIDERING 302 CONTROL
•BKGD: DUPONT ANNOUNCED PLANS TO ERECT A CHEMICAL
PLANT NEAR ATHENS, GEORGIA. THE PLANT NILL HAVE
THREE COAL-FIRED BOILERS, WITH ONE ON STANDBY.
THE COMPANY HAS SELECTED THE DOUBLE ALKALI PROCESS
AS THE BASIS FOR A PRELIMINARY EVALUATION OF AIR
POLLUTION CONTROL STRATEGY.
•1ST QTR 791 THE PLANT IS SCHEDULED TO STARTUP BY
LATE 1985.
FIRESTONE TIRE AND RUBBER CO.
POTTSTONN, PENNSYLVANIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (2.5 - 3.OX SULFUR)
8070 SCFM (13,000 ACFM a 300 F)
START-UP 1/75
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
•BKGD: THE FGD SYSTEM AT FIRESTONE-POTTSTOWN
CONSISTS OF AN FMC DOUBLE ALKALI DUAL THROAT
VENTURI SCRUBBER. THIS CONTROL SYSTEM HAS BUILT
AS A DEMONSTRATION PROJECT FUNDED BY FIRESTONE.
•1ST QTR 79: DURING THE PERIOD, FGD SYSTEM OPER-
ATED NITM RELIABILITY VALUE OF 93.6X. THE MAJOR
CAUSES OF DOHNTIME MERE PLU6GIN6 OF SPRAY NOZZLES,
REPAIRS ON VACUUM FILTER, SEPARATOR AND RECIRCU-
LATION LINE.
-------
STATUS TO APRIL 1979
SECTION 3 (CONTINUED)
SUMMARY OF FGD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
FMC (SODA ASH PLANT)
GREEN RIVER, NYOMING
FMC ENVIRONMENTAL EQUIPMENT
COAL (IX SULFUR)
446*000 SCFM (TOTAL - 2 BOILERS)
START-UP 5/76
'SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
•BKGD: THE FGD SYSTEM CONSISTS OF TMO FMC SODIUM
SCRUBBING UNITS TO REMOVE SULFUR DIOXIDE AND PART-
ICULATE MATTER FROM THE FLUE GAS OF TWO BOILERS.
•1ST QTR 79! THE PLANT REPORTED NO MAJOR OPERATING
PROBLEMS. DURING THIS PERIOD THE RELIABILITY
VALUE OF THE FGD SYSTEM HAS REPORTED TO BE
CLOSE TO 100X.
GENERAL MOTORS CORPORATION
DAYTON* OHIO
ENTOLETERr INC.
COAL(0.7Jt - a.OX SULFUR)
36,000 SCFM (TOTAL - 2 BOILERS)
START-UP 9/74
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGD: THE FGD SYSTEM CONSISTS OF TWO ENTOLETER
SODIUM HYDROXIDE SCRUBBING UNITS TO CONTROL EMIS-
SIONS FROM TMO 60,000 LB/HR COAL-FIRED BOILERS.
•1ST OTR 79: INSTALLATION OF THE NEW HASTELLOY-Q
MIST ELIMINATORS HAS BEEN COMPLETED. AN
AVAILABILITY OF 80X WAS REPORTED FOR THIS PERIOD.
GENERAL MOTORS CORPORATION
PARMA, OHIO
GM ENVIRONMENTAL
COAL (Z.5X SULFUR)
128,400 SCFM (TOTAL - 4 BOILERS)
START-UP 3/74
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
•BKGD: THE FGD SYSTEM CONSISTS OF 4 CM-DESIGNED
DUAL ALKALI SCRUBBERS OPERATING ON 4 BOILERS. THE
SCRUBBERS HANDLE A TOTAL 310,000 ACFM OF FLUE GAS.
•1ST OTR 79: AN OPERABILITY OF 39X HAS REPORTED
FOR THE PERIOD. CHEMICAL BALANCE PROBLEMS HERE
ENCOUNTERED IN DECEMBER AND CONTINUED THROUGH MOST
OF THE PERIOD. HIGH PH CAUSED PLUGGING IN THE TOP
TRAY, THE PH PROBES USED FOR CONTROLLING CHEMICAL
FEED MERE RELOCATED. HIGH EXCESS AIR AND CHANGES
IN THE L/G RATIO ARE BELIEVED TO BE THE CAUSE.
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
GM ENVIRONMENTAL
COAL (0.84X SULFUR)
107r360 SCFM (TOTAL - 2 BOILERS)
START-UP 4/76
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGDI THE SCRUBBER SYSTEM CONSISTS OF TNO G.M.
SODIUM UNITS FOR THE REMOVAL OF FLYASH AND SULFUR
DIOXIDE FROM THE FLUE GAS OF TNO COAL-FIRED
BOILERS.
•1ST OTR 79: PRESSURE FILTERS HAVE BEEN INSTALLED
IN THE RECIRCULATION LINES TO PREVENT FURTHER
ABRASION PROBLEMS IN PUMPS AND PIPING DUE TO
FLYASH. TO DATE, AN AVAILABILITY OF 100X WAS
REPORTED FOR THE PERIOD.
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
A.D. LITTLE
COAL CS.2X SULFUR)
64,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/72
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGO: THIS S02 CONTROL SYSTEM CONSISTS OF TWO GM
DESIGNED SODIUM SCRUBBING UNITS OPERABLE ON TWO
OF THE FOUR COAL-FIRED BOILERS. THE SYSTEM IS
EQUIPPED WITH 60 F REHEAT AND HAS THE CAPABILITY
FOR FGD SYSTEM BYPASS.
•1ST QTR 79: A SHORTAGE OF CAUSTIC AND A FAN
BEARING FAILURE CAUSED SOME DOWNTIME DURING MARCH.
THE SYSTEM WAS SHUT DOWN FOR THE SUMMER SEASON
AT THE END OF MARCH.
GENERAL MOTORS CORPORATION
TONONANDA, NEW YORK
FMC ENVIRONMENTAL EQUIPMENT
COAL (1.2X SULFUR)
92,000 SCFM (TOTAL - 4 BOILERS)
START-UP 6/75
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKGD: THE FGD SYSTEM CONSISTS OF FOUR CM SODIUM
SCRUBBING UNITS FOR THE REMOVAL OF PARTICULATES
AND SULFUR DIOXIDE FROM FOUR COAL-FIRED BOILERS.
•1ST QTR 79: THE FOUR STAINLESS STEEL STUB STACKS
HAVE CORRODED DUE TO ACID CARRY. A DECISION
TO EITHER RELINE OR REPLACE THEM HAS NOT BEEN
MADE. TO DATE, AN AVAILABILITY OF 100X MAS
REPORTED FOR THE PERIOD.
GEORGIA-PACIFIC PAPER CO.
CROSSETT, ARKANSAS
NEPTUNE AIRPOL, INC.
BARK,COAL/OIL (1.5X - 2.OX SULFUR)
220,000 SCFM (1 BOILER)
START-UP 7/75
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
•BKGD: THE FGD SYSTEM CONSISTS OF AN AIRPOL
CAUSTIC SCRUBBING UNIT TO REMOVE SULFUR DIOXIDE
AND PARTICULATE MATTER FROM THE FLUE GAS OF A
COAL/BARK OR OIL/BARK POWER BOILER. THE SYSTEM IS
PRECEDED BY CYCLONES FOR PARTICULATE REMOVAL.
•1ST QTR 79: THE PLANT REPORTED NO OPERATING
PROBLEMS THIS QUARTER. BARK WAS BURNED DURING THE
PERIOD WITH SUPPLEMENTAL OIL BURNED PART OF THE
TIME.
-------
STATUS TO APRIL 1979
SECTION 3 (CONTINUED)
SUMMARY OF F6D SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
6ETTY OIL COMPANY
BAKERSFIELO, CALIFORNIA
FMC ENVIRONMENTAL EQUIPMENT
OIL (1.1X SULFUR)
73,000 SCFM (TOTAL - 6 BOILERS)
START-UP 6/77
SODIUM CARBONATE SCRUBBING
STATUS " OPERATIONAL
*BK60l FMC SUPPLIED THIS SODIUM CARBONATE SCRUB-
BING SYSTEM IN JUNE 1977. GETTY ENGINEERS HAVE
PERFORMED MAJOR MODIFICATIONS TO IMPROVE THE
PERFORMANCE.
•1ST OTR 791 THE SYSTEM MAS SHUT DONN DURING THIS
PERIOD, AND MAY REMAIN INOPERABLE IN THE NEAR
FUTURE DUE TO THE INTRICACIES IN THE CURRENT OIL
PRICING REGULATIONS.
GETTY OIL COMPANY
BAKERSFIELO, CALIFORNIA
IN-HOUSE DESIGN
OIL (l.U SULFUR)
d91,000 SCFM (TOTAL - 61 BOILERS)
START-UP 12/78
SODIUM CARBONATE SCRUBBING
STATUS • OPERATIONAL
•BKGOt GETTY OIL COMPANY HAS DEVELOPED AN IN-
HOUSE FGD PROCESS DESIGN TO CONTROL EMISSIONS FROM
81 STEAM GENERATORS, AT THE BAKER8FIELD EOR SITE.
THERE WILL BE 9 FGD SYSTEMS, EACH CONTROLLING FLUE
GAS GENERATED BY 9 STEAM GENERATORS. EACH SYSTEM
WILL INCLUDE AN ABSORBER MODULE CONTAINING THREE
FLEXITRAYS AND ONE FLEXIMESH MIST ELIMINATOR.
*1ST OTR 791 LAST FOUR SYSTEMS HERE STARTED UP
DURING THIS PERIOD* AFTER PERFORMANCE TESTING,
ONLY 4 OUT OF THE 9 SYSTEMS REMAINED OPERATIONAL.
GETTY OIL COMPANY
ORCUTT, CALIFORNIA
IN-HOUSE DESIGN
OIL (4.OX SULFUR)
SOOO SCFM (1 BOILER)
START-UP 6/77
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
*BKGDI FMC SUPPLIED THE ORIGINAL F6D SYSTEM.
HOWEVER, GETTY ENGINEERS HAVE PERFORMED EXTENSIVE
MODIFICATIONS TO IMPROVE THE 802 REMOVAL. THE
DI8C-ANO-OONUT TRAYS HAVE BEEN REPLACED BY A
MUNTERS MIXING UNIT AS THE PACKING MATERIAL.
*18T QTR 791 THE FOD SYSTEM HAS BEEN OPERATIONAL
SINCE MARCH 10. COMPLIANCE TESTING NAB CARRIED
OUT AND AT THE TIME OF THE REPORT RESULTS HAD NOT
BEEN RECEIVED. NO PLUGGING HAS OCCURRED BECAUSE
OF THE HYDROCLONES IN THE RECIRCULATION LINES.
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
NEPTUNE AIRPOL. INC.
BARK,COAL/OIL U.OI - 2.OX SULFUR)
410,000 SCPM (TOTAL - 2 BOILERS)
START-UP 0/75
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
*BKGDI THE FGD SYSTEM CONSISTS OF TNO AIRPOL
CAUSTIC SCRUBBERS TO CONTROL PARTICULATE AND
SULFUR DIOXIDE FROM TNO PONER BOILERS. THE
PRIMARY FUEL IS BARK/COAL (BARK/OIL IS FIRED
OCCASIONALLY).
•1ST OTR 791 PROBLEMS ARE STILL ENCOUNTERED WITH
PUMP SEALS. THE RECIRCULATION PUMPS NITH MEN SEAL
WATER PRESSURE SNITCHES, ARE NOW OPERATING WITH
CONVENTIONAL PACKING AND ARE ROTATED DAILY TO
REPLACE RINGS.
GRI8SOM AIR FORCE BASE
BUNKER HILL, INDIANA
NEPTUNE AIRPOL, INC.
COAL (S.0» - 3.SI SULFUR)
32,000 8CFM (TOTAL • 3 BOILERS)
START-UP 11/79
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
*18T OTR 791 CONSTRUCTION HAS BEGUN ON A 32,000
SCFM CONCENTRATED DOUBLE ALKALI FGD SYSTEM. THE
SYSTEM IS BEING SUPPLIED BY AIRPOL INDUSTRIES AND
CONSISTS OF 2 PARALLEL VENTURI SCRUBBERS, EACH
FOLLOWED BY A CYCLONIC SEPARATOR AND A STUB BTACK.
AIRPOL HAS GUARANTEED THAT EMISSIONS FROM THE
SCRUBBER WILL NOT EXCEED 1.2 LB/MM BTU SOI OR
0.171 LB/MM BTU FOR PARTICULATE.
HARRIS MINING CO.
SPRUCE PINE, NORTH CAROLINA
W.N. SLY MANUFACTURING CU.
COAL (0.81 SULFUR)
•,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/73
RATER BCRUBBINB (NA,NH3 OPTN.)
BTATUB - INDEFINITELY SHUT DOWN
*BKGD! THE FOD SYSTEM CONSISTS OF A W.W. SLY IM"
PINJET 8CNUBBER CURRENTLY BEIN6 USED STRICTLY A8 A
PARTICULATE CONTROL DEVICE. THE SYSTEM HAS THE
CAPABILITY OF SCRUBBING WITH AMMONIA OR CAUSTIC
IF 802 CONTROL IS NECES8ARY. HOWEVER, AS LONG AB
CURRENT LOW-SULFUR COAL SUPPLIES LAST, THERE IB NO
NEED FOR 802 CONTROLS.
INLAND CONTAINER CORPORATION
NEN JOHNBONVILLE. TENNESSEE
NEPTUNE AIRPOL INC.
WOOD/SPENT LIQUOR (43.01 SULFUR)
194,000 SCFM Cl BOILER)
START-UP SW
AMMONIA SCRUBBING
BTATUB - CONSTRUCTION
*BKGOI AN AIRPOL DESIGNED PARTICULATE AND B02
CONTROL SYSTEM AT THIB PAPER MILL MILL CONBIBT OF
A VENTURI SCRUBBER AND SEPARATOR/ABSORBER COMBINA-
TION WITH A CHEVRON MIBT ELIMINATOR.
10
-------
STATUS TO APRIL 1979
SECTION 3 (CONTINUED)
SUMMARY OF FCD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
ITT RAYONIERi INC.
FERNANOINA BEACH* FLORIDA
NEPTUNE AIRPOL, INC.
BARK,OIL (2.OX - 2.5X SULFUR)
176,000 SCFM (TOTAL - 4 BOILERS)
START-UP 0/75
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
*BKGDI AT FERNANDINA BEACH* ITT RAYONIER FIRES
BARK AND OIL IN TWO OF THE FOUR PROCESS STEAM
BOILERS. PARTICULATE AND 802 EMISSIONS ARE CON-
TROLLED IN TNO AIRPOL SCRUBBING TRAINS.
•1ST OTR 79! THE F60 SYSTEM OPERATED CONTINUOUSLY
THROUGHOUT THE PERIOD WITH 100X RELIABILITY.
KERR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
COMBUSTION EQUIPMENT ASSOC.
COKE/COAL/OIL (0.5X - S.OX SULFUR)
490*000 SCFM (TOTAL - 2 BOILERS)
START-UP 6/78
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
*BKGDI THE FGD SYSTEM CONSISTS OF A COMBUSTION
EQUIPMENT (CEA) SODA ASH SCRUBBING SYSTEM NHICH
REMOVES FLYASH AND SULFUR DIOXIDE FROM THE FLUE
GAS OF THE TWO COAL-FIRED BOILERS.
*18T DTK 791 THE 317L S3 SIEVE TRAYS ARE WORKING
WELL. FUEL USED, WAS A MIXTURE OF O.SX SULFUR
COAL AND 3.5X SULFUR COKE. BOTH SCRUBBERS
DEMONSTRATED 100X RELIABILITY DURING THIS PERIOD.
MEAD PAPERBOARD CO.
STEVENSON, ALABAMA
NEPTUNE AIRPOLr INC.
OIL (l.SX - 3X SULFUR)
100,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/75
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
•BKGDl AIRPOL HAS SUPPLIED A PARTICULATE
AND S02 CONTROL SYSTEM FOR THE TWO OIL-FIRED
BOILERS AT THIS MEAD PULP MILL.
•1ST QTR 791 THE SCRUBBER DEMONSTRATED 100X RELI-
ABILITY DURING THE REPORT PERIOD.
MINN-DAK FARMER'S CO-OPERATIVE
NAHPETON, NORTH DAKOTA
KOCH ENGINEERING
LIGNITE (l.OX SULFUR)
164,000 SCFM (TOTAL - 2 BOILERS)
START-UP 6/77
AMMONIA SCRUBBING
STATUS - OPERATIONAL
•BKGOt KOCH ENGINEERING HAS SUPPLIED TWO AMMONIA*
BASED 802 CONTROL SYSTEMS FOR THESE COAL-FIRED
BOILERS. EACH YEAR THE PLANT ONLY PRODUCES SUGAR
DURING THE SEPTEMBER-FEBRUARY PERIOD.
*18T QTR 79t MODIFICATIONS TO CORRECT AN EXCESS
HEAT PROBLEM AT THE DIGESTERS ARE PLANNED FOR
THIS SUMMER. THE SYSTEM HAS OPERATED ALMOST
TROUBLE-FREE THIS QUARTER.
MOBIL OIL COMPANY
8UTTONWILLOW, CALIFORNIA
HEATER TECHNOLOGY
OIL (1.1X SULFUR)
SO,500 SCFM (TOTAL - 7 BOILERS)
START-UP 4/79
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
•BKGDl MOBIL OIL HAS PURCHASED SEVEN EOUCTOR-TYPE
SCRUBBERS FROM HEATER TECHNOLOGY FOR THE CONTROL
OF EMISSIONS FROM 7 STEAM GENERATORS (25 MM BTU/
HR). EACH SYSTEM CONSISTS OF A VENTURI SECTION, A
RECYCLE TANK, AND AN OUTLET DUCT WITH A MIST
ELIMINATOR.
•1ST QTR 791 START-UP DATE HAS BEEN EXTENDED TO
APRIL 1979 DUE TO DELAYS IN AWARDING SUBCONTRACTS
FOR PIPING AND OTHER WORK.
MOBIL OIL COMPANY
SAN AROO, CALIFORNIA
IN-HOUSE DESIGN
OIL (2.OX - 2.2SX SULFUR)
175,000 SCFM (T01AL - 28 BOILERS)
START-UP 0/74
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
•BKDGI MOBIL HAS DESIGNED THE FGD SYSTEM BY IN-
HOUSE ENGINEERING BASED ON A PATENTED SODIUM HYDR-
OXIDE SCRUBBING PROCESS. THE I.D. FANS ARE LINED
WITH EPOXY RESIN TO REDUCE CORROSION.
•1ST QTR 791 ONLY 9 OUT OF THE 25 STEAM GENERATORS
WERE OPERATING DURING THIS PERIOD. MOBIL REPORTS
THAT THIS SITUATION MAY CONTINUE THROUGH SEPT.
1979 BECAUSE OF THE INTRICACIES IN THI CURRENT
PRICING REGULATIONS.
NEK008A PAPERS, INC.
A8HDOWN, ARKANSAS
NEPTUNE AIRPOL, INC.
COAL UX - l.SX SULFUR)
211,000 SCFM (TOTAL - 1 BOILER)
START-UP 2/76
CAUSTIC SCRUBBING
STATUS • OPERATIONAL
•BKGDl THE FOD SYSTEM CONSISTS OF TWO AIRPOL
CAUSTIC SCRUBBERS CONTROLLING FLYASH AND SULFUR
DIOXIDE.
•1ST QTH 791 NO MAJOR FOD SYSTEM RELATED PROBLEMS
WERE ENCOUNTERED. THE SYSTEM WAS DOWN FOR ABOUT
ONE WEEK DUE TO MILL EXPANSION WORK AND
PULVERIZER AND BUCKET ELEVATOR PROBLEMS. THE
PLANT HAS BEGUN TO BURN SOME BARK. AN AVAILABIL-
ITY VALUE OF 100S WAS REPORTED FOR THE FGO SYSTEM,
11
-------
STATUS TO APRIL 1979
SECTION 3 (CONTINUED)
SUMMARY OF FGD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OP RECENT OPERATIONS
NORTHERN OHIO SUGAR COMPANY
FINDLAV, OHIO
GREAT WESTERN SUGAR
COAL (1.2* SULFUR, AVERAGE)
65*236 8CFM (TOTAL • 2 BOILERS)
START-UP 10/74
SODIUM CARBONATE SCRUBBING
STATUS • TERMINATED
•BKGOI THE VENTURI TONER MAS MAINLY DESIGNED FOR
PARTICULATE CONTROL* AND WAS STARTED UP IN OCTOBER
1974. PARTICULATE AND 802 REMOVAL EFFICIENCIES
WERE 90S AND 76* RESPECTIVELY. THE 302 CONTROL
WAS EFFECTED BY THE PROCESS CONOEN8ATE USED FOR
SCRUBBING (PHiB.7).
THIS PLANT HAS TERMINATED ALL SUGAR PRODUCTION
OPERATIONS. THE SCRUBBER OPERATED FROM OCTOBER
1974 THROUGH THE 1977-1978 SEASON BEFORE THE
SHUTDOWN OCCURRED.
NORTHERN OHIO SUGAR COMPANY
FREEMONTr OHIO
GREAT WESTERN SUGAR
COAL (IS SULFUR)
40*000 SCFM (TOTAL • 2 BOILERS)
START-UP 10/73
SODIUM HYDROXIDE SCRUBBING
STATUS • OPERATIONAL
*BKGOI PARTICULATE AND 802 EMISSIONS ARE BEING
CONTROLLED BY A SCRUBBER/ABSORBER MODULE OF PRO-
PRIETARY DESIGN. THE FLUE GAS IS GENERATED BY TWO
UNION BOILERS, EACH RATED 8 70,000 LB/HR STEAM.
NO INFORMATION ON OPERATIONAL EXPERIENCE HAS BEEN
MADE AVAILABLE BY PLANT PERSONNEL.
PFIZER* INC.
EAST ST. LOUIS* ILLINOIS
IN-HOUSE DESIGN
COAL (3.5* SULFUR)
40*000 SCFM (TOTAL 3 BOILERS)
START-UP 9/78
LIME SCRUBBING
STATUS - OPERATIONAL
*BKGDI PFIZER HAS PERFORMED FULL-SCALE TESTING ON
THE NLA-LEWIS SCRUBBER AT THE E. 8T. LOUIS PLANT
FOR FOUR YEARS. WITH SOME DESIGN MODIFICATIONS,
THE LIME SCRUBBING SYSTEM MET THE REQUIRED
STANDARDS BY THE END OF 1978.
•1ST OTR 791 A RELIABILITY OF 99* NAB REPORTED.
THE DOWNTIME WAS REQUIRED FOR THE INSPECTION OF
THE MIST ELIMINATOR AND SCRUBBER INTERVALS.
PHILLIP MORRIS, INC.
CHESTERFIELD, VIRGINIA
FLAKT, INC.
COAL (1.4* SULFUR DESIGN)
39*000 SCFM (TOTAL - 1 BOILER)
START-UP 6/79
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
•1ST OTR 791 CONSTRUCTION 18 NEARIN6 COMPLETION ON
A NON-NEGENERABLE 80DIUM CARBONATE F6D SYSTEM
(SUPPLIED BY FLAKT* INC.) WHICH WILL CONTROL
EMISSIONS FROM A NEW PULVERIZED COAL-FIRED BOILER
GENERATING FLUE GAS EQUIVALENT TO 30 MW. THE
FLAKT SYSTEM WILL REMOVE A MINIMUM OF 90S OF THE
802 FROM 2/3 OF THE FLUE 6A8I THE REMAINDER OF THE
GAB WILL BE USED FOR REHEAT.
REICHHOLD CHEMICALS* INC.
PENSACOLA* FLORIDA
NEPTUNE AIRPOL* INC.
MOOD 8 OIL (21 SULFUR)
80*000 SCFM (TOTAL - 2 BOILERS)
START-UP 4/75
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
•BKGOI AT PENSACOLA* REICHHOLO CHEMICALS FIRE8
WOOD AND OIL IN TWO STEAM BOILERS. PARTICULATE
AND 802 EMISSIONS ARE CONTROLLED IN TWO AIRPOL
SCRUBBING TRAINS CONSISTING OF VENTURI SCRUBBER
AND SEPARATOR COMBINATION.
*18T OTR 791 NO INFORMATION ON OPERATIONAL EXPER-
IENCE WAS MADE AVAILABLE.
RICKENBACKER AIR FURCE BASE
COLUMBUS* OHIO
RESEARCH-COTTRELL/BAHCO
COAL (3.M SULFUR)
59*000 SCFM (TOTAL - 7 BOILERS)
START-UP 3/76
LIMESTONE SCRUBBING
STATUS - OPERATIONAL
*BK6DI THIS RE8EARCH-COTTRELL/BACHO LIME F6D UNIT
WAS FIRST PLACED IN SERVICE MARCH II* 1976.
THE SYSTEM MAS SWITCHED UVER TO LIMESTONE IN APRIL
1977* AND HAS REMAINED IN THAT OPERATING MODE TO
DATE.
•1ST OTR 791 A TOTAL OF 4 DAYS DOWNTIME WERE
REPORTED FOH THIS PERIOD, YIELDING AN AVAILABILITY
OF 95.6*. PLUGGING OCCURRED IN THE 1ST STAGE
LEVEL TANK LINE. 802 REMOVAL EFFICIENCIES OF SO-
85* WERE ACHIEVED WITH INCREASED THE LIMESTONE
FEED.
SANTA FE ENERGY CORP.
BAKERSFIELO, CALIFORNIA
PMC ENVIRONMENTAL EQUIPMENT
OIL (US* SULFUR)
70*000 SCFM (TOTAL - 8 BOILERS)
START-UP 5/79
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
•BK6DI SANTA FE ENERGY CORP., FORMERLY CHANSLOR
WESTERN OIL CO., PURCHASED A DOUBLE ALKALI FGD
SYSTEM FROM FMC.
•1ST OTR 791 CONSTRUCTION IB NEARIN6 COMPLETION,
BUT THE START-UP DATE HAS BEEN FURTHER EXTENDED TO
MAY 1979 DUE TO PROJECTED DELAYS IN DUCTING
INSTALLATION AND GENERATOR START-UP.
12
-------
STATUS TO APRIL 1979
SECTION 3 (CONTINUED)
SUMMARY OF FGD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
•HELL OIL COMPANY
BAKERSFIELDi CALIFORNIA
VENDOR NOT VET SELECTED
OIL (I.IX SULFUR)
99*000 8CFM CTOTAL • 8 BOILERS)
START-UP O/ 0
PROCESS NOT YET SELECTED
STATUS » PLANNED-CONSIDERING 302 CONTROL
•BKGDI SHELL OIL IS CONSIDERING IMPLEMENTING FGO
TECHNOLOGY TO CONTROL EMISSIONS FROM S SMALL OIL-
FIRED (1,1* SULFUR) STEAM GENERATORS. NO PROCESS
OR START-UP DATE HAVE AS YET BEEN SPECIFIED. AN
802 REMOVAL EFFICIENCY OF 94X WILL BE REQUIRED.
SHELL OIL COMPANY
TAFT, CALIFORNIA
VENDOR NOT YET SELECTED
OIL (I.IX SULFUR)
19*000 SCFH (TOTAL - 2 BOILERS)
START-UP Of 0
PROCESS NOT YET SELECTED
STATUS » PLANNED-CONSIDERING 808 CONTROL
*BKGDI SHELL OIL IS CONSIDERING IMPLEMENTING FGO
TECHNOLOGY TO CONTROL EMISSIONS FROM 2 SMALL OIL-
FIRED (U1X SULFUR) STEAM GENERATORS. NO PROCESS
OR START-UP DATE HAVE AS YET BEEN SPECIFIED. AN
302 REMOVAL EFFICIENCY OF 94X HILL BE REQUIRED.
8HELLER GLOBE CORP.
NORFOLK* VIRGINIA
M.N. SLY MANUFACTURING CO.
COAL (« 1.01 SULFUR)
SiOOO'SCFM (TOTAL - 1 BOILER)
START-UP 0/73
SODIUM HYDROXIDE SCRUBBING
STATUS • INDEFINITELY SHUT OOHN
*BKGOI AFTER SYSTEM RESTART IN OCTOBER 1977,
THERE HAVE BEEN NO PROBLEMS RESULTING FROM EITHER
BOILER OR SCRUBBER OPERATIONS. THE PLANT UNDER-
WENT A VIRGINIA EPA INSPECTION AND WAS FOUND TO BE
IN COMPLIANCE WITH THE PARTICULATE EMISSION
REGULATIONS.
*4TH QTR 7SI NO SCRUBBER RELATED PROBLEMS HAVE
OCCURRED DURING THIS REPORT PERIOD. AT PRESENT
THE USE OF NAOH HAS BEEN DISCONTINUED* 80 THIS
SYSTEM HAS BEEN MOVED TO OUR "INDEFINITELY
SHUTDOWN* STATUS.
ST. JOE ZINC CO.
MONACAr PENNSYLVANIA
BUREAU OF MINES
COAL C2.S* - 4.SX SULFUR)
142*000 8CFM (TOTAL - I BOILER)
START-UP 4/79
CITRATE PROCESS
STATUS • CONSTRUCTION
*BKGDI CONSTRUCTION CONTINUES ON THE CITRATE
PROCESS SCRUBBING SYSTEM NHICH MILL CONTROL 802
EMISSIONS FROM A 60-MW (NOMINAL PEAK CAPACITY)
COAL-FIRED POWER GENERATING UNIT. STARTUP 18 NOW
SCHEDULED FOR APRIL 1979. THIS SYSTEM WILL ALSO
BE REPORTED IN THE EPA/PEDCO UTILITY FGD SURVEY,
SINCE THE 8V8TEM HILL BE OPERATED WITH A UTILITY-
TYPE LOAD PROFILE* DURING THE ONE-YEAR DEMONSTRA-
TION PERIOD.
•TRATHMORC PAPER COMPANY
MORONOCO* MASSACHUSETTS
aiWfOfUL" CORPORAtION
COAL/OIL (0.75-J.OX SULFUR)
22*000 SCFM (t BOILER)
BTART-UP 4/79
PRY LIME SCRUBBING
STATUS - CONSTRUCTION
tBKGDI THE DRY SCRUBBING SYSTEM SUPPLIED BY
MIKROPUL TO REMOVE PARTICULATE MATTER AND 802
FROM THE FLUE GAS WILL HAVE A SPRAY DRYER AND
FABRIC FILTER CONFIGURATION. IT WILL GENERATE A
DRV WASTE. STARTUP IS SLATED FOH MAT 1979.
SUN PRODUCTION COMPANY
FELLONS* CALIFORNIA
C-E NATCO
OIL (1.4X SULFUR)
6,000 SCFM (12*000 ACFM * 970 F)
START-UP 5/79
SODIUM HYDROXIDE SCRUBBING
STATUS - CONSTRUCTION
*BKGDI SUN OIL HAS FOUR 25 MM BTU/HR AND TWO 50 MM
BTU/HR STEAM GENERATORS AT THIS OIL SITE. THE
CRUDE OIL HAS 1.4 PERCENT SULFUR.
•15T OTR 791 C-E NATCO IS CONSTRUCTING THE SYSTEM.
STARTUP DATE HAS BEEN MOVED BACK TO MAY 1* 1979.
SUN PRODUCTION COMPANY
OILDALE* CALIFORNIA
C-E NATCO
OIL (1.2X SULFUR)
6,000 SCFM (12*000 ACFM * 570 F)
START-UP 4/79
SODIUM HYDROXIDE SCRUBBING
STATUS - CONSTRUCTION
*BKGDI SUN OIL HAS TWO 25 MM BTU/HR STEAM GENERA'
TORS AT THIS OIL SITE. THE CRUDE OIL HAS 1.2
PERCENT SULFUR.
•1ST OTR 791 THE SYSTEM, SUPPLIED BY C-E NATCO,
IS UNDER CONSTRUCTION. STARTUP DATE IS APRIL I,
1979.
-------
STATUS TO APRIL
SECTION 3 (CONTINUED)
SUMMARY OF F60 SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
TENNECO OIL CO.
GREEN RIVER, WYOMING
VENDOR NOT YET SELECTED
COAL (1.5X SULFUR, MAXIMUM)
140,000 SCFM (TOTAL - 2 BOILERS)
START-UP 1/82
SODIUM CARBONATE SCRUBBING
STATUS - PLANNED-REQUESTING/EVALUATING BIDS
•BKGO: TENNECO OIL HAS RETAINED BROHN AND ROOT
FUK THE DESIGN OF A SODA ASH PLANT AND THE
CONCOMMITTANT POLLUTION CONTROL EQUIPMENT.
THE PLANT DULL BE LOCATED IN GREEN RIVER, WYOMING
AND WILL HAVE TWO BOILERS BURNING WYOMING COAL.
•1ST QTR 791 TENNECO AND BtR ARE EVALUATING BIDS
FOH THE SODIUM CARBONATE SCRUBBING SYSTEMS WHICH
HILL CONTROL 302 EMISSIONS FROM- THE BOILERS.
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
CEILCOTE
OIL U.7X SULFUR)
347,000 SCFM (TOTAL - 29 BOILERS)
START-UP 11/73
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
*BKGD: FGD SYSTEM CONSISTS OF A HORIZONTAL, PACK-
ED-BED SCKUBBER FOR EACH OF THE OIL-FIRED BOILERS.
•1ST OTR 791 CORROSION IN THE QUENCHER AND ABRA-
SION/PLUGGING IN THE ABSORBER CONTINUE TO BE PROB-
LEM AREAS. DURING THIS QUARTER EACH SCRUBBER MAS
SHUTDOWN FOR MAINTENANCE AN AVERAGE OF 100 HOURS.
TEXACO is PLANNING TO PHASE OUT THIS GROUP OF
SCRUBBERS BY LATE 1979.
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
DUCON COMPANY
OIL (1.7X SULFUR)
99,000 SCFM (TOTAL - 9 BOILERS)
START-UP 3/79
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
•8KGO: TEXACO IS PLANNING TO PHASE OUT THE
EXISTING FGO SYSTEMS AT THEIR SAN ARDO, CALIFORNIA
SITE. AS THE FIRST STEP OF THE PROGRAM, 9 OF THE
PRESENT 36 SCRUBBERS ON SO MM BTU/HR STEAM GENER-
ATORS ARE BEING REPLACED BY A NEW SYSTEM, SUPPLIED
BY DUCON COMPANY. THE NEW FGD SYSTEM WILL CON-
SIST OF THREE TRAINS OF A VENTURI SCRUBBER/SPRAY
ABSORBER COMBINATION.
•1ST QTR 79: THE FGD SYSTEMS ARE SCHEDULED FOR
START-UP IN MAY 1979.
TEXASGULF
GRANGER, WYOMING
SMEMCO INC.
COAL (0.75X SULFUR)
140,000 SCFM (TOTAL - 2 BOILERS)
START-UP 9/76
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
*BKGDI THIS SODIUM CARBONATE SCRUBBING SYSTEM MAS
DESIGNED BY SMEMCO. 302 ABSORPTION OCCURS IN THE
QUENCHER AND THE SIEVE-TRAY ABSORBER MODULE. AN
INTERESTING FEATURE IS AN INTERNAL DAMPER WHICH
ALLOWS A 4 TO 1 TURNDOWN RATIO.
•1ST QTR 791 THE SCRUBBERS OPERATED WITH 100X
RELIABILITY DURING THIS PERIOD. BOTH THE RECIRCU-
LATIDN LIQUOR DENSITY AND PH WILL BE USED TO
CONTROL THE MAKEUP LIQUOR FLOW RATE.
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
FMC ENVIRONMENTAL EQUIPMENT
FUEL OIL (2X MAX. SULFUR)
50,000 ACFM
START-UP 3/75
SODIUM CARBONATE SCRUBBING
STATUS - INDEFINITELY SHUT DOWN
*BKGDI THE FGO OPERATIONS HAVE BEEN TERMINATED FOR
AN INDEFINITE PERIOD. THE PLANT BURNS NUMBER 6
FUEL OIL ANO THE SULFUR DIOXIDE EMISSIONS ARE SOX
OF THE EXISTING REGULATIONS. THE BOILER 18 RATED
AT 20 MM (EQUIVALENT) AND PRODUCES 150,000 LB8/HR
STEAM. WHEN OPERATIONAL* THE SCRUBBER SYSTEM HAD
A FLUE GAS VOLUME OF 50,000 ACFM AT 140 DEGREES F.
SYSTEM START-UP OCCURRED IN MARCH 1975 AND SCRUB-
BEK OPERATIONS WERE TERMINATED LATER IN THE SAME
YEAR. THERE ARE CURRENTLY NO PLANS TO INITIATE
OPERATIONS.
U.S. GYPSUM CORP.
UAKMONT, PENNSYLVANIA
NEPTUNE AIRPOLf INC.
COAL
19.30U SCFM (TOTAL - 4 BOILERS)
START-UP O/ 0
DOUBLE ALKALI (DILUTE)
STATUS • NEVER STARTED-UP
•BKGDJ AN AIRPOL DOUBLE ALKALI SCRUBBIN6 SYSTEM
IS ON-8ITE, INSTALLED, AND READY FOR OPERATIONS.
HOWEVER, US GYPSUM DECIDED NOT TO INITIATE
PRODUCTION AT THIS FACILITY FOR ECONOMIC REASONS.
*4TH QTR 781 A CHECK DURING THIS PERIOD REVEALED
THAT THE PLANT HAS NOT BEEN STARTED YET.
14
-------
STATUS TO APRIL 1979
SECTION 3 (CONTINUED)
SUMMARY OF F6D SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
BACKGROUND AND SUMMARY OF RECENT OPERATIONS
WESTERN CORRECTIONAL INST.
PITTSBURGH, PENNSYLVANIA
PITTSBURGH ENV.SENGV. SYSTEMS
COAL C3.5X SULFUR)
10,000 SCFM (TOTAL - 1 BOILER)
START-UP 1/ttO
SULF-X SCORE PROCESS
STATUS - PLANNED-CONTRACT AWARDED
•BKGDt A NEW FGO PROCESS KNOWN AS THE SULF-X CON-
CURRENT OXIDES REMOVAL PROCESS HAS BEEN DEVELOPED
BY PITTSBURGH ENVIRONMENTAL AND ENERGY SYSTEMS,
INC. IT MILL CONTROL 802 EMISSIONS FROM AN EXIST-
ING BOILER AT THE WESTERN CORRECTIONAL INSTITUTE
IN PITTSBURGH. THE PROJECT IS BEING FUNDED BY
COMMONWEALTH OF PENNSYLVANIA. MINE ACID WASTES
WILL BE USED AS THE REAGENT TO REMOVE 302 AND NOX
FROM THE FLUE GASES.
*1ST OTR 791 PRELIMINARY TEST OF ABSORPTION SEC-
TION HILL BE PERFORMED IN SEPTEMBER 1979. START-
UP OF THE FGD SYSTEM IS SLATED FOR EARLY 1980.
IS
-------
STATUS TO APRIL 1979
SECTION 4
SUMMARY BY VENDOR OF FGD SYSTEMS ON INDUSTRIAL BOILERS
VENDOR
INSTALLATION NAME / LOCATION
CONTROL SYSTEM PROCESS / SCFM
A.D. LITTLE
BUREAU OF MINES
C-E NATCO
CARBORUNDUM ENVIR. SYS. LTD.
CEILCOTE
COMBUSTION EQUIPMENT ASSOC.
ORAVO CORP./NAT'L LIME ASS'N
DUCON COMPANY
ENTOLETER, INC.
FLAKT, INC.
FMC ENVIRONMENTAL EQUIPMENT
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
ST. JOE ZINC CO.
MUNACA, PENNSYLVANIA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
DOUBLE BARREL OIL CO.
BAKERSFIE.LO, CALIFORNIA
SUN PRODUCTION COMPANY
FELLOWS, CALIFORNIA
SUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
CARBORUNDUM ABRASIVES
BUFFALO, NEW YORK
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
KERR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
BUNGE, INC.
CAIRO, ILLINOIS
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
GENERAL MOTORS CORPORATION
DAYTON, OHIO
PHILLIP MORRIS, INC.
CHESTERFIELD, VIRGINIA
ALYESKA PIPELINE SERVICE CO.
VALDEZ, ALASKA
ARCO/POLYMEHS, INC.
MONACA, PENNSYLVANIA
CANTON TtXIILfcS
CANTON, GEORGIA
CATERPILLAR TRACTOR CO.
EAST PEURIA, ILLINOIS
CATERPILLAR TRACTOR CU.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLE, ILLINOIS
FIRESTONE TIRE AND RUBBER CO.
POTTSTUWN, PENNSYLVANIA
FMC (SODA ASH PLANT)
GREEN RIVER, WYOMING
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
SODIUM HYDROXIDE SCRUBBING
64,000
CITRATE PROCESS
142,000
SODIUM HYDROXIDE SCRUBBING
12,000
SODIUM HYDROXIDE SCRUBBING
12,000
SODIUM HYDROXIDE SCRUBBING
6,000
SODIUM HYDROXIDE SCRUBBING
6,000
LIME SCRUBBING
30,000
SODIUM HYDROXIDE SCRUBBING
347,000
SODIUM CARBONATE SCRUBBING
490,000
LIME SCRUBBING
44,000
SODIUM CARBONATE SCRUBBING
99,000
SODIUM HYDROXIDE SCRUBBING
36,000
SODIUM CARBONATE SCRUBBING
39,000
SODIUM HYDROXIDE SCRUBBING
50,000
DOUBLE ALKALI (CONCENTRATED)
305,000
CAUSTIC WASTE STREAM
2S,OOG
DOUBLE ALKALI (CONCENTRATED)
210,000
DOUBLE ALKALI (CONCENTRATED)
131,000
DOUBLE ALKALI (CONCENTRATED)
105,000
DOUBLE ALKALI (CONCENTRATED)
140,000
DOUBLE ALKALI (CONCENTRATED)
8070
SODIUM CARBONATE SCRUBBING
446,000
SODIUM HYDROXIDE SCRUBBING
92,000
16
-------
STATUS TO APRIL 1979
SECTION 4 (CONTINUED)
SUMMARY BY VENDOR OF FGD SYSTEMS ON INDUSTRIAL BOILERS
VENDOR
fMC ENVIRONMENTAL EQUIPMENT
CM ENVIRONMENTAL
GREAT WESTERN SUGAR
HEATER TECHNOLOGY
IN-HOUSE DESIGN
KOCH ENGINEERING
M1KROPUL CORPORATION
NEPTUNE AIRPOL INC.
NEPTUNE AIRPOL, INC.
INSTALLATION NAME / LOCATION
6ETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
SANTA FE ENERGY CORP.
BAKERSFIELO. CALIFORNIA
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
GENERAL MOTORS CORPORATION
PARMA, OHIO
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
NORTHERN OHIO SUGAR COMPANY
FINOLAY, OHIO
NORTHERN OHIO SUGAR COMPANY
FREEMONT, OHIO
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
MOBIL OIL COMPANY
BUTTONWILLOM, CALIFORNIA
GETTY OIL COMPANY
BAKERSFIELO, CALIFORNIA
GETTY OIL COMPANY
ORCUTT, CALIFORNIA
MOBIL OIL COMPANY
SAN AROO, CALIFORNIA
PFIZER, INC.
EAST ST. LOUIS* ILLINOIS
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
MINN-OAK FARMER'S CO-OPERATIVE
WAHPETON, NORTH DAKOTA
STRATHMORE PAPER COMPANY
WORONOCO, MASSACHUSETTS
INLAND CONTAINER CORPORATION
NEW JOHNSONVILLE, TENNESSEE
GEORGIA-PACIFIC PAPER CO.
CROSSETT, ARKANSAS
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
GRISSOM AIR FORCE BASE
BUNKER HILL, INDIANA
ITT RAYONIER, INC.
FERNANDINA BEACH, FLORIDA
MEAD PAPERBOARD CO.
STEVENSON, ALABAMA
CONTROL SYSTEM PROCESS / SCFM
SODIUM CARBONATE SCRUBBING
72,000
DOUBLE ALKALI (CONCENTRATED)
70,000
SODIUM CARBONATE SCRUBBING
50,000
DOUBLE ALKALI (DILUTE)
126,400
SODIUM HYDROXIDE SCRUBBING
107,300
SODIUM CARBONATE SCRUBBING
65,230
SODIUM HYDROXIDE SCRUBBING
40,000
SODIUM HYDROXIDE SCRUBBING
12,000
SODIUM CARBONATE SCRUBBING
SO,500
SODIUM CARBONATE SCRUBBING
891,000
SODIUM HYDROXIDE SCRUBBING
5000
SODIUM HYDROXIDE SCRUBBING
175,000
LIME SCRUBBING
40,000
SODIUM CARBONATE SCRUBBING
248,000
SODIUM CARBONATE SCRUBBING
146,000
AMMONIA SCRUBBING
164,000
DRY LIME SCRUBBING
22,000
AMMONIA SCRUBBING
154,000
CAUSTIC WASTE STREAM
220,000
CAUSTIC WASTE STREAM
420,000
DOUBLE ALKALI (CONCENTRATED)
32,000
SODIUM HYDROXIDE SCRUBBING
176,000
SODIUM CARBONATE SCRUBBING
100,000
17
-------
STATUS TO APRIL 1979
SECTION 4 (CONTINUED)
SUMMARY BY VENDOR OF FGD SYSTEMS ON INDUSTRIAL BOILERS
VENDOR
INSTALLATION NAME / LOCATION
CONTROL SYSTEM PROCESS / SCFM
NEPTUNE AIRPOL* INC,
PITTSBURGH ENV.tENSY. SYSTEMS
RESEARCH-COTTRELL/BAHCO
3HEMCO INC.
THERMOTICS INC.
VENDOR NOT VET SELECTED
N.M. SLY MANUFACTURING CO.
MHEELABRATOR-FRYE/ROCKHELL INT
ZURN INDUSTRIES
NEKOOSA PAPERS, INC.
ASHDOMN, ARKANSAS
REICHHOLD CHEMICALS, INC.
PENSACOLAr FLORIDA
U.S. GYPSUM CORP.
OAKMONTr PENNSYLVANIA
MESTERN CORRECTIONAL INST.
PITTSBURGH, PENNSYLVANIA
RICKENBACKER AIR FORCE BASE
COLUMBUS, OHIO
TEXA8CULF
GRANGERr WYOMING
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
C.A.M.(CARBIOE-AMOCO-MONSANTO)
HOUSTON, TEXAS
DUPONT, INC.
ATHENS, GEORGIA
SHELL OIL COMPANY
BAKERSFIELD, CALIFORNIA
SHELL OIL COMPANY
TAFT, CALIFORNIA
TENNECO OIL CO.
GREEN RIVER, WYOMING
HARRIS MINING CO.
SPRUCE PINE, NORTH CAROLINA
8HELLER GLOBE CORP.
NORFOLK, VIRGINIA
CELANESE CORPORATION
CUMBERLAND, MARYLAND
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
CAUSTIC SCRUBBING
211,000
SODIUM CARBONATE SCRUBBING
60*000
DOUBLE ALKALI (DILUTE)
19,300
SULF-X SCORE PROCESS
10*000
LIMESTONE SCRUBBING
55,000
SODIUM CARBONATE SCRUBBING
140,000
SODIUM HYDROXIDE SCRUBBING
12*000
DOUBLE ALKALI
1,200,000
DOUBLE ALKALI
260,000
PROCESS NOT YET SELECTED
99,000
PROCESS NOT YCT SELECTED
25,000
SODIUM CARBONATE SCRUBBING
140,000
MATER SCRUBBING (NA,NH3 OPTN.)
4*000
SODIUM HYDROXIDE SCRUBBING
S,000
DRV LIME SCRUBBING
50*700
DOUBLE ALKALI (DILUTE)
67*000
DOUBLE ALKALI (DILUTE)
36*000
16
-------
STATUS TO APRIL 1979
SECTION 5
SUMMARY BY CONTROL PKOCE33 OF FGO SYSTEMS ON INDUSTRIAL BOILERS
CONTROL SYSTEM PROCESS
INSTALLATION NAME / LOCATION
VENDOR / SCFM
AMMONIA SCRUBBING
CAUSTIC SCRUBBING
CAUSTIC WASTE STREAM
CITRATE PROCESS
DOUBLE ALKALI
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (DILUTE)
DRV LIME SCRUBBING
INLAND CONTAINER CORPORATION
NEW JOHN50NVILLE, TENNESSEE
MINN-DAK FARMER'S CO-OPERATIVE
MAHPETON, NORTH DAKOTA
NEKOOSA PAPERS* INC.
ASHDOWN, ARKANSAS
CANTON TEXTILES
CANTON, GEORGIA
GEORGIA-PACIFIC PAPER CO.
CROSSETT, ARKANSAS
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
C.A.M.(CARBIDE-AMOCO-MONSANTO)
HOUSTON, TEXAS
OUPONT, INC.
ATHENS, GEORGIA
ARCU/POLYMER3, INC.
MONACA, PENNSYLVANIA
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLEt ILLINOIS
FIRESTONt TIRE AND RUBBER CO.
POTT3TOWN, PENNSYLVANIA
GRISSOM AIR FORCE BASE
BUNKER HILL, INDIANA
SANTA FE ENERGY CORP.
BAKERSFItLO, CALIFORNIA
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
GENERAL MOTORS CORPORATION
PARMA, OHIO
U.S. GYPSUM CORP*
OAKMONT, PENNSYLVANIA
CELANESE CORPORATION
CUMBERLAND, MARYLAND
STRATHMONE PAPER COMPANY
MORONOCO, MASSACHUSETTS
NEPTUNE AIRPOL INC.
151,000
KOCH ENGINEERING
164,000
NEPTUNE AIRPOL, INC.
211,000
FMC ENVIRONMENTAL EQUIPMENT
25,000
NEPTUNE AIRPOL, INC.
220,000
NEPTUNE AIRPOL, INC.
420,000
BUREAU OF MINES
142,000
VENDOR NOT YET SELECTED
I,ZOO,000
VENDOR NOT YET SELECTED
280,000
FMC ENVIRONMENTAL EQUIPMENT
305,000
FMC ENVIRONMENTAL EQUIPMENT
210,000
FMC ENVIRONMENTAL EQUIPMENT
131,000
FMC ENVIRONMENTAL EQUIPMENT
105,000
FMC ENVIRONMENTAL EQUIPMENT
140,000
FMC ENVIRONMENTAL EQUIPMENT
6070
NEPTUNE AIRPOL, INC.
32,000
FMC ENVIRONMENTAL EQUIPMENT
70,000
ZU«N INDUSTRIES
67,000
ZURN INDUSTRIES
38,000
GM ENVIRONMENTAL
126,400
NEPTUNE AIRPOL, INC.
19,300
KHEELABRATOR-FRYE/ROCKKELL INT
50,700
MIKROPUL CORPORATION
22,000
19
-------
STATUS TO APRIL 1979
SECTION 5 (CONTINUED)
SUMMARY BY CONTROL PROCESS OF FGD SYSTEMS ON INDUSTRIAL BOILERS
CONTROL SYSTEM PROCESS
INSTALLATION NAME / LOCATION
VENDOR / 3CFM
LIME SCRUBBING
LIMESTONE SCRUBBING
PROCESS NOT YET SELECTED
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
BUNGEr INC.
CAIRO* ILLINOIS
CARBORUNDUM ABRASIVES
BUFFALO* NEW YORK
PFIZER. INC.
EAST ST. LOUIS* ILLINOIS
RICKENBACKER AIR FORCE BASE
COLUMBUS, OHIO
SHELL OIL COMPANY
BAKERSFIELO* CALIFORNIA
SHELL OIL COMPANY
TAFT, CALIFORNIA
CHEVRON U.S.A. INC.
BAKERSFULD* CALIFORNIA
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
FMC (SODA ASH PLANT)
GREEN RIVER* WYOMING
GETTY OIL COMPANY
BAKERSFIELD* CALIFORNIA
GETTY OIL COMPANY
BAKERSFIELD. CALIFORNIA
KERR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
MEAD PAPERBOARD CO.
STEVENSON* ALABAMA
MOBIL OIL COMPANY
BUTTONWILLOW, CALIFORNIA
NORTHERN OHIO SUGAR COMPANY
FINULAY. OHIO
PHILLIP KORKIS, INC.
CHESTERFIELD. VIRGINIA
REICHHOLD CHEMICALS* INC.
PENSACOLA. FLORIDA
TENNECO OIL CO.
GREEN RIVER* WYOMING
TEXACO INCORPORATED
SAN AKOU. CALIFORNIA
TEXASGULF
GRANGER* WYOMING
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
ALYESKA PIPELINE SERVICE CO.
VALDEZ. ALASKA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
DRAVO CORP./NAT'L LIME ASS'N
44,000
CARBORUNDUM ENVIR. SYS. LTD.
30*000
IN-HOUSE DESIGN
40*000
RESEARCH-COTTRELL/BAHCO
55,000
VENDOR NOT VET SELECTED
99,000
VENDOR NOT YET SELECTED
25,000
KOCH ENGINEERING
348,000
KOCH ENGINEERING
146,000
FMC ENVIRONMENTAL EQUIPMENT
446,000
FMC ENVIRONMENTAL EQUIPMENT
72,000
IN-HOUSE DESIGN
891,000
COMBUSTION EQUIPMENT ASSOC.
490,000
NEPTUNE AIRPOL, INC.
100,000
HEATER TECHNOLOGY
80*500
GREAT WESTERN SUGAR
65*230
FLAKT, INC.
39,000
NEPTUNE AIKPOL, INC.
80,000
VENDOR NOT VET SELECTED
140,000
DUCON COMPANY
99,000
SWEMCU INC.
140,000
FMC ENVIRONMENTAL EQUIPMENT
50.000
FMC ENVIRONMENTAL EQUIPMENT
50.000
C-E NATCO
12,000
20
-------
STATUS TO APRIL 1979
SECTION 5 (CONTINUED)
SUMMARY BY CONTROL PROCESS OF FGO SYSTEMS ON INDUSTRIAL BOILERS
CONTROL. SYSTEM PROCESS
INSTALLATION NAME / LOCATION
VENDOR / SCFM
SODIUM HYDROXIDE SCRUBBING
3ULF-X SCORE PROCESS
MATER SCRUBBING (NA,NH3 OPTN.J
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
DOUBLE BARREL OIL CO.
BAKERSFIELO, CALIFORNIA
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
GENERAL MOTORS CORPORATION
DAYTON* OHIO
GENERAL MOTORS CORPORATION
TONOMANOA, NEM YORK
GENERAL MOTORS CORPORATION
PONTIACt MICHIGAN
GETTY OIL COMPANY
ORCUTT, CALIFORNIA
ITT RAYONIER, INC.
FERNANOINA BEACH, FLORIDA
MOBIL OIL COMPANY
SAN AROO, CALIFORNIA
NORTHERN OHIO SUGAR COMPANY
FREEMONT, OHIO
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
SUN PRODUCTION COMPANY
FELLOWS, CALIFORNIA
SUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
TEXACO INCORPORATED
SAN AROO, CALIFORNIA
WESTERN CORRECTIONAL INST.
PITTSBURGH, PENNSYLVANIA
HARRIS MINING CO.
SPRUCE PINE, NOKTH CAROLINA
HEATER TECHNOLOGY
12,000
THERMOTICS INC.
12,000
C-E NATCO
12,000
A.O. LITTLE
64,000
ENTOLETER, INC.
36,000
FMC ENVIRONMENTAL EBUIPMENT
92,000
6M ENVIRONMENTAL
107,300
IN-HOUSE DESIGN
5000
NEPTUNE AIRPOL, INC.
176,000
IN-HOUSE DESIGN
175,000
GREAT WESTERN SUGAR
40,000
W.H. SLY MANUFACTURING CO.
8,000
C-E NATCO
6,000
C-E NATCO
6,000
CEILCOTE
347,000
PITTSBURGH ENV.iENGY. SYSTEMS
10,000
M.M. SLY MANUFACTURING CO.
4,000
-------
SECTION 6
OPERATIONAL FGU SYSTEMS ON INDUSTRIAL BOILERS
STATUS TO APRIL 1979
COMPANY/LOCATION/FUEL
5CFM
PROCESS/VENDOR
START UP
MO/YR
NUMBER
OF F60
SYSTEMS
NUMBER
OF BOILED
CONTROLLf
ALYESKA PIPELINE SERVICE CO.
VALOEZ, ALASKA
OIL (0.03X - 0.1X SULFUR)
50,000 SODIUM HYDROXIDE SCRUBBING 6/77
FMC ENVIRONMENTAL EQUIPMENT
BELRID6E OIL CO.
MCKITTRICK, CALIFORNIA
CRUDE OIL U.1X SULFUR)
12,000 SODIUM HYDROXIDE SCRUBBING
C-E NATCO
1/79
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
OIL (I.IX SULFUR)
12,000 SODIUM HYDROXIDE SCRUBBING
HEATER TECHNOLOGY
6/78
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
CRUDE OIL (I.IX SULFUR)
12,000
SODIUM HYDROXIDE SCRUBBING
THERMOTICS INC.
7/78
CANTON TEXTILES
CANTON, GEORGIA
COAL (0.8X SULFUR)
INTERRUPTIBLE NATURAL GAS
25,000 CAUSTIC WASTE STREAM
FMC ENVIRONMENTAL EQUIPMENT
6/74
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
COAL (3.2X SULFUR)
210,000 DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
4/7S
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
COAL (3.2X SULFUR)
131,000 DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
3/79
CATERPILLAR TRACTOR CO.
MOSSVILLE* ILLINOIS
COAL (3.2X SULFUR)
100,000 DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
10/79
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
COAL (3.2X SULFURI
67,000 DOUBLE ALKALI (DILUTE)
2URN INDUSTRIES
9/74
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
COAL (3.2X SULFUR)
38,000 DOUBLE ALKALI (DILUTE)
ZURN INDUSTRIES
1/78
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
OIL (1.1X SULFUR)
248,000 SODIUM CARBONATE SCRUBBING 7/78
KOCH ENGINEERING
18
DOUBLE BARREL OIL CO.
BAKERSFIELO, CALIFORNIA
OIL (1.1X SULFUR)
12,000 SODIUM HYDROXIDE SCRUBBING
C-E NATCO
6/78
FIRESTONE TIRE AND RUBBER CO.
PUTTSTONN, PENNSYLVANIA
COAL (2.5 - 3.OX SULFUR) /
8070 DOUBLE ALKALI (CONCENTRATED) 1/75
FMC ENVIRONMENTAL EQUIPMENT
22
-------
SECTION 6 (CONTINUED)
OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
STATUS TO APRIL 1979
COMPANY/LOCATION/FUEL
SCFM
PROCESS/VENDOR
START UP
MO/YR
NUMBER
OF FGD
SYSTEMS
NUMBER
OF BOILERS
CONTROLLED
FMC (SODA ASH PLANT)
GREEN RIVER. WYOMING
COAL (IX SULFUR)
446*000 SODIUM CARBONATE SCRUBBING 5/76
FMC ENVIRONMENTAL EQUIPMENT
GENERAL MOTORS CORPORATION
PARMA* OHIO
COAL (2.5X SULFUR)
128,400 DOUBLE ALKALI (DILUTE)
GM ENVIRONMENTAL
3/74
GENERAL MOTORS CORPORATION
ST. LOUIS* MISSOURI
COAL (3.2X SULFUR)
64,000 SUDIUM HYDROXIDE SCRUBBING
A.D. LITTLE
0/72
GENERAL MOTORS CORPORATION
OAYTONi OHIO
COALC0.7X • 2.UX SULFUR)
36*000 SODIUM HYDROXIDE SCRUBBING
ENTOLETER* INC.
9/74
GENERAL MOTORS CORPORATION
TONONANOA, NEW YORK
COAL (1.2X SULFUR)
92,000
SUDIUM HYDROXIDE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
6/75
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
COAL (0.64X SULFUR)
ALSO MOOD* PAPER, AND CARDBOARD.
107,300 SODIUM HYDROXIDE SCRUBBING
GM ENVIRONMENTAL
4/76
GEORGIA-PACIFIC PAPER CO.
CROS3ETT, ARKANSAS
BARK,COAL/OIL (l.SX - 2.OX SULFUR)
220,000 CAUSTIC WASTE STREAM
NEPTUNE AIRPOL, INC.
7/75
GETTY OIL COMPANY
BAKEH8FIELO, CALIFORNIA
OIL (1.1X SULFUR)
72,000 SODIUM CARBONATE SCRUBBING 6/77
FMC ENVIRONMENTAL EQUIPMENT
GETTY OIL COMPANY
BAKERSF1ELD, CALIFORNIA
OIL (1.1X SULFUR)
891,000 SODIUM CARBONATE SCRUBBING 12/7B
IN-HOUSE DESIGN
81
GETTY OIL COMPANY
ORCUTT* CALIFORNIA
OIL (4.OX SULFUR)
5000 SODIUM HYDROXIDE SCRUBBING
IN-HOUSE DESIGN
6/77
GREAT SOUTHERN PAPER CO.
CEOAR SPRINGS, GEORGIA
BARK,COAL/OIL (l.OX - 2.UX SULFUR)
420,000 CAUSTIC WASTE STREAM
NEPTUNE AIRPOL, INC.
0/75
ITT RAYUN1ER, INC.
FERNANDINA BEACH, FLORIDA
BARK,OIL (2.OX - 2.5X SULFUR)
176,000 SODIUM HYDROXIDE SCRUBBING
NEPTUNE AIRPOL* INC.
0/7S
KERR-MCGEE CHEMICAL COUP.
TRONA, CALIFORNIA
COKE/COAL/OIL (0.5X - 5.OX SULFUK)
49U,000
SODIUM CARBONATE SCRUBBING
COMBUSTION EQUIPMENT AS30C.
6/78
-------
SECTION 6 (CONTINUED)
OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
STATUS TO APRIL 1979
COMPANY/LOCATION/FUEL
SCFM
PROCESS/VENDOR
START UP
MO/YR
NUMBER
OF F6D
SYSTEMS
NUMBER
OF BOILER
CONTROLLE
HEAD PAPERBOARO CO.
STEVENSON, ALABAMA
OIL C1.5X - JX SULFUR)
100,000 SODIUM CARBONATE SCRUBBING 0/75
NEPTUNE AIRPOL, INC.
MINN-DAK FARMER'S CO-OPERATIVE
MAHPETON, NORTH DAKOTA
LIGNITE Cl.OX SULFUR)
164,000 AMMONIA SCRUBBING
KOCH ENGINEERING
6/77
MOBIL OIL COMPANY
SAN AROO, CALIFORNIA
OIL (2.OX - 2.25X SULFUR)
175,000 SODIUM HYDROXIDE SCRUBBING
IN-HOUSE DESIGN
0/74
28
28
NEKOOSA PAPERS, INC.
A3HOONN, ARKANSAS
COAL (U - 1.5X SULFUR)
211,000 CAUSTIC SCRUBBING
NEPTUNE A1RPOL, INC.
2/76
NORTHERN OHIO SUGAR COMPANY
FREEMONT, OHIO
COAL (IX SULFUR)
40,000 SODIUM HYDROXIDE SCRUBBING 10/75
GREAT WESTERN SUGAR
PFIZER, INC.
EAST ST. LOUIS, ILLINOIS
COAL (3.5X SULFUR)
40,000
LIME SCRUBBING
IN-HOUSE DESIGN
9/78
REICHHOLD CHEMICALS, INC.
PEN3ACOLA, FLORIDA
MOOD « OIL <2X SULFUR)
60,000 SODIUM CARBONATE SCRUBBING
NEPTUNE AIRPOL, INC.
6/75
RICKENBACKER AIR FORCE BASE
COLUMBUS, OHIO
COAL (3.6X SULFUR)
55,000 LIMESTONE SCRUBBING
RESEARCH-COTTRELL/BAHCO
3/76
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
OIL (1.7X SULFUR)
347,000 SODIUM HYDHUXIDE SCRUBBING
CEILCOIE
11/73
29
TEXASGULF
GRANGER, WYOMING
COAL (0.75X SULFUR)
140,000 SODIUM CARBONATE SCRUBBING
SWEMCO INC.
9/76
-------
SECTION 7
FUTURE F6D SYSTEMS ON INDUSTRIAL BOILERS
UNDER CONSTRUCTION
STATUS TO APRIL 1979
COMPANY/LOCATION/FUEL
SCFH
PROCESS/VENDOR
START UP
MO/YR
NUMBER
OF FGD
SYSTEMS
NUMBER
OF BOILERS
CONTROLLED
ARCO/POLVMERS, INC.
KONACA, PENNSYLVANIA
COAL (3.OX SULFUR)
305,000 DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
6/SO
CHEVRON U.S.A. INC.
0AKERSFIELD, CALIFORNIA
OIL (1.IX SULFUR)
146,000 SODIUM CARBONATE SCRUBBING
KOCH ENGINEERING
7/79
12
BRI3SOM AIR FORCE BASE
BUNKER HILL, INDIANA
COAL (3.OX - 3.5X SULFUR)
32,000 DOUBLE ALKALI (CONCENTRATED 11/79
NEPTUNE AIRPOL, INC.
INLAND CONTAINER CORPORATION
MEN JOHNSONVILLE, TENNESSEE
HOOD/SPENT LIQUOR «3.0X SULFUR)
194,000 AMMONIA SCRUBBING
NEPTUNE AIRPOL INC.
5/79
MOBIL OIL COMPANY
BUTTONMILLOW, CALIFORNIA
OIL (1.1* SULFUR)
60,500 SODIUM CARBONATE SCRUBBING
HEATER TECHNOLOGY
4/79
PHILLIP MORRIS* INC.
CHESTERFIELD, VIRGINIA
COAL (1*«X SULFUR DESIGN)
39,000 SODIUM CARBONATE SCRUBBING
FLAKT, INC.
6/79
SANTA FE ENERGY CORP.
BAKER8FIELD, CALIFORNIA
OIL (1.3* SULFUR)
70,000 DOUBLE ALKALI (CONCENTRATED) 5/79
FMC ENVIRONMENTAL EQUIPMENT
IT. JOE ZINC CO.
"NOHACA, VEWSYLVANI A
'COAL'U.SX • 4.SX SULFUR)
142,000 CITRATE PROCESS
BUREAU Or MINE*
4/79
STRATHMORE PAPER COMPANY
NORONOCO, MASSACHUSETTS
COAL/OIL (0.75-3.OX SULFUR)
22,000 DRY LIME SCRUBBING
MIKROPUL CORPORATION
5/79
SUN PRODUCTION COMPANY
FELLOWS, CALIFORNIA
OIL (1.4X SULFUR)
6,000 SODIUM HYDROXIDE SCRUBBING
C-E NATCO
5/79
SUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
OIL (1.2X SULFUR)
6,000 SODIUM HYDROXIDE SCRUBBING
C-E NATCO
4/79
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
OIL (1.7X SULFUR)
99,000 SODIUM CARBONATE SCRUBBING 3/79
OUCON COMPANY
25
-------
SECTION 7 (CONTINUED)
FUTURE FGO SYSTEMS ON INDUSTRIAL BOILERS
PLANNED
STATUS TO APRIL 1979
COMPANY/LOCATION/FUEL
SCFM
PROCESS/VENDOR
START UP
MO/YR
NUMBER
OF F6D
SYSTEMS
NUMBER
OF BOILERI
CONTROLLEI
CARBORUNDUM ABRASIVES
BUFFALOr NEH YORK
COAL (2.2X SULFUR)
30,000 LIME SCRUBBIN6 0/60
CARBORUNDUM ENVIR. SYS. LTD*
CATERPILLAR TRACTOR CO,
MAPLETON, ILLINOIS
COAL (3.2* SULFUR)
105,000 DOUBLE ALKALI (CONCENTRATED) 1/80
FMC ENVIRONMENTAL EQUIPMENT
CELANESE CORPORATION
CUMBERLAND* MARYLAND
COAL (1.0-2.OX SULFUR)
50,700 DRY LIME SCRUBBING 12/79
WHEELABRATOR-FKYE/KOCKMELL INT
WESTERN CORRECTIONAL INST.
PITTSBURGH, PENNSYLVANIA
COAL (3.SX SULFUR)
10,000 SULF-X SCORE PROCESS I/SO
PITTSBURGH ENV.tENBV. SYSTEMS
TENNECO OIL CO.
6REEN RIVER, WYOMING
COAL (1.51 SULFUR, MAXIMUM)
140,000 SODIUM CARBONATE SCRUBBING
VENDOR NOT YET SELECTED
C.A.M.(CARBIDE-AMOCO-MONSANTO)
HOUSTON, TEXAS
FUEL NOT VET SELECTED
1,200,000 DOUBLE ALKALI
VENDOR NOT YET SELECTED
0/S4
OUPONT, INC.
ATHENS, GEORGIA
COAL (l.SX SULFUR)
280,000 DOUBLE ALKALI
VENDOR NOT YET SELECTED
12/85
SMELL OIL COMPANY
BAKERSFIELOr CALIFORNIA
OIL (1.1X SULFUR)
99,000
PROCESS NOT YET SELECTED
VENDOR NOT YET SELECTED
O/ 0
SHELL OIL COMPANY
TAFT, CALIFORNIA
OIL (1.1X SULFUR)
23,000 PROCESS NOT YET SELECTED
VENDOR NOT YET SELECTED
O/ 0
2ft
-------
STATUS TO APRIL 1979
SECTION a
SUMMARY OF DISPOSAL PRACTICES FOR F6D SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME / LOCATION
STATUS/COMMENTS
ALKALINE SULFITE/BISULFITE RECYCLED TO PULP PROCESS
MEAD PAPERBOARD CO.
STEVENSON* ALABAMA
NEKOOSA PAPERS* INC.
A8HDONN, ARKANSAS
OPERATIONAL
RECOVERED SOLUTION USED AS MAKE-UP TO COOKING LIBUOR IN PULP
MILL.
OPERATIONAL
802 RECOVERED FROM SODIUM SULFITE/8ULFATE LIQUOR AND RE-
CYCLED TO PULPIN6 PROCESS.
CLOSED LOOP - UNTREATED SCRUBBING LIQUOR RECYCLED
INLAND CONTAINER CORPORATION
NEN JOHNSONVILLE* TENNESSEE
CONSTRUCTION
AMMONIUM SULFITE/BISULFITE RECYCLED TO PULP PROCESS
RECOVERED SOLUTION USED AS MAKE-UP TO COOKIN6 LIQUOR
IN THE PULP MILL.
OENATERED SLURRY TO LANDFILL
ARCO/POLYMERS, INC.
MONACAi PENNSYLVANIA
BUNGE* INC.
CAIRO* ILLINOIS
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON* ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLE* ILLINOIS
CATERPILLAR TRACTOR CO.
JOLIET* ILLINOIS
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
CATERPILLAR THACTOR CO.
MAPLETON, ILLINOIS
DUPONT, INC.
ATHENS* GEORGIA
FIRESTONE TIRE AND RUBBER CO.
POTTSTOMN* PENNSYLVANIA
GENERAL MOTORS CORPORATION
PARMA* OHIO
GENERAL MOTORS CORPORATION
PONTIAC* MICHIGAN
GRIS30M AIR FORCE bASE
BUNKER HILL* INDIANA
PFIZER* INC.
EAST ST. LOUIS, ILLINOIS
SANTA FE ENERGY CORP.
BAKERSFIELD* CALIFORNIA
CONSTRUCTION
FLYA8H ADDITION TO DENATERED CA80J/CA804 FILTER CAKE*
THEN TO LANDFILL.
INDEFINITELY SHUT DOWN
OPERATIONAL
60*1 SOLIDS (CAS04) SLUDGE DIRECTLY TO LANDFILL
OPERATIONAL
*0+X SOLIDS (CA894) SLUDGE DIRECTLY TO LANDFILL
OPERATIONAL
60+1 SOLIDS (CA304) SLUDGE DIRECTLY TO LANDFILL
OPERATIONAL
OPERATIONAL
PLANNED-CONTRACT AWARDED
60+X SOLIDS (CA304) SLUDGE DIRECTLY TO LANDFILL.
PLANNED-CONSIDERING 302 CONTROL
OPERATIONAL
OPERATIONAL
50»X SOUOS (CA303/S04) SLUDGE TO DRYING POND AND LANDFILL
OPERATIONAL
SX SOLIDS SLURRY DENATERED AND TO LANDFILL
CONSTRUCTION
OPERATIONAL
CONSTRUCTION
27
-------
STATUS TO APRIL 1979
SECTION S (CONTINUED)
SUMMARY OF DISPOSAL PRACTICES FOR F60 SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME / LOCATION
STATUS/COMMENTS
OEMATERED SLURRY TO LANDFILL
UtSt SYPSUM CORP.
OAKMONT, PENNSYLVANIA
NEVER STARTED-UP
SLUD6E TO POND FOR DRYING. THEN TO LANDFILL.
HOLDING POND FOR EVAPORATION
PMC (SODA ASH PLANT)
CREEN RIVER, WYOMING
6CTTV OIL COMPANY
BAKERSFIELO, CALIFORNIA
KERR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
MOBIL OIL COMPANY
SAN AROOi CALIFORNIA
NOBIL OIL COMPANY
BUTTONWILLOW, CALIFORNIA
SUN PRODUCTION COMPANY
FELLOWS, CALIFORNIA
BUN PRODUCTION COMPANY
OILDALE, CALIFORNIA
TENNECO OIL CO.
GREEN RIVER* WYOMING
OPERATIONAL
NA2803/S04 LIOUOR DISPOSED TO COLLECTION POND • NO PRIOR
AERATION. LANDFILL IN THE FUTURE
OPERATIONAL
6 6PM BLEEOOFF TO A SLOWDOWN TANK. THE SLOWDOWN IS THEN
SENT TO A DISPOSAL POND ONCE A WEEK.
OPERATIONAL
SCRUBBER EFFLUENT IS CLARIFIED AND THEN PUT INTO A MINERAL
DEPOSIT.
OPERATIONAL
CONSTRUCTION
INTERMITTENT SLOWDOWN TO WASTE DISPOSAL SITE.
CONSTRUCTION
1 GPM BLEEDOFF TO DISPOSAL POND
CONSTRUCTION
1 GPM BLEEOOFF TO DISPOSAL POND
PLANNED-REQUESTING/EVALUATING BIDS
NON-FIXATED SLURRY TO LINED PONO
CANTON TEXTILES
CANTON, GEORGIA
DOUBLE BARREL OIL CU.
BAKERSFIELD, CALIFORNIA
GETTY OIL COMPANY
ORCUTT, CALIFORNIA
OPERATIONAL
NA S03/S04 LIOUOH DISPOSED TO LINED HOLDING PONDS
OPERATIUNAL
1.5 GPM bLEED-UFF STREAM TO SETTLING POND.
OPERATIONAL
1.4 GPM TO SETTLING POND, DEEPNELL INJECTED.
GREAT SOUTHERN PAPER CO.
CEOAR SPRINGS, GEORGIA
RICKENBACKER AIR FORCE BASE
COLUMBUSr OHIO
OPERATIONAL
CLARIFICATION FOLLOWED BY PONOING AND DISCHARGE TO RIVEN
OPERATIONAL
UNSTABILI2ED CAS03/S04 SLUDGE TO LINED PONO
REGENERABLE • ELEMENTAL SULFUR PRODUCT
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
NE3TERN CORRECTIONAL INST.
PITTSBURGH, PENNSYLVANIA
CONSTRUCTION
PLANNED-CONTRACT AWARDED
-------
STATUS TO APRIL 1979
SECTION a (CONTINUED)
SUMMARY OF DISPOSAL PRACTICES FOR F6D SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME / LOCATION
STATUS/COMMENTS
NASTEMATER TREATMENT AND DISCHARGE TO CITY SEWER
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
GENERAL MOTORS CORPORATION
DAYTON* OHIO
GEORGIA-PACIFIC PAPER CO.
CR08SETT. ARKANSAS
NORTHERN OHIO SU6AR COMPANY
FREEMONTt OHIO
NORTHERN OHIO SUGAR COMPANY
FINOLAY, OHIO
OPERATIONAL .
NA2S03 OXIDIZED TO NA2304, PH NEUTRALIZED AND DISCHARGED TO
CITY SENER SYSTEM
OPERATIONAL
NA2303/304 LIQUOR AT 35 6PM TO ON-SITE CLARIFICATION AND
DEWATERING FACILITY
OPERATIONAL
OPERATIONAL
TERMINATED
BLEED-OFF STREAM TO HOLDING TANK
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
TRANSCO TEXTILES, INC. INDEFINITELY SHUT DOWN
AUGUSTA, GEORGIA NA2S03/S04 LIQUOR DISCHARGED TO A HOLDING POND
WASTEWATER TREATMENT AND DISCHARGE TO TAILINGS POND
CHEVRON U.S.A. INC. OPERATIONAL
BAKER8FIELD, CALIFORNIA
GETTY OIL COMPANY . OPERATIONAL
BAKER8FIELD, CALIFORNIA HOLDING POND FOR EVAPORATION.
9 GPM BLEEDOFF TO A SLOWDOWN TANK. THE BLOWDOWN IS EMPTIED
INTO A DISPOSAL POND ONCE A WEEK.
ITT RAYONIER, INC. OPERATIONAL
FERNANblNA BEACH, FLORIDA
REICHHOLD CHEMICALS, INC. OPERATIONAL
PENSACOLA, FLORIDA
WASTEWATER TREATMENT
ALYESKA PIPELINE SERVICE CO.
VALOEZ, ALASKA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
CARBORUNDUM ABRASIVES
BUFFALO, NEW YORK
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
OPERATIONAL
SLUDGE MIXED WITH BALLAST WATER FROM TANKERS IN PORT
VALDEZ AND TREATED IN MASTEWATER TREATMENT FACILITY.
OPERATIONAL
OPERATIONAL
PLANNED-CONTRACT AWARDED
CONSTRUCTION
OPERATIONAL
FLY ASK AND NA2503/S04 WASTE LIQUOR DEWATERED AND THEN TO
SANITARY LANDFILL
-------
STATUS TO APRIL 1979
SECTION 6 (CONTINUED)
SUMMARY OF DISPOSAL PRACTICES FOR FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME / LOCATION
STATUS/COMMENTS
MA8TENATER TREATMENT
MINN-DAK FARMER'S CO-OPERATIVE OPERATIONAL
WAHPETON, NORTH DAKOTA BLEED STREAM GOES TO AN ACTIVATED SLUDGE SYSTEM 8 160 6PM
ANAEROBIC DIGESTION* FOLLOWED BY AN OPEN POND* FOLLOWED BY
AEROBIC DIGESTION.
TEXACO INCORPORATED OPERATIONAL
SAN ARDOf CALIFORNIA HALF OF THE SCRUBBER UNDERFLOW IS TREATED AND RECYCLED AS
BOILER FEEDNATERf THE OTHER HALF GOES TO NA8TEMATER
DISPOSAL WELLS.
TEXASGULF OPERATIONAL
GRANGER* WYOMING
OVERFLOW TO 3EHER/SLUDGE TO LANDFILL
SHELLER GLOBE CORP. INDEFINITELY SHUT DOWN
NORFOLK* VIRGINIA
DISPOSAL TECHNIQUE NOT KNOWN
C.A.M.CCARBIDE-AMOCO-MONSANTO) PLANNED-CONSIDERING S02 CONTROL
HOUSTON* TEXAS
HARRIS MINING CO. INDEFINITELY SHUT DOWN
SPRUCE PINE* NORTH CAROLINA
SHELL OIL COMPANY PLANNED-CONSIDERING 802 CONTROL
BAKERSFIELD* CALIFORNIA
SHELL OIL COMPANY PLANNED-CONSIDERING 302 CONTROL
TAFT, CALIFORNIA
SCRUBBER EFFLUENT DISPOSED OF IN HASTE NELLS'
TEXACO INCORPORATED CONSTRUCTION
SAN AROO. CALIFORNIA
DRY HASTE IS TRUCKED TO A DUMPING AREA
CELANESE CORPORATION
CUMBERLAND* MARYLAND
STRATHMORE PAPER COMPANY
WORONOCO. MASSACHUSETTS
PLANNED-CONTRACT AWARDED
CONSTRUCTION
30
-------
STATUS TO APRIL
SECTION <»
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BE INS CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDCE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ALYESKA PIPELINE SERVICE CO.
VALDEZ, ALASKA
OIL (0.03X - 0.11 SULFUR)
50,000 SCFM (DESIGN MAXIMUM)
1
3
35 MW (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM * I EQUIVALENT I
THIS IS BECAUSE GAS FLOrt RATE IS THE PRIMARY FACTOR IN MODULE SIZING,
FMC ENVIRONMENTAL EQUIPMENT
SODIUM HYDROXIDE SCRUBBING
NEW
JUNE, 1977
OPERATIONAL
96+X (150-160 PPM » INLET)
PARTICULATE EMISSIONS MEET NSPS.
2 SPh - OPEN LOOP
WASTEWATER TREATMENT
SLUDGE MIXED NlTH BALLAST MATER FROM TANKERS IN PORT
VALDEZ AND TREATED IN WASTEMATER TREATMENT FACILITY.
SEE SECTION IS FOR DETAILED ECONOMIC INFORMATION
BTCKWOUND INFORMATION
AT THE VALOEZ TERMINAL OF THE ALASKAN OIL PIPELINE, ALYESKA PIPELINE SERVICE COMPANY OPERATES
THE OIL STORAGE ANO TRANSFER FACILITY. OIL FLOWING IN FROM THE PIPELINE IS TEMPORARILY STORED IN
HUGE TANK FARMS, THEN TRANSFERRED FROM THE TANKS TO OIL TANKER SHIPS IN NEARBY PORT VALDEZ;
ALYESKA NEEDED NEUTRAL BLANKET AIR FOR THE OIL STORAGE TANKS, A LOM OXYGEN CONTENT BEING PARTICULAR-
,LY DESIRABLE. IT HAS DETERMINED THAT ON-SITE BOILER FLUE GAS MOULD HAVE THE REQUIRED LOW OXYGEN
CONTENT. CORROSION PREVENTION IN THE OIL STORAGE TANKS DICTATED THE NEED FOR S02 CONTROLS.
v
THAT IS» THExDEVICE HAS NOT INSTALLED TO MEET AN EMISSIONS REGULATION. NEVERTHELESS, THE
•INERT GAS* SYSTEM IS BASICALLY A SODIUM HYDROXIDE FGD SYSTEM AND WAS DESIGNED ANO INSTALLED BY
FMC ENVIRONMENTAL EQUIPMENT DIVISION.
THE BOILERS DO NOT OPERATE AT STEADY STATE CONDITIONS. THIS IS DUE TO THE FACT THAT WHEN OIL
IS REMOVED FROM THE TANKS AT A FASTER RATE THAN IT IS BEING FED BY THE PIPELINE, AN ADDITIONAL INERT
AIR BLANKET IS NEEDED. THIS REQUIRES INCREASING THE BOILER LOAD FROM THE NORMAL LEVEL OF PLANT
POWER PRODUCTION TO RUN THE COMPRESSORS ANO PRODUCE ADDITIONAL GAS FOR BLANKET PRODUCTION.
IF THE TANKS ARE FILLING FASTER THAN THEY ARE BEING EMPTIED, THE AIR FORCED OUT BV THE INCOMING
OIL IS INCINERATED.
31
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
ALYESKA PIPELINE SERVICE CO.I VALDEZ, ALASKA (CONTINUED)
THE BOILER PLANT AT THE VALDEZ TERMINAL CONSISTS OF THREE 250 MM BTU/HR OIL-FIRED BOILERS,
MANUFACTURED BY COMBUSTION-ENGINEERING. THE OIL BEING USED IN THE BOILERS PRODUCES A VERY LOW
PARTICULATE GRAIN LOADING, AND HAS AN EXTREMELY LOW SULFUR CONTENT WHICH RANGES FROM 0.03X TO 0.1*.
THERE IS NO PARTICULATE CONTROL OTHER THAN WHAT OCCURS IN THE FMC S02 ABSORBER MODULE.
FLUE -GAS FROM THE BOILERS IS HEADEREO INTO FOUR PARALLEL FIN/FAN COOLERS IN WHICH THE GAS
PASSES THROUGH NARROW FIN TUBES WHILE AN EXTERNAL FAN BLOWS COOL AIR AGAINST THEM. THE COOLER IS
STAINLESS STEEL AND CAUSES A PRESSURE DROP OF 0.5 TO 1 PSI. SINCE FLUE GAS IS PULLED THROUGH THE
THE SYSTEM UNDER NEGATIVE PRESSURE BY COMPRESSORS (DOWNSTREAM OF THE FGD SYSTEM) RATED AT 25 PSIG.
THE HIGH PRESSURE DROP IS NOT A PROBLEM. FOLLOWING THE FIN TUBES, THE GAS IS TAKEN THROUGH A 48 IN.
DUCT BEFORE BEING DIRECTED TO ONE OF THE TWO PARALLEL SCRUBBING UNITS.
THE MAXIMUM DESIGN CAPACITY OF THE SCRUBBER MODULE IS SO,000 SCFM, WHICH REPRESENTS ABOUT 2SX
OF THE TOTAL FLUE GAS GENERATED. THE S02 CONTROL SYSTEM IS DESIGNED WITH 100X REDUNDANCY, THAT IS,
ONLY ONE OF TWO MODULES IN PARALLEL IS USED AT ANYTIME. THE MODULES ARE IDENTICAL FOUR-STAGE
OISC-ANO-OONUT TRAY TYPE ABSORBERS WITH A MAXIMUM RECIRCULATION RATE OF 600 GPM AND A L/G RATIO
OF 12 GAL/1000 ACF. A 4000 GALLON RECIRCULATION TANK IS LOCATED IN THE BOTTOM OF EACH MODULE.
THE ABSORBERS ARE STAINLESS STEEL-CLAD AND HAVE MESH-TYPE MIST ELIMINATORS. FLUE GAS EXITING THE
ABSORBERS PASSES THROUGH A KNOCK-OUT DRUM (8 FT OIA X 16 FT LONG) WHERE ADDITIONAL MIST SEPARATION
OCCURS. FINALLY THE GAS STREAM IS HEAOERED INTO FIVE PARALLEL COMPRESSORS WHICH DRIVE THE GAS TO
THE TANK FARMS AND MAINTAIN A POSITIVE PRESSURE IN THE OIL STORAGE TANKS. GAS INLET TO THE TANKS
IS REGULATED BY PRESSURE CONTROL VALVES WHICH MAINTAIN A GAGE PRESSURE OF 0.6 TO 1.0 IN. W.G.
INSIDE THE TANKS.
IN ADDITION TO THE PRIMARY 600 GPM RECIRCULATION LINE, A SMALLER SECOND LOOP EXISTS FOR SCRUBBER
BLEED-OFF AND REAGENT MAKE-UP. JUST DOWNSTREAM OF THE 2 HP RECIRCULATION PUMP, A 10 GPM BLEED
STREAM IS TAKEN TO THE ONSITE OIL TANKER BALLAST WATER TREATMENT FACILITY. MAKE-UP SUDIUM
HYDROXIDE IS ADDED JUST DOWN STREAM OF THE BLEED-OFF POINT. CONTROL PH 6.0 IS HIGHER THAN THE
DESIGN PH 6.5 BECAUSE THE OPERATIONS HAVE INDICATED THAT A HIGHER PH IS DESIRABLE.
REFER TO FIGURE 14-1 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD 8UARTER-1977 CORROSION HAS OCCURRED IN THE PIPING FOR THE WATER RECIRCULATION SYSTEM.
AT THE TIME OF THIS REPORT, THE CAUSE MAS NOT KNOWN. ALYESKA TESTS HAVE DEMONSTRATED ABOUT
5 PPM S02/S03/S04 AT THE ABSORBER OUTLET. INLET 302 CONCENTRATION RANGES FROM 150 TO 160 PPM.
THE SYSTEM MAS THEREFORE REMOVING ABOUT 961 OF THE INLET SULFUR OXIDES. AT THE TIME OF THIS REPORT,
THERE WAS NO CONTINUOUS S02 MONITOR ON THE SYSTEM.
4TH OUARTER-1977 THE CONTROL SYSTEM OPERATED NEARLY PROBLEM-FREE, WITH NO DOWNTIME
BEING ASSIGNED TO THE 302 REMOVAL SYSTEM. THE CURRENT LOAD IS APPROXIMATELY 201 OF DESIGN
32
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
ALYESKA PIPELINE SERVICE CO.; VALOEZ, ALASKA (CONTINUED)
CAPACITY. THIS IS A RESULT OF OIL FLOW BEING LOrt AT PRESENT. PLANS WERE BEING MADE TO DEAL WITH
THE MET AREAS CORROSION PROBLEM BY INTRODUCING NEUTRALIZING AMINE SPRAYS.
1ST OUARTER-1978 DURING THIS PERIOD, THE CORROSION PROBLEM WAS ALLEVIATED BY SPRAYING HYORAZ1NE
INTO THE SYSTEM UPSTREAM OF THE MIST ELIMINATOR. THIS MEASURE RAISED FROM 4 TO 6.5 THE PH OF THE
LIQUOR RECOVERED BY THE MIST ELIMINATOR. CYCLOHEXYLAMINE MAY BE TESTED IN PLACE OF THE HVDRAZINE.
THE PLANT HAS NOT YET AWARE OF THE CAUSE OF THE CORROSION, ALTHOUGH THEY SUSPECTED CARBON, SULFUR,
AND NITROGEN ACID GASES. CHLORIDES HAVE VIRTUALLY BEEN RULED OUT AS THE SOURCE OF THE CORROSION.
2ND OUARTER-1978 THE FMC FGD SYSTEM CONTINUED TO OPERATE ON A CONTINUOUS BASIS, BEING RESPONSI-
BLE FOR NO DOWNTIME. ANY MAINTENANCE OPERATIONS MERE EFFECTED WHILE THE SYSTEM MAS OPERATING.
IT IS IMPORTANT TO NOTE AGAIN THAT THE SYSTEM IS DESIGNED WITH 100X REDUNDANCY.
3RD OUARTER-1978 THE SYSTEM CONTINUED TO DEMONSTRATE 100X AVAILABILITY DURING THIS PERIOD.
CYCLOHEXYLAMINE IS NOW BEING USED INSTEAD OF HYDRAZINE TO CONTROL PH DOWNSTREAM OF THE ABSORBER. PH
IS NOW IN THE 6-7 RANGE AND CORROSION SEEMS TO HAVE STOPPED. IF FURTHER CONTROL OF PH IS NEEDED,
ADDITIONAL CYCLOHEXYLAMINE SPRAY POINTS MAY BE INSTALLED.
4TH gUARTER-1978 SYSTEM AVAILABILITY FOR THIS PERIOD CONTINUED TO BE 100*. CYCLOHEXYLAMINE MILL
CONTINUE TO BE SPRAYED INTO THE FLUE GAS EXITING THE SCRUBBER. THIS RAISES THE PH OF THE ENTRAINED
LIQUID AND HAS STOPPED THE ACID CORROSION IN THE CARBON STEEL OIL STORAGE TANKS. PRIOR TO THE
ADDITION OF THE AMINE SPRAYS, THE TANKS WERE CORRODING AT A RATE OF ABOUT 40 MILS PER YEAR.
1ST QUARTER-1979 SCRUBBER OPERATIONS CONTINUED TO BE PROBLEM-FREE DURING THE PERIOD. PLANS ARE
BEING MADE TO TEST MORE VOLATILE AMINE CHEMICALS IN PLACE OF THE CYCLOHEXYLAMINE. THE PRESENT
POINT OF INJECTION IS JUST DOWNSTREAM OF THE KNOCKOUT DRUM.
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER Of SEPARATE FGl) UNITS
NUMbER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
WATER MAKE-UP
CONTROL SYSTEM COST
BELRlOGt OIL CO.
MCKITTHICK, CALIFORNIA
CSUDt OIL (l.lk SULFUR)
U,000 SCFM
24,000 ACFM a 570 F
1
1
6 MN (EQUIVALENT)
SO MM BTU/HR
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM • 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
C-E NATCO
SODIUM HYDROXIDE SCRUBBING
NEN
JANUARY, 1979
OPERATIONAL
90S (500 PPM 302 d INLET)
IS GPM
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BELRIUGE OIL COMPANY HAS AN ENHANCED OIL KECOVERY SITE IN MCKITTRICK, CALIFORNIA. THE SITE IS
LOCATED IN WESTERN KERN" COUNTY 'AND HAS SEVERAL SMALL STEAM GENERATORS RATED AT 30 AND 2S MM BTU/HR.
THE CRUDE OIL HAS 1.1 PERCENT SULFUR CONTENT.
, IN VIE* UF THE NEN REGULATIONS OF THE CALIFORNIA AIR RESOURCE BOARD (CARS), BELRIDGE HAS UNDER-
TAKEN A PROGRAM TO EVALUATE THi COMMERCIALLY AVAILABLE FGD TECHNOLOGY FOR APPLICATIONS TO A SMALL
(TYPICALLY 50 MM BTU/HR) STEAM GENERATOR. THEY HAVE ALREADY INSTALLED TfcO FGD SYSTEMS SUPPLIED BY
HEATER TECHNOLOGY AND THERMOTICS. (SEE SECTION 9 OF THIS REPORT FOR DESCRIPTIONS OF THESE SYSTEMS).
A THIRD SYSTEM, BEING SUPPLIED BY C-E NATCO, IS UNDER CONSTRUCTION. C-E NATCO, A SUBSIDIARY OP
COMBUSTION ENGINEERING, IS THE PRINCIPAL SUPPLIER OF THE STEAM GENERATORS TO THE OIL FIELDS. THE
FGD SYSTEM IS SCHEDULED TO 60 ONSTREAM BY EARLY JANUARY 1979.
THE FLUE GAS (29,000 ACFM AT 570 F) is UUENCHED BY A SET or SPRAYS IN THE BOTTOM PART OF THE
ABSORBER (7 FEET DIA X 35 FEET HIGH). THE QUENCHER SECTION HAS A SEPARATE RECIRCULATION PUMP
(300 GPM) WHICH ALSO BLEEDS OFF A PURGE STREAM (10 GPM). THE PH IN THIS STAGE IS RANGES FROM t-6.5.
THE COOLED GAS PASSES THROUGH A "CHIMNEY-TRAY* (TRAY HITH A CENTRAL DONNCOMER) AND IS FURTHER CON-
TACTED MITH LIQUOR SPRAYS (PH BETWEEN 7.5-6.0). THE ABSORPTION, STAGE HAS A SEPARATE
RECIRCULATION PUMP (300 GPM) NHICH ALSO RECEIVES A CONTINUOUS STREAM OF FRESH SODIUM HYDROXIDE
SOLUTION (0.15 GPM). THE FLUE GAS PASSES THROUGH A CHEVRON MIST ELIMINATOR AND A STUB STACK AT THE
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
BELRIDGE OIL CO.l MCKITTRICK, CALIFORNIA (CONTINUED)
TOP OF THE ABSORBER.
THE ABSORBER, TRAY, RECIRCULATION PUMPS, PIPING, AND STACK ARE MADE OF 316L SS. THE
CAUSTIC ASH MIX TANK, FEED PUMP AND PIPING ARE CARBON STEEL, AND THE MIST ELIMINATOR IS FRP.
OPERATING HISTORY
4TH OUARTER-1978 THE SYSTEM IS UNDER CONSTRUCTION AND THE STARTUP DATE IS DELAYED TO EARLY
JANUARY 1979 FROM NOVEMBER 1970.
1ST OUARTER-1979 THE SYSTEM WAS FIRST STARTED UP IN FEBRUARY. HOWEVER, IT DID NOT ACHIEVE THE
REOUIftEO SOd REMOVAL (90S). THE PRIMARY REASONS OF THE LOWER REMOVAL (85*) WERE THE INEFFICIENT
SPRAY NOZZLE DESIGN, HIGH BLONOOwN RATE AND LOW MAKEUP OF FRESH CAUSTIC. THE SECOND TESTING
PERFORMED ON MARCH 15, APPEARS TO HAVE ACHIEVED HIGH 308 REMOVAL O95X). THERE HERE NO STARTUP
PROBLEMS AND THE SYSTEM IS OPERATIONAL.
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUN OPERATIONAL F6D SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATIN6
NUMBER OF SEPARATE F6D UNITS
NUMBER OF BOILERS BEING CONTHOLLEU
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP MATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
MATER MAKE-UP
8LUD6E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
BELM106E OIL CO.
MCKITTRICK, CALIFORNIA
OIL II.IX SULFUR)
12,000 SCFM (1 BOILER)
£4,000 ACFM a 570 F
i
t
b MH (EQUIVALENT)
50 MH BTU/HR
(FOR THIS REPORT* UNLESS STATED OTHERWISE, 2000 SCFM • 1 EQUIVALENT MN.
THIS IS BECAUSE GAS FLON RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
HEATER TECHNOLOGY
SODIUM HYDROXIDE SCRUBBING
NEW
JUNt, 1978
OPERATIONAL
90S (SOU PPM SU2 AT INLET)
IS 6PM
WA8TENATER TREATMENT
SEE SECTION IS FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BELRIDGE OIL COMPANY HAS AN ENHANCED OIL RECOVERY SITE IN MCKITTRICK, CALIFORNIA. THERE ARE
SEVERAL SMALL STEAM GENERATORS* EACH RATED AT 50 MM BTU/HR, WHICH BURN A PART OF THE OIL PRODUCED
BY THE RECOVERY OPERATIONS. THE CRUDE OIL HAS t.t PERCENT SULFUR.
THE FGU SYSTEM, WHICH HAS SUPPLIED NEW BY HEATER TECHNOLOGY IN JULY 1976* TREATS A FLUE GAS
FLON OF 24,000 ACFM AT S70 F. THE SYSTEM CONSISTS OF AN EDUCTOR-TYPE VENTURI MOUNTED ON ONE SIDE •
OF A RECYCLE TANK* AND A STUB STACK MOUNTED ON THE OTHER, THE VENTURI HAS AN ADJUSTABLE DISK* WHICH
FORMS THE CONTACT STAGE FOR THE GAS AND RECIRCULATING LIQUOR. THE GAS THEN FLOWS THROUGH THE MIST
ELIMINATOR HOUSED INSIDE THE STUB STACK. THE LIQUOR* DISENGAGED FROM THE GAS* IS RECIRCULATEO WITH
A CONSTANT BLEED-OFF OF 4 GPM. THE DESIGN L/G RATIO IS 40 GAL/1000 ACF. THE PROCESS USED IS
SODIUM HYDROXIDE SCRUBBING AND FRESH CAUSTIC MAKEUP IS ADDED TO THE RECYCLE TANK. THE VENTURI
SECTION* CONTACTING DISC* RECIRCULATING PIPING AND THE RECIRCULATING PUMP ARE MADE OF J16L 88. THE
RECYCLE. TANK IS CARBON STEEL WITH EPOXY TAR COATING AND THE MIST ELIMINATOR IS FRP. THE PRESSURE
DROP ACROSS THE ENTIRE SYSTEM IS LESS THAN THE VACUUM CREATED BY THE EDUCTOR* ABOUT 1 IN. W.G.
THE BLEED-OFF STREAM IS TAKEN TO WASTEWATER TREATMENT. IN ADDITION, IT IS NECESSARY TO BLOW
DOMN FROM THE RECYCLE TANK INTERMITTENTLY.
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
BELRIDCE OIL CO.l MCKITTRICKr CALIFORNIA (CONTINUED)
OPERATING HISTORY
3RD OUARTER-1978 SINCE F60 SYSTEM START-UP ON JULY 6, 1978 THE SCRUBBER HAS EXPERIENCED
APPROXIMATELY 1 1/Z WEEKS OF DOWNTIME. MAJOR PROBLEMS HAVE BEEN FAULTY RELAYS IN THE INSTRUMEN-
TATION* AND PUMP FAILURE. THE RECIRCULATION PUMP WAS REPLACED.
4TH OUARTER-1976 THE SCRUBBER OPERATED 95 DAYS OUT OF 105 DAYS OF GENERATOR OPERATIONS. THIS
CORRESPONDS TO AN AVAILABILITY OF 69 PERCENT. SEVERE VIBRATIONS IN THE RECIRCULATION PUMP CAUSED
FAILURE OF THE RECYCLE PIPING. THE PUMP FOUNDATION WAS REINFORCED AND THE PIPING WAS REPLACED.
LEAKS IN CAUSTIC LINES MERE ALSO A PROBLEM AREA.
1ST QUARTER-1979 THE SCRUBBER OPERATED ABOUT 75 DAYS OUT OF A TOTAL OF 90 DAYS. THIS CORRESPONDS
TO A RELIABILITY VALUE OF 84X. THE CONDENSATION OF MOISTURE FROM THE EXIT FLUE GAS NAS AN AREA OF
CONCERN. WHILE WELDIN6 AN EXTENSION TO THE STACK* A SPARK CAUSED A FIRE WHICH DAMAGED THE FRP
MIST ELIMINATOR AND THE EPOXV LINING OF THE ABSORBER* THE EXTENT OF DAMAGE AND REPAIRS REQUIRED
IS UNDER INVESTIGATION.
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOKjOPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BUILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
BELR10GE OIL CO.
MCKI1THICK, CALIFORNIA
CRUDE OIL It.IX SULFUR)
12,000 SCFM
24,000 ACFM a 570 F
1
1
5000 LB/HR STEAM
6 MM (EQUIVALENT)
SO MN BTU/HH; 50,000 LB/HR STEAM
(FOR THIS REPORT, UNLE5S STATED OTHERWISE, 2000 SCFM a 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
THERMOTICS INC.
SODIUM HYDROXIDE SCRUBBING
NEN
JULY, 1978
OPERATIONAL
9oz (500 PPM S02 a INLET)
15 GPM
^ASTEHATER TREATMENT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BELRIDGE OIL COMPANY HAS AN ENHANCED OIL RECOVERY SITE IN MCKITTRICK, CALIFORNIA. THERE ARE
SEVERAL SMALL STEAM GENERATORS, EACH RATED AT 50 MM BTU/HR, NHICH BURN A PART OF THE OIL PRODUCED
BY THE RECOVERY OPERATIONS. THE CRUDE OIL HAS 1.1 PERCENT SULFUR.
THE FGD SYSTEM, WHICH HAS SUPPLIED NEK BY THERMOTICS INC. IN JULY 1978, TREATS A FLUE GAS
i
FLOW OF 24,000 ACFM AT 570 F. THE SYSTEM CONSISTS OF AN INLET OUCT HHICH HOUSES A NOZZLE DELIVERING
FRESH HATER AT HIGH PRESSURE (SO PSIA). THE "JET-NOZZLE" CREATES ENOUGH VACUUM (1-2 IN MG)| TO OFF-
SET THE SYSTEM PRESSURE DROP. 'THE GAS AND EXCESS HATER IMPINGE THE CENTRAL DOWNCOMER FROM THE
! i : '
ABSORPTION STA6E. THE GAS RISES UP THROUGH THE DOWNCOMER AND IS CONTACTED KITH 2 OR 3 LAYERS OF
RECIRCULATION LIQUOR SPRAYS (PH=6.5). THE DESIGN L/G RATIO IS 30 GAL/1000 ACF IN THE ABSORBER.
THE OVERFLOM LIQUOR FROM THE ABSORPTION STAGES AND THE EXCESS FRESH WATER ARE TAKEN TO HASTE
DISPOSAL (4 GPM). A PART OF THE MAKEUP MATER IS ADDED TO THE RECIRCULATION TANK. THE TOTAL
MAKEUP HATER FLON IS ABOUT 15 GPM.
THE ENTIRE FGO SYSTEM IS MADE OF 316L SS, EXCEPT FOR THE CAUSTIC STORAGE TANK, FEED PUMP AND
THE FEED LINES, HHICH ARE CARBON STEEL.
3«
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
BELRIDGE OIL CO.T MCKITTRICK, CALIFORNIA (CONTINUED)
OPERATING HISTORY
3RD 8UARTER-1978 SINCE FGD SYSTEM START-UP ON JULY 61 1978 THE SCRUBBER HAS EXPERIENCED
APPROXIMATELY 1 I/a NEEK3 OP DOWNTIME. MAJOR PROBLEMS HAVE BEEN FAULTY RELAYS IN THE INSTRUMENTA-
TION, AND PUMP FAILURE. THE RECIRCULATION PUMP NAB REPLACED.
4TH QUARTER-1978 THE SCRUBBER OPERATED 96 DAYS OUT OF 105 DAYS OF GENERATOR OPERATIONS. THIS
CORRESPONDS TO AN AVAILABILITY OF 93 PERCENT. ELECTRICAL CONNECTION MALFUNCTIONS AND LEAKS IN
CAUSTIC FEED LINE NERE THE MAJOR PROBLEMS. THE RECIRCULATION PUMP SEAL REQUIRED REPLACEMENT.
1ST QUARTER-1979 THE FGD SYSTEM HAS DONN FOR THE ENTIRE PERIOD DUE TO MAJOR LEAKS IN ONE NELO
LINE AROUND THE CIRCUMFERENCE OF THE ABSORBER. APPARENTLY, THE MELDING MAS PERFORMED ONLY ON THE
EXTERNAL SIDE. THIS LED TO SEVERE STRESS CORROSION CRACKING AND PITTING ON THE INSIDE TO THE
EXTENT OF CAUSING SERIOUS LEAKS. THE ABSORBER NAS DISMANTLED FROM THE FOUNDATION, THE MELDING HAS
REPAIRED AND THE ABSORBER MAS ERECTED AGAIN BY MID-MARCH. THE SYSTEM IS SCHEDULED TO STARTUP
BY THE END OF THE QUARTER.
39
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F6D UNITS
NUMBER OF 8UILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
MEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUOSE OR BY-PROOUCT DISPOSAL
CONTROL SYSTEM COST
CANTON TEXTILES
CANTON, GEORGIA
COAL (O.BX SULFUR)
INTERRUPTIBLE NATURAL GAS
25,000 SCFM (1 BOILER)
1
1
13 Mh (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLUN RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FHC ENVIRONMENTAL EQUIPMENT
CAUSTIC HASTE STREAM
RETROFIT
JUNE, 1974
OPERATIONAL
70S (500 PPM H INLET)
801 - 90S (5.92 LB/MM BTU AT INLET)
OPEN LOOP
CLOSED LOOP; 0.5 6PM
NON-FIXATED SLURRY TO LINED POND
NA S03/S04 LIQUOR DISPOSED TO LINED HOLDING PONDS
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
CANTON TEXTILE MILLS IN CANTON, GEORGIA HAS A 13 MM (EQUIVALENT) STEAM BOILER WHICH FIRES COAL
FROM OCTOBER TO MAY AND INTERRUPTIBLE NATURAL GAS THE REMAINDER OF THE YEAR. THE BOILER IS A COM-
BUSTION ENGINEERING (C-E) VERTICAL UNIT EQUIPPED MITH A CYCLONIC DUST COLLECTOR, TH| DUST COLLECTOR
CAPTURES APPROXIMATELY 75 TO 100 POUNDS OF FLY ASH PER HOUR. THE TYPICAL COAL BURNED HAS A SULFER
CONTENT OF 0.8 PERCENT AND AN AS-RECEIVED HEAT VALUE OF 13,600 BTU PER POUND OF COALJ SULFER DIOXIDE
CONCENTRATION IN THE FLUE GAS IS 500 PPM HITH * PARTICULATE LOADING OF 5.92 LB/MM BTU.
THE FED SYSTEM, DESIGNED BY R.5. NOONAN, INC., CONSISTS OF AN FMC MEDIUM ENERGY* jVENTURI-TYPE
SCRUBBER MADE OF 316L SS AND A SEPARATOR (8 FT OIA X 12 FT HIGH) OF FRP. THE FLUE C/iS ENTERS THE
VENTURI (PRESSURE DROP-6 TO 12 IN N.G.) AT A RATE OF 42,000 ACFM « 430 F THROUGH A 3d HP. BUFFALO
FORCE FD FAN. THE DUCTING LEADING TO AND FROM THE SCRUBBER IS MADE OF 1/4 IN. 316L SS, AND FRP
RESPECTIVELY. THE FLUE GAS LEAVES THE SYSTEM THROUGH AN FRP STACK. DYEING WASTE WATER CONTAINING
SODIUM SULFATE NITH A PH OF APPROXIMATELY 10.5 TO IZ IS THE SCRUBBING LIQUOR. THE SCRUBBING LIQUOR
IS INJECTED INTO THE FLUE 6AS STREAM THROUGH 1 IN. DIA. 316L SS SPRAY NOZZELS AHEAD OF THE VENTURI
THROAT. THE NASTENATER IS COLLECTED IN AN EQUALIZATION BASIN. DEPENDING ON THE OESIREO DEGREE OF
40
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
CANTON TEXTILES; CANTON* GEORGIA (CONTINUED)
NEUTRALIZATION, THE WASTEHATER IS THEN RECYCLED TO THE SCRUBBER OR PUMPED TO THE WASTEWATER TREAT-
MENT FACILITY. A PH LEVEL OF 8.0 IS OBTAINED IN THE FRP RECIRCULATION TANK. THE ALLIS CHALMERS RE*
CIRCULATION PUMP IS MADE OF RUBBER LINED CAST IRON WHILE DYE RETENTION TANK IS OF CONCRETE.
OPERATING HISTORY
SEVERAL OPERATIONAL PROBLEMS HERE ENCOUNTERED UPON INITIAL STARTUP. A SEVERE PLUGGING PROBLEM
MAS ENCOUNTERED IN SEVERAL PUMPS DUE TO THE PRESENCE OF COTTON FIBERS IN THE WASTEWATER. A SCREEN
BASKET AROUND THE INITIAL SCRUBBER SYSTEM INTAKE PIPE IN THE DYE COLLECTION MANHOLE HAS BEING USED
TEMPORARILY UNTIL FURTHER INVESTIGATION IS COMPLETED. SURFACE-ACTIVE AGENTS IN THE DYEING HASTE-
HATERS HHICH PRODUCE FOAMING IN THE SCRUBBER PUMP HERE DETECTED AND A DEFOAMER ADDITIVE IS NOH
INJECTED INTO THE SCRUBBER FEED FROM THE DYE RETENTION BASIN. FOULING OF THE PH PROBES AND MIST
CARRYOVER ARE OTHER PROBLEM AREAS THAT HAVE BEEN INVESTIGATED.
REFER TO FIGURE 14-3 IN SECTION 14 FOR A DETAILED PROCESS FLOH DIAGRAM OF THIS SYSTEM.
3RD OUARTER-1977 NO OPERATIONAL PROBLEMS HERE REPORTED DURING THIS SURVEY PERIOD. THE PLANT
REPORTED THE SYSTEM HAS WORKING SATISFACTORILY. THE PLANT HAS BURNING NATURAL GAS BUT EXPECTED
TO RETURN TO COAL DURING THE HEATING SEASON (DECEMBER-MAY).
4TH OUARTER-1977 THE PLANT STARTED BURNING COAL AND OPERATING THE SCRUBBER 100 PERCENT OF THE
TIME IN MID-OCTOBER. NO OPERATIONAL PROBLEMS HERE ENCOUNTERED DURING THIS PERIOD.
1ST OUARTER-1978 THE SCRUBBER DEMONSTRATED AN OPERABILITY OF 100X.
2ND OUARTER-1978 THE SCRUBBER HAS SHUTDOWN IN MID-MAY NHEN GAS FIRING RESUMED FOR SUMMER. COAL-
FIRING MILL RESUME IN MID-OCTOBER. DURING COAL-FIRED OPERATIONS IN 1977 AND 1978, THE SCRUBBER RAN
AT A 100X OPERABILITY.
3RD OUARTER-1978 NO UPDATE INFORMATION WAS AVAILABLE FOR THIS REPORT PERIOD.
4TH OUARTER-1978 COAL FIRING RESUMED IN MID-OCTOBER. AND WOULD CONTINUE FOR THE REST OF WINTER
MONTHS. DURING THIS SURVEY PERIOD (6 DAYS PER WEEK), THE SCRUBBERS OPERATED AT 99Z RELIABILITY.
THE DOHNTIME OF 10 HOURS HAS CAUSED BY BUILD-UP OF ABRASIVE FLVASH IN THE SCRUBBER, THE INTERIOR OF
THE SCRUBBER WAS THEN CLEANED. THE 316L S3 DUCTWORK ENTERING THE SCRUBBER HAS AFFECTED BY FLVASH
EROSION AND HILL BE REPLACED WITHIN A YEAR. NO OTHER OPERATING PROBLEMS MERE REPORTED.
1ST OUARTER-1979 THE FGD SYSTEM OPERATED TROUBLE-FREE UNTIL THE BEGINNING OF MARCH WHEN THE FAN
MOTOR BURNED OUT. THE MOTOR WAS REWIRED AND RETURNED TO SERVICE. TOTAL DOHNTIME WAS ABOUT ONE
MEEK.
41
-------
STATUS TU APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR UPEhAl1UNAL FGO SYSTEMS ON INDUSTRIAL BOILERS
IN8TALLATIUN NAME
INSTALLATION LOCATION
BOUNCE CHARACUHISTICS
SOURCE RA1IN&
NUMbER OF SEPARATE FGD UNI IS
NUMBER OF BUlLtKb bfcING CONTHOLLtU
SOURCE CAPACITY
CONTNUL SYSTEM VENOClM
CONTROL PROCESS
MEN / ftETHllFIT
START-UP OA1E
CONTHUL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO.
EAST PfiURIA, ILLINOIS
COAL 14.2* SULFUR)
21(1,000 SCFM (TOTAL - 4 BOILEHS)
80,000 ACFM a 35U F, FOR EACH OF 4 FGD SYSTEMS
4
4
105 MM (EQUIVALENT)| TOTAL - 4 BOILERS
(FOK THIS REPORT, UNLESS STATED OTHERWISE* 4000 SCFM » I EQUIVALENT MN.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
OOOBLE ALKALI (CONCENTRATED)
2 NEfc, 2 RETHO
APRIL, 197«
OPERATIONAL
90S (2,000 PPM »• INLET)
DEMATEREO SLURRY TO LANDFILL
60** SOLIDS (CAS04) SLUDGE DIRECTLY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE CATERPILLAR TKACTOR COMPANY PLANT LOCATED IN EAST PEURIA, ILLINOIS HAS FOUR COAL-FIRED
BOILERS. TWO OF THE BOILERS ARE RATED AT 200,000 POUNDS OF STEAM PER HOUR AND THE REMAINING ThO ARE
HATED AT 210, OVO POUNDS OF STEAM PEH HOUR. THE COAL BURNEO IS ILLINOIS COAL WITH A HEATING VALUE
OF iOibOO ttTU/LB ANU AN AVERAGE SULFUR CONTENT OF 3.2*. THE TOTAL BOILER CAPACITY IS ABOUT 100 MN
(EUUIVALEM). MECHANICAL COLLECTORS ARb USED FOK PRIMARY PARTICULATE CONTROL. GASES EXHAUST
THROUGH A LINED STACK WHICH IS APPROXIMATELY 175 FT TO ISO FT HIGH. THE STACK CONSISTS OF TWO
KIDNEY SHAPED FLUES EMBODIED NITHIN ONE OUTER SHELL.
THE AIR QUALITY CONTROL SYSTEMS HAVE BEEN SUPPLIED BY FMC ENVIRONMENTAL EQUIPMENT, DIVISION.
THERE IS ONE SCHUHBER TRAIN FOR EACH OF 1HE FOUR BOILERS, tfHICH CONTROLS BOTH PARTICULATE AND 802
EMISSIONS FROM ABOUT 80*000 ACFM • 390 F. THE FOUR FGD SYSTEMS SHARE COMMON REGENEKATION
FACILITIES, VACUUM FILTERS, AND SLUDGE DISPOSAL.
REFER TU FIGURE 14-5 IN SECTION 14' FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTUKY
4TM OUARTEH-1977 START-UP MAS SCHEDULED FOK MARCH 1978 AND CONSTRUCTION ,t»AS PROGRESSING SMOOTHLY.
1ST (IUARTER-1978 CONSTRUCTION OF THE FOUR FGU SYSTEMS HAS COMPLETED. START-UP HAS DELAYED DUE
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOH OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.} EAST PEORIA, ILLINOIS (CONTINUED)
TO THE COAL SHORTAGE.
2ND UUARTER-1976 DURING THIS REPORT PERIOD START-UP OCCURRED, BECAUSE THE BOILER PLANT MAS NEAR
THE END OF THE HEATING SEASON, THE BOILER LOADS MERE IN THE 70,000-100,000 LB/HR STEAM RANGE.
DURING COLD HEATHER OPERATIONS, THE BOILEN LOADS, ARE APPROXIMATELY 800,000 LB/HR. THE SYSTEM MAS
BUILDING GOOD FILTER CAKE DURING THE START-UP PHASE OF OPERATIONS. FINAL STEADY STATE OPERATIONS
MERE NOT ACHIEVED BEFORE SUMMER SHUTDOWN.
3RD QUARTER-197S THE FGD SYSTEM HAD JUST STARTED UP AGAIN AFTER SUMMER SHUTDOWN.
NO MAJOR START-UP PROBLEMS MERE REPORTED.
4TH QUARTER-1978 PLANT PERSONNEL REPORT THAT AN ABNORMALLY HIGH PRESSURE DROP THROUGH THE
SCRUBBERS IS RESTRICTING THE BOILERS TO ABOUT 60S OF THEIR CAPACITY. FAN AND DRAFT TESTS MERE
BEING RUN IN DECEMBER TO PINPOINT THE PROBLEM AREA. THE FAN AND DRAFT TESTS FURTHER DELAYED
SCHEDULED EMISSION TESTING. SINCE START-UP IN SEPTEMBER SCRUBBER OPERATIONS HAVE NOT BEEN SUFFICI-
ENTLY CONSISTENT TO COMPLETE ANY EMISSION TESTS.
A TEN-INCH PLASTIC RECIRCULATION LINE BROKE ON ONE SCRUBBER ANO\HAD TO BE REPLACED.
1ST QUARTER-1979 DURING THE REPORT PERIOD. THREE BOILERS ALONG WITH THE F6D SYSTEMS OPERATED
IN JANUARY. NO MAJOR OPERATING PROBLEMS WERE REPORTED EXCEPT CORROSION IN 802 MONITORS. THE
RELIABILITY VALUES OF THE FGO SYSTEMS ABOUT 90S. THE FGD SYSTEMS HERE SHUTDOWN FROM FEBRUARY 5
UNTIL MARCH 19 DUE TO UNAVAILABILITY OF SODA ASH.
-------
STATUS TU APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUN OPERATIONAL FGD SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME CATERPILLAR TRACTUK CO.
INSTALLATION LOCATION JULIET, ILLINOIS
SOURCE CHARACTERISTICS COAL (3.2X 3ULFUK)
SOURCE. RATING 67,ObO SCFM (101AL - 2 BOILERS)
NUMBER OF SEPARATE F6D UNI1S Z
NUMBER UF BOILERS BEING CONTROLLED 2
SOUKCE CAPACITY 54 M* (EQUIVALENT); TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 20UO SCFM • 1 EQUIVALENT MM,
THIS IS BECAUSE GAS FLOW MATE IS THE PRIMARY FACTOR IN MODULE SUING*)
CONTROL SYSTEM VENOUM ZURN INDUSTRIES
CONTkUL PROCESS DOUBLE ALKALI (DILUTE)
NEw / RETROFIT RETROFIT
START-UP DATE SEPTEMBER* 1974
CONTROL SYSTEM STATUS OPERATIONAL
802 KtMUVAL EFFICIENCY 9W»X (3000 PPM ti INLET)
MATER MAKE-UP CLOSED LOOP» O.S GPM
SLUoSfc OK ttY-PKOOUCl DISPOSAL DEHATERED SLURRY TU LANDFILL
CONTROL SYSTEM COST SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
ThE JOLIET PLANT OPERATES TrtO COAL-FIRED BOILERS RATED AT 100,000 AND 00,000 POUNDS OF STEAM
PER HOUR. THESE BOILERS ARE ON-LINE ONLV DURING WINTER MONTHS, ONE UF WHICH OPERATES 24 HR/DAY
AND THE OTHER ONLY MHEN A GREATER STEAM RATE IS REQUIRED DUE TO COLO WEATHER. THE COAL HAS A
HEATING VALUE OF lOrbOO BTU/LB AND IS FIRfcD Al A RATE OF 9.65 TONS/HH. TOTAL 302 EMISSIONS FROM
THE BOLER IS 6.7« LBS/MM BTU.
THE F6D SYSTEM UN tACH BOILER IS A ZURN DOUBLE ALKALI SCRUBBER CONSTRUCTED OF 316L STAIN-
LESS STEEL. EACH SCRUBBER EXHAUSTS THROUGH A CARBON STEEL STACK. THE TOTAL FLUE GAS FLOW RATE
IS 103,500 ACFM 8 SbU F. THE SCRUBBER UNITS ARE PRECEDED BY MECHANICAL COLLECTORS FOR PARTICULATE
REMOVAL. THE ZURN SCRUBBER UTILIZES A DUSTRAX10R MODULE FUR BOTH PARTICULATE AND 302 CONTROL.
SPENT SCRUBBING LIUUOR IS PUMPED TO THE REGENERATION AREA WHERE LIME IS ADDED TO PRODUCE CALCIUM
3ULFITE/SULFAT6 IN CLAHIFIERS. CLARIFIER UNDERFLOW, WHICH IS 1S-2UX SOLIDS BY WEIGHT* IS
DEWATEREO BY VACUUM FILTERS TO APPROXIMATELY 6SX SOLIDS BY WEIGHT. THE THIXOTRUPIC SLUDGE
PRODUCED IS READY FOR DISPOSAL AT A LANDFILL. CLARIFIER OVERFLOW IS RETURNED TO THE SCRUBBER AS
REGENERATED SCRUBBING LIOUOK. SODA ASH IS ALSO ADDED TO THE REGENERATED LIQUOR TO REPLENISH
SODIUM LOST IN THE SLUDGE. LIME ANU SUDA ASH ARE STORED IN OUTSIDE SILOS AND PNEUMATICALLY CONVEYED
TO USE POINTS. * CHEMICAL TREATMENT BUILDING WAS ERECTED TO HOUSE REGENERATION AND SLUDGE HANDLING
EQUIPMENT.
REFER TO FIGURE 14-6 OF SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
44
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.i JOLIET, ILLINOIS (CONTINUED)
OPERATING HISTORY
3RD QUARTER-1977 PROBLEMS OCCURRED WHEN A TANK RAN DRY AND DAMAGED A PUMP. SOME PIPE PLUGGING
PROBLEMS ALSO OCCURRED AS A RESULT OF THE PUMP FAILURE. A MAJOR PROBLEM AREA MAS THE HEAVY
NEAR OF THE FILTER CLOTHS ON THE VACUUM FILTERS. THE FILTER CLOTH LASTS ONLY 2 TO 3 WEEKS.
NO SOLUTIONS HAD BEEN FOUND BUT FILTER DESIGN MODIFICATIONS MERE BEING CONSIDERED.
THE UNITS HERE ULTRASONICALLY TESTED AND RESULTS SHOW THAT THE SYSTEMS ARE ON THE HIGH
SIDE OF TOLERANCE LEVELS. A MINOR LEAK WAS DETECTED AS A RESULT OF A FAULTY WELD.
4TH QUARTER-1977 FGO SYSTEM RESTART OCCURRED AT THE BEGINNING OF THE HEATING SEASON.
PLANT HAD INITIATED A PROCESS OF DETAILED RECORD KEEPING BUT WAS STILL WORKING
ON THE INTERNAL INFORMATION TRANSFER PROCESS. PLANT HAS INDICATED THAT A SUMMARY OF THESE
RECORDS MILL BE AVAILABLE TO THIS REPORT IN THE FUTURE.
1ST OUARTER-197S FILTER CLOTH PROBLEMS CONTINUED WITH REPLACEMENT BEING REQUIRED EVERY 2-3 WEEKS.
THE SYSTEMS WERE DOWN IN MARCH BECAUSE OF PLUGGED PIPELINES.
2ND OUARTER-1976 UNRELIABLE S02 MONITORS WERE A PROBLEM DURING THIS PERIOD. HEAVY ATTRITION OF
FILTER CLOTHS CONTINUED*
3RD OUARTER-197B DUE TO SHORT FILTER FABRIC LIFE AND SLUDGE FREEZE UP PROBLEMS, FILTER DESIGN
MODIFICATIONS WERE STILL BEING CONSIDERED* BUT HAD NOT YET BEEN MADE.
808 MONITORS ARE STILL A PROBLEM EXHIBITING PLUGGING, CORK03ION, AND UNRELIABLE PERFORMANCE.
PROBES OF 304 S3, 316L SS AND TEFLON COATING HAVE ALL BEEN TRIED WITHOUT SUCCESS, HASTELLOY-C
PROBES HAVE BEEN INSTALLED, BUT THE PLANT HAS NOT HAD TIME TU EVALUATE THEIR PERFORMANCE. REHEAT
EQUIPMENT WAS SCHEDULED TO BE INSTALLED BUT HAS NOT BEEN AS OF THIS UP-DATE. GUILLOTINE-TYPE
DAMPERS REPLACED THE LOUVER-TYPE ISOLATION DAMPERS ORIGINALLY INSTALLED. HOWEVER* THE GUILLOTINE-
TYPE CANNOT BE CLOSED TIGHTLY BECAUSE FLY ASH COLLECTS IN THE BOTTOM OF THE GUILLOTINE SHEATH.
4TH OUARTER-1976 THE BOILERS STARTED OPERATIONS IN THE LAST WEEK OF OCTOBER. FILTER CLOTH WEAR
CONTINUES TO BE A PROBLEM. THE HASTELLOY-C 802 PROBES HE8UIRE EXCESSIVE MAINTENANCE FOR PROPER
FUNCTIONING. CORROSION AND EROSION OF THE PROBES IS NOT YET EVIDENT. FLYASH ACCUMULATION IN THE
BOTTOM OF THE GUILLOTINE DAMPERS IS STILL A PROBLEM.
ALTHOUGH PIPE PLUGGING is NOT NORMALLY A PROBLEM (THE ENTIRE SYSTEM is FLUSHED AND CLEANED
DURING THE SUMMER OFF SEASON), SLIGHT BUILDUPS IN THE PIPING HAVE OCCURRED.
1ST QUARTER-1979 DURING THE QUARTER THE FGD SYSTEMS WERE PLAGUED 8Y A SERIES OF PROBLEMS. DURING
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.; JOLIEl, ILLINOIS (CONTINUED)
JANUARY, BOTH F6D SYSTEMS MERE DOWN. THE PROBLEMS STARTED WITH A FAILURE OF THE THICKENER UNDERFLOW
PUMP ALONG WITH THE SPAKE PUMP. THE THICKENER RAKES STOPPED TURNING. THE SLUDGE RETURN LINE COT
PLUGGED AT THE VACUUM FILTER. THE STORAGE CLARIFIES RAKES FAILED TO TURN AND THE BEARING SUPPORTING
THE RAKES BROKE DOWN DUE 10 A LARGE AMOUNT OF SLUDGE ACCUMULATION. THE PROCESS FLOW VALVE COULD
NOT BE TURNED IN ANY DIRECTION, IN ADDITION, DUE TO SEVERE WEATHER CONDITIONS, THE SODA ASH SCREW
FEEDER 6UT FROZEN STUCK. ALL T06ETHEW THE FGD SYSTEM WAS RESPONSIBLE FOR 717 HOURS OF DONNTIME IN
JANUARY. DURING FEBRUARY AND EARLY MARCH, THE SYSTEMS OPERATED SPORADICALLY BECAUSE OF A SLUDGE
PUMP MALFUNCTION AND A LACK OF THE REQUIRED AMOUNT OF SODA /ASH. IN MARCH THE SYSTEMS WERE
OPERATING NORMALLY.
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR dPERAIIONAL FGD SYSTEMS OH INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENOOM
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUD6E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
COAL (3.a* SULFUR)
131,000 SCFH (TOTAL - 3
BO,000 ACFM 4 550 F, FOR EACH OF 2 FGO SYSTEMS
40,000 ACFM o) 150 F, FOR 1 FSO SYSTEM
600,000 LB/HH STEAM (TOTAL - 3 BOILERS)
3
3
65 Mft (EQUIVALENT)ij TOTAL - 5 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM • 1 EQUIVALENT MW.
THIS IS BECAUSE GASiFLON RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEW
MARCH, 1979
OPERATIONAL
90S (2000 PPM (t INLET)
OEWATERED SLURRY TO LANDFILL
60*1 3ULIDS (CA804) SLUDGE DIRECTLY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE MAPLEION, ILLINOIS PLANT, CATERPILLAR IRACTOrt IS INSTALLING FIVE NEH BOILERS, THREE OF
WHICH ARE SLATED TO BEGIN OPERATIONS DURING JANUARY 1979. THE OTHER TnO WILL BEGIN OPERATIONS IN
THE EARLY 19BO'S. BECAUSE CONSTRUCTION HAS NOT YET BEGUN ON THESE TflO FGO SYSTEMS THEY ARE REPORTED
IN SECTION 11 OF THIS REPORT. TNO BOILERS STARTING IN JANUARY 1979 ARE RATED AT 250,000 LB/HR STEAM
EACH, THE OTHER IS MATED AT 100,000 LB/HR STEAM. BOTH BOILERS STARTING IN THE EARLY 1980'8 HILL BE
1,100,000 LB/HR.
CATERPILLAR HAS AnAROED A CONTRACT TO FMC ENVIRONMENTAL EQUIPMENT TO PROVIDE CONCENTRATED MODE
DUAL ALKALI FGD SYSTEMS FOR ALL FIVE BOILERS. EACH BOILER HILL HAVE A SEPARATE FGD SYSTEM. EACH
SYSTEM HILL INCLUDE A VENTURI 3CKUBBEK FOLLOWED BY A CYCLONIC MIST ELIMINATOR.
FACILITIES FOR REGENERATION, SLUDGE HANDLING AND DISPOSAL MILL BE SHARED 8* ALL FIVE BOILERS.
THE SAME FACILITIES HAVE BEEN DESIGNED TO HANDLE A TOTAL OF EIGHT BOILERS. THE ADDITIONAL CAPACITY
FOR THREE BOILERS HAS PLANNED FOR PROBABLE PLANT EXPANSION IN THE FUTURE. THERE IS NO PLANNED
START-UP DATE FOR THESE THREE BOILERS.
47
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STATUS TO APRIL W9
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS UN INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.; MAPLETON, ILLINOIS (CONTINUED)
OPERATING HISTORY
3RD QUARTER-1977 SYSTEM HAS UNDER CONSTRUCTION. START-UP WAS EXPECTED LATE IN THE FALL OF 1977.
4TH OUARTER-1977 CONSTRUCTION DELAYS ON THE STEAM GENERATION SIDE PUSHED PLANT START-UP BACK TO
THE FALL OF 1976.
2ND OUARTER-1978 START-UP MAS STILL PLANNED FOft THE 1976-1979 HEATING SEASON. THREE BOILERS AND
THEIR INDIVIDUAL FMC FGO SYSTEMS WILL COME ON-LINE AT THAT TIME.
3RD OUARTER-1978 CONSTRUCTION WAS NEAK1NG COMPLETION. SPECIAL MODIFICATIONS NERE BEING MADE
WHICH WERE DELAYING STAKT-UP. EXPERIENCE GAINtD AT MOSSVILLE IS BEING APPLIED TO MAPLETON SINCE THE
SYSTEMS ARE SIMILAR.
«TH OUARTER-1978 INSTALLATION OF SPECIAL MODIFICATIONS HAS EXTENDED THE START-UP DATE FOR THE
THREE BOILERS AND THEIR RELATED FGD SYSTEMS. CONSTRUCTION OF THESE THREE BOILERS
HAS BEEN COMPLETED; START-UP is EXPECTED AT THE. END OF DECEMBER ox BEGINNING OF JANUARY. INSTALLA-
TION HAS JUST BEGUN ON THE OTHER TwO £50,000 Lb/HR BOILERS. STAKT-UP FUR THESE TWO BOILERS WILL BE
IN THE EARLY 1980'S.
1ST OUARTER-1979 THE START-UP OPERATIONS FOR THE TWO BOILERS AND THEIR RELATED FGD SYSTEMS BEGAN
ON MARCH 39. CONSTRUCTION OF ANOTHER LARGE BOILER ALONG WITH FGD SYSTEM IS OVER BUT THE BOILER
MILL NOT BE OPERATED THIS YEAR. DURING EARLY APRIL, PERFORMANCE TESTING WILL BE UNDERWAY FOR THE
TWO FGD SYSTEMS. NO START-UP PROBLEMS ARE REPORTED.
-------
STATUS TU APRIL 1979
SECTION 9 (CONTINUE!})
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGU SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLU06E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO.
MUKTON, ILLINOIS
COAL (3.2X SULFUR)
36,000 SCFM (TOTAL • 2 80ILEKS)
19 Mh (EQUIVALENT ); TOTAL 2 BOILERS
((•OK THIS KEPUKT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MW.
THIS I.S BECAUSE GAS FLOW HATE IS THE PRIMARY FACTOR IN MUOOLE SIZING.)
ZUKN INDUSTRIES
DOUBLE ALKALI (DILUTE)
RETROFIT
JANUARY, 1978
OPERATIONAL
90X (£000 PPM a) INLET)
OEWATEHED SLURHY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE MORTON PLANT, A PARTS DISTRIBUTION CENTER* CATERPILLAR TRACTOR OPERATES A TwO-BOILER STEAM
PLANT WHICH GENERATES A TOTAL OF 66,000 ACFM AT 450 f AT MAXIMUM LOAD. THE STOKER COAL-FIRED
BOILERS' ARE MANUFACTURED BY HICKS AND ARE RATED FOR 60,000 LB/HR STEAM EACH AT 150 PSIG. AN OIL-
FIRED BOILER RATED AT 120,000 LB/HR STEAM IS AVAILABLE AS SACK-UP. HEAT INPUT IS 70.7 MM BTU/HR.
THE HEATING VALUE OF THE COAL IS 10,400 BTU/LB.
EMISSIONS ARE CONTROLLED BY A ZURN INDUSTRIES AIR QUALITY CONTROL SYSTEM CONSISTING OF A DUS-
TRAXTOR SCRUBBER IN WHICH PARTICULATE AND 302 REMOVAL OCCUR SIMULTANEOUSLY. SULFUR DIOXIDE REMOVAL
IS BROUGHT ABOUT BY THE USE OF ZURN DILUTE MODE DOUBLE ALKALI FGD TECHNOLOGY. THE TWO BOILERS AND
THE TNO SCRUBBING TRAINS AND MOST ANCILLARY EQUIPMENT ARE WITHIN THE BOILER HOUSE.
THE SYSTEM AT MORTON IS VERY SIMILAR TO THAT AT THE CATERPILLAR JOLIET PLANT, WHICH HAS BEEN
OPERATING EACH HEATING SEASON SINCE OCTOBER 1971. WHENEVER POSSIBLE, PROBLEM AREAS AND
SOLUTIONS IDENTIFIED IN JOLIET OPERATIONS HAVE BEEN IMPLEMENTED TO IMPROVE THE SYSTEM DESIGN
AT MORTON. SPECIFIC AREAS IN WHICH MODIFICATIONS TO DESIGN HAVE BEEN MADE ARE WATER BALANCE,
PUMPS, PH MONITORING, PIPING, LIME STORAGE, AND COLD WEATHER PROTECTION.
REFER TO FIGURE 14-7 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
1ST BUARTER-1978 SYSTEM START-UP OCCURRED AT THE BEGINNING OF JANUARY. INITIAL OPERATIONS MERE
PROBLEM-FREE. THROUGH JANUARY AND PART OF FEBRUARY, ZURN PERSONNEL WERE TRAINING THE BOILER PLANT
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.) MORTON, ILLINOIS (CONTINUED)
PERSONNEL IN THE OPERATION OF THE F6D SYSTEM. OPERATIONAL EXPERIENCES AT JOLlET AND MQSSVILLE HAVE
SHOWN THAT THE BOILER OPERATORS CAN BE EFFECTIVELY TRAINED TO OPERATE AND MAINTAIN THE FGD SYSTEMS.
CURRENT PLANS CALLED FOR ACCEPTANCE TESTING IN THE SPRING, BUT THE COAL SITUATION MAY DELAY THE TEST
PERIOD.
ZND OUARTER-197S FGD OPERATIONS CONTINUED TO BE TROUBLE-FREE. THE BOILER HAS EXPERIENCING SOME
PUFFING (BACK PRESSURE), THE CAUSE OF WHICH MAS NOT KNOWN.
3RD OUARTER-197* ACCEPTANCE TESTING WAS DELAYED DUE TO THE PUFFING PROBLEM. THE TESTING
WILL BE ATTEMPTED LATE THIS FALL. EVEN THOUGH PUFFING REMAINS A PROBLEM, PLANT PERSONNEL PEEL THEY
ARE CLOSER TO RESOLVING IT DUE TO NEW DESIGN MODIFICATIONS TO THE SCRUBBER.
4TH QUARTER-J97S DURING THIS QUARTER, THE PUFFING PROBLEM NAS CORRECTED. THE PUFFING PROBLEM
WAS A RESULT OF SEVERE PRESSURE PULSATIONS INSIDE THE ABSORBER DURING OPERATIONS. INSTANTANEOUS
PRESSURE DROPS OF 10 INCHES H.G. ACROSS THE SCRUBBER OCCURRED SEVERAL TIMES. ZURN INDUSTRIES PER-
SONNEL TRIED TO SOLVE THE PROBLEM BY INSTALLING TURNING ELBONS IN THE STACK, BUT THIS FAILED TO
SOLVE THE PROBLEM. FINALLY PLANT PERSONNEL INSTALLED WINDOWS IN THE ABSORBER AND THROUGH THE USE
OF SPOTLIGHTS OBSERVED THE ACTION OF BLOWING COLD AIR THROUGH THE ABSORBER. IT HAS NOTICED THAT A
HAVE BEGAN TO PROPAGATE BACK AND FORTH ACROSS THE ABSORBER CAUSING THE WATER LEVEL AT THE BOTTOM
OF THE OOWNCOMER CHANNELS TO DROP BELOW THE BOTTOM OF THE CHANNELS. GAS MAS THEN ALLOWED TO PASS
UP THE DONNCOMER CHANNELS (ONE ON EACH SIDE OF THE ABSORBER) INSTEAD OF THE NORMAL SCRUBBING TUBES
AND PREVENTED THE SCRUBBING LIQUOR TO RETURN TO THE BOTTOM POOL. AS A RESULT, PULSATIONS OCCURRED
ALONG THE OOHNCOMER. THE PROBLEM WAS SOLVED BY SEALING THE OOWNCOMER HITH WELDED PLATES EXCEPT FOR
THREE TUBES. THESE TUBES WERE LONGER THAN THE ORIGINAL DOHNCOMER CHANNEL TO ENSURE THE TUBE BOTTOMS
REMAINED CONTINUOUSLY SUBMEMGED.
SINCE THE PH PROBES CONTINUOUSLY BECAME PLUGGED AND GAVE FALSE READINGS, PH IS MEASURED HOURLY
WITH A MULTI-BAND LITMUS PAPER.
AN INITIAL WATER BALANCE PROBLEM WAS CAUSED BY TOO MUCH WATEH ENTERING THE F6D SYSTEM AS PUMP
SEAL NATER. IT WAS CORRECTED BY INSTALLING RUTAMETERS ON SEAL WATER LINES TO REGULATE FLOW.
ACCEPTANCE TESTING HAS BEEN COMPLETED AND AN APPLICATION HAS SEEN SUBMITTED TO THE STATE FOR
A STATE PERMIT TO OPERATE. THE PLANT BELIEVES THEY WILL RECEIVE THE FIRST SUCH PERMIT IN ILLINOIS
TO BURN HIGH SULFUR COAL IN AN INDUSTRIAL BOILER.
50
-------
MONTH
JAN. 79
FEB. 79
BOILER
1
320
565
FGD
SYSTEM 1
108
563
OPEKA-
BILITYU)
33.8
99.6
RELIA-
BILITYU)
too
99.6
BOILER
2
590
555
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.I MORTON, ILLINOIS (CONTINUED)
1ST QUARTER-1979 DURING THE REPORT PERIOD IN DECEMBER 1978 NEITHER OF THE BOILERS OPERATED.
THE OPERATING HOURS It* JANUARY AND FEBRUARY FOLLOWS:
F60 OPERA- RELIA-
SY3TEM 2 BILITYU) BILITY(X)
513 86.9 60.2
548 98.7 81.5
IN MARCH, UP TO THE END OF THE REPORT PERIOD* BOTH THE SYSTEMS OPERATED AT RELIABILITY VALUE CLOSE
TO 100S. THE OPERABILITY OF FGD SYSTEM 1 IN JANUARY MAS LON BECAUSE THE SCRUBBER HAS NOT OPERATED
DUE TO A MANPOWER SHORTAGE. NO OPERATING PROBLEMS HAD OCCURRED. DURING JANUARY AND FEBRUARY,
FOR BUILER 1 AND SCRUBBER 1, MIST ELIMINATOR PLUGGING CAUSED DOWNTIME OF 50 HOURS AND 117 HOURS
RESPECTIVELY. OTHER MAJOR DOWNTIME ON SCRUBBER 1 IN JANUARY WAS DUE TO FROZEN PIPE LINES. ONE OF
THE CAUSES OF MIST ELIMINATOR PLUGGING APPEARS TO BE HIGH SOLIDS CONTENT IN THE SLURRY. PLANT
PERSONNEL FEEL THAT PROPER CONTROL OF PROCESS CHEMISTRY WOULD ALLEVIATE THE PROBLEM. DURING MARCH,
THE SLUDGE DEWATERING SYSTEM PIPING WAS CLEANED. AN ACCIDENTAL MANUAL VALVE CLOSURE CAUSED 5
HOURS OF DOWNTIME. SOME LEAKAGE IN THE PACKING OF A POSITIVE DISPLACEMENT MOYNA PUMP WAS NOTED
IN MARCH.
THE PLANT RECEIVED AN OPERATING PERMIT FROM ILLINOIS ENVIRONMENTAL PROTECTION AGENCY IN
FEBRUARY. THIS WAS ONLY THE SECOND SUCH PERMIT GRANTED IN THE STATE OF ILLINOIS FOR A SYSTEM
BURNING HIGH SULFUR COAL.
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL bOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE HATING
NUMbtR OF SEPARATE FGD UNITS
NUMbEH OF BOILERS BEING CONTROLLED
souRCt CAPACITY
CONTROL SrSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
STAKT-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PHOOUCI DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO.
MOSSVILLE, ILLINOIS
COAL (i.2X SULFUR)
l«0,000 SCFM (TOTAL - a BOILERS)
70 Mfc (EQUIVALENT); TOTAL - 4 BOILERS
(FOR (HIS REPORT, UNLESS STATED OTHERWISE* 2000 SCFM » 1 EQUIVALENT MM,
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUbLE ALKALI (CONCENTRATED)
Z Hit, 2 RETRO
OCTOBER, 1975
OPERATIONAL
90tX (£000 PPM H INLET)
DEttATERtO SLURRY TO LANDFILL
60+X SOLIDS (CAS04) SLUDGE DIRECTLY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE MOSSVILLE PLANT, CATERPILLAR TRACTOR OPERATES A FOUR-BOILER STEAM PLANT. TWO OF THE
ttOILEHS ARE RATED AT 1SO.UOO LflS/MR STEAM AND TMO ARE RATED AT SO,000 LflS/MR STEAM. THE ENTIRE
1-UNIT PLANT IS ROUGHLY EQUIVALENT TO 70 MM OF ELECTRICAL GENERATING POWER. THE COAL FIRED IS
HIGH-SULFUR (3.2X-4.0X) ILLINOIS COAL. THE FOURTH BOILER. AT 150,000 LBS/HR, BEGAN OPERATIONS
IN JUNE 1977 AMU ITS FGD SYSTEM NAS BYPASSED UNTIL OCTOBER 1977. THE TftO MUST RECENTLY INSTALLED
BOILERS HAVE MECHANICAL COLLECTORS PRECEEDING THE SCRUBBERS.
FMC ENVIRONMENTAL EUUIPMENT DIVISION HAS SUPPLIED AN AIR QUALITY CONTROL SYSTEM CONSISTING OF A
VENTUHI SCRUBUEH FOR PARTICULAR CONTROL AND AN ABSORBER MODULE FOR S02 CONTROL. FMC CONCENTRATED
MODE, DOUBLE ALKALI FGD TECHNOLOGY IS BEING USED IN THE ABSORBER MODULES. THE TMO 150,000
L0/HR BOILERS HAVE MECHANICAL COLLECTORS REMOVING ABOUT 90S OF THE INLET FLYASH. THE SCRUBBING
TRAINS ON THE TWO SMALLER BOILERS HAVE NO PRECEDING MECHANICAL COLLECTORS. THE POSITION OF THE
VENTURI CAN BE CONTROLLED AUTOMATICALLY BY STEAM FLOW, BUT CURRENTLY IS NOT IN OPERATION.
MHILE THE FLYASH IN THE FINAL FILTER CAKE PROVIDES ADOEO MECHANICAL STABILITY, THE HIGH ASH
CONTENT IN THE RECIRCULATING SLURRY CAUSED SEVERE EROSION/ABRASION PROBLEMS IN EARLY OPERATIONS.
THE ORIGINALLY INSTALLED MEIR-TYPE CONTROL VALVES HAVE BEEN REPLACED nITH SPOOL PIECES AND A
CONSTANT VOLUME PUMPING SYSTEM. THERE HAS ALSO SIGNIFICANT NEAR IN THE VENTURI SCRUBBER BOTTOMS,
WHICH NAS SOLVED BV THE INSTALLATION OF HEAR PLATES.
SEVERAL PROBLEM AREAS MERE IDENTIFIED AND DEALT NITH DURING THE TNO HEATING SEASONS PRIOR TO
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.) MOSSVILLE, ILLINOIS (CONTINUED)
THE 1977-78 SEASON. THESE ARE LISTED BELOW.
PUMPS - THE RUBBER-LINED SLURRY PUMPS MERE OVERSIZED WHICH CAUSED HIGH PIPE VELOCITIES AND
ACCELERATED WEAR ON THE PUMP LININGS. THESE PUMPS WERE REVISED TO LOWER THEIR OUTPUT. LOW SEAL
HATER PRESSURE ALLOWED PROCESS LIQUOR TO GET INTO THE PUMP AND PACKING. ALL SEAL WATER
IS NOW ONCE-THROUGH AND SYSTEM PRESSURES HAVE BEEN ADJUSTED TO MAINTAIN SEAL WATER PRESSURE
ABOVE PROCESS LIQUID PRESSURES.
SLUpSE HANDLING "SLUDGE IS TRANSPORTED FROM THE VACUUM FILTERS TO THE LOADING AREA ON A BELT
CONVEYOR. SEVERAL STRATEGIESr ALL INVOLVING SCRAPING OR PLOWING THE DEWATERED SLUDGE OFF THE BELT,
RESULTED IN EXCESSIVE WEAR OF EITHER THE BELTS OR THE PLOaS. THE PRESENT APPROACH SIMPLY DUMPS
THE MATERIAL OFF THE END OF THE BELT INTO BINS. THE POSITION OF THE BELT IS CHANGEABLE SO THAT
EI6HT BINS CAN BE FILLED BEFORE THEY MUST BE EMPTIED. A FURTHER MODIFICATION HAS A DUAL POSITION
CHUTE UNDER EACH BELT END POSITION, SO THAT A TOTAL OF 16 BINS CAN BE WORKED AT A TIME.
SLUDGE 8INS ARE THEN LOADED HYDRAULICALLY INTO TRUCKS AND HAULED TO THE SANITARY LANDFILL AREA.
ANOTHER PROBLEM, COLD WEATHER ICING ON THE SLUDGE LOADING AREA, WAS SOLVED BY ENCLOSING THE AREA.
INSTRUMENTATION - ORIGINAL DESIGN PLANS CALLED FOR CONTROL BY THE MONITORING OF THE 303/304
RATIO AND SODIUM ION CONCENTRATION. THE CONTROL RANGE WAS FOUND TO BE TOO SMALL AND THE PRESENT
APPROACH IS PH CONTROL (6.5) AND CLEANING OF THE PROBES EVERY OTHER DAY.
ORIGINAL DESIGN DID NOT MONITOR 302 CONCENTRATION BUT A COMPLETE MONITOR SYSTEM WAS INSTALLED
PRIOR TO THE 1977-78 SEASON.
PIPING - MODIFICATIONS HAVE BEEN MADE WHICH FACILITATE CLEANING OR SCHEDULED REPLACEMENT.
REFER TO FIGURE 14-ft IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH OUARTER-1977 CATERPILLAR BEGAN A PROCEDURE OF DETAILED RECORD KEEPING, BUT THE INFORMATION
MAS NOT YET AVAILABLE TO THIS REPORT.
2ND OUARTER-1978 NUMEROUS BOILER-RELATED PROBLEMS HAVE COMPOUNDED FGD SYSTEM PROBLEMS. MAJOR
FGO PROBLEM AREAS WERE AS FOLLOWS;
EROSION OF SCRUBBER LINER MATERIAL.
EXCESSIVE WEAR OF PIPING, PUMPS, AND CONTROL VALVES.
SLUDGE FREEZE-UP ON THE CONVEYOR BELT PLUGGED SLUDGE CHUTES.
3RD QUARTER-1978 PERFORMANCE OF THE VENTURI SPRAY NOZZLES HAS NOT BEEN SATISFACTORY. NOZZELS OF
3161. S3 WERE ORIGINALLY INSTALLED AND LASTED ABOUT FOUR MONTHS. CERAMIC NOZZLES WERE THEN TRIED BUT
BROKE NHEN BEING REMOVED. THE PLANT RETURNED TO USING 316L S3 SINCE THE STEEL NOZZLES WERE CHEAPER
THAN THE CERAMIC NOZZLES. PLANS ARE BEING MADE TO MODIFY THE NOZZLE CONFIGURATION. THE VENTURI
U BEING OPERATED MANUALLY SINCE PLANT PERSONNEL HAVE NOT HAD TIME TO DEBUG THE AUTOMATIC CONTROL.
S3
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.F MOSSVILLE, ILLINOIS (CONTINUED)
END-DISCHARGING DISH CONVEYORS FOR THE SLUDGE CONVEYOR SYSTEM HAVE NOT VET BEEN INSTALLED
BECAUSE THE ENTIRE SLUDGE HANDLING FACILITY IS CURRENTLY BEING REEVALUATED. THIS REEVALUATION 18
A RESULT OF THE MANY PROBLEMS CATERPILLAR HAS HAD NITH THEIR SLUDGE HANDLING SYSTEM.
MODIFICATIONS TO PIPING IN ORDER TO FACILITATE PIPE CLEANING AND SCHEDULED REPLACEMENTS HAVE NOT
BEEN SIGNIFICANT. THE GUILLOTINE DAMPERS AT THIS PLANT ARE EXPERIENCING THE SAME PROBLEMS AS THE
DAMPERS AT THE JOLIET PLANT> FLYASH COLLECTING IN THE BOTTOM OF THE DAMPER PREVENTS THE DAMPER FROM
BEING CLOSED TIGHTLY. NEAR PLATES MERE INSTALLED IN THE BOTTOM OF THE VENTURI SCRUBBERS TO PREVENT
ABRASIVE WEAR AND ARE WORKING NELL. PLANT PERSONNEL FEEL THEY ARE STILL IN A DEBUGGING PHASE.
4TH QUARTER-1976 PLANT PERSONNEL DESCRIBED THE FGD SYSTEM OPERATION AS SPORADIC AND FLUCTUATING.
PROBLEMS ARE ENCOUNTERED. CONTINUOUSLY CAUSING SYSTEM SHUTDOWN. EROSION CONTINUES TO BE A SIG-
NIFICANT PROBLEM. VALVES, FITTINGS* LININGS, PUMPS. FANS* AND SCRUBBER NOZZLES ARE ALL ERODING.
THE NEAR PLATE INSTALLED IN THE BOTTOM OF THE SCRUBBER HAS SLOWED THE EROSION THERE.
THE VENTURI NOZZLE CONFIGURATION WAS NOT CHANGED AND THE VENTURI IS STILL OPERATED MANUALLY.
THE SLUDGE HANDLING FACILITIES HAVE NOT BEEN REEVALUATED OR CHANGED YET. FILTER FABRIC NEAR AND
SLUDGE FREEZE-UP CONTINUE TO BE A PROBLEM.
A MAINTENANCE PROGRAM TO CLEAN THE GUILLOTINE DAMPER OF FLYASH HAS NOT YET BEEN DEVELOPED.
AN EMISSIONS TEST IS SCHEDULED FOR LATE JANUARY OR EARLY FEBRUARY 1979.
1ST QUARTER-1979 THE PLANT PERSONNEL REPORTED THAT THE FGD SYSTEM OPERATION CONTINUES TO BE
FLUCTUATING AND SPORADIC. EARLIER PROBLEMS CONTINUE TO CAUSE SYSTEM SHUTDOWNS. THE MAJOR PROBLEMS
ARE MIST ELIMINATOR PLUGGING. CHEMICAL INBALANCE. WEAR ON PIPES AND MANUAL OPERATION OF THE VENTURI.
IN ADDITION. DRY CHEMICAL HANDLING IS ALSO A MAJOR PROBLEM. SODA ASH HAS NOT BEEN AVAILABLE IN
SUFFICIENT QUANTITY.
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME.
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGU UNITS
NUMBER OF BOILERS BEING CON!HULLED
SOURCE CAPACITY
CONTROL SYSJEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
WATER MAKE-UP
8LU06E ON BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CHfcVKUN U.S.A. INC.
6AKE&5FIELD, CALIFORNIA
OIL U.U SULFUR)
2«8,OuO SCFM (TOTAL - 16 BOILERS)
150,000 ACFM i SOOF, FUR EACH OF 3 FGD SYSTEMS.
3
IB
125 MM (EQUIVALENT)! TOTAL " 16 BOILERS
900 MM BTU/HH (TOTAL - IB BOILERS* 6 BUILEKS/FGD SYSTEM)
(FOR THIS REPORT, UNLESS STATED OTHERWISE^ 2UUO SCFM * 1 EUUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SUING.)
KOCH ENGINEERING
SODIUM CARBONATE SCRUBBING
RETROFIT
JULY, 1976
OPERATIONAL
90X (70 PPM «l OUTLET)
75 &PM
WASTEWATER TREATMENT AND DISCHARGE TO TAILINGS POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
CHEVRON U.S.A. HAS AN OIL SITE AT BAKERSFIELO, CALIFORNIA. THERE ARE ABOUT 50 STEAM GENERATORS
NHICH BURN l.U SULFUR CRUDE OIL. EACH GENERATOR IS RATED AT 50 MM BTU/HK. THE STEAM IS USED FOR
ENHANCED OIL RECOVERY FROM THE OIL "ELLS.
KOCH ENGINEERING COMMISSIONED THREE FGD SYSIEMS IN JUNE/JULY 1970. THE SODIUM CARBONATE
SCRUBBING PROCESS IS USED. EACH SCRUBBER 1HEA1S FLUE GASES FROM 6 GENERATORS WITH A TOTAL
FLOW RATE OF 150*000 ACFM AT 5UO F. THE GAS IS UUENCHED IN THE BOTTOM PORTION OF THE ABSORBER BY
120 6PM OF THE RECIRCULAUNG L1CIUOR. THERE ARE 6 KOCH FLEXITHAYS AND A KOCH FLEXlMtSH MIST
ELIMINATOR IN EACH SCRUBBER. THE SPENT LIQUOR IS MIXED WllH FRESH SODIUM CARBONATE SOLUTION IN THE
BOTTOM OF THE SCRUBBER. A CONTINUOUS BLEED STREAM (9 5PM) IS TAKEN TO A BLEED STORAGE TANK,
WHEREAS THE REST OF THE LlbUOft IS RECIRCULATEO AT A TOTAL RATE OF 900 GPM (15 MTX DISSOLVED SOLIDS).
A PH OF 6.5 IS MAINTAINED AT THE TOP TRAY AND AN L/G RATIO OF 6 GAL/1000 ACF IS USED. THERE IS
NO REHEAT FACILITY BUT THE SCRUBBER CAN BE BYPASSED. THE BOILER 1.0. FANS WERE UPGRADED
FROM SO HP TO 75 HP TO OFFSET THE PRESSURE DROP OF 9 IN. WG. ACROSS THE ABSORBER. THE SCRUBBERS ARE
OE3IGNEO 10 REMOVE 9UX OF THE 302 AND MAINTAIN AN EXIT S02 CONCENTRATION BELOW 70 PPM. EACH
SCRUBBER IS 16.5 FT IN OIAMETER AND 35 FEET HIGH. THE STUB STACK SITUATED ON TOP OF EACH SCRUBBER
IS ABOUT 20 FEET HIGH AND 6 FEET IN DIAMETER. THE SCRUBBERS AND TRAYS ARE MADE OF 316L S3 AND THE
55
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
CHEVRON U.S.A. INC.» BAKERSFIELO, CALIFORNIA (CONTINUED)
FLEXIMESN IS INCOLOT 825. THE STACK IS MADE OF 316 SS AND THE PIPING IS FRP.
REFER TO FIGURE 14-9 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1978 BECAUSE OF LOW STEAM DEMAND ONLY TNO OF THE EXISTING THREE SCRUBBERS ARE OPERA-
TIONAL (OUT OF THE 16 STEAM GENERATORS 12 ARE OPERATIONAL). ONE SCRUBBER CONTROLS 7 GENER-
ATORS NHILE THE OTHER CONTROLS 5 GENERATORS. THE REMAINING 6 STEAM GENERATORS AND THE CORRESPOND-
ING SCRUBBER MILL BE BROUGHT ON-LINE AS STEAM DEMAND INCREASES (POSSIBLY IN DECEMBER OR JANUARY).
NO MAJOR PROBLEMS HAVE OCCURRED SINCE START-UP IN JUNE-JULY 1978. HOWEVER, SOME CLOGGING OF
THE SODA ASH FEED CHUTE FROM THE STORAGE SILO DOES OCCUR. THIS CLOGGING IS EASILY CORRECTED WITH NO
DOWNTIME NECESSARY. SYSTEM OPERABILITY FOR THE PERIOD MAS 951.
GOOD OPERATION IS ATTRIBUTED TO REGULAR MAINTENANCE PRACTICE WITH EMPHASIS ON DAILY CLEANING OF
THE PH PROBES.
4TH OUARTER-1978 SYSTEM AVAILABILITY OF 100X WAS REPURTED FOR THIS PERIOD. THERE HERE NO
SCALING OR PLUGGING PROBLEMS. ROTATING EQUIPMENT (FANS, PUMPS) HAVE OPERATED NITHOUT TROUBLE. THE
MIST ELIMINATOR MASH FREQUENCY is TWICE A DAY, ABOUT 20 MINUTES AT A TIME, APPROXIMATELY so GPM
FLOW OF FRESH MATER.
1ST OUARTER-1979 THE VIBRATING FEEDER AND THE SCREW CONVEYOR ON THE SODA ASH SILOS MAY BE
REPLACED TO ELIMINATE FEED CHUTE CLOGGING. APART FROM THIS MINOR PROBLEM, THE SYSTEMS OPERATED
TROUBLE-FREE DURING THIS PERIOD WITH 100* AVAILABILITY. THE SODA ASH CONSUMPTION (ABOUT 1.25
LB/LB S02 REMOVED) IS LOW ENOUGH TO BE FAVORABLE OVER CAUSTIC.
JHE BLEED FLOW RATE (9 GPM) is SET so AS NOT TO EXCEED 1000 PPM CHLORIDES IN THE RECIKCULATION
LOOP. THIS CORRESPONDS TO A PH OF 6.6, SPECIFIC GRAVITY OF 1.15 AND TOTAL DISSOLVED SOLIDS OF
15 X BY WEIGHT.
56
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER UF SEPARATE FGO UNITS
NUMBER OF BOILERS BtINC, CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENOUR
CONTROL PROCESS
Nfcw / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLU06E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
DOUBLE BARREL OIL CD.
UAKEHSFIELD, CALIFORNIA
OIL 11.U SULFUR)
12.000 SCFM (1 BOILER)
34,000 ACFM a 550 F.
1
1
ft MN CEUUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 3CFM t 1 EQUIVALENT MN.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
C-E NATCO
SODIUM HYDROXIDE SCRUBBING
NEW
JUNE, 1978
OPERATIONAL
9bX (650 PPM S02 » INLET)
6.5 GPM
NON-FIXATED SLURRY TO LINED POND
1.5 GPM BLEED-OFF STREAM TO SETTLING POND.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
DOUBLE BARREL OIL IS ONE OF SEVERAL SMALL, INDEPENDENT OIL COMPANIES IN BAKERSFIELDr CALIFORNIA.
THE EOR OPERATIONS UF THE DOUBLE BARREL OIL COMPANY CONSIST OF ONLY ONE 50 MM BTU/HR STEAM
GENERATOR. THE FUEL BURNED IS A PART OF THE CRUDE OIL PRODUCED U.1I SULFUR).
THE FGD SYSTEM MAS SUPPLIED NEW ALONG WITH THE STEAM GENERATOR BY C-E NATCO IN APRIL 1976.
THIS SYSTEM HAS THE FIRST FULL-SCALE DEMONSTRATION OF THE C-E NATCO DESIGN IN THE CALIFORNIA OIL
FIELDS. THE ORIGINAL DESIGN CONSISTED OF 'A UUfcNCHER AND AN ABSORBER, WITH THE ABSORBER BLEED
STREAM BEING RECIRCULATED IN THE QUENCHER 'BEFORE BEING DISPOSED OF; SEVERAL LAYERS OF SPRAYS MERE
PROVIDED IN BOTH OF THE TONERS TO VARY THE L/G RATIOS OVER A MIDE RANGE, ALONG WITH THE MAXIMUM
HORSEPOWER MOTORS ON THE PUMPS. IN THE INITIAL 2-3 MONTHS PERIOD, AN EXTENSIVE TEST PROGRAM HAS
CONDUCTED BY C-E NATCO IN ORDER TO CORRELATE SEVERAL PROCESS PARAMETERS TO 802 REMOVAL, PARTICULATE
REMOVAL, AND ALKALI UTILIZATION. DOUBLE BARREL HAS MODIFIED THE OPERATING PROCEDURE AS FOLLOWS!
THE FLUE GAS (24,000 ACFM a b50 F) IS[CONTACTED WITH THE FIRST LAYER OF SPRAYS IN THE BOTTOM
OF THE ABSORBER, WHERE A PH OF 6.0 IS MAINTAINED. THE GAS RISES UP THROUGH THE CENTRAL OOMNCOMER
OF A 'CHIMNEY-TRAY*, AND CONTACTS THE SECOND SET OF SPRAYS WITH A PH OF 6.8. A L/G RATIO OF
25 GAL/1000 SCF IS MAINTAINED IN BOTH THE{STAGES. THE GAS PASSES THROUGH A CHEVRON MIST ELIMINATOR
57
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
DOUBLE BARREL OIL CO.f BAKERSFIELD, CALIFORNIA (CONTINUED)
AND A STUB STACK TO THE ATMOSPHERE. FRESH CAUSTIC (SO MT. X) IS ADDED TO THE SECOND STA6E
(0.13 6PM), WHILE MAKEUP NATER IS ADDED TO THE FIRST STAGE (9.5 6PM). A CONSTANT BLEED-OFF STREAM
(1.5 GPM) IS WITHDRAWN FROM THE BOTTOM STAGE AND TAKEN TO A SETTLING POND. THE ENTIRE FGD SYSTEM
(ABSORBER, TRAY, RECIRCULATION PUMP, PIPING, DUCTNORK, MIST ELIMINATOR, AND STACK) ARE MADE OF
316L SS, EXCEPT FOR THE CAUSTIC TANK, PUMP, AND PIPING WHICH ARE CARBON STEEL.
OPERATING HISTORY
1ST QUARTER 1979 THE RELIABILITY VALUE OF THE FGD SYSTEM MAS ABOUT 99X. THERE WERE TMO SHORT
SHUTDOWNS (4 HOURS EACH) DUE TO FAILURE OF THE RECIRCULATION PUMP SEAL* WHICH HAS REPLACED.
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STATUS TU APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FSO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COSI
FIRESTONE TIRE AND RUBBER CO.
POTTSTOMN, PENNSYLVANIA
COAL (2.5 - 3.OS SULFUR)
8070 SCFM (13,000 ACFM * 300 F)
1
1
4 MM (EQUIVALENT)
(FOR THIS REPORT. UNLESS STATED OTHERWISE, 2000 SCFM s 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
RETROFIT
JANUARY, 1975
OPERATIONAL
90.51 (1000 PPM a INLET)
97.4X (5 LB/MM 8TU it INLET TO MECHANICAL) COLLECTOR.)
DEWATERED SLURRY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FIRESTONE TIRE AND RUBBER CO. LOCATED IN POTTSTONN, PENNSYLVANIA HAS BEEN OPERATING AN FGO
SYSTEM SINCE JANUARY 1975 AS A DEMONSTRATION-SIZE PLANT, DESIGNED TO TEST THE FEASIBILITY OF FGD
ON INDUSTRIAL BOILERS, THE UNIT IS DEMONSTRATING 90 PERCENT S02 REMOVAL EFFICIENCY AND TREATS
A FLUE CAS CAPACITY OF 13,000 ACFM OR 3 MW (EQUIVALENT). THIS FLOW REPRESENTS APPROXIMATELY
1/3 OF THE TOTAL OUTPUT OF ONE 120,000 LB/HR STEAM BOILER. THE SULFUR DIOXIDE EMISSION REGULATION
FOR THE PLANT IS 0.86 L8S/MILLION BTU OF HEAT INPUT.
THE PLANT IS USING THE CONCENTRATED DOUBLE ALKALI PROCESS PATENTED BY FMC CORPORATION. THE LOAD
CAPACITY OF THE BOILER ON NHICH THE SCRUBBER IS OPERATING IS APPROXIMATELY 15 MM. IN OCTOBER 1976,
THE BOILER WAS CONVERTED FROM BURNING RESIDUAL FUEL OIL (2.2X S) TO COAL (2,5-3.OX S).
THE VENTURI SCRUBBER IS SPRAYED WITH ALKALINE LIQUOR WHERE THE FLUE GAS ENTERS. THE FAN AND
DAMPER UPSTREAM OF THE VENTURI CONTROL THE FLUE GAS FEED. SCRUBBING LIQUOR FLOWS FROM THE VENTURI
TO THE BOTTOM OF THE CYCLONE OEMISTER AND THEN INTO THE RECIRCULATION TANK. DROPLETS OF SCRUBBING
LIQUOR ARE SPUN OUT IN THE CYCLONE AND RUN BACK OONN INTO THE RECIRCULATION TANK. THE SCRUBBING
LIQUOR 13 PARTLY RECIRCULATEO TO THE VENTURI THUS COMPLETING THE SCRUBBING CYCLE. ACCUMULATION OF
SOLUBLE SODIUM BISULFITE IS PREVENTED BY CONTINUOUSLY DRAWING OFF A SMALL STREAM OF SCRUBBER SOLU-
TION TO THE LIME REACTOR TANK WHERE THE SODIUM SULFITE REACTS WITH LIME TO FORM CALCIUM SULFITE AND
SODIUM HYDROXIDE WHICH IS RECYCLED TO THE ABSORBER. CALCIUM SULFITE SLURRY IS TRANSFERRED TO THE
ROTARY FILTER. THE FILTER CAKE FORMED (180 LBS/HH, SSX SOLIDS) IS HAULED TO THE LANDFILL. THE
59
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOH OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
FIRESTONE TIRE AND RUBBER CO. I POTTSTUKN, PENNSYLVANIA (CONTINUED)
HATER BALANCE 13 MAINTAINED BY MAKING UP FOR THE LOSSES BY EVAPORATION AND IN THE FILTER CAKE.
THE VENTURI SCRUBBER HAS A VARIABLE THROAT (6 IN. TO 15 IN.) AND IS HADE OF 316L SS. THE OPER-
ATING VELOCITY THROUGH THE VENTURI THROAT IS 200 FT/SEC i 130 F, THE OPERATING L/6 IS 10 GAL/
1000 ACF. THE SPRAY NOZZLES ARE ALSO MADE OF 316L SS. THE CYCLONIC DEMI8TER 14.67 FT DIA X 7.17
FT HIGH) OPERATES WITH A PRESSURE DROP OF 2* HG. GAS VELOCITY THROUGH THE DEMISTER IS 100 FT/SEC
8 130 F. THE DEMISTER, RECIRCULATION TANK, AGITATOR, RECIRCULATION PIPING, AND THE FILTER ARE MADE
OF 316L S3. THE INLET OUCTNORK, F.D. FAN, THICKENER, ANO LIME REACTOR TANK ARE OF CARBON STEEL.
THE RECIRCULATION PUMP IS CAST IRON KITH KUBBER LINING AND THE STACK IS FRP.
REFER TO FIGURE 14-10 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
1ST QUARTER-1975 THE SYSTEM WENT ONSTREAM BURNING 2.2X SULFUR OIL. THE FGD SYSTEM OPERATED 687
HOURS AND MAS CALLED UPON TO OPERATE 619 HOURS, YIELDING A RELIABILITY OF 64.SX. DOWNTIME HAS DUE
PRIMARILY TO FAILURES OF COMPONENTS SUCH AS PUMP PACKING.
2ND OUARTER-1975 THE SYSTEM OPERATED 1454 HOURS AND MAS CALLED UPON TO OPERATE 1509 HOURS,
YIELDING A RELIABILITY INDEX VALUE OF 96.4X.
3RD OUAHTER-197S SYSTEM OPERATED 1436 HOURS, HAS CALLED UPON TO OPERATE 1503 HOURS, YIELDING
A RELIABILITY INDEX VALUE OF 95.SS.
4TH OUARTER-1975 SYSTEM OPERATED 1320 HOURS, WAS REQUIRED TO OPERATE 1493 HOURS, YIELDING A RELI-
ABILITY INDEX VALUE OF B8.4X. LIME FfcEDEH MALFUNCTIONING ANU THICKENER PLUGGING NEHE PROBLEMS.
1ST QUAftTER-1976 SYSTEM OPERATED 1961 HOUXS, MAS CALLED ON TU OPERATE 2UJ5 HUUKS, YIELDING A
RELIABILITY INDEX VALUE OF 96.4k.
2ND QUAMTER-1976 SYSTEM OPERATED 1280 HOURS, HAS CALLED UPON 10 OPERATE 1335 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 95.9X.
3RD OUAHTER-1976 SYSTEM OPERATED 1157 HOURS, HAS CALLED UPON TO OPERATE 1166 HOURS* THUS DEMON-
STRATING ITS HIGHEST RELIABILITY INDEX VALUE, 99.2*.
4TH OUARTER-1976 IN OCTOBER* THE SYSTEM OPERATED AT A RELIABILITY INDEX OF IOOX, UNTIL THE UNIT
MAS CONVERTED TO COAL FIRING (2.5 - 3.OX SULFUR). THE SYSTEM OPERATED FOR AN ADDITIONAL 511 HOURS,
OF THE 526 REQUIRED, DEMONSTRATING A RELIABILITY INDEX VALUE OF 97.2X. IN NOVEMBER AND DECEMBER,
60
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
FIRESTONE TIRE AND RUBBER CO. I POTTSTONM, PENNSYLVANIA (CONTINUED) .
THE SYSTEM OPERATED FOR 1172 HOURS AGAINST THE REQUIREMENT OF 1211 HOURS. THEREFORE, THE AVERAGE
RELIABILITY INDEX FOR THE TWO MONTHS WAS 96.7*.
1ST OUARTER-1977 SYSTEM OPERATED 1193 HOURS, MAS REQUIRED TO OPERATE FOR 1459 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 81.7X. SYSTEM MAS DESIGNED FOR A MUCH LOWER PARTICULATE LOADING THAN
THAT ACTUALLY ENCOUNTERED ON COAL FIRING. THE HIGH GRAIN LOADING CAUSED ABNORMAL MEAR AND DOWNTIME
OF THE P.O. FAN.
2ND QUARTER-1977 SYSTEM OPERATED 139ft HOURS* HAS REQUIRED TO OPERATE 1690 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 62.7X. THE MAJOR CAUSES OF DOWNTIME HERE F.D. FAN EROSION AND PUMP
COMPONENT FAILURES.
3RD OUARTER-1977 SYSTEM OPERATED 1131 HOURS, WAS REQUIRED TO OPERATE 1197 HOURS, YIELDING A
RELIABILITY FIGURE OF 94.SS, THE TOTAL REQUIRED HOURS WERE LOW IN JULY DUE TO BOILER HOUSE
SHUTDOWN AND SUBSEQUENT START-UP.
«TH OUARTER-1^77 IN OCTOBER* THE SYSTEM OPERATED 432 HOURS OUT OF THE 5U REQUIRED AS THE BOILER
MAS FIRING COAL. THE RELIABILITY VALUE MAS THEREFORE 60.6X. DOWNTIME WAS CAUSED BY PROBLEMS WITH
THE LIME CONVEYOR. WHEN OIL WAS BEING FIRED THE SYSTEM OPERATED 95 OF THE 198 HOURS REQUIRED,
DEMONSTRATING A RELIABILITY VALUE OF 92.6X. IN NOVEMBER AND DECEMBER, THE SYSTEM OPERATED 792 HOURS
OF THE REQUIRED 654, WHILE BURNING COAL, YIELDING A RELIABILITY OF 86.TX. DOWNTIME MS CAUSED BY
FAN PROBLEMS AND LIME FEEDER PROBLEMS,
1ST QUARTER-1978 THE SPRAY NOZZLES, ORIGINALLY 316 STAINLESS STEEL, MERE HEPLACED BY 316L 83.
THE SPRAY BARS HERE METALLIZED WITH 316 88.
2ND QUARTER-1978 THE FAN WAS REPLACED 8V A NEW FAN CONSTRUCTED OF AN ABRASION RESISTANT CARBON
STEEL. THE FAN HOUSING WAS METALLIZED WITH 316 S3. LEAKS IN THE VEMTURI SECTION AND DOWNSTREAM
DUCTWORK WERE REPAIRED. THE FGD SYSTEM EXHIBITED AN AVAILABILITY OF 89.5* FUR THIS REPORT PERIOD.
3RD OUARTER-19T8 NO UNUSUAL PROBLEMS WERE ENCOUNTERED DURING THIS PERIOD. DOWNTIME WAS DUE
TO NORMAL MAINTENANCE. PRELIMINARY EN6INEERIN6 FOR THE FULL SCALE-UP SYSTEM IS COMPLETE. FINAL
DESIGN WILL BE DELAYED UNTIL THE ENERGY BILL CURRENTLY BEFORE CONGRESS IS FINALIZED. PLANT
PERSONNEL ATTRIBUTE THEIR SUCCESSFUL OPERATION OF THE FGD SYSTEM TO A GOOD UNDERSTANDING AND
IN-DEPTH KNOWLEDGE OF PROCESSES AND CONTROLS.
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
FIRESTONE TIRE AND RUBBER CO. f POTTSTOWN, PENNSYLVANIA (CONTINUED)
4TH OUARTER-1978 IN OCTOBER, THE BOILER HAS DOWN FOR MAINTENANCE* HENCE THE SCRUBBER DID NOT OP-
ERATE. DURING NOVEMBER AND DECEMBER, THE SYSTEM OPERATED 311 HOURS OF A REQUIRED 332
HOURS* NHILE BURNING COAL* YIELDING A RELIABILITY OF 93.7X. DOWNTIME OF 20 HOURS MAS
CAUSED BY BREAKAGE OF BELT ON RECIRCULATION PUMP WHICH MAS THEN REPLACED. SCHEDULED MAINTENANCE
REQUIRED AN ADDITIONAL HOUR OF DOWNTIME.
1ST QUARTER-1979 DURING THE REPORT PERIOD THE FGD SYSTEM OPERATED 1516.5 HOURS OF THE REQUIRED
1620.5 HOURS, YIELDING A 93.6* RELIABILITY. IN DECEMBER, 197*, THE SYSTEM OPERATED 442 HOURS OUT OF
THE REQUIRED 451.5 HOURS, IN JANUARY, 490 HOURS OFTHE REQUIRED 536 HOURS, IN FEBRUARY, 446 HOURS OUT
OF 489 HOURS, AND UNTIL THE REPORT PERIOD IN MARCH, 136.5 HOURS OUT OF 144 HOURS, YIELDING
RELIABILITY VALUES OF 97.9*, 91.4*, 91.2X, AND 96.2X, RESPECTIVELY. OF THE TOTAL DOWNTIME OF 104
HOURS, CLEANUP OF SPRAY NOZZLES REQUIRED 26.5 HOURS AND LIME REACTOR TANK CLEANUP REQUIRED 6.5
HOURS.
IN JANUARY, RECENTLY INSTALLED SPIRAL NOZZLES WITH SEVERE PLUGGING PROBLEMS WERE REPLACED 8V
•HIRL CHAMBER NOZZLES. THE WHIRL CHAMBER NOZZLES ARE OPERATING SATISFACTORILY. THESE REPLACEMENTS
CAUSED 12.5 HOURS DOWNTIME. THE DOWNTIME HOURS CAUSED BY REPAIRS ON VACUUM FILTER, MELDING ON
SEPARATOR AND RECIRCULATION LINE WELDING WERE 25, 4.5, AND 11.5 RESPECTIVELY. REPLACEMENT OF SOME
PARTS IN VALVE BODY OF THE VACUUM FILTER AND GAS LEAKAGE FROM FAN HOUSING CAUSED DOWNTIME OF 11.5
AND 4 HOURS RESPECTIVELY.
DURING SHUTDOWN, INCOMPLETE CLOSURE OF DAMPERS ALLOWS A SMALL AMOUNT OF FLY ASH TO ENTER THE
SPRAT NOZZLES. THE CONDENSATION IN THE PIPING AND NOZZLES DURING SHUTDOWN ADDS TO THE PLUGGING
PROBLEM. HENCE, EVERY MAJOR SHUTDOWN OF SCRUBBING SYSTEM IS FOLLOWED BY CLEANUP OF SPRAY NOZZLES.
62
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHAKACtbKISTJ.es
SOUHCE HATING
NUMBER OF SEPARATE FliO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOUHCE CAPACITY
CONTROL SYSTEM VEUUOK
CONTROL PROCESS
NEH / RETROFIT
START-OP OATE
CONTROL SYSTEM STATOS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKE-OP
SLOOSE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
FMC CSOOA ASri PLANT)
GREEN RIVER. WYOMING
COAL (IX SULFUR)
UMbiOOO SCFM (TOTAL - 2 BOILERS)
2
Z
223 MN (EQUIVALENT)J TOTAL - Z BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM * 1 EQUIVALENT MN,
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
NEH
MAY, 197b
OPERATIONAL
95X 1800 PPM AT INLET)
REMOVED BY PRECEDING ESP (99.sx)
OPEN LOOP: L/G s 15-20 GAL/1000 ACF
HOLOING POND FOR EVAPORATION
NA2S03/S04 LIQUOR DISPOSED TO COLLECTION POND - NO PRIOR
AERATION. LANDFILL IN THE FUTURE
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
FMC CHEMICAL CORP. HAS A SODA ASH PLANT IN GREEN RIVER* WYOMING. THE PLANT HAS TWO COAL-FIRED
POWER BOILERS WHICH BURN 1.0 PERCENT SULFUR COAL. THE FLUE GAS FHOM EACH BOILER (330,000 ACFM AT
380 F) IS TREATED HY A HOTS1DE fcSP MTH 2B8 PLATES AND A PARTICULATE REMOVAL EFFICIENCY OF 99.5 X.
THE FLUE GASES ARE SCRUBBED BY THE PLANT ENO-LIUUOR IN TWO 5CKUB8ERS, EACH WITH THREE PAIRS OF
DISC-ANU-DONUT TRAYS. THE SCRUBBERS AND THE DISCS ARE LINED WITH CEILCOTE 103 WHEREAS THE DONUT
PARTS OF THE TRAYS ARE MADE FROM INCONEL 825. THE SCRUBBER LIQUOR IS MAINTAINED AT A PH OF 6.5 AND
IS RECIRCULATEO AT A RATE OF IS - 20 GALLONS/1000 ACF OF FLUE GAS. A PART OF THE RECIRCULATING
LIQUOR IS CONTINUOUSLY PURGED TO REMOVE SULFITES AND SULFATES FORMED BY THE REACTION OF 302 WITH
SODA ASH. THE RECIRCULATING PUMPS AND THE RELATED PIPING IS RUBBER LINED. A MESH-TYPE DEMISTER IS
USED IN EACH SCRUBBER. THE GASES ARE REHEATED BY DIRECT FIRING OF NATURAL GAS AT THE EXIT OF THE
SCRUBBERS. THE REHEATED FLUE GAS IS MIXED WITH BYPASSED GAS BEFORE GOING TO THE STACK AT ABOUT
180 F. DAMPERS WITH REMOTE CONTROLS KECiULATE THE FLOW OF OFFGAS THROUGH AND AROUND THE SCRUBBERS.
APPROXIMATELY SOX OF THE TOTAL FLUE GAS IS RUN THROUGH THE SCRUBBERS.
AUTOMATIC CONTROLS MAINTAIN SOLUTION LEVEL IN THE SCRUBBER BASIN. THE PRIMARY SOURCE OF WATER
MAKE-UP IS PROCESS WASTtWATER WHICH IS CHANNELED TO A MAKE-UP TANK. IF MORE MAKE-UP IS REQUIRED,
63
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOK OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
FMC (SODA ASH PLANT); GREEN RIVER* WYOMING (CONTINUED)
RIVER MATER IS TAPPED. THE SCRUBBER BLEED STREAM IS DISCHARGED TO A WASTE POND AT A RATE OF ZOO-250
6PM AT THE SITE.
REFER TO FIGURE 14-11 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1977 SOME PROBLEMS OCCURRED WITH THE SCRUBBER LINING AS A RESULT OF FAULTY
INSTALLATION. THE POSSIBILITY OF RUNNING THE SYSTEM WITH NO REHEAT NAS BEING INVESTIGATED.
4TH 8UARTER-1977 THE SCRUBBERS CORRODED AS A RESULT OF FAULTY INSTALLATION OF THE LINING.
TNE IMPURITIES IN THE SCRUBBING LIOUOR CAUSE FOAMING AND SEDIMENTATION ON THE TRAYS.
1ST OUARTER-1978 PIPELINE FREEZUPS, AND LEAKS FROM THE VANE DAMPERS MERE THE MAIN PROBLEM AREAS.
2ND OUARTER-1978 THE DEMISTER WAS PLUGGED, AND THE RECIRCULATION PUMP MAS DOHN FOR SOME PERIOD.
PH CONTROL IS NOT VERY EFFECTIVE, CAUSING PH EXCURSIONS TO ABOUT 3.0. THIS HAS CAUSED SCALING IN
THE PIPELINES AND IN THE TOWER. FMC TESTS HAVE MEASURED 302 REMOVAL EFFICIENCY IN THE RANGE OF 87X-
94*' DEPENDING ON L/G AND PH.
SRD OUARTER-1978 TWO ANNUAL SCHEDULED OUTAGES OCCURRED DURING THIS PERIOD. ONE LASTED 2 WEEKS
IN AUGUST WHILE THE OTHER LASTED 1 WEEK IN SEPTEMBER. MAINTENANCE ON THE FGD SYSTEM DURING THESE
OUTAGES INCLUDED CLEANING OF THE SYSTEM AND FREEING OF THE DAMPER. THE DAMPERS HAD A PROBLEM
OPERATING PROPERLY DURING COLD WEATHER. IT WAS DETERMINED THAT THE PUMP OUTAGE DURING THE 2ND
QUARTER WAS CAUSED BY A BROKEN SHAFT. THE SHAFT NAS REPLACED.
4TH UUARTER-1978 DURING THE REPORT PERIOD, NO MAJOR OPERATING PROBLEMS OCCURRED. ORIGINAL LINING
WAS REINSTALLED ON THE RECIRCULATION PUMP WHILE USING A SPARE PUMP. THE BEARINGS OF THE SHAFT ON
THE LOUVER DAMPER WERE ADJUSTED FOR FREE OPERATION OF THE DAMPERS. NO SCALING PROBLEMS HAVE BEEN
REPORTED. THE RELIABILITY VALUE OF THE FGD SYSTEM WAS CLOSE TO 100X.
1ST QUARTER-1979 DURING THE REPORT PERIOD, NO MAJOR OPERATING PROBLEMS OCCURRED. THE PLANT
REPORTED THE FOLLOWING OPERATING HOURS FOR THE PERIOD!
BOILER BOILER
MONTH FGD CAPACITY FACTOR FGD CAPACITY FACTOR
UNIT 1 (S MAX. LOAD) UNIT 2 (X MAX. LOAD)
DEC. 1978 714.0 82.2 637.0 79.3
JAN. 1979 742.5 62.7 691. 80.3
FEB. 1979 6*7.0 73.1 646.0 88.0
THE RELIABILITY VALUE OF THE FGD SYSTEM HAS CLOSE TO 100X.
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FKU UNITS
NUMBER UF BOILERS BEIN6 CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENT
PARTICIPATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
DAYTON, OHIO
COAL10.7X - 3. OX SULFUR)
36,000 SCFM (TOTAL • 2 BOILERS)
34,000 ACFM ol bOOF, FOR EACH UF TWO BOILERS.
120,000 LB/HR STEAM (TOTAL)
16 M* (EQUIVALENT); TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW RA1E IS THE PRIMARY FACTOR IN MODULE SIZING.)
ENTULETER, INC.
SODIUM HYDROXIDE SCRUBBING
RETROFIT
SEPTEMBER, 197«
OPERATIONAL
8bX (1.43 LB/MM BTU o) INLET)
97. bX (0.107 LB/MM bTU d OUTLET)
50 GPM
WASTENATEH TREATMENT AND DISCHARGE TO CITY :SEWER
NA2S03/S04 LIQUOR AT 35 GPM TO ON-SITE CLARIFICATION AND
DEWATERING FACILITY
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMAIION
BACKGROUND INFORMATION
IN DAYTON, OHIO, GENERAL MOTORS OPERATES A FACTORY WHICH MANUFACTURES BRAKES AND OTHER PARTS
FOR THEIR AUTOMOBILES. THE PLANT HAS TWO STOKER-FEED, COAL-FIRED BOILERS WHICH MERE INSTALLED IN
1954 BY BABCOCK AND WlLCOX. EACH BOILER IS RATED AT 60,000 LB/HH STEAM, AND BURNS A MAXIMUM OF 3
TONS OF COAL PER HOUR. THE BOILERS ARE EQUIPPED NITH INTERNAL MULUCLONES FOR PRIMARY PARTICULATE
CONTROL. THE STEAM GENERATED BY THESE BOILERS IS USED FOR BUILDING HEAT AND PROCESS NEEDS. ONE
BOILER IS OPERATED CONTINUOUSLY THROUGHOUT THE YEAR AND THE OTHER IS OPERATED APPROXIMATELY 6 MONTHS
PER YEAR. THE MAJORITY OF THE TIME (8 - 10 MONTHS/YR) ONLY ONE BOILER IS IN SERVICE.
THE EMISSION CONTROL SYSTEM WAS DESIGNED TO CONTROL BOTH FLYA3H AND 302, AND HAS SUPPLIED AS A
RETROFIT APPLICATION BY ENTOLETER, INC. IN SEPTEMBER 1974. EACH BOILER IS FOLLOWED BY A BOILER I.D.
FAN, A PLENUM, AND A SCRUBBER F.O. FAN. THE PLENUM CAN FUNCTION IN ONE OF THREE MAYS: IT CAN FEED
FLUE CASES TO THE SCRUBBER MODULE; IT CAN BYPASS THE GASES TO THE ATMOSPHERE IN CASE OF A SCRUBBER
MALFUNCTION? OR IT CAN MIX AMBIENT AIR MITH THE FLUE GASES IN CASE OF LOW LOAD IN ORDER TO MAINTAIN
CONSTANT AIR FLOW TO THE SCRUBBER FAN.
65
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
6ENERAL MOTORS CORPORATION! DAYTON, OHIO (CONTINUED)
THE SCRUBBER CONSISTS OF THE ENTOLETEK "VANE-CAGE" (5 FT. DlA. X 5 FT. HIGH) WHICH IS HOUSED IN
A CONICAL BOTTOM SECTION (6 FT. DIA. X 5 FT. HIGH), AN INTERMEDIATE SECTION (6 FT. DIA. X
5 FT. HISH), AND A DISENGAGEMENT ZONE (10 FT. DIA. X 12 FT. HIGH). THE FLUE GAS (34,000 ACFM
9 SOOF) ENTERS THE BOTTOM SECTION TANGENTIALLY. RECIRCULATING LIQUOR IS SPRAYED FROM THE TOP OF
THE VANE CAGE SECTION, WHICH CAN BE MOVED VERTICALLY TO VARY THE PRESSURE DROP ACROSS THE SCRUBBER.
A PRIMARY DEMISTER IS LOCATED ABOVE THE PREVIOUSLY MENTIONED INTERMEDIATE SECTION AND A SECONDARY
DEMISTER IS LOCATED ATOP THE DISENGAGEMENT ZONE. THE GAS THEN PASSES THROUGH A STUB STACK TO THE
ATMOSPHERE. SCRUBBING LIQUOR IMPINGES ON THE BOTTOM OF THE VANE CAGE AND A SPRAY CHAMBER EFFECT
PROVIDES THE 802 REMOVAL. SCRUBBER UNDERFLOW, CONTAINING PARTICULATE AND A NA2803/S04 SOLUTION IS
SENT TO THE RECYCLE TANK, WHERE MAKEUP wAIER AT A RATE OF SO 6PM IS ADDED. RECYCLE PUMPS TAKE
LIQUOR FROM THE RECYCLE TANK TOP, ALONG NITH THE CAUSTIC STREAM ADDED AT A RATE OF 14 GALLONS
PER HOUR TO THE FEED LINE, AND RECIRCULATE IT TO THE TOP OF THE VANE CAGE AT A RATE OF ZOO GPM.
THE L/6 RATIO IS 6 GAL/1000 ACF, AND A TYPICAL PRESSURE DROP ACROSS THE SCRUBBER IS 7 IN. N6. A
BLEED OFF FROM THE RECIRCULATION LINE (SO GPM) IS PURGED TO A WASTENATER TREATMENT FACILITY, WHICH
CLARIFIES ALL THE PLANT NASTE STREAMS, ADJUSTS THE PH (7-9), AND DISCHARGES TO CITY SEDERS.
ABSORBER MODULES, DEMISTERS, STACKS, AND THE RECYCLE TANK ARE CONSTRUCTED OF 316L STAINLESS
STEEL. THE SCRUBBER F.O. FANS, PLENUMS, CAUSTIC TANK, CAUSTIC PUMP, AND INLET DUCTWORK ARE ALL
CARBON STEEL. THE RECIRCULATION PUMPS AND PIPING ARE RUBBER-LINED.
THE TOTAL INSTALLED COST OF THE SYSTEM MAS 8668,000 IN 1974 DOLLARS. THE AVERAGE OUTLET 802
CONCENTRATION IS 0.21 LB/MM B1U, NELL UNDER THE REGULATION OF 1.0 LB/MM BTU. THE OUTLET PARTICULATE
LOADING IS 0.107 LB/MM BTU AND THE REGULATION IS 0.177 LB/MM BTU.
REFER TO FIGURE 14-12 IN SECTION 14 FOR A'DETAILEO PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH OUARTER-1974 UPON START-UP, SEVERAL PROBLEMS MERE ENCOUNTERED. PARTICULATE BUILDUP CAUSED
PLUGGING OF THE RECYCLE TANK CHAIN AND NASTE STREAM SUMP PUMPS. AIR PURGE STREAMS WERE INSTALLED TO
ALLEVIATE THESE PROBLEMS.
1ST OUARTER-197S THE DAMPERS AND DAMPER CONTROL SYSTEMS HERE MAJOR PROBLEMS. THREE SETS OF
EXPANSION JOINTS HAD TO BE INSTALLED BEFORE ACHIEVING PROPER FLOW CONTROL.
2ND OUARTER-1975 A FAN BEAMING HAD TO BE REPLACED THREE TIMES.
3RD OUARTER-1975 INSTRUMENTATION AND CONTROL PROBLEMS PROMPTED MIRING REVISIONS.
4TM 8UARTER-1976 THE FGD SYSTEM DEMONSTRATED AN AVAILABILITY OF 93 PERCENT.
66
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; DAYTON. OHIO (CONTINUED)
1ST UUARTtR-1977 THERE MERE MECHANICAL PROBLEMS WITH THE VANE CA6E DRIVE. THE ACCESS DOOR
DEVELOPED LEAKS AND THE LIQUOR CORRODED THE OUTER SURFACE OF THE INLET DUCT AROUND THE ACCESS DOOR.
4TH QUARTER-1977 CORROSION AND PLUGGING PROBLEMS CONTINUED TO HAMPER SCRUBBER OPERATIONS.
HOWEVER, USUALLY MHEN A SCRUBBER IS DOWN, THE OTHER BOILER IS FIRED UP NHILE REPAIRS ARE MADE TO THE
DONNED UNIT.
1ST QUAHTER-1978 THE PRIMARY DEMISTER MAS SEVERELY CORRODED DUE TO ACID DROPPING DOWN ONTO IT
FROM THE UPPER DEMISTER.
2ND UUAKTER-1978 THE FOLLOWING SYSTEM MODIFICATIONS WERE BEING PLANNED! THE INTERMEDIATE SECTION
WILL BE REMOVED, THE PRIMARY OEMlSTEH WILL BE REPLACED BY A SIMILAR VANE-TYPE HASTELLOY-6 OEMI3TER,
THE SECONDARY DEMISTER WILL BE REPLACED BY A RADIAL VANE HASTELLOY-G DEMISTER. AND A CONVEX
IMPINGEMENT BAFFLE PLATE OF HASTELLOY-G HILL BE INSTALLED ABOVE THE PRIMARY DEMISTER TO ASSIST IN
RAPID DRAINAGE OF THE ACID DROPLETS.
3RD OUARTER-1976 THE MODIFICATIONS DESCRIBED IN THE 2ND QUARTER 1978 ARE STILL IN THE DESIGN PRO-
CESS. WORK INCORPORATING THE MODIFICATIONS SHOULD BEGIN ABOUT THE END OP OCTOBER*
THE SCRUBBER LINING OF COAL TAR EPOXY MAS ABRADED OFF AND A CARBOLENE LINER MAS INSTALLED.
THIS LINING HAS BEEN FLAKING OFF IN PLACES.
THE PH PHUHE9 AND PH MONITORING SYSTEM AKE BEING REDESIGNED SINCE THE SYSTEM CURRENTLY IN USE
SEEMS TO bt CUNTINUALLY OUT UF CALIBRATION. AN ULTRASONIC CLEANER WAS INSTALLED BUT IS NOT WORKING
WELL. THE PH MONITORING SYSTEM IS A DUAL PRUBE SYSTEM WHICH ALLOWS A PROBE TO BE IN USE WHILE THE
OTHER IS CLEANED.
«TH gUAHTER-1976 DURING THE REPORT PERIOD THE SCRUBBERS MERE RECONSTRUCTED. NEW HASTELLOY-6 MIST
ELIMINATORS WERE INSTALLED* AS DESCRIBED IN 2ND OUARTER-197*. ttOKK IS SCHEDULED TO BEGIN ON
INSTRUMENTATION MODIFICATIONS ABOUT MID-JANUARY. THESE INCLUDE REMOVAL OF THE FLUE GAS FLOW SENSORS
AND INSTALLATION UF A NEW PH MONITORING SYSTEM. WORK "ILL BE DONE ON ONE MODULE AT A TIME, AND
ONLY 4S HOUKS UF MUTUAL DOWNTIME ANE EXPECTED FOR HOOK-UP. THE PHENOL SCRUBBER LINING SUPPLIED BY
CARBOLINE HAS FLAKED OFF. NO PLANS CURRENTLY EXIST TO RELINK THE SCRUBBERS.
1ST QUARTER-1979 THE INSTALLATION OF 1HE NEW HASTtLLOY-6 MIST ELIMINATORS HAS BEEN COMPLETED.
AN AVAILABILITY INDEX OF BOX WAS REPORTED FOR THE PERIOD.
67
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL fSD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE HATING
NUMBER OF SfcPARATE FGD UNITS
NUMBER OF BOILERS BtlNG CONTKULLEU
SOURCE CAPACITY
CONTROL SYSTEM VfcNUUR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SO* REMOVAL Et-'FICItNCY
PAHTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUUSfc OR BY-PRUOUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
PARMA, OHIO
CUAL 12.5» SULFUR)
128,400 SCFM (TOTAL - 4 BOILERS)
320,000 Ltt/HH STEAM (TOTAL)
1
a
64 Mft (EQUIVALENT); TOTAL - 4 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLON RATE IS THE PRIMARY FACTOR IN MODULE SUING.)
GM ENVIRONMENTAL
DOUBLE ALKALI (DILUTE)
RETROFIT
MAHCH, 1974
OPERATIONAL
90X (800-1300 PPM * INLET)
six (AT INLET: UNITS i&2 - 1.75 LB/MIN; UNITS 3*4 - 1.22
L8/MIN)
CLOSED LOOP
OEWATERED SLURRY TO LANDFILL
SOfX SOLIDS (CAS03/SU4) SLUDGE TO DRYING POND AND LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE CHEVROLET PARMA PLANT OF GENERAL MOTORS IS LOCATED NEAR CLEVELAND, OHIO. THE PLANT HAS FOUR
SPREADER-STOKER BOILERS FIRED BY TRAVELING GRATES, CAPABLE OF PRODUCING A TOTAL OF 320,000 LB/HR OF
STEAM AND GENERATING 120,400 SCFM UP FLUE GAS, WHICH IS EQUIVALENT TO ABOUT 64 MM OF ELECTRICAL CAP-
ACITY. THE COAL FIRED IN THESE UNITS ORIGINATES PRIMARILY FROM THE SOUTHEASTERN PORTION OF OHIO AND
HAS THE FOLLOWING AVERAGE CHARACHTERISTICSt HEAT CONTENT OF 11,300 BTU/LB, SULFER CONTENT OF 1.7 TO
2.7 PERCENT, ASH CONTENT OF 6.0 TO 14.8 PERCENT, AND A TOTAL MOISTURE CONTENT OF 7.8 PERCENT.
THE POWER BOILERS HAVE AN EMISSION CONTROL SYSTEM CONSISTING OF CYCLONE-TYPE MECHANICAL
COLLECTORS UPSTREAM OF A DILUTE DOUBLE ALKALI SCRUBBING SYSTEM. THE FGD SYSTEM SCRUBBING MODULES
HERE SUPPLIED BY KOCH ENGINEERING. INSTALLATION HAS COMPLETED ON FEBRUARY 26, 1974. THE SYSTEM
CONSISTS OF FOUR SCRUBBERS OPERATING IN PARALLEL. EACH SCRUBBER CONTAINS THREE BUBBLE-CAP
ABSORPTION TRAYS AND A MESH MIST ELIMINATOR. THE FLUE GAS RATE IS 61,500 ACFM AT 393 F FOR EACH OF
THE FIRST TWO SCRUBBERS AND THE OUTLET TEMPERATURE IS 137 F. THE INLET 302 CONCENTRATION IS 765
PPM. THE FLUE GAS FLOW RATE IS 58,600 ACFM AT 550 F FOR THE OTHER TWO SCRUBBERS AND THE OUTLET
TEMPERATURE IS 152 F. THE INLET S02 CONCENTRATION IS 800-1300 PPM. OUTLET CONCENTRATION VARIES
68
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PARMA, OHIO (CONTINUED)
FROM 136-220 PPM FOR THE SCRUBBERS.
THE SULFUR DIOXIDE CONTAINED IN THE BOILER FLUE GAS IS ABSORBED BY A REGENERATED CAUSTIC
SOLUTION (0.1 MOLAR NAOH), FORMING A SOLUTION OF SOLUBLE SODIUM SALTS. THE SPENT CAUSTIC IS THEN
REGENERATED BY REACTING THE SODIUM SALT SOLUTION WITH SLAKED LIME, RESULTING IN THE FORMATION OF
CALCIUM SULFITE/SULFATE SOLIDS, WHICH ARE SEPARATED OUT OF THE SOLUTION. NEXT, SODA ASH IS
ADDED TO THE SOLUTION IN ORDER TO MAKE UP FOR SODIUM LOSSES AND MINIMIZE THE SCALE POTENTIAL FROM
THE CALCIUM WHICH REMAINS IN SOLUTION. THE REGENERATED CAUSTIC FORMED IS THEN RECYCLED BACK TO THE
SCRUBBER FOR ADDITIONAL SULFUR DIOXIDE REMOVAL. THE CALCIUM SALT AND FLY ASH SLUDGE WHICH RESULTS
IS DEHATEREO AND HAULED ANAY BY THUCK TO AN OFF-SITE LANDFILL.
EQUIPMENT SPECIFICATIONS
SCRUBBERS. EACH OF THE 4 SCRUBBERS IS 10.5 FT OIA X 22.5 FT HIGH X It GAUGE THICK AND CONTAINS 3
BUBBLE-CAP TRAYS. ALL THE SCRUBBERS AND TRAYS ARE MADE OF 316L SS. THE SCRUBBERS HAVE A TURNDOWN
RATIO OF 3 AND ALSO HAVE A BYPASS DUCT. THE DESIGN L/G RATIO IS 20 GALLONS/ACF BUT THIS
MAY BE VARIED DURING OPERATION. THE PRESSURE DROP ACROSS THE SCRUBBER RANGES BETWEEN 6-9 IN. HG.
DEMI8TERS. ORIGINAL 316 SS MIST ELIMINATORS HERE CORRODED DUE TO CONDENSATION AND WERE REPLACED BY
FLEXIMESH-TYPE POLYPROPYLENE MIST ELIMINATORS.
RECYCLE TANKS/PUMPS. ALL THE 4 RECYCLE TANKS ARE MILD STEEL WITH TAR TYPE RESIN COATING. THE PUMPS
(6 TOTAL, 2 SPARE) ARE CENTRIFUGALS WITH MILD STEEL CASING AND HAVE RUBBER LININGS. THE PUMP MOTORS
ARE 40 HP.
CHEMICAL MIX TANKS & AGITATORS. BOTH THE MIX TANKS ARE MILD STEEL WITH 5000 GALLONS CAPACITY. THE
DESIGN RESIDENCE TIME IS 7 MINUTES. NEW AGITATORS ARE PROPELLER TYPE. THESE ARE SPECIALLY DESIGNED
TO GIVE HIGHER FLOW RATE THROUGH THE BLADES. THE DRIVE RATINGS ARE 5 HP AND 45 RPM.
CLARIFIERS. BOTH THE CLARIFIEftS (60 FT OIA X 14 FT LIQUID DEPTH) HAVE A CONICAL BOTTOM AND 300,QUO
GALLONS CAPACITY. THE DESIGN RETENTION TIME IS ABUUT 4 HOURS AT A FLOW RATE OF 1200 GPM.
VACUUM FILTERS. BOTH THE VACUUM FILTERS HAVE 500 SQ. FT. OF SURFACE AREA WITH A 10 FT URUM DIA-
METER. THE DRUM DRIVE SPEED IS 0.5 RPM MAXIMUM.
FILTRATE TANK/PUMPS. THE TANK (4 FT OIA X 7 FT HIGH) IS MILD STEEL AND HOLDS 660 GALLONS OF
FILTRATE. THE PUMPS ARE MILD STEEL CENTRIFUGAL AND HAVE A CAPACITY OF 300 GPM AT IS FT. OF HEAD.
EARLY PROBLEMS AND SOLUTIONS
THE SYSTEM MAS STARTED UP ON FEBRUARY 28, 1974 AND BY APRIL 31, IT HAD OPERATED FOR 264 HOURS.
THERE WERE TWO SCHEDULED SHUTDOWNS DURING THIS PERIOD FOR EQUIPMENT INSPECTION. THE SECOND SHUTDOWN
69
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FSD SYSTEMS ON INDUSTRIAL BOILERS
6ENERAL MOTORS CORPORATION! PARMA. OHIO (CONTINUED)
REVEALED THAT SOLIDS MERE NOT BEING DISCHARGED FROM THE PRIMARY CLARIFIER RAPIDLY ENOUGH.
AS A RESULT, THE CLARIFIER RAKE JAMMED. A PIPING CHANGE HAS MADE TO BLEND THE CAUSTIC FEED
IN KITH THE RECYCLE LIQUOR. THIS IMPROVED PERFORMANCE BUT DID NOT COMPLETELY ELIMINATE
THE PROBLEM. PREMATURE CAKE CRACKING IN THE VACUUM FILTERS REQUIRED THE PRESENCE OF AN OPERATOR
DURING OPERATION. CAKE MASHING TO REDUCE LOSSES NAS NOT INITIALLY SUCCESSFUL BECAUSE THE SPRAY
NATER TENDED TU KNOCK THE CAKE OFF THE DRUM. ALTERATIONS IN SPRAY PATTERN AND OTHER MEASURES
APPARENTLY SOLVED THIS PROBLEM. THERE NAS NO EVIDENCE OF COKROSION OR ABRASION IN THE PUMPS
OR PIPING.
THE SYSTEM NAS SHUT OOHN FROM MAY 1 TO MAY 26, 197«, BECAUSE OF UNEXPECTED BUILDUP OF SOLIDS IN
THE CLARIFIER, NITH SUBSEQUENT OVERFLON INTO THE SCRUBBER. THE PROBLEM NAS SOLVED BY 1| USING
* POLYMERIC FLOCCULATION AGENT TO ATTAIN BETTER SETTLING AND 2f WITHDRAWING SLUDGE FROM THE
CLARIFIER AT MORE FREQUENT INTERVALS. SYSTEM AVAILABILITY TO THE BOILER NAS 67 PERCENT IN APRIL
1974, LESS THAN 10 PERCENT IN MAY, AND 100 PERCENT IN JUNE, JULY, AND AUGUST AFTER THE SYSTEM NAS
RESTARTED. PLUGGING BY GYPSUM DEPOSITS IN THE OVERFLON LINE BETWEEN THE CLARIFIER8 AND IN THE
LINE FROM CLARIFIER NO. Z TO THE MIX TANKS NAS CORRECTED BY RELOCATING A CHEMICAL FEED LINE AND
REPLACING SOME PIPING. THE SYSTEM NAS OONN THROUGH JULY AND AUG. 1975 FOR REPLACEMENT OF GRAVITY
PLOW LINES NITH AN OPEN FLUME THAT CAN BE EASILY CLEANED. THE OPERABILITY INDEX FOR THE FSD SYSTEM
INCREASED SIGNIFICANTLY THROUGHOUT THE COURSE OF 197*.
REPER TO FIGURE 14-13 IN SECTION 14 FOR A DETAILED PROCESS FLON DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
OPERATION HOURS
MONTH BOILER FGO SYSTEM OPERABILITY (»)
MAY-JUN. 75
THE SYSTEM NAS RESTARTED AND PARTICULATE TESTS NEHE CONDUCTEU IN MAY. THE SYSTEM NAS SHUT DONN DUE
TO PLUGGED CHEMICAL FEED LINE TO THE CLARIFIED AFTER RESTART. AROUND JUNE to, THE SYSTEM MAS
SHUTDOWN BECAUSE OF SIMILAR PLUGGING IN ANOTHER PART OT THE LINE. THE UNIT RAN FOR ABOUT TWO WEEKS
IN JUNE.
JUL.-AUG. 75
THE PSD SYSTEM NAS DOWN IN JULY AND AUGUST FOR REPLACEMENT OF GRAVITY FLOW LINE WITH AN OPEN FLUME.
OCT. 75 2131 184S 79
THE PSD SYSTEM RESTARTED ON SEPTEMBER 6, AND OPERATED DURING THIS PERIOD AT AM AVAILABILITY FACTOR
OP SO PERCENT. THE FIGURES GIVEN FOR OCTOBER REPRESENT THE OPERATION HOURS FROM SEPTEMBER S TO
NOVEMBER 9.
DEC. 79 8135 1250 59
HOLIDAY SHUTDOWN FROM 18/23 TO 1/4. DUE TO PROBLEMS NITH SOLIDS AND SOLIDS CARRY-OVER, G.M. CON*
70
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
6ENERAL MOTORS CORPORATION! PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER F6D SYSTEM OPEHABILITY (X)
DUCTED STREAM TESTS DURING DECEMBER TO DETERMINE WHETHER THE CARRY-OVER OF SOLIDS NAS DUE TO A HIGH
SOLIDS KECIRCULATION RATE. THE FGD SYSTEM NAS DOWN MOST OF DECEMBER BECAUSE OP THESE TESTS, NHICH
CAUSED THE LOM OPERABILITY FACTOR.
FEB. 76 2997 1196 40
G.M. HAS FOUND SOLIDS CONCENTRATION IN THE CLARIFIER TOO HIGH FOR EFFICIENT SYSTEM OPERATION. A.D.
LITTLE NAS SCHEDULED TO CONDUCT TESTS ON THE SYSTEM IN APRIL AS PART OF AN EPA EVALUATION PROGRAM.
MAR. 76 1379 240 7
APR. 76 1064 647 76
THE LOM OPERABILITY INDEX DURING THE MONTH OF MARCH RESULTED FROM EXTENSIVE MODIFICATIONS PERFORMED
ON THE SYSTEM BY G.M. DURING THIS PERIOD THE SCRUBBER BLONOOMN AND SCRUBBER FLOW INDICATION SYSTEM
MAS REVISED. FROM APRIL 19 TO THE END UF THE MUNTH THE SYSTEM MAS OPERABLE 100X. DURING THIS
PERIOD ALL SYSTEM MODIFICATIONS HERE COMPLETED AND ALL MAJOR PROBLEM AREAS CORRECTED.
MAY 76 1149 1042 91
JUN. 76 924 616 66
ONE SYSTEM UPSET OCCURRED DURING THE PERIOD DUE TO AN OPERATOR ERROR. BOILER HOURS MERE LOM IN JUNE
BECAUSE OF LOM PROCESS DEMAND. THE SCRUBBING SYSTEM CHARACTERIZATION STUDY MAS CONCLUDED ON MAY 14.
JUL. 76 599 599 100
AUG. 76 715 715 100
THE BOILER LOAD DEMAND NAS VERY LIGHT DURING THE REPORT MONTHS, REQUIRING ONLY ONE BOILER BEING
CONTINUOUSLY ON LINE. THE SYSTEM MAS DOMN FOR A ONE-MEEK PERIOD BECAUSE OF THE ANNUAL PLANT
INVENTORY. MODIFICATIONS tU THE OPERATION OF THE OF THE GAS SCRUBBING SYSTEM HAVE INCLUDED!
ELIMINATION OF POLYMERIC ADDITION.
ELIMINATION UF SLUDGE BLANKET FOR FILTRATION.
HIGH PERCENT SULFATE CONCENTRATION IN THE FILTER CAKE.
INCORPORATION UF PH CONTROLLER IN THE CHEMICAL MIX TANK REGULATING THE LIME FEED INTO SYSTEM.
PH CONTROL SHOULD REDUCE THE STOICHIUMETRIC REQUIREMENTS FROM THE 1.25-1.50 RANGE OOMN TO
i.io-i.eo.
SEP. 76 809 223 40
OCT. 76 1174 734 63
TMO BOILERS AND THEIK CORRESPONDING SCRUBBER MODULES MERE IN SERVICE DURING THE MONTH. OPERATION
TIME MAS LODGED PRIMARILY IN THE INITIAL PART OF THE MONTH. A NUMBER OF PROBLEMS MERE ENCOUNTERED,
FORCING A SHUTDOWN THROUGHOUT THE REMAINDER OF THE MONTH. THESE INCLUDED!
SOLIDS DEPOSITION AND PLUGGING OF THE. CHEMICAL TANKS AND REACTORS* REQUIRING 8HUTDOMN/CLEANOUT.
71
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER FGD SYSTEM OPERABILITY (X)
REPLACEMENT OF DEMISTER PADS.
AGITATOR PROBLEMS.
THE SYSTEM HAS RETURNED TO SERVICE THE SECOND WEEK IN OCTOBER. TMU BOILERS AND THEIR CORRESPONDING
SCRUBBERS MERE PUT BACK IN THE GAS STREAM. PROBLEMS ENCOUNTERED STEMMED PRIMARILY FROM A MECHANICAL
COLLECTOR MALFUNCTIONING RESULTING IN EXCESSIVE PARTICULATE LOADING IN THE MODULES AND EVENTUALLY
CAUSING WIDESPREAD PLUGGING OF THE LOWER BUBBLE-CAP TRAYS. SHUTDOWN AND CLEANOUT OF MODULES PLUS
REPAIRS TO THE MECHANICAL COLLECTOR WERE REQUIRED. SYSTEM RESTART OCCURRED NOVEMBER 6.
MAJOR MODIFICATIONS PERFORMED TO THE DOUBLE ALKALI SYSTEM DURING THE PERIOD INCLUDED THE INSTAL-
LATION OF A GREAT LAKES PH MONITOR AND CONTROL UNIT FOR THE REGULATION OF LIME FEED TO THE REGEN-
ERATION REACTOR-CLARIFIES UNIT. THIS UNIT EMPLOYS A DIGITAL READOUT AND MAS SCHEDULED FOR OPERATION
SOMETIME IN NOVEMBER. SUPERIOR CRYSTAL GROWTH OF THE CALCIUM SULFITE/SULFATE SALTS RESULTED BY
RUNNING A SEEDING LINE BACK TO THE REACTOR-CLARIFIES UNIT.
NOV. 76 1321 787 60
DEC. 76 1559 349 22
DURING THE LATTER PART OF NOVEMBER AND EARLY DECEMBER, THE SCRUBBERS WERE TAKEN OUT OF THE FLUE GAS
PATH BECAUSE OF CONTINUED SOLIDS BUILDUP IN THE MIX TANK. IN ADDITION, SOME PIPING ARRANGEMENTS
MERE MODIFIED AND THE GEAR REDUCER IN THE MIX TANK HAD TO BE REPLACED. THE FGD FIGURES REPORTED FOR
THE MONTH OF DECEMBER ARE NOT FULLY REPRESENTATIVE BECAUSE IT IS PART OF THE LOCAL UAN CONTRACT THAT
ONLY UAN PERSONNEL CAN OPERATE THE FGD SYSTEM AND THEREFORE THE SCRUBBERS COULD NOT BE OPERATED.
JAN. 77 1652 608 33
FEB. 77 1462 892 61
THERE WAS A FAILURE OF THE AGITATORS AT THE MIX TANKS. THEY WERE LATER REPLACED WITH NEW ONES.
THE PLANT NAS SHUTDOWN FOR SOME PERIOD DUE TO CUTBACK OF NATURAL GAS SUPPLY AND REQUEST TO CURTAIL
ELECTRICAL CONSUMPTION.
APR. 77 1300 1158 89
MAY 77 1222 1118 92
BOILER HOURS WERE LOW DUE TO REDUCED SUMMER REQUIREMENTS.
JUN. 77 1180 111/3 94
JUL. 77 702 276 39
THE FGD SYSTEM GAVE A VERY HIGH UPERABILI1Y FOR JUNE. THE FGD SYSTEM WAS DOWN FOR A CONSIDERABLE
PORTION OF JULY. THE CHEMICAL MIX TANK BLEED OFF LINES AND OTHER PIPING HAD TO BE CLEANED OF
SEDIMENTED SOLIU3.
AUG. 77 755 67tt 90
SEP. 77 764 480 71
72
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER FGD SYSTEM OPERABILITY (X)
DURING THIS LOW-LOAD PERIOD THE LIME FEED PUMP AND LIME FEED LINES MERE CLEANED. GENERALLY* EVERY
SUMMER AN ANNUAL FGD OVERHAUL IS CARRIED OUT.
OCT. 77 1277 398 31
NOV. 77 1380 920 67
DEC. 77 1790 968 54
THE CHEMICAL MIX TANK AGITATORS HERE TOTALLY REDESIGNED AND REPLACED BY HIGH-CARSON STEELi PROPELLER
TYPES. THE BLADES WERE SPECIFICALLY DESIGNED TO INCREASE THE FLOW THROUGH THE PROPELLERS, THUS
INCREASING THE INTENSITY OF MIXING. DUE TO THANKSGIVING HOLIDAYS IN NOVEMBER AND CHRISTMAS AND NEW
YEAR HOLIDAYS IN DECEMBER, THE FGO SYSTEM HAD LOWER OPERATION HOURS. SOME OF THE BOILERS HAD TO BE
RUN FOR BUILDING MAINTENANCE.
1ST QUARTER-1978 THE BOILERS OPERATED FOR 3370 HOURS NHEREAS THE FGO OPERATED FOR 70 HOURS.
THE OPERABILITY INDEX MAS THEREFORE 1.25X. THE RAKE SHAFT IN THE THICKENER WAS BROKEN IN EARLY
JANUARY. THERE WAS A CONSIDERABLE DELAY IN RECEIVING REPLACEMENT PARTS. IN ADDITION, SEVERE WINTER
(BLIZZARD, HEAVY SNOw) MADE IT IMPOSSIBLE TO PERFORM ANY REPAIRS.
2ND OUARTER-1978 THE FGD SYSTEM OPERATED FOR 2669 HOURS, AND THE BOILERS OPERATED FOR 3414 HOURS.
THE OVERALL OPERABILITY WAS 78.2 PERCENT. IN APRIL, THE PIPELINES WERE FLUSHED ANO CHEMICAL TANKS
MERE CLEANED ALONG KITH SCRUBBER INTERNALS, STACKS ANO MIST ELIMINATORS. IN JUNE, THE AVAILABILITY
HAS 109 PERCENT. DURING THE SUMMER QUARTER, USUALLY A LOW-LOAD PERIOD, SEVERAL MODIFICATIONS WERE
SCHEDULED* NEW VACUUM PUMPS AND FILTERS WILL BE INSTALLED, AND THE LIME SLURRY FEED PUMPS
MILL BE REPLACED BY DIAPHRAGM PUMPS TO AVOID PLUGGING OF CONTROL VALVES. THE NEW FILTER CLOTH, MADE
OF POLYPROPYLENE, HAS GIVEN MUCH LONGER FILTERING LIFE (ABOUT 3 MONTHS) THAN THE OLD ONE, MADE OF
NYLON. THIS IS DUE TO THE POOR FILTERING CHARACTERISTICS OF THE NYLON (PLUGGING).
3RD QUARTER-1978 FOR THIS PERIOD THERE HAS BEEN NO DOWNTIME DUE TO EQUIPMENT OR PROCESS FAILURE.
WARREN-RUPP DIAPHRAGM PUMPS WERE INSTALLED TO REPLACE THE EXISTING LIME SLURRY FEED PUMPS. THE
PLANT REPORTED 100X OPEMABILITY.
4TH QUARTER-197B DURING OCTOBER AND NOVEMBER THE BOILERS OPERATED 2815 HOURS AND THE FGD SYSTEM
OPERATED 670 HOURS FOR AN UPERABILITY OF 23.8X. NEW FRP STACKS (4.5 FT. DIA. X 38 FT. HIGH) WERE
MOUNTED ON TOP OF THE ABSORBERS, REPLACING THE OLD STAINLESS STEEL-LINED ONES WHICH WERE BADLY
CORRODED. MODIFICATIONS WERE MADE TO THE TOP OF THE SCRUBBERS. THESE INCLUDED ENLARGING THE
OPENING TO THE STACK TO REDUCE THE GAS VELOCITY, ANO REPLACING THE FLEXIME3H MIST ELIMINATOR WITH A
POLYPROPYLENE CHEVRON DEMISTER. DURING THE RECONSTRUCTION, HATERLINES WERE TESTED IN PREPARATION
73
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL PGD SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION! PARMA, OHIO (CONTINUED)
FOR MINTER AND THE NEM VACUUM FILTER PUMPS WERE INSTALLED. PEAK BOILER LOADS FOR THIS WINTER ARE
EXPECTED TO BE ABOUT 175,000 LBS/HOUR NITH 3 BOILERS OPERATING SIMULTANEOUSLY.
1ST OUARTER-1979 DURING THE PERIOD OF DECEMBER, JANUARY, AND FEBRUARY, THE BOILERS OPERATED A
TOTAL OF 624Z HOURS, AND THE SCRUBBERS 2436 HOURS. THE OPERABILITY INDEX HAS THEREFORE 391.
CHEMICAL BALANCE PROBLEMS MERE ENCOUNTERED IN DECEMBER AND CONTINUED THROUGH MOST OF THE PERIOD.
HI6H PH CAUSED PLUGGING IN THE TOP THAT. THE PH PROBES USED FOR CONTROLLING CHEMICAL FEED HERE
RELOCATED. HIGH EXCESS AIR AND CHANGES IN THE L/G RATIO ARE BELIEVED TO BE THE CAUSE. THE LIQUOR
IN THE BOTTOM TRAY IS BEING ACIDIFIED NHILE THE TUP TRAY IS NOT. NORMAL PH CHANGE (TOP TRAY TO
BOTTOM TRAY) IS IN THE 1-2 RANGE. CHANGES IN PH OF 3*4 UNITS ARE BEING NOTED, HITH A LOWER-THAN-
NORMAL PH IN THE BOTTOM TRAY ANO A HIGHER»THAN»NORMAL PH IN THE TOP TRAY.
74
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGD SYSTEMS ON INDUSTRIAL OUILEKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS btING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
PUNT1AC* MICHIGAN
COAL (0.64k SULFuM)
ALSO HOOD. PAPER, AND CARU80ARD.
107,300 SCFM (TOTAL - 2 BOILERS)
350,000 LB/HR STEAM (TOTAL - 2 BOILERS)
2
2
S3 Ml* (EQUIVALENT)» TOTAL - 2 BOILERS
(FUR THIS REPURTi UNLESS 3TATEO OTHERWISE* 20UO SCFM • 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
GM ENVIRONMENTAL
SODIUM MYUHOXIDt SCRUBBING
NEW
APRIL* 1976
SYSTEM OPERATED 1*0 MONTHS IN EARLY (973.
OPERATIONAL
NOT DETERMINED
85X
OPEN LOOP I 90 GPM
OENATERED SLURRY TO LANDFILL
5X SOLIDS SLURRY OEWATERED ANO TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GENERAL MOTORS TRUCKS ANO COACH PLANT LOCATED AT PUNTIAC, MICHIGAN OPERATES SEVERAL BOILERS
TO GENERATE STEAM FOR BUILDING HEAT AND PROCESS REQUIREMENTS. TWO OF THESE BOILERS* N08. 6 ANO 8.
ARC SPREADER STOKERS AND FIRE A MIXTURE OF COAL (O.S4X SULFUR) ANO SOLID REFUSE (PAPER AND CARD-
BOARD) i BOILER I»Q. b» INSTALLED IN 1972 8V ERIE CITY* IS RATED AT 198 MM BTU/HH OR 150*000 LBS/MR
'OF 8TEAN* BOILER NO. S* INSTALLED IN 1972 BY RILEY. IS RATED AT 250 MM BTU/HR ORi200*000 L8S/HR
OP STEAM. THE PARTICULATE EMISSIONS ARE CONTROLLED BY MECHANICAL COLLECTORS SUPPLIED BY ZURN
INDUSTRIES* DESIGNED TO OPERATE AT 93* EFFICIENCY* WITH A PRESSURE DROP OF ABOUT I IN. NG.
PEABOOY ENGINEERING SUPPLIED i NET SCRUBBERS IN APRIL 1976* PRIMARILY FOR ADDITIONAL PARTICULATE
CONTROL. EACH SCRUBBEKU2 FEET OIA X 81.5 FEET HIGH) CONTAINS 3 IMPINGEMENT 1RAY8 AND OPERATES
KITH AN L/C OF S GAL/10UO ACF. THE SCRUBBER EFFLUENT IS MIXED WITH CAUSTIC AND MAKEUP NATER IN A
MOLD TANK* ANO PUMPED TO A CLARIFIER. THE OVERFLOW IS RECYCLED TO THE SCRUBBER* THUS SIGNIFICANT
SOS CONTROL IS ACHIEVED. THE UNDERFLOW IS SENT TO A NASTE TREATMENT PLANT* WHERE THE FLYA8H IS RE-
MOVED AND LANDFILLEO. THE EFFLUENT DISCHARGE FROM THE WASTE TREATMENT PLANT IS 10 - 85 GPM.
7S
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STATUS TO APRIL 1979
SECTION 9 (CONTINUtO)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FBI) SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PONT I AC, MICHIGAN (CONTINUED)
THE SCRUBBERS, TRAYS, AND MIST ELIMINATORS (RADIAL VANE TYPE) ARE ALL MADE OF 316L S3.
REFER TO FI6UKE 14-14 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
2ND OUARTER-1976 UNSTABLE PH CONTROL AND NEAR OF MECHANICAL EQUIPMENT HANDLING THE FLYASH SLUHRY
MERE MAJOR STARTUP PROBLEMS.
5RD OUARTER-1977 AN AVAILABILITY OF 100 PERCENT HAD BEEN REPORTED HHEN BURNING A MIXTURE OF COAL
AND REFUSE. THE SCRUBBER DISCHARGE SLURRY CAUSED WEAR DUE TO ITS FLYASH CONTENT.
4TH OUARTER-1977 FLYASH ABRASION IN THE PUMPS AND PIPING CONTINUED TO BE THE PROBLEM.
1ST OUARTER-1978 FLYASH CAUSED SERIOUS EROSION OF LIQUID HANDLING EQUIPMENT.
2ND OUARTER-1978 IT MAS DECIDED TO INSTALL PRESSURE FILTERS IN THE SCRUBBER EFFLUENT LINES TO
REMOVE FLYASH.
3RD OUARTEN-197* THE PRESSURE FILTERS WERE INSTALLED AND ARE WORKING MELL. NO OTHER
PROBLEMS OCCURRED DURING THE REPORT PERIOD.
«TH OUARTER-1978 NO NEN OPERATING PROBLEMS DEVELOPED DURING 1HIS REPORT PEMUD. THE PRESSURE
FILTERS MERE INSTALLED IN THE RECIRCULATION PIPING BETWEEN THE RECYCLE PUMP AND THE INLET TO THE
ABSORBER. THEIR PERFORMANCE THUS FAR HAS BEEN RATED AS EXCELLENT.
1ST 8UARTER-1979 AN AVAILABILITY OF JOOX WAS REPORTED FOR THE PERIOD. NO OPERATING PROBLEMS
KERE ENCOUNTERED.
7b
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STATUS TO APRIL 1979
SECTION <* (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILEHS
INSTALLATION NAME
INSTALLATION LOCATIUIv
SOURCE CHARACTERISTICS
SOURCE HATING
NUMBER OF SEPARATE Ffai» UMTS
NUMBER OF bOILEKS bEING CUNTWOLLtO
SOURCE CAPACITY
CONTROL SYSTEM
CONTROL PROCESS
NEW / RETKOUT
START-UP OA1E
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PAKTICULATt REMOVAL EFFICIENCY
WATER MAKE-OP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
ST. LOUISf MISSOURI
COAL (J.2X SULFOK)
6<*,OUO SCFM (TOTAL - i BOILERS)
2
2
3* MA (TOTAL - 2 UUILERS)
(FOK THIS KEPOHT, UNLESS STATED OTHERWISE, 20UO SCFM - 1 EQUIVALENT MW.
THIS IS bECAUSE GAS FLOM KAfE IS THE PRIMARY FACTOR IN MODULE SIZING.)
A.U. LITTLE
SODIUM HYOROXIOE SCKUBBING
RETROFIT
OPERATIONAL
90+1 (auuu PPM d INLET)
REMOVED bY PRECEDING CYCLONE AND ESP
OPEN LOOP
WASTEnATER TREATMENT AND DISCHARGE TO CITY SEWER
NA2S01 OXIDIZED TO NA230U, PH NEUTRALIZED AND DISCHARGED TO
CITY SEhEH SYSTEM
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GENERAL MOTORS CORPORATION PLANT LOCATED IN ST. LOUIS, MISSOORI OPERATES 4 COAL-FIRED BOIL-
ERS. TWO OF THESE BOILEHS, ONE PULVERIZED COAL-FIRED AND THE UfHER A SPREADER STOKER, ARE RATED AT
A TOTAL OF 250,000 Lti/HR STEAM AND GENERATE ABOUT 64,000 SCFM OF FLUE GAS. COAL COMPOSITION IS
TYPICALLY 3.2» SULFUR ANO 10* ASH. THE ST. LOUIS S02 EMISSION REGULATION OF 1.4 L8S/MM BTU APPLIES
ONLY FROM OCTOBER THROUGH MARCH, AND THE SCRUUbERS OPERATE ONLY DURING THIS PERIOD. FLUE GAS FROM
ALL FOUR BOILERS EXITS THROUGH A COMMON STACK AND SUFFICIENT FLUE UAS FROM THE TWO CONTROLLABLE
BOILERS IS SCRUBBED TO MAINTAIN THE REGULATION AT THE STACK UOTLET. THE REMAINING FLUE GAS BYPASSES
THE SCRUBBERS, AND A CUMPLEX DAMPER SYSTEM ALLUrtS PLANT PERSONNEL TO VARY THE SCRUBBER/BYPASS RATIO.
BOTH BOILERS ARE EQUIPPED WITH CYCLONES FOR PARTICIPATE REMOVAL, AND THE PULVERIZED COAL UNIT ALSO
UTILIZES AN ESP.
THE SCRUbBER CONSISTS OF A THREE-STAGE IMPINGEMENT TOWER WITH A CHEVRON MIST ELIMINATOR. THE
SYSTEM IS EUU1PPEO WITH DIRECT STtAM COIL REHEAT. THE 1RAY lUttER AND MIST ELIMINATOR ARE CONSTRUC-
TED OF 310L STAINLESS SI EEL.
77
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION! ST. LOUIS, MISSOURI (CONTINUED)
OPERATING HISTORY
3RD QUARTER-1977 AN OPERADILITY OF 100X MAS REPORTED DURING THE MAY-AUGUST PERIOD.
4TH BUAKTER-1977 IN SPITE OF A CHEVRON DEMISTER AND 60 F REHEAT, THE STACK LINER WAS CORRODED.
1ST 8UARTER-1978 THE DUCTWORK DOWNSTREAM OF THE SCRUBBERS DEVELOPED SOME LEAKS.
2ND QUARTER-1976 A HORIZONTAL PORTION OF THE DOWNSTREAM OUCT40RK,ABOUT 15-20 FEET IN LENGTH, MILL
BE REDESIGNED TO AVOID STAGNATION OF EXHAUST GASES
3RD OUARTER-197U THE DOWNSTREAM DUCTWORK WAS RECONSTRUCTED DURING THE REPORT PERIOD.
4TH OUARTER-1978 NO NEW FGO-RELATED PROBLEMS HAVE DEVELOPED DURING THE REPORT PERIOOf HOWEVCRr
THE PLANT HAS REPORTED THAT PLUME OPACITY HAS BECOME A PROBLEM.
1ST OUARTER-1979 PLANT PERSONNEL REPORTED AN AVAILABILITY OF 90X FOR THIS PERIOD. A SHORTAGE OF
CAUSTIC REAGENT MAS RESPONSIBLE FOR SOME DOWNTIME DURING MARCH. ALSO* FAN BEARINGS HAD TO BE
REPLACED. THE COAL FIRED BOILERS AND ACCOMPANYING 302 CONTROL SYSTEMS WERE SHUT DOWN FOR THE
SUMMER AT THE END OF MARCH.
76
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DE3CKIPTIUN FOH OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE HATING
NUMBER UF SEPARATE FBO UNITS
NUMBER OF BUILENS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENOUH
CONTROL PROCESS
NEH / RtTKOFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE Oft BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
COAL (1.2X SULFUH)
92iUUO SCFM (TOTAL * 4 BOILERS)
36,000 ACFM a) 406 F, FUrt EACH OF 3 FGO SYSTEMS
19,600 ACFM «l 350 F, FOR 1 FGO SYSTEM
jaO,000 Lfl/HK STEAM (IOTAL - 4 BOILERS)
4
4
46 Mh (EQUIVALENT)! 1UTAL - 4 BOILEKS
(FOR THIS REPORT* UNLESS STATED OTHERHISE, 2000 SCFM * 1 EUUIVALbNT MM.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM HYDROXIDE SCRUBBING
RETROFIT
JUNE, 1973
OPERATIONAL
90X-95X 11,000 PPM 8 INLEt)
90S (1.0 LB/MM OTU AT INLET)
OPEN LOOP
NASTEMATtR TREATMENT
FLY ASH AND NA2803/3D4 WASTE LIUUUR OEKATERED AND THEN TO
SANITARY LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE CHEVROLET DIVISION UF GENERAL MOTORS HAS A MOTOK PRODUCTION PLANT AT TONONANOA, NEW YORK.
THERE ARE 4 COAL-FIRED BOILERS AT THE FACILITY WHICH BURN 1.16 PERCENT SULFUR COAL WITH A HEATING
VALUE OF 12,650 BTU/LB. THE TOTAL COAL FEED RATE IS 17 TONS/HR NHICH IS EQUIVALENT TO 412 MM BTU/HR
HHICH IS EQUIVALENT TO 46 M« OF ELECTRICAL GENERATION.
ONE SCRUBBER HANDLES 39,000 ACFM AT 350 F hHEREAS EACH OF THE OTHER THREE 36,000 ACFM AT 406 F.
THERE IS A CYCLONE BEFORE AND AFTER SCRUBBER FOR OUST COLLECTION AND MIST REMOVAL PURPOSES, RESPEC-
TIVELY. THE VARIABLE THROAT VENTUHI SCRUBBERS MERE SUPPLIED BY FMC CORP. THE PH OF RECYCLE
SCRUBBER LIUUOR IS CONTROLLED AT 7.0 AND A L/G RATIO OF 20 GALLONS/1000 ACF IS USED. PRESSURE DROP
ACROSS EACH SCRUBBER IS 1U IN. ttG. CAUSTIC SODA IS ADDED TO THE SPENT LIQUOR IN A SEPARATE RECYCLE
TANK. THE BLEED OFF RATE FROM THE RECYCLE TANK VARIES FROM 25 - 100 GPM. THE DISCHARGE CONTAINS
FLYA3H AND SODIUM SULFATE. THE FLYASH IS CONTROLLED AT LESS THAN IX SUSPENDED SOLIDS. THE EFFLUENT
IS DISCHARGED TO THE WASTE TREATMENT PLANT AFTER AERATION. THE AVERAGE INLET CONCENTRATIONS ARE
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; TONOWANDA, NEn YORK (CONTINUED)
0.85 LB/MM BTU OF 802 AND 1 L8/MM BTU OF PARTICULATE. THE EFFICIENCY OF S02 REMOVAL IS 90* WHEREAS
THAT OF PARTICULATE REMOVAL IS 60X-95X.
EACH SCRUBBER AND THE CYCLONIC OEMISTER 15 MADE OF 316L S3. PLUME REHEAT IS NOT INCORPORATED
INTO THE SYSTEM. THE ENERGY REOOIREMENTS FOR THE SYSTEM ARE ABOUT 3 - 5X OF THE FUEL BURNED.
REFER TO FIGURE 11-15 IN SECTION la FOR A DETAILED PKOCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QUARTER-1977 AVERAGE UPERABILITY DURING 1HIS PERIOD MAS REPORTED TO BE 1UOZ.
4TH OUARTER-1977 MAJOR PROBLEMS HAVE BEEN Ph CONTROL AND RECYCLE PIPE EROSION. CONTROL
SENSORS/MODULATING MIXER VALVE REPLACED FUR PH CONTROL AND CAST IRON PIPE WAS USED TQ
REPLACE S3 RECYCLE PIPING. DURING NOV - DEC CONDENSATION FOLLOWING THE OEMISTER
HAS CORRODED THE STACK LINING. A DECISION HAS BEEN MADE TO RELINE THE STACK.
1ST OUARTER-1976 THE STACK MAS NOT RELINED.
2ND OUARTER-1978 ONE MORE CYCLONE MILL BE RETROFITTED AFTER EACH BOILER IN ORDER TO REDUCE THE
PARTICULATE LOADING TO THE SCRUBBERS.
3RD 8UARTER-1978 A MIST ELIMINATOR MILL BE INSTALLED TO PREVENT FURTHER CORROSION OF THE STACK
LINER. THE LINER HILL EITHER BE REPLACED OR COATED NITH AN ACID-RESISTANT MATERIAL.
4TH QUARTER-197B NO DEFINITE PLANS HAVE BEEN MADE REGARDING THE STACKS. THE ORIGINAL STACKS
(MOUNTED ATUP THE ABSORBERS) AKE STAINLESS STEEL. THEY ARE CORHOUEOf BUT NUT BEYOND USE. THE MIST
ELIMINATORS TO BE INSTALLED "ILL Bt CHEVRON-1YPE. THE MATERIAL HAS NOT BEEN SELECTED* BUT SOME SORT
OF PLASTIC IS CONSIDERED LIKELY. THEKE AKE NO PLANS TO ADO CYCLONES FOLLOWING THE BOILERS, A FACT
ERRONEOUSLY REPORTED DURING THE 2ND UUAKTfcR.
1ST OUARTEH-1979 AN AVAILABILITY INDEX OF 1001 HAS REPORTED FOR THE PERIOD. NO DECISION
HAS BEEN MADE REGARDING THE STACKS.
-------
STATUS TO APRIL 1979
SfcCTlON 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME.
INSTALLATION LUCATIUN
SOURCE CHARACTERISTICS
SOURCE KATIHG
NUMBER OF SEPARATE Fti) UMTS
NUMBER OF BOILERS btING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICUNCY
PARTICULAIE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUUGfc OR tiY-HROOUCT DISPOSAL
CONTROL SYSTEM COST
GEORblA-PACIFIC PAPER CO.
CSOSSETT, ARKANSAS
BARK.CUAL/01L (l.SX - 2.OX SULFUR)
220,000 SCFM (1 BOILER)
1
1
110 M« (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM s 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW KATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
NEPTUNE AlNPOL, INC.
CAUSTIC WASTE STREAM
MEW
JULY, 1975
OPERATIONAL
fl(JX (500 PPM a! INLET)
901 (0.5 GR/SCF AT INLET)
OPEN LOOP; SCRUBBED WITH 2,300 GPM "BLACK WATER* FROM PULP
MILL,
KASTtWATER TREATMENT AND DISCHARGE TO CITY SEWER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGD SYSTEM AT GEORGIA-PACIh1C PAPER CO., CKOSSETT, ARKANSAS UTILIZES A CAUSTIC PULP MILL
WASTEWATER STREAM (BLACK MATER) TO REMOVE PARTICIPATE AND S02 FROM FLUE GAS GENERATED BY A BARK/OIL
OR BARK/COAL bOILER. THE BOILER IS AN ERIE CITY POWER BUILER RATED AT 600,000 LB/HOUR STEAM, AND
GENERATES 220,000 SCFM UF FLUE GAS, WHICH IS EbUIVALENT TO 110 MM OF ELECTRICAL CAPACITY. THE
NORMAL OPERATING RANGE IS BEtwEEN 400,000 AND 500,000 LBS STEAM/HOUR WITH AN OPERATING SCHEDULE OF
24 HOURS/OAT, 359 UAYS/YtAH. IT IS UNfc OF ELEVEN BOILERS THAT TURN 5 TURBINES AND GENERATE 45 MM.
THE FLUE GAS IS DUCTED TO A SINGLE SCRUBBER AT THE RATE OF 320,000 ACFM A 310 F BY MEANS OF A
BUFFALO FORGE I.D. FAN WHICH IS DRIVEN BY A 4000 HP wESUNGHOUSE TURBINE. THE SCRUBBER ITSELF IS
HADE OF 304 SS AND CONSISTS OF AN UNLIwED VENTURI THROAT (9.5 FT X 30 FT) AND A FIBERGLASS LINED
LI8UIU-GAS SEPARATOR (2« FT X 55 FT) WITH NO INTERNAL PARTS. THE DUCTWORK LEADING TO AND FROM THE
SCRUBBER IS MADE OF STEEL AND THE DOWNSTREAM PORTION IS FIBERGLASS LINED. NO MIST ELIMINATOR OR RE-
HEATER IS USED BECAUSE THE 304 SS STACK IS FIBERGLASS LINED. THE RECICULATION SYSTEM CONSISTS OF A
104 S3 UNLINEO RECIRCULATION TANK AND A 5000 GPM INGERSOLL-RAND PUMP. AN IDENTICAL SPARE PUMP IS
ALSO ON HAND BUT IS NOT TIED INTO THE SYSTEM. THESE PUMPS ARE MAOE OF 304 SS AND ARE RUBBER LINED.
THEY OPERATE AT MAXIMUM CAPACITY. THE PIPING IS MADE OF FIBERGLASS. THE BLEED STREAM FROM THE RE-
CIRCULATION SYSTEM IS FED TO THE CITY SEWERS AT A RATE OF 2000 GPM AND THE MAKE-UP SCRUBBING LIQUOR
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
GEORGIA-PACIFIC PAPER CO. I CROSSETT, ARKANSAS (CONTINUED)
IS FED TO THE SYSTEM AT A RATE OF 2300 GPM.
REFER TO FIGURE 14-16 IN SECTION 14 FOR A DETAILED PROCESS FLON DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-I977 PLANT REPORTED SATISFACTORY OPERATIONS WITH NO MAJOR PROBLEMS. THE FIBERGLASS
LINING IN THE SCRUBBER FAILED FREQUENTLY AND HAS REPLACED AS IT FAILED.
4TH OUARTER-I977 NO FIBERGLASS LINER FAILURE MAS DETECTED DURING THIS REPORT PERIOD.
ZNO QUARTER-1978 PLANT REPORTED NO MAJOR PROBLEMS DURING THE FIRST SIX MONTHS OF 1974. TOTAL
BOILER-SCRUBBER DOWNTIME SINCE JANUARY I, HAS ABOUT IS DAYS. THE PROBLEMS MERE THE LOSS OF A PUMP
LINER AND A BOILER I.D. FAN TROUBLE.
3RD QUARTER-1978 THE PUMP WITH LINING PROBLEMS HAS REPLACED. THIS CAUSED A SCRUBBER DOHN TIME OF
APPROXIMATELY 36 HOURS. THE REASON FOR THE PUMP FAILURE IS UNKNOWN, BUT UNEVEN LINING APPLICATION
IS LIKELY. THIS PUMP LASTED ROUGHLY 3 MONTHS BEFORE THE LINING OF THE IMPELLER BEGAN COMING OFF IN
CHUNKS. THE NEW PUMP IS THE SAME TYPE AND HAS HAD NO PROBLEMS. THE SPARE IS ALSO OF THE SAME TYPE.
SINCE REPLACEMENT OF THE RECIRCULATION PUMP THE SCRUBBER HAS OPERATED CONTINUOUSLY (SCRUBBER SHUTS
OOHN NHEN THE RECIRCULATION PUMP GOES OUT).
4TH QUARTER-1978 NO OPERATING PROBLEMS MERE REPORTED DURING THIS SURVEY PERIOD. THE OPERATION OF
THE RECIRCULATION PUMP HAS SATISFACTORY. THE BOILER MAS BURNING MOSTLY BARK SUPPLEMENTED NITH OIL.
THE FGD SYSTEM DEMONSTRATED A RELIABILITY FIGURE OF 100X.
1ST OUARTER-I979 THE FGD SYSIEM OPERATED NITH NO PROBLEMS THROUGHOUT THE QUARTER. BARK HAS
BURNED DURING THE PERIOD AND OIL HAS ADDED 5-10X OF THE TIME TU HELP MITH STEAM PRODUCTION.
B2
-------
STATUS TO APKIU 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUK OPERATIONAL FGD SYSTEMS ON INOUSTKlAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE MATING
NUMBER OF SEPARATE F(iO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
502 REMOVAL EFFICIENCY
SLUUGE UK BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GETTY OIL COMPANY
BAKERSHELD, CALIFORNIA
OIL U.U SULFUM)
72,000 SCFM (TOTAL - 6 riUILERS)
1
b
36 MW (EQUIVALENT) J b bOlLEKS, EACH ol 50 MM BTU/HH
(FOK [HIS REPORT, UNLESS STATED OTHERWISE, dOOU SCFM = 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW KATE IS THE PRIMARY FACTOR IN MODULE SUING.)
FMC ENVIRONMENTAL EQUIPMENT
SOUIUM CARbONATE SCRUBBING
HETMGF1T
JUNE, 1977
OPERA UONAL
90+X 1600 PPM d INLET)
HOLDING POND FOK EVAPORATION
6 GPH ULEEOOFF TO A BLOwOOflN TANK. THE BLOWOOXN IS THEN
SENT TO A DISPOSAL POND ONCE A MEEK.
SEt SECTION 13 FOK DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
GETTY OIL COMPANY HAS AN OIL FIELD NEAR BAKERSFIELD, CALIFORNIA «HICH OCCUPIES ABOUT 15 SQUARE
MILES. THERE"ARE 136 STEAM GENERATORS) 100 wIlH A HEAT RATE OF SO MM BTU/HK AND 36 *ITH A HEAT
HATE OF 20 MM BTU/HR. THE FUEL USED IS CRUDE OIL HlTh 1.1X SULFUR ANU A HEATING VALUE OF 6.4 MM
BTU/BBL. STEAM IS DISTRIBUTED THROUGHOUT THE OIL FIELD BY INSULATED PIPELINES AND INJECTED INTO
THE OIL WELLS. CONDENSATION OF THE STEAM REDUCES THE VISCOSITY OF THE OIL, NHICH FLOfcS FREELY TO
THE SURFACE ALONG WITH THE WATER. THE UIL IS SEPARATED FROM WATER BY DECANTATIUN IN SETTLING TANKS,
AND PURIFIED BY DISTILLATION IF REQUIRED.
THE FLUE GASES (130,000 ACFM « 500 F) FROM SIX BOILERS (bO MM BTU/HR EACH) ARE MANIFOLDED
INTO « THAY ABSORBER (13.5 FEET DIA X 35 FEET HIGH) WHICH HAS RETROFITTED IN JUNE 1977 BY FMC
ENVIRONMENTAL EQUIPMENT DIVISION. THE PROCESS IS SODIUM CARBONATE SCRUBBING. THE RECIKCULATION
LIQUOR IS MAINTAINED AT A PH OF 6.6, WITH AN L/G RATIO OF 8.4 GAL/1000 ACF. THE RECIRCULATION FLOW
18 1000 GPM. A BLEED STREAM OF 6 GPM IS CONTINUALLY SENT TO THE BLOHDOMN TANK WHICH IS EITHER
EMPTIED INTO A DISPOSAL POND OK INJECTED INTO DEEP WELLS EVERY MEEK. THE INLET AND OUTLET 302 CON-
CENTRATIONS ARE 600 PPh AND 60 PPM RESPECTIVELY. THE ABSORBER, THEREFORE, HAS 90S S02 REMOVAL
EFFICIENCY.
THE ORIGINAL ABSORBER CONTAINED THREE DISK-AND-DONUT TRAYS AND AN INCONEL MIRE MESH MIST ELIMI-
NATOR. THE ABSORBER MODULE ANU THE STACK ARE MADE OF 316L SS, WHEREAS THE DOMNSTREAM DUCTWORK
83
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPEKATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
6ETTY OIL COMPANY) BAKERSFIELO, CALIFORNIA (CONTINUED)
AND THE RECIRCULATION PIPING ARE MILD STEEL. THE RECIRCULATION PUMP IS RUBBER LINED.
SOME IMPORTANT MAINTENANCE PRACTICES ARE<
1. DAILY CHECK AND CALIBRATION OF PH CONTROLLERS.
2. FREQUENT CHECKS ON FLUM HATERS (MAKEUP WATER, SODA ASH, RECIRCULATION LI8UOR, AND SLOWDOWN)
AND FLUID LEVELS (SLOWDOWN TANK, SODA ASH TANK, AND SCRUBBER).
3. MEEKLY FILLING OF SODA ASH TANK AND DISPOSAL OF BLOWDOrtN.
«. SCHEDULED LUBRICATION OF PUMPS AND FAN, SEAL REPLACEMENT.
REFER TO FISURE 14-17 IN SECTION 14 FUR A DETAILED PROCESS FLON DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QUARTER-1977 THE RECIRCULATION PUMP LINER HAS CHANGED FROM BUNA-N TO NATURAL RUBBER, DUE TO
THE SMELLING OF THE FORMER LINER. 1HE RUBBER PINCH VALVE ON THE RECIRCULATION PUMP HAS REPLACED BY
A 38 OLOBE VALVE. THERE HERE SOME MINOR PROBLEMS HITH THE PH AND LEVEL CONTROLLERS.
4TH QUARTER-1977 THE FAN ROTOR HAS STRENGTHENED AND CLEANED OF THE SCALING. THE FAN BEARING
BURNED UP. IT MAS REPLACED AND THE FAN MAS REALIGNED.
1ST QUARTER-1978 HIGH STACK DISCHARGE VELOCITY (60 FPS) CAUSED BY SMALL STACK DIAMETER AND POOR
LOCATION OF MIST ELIMINATOR (TOO CLOSE TO STACK TRANSITION SECTION) RESULTED IN HIGH ENTRAPMENT OF
DROPLETS. THE STACK AND TOP SECTION OF THE SCRUBBER HERE REDESIGNED.
2ND QUARTER-1978 THE MESH OEMISTER MAS REPLACED BY A MUNTEHS CHEVRON TYPE MIST ELIMINATOR.
A KOCH FLEXITRAY HAS INSTALLED ABOVE THE SRD TRAY IN ORDER TO IMPROVE soz REMOVAL EFFICIENCY,
PARTICULARLY DURING TURNDOWN CONDITIONS. THE PH PROBES ARE FOULED FREQUENTLY. SEVERAL
TYPES OF CONTROLLERS AHE PRESENTLY BEING TESTED FOR HIGH RELIABILITY. THE MILD STEEL RECIRCULATION
LINES MERE ERODED, AND MILL HE REPLACED BY 316L 38. THE AIR BUBBLER IN THE 300* ASH TANK LEVEL
CONTROLLER IS UFTEN PLUGGED. IT WILL BE REPLACED BY A DIAPHRAGM-TYPE LEVEL CONTROL DEVICE. THE
BLOMDONN TANK OUTLET LINE HAS DEVELOPED SCALING. A POSITIVE DISPLACEMENT PUMP HAS TO BE INSTALLED
IN THIS LINE, AND A SCALING INHIBITOR HAS POSSIBLY TO BE ADDED IN THE TANK LlUUUR.
3RD QUARTER-1978 THb BLOftOUHN TANK UU1LET LINE HAS REPLACED HITH A ONE-INCH LINE TO INCREASE
VELOCITY AND THUS SOLVE THE SCALING PROBLEM. NEW 316L S3 HECIRCULATION LINES HAVE BEEN INSTAL-
LED, AS HAS THE DIAPHRAGM-TYPE LEVEL CONTROL DEVICE IN THE SODA ASH TANK. PH CONTROLLERS ARE STILL
BEING TESTED. A SCHEN-TYPE POSITIVE DISPLACEMENT PUMP MAS INSTALLED, REPLACING AN EARLIER PUMP
NHICH ERODED DUE TO HIGH RPM. A SILICON DI8PEKSANT IS NDM "BEING ADDED TO THE LIQUOR TO ASSIST IN
ALLEVIATING THE SCALING PROBLEM, BUT THERE HAS NOT BEbN SUFFICIENT TIME TO EVALUATE ITS
EFFECTIVENESS. SINCE AUGUST 7 THE SYSTEM HAS EXPERIENCED ONLY 2 DAYS DOWNTIME DUE TO REPLACEMENT
OF FAN BEARINGS.
84
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
GETTY OIL COMPANY* BAKERSFIfcLD. CALIFORNIA (CONTINUED)
4TH QUARTER-1976 THE POSITIVE DISPLACEMENT (MOYNO) PUMP, WHICH HAS A NATURAL RUBBER STATOR AND
316L S3 ROTOR* HAS EXPERIENCED ABRASION ON THE ROTOR. EROSION IS CAUSED BY THE ASH COLLECTED IN THE
SCRUBBER AND SCALING. SEVERAL OTHER MATERIALS SUCH AS CHROME-ALLOY AND NI-HARD ARE BEING
REVIEWED AS REPLACEMENTS. THE BLEED-OFF STREAM FLOW IS CONTROLLED MANUALLY AS A FUNCTION OF ITS
SPECIFIC GRAVITY (SET PH-1.15).
18T~OUARTER-1979 THE SYSTEM MAS NOT OPERATED DURING THIS PERIOD AND MAY REMAIN SHUT DOWN IN THE
NEAR FUTURE DUE TO THE INTRICACIES IN THE CURRENT OIL PRICING REGULATIONS.
85
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SUUHCE RATINE
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONT«OLLEU
SUUKCE CAPACITY
CONTROL SYSTEM VENUUK
CONTROL PROCESS
Ntw / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICIPATE KEMOVAL EFFICIENCY
SLUUGE UR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
'GETTY OIL COMPANY
bAKERSFIELO, CALIFORNIA
OIL (1.1X SULFUR)
691,000 SCFM (TOTAL -61 BOILERS)
9 FtiO SYSTEMS, EACH TREATING 180,000 ACFM S 500 F.
9
«1
245 KM (EQUIVALENT); 4050 MM BTU/HR (TOTAL-81 BOILERS)
EACH BOILER RATED AT 42,000 LBS/HR STEAM
(FUN IHIS REPORT, UNLESS STATED OTHERWISE. 2000 SCFM s 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMART FACTOR IN NODULE SIZING.)
IN-MUUSt DESIGN
SODIUM CARBONATE SCRUBBING
RETROFIT
DECEMBER, lira
OPERATIONAL
9bZ (600 PPM 302 d INLET)
SOX (35 LB/HR ASH it INLET)
NASTEHAIER TREATMENT AND DISCHARGE TO TAILINGS POND
HOLDING POND FOR EVAPORATION.
9 GPh tiLEEOOFF TO A dLOMOOwN TANK. THE BLOfcOOWN IS EMPTIED
INTO A DISPOSAL POND ONCE A WEEK.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
GETTY OIL, COMPANY HAS AN UIL FIELD N£Ah BAKEH3FIELO, CALFURNIA, NHICH OCCUPIES ABOUT 15 SQUARE
I
MILES. THERE ARE lib STEAM GENERATORS; 100 MTU A HEAT RATE OF SO MM STU/HR AND 36 NITH A HEAT
MATE OF 20 MM 8TU/HK. THE FUEL USED IS CRUDE UIL MITH 1.1X SULFUR AND A HEATING VALUE OF 6.4 MM
i
UTU/BbL. STEAM IS DISTRIBUTED THRUUGHUUT THE OIL FIELD BY INSULATED PIPELINES AND INJECTED INTO
THE OIL NELLS. CUNUENSATION OF THE STEAM REDUCES THE VISCOSITY OF THE OIL, MHICH FLOMS FREELY TO
THE SURFACE ALONG WITH THE WATER. THE OIL IS SEPARATED FROM HATER BY OECANTATION IN SETTLING TANKS,
AND PURIFIED BY DISTILLATION IF REQUIRED.
THE FLUE GASES (180,000 ACFM AT iOO F) FROM NINE BOILERS (50 MM BTU/HR EACH) ARE MANIFOLDED
INTO ONE ABSORBER (IB FT DIA X 55 FT HI6H)j EACH ABSORBER HAS 3 FLEXITRAYS AND ONE FLEXICHEVRON
DEHISTEK SUPPLIED BY KOCH ENGINEERING. THE OVERALL DESIGN OF THE FGD SYSTEMS, HOWEVER, IS PERFORM-
ED INHOUSE BY GETTY OIL ENGINEERS. THE PROCESS USED IS SODIUM CARBONATE SCRUBBING. THE FLUE 6A3ES
|
ARE QUENCHED IN THE BOTTOM PAR1 OF THE ABSORBER. THE RECIRCULATION LIQUOR PH IS MAINTAINED BETWEEN
fr.S-6.ft AND HAS 17 PERCENT DISSOLVED SOLIDS BY HEIGHT. THE DESIGN L/6 RATIO IS 9 GAL/1000 ACF AND
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOH OPERATIONAL FGD SYSTEMS UN INDUSTRIAL BOILERS
6ETTY OIL COMPANY; BAKERSFIELD, CALIFORNIA (CONTINUED)
THE FLOW TO THE TOP TRAY IS ABOUT 1300 GPM. A BLEED-OFF STREAM OF 9 6PM IS CONTINUOUSLY SENT TO A
SLOWDOWN TANK, WHICH is EMPTIED INTO A DISPOSAL POND ONCE A WEEK, THE ABSORBER is DESIGNED TO
REMOVE 96X OF S02 (600 PPM AT INLET) AND ABOUT 50 PERCENT OF THE ASH (35 LB/HR AT INLET).
REFER TO FIGURE 14-16 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD UUARTER-1978 OF THE 9 FGD SYSTEMS UNDER CONSTRUCTION, ONE HAS STARTED UP ON SEPT. 10, 19T8
AND ANOTHER IS SCHEDULED FOR START-UP THE FIRST WEEK IN OCTOBER. THE LAST OF THE SYSTEMS IS
SCHEDULED FOR START-UP BY MID FEBRUARY.
4TH QUARUR-ma A TOTAL OF FIVE FGD SYSTEMS HAVE STARTED UP. THE MAIN STARTUP PROBLEMS AND THEIR
SOLUTIONS ARE I
1. SCALING—THE STEAM CONDENSATE IS FILTERED, SOFTENED AND RECYCLED TO THE GENERATORS AND THE FCO
SYSTEMS. STILL, SOME OF THE DISSOLVED SPECIES SEEM TO CAUSE SCALING IN THE ABSORBERS NHEN
SUBJECTED TO A PH CHANGE. SILICON OISPERSANTS HAVE BEEN USED TO REDUCE THE SCALING.
2. FANS—MISALIGNMENT UF BEARINGS HAS BEEN A FREQUENT SOURCE OF HIGH VIBRATIONS. ALL THE FANS ARE
FORNARO-CURVEU-BLADE CENTIFUGAL TYPE. WITH A DESIGN RATING OF 11 IN N6. AT 500 HP. SOME OF THE
FANS, HOWEVER, HAVE NOT BEEN ABLE TO GENERATE THE SPECIFIED POSITIVE PRESSURE. PROPER VENDOR
SELECTION MAY BE THE SOLUTION.
3. MIST ELIMINATOR—IN ONE ABSORBER, THE FLEXI-CHEVRON MIST ELIMINATOR HAS ACHIEVED LON DROPLET
REMOVAL. THIS MAY tfE DUE TO CHANNELING IN THE ABSORBER, AND THE PROBLEM IS UNDER INVESTIGATION.
SOME OTHER CHEVRON MIST ELIMINATORS MAY BE EVALUATED.
OUT OF THE <4 REMAINING UNITS, 2 AXE SCHEDULED 10 STAKT-UP IN MID-JANUARY AND 2 IN MID-FEBRUARY
1979. ONE FGU SYSTEM WHICH STARIED-UP IN OECEMbEK 1970 IS USING SODIUM HYDROXIDE SCRUBBING IN AN
ATTEMPT TO EVALUATE THt PERFORMANCE OF CAUSTIC AGAINST SOU* ASH AS THE ALKALI.
1ST OUARTEH-1979 GETTY UIL COMMISSIONED ALL THE REMAINING 4 SYSTEMS IN THE END OF JANUARY/EARLY
FEBRUARY PEKIUD. AFTER CONDUCTING PERFUHHANCE TESTING, HOWEVEK, FIVE OF THE SYSTEMS WERE
SHUT DOWN FUN THE REST OF THE PEKIOO. DURING THE NEXT UUARTER, TNU ADDITIONAL SYSTEMS WILL BE
SHUT DOftN. THUS ONLY TWO OF THE TOTAL 9 SYSTEMS WILL REMAIN OPERATIONAL IN THE NEAR FUTURE. THIS
DECISION HAS BEEN MAUE UUb TO INTRICACIES IN CUrtKENT OIL PRICING REGULATIONS.
DURING THIS PtKIOO, THE FUUK OPEKATIONAL SYSTEMS HAVE DEMONSTRATED A RELIABILITY OF 100*.
87
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PEKFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE MATING
NUMbER OF SEPARATE FCU UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOUkCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUD6E OR BV-PROOUCT DISPOSAL
CONTROL SYSTEM COST
GETTY OIL COMPANY
ORCUTT, CALIFORNIA
OIL (4.OX SULFUR)
5000 SCFM (1 BOILER)
10,000 ACFM a 500 F.
1
1
2.5 MM CE8UIVALENT)
(FOX THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EOUIVALENT MM.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
IN-HOUSE DESIGN
SODIUM HYDROXIDE SCRUBBING
RETROFIT
JUNE, 1977
OPERATIONAL
94X (1600 PPM 4 INLET)
NON-FIXATED SLURRY TO LINED POND
1.4 GPM TO SETTLING POND, DEEPNELL INJECTED.
6 4.0
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE ORCUTT SITE, GETTY OIL HAS ONE FGO SYSTEM ON ONE UF ITS 22 MM BTU/HR S1EAM GENERATORS.
ALTHOUGH THIS GENERATOR FIRES 4.0 PERCENT SULFUR, LOW GRAVITY, HIGH GRIT OIL, THE OTHER STEAM
GENERATORS AT THIS EOK SITE FIRE 0.03 PERCENT SULFUR INDONESIAN CRUDE OIL. THIS UNIT HILL SERVE AS
A TEST UNIT AND ONGOING RESULTS HILL BE USED TO MAKE DECISIONS CONCERNING POSSIBLE ADDITIONAL FGD
OPERATIONS AT THE ORCUTT FACILITY.
SINCE THE STARTUP UF THE SYSTEM, IT HAD SEVERAL OPERATIONAL PROBLEMS. THt FAN MOTOR HAS
APPARENTLY UNDEHOESIGNtU. THE THREE 01SC-AND-UONUT TRAYS HERE UNABLE TO OBTAIN MORE THAN 85
PERCENT 802 REMOVAL. THE HIGH SILICA CONTENT OF THE MAKEUP MATER CAUSED SERIOUS EROSION OF THE
RUBBER-LINED PUMP. THE SODA ASH STORAGE TANK, BECAUSE UF ITS EXCESSIVE CAPACITY, HAS NOT MIXED
COMPLETELY. THIS FREUUENTLY LED TO SOLIDIFICATION OF THE SOLUTION. IN VIEW OF THE NUMEROUS
OPERATIONAL PROBLEMS, THE FOLLOWING EXTENSIVE MODIFICATIONS HERE PERFORMED IN LATE 1978/EARLY 1979!
1. THE FAN MOTOR HAS REPLACED BY A HIGHER H.P. MOTOR.
2. THE UlSC-ANO-DONUT TRAYS MERE REMOVED COMPLETELY AND REPLACED BY A HUNTERS STATIC MIXING
DEVICE A3 THE PACKING MATERIAL FOR GAS-LIQUID CONTACT.
3. THE RUBBER-LINED RECIRCULATION PUMP MAS REPLACED BY A 316L SS PUMP AND HYDROCLUNES HERE
INSTALLED IN THE RECIRCULATION LINE AFTER THE PUMP.
aa
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
6ETTY OIL COMPANY) ORCUTT, CALIFORNIA (CONTINUED)
4. THE SOOA ASH TANK IS NO LONGER BEING USED, AS THE SYSTEM MAS CHANGED TO SODIUM HYDROXIDE
REFER TO FIGURE 14-19 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
SCRUBBING.
OPERATING HISTORY
1ST QUARTER 1979 THE ABOVE MODIFICATIONS HERE COMPLETED BY THE END OF FEBRUARY 1979. THE SYSTEM
MAS STARTED UP ON MARCH 10, AND OPERATED WITHOUT ANY DOWNTIME FOR THE REST OF THE PERIOD. THE
RELIABILITY WAS, THEREFORE, ABOUT 20X. COMPLIANCE TESTS WERE PERFORMED IN THE 4TH WEEK OF MARCH
AND THE RESULTS ARE AWAITED. IN LATE APRIL, SODIUM ALUMINATE WILL BE USED IN TRIAL RUNS TO COMPARE
THE MATERIAL WITH CAUSTIC FOR ITS 302 REMOVAL ABILITY AND COSTS IS/LB 302 REMOVED).
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PfcRFUKMAMCE DESCRIPTION FUH OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BUILEKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE HATING
NUMUER OF SEPARATE FUO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
HATER MAKE-OP
3LUU6E OR HY-PHUUUC1 DISPOSAL
CONTROL SYSTEM COST
GREAT SOUTHERN PAPER CO.
CLOAK SPRINGS, GEORGIA
BARK,COAL/OIL It.OX - 2.OX SULFUR)
420,000 SCFM (TOTAL - 2 BOILERS)
2
2
£10 MM (EQUIVALENT)! TOTAL - I BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM « 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLOrt RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
NEPTUNE AIRPOL, INC.
CAUSTIC WASTE STREAM
RETROFIT
197S
OPERATIONAL
OSX-90X (1,000 PPM AT INLET)
99.IX (DESIGN! 4.5 6R/3CF AT INLET)
OPEN LOOP) 350 - 400 GPM PER ABSORBER
NON-FIXATtO SLURRY TO LINED POND
CLARIFICATION FOLLOWED BY PONDING AND DISCHARGE TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN CEDAR SPRINGS* GEORGIA, THE GREAT SOUTHERN PAPER COMPANY OPERATES TWO BOILERS* EACH RATCD AT
500,000 LB/HR STEAM « 900 F AND 850, PSIG GENERATING A TOTAL OF 700,000 ACFM FLUE 6A8 AT 425 F.
THE BOILERS NORMALLY HUN AT NEARLY PEAK CAPACITY AND FIRE BARK AND PULVERIZED COAL MHICH HAS JX
MOISTURE, 12X ASH, l.SX SULFUR, AND A HEATING VALUE OP 12,500 BTU/LB. EACH BOILER BURNS APPROXI-
MATELY 20 TUNS/HR OF COAL AND BARK AND USES SOX EXCESS AIR. A FUEL OIL BACK-UP SYSTEM IS ALSO
AVAILABLE.
FLUE GAS FROM THE TdO BOILERS 18 FED TO TNO AINPOL VARIABLE THROAT VENTURI SCRUBBERS, BY FOUR
IDENTICAL 900 HP FANS. EACH SCRUBBING UNIT INCLUDES A RADIAL VANE SEPARATOR (24 FT DIA X 45
FT HEIGHT) AND A STUB STACK. PRESSURE DROP ACROSS THE SCRUBBER IS ABOUT 7 INCHES K.6.,
AND THE DESIGN S02 REMOVAL EFFICIENCY IS 0S-90X. THE SCRUBBERS OPERATE WITH AN L/6 RATIO OF ABOUT 5
1
GAL/1000 ACF. THE INLET 802 CONCENTRATION OF THE FLUE GAS IS TYPICALLY 1000-1200 PPM AND THE
PARTICULATE LOADING IS 4.S GR/SCFO.
SCRUBBER UNDERFLOW, CONTAINING FLYASH AND SODIUM SULFATE, GOES TO A COMMON STAINLESS STEEL
RECIRCULATION TANK (10 FT OIA X Ib FT HEIGHT). SULIDS CONTENT IN THE TANK IS 3-5X AND PH IS MAIN-
TAINED AT 3.5-b USING A 5X CAUSTIC HASTE STREAM FROM AN ONSITE OEMINERALIZER. A BLEED STREAM OF ,
ABOUT 600 GPM IS PUMPED TO AN ASH SETTLING POND nHICH HAS A VOLUME OF 110 ACRE-FT.
90
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
GREAT SOUTHERN PAPER CO.I CEDAR SPRINGS, 6EOR6IA (CONTINUED)
THE SCRUBBERS, SEPARATORS, RECIRCULATION TANK, AND STUB STACKS ARE ALL STAINLESS STEEL. THE
PIPING, KECIRCULATION PUMPS (3 AT 2400 GPM) AND SLUDGE PUMPS (2 AT 500 GPH) ARE RUBBER LINED. THE
BLEED-OFF PIPING IS 316 SS. ALL OTHER PIPING IS RUBBER-LINED CARBON STEEL, EXCEPT MAKE-UP WATER
PIPING, WHICH IS UNLINED.
REFER TO FIGURE 14-20 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH OUARTER-1977 THE EXPANSION JOINT BETWEEN THE EXISTING STACK AND SCRUBBER HAD TO BE REPLACED
IN SEPTEMBER. SOME INTERNAL WEAR WAS DETECTED ON THE PUMPS DUE TO ASH CONTENT. EROSION AND PLUG-
GING PROBLEMS WITH THE PH PROBES HAVE BEEN ENCOUNTERED. THE PLANT WAS IN PROCESS OF CHANGING THE
CONTROL PH AND MOVING THE PROBES. TANKS AND NECESSARY EQUIPMENT TO CONTROL THE PROPER PH ARE
EXPECTED TO BE COMPLETED IN A COUPLE OF MONTHS. OME EROSION WAS DETECTED IN THE RECIRCULATION
LINES OF THE POWER BOILER SCRUBBER. THE LINES AND SOME OF THE VALVES HAD TO BE REPLACED.
1ST, 2ND, 3RD OUARTER-1978 GREATER PH CONTROL WAS ACHIEVED BY INSTALLING A CAUSTIC HOLD TANK AND
REGULATING THE FLOW FROM THAT TANK TO MAINTAIN A CONSTANT PH IN THE RECIRCULATION TANK. THE RUBBER-
LINED PIPING HAS ERODED AND IS GRADUALLY BEING REPLACED WITH STAINLESS STEEL. THE VENTURI SCRUBBER
AND SEPARATOR WERE INSPECTED FOR CORROSION AND FOUND fO BE IN GOOD CONDITION.
4TH OUARTER-1976 PROBLEMS HAVE BEEN EXPERIENCED WITH PACKINGS IN ALL THE PUMPS. A MECHANICAL
SEAL WAS TRIED AND LASTED 3 WEEKS. NEW SEALS WILL BE INSTALLED, AND SINCE THERE ARE BACK-UPS FOR
ALL THE PUMPS IN THE SYSTEM, THIS SHOULD NOT CAUSE ANY DOWNTIME. PLANS FOR 1479 INCLUDE UPGRADING
THE ASH HANDLING SYSTEM AND POSSIBLY INSTALLING A MIST ELIMINATOR IN THE TOP OF THE SEPARATOR.
THE SOLIDS CONTfcNT IN THE HECikCULATEO LIQUOR WILL BE REDUCED BY INCREASING THE MAKE-UP WATER
INPUT AND THE BLEED-OFF RATE AT THE RtCIRCULATION TANK. ALSO, THE PRESENT BLEED LINE AND ASH PUMPS
MILL BE REPLACED WITH A GRAVITY LINE.
1ST OUARTER-1979 PROBLEMS AttE STILL BEING ENCOUNTERED WITH THE PUMP SEALS. A SEAL WATER PRESSURE
SWITCH IS BEING INSTALLED ON THE RECINCULATION PUMPS. PRESENTLY, THE PUMPS ARE OPERATING NITH
CONVENTIONAL PACKINGS AND ARE ROTATED DAILY TO REPLACE MINGS.
THE GRAVITY LINE TO THE SETTLING POND HAS BEEN INSTALLED. AN ATTEMPT IS BEING MADE TO GET
SOLIDS BELOW £1. NEW MIST ELIMINATORS WILL NUT BE REQUIRED* AS SPIN VANES ARE PROVIDING ADEQUATE
OKOPLET REMOVAL.
-------
STATUS TU APNIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS Ow INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE HATING
NUMBEK OF SEPAHA1E FGO UNITS
NUMBER OF BUILEKS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VtNDOH
CONTROL PROCESS
NEN / RETROFIT
STAHT-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ITT HAYUNIEK, INC.
FEKNANDINA BEACH, FLORIDA
BARK,OIL (2.OX - 2.SX SULFUR)
176,000 3CFM (T01AL - 4 BOILERS)
2
H
80 MM (EUUIVALENT)J TOTAL - 4 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 4000 SCFM x I EQUIVALENT MM.
THIS IS BECAUSE GAS f-LUn RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
NEPTUNE AIRPOL, INC.
SODIUM HYDROXIDE SCRUBBING
RETROFIT
1975
OPERATIONAL
SOX - 65X (1,200 PPM AT INLET)
97X 11.7 GK/SCF AT INLET)
OPkN LOOP
WASTtHATER TREATMENT AND DISCHARGE TO TAILINGS POND
SEE SECTION 13 FUR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
ITT RAYUNIER OPERATES AN AMMONIA-BASED SULFITE PULP MILL IN FERNANOINA BEACH, FLORIDA. THERE
ARE FOUR PROCESS STEAM BOILERS TYPICALLY OPERATING AT APPROXIMATELY 00 TO 90X LOAD. TWO ARE RATED
AT 125,000 LB/HR STEAM, ONE AT 100,000 LB/HR STEAM AND ONE AT 150,000 LB/HR STEAM. ALL ARE RATED AT
600 PSI6. THE FOUR BOILERS OPERATE IN THE FOLLOWING MANNER:
NO. 1 - 100,000 LB/HR STEAM - FIRES FUEL OIL (NO. 6)
NO. 2 - 125,000 LB/HH STEAM - FlhES A COMBINATION OF BARK AND NO. 6 FUEL OIL
NO. 3 - SAME AS NO. 2
NO. 4 - 130,000 LB/HR STEAM - FIRES FUEL OIL (NO. b)
FLUE GASES LEAVING THE NUMBER TnO AND THREE BOILERS ENTER INTO SEPARATE MECHANICAL COLLECTORS
(BUELL CYCLONE COLLECTORS) FOR PARTICULATE REMOVAL OF ABOUT 97X (1.7 GR/SCF
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
XTT RAVONIER, INC.I FERNANOINA BEACH, FLORIDA (CONTINUED)
CHASED CAUSTIC IS USED AND THE CAUSTIC FROM THE BLEACHING OPERATION IS SOLO TO KRAFT MILLS.
CONTROL PH IS IN THE RANGE OF 5.5 TO 6.0. THE LIQUID-GAS MIXTURE ENTERS A SEPARATOR (38 FT HIGH X
16.5 FT DIA.) WHICH INCORPORATES SPIN VANES FOR LIQUID SEPARATION. THE LIQUID DROPS TO THE BOTTOM
OF THE SEPARATOR INTO THE RECIRCULATION TANK. THE GASES LEAVE THE TOP OF THE SEPARATOR AND LEAD
DIRECTLY TO THE STACK* EXITING AT A TEMPERATURE OF APPROXIMATELY 135 F.
THE VENTURIS, SEPARATORS (INCLUDING SPIN VANES), SPENT LIQUOR PIPING AND HOLD TANKS ARE ALL
CONSTRUCTED OF 316L SS.
REFER TO FIGURE 14-21 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH OUARTER-1977 PLANT REPORTED THAT BOILERS NO. Z AND 3 WERE OPERATING AT REDUCED LOADS,
EACH IN THE RANGE OF 75,000 - 90,000 LBS/HR STEAM. THE SPENT CAUSTIC WAS NOT BEING
USED FOR SCRUBBING LIQUOR. ITT WAS SELLING THE SPENT CAUSTIC TO KRAFT MILLS MHO USE IT
FOR THEIR SODA BASE. CONDENSATE STEAM WAS BEING RECYCLED AND USED FOR SCRUBBING PURPOSES.
SOME EROSION HAS BEEN NOTED AT THE VENTURI THROAT.
ZND QUARTER-1978 THE PLANT WAS STILL UTILIZING CONDENSATE WATER FOR SCRUBBER LIQUOR. APPROX-
IMATELY 3 TONS PER DAY OF SODIUM HYDROXIDE WAS BEING USED TO MAINTAIN PH. THE ORIGINAL HOT WASTE
STREAM CAUSTIC WAS NOT USED FOR SCRUBBER PURPOSES, DUE TO PROCESS-RELATED PROBLEMS THAT OCCURRED.
SCRUBBER EFFLUENT MAS STILL BEING SOLD TO KRAFT HILLS. THE SYSTEM HAS TWO SCRUBBERS, 'A' AND 'B*.
A-NOOULE WAS DOWN 4 WEEKS IN JUNE AND JULY BECAUSE OF AN F.D. FAN FAILURE, BELIEVED TO BE A RESULT
OF POORLY OPERATED MECHANICAL COLLECTORS. NEW MECHANICALS WERE BEING INSTALLED TO PREVENT FURTHER
ABRASION. THE PLANT REPORTED THAT SINCE JANUARY, SCRUBBER OPERABILITY HAD BEEN APPROXIMATELY 95*.
3RD OUARTER-1978 THE BOILER AND FGD SYSTEM OPERATED APPROXIMATELY 95X OF THE PERIOD. THE
ONLY OUTAGE DURING THE PERIOD WAS BOILER-RELATED AND LASTED THKEE DAYS. THE BEARINGS IN THE I.D.
FAN HAD TO BE REPLACED.
4TH OUARTER-1978 THE FGD SYSTEM DEMONSTRATED AN ESTIMATED 95X RELIABILITY. A CRACKED FAN FOUNDA-
TION ON MODULE A CAUSED THAT MODULE TO BE NON-OPERABLE FOR 10 DAYS. I-BEAMS WERE PLACED UNDER THE
FOUNDATION TO RESTORE SUPPORT. AT THE SAME TIME, NEW SEALS WEKE PLACED IN THE DUST COLLECTOR TO
SLOW DOWN THE SEVERE EROSION PROBLEMS ON THE FAN. THE FAN SHROUD HAS BEEN REBUILT SEVERAL TIMES;
THAT HAS THE SECOND FAN. THE PLANT PLANNED TO INSTALL NEW DUST COLLECTORS SOMETIME IN APRIL. UNTIL
THEN, INTERMITTENT DOWNTIME WAS EXPECTED.
1ST OUARTER-1979 THE FGD SYSTEM OPERATED CONTINUOUSLY THROUGHOUT THE PERIOD. THE SYSTEM HAS NOT
BEEN SHUT DOWN SINCE THE REPAIRS ON THE FAN WERE COMPLETED, YIELDING A RELIABILITY VALUE OF 100X.
93
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STATUS TO APKIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS ON INDUSTHUL BOILEHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RAT INS
NUMBER OF SEPARATE F6D UNITS
NUMBER OF BOILEHS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
8LUDCE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
KERR-MC6EE CHEMICAL CUHP.
IRON*, CALIFORNIA
COKE/COAL/OIL CO.SI - b.OX SULFUR)
490*000 SCFM (TOTAL - 2 BOILERS)
726,OUU ACFM 4 320 f (TOTAL - 2 BOILERS)
2
e
245 MM (64 MN ELECTRIC POHER. ANO THE BALANCE IS PROCESS
STEAM) TOTAL - 2 BOILERS
(FOR THIS KEPORT, UNLESS STATED OTHERWISE, 2000 SCFM * 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOM RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
COMBUSTION EQUIPMENT ASSOC.
SODIUM CARBONATE SCRUBBING
NEN
JUNE, 1979
OPERATIONAL
9S«X (AT MAXIMUM LOADJN0)
98.5* (COLLECTED BY PRECEDING ESP'S)
OPEN LOOP! 125 GPM BURKITE SCRUBBING LIQUOR 147X NA2C03 AND
4U NA2S04)
HOLDING POND FUR EVAPORATION
SCRUBBER EFFLUENT 19 CLARIFIED AND THEN PUT INTO A MINERAL
DEPOSIT,
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
KERR-MCGEE CHEMICAL CORP. HAS A NEN 1.3 MM TON/Vtt SODA ASH PLANT AT TftONA, CALIFORNIA. THE
PLANT. LOCATED ALONG THE SHORE OF SEARLE8 LAKE, IS THE LARGEST YET BUILT TO YIELD SODA ASH BY DIRECT
CARBONAT ION OF BRINE ANO MAS COMMISSIONED IN JUNE 1976. THE PROCESSING INNOVATIONS* WHICH
HAVE IMPROVED THE PLANT EFFICIENCY, INCLUDE CARBONATION UNDER 13.5 PSI PRESbUNE* USE OF A COAL-
FIRED POWER PLANT, ANO RECOVERY OF C02 FROM THE FLUE GASES.
THE PLANT HAS TMO BOILERS, EACH PRODUCING 600,000 LB/HR STEAM AT 1SOO PSI. THE STEAM IS INITIAL-
LY USED TO DRIVE TuO 32 MM NON-CONDENSING STEAM TURBINES FOR ELECTRIC POKER, THEN IS USED AS PROCESS
STEAM. THE TOTAL MH EQUIVALENT IS ABOUT 245 MM. EACH BOILER BURNS A MIXTURE OF MESTERN COAL
(•.7 PERCENT SULFUR) ANO PETROLEUM COKE (5.5 PERCENT SULFUR). THE HIGH SULFUR COKE IS MIXED MITH
INC COAL IN ORDER TO IMPROVE THE PARTIAL IONI2ATION AND THEREFORE IMPROVE FLY-ASH COLLECTION IN THE
ESP WHICH OPERATES ON THE COLO SIDE OF THE PREHEATER AT 96.5 PERCENT EFFICIENCY AND 300 F. THE FLUE
CAS FLOH RATE FROM EACH BOILER IS 363*000 ACFM AT 320 F ANO MAY CONTAIN S02 BETWEEN 335 TO 5945 PPM
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
KERR-MCGEE CHEMICAL CORP.) TRONA. CALIFORNIA (CONTINUED)
DEPENDING UPON THE FUEL. THE AIR POLLUTION REGULATIONS,DICTATE THAT EACH BOILER MAY RELEASE NOT
MORE THAN 10 LBS/HR PARTICULAR. 200 LBS/HR OF 302 AND uo LHS/HR OF NOX.
THE FLUE GASES ARE SCRUBBED BY THE END LIQUOR FROM THE SODA ASH PLANT IN THO SCRUBBERS
(30 FT UIA X 35 FT HIGH EACH) WHICH ARE MILD STEEL VESSELS WITH FLAKE LINING AND THREE 3I7L 88 SIEVE
TRAYS. THE TOP TRAY RECEIVES PLAIN WATER WHEREAS THE SECOND THAT RECEIVES THE RECIRCULATIN6 LIQUOR
AT PH OF t> - 6.5. THE SPENT LIQUOR FROM THE BOTTOM OF THE SCRUBBERS IS RECIRCULATEO BY RUBBER
LINED PUMPS, FRESH END-LIQUOR IS ADDED DIRECTLY TO THE R£CIRCULAT10N\ LINE. A BLEED OFF STREAM IS
CONTINUOUSLY TAKEN BACK TO THE SALT PONDS.
THE BOILER I.D. FANS (1600 HP) FORCE THE GASES THROUGH THE SCRUBBERS AND EXPERIENCE 6 IN. H6
PRESSURE DROP. THE FANS HAVE MILD STEEL CASINGS. THE DOWNSTREAM DUCTWORK IS MILD STEEL WITH FLAKE
LINING WHEREAS THE STACK IS CONCRETE WITH FRP LINER. AMBIENT AIR IS HEATED IN AN EXTERNAL
STEAM HEATER AND MIXED WITH THE EXIT FLUE GASES TO INCREASE THE TEMPERATURE, FROM 125 F TO ABOUT
175 F. AT MAXIMUM LOADING, THE SCRUBBEHS HAVE A 802 REMOVAL EFFICIENCY OF 96 PERCENT. THE SCRUBBED
FLUE GASES ARE PROCESSED THROUGH THO MONOETHANOLAMINE (MEA) PLANTS FOR EXTRACTION OF C02. EACH MEA
PLANT WILL PRODUCE 300 TONS/DAY OF C02 AND WILL BE THE MAIN SOURCE OF MAKEUP C02 FOR THE CARBONATION
STEP.
REFER TO FIGURE 14*22 IN SECTION 14 FDR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
1ST QUARTER-1978 THE MAJOR CONSTRUCTION WORK NAB OVER. PRECOMMISSIONING ACTIVITIES WERE UNDERWAY.
THE PLANT WAS PROJECTED TO GO ONSTREAM BY APRIL I, 197S.
2ND OUAHfER-1978 THt FGO SYSTEM WAS COMMISSIONED DURING THE REPORT PERIOD. THE BOILERS WERE RUN
TO FULL CAPACITY WITH IOOX UIL FEED. COAL AND COKE WERE USED UP TO SOX AS THE FUEL. THE MAJOR
STARTUP PROBLEM WAS TKAY TIEOUwN. THE POLYPROPYLENE SIEVE TRAYS WERE NOT STRONG ENOUGH TO TAKE THE
LOAD OF INVENTORY LIQUID. THESE WILL BE REPLACED BY 316L SS OK A HIGHER GRADE ALLOY. THE PRESENCE
OF CHkOMATE IONS IN THE MAKEUP NATEK CAUSED SOME CONCERN.
3RD QUARTfcR-1970 THERE HERE ONLY 2 BOILER AND FGD OUTAGES DURING THE PERIOD. BOTH OUTAGES WERE
FOR REPLACING THE SIEVE TRAYS IN THE ABSORBER MODULES. TRAYS WERE REPLACED BY 317L SSI IN THE
FIRST MODULE DURING A 5-OAY OUTAGE IN AUGUST, AND IN THE SECOND DURING A 4-DAY OUTAGE IN SEPTEMBER.
COAL AND COKE WERE USED FOR 90 TO 95 PERCENT AS THE FUEL. OIL WAS NOT USED AT ALL* WHILE GAS MAS
AVAILABLE ONLY AS A bACK-UP.
4TH QUARTER-1978 THE 317L SS TRAYS ARE WORKING QUITE WELL. THE PROBLEM KITH THE POLYPROPYLENE
SIEVE TRAYS WAS NUT THAT THEY WERE NOT STRONG ENOUGH TO SUPPORT THE LOAD OF INVENTORY
95
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
KERR-MCGEE CHEMICAL CORP.; TRONA. CALIFORNIA (CONTINUED)
LIQUID AS REPORTED IM THE 2ND QUARTER I
-------
STATUS TU APRIL 1979
SECTION 9 (CONTINUED)
PERFUKMANCE DESCRIPTION FOR OPERATIONAL FGU SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACIIY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OH BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MEAD PAPERBOARD CO.
STEVENSON, ALABAMA
OIL U.5X - 3X SULFUR)
100,UOO SCFH (TOTAL - 2 BOILERS)
1
2
SO MW (EQUIVALENT)! TOTAL - 2 BOILERS
IFOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MK.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
NEPTUNE AIRPOL, INC.
SODIUM CARBONATE SCRUBBING
NEn
1975
OPERATIONAL
95* 11,500 PPM o) INLET)
90*
ALKALINE SULF1TE/6ISULFITE RECYCLED TO PULP PROCESS
RECOVERED SOLUTION USED AS MAKE-OP TO COOKING LIOUOH IN PULP
MILL.
SEE SECTION 13 FOR OEIAILEU ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE MEAD PAPERBOARQ COMPANY IN STEVENSON, ALABAMA, IS A NEUTRAL SULFITE PULP MILL WITH A 500
TON/DAY POLP PRODUCTION RATE. THE MILL HAS A CHEMICAL RECOVERY SYSTEM THAT ABSORBS S0£ FROM THE
eiLLERUO REACTOR. EFFLUENT FROM THE RECOVERY SYSTEM FLOnS BACK TO THt PULPING OPERATION.
ELSEWHERE ON-SITE, AN AIRPOL INDUSTRIES ABSORBER TOWER CONTROLS PARTICULATE AND S02 EMISSIONS
FROM TWO OIL-FIRED U.bX - S.tU SULFOR) COMBUSTION-ENGINEERING PACKAGE BOILERS EACH PRODUCING
175,000 Lb/HR STEAM AT 600 PSI. tHE BOILERS ARE TYPICALLY OPERATED AT 80X OF MAXIMUM LOAD. FLUE
GAS VOLUME INTU THE SCROBBER IS 173,000 ACFM id 450 F. HOT GASES PASS THROUGH A STAINLESS STEEL
VENTUR1/UUENCH SECTION FOR COOLING AND INITIAL 802 REMOVAL. THE FLUE GAS THEN ENTERS THE BOTTOM OF
THE ABSORBER SECTION ANU PASSES UP THROUGH THREE BUBBLE-CAP TRAYS. A SODIUM CARBONATE SOLUTION IS
INTRODUCED THROUGH A DANK OF EIGHT, 1.5-INCH NOZZLES CONSTRUCTED OF 316L SS AND SPIN VANES. THE
SOLUTION IS AOOED TU tHE REC1RCULATION LINE ON THE SUCTION SIDE OF THE RECIRCULAUON PUMP AT A HATE
OF 20-25 tPM. SCRUbBER EFFLUENT, MOSTLY SODIUM SULFITE, IS SENT TO THE MILLS PULPING OPERATIONS BY
A CONTINUOUS bLEED-OFF LINt AT 30-35 GPM FOR EVENTUAL 'USE IN THE DIGESTERS.
MILL WATER IS AOOED TO THE RECIRCULATION TANKS WHEN NEEOED TU COVER EVAPORATION LOSSES. IT IS
NOT A CONTINUOUS FLU*. EVAPORATION LOSSES ARE ESTIMATED TO HE APPROXIMATELY 100 GPM. THE RECIBCUL-
ATION RATE TO THE VENTURI IS APPROXIMATELY 2000 UPM AND THE RtCIRCULATION RATE TO THE ABSORBER IS
97
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
MEAD PAPERBOARD CO.I STEVENSON* ALABAMA (CONTINUED)
ABOUT 1200 6PM. THE GAS EXITS THROUGH A FIBERGLASS STACK AT APPROXIMATELY 140 F,
THE PH MONITORING SYSTEM CONSISTS OF A FIBERGLASS BOX MOUNTED ON THE RECIRCULATION TANK. OVER-
FLOW FROM THE TANK TO THE BOX INSURES CONTINUOUS FLOW.
OPERATING HISTORY
EARLY OPERATIONS
THE 302 SCRUBBING SYSTEM MAS DOWN FROM MARCH THROUGH JULY 1976 DUE TO ABRASION PROBLEMS. THE
ABRASION MAS CAUSED PARTIALLY BY HIGH STREAM VELOCITY THROUGH THE EXISTENT VENTURI PARTICULATE
SCRUBBER INTO THE 802 SCRUBBER. SODIUM CARBONATE AND CARBON PARTICLES THAT HAD NOT 60NE INTO SOLU-
TION ALSO HERE VERY ABRASIVE TO THE 302 SCRUBBER LINING. IN ADDITION* THE ORIGINAL GLASS-FLAKED
LINER (5 MM THICK) MAS EXPERIENCING STRESS CRACKING.
THE HIGH VELOCITIES INTRODUCED BY THE VENTURI MERE ELIMINATED BY REMOVING THE PARTICULATE
VENTURI SECTION OF THE SYSTEM. THE GLASS-FLAKED LINING MAS PATCHED WITH 860*000 WORTH OF CARPENTER
20 LINER. THESE CORRECTIVE ACTIONS HELPED FOR A WHILE* BUT AS IT TURNED OUT, THE CARPENTER 20 WAS
NOT INSTALLED PROPERLY AND SOLUTION HAS GETTING BETWEEN IT ANO THE MILD STEEL SHELL. IT MAS FINALLY
DECIDED TO INSTALL NEW RUBBER LINING INSIDE THE ENTIRE SCRUBBER* INCLUDING THE SPIN VANE8* AT A COST
OF 1150*000. TO PREVENT ANY HEAT PROBLEMS* ADDITIONAL NOZZLES MERE INSTALLED. TO DATE* NO MAJOR
PROBLEMS HAVE OCCURRED MITH THE RUBBER LINING.
SCRUBBER MAINTENANCE IS PERFORMED WHENEVER MILL OPERATIONS CEASE FOR ROUTINE PLANT MAINTENANCE
MHICH OCCURS SEVERAL TIMES PER YEAR. THE PH CONTROL SYSTEM RECEIVES CONTINUING MAINTENANCE ANO THE
PH PROBES ARE CLEANED ONCE PER MEEK.
REFER TO FIGURE 14-23 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH QUARUR-1977 MINOK EMBRITTLEMENT, DUE TO LOCALIZED HIGH TEMPERATURE* HAS BEEN DETECTED ON THE
LINING SURFACE. SOME METAL* NOZZLES* AND RUBBER HVAVE BEEN REPLACED.
2ND OUARTER-1976 THE PLANT MAS DOWN 12 DAYS IN JUNE FOR A MAJOR PAPER MACHINE UPDATE* AND THE
BOILERS MERE DOWN 9 DAYS DURING THAT PERIOD. DURING DUILER DOWNTIME* THE RUBBER LINERS IN THE
ABSORBER MODULE MERE REPAIRED AND MODIFICATIONS MERE MADE AT THE INLET TO THE ABSORBER* REDIRECTING
AIR FLON TO MINIMIZE FURTHER FLYASH ABRASION OF THE LINERS. THE PLANT REPORTED AN OPERABILITV OF
100* FOR THE FGD SYSTEM.
3RD 8UAHTER-19T8 AN AVAILABILITY OF 100X MAS REPORTED FOR THE FGO SYSTEM DURING THIS PERIOD*
4TH OUARTER-1978 THE RUBBER LINER IN THE ABSORBER AND THE DEFLECTOR SHIELD AT THE INLET OF THE
96
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STATUS TO APRIL 197*
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
MEAD PAPERBOARD CO.} STEVENSON, ALABAMA (CONTINUED)
ABSORBER MERE HOLDING WELL. THE PLANT REPORTED 100X RELIABILITY FOR THE SCRUBBER. ONE OF THE
BOILERS WAS DOWN FOR 24 HOURS AND THE OTHER MAS DOWN FOR 48 HOURS IN NOVEMBER FOR THE REPLACEMENT
OF SEALS AND PREHfcATERS. THE SCRUBBER MAS CHECKED AT THAT TIME. NORMALLY THE SCRUBBER 13 INSPECTED
NO MORE THAN TWICE A YEAR AND THESE INSPECTIONS ARE DURING SCHEDULED MILL SHUTDOWNS. FOUR NOZZLES
IN THE ABSORBER WERE REPLACED ON DECEMBER 1ST* WITHOUT ANY DOWNTIME.
THE PLANT WAS CONSIDERING CHANGING THE PH CONTROLLED MAKE-UP LIQUOR FEED TO A FLOW CONTROLLED
FEED BECAUSE THE PH PROBES WERE HARD TO KEEP CALIBRATED ANO HERE UNRELIABLE.
1ST QUAKTER-1979 NO F60-RELATED PROBLEMS MERE ENCOUNTERED DURING THE PERIOD. A SHUTDOWN IS
SCHEDULED FOR APRIL AT WHICH TIME THE UNIT WILL BE INSPECTED.
-------
STATUS TO APRIL 1979
SECTION 9 (CONTINUED}
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SY3TtM3 ON INOUSTRIAL BOILERS
INSTALLATION
INSTALLATIUN LOCATION
SOURCE CHARACTERISTICS
SUUHCE HATING
NUMbEK OF SEPARATE FGO UNITS
NUMBER UF bUILfcHS btlNli CONTNULLEU
SUUHCE CAPACITY
CONTROL SYSTEM V£MOUK
CONTROL PROCESS
NEW / RETROFIT
STAKT-UP OATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
HATEH MAKE-UP
SLUDGE UK BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MINN-OAK FARMER'S CO-OPERATIVE
HAHPETOfK, NORTH DAKOTA
LIGNITE 11.OX SULFUH)
164,000 SCFM (TOTAL - 2 BOILERSJ
2
2
02 Mtl (EQUIVALENT] ; TUTAL - 2 BUILEKS
TWO BOILERS, EACH H £75,000 L83/HK STEAM (250 PSI6 - OSS F)
(FOR THIS REPORT, UNLESS STATED OTHERWISE. 20UK 3CFM • 1 EQUIVALENT Hft.
THIS 19 BECAUSE GAS FLO* HATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
KOCH ENGINEERING
AMMONIA SCRUBBING
RETROFIT
JUNE, 1977
OPERATIONAL
TESTS INCONCLUSIVE.
200 GPM AMttUfclACAL HASTE STREAM
HASTMATER TREATMENT
BLEED STREAM GOES TO AN ACTIVATED SLUDGE SYSTEM 9 160 GPM
ANAEROBIC DIGESTION, FOLLOWED BY AN OPEN POND, FOLLOWED BY
AEROBIC DIGESTION.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFUMMATION
MINN-DAK FARMtR'S CO-OP. HAS A SUGAR FACTORY AT MHPETUN, NORTH DAKOTA. THERE ARE T*0 BOILERS,
EACH KITH A CAPACITY OF 275,OUU LBS STEAM/HR AT 250 P31G AND 4SS F. t»CH BOILER GENERATES 125,000
ACFM OF FLUE GAS AT 350 F. THE FUEL BURNED IS IS SULFUR LIGNITE. SULFUR DIOXIDE REMOVAL IS EFFECT-
ED BY AN AMMONIA MASTE STREAM FROM AN ON-SITE PROCESS ADDED TO THE RECIRCULATING SCRUBBER LIQUOR.
KOCH ENGINEERING HAS SUPPLIED THO VARIABLE THROAT VENTURI SCRUBBERS NITH OPEN ENDED PIPE INLETS
FOR SCRUBBING LIOUOH. THE SYSTEM HAS PRIMARILY DESIGNED FOR PARTICULATE CONTROL. INLET CONCENTRA-
TIONS OF 302 AMD PARTICULATE ARE 76-195 LB/HR AND .3-.4 GR/SCF RESPECTIVELY. OUTLET CONCENTRATIONS
OF SOZ AND PAHTICULATE ARE 10-37 LB/HR AND .027-.058 GK/SCF RESPECTIVELY. THE GAS FROM EACH VENTURI
IS ROUTED THROUGH A CHEVRON-TYPE MIST ELIMINATOR AND ONE 7 FOOT X ISO FOOT STACK. THE PRESSURE DROP
ACROSS EACH SCRUBBER IS 11 INCHES M.G. THE SCRUBBER LIQUOR IS RECIRCULATED AT A RATE OF 2000 GPM
FROM A CONCRETE TAB-LINED RECIRCULATION PIT APPROXIMATELY 10 FT X 10 FT X 10 FT. THE RECIRCULATION
PUMP IS RATED Al 75 HP AND 3UOO GPM. ANOTHER PUMP IS KEPT ON STANDBY. SCRUBBER BLONOOMN 13 «8b 6PM
TO AN AEROBIC DIGESTER. AFTER THE DIGESTER THE HASTE STREAM GOES TO Ah OPEN POND* THEN AN AEROBIC
DIGESTER, THEN AGAIN TO A POND.
100
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
MINN-OAK FARMER'S CO-OPERATIVE) WAHPETON, NORTH DAKOTA (CONTINUED)
THERE ARE A TOTAL OF FIVE PONDS ON SITE* FOUR WASTEWATER AND ONE MAIN RESERVOIR. THE FOUR
MASTEMATER PONDS ARE USED INTERCHANGEABLY FOR MAKE-UP AND WASTE DISPOSAL. MAKE-UP TO THE RECIRCUL-
ATION TANK IS 500 GPM NHERE PH IS MAINTAINED AT APPROXIMATELY 5.4. WHEN ADDITIONAL MAKE-UP IS
REQUIRED, IT IS OBTAINED FROM THE BAROMETRIC CONDENSORS. THE BAROMETRIC CONDENSER HATER IS THE
MAKE-UP HATER THAT CONTAINS THE AMMONIACAL WASTE WASTE WHICH REMOVES S02. THIS MAKE-UP IS NUT A
CONTINUOUS FLOW.
DEMISTER WASH WATER IS ALSO BAROMETRIC CONDENSOR WATER AND IS A 250 GPM SPRAY EVEKY 8 HOURS.
THE PUMPS USED FOR PUMPING MAKE-UP FROM THE PONDS AND SCRUBBER BLOWDOWN ARE LOCATED IN A CENTRAL
PUMPHOUSE. THERE ARE SEVERAL PUMPS WHICH ARE USED INTERCHANGEABLY. 00 GPM MATER LOSS TO THE
ATMOSPHERE THROUGH THE STACK HAS BEEN CALCULATED, BUT NEVER MEASURED.
THE SCRUBBERS AND THE LIQUOR INLET PIPES ARE MADE OF 316L S3, THE DEMISTER AND STACK ARE 316 SS,
AND THE RECIRCULATING PIPING IS FIBERGLASS. THE TOTAL PURCHASE COST OF THE EQUIPMENT MAS $300,000
IN 197? DOLLARS. INITIALLY THE SYSTEM WAS DESIGNED TO USE A LIME SLURRY OF PH 10.0 AS THE SCRUBBING
LIQUOR. HOWEVER, DURING THE FIRST SIX WEEKS OF OPERATION, NUMEROUS PLUGGING AND SCALING PROBLEMS
OCCURRED. HENCE* PLANT PERSONNEL BEGAN USING THE AMMONIA-RICH WASTE STREAM FROM ANOTHER ON-SITE
PROCESS IN EARLY 1976.
EACH YEAR* THE PLANT ONLY OPERATES FROM SEPTEMBER - FEBRUARY. THIS IS THE BEET SUGAR PRODUCTION
PERIOD. DURING THE REMAINDER OF THE YEAR, PRODUCTION DISTRIBUTION IS THE MAIN PLANT ACTIVITY.
REFER TO FIGURE 14-24 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QUARTER-1976 THE FGD SYSTEM BEGAN OPERATIONS FOR THE 1976-1979 SEASON ON SEPTEMBER 12. NO
MO-RELATED PROBLEMS OCCURRED. THE WASTE TREATMENT HAS BEEN MODIFIED TO INCLUDE AN ANAEROBIC
DIGESTER FOLLOWED BY AN OPEN POND AND AN AEROBIC DIGESTER.
«TH OUARTER-1976 EXCESSIVE HEAT LOSS WAS A PROBLEM FOR THE DIGESTERS. THEY WERE CURRENTLY ONLY
PARTIALLY ENCLOSED. PLANS WERE BEING MADE TO ENCLOSE MORE OF THE WASTE TREATMENT FACILITIES. OTHER
WISE, THE FGD SYSTEM PERFORMED WELL FOR THE QUARTER. PLANT PERSONNEL FELT MOST OF THEIR INITIAL
PROBLEMS HAD BEEN SOLVED.
1ST OUARTER-1979 THERE WAS ONE MINOR FGD RELATED SHUTDOWN DURING THE QUARTER TO CLEAN OUT THE
BOTTOM OF THE STACK. A PROBLEM WITH EXCESSIVE HEAT AT THE DIGESTERS STILL PERSISTS. CURRENT PLANS
CALL FOR MODIFICATIONS TO ALLEVIATE THE PROBLEM THIS SUMMER.
101
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STATUS TO APRIL 1979
SECTION t (CONTINUED)
PERFORMANCE DESCRIPTION FUH OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBE* OF SEPARATE FGO UNITS
NUMBER OF BOILERS bElNS CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENUvJk
CONTROL PROCESS
NEH / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOBIL UIL COMPANY
SAN AttUOt CALIFORNIA
OIL 12.OX - 2.25X SULFUK)
175,000 SCFM (TOTAL - 58 BOILERS)
28
28
91 MM (EQUIVALENT); 800 MM BTU/HR: TOTAL - 26 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM a 1 EQUIVALENT MN.
THIS IS BECAUSE GAS FLOW RATE IS THE PhlMAKY FACTOR IN MODULE SIZING.)
IN-HOUSE DESIGN
SODIUM HYDRUXIOE SCRUBBING
RETROFIT
1974
OPERATIONAL
90X UbOO PPM • IHLtT)
HOLDING POND FUR EVAPORATION
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE MOBIL UIL COMPANY HAS AN UIL SITE IN SAN ARDO, CALIFORNIA MHtRE 2B STEAM GENERATORS ARE
USED TO FORCE OIL OUT OF HCLL3 BY A DEEP NELL STEAM INJECTION PROCESS. T«t FUEL USED IS CRUDE OIL
HITH 2 - 2.5* SULFUR. EACH STEAM GENERATOR IS FOLLOWED bY AN INDIVIDUAL FGD SYSTEM DESIGNED BY
IN-HOUSE ENGINEERING. THE UNITS EXPERIENCED STARTUP IN THE PERIOD FKOM 1973 THROUGH 197«.
THEME ARE TNO SIZES OF STEAM GENERATORS* 22MM BTU/Hft C20 UNITS) AND 5VM* BTU/HR 16 UNITS).
THE SMALL UNITS GENERATE BfOOO ACFM, ANtl THE LARGE UNITS 18,000 ACFM. THE GASES ARE
SCRUBBED BY A LIQUUK CONSISTING OF NAOH AND ALKALINE UIL FIELD MASTENATER INA2COJ). THE PROCESS IS
ONCE-THROUGH AND PH VALUES OF 8.0 AND b.O ARE MAINTAINED AT THE INLEI AND UUTLET OF THE SCRUBBERS,
RESPECTIVELY. THE SPENT LIUUOfi FROM THE BOTTOM OF THE SCflUBeEfcS IS DISPOSED OF IN THE NASTENATER
DISPOSAL ZONE. THEKt IS NO RECYCLE FRUM THE DISPOSAL ZONE. THfc LIQUOR .FLOW NATES TO THE TNO SIZES
OP THE SCRUBBERS ARE 75 GPM AND 200 6PM. THE SCRUBBER SIZES ARE 4 FT DIAMETER X 20 FT HIGH, AND
6.5 FT DIAMETER X 25 FT HIGH. EACH SCRUBBER HAS THREE V-SHATE TYPE TRAYS. THE I.D. FANS ON EACH
SCRUBBER EXPERIENCE 3 - 4 IN. N.6. PRESSURE OHUP. THE 802 REMOVAL EFFICIENCY OF THE PROCESS IS 90
PERCENT KITH AN INLET CONCENTRATION OF 1300 PPM. CHEVRON-TYPE MIST ELIMINATORS ARE USED.
THE SCRUBBERS ARE 3161 SS AND THE TRAYS 316 SS. THE INLET DUCTWORK IS CARBON STEEL UP TO THE
ECONOMIZERS AND THEN 316L 83. THE OOMNSTHEAM DUCTNOKK IS FIBEKSLASS AND THE 1.0. FANS ARE CAHBON
BTEEL KITH 316L SS LINING ON THE CASING. THE STACKS ARE FIBERGLASS. THE FLUE GASES ARE NOT REHEAT-
102
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
MOBIL OIL COMPANY; SAN ARDO» CALIFORNIA (CONTINUED)
ED ANO CANNOT BE BYPASSED. THE MIST ELIMINATORS, ORIGINALLY 316L 38, HAVE BEEN LINED WITH PHENOLIC
EPUXY RESIN TO COMBAT CORROSION.
KEFtR TO FIGURE 14-26 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS ST3TEM.
OPERATING HISTORY
INADtOUATfc MIST REMOVAL HAS RESULTED IN CORROSION OF THE I.D. FAN IMPELLER* BLADES* AND HUBS,
WHICH NtEP REPLACEMENT EVERY YEAH. THE HIGH CHLORIDE CONTENT IN THE NASTEHATER IS THE PRIMARY CAUSE
OF PITTING OF Sb MATERIAL.
JHD OUAHTER-197B FOK THIS PERIOD. THERE MAS NO MAJOR DOWNTIME REPORTED AS A RESULT OF EQUIP-
MENT UR PHUCE3S FAILURE. RELIABILITY HAS ESTIMATED AT AbOUT 90*. A BECKMAN PH CONTROL UNIT WAS
INSTALLED ON A SCRUBBING UNIT WITH PLANS TO ADD MORE CONTROLLERS.
OTH QUAHTEK-197B Tht I.D. FANS AHt ALSO LINED WITH EPUXY RESIN TO REDUCE CORROSION. THE BECK-
MAN PH CONTROLLER HAS PERFORMED WELL AND SEVERAL MORE OF THESE DEVICES HAVE BEEN INSTALLED. THE
AVERAGE AVAILABILITY OF AN FGD SYSTEM WAS ABOUT 95 PERCENT.
1ST QUARTER-1979 MOBIL HAS DECIDED TO OPERATE ONLY 9 SMALL STEAM GENERATORS (22 MM BTU/HR EACH)
FOR MOST OF THIS YEAR. MOBIL CLAIMS THAT THIS HAS HAS BEEN THE RESULT OF "LOWER-TIER" PRICES
SANCTIONED FOR MOST OF THEIR OIL, WHICH MAKES IT UNECONOMICAL TO PRODUCE THE OIL BY STEAM FLOODIN6.
103
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERAIIONAL FGU SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGU UNITS
NUMdER OF BOILERS bEI*U CONTROLLED
SOURCE CAPACITY
CONTHUL SYSTEM VENUUR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SO2 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE UK BY-PRODUCT OISPOSAL
CONTHUL SYSTEM COST
NEKUUSA PAPERS, INC.
ASHUUHN, ARKANSAS
COAL (IX - 1.5X SULFUR)
111,000 SCFM (TOTAL - 1 BOILER)
i.
I
105 ** (EUUIVALENT); DESIGN - 5UO,UUO LB/HR STEAM
(FOR THIS REPORT, UNLESS STATED OTHERWISE* £000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE UAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
NEPTUNE AIRPOL, INC.
CAUSTIC SCRUBBING
NEW
FEBRUARY, 1976
OPERATIONAL
9u«X (600 PPM a) INLET)
98X - 99X (1.42 GH/SCF AT INLET)
OPEN LOOP
ALKALINE SULFITE/BISULFITE RECYCLED TO PULP PROCESS
SU2 RECOVERED FROM SODIUM SULFITE/SULFATE LIQUOR AND RE-
CYCLED TO PULPING PROCESS.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE NEKUUSA-EDNARDS PAPER PULP MILL IN ASHOONN. ARKANSAS OPERATES A SINGLE 105 Mw EQUIVALENT
STEAM BOILER F1REU rtlTM CUAL UR FUEL OIL. THE BOILER IS DESIGNED FOR 500,000 LB/HR STEAM AT 650
PSI. THE COAL HAS 1-1.bX SULFUR AND A HEATING VALUE OF 12,000 UTU/LB. IT IS BURNED AT A RATE OF 27
TON3/HH. THE BOILER IS OPERATED CONTINUOUSLY AT (24 HRS/DAY) 40X TO bOX LOAD.
T«0 AIRPUL VARIABLE THROAT VENTURl SCRUBBERS ARE DESIGNED TO REMOVE BOTH SULFUR DIOXIDE AND
PARTICULATE AT AN AVERAGE PRESSURE DROP OF 14-16 INCHES N.G. IHE INTENT OF NEKOOSA-EOftAKDS MAS TO
MAKE, FROM THE SCRUbbER EFFLUENT, SALTCAKE HHlCH WOULD HE USED AT THE MILL. EACH VENTURl IS FOLLOW-
ED BY A CYCLONIC SEPARATOR. THE SEPARATORS ARE MILD STEEL WITH FLAKEGLASS LININGS. EACH SCRUBBER
HANDLES HALF OF THE INCOMING FLUE GAS, THE TOTAL AMOUNT OF GAS BEING 325,000 ACFM AT 355 F. THE
INLET SOe CONCENTRATION IS TYPICALLY 600 PPM MlTH A PARTICULATE LOADING OF 1.42 GR/SCF. SCRUBBING
LI8UOR IS REC1HCULATED AT A RATE Of 2,000 GPM THROUGH PUMPS RATED AT 2,200 GPM.
THE TnO HECIKCULATION TANKS ARE MILD STEEL AND ARE LINED. THEIR SIZE IS ESTIMATED TO BE 15 FEET
HIGH X 10 FEET IN DIAMETER. BLOMDOHN FROM THE RECIRCULATIUN TANKS IS 300 GPM THROUGH PUMPS RATED AT
300 GPM. FROM THE REC1HCULATION TANKS, THE BLOrtOONN GOES TO AN ASH POND, THEN A STABILIZATION POND
AND FINALLY THE RIVER. SCRUBBER UNOERFLOH CONSISTS OF FLYASH AND A SOLUTION OF NA2S03/S04.
104
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
NEKOOSA PAPERS, INC.; ASHDOWN, ARKANSAS (CONTINUED)
CAUSTIC IS USUALLY OBTAINED AS A WASTE STREAM AFTER THE PULP BLEACHING STAGE. II IS USED AT A
RATE OF 500-600 GPM, OR 12 LB/MIN OF SODIUM HYDROXIDE AND IS ADDED TO THE RECIRCULATION TANK,
PURCHASED CAUSTIC IS OCCASIONALLY USED. IT IS USED AS A SOX SOLUTION! EXACTLY THE HAY IT IS PUR-
CHASED. THE USAGE RATE IS 1 TO 4 GPM AND IT IS INJECTED ON THE SUCTION SIDE OF THE RECIRCULATION
PUMP. THE PH OF THE ENTERING CAUSTIC IS 10.5 TO 11. THE PH IN THE RECIRCULATION TANK IS 5.5 TO
6.0. PH PROBES ARE LOCATED IN THE FIBERGLASS LINE BETWEEN THE SEPARATOR AND RECIRCULATION TANK.
GASES ARE EXHAUSTED THROUGH A FLAKEGLASS LINED STACK APPROXIMATELY 12 FEET IN DIAMETER AND 200*
FEET IN HEIGHT. THE OUTLET TEMPERATURE IS 125 F. THERE IS NO REHEAT.
THE PREDOMINANT DIFFICULTIES WITH THE FGD SYSTEM HAVE BEEN TWO-FOLD. FIRST* THE PLANT HAS BEEN
UNABLE TO DEVELOP AN ADEQUATE PH CONTROL MECHANISM. THE PH CONTROL SYSTEM MONITORS THE AMOUNT OF
CAUSTIC AGENT, I.E., SODIUM HYDROXIDE, WHICH GOES INTO THE RECYCLE TANK, KEEPING THE PH OF THE
SCRUBBER SOLUTION AT A NONCORROSIVE LEVEL. THE PLANT HAS BEEN PLAGUED KITH PROBLEMS IN
OPERATING THE PH CONTROL SYSTEM AND HAS SUFFERED A CHEAT DEAL OF CORROSION. THE SECOND PROBLEM
CONCERNS THE CHEMICAL REGENERATION PORTION OF THE SYSTEM. THE INTENT OF THE PLANT WAS TO SEPARATE
THE FLY ASH FROM THE SCRUBBER LIQUID AND TAKE THE SCRUBBER LIQUID THROUGH A SERIES OF EVAPORATORS
WHERE SODIUM SULFATE, I.E., SALTCAKE, WOULD BE GENERATED. THE PLANT HAS BEEN UNABLE TO OPERATE THE
FLY ASH SEPARATION SYSTEM PROPERLY, AND THERE IS NOT ENOUGH EVAPORATION CAPACITY FOR THE PLANT TO
PROCESS THE SCRUBBER EFFLUENT AT FULL OPERATIONAL CAPACITY.
IN SPITE OF THE OPERATIONAL PROBLEMS, THE SULFUR DIOXIDE AND PARTICULATE REMOVAL EFFICIENCIES
OF THE F6D SYSTEM ARE 90 AND 99 PERCENT, RESPECTIVELY, ACCORDING TO THE PLANT ENGINEER. THE WASTE
PRODUCT FROM THE SCRUBBER IS NOT RECYCLED, AT PRESENT, AND IS PUMPED TO THE WASTEWATER TREATMENT
PLANT.
UPON STARTUP, PROBLEMS OCCURRED "ITH THE PIPING AND VALVES WHICH WERE CONSTRUCTED OF CARBON
STEEL. THE CARBON STEEL SYSTEM WAS REMOVED AND REPLACED WITH STAINLESS STEEL VALVES AND PIPING.
SOME PIPING LEAKS OCCURRED AND MERE REttELOED. SUME CORROSION OF OUCT DAMPERS OCCURRED AND MERE RE-
LIEVED BY ADJUSTING THE PH OF THE SCRUBBING LIUUOR.
REFER TO FIGURE 14-27 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QUARTER-1977 NO MAJOR PROBLEMS WERE REPORTED. CORROSION PROBLEMS STILL EXIST AND PH CONTROL
IS STILL A PROBLEM. FLOW METERS ARE BEING INSTALLED TO MONITOR SCRUBBER WATER.
«TH QUARTER-1977 TWO IN LINE FLOW METERS WERE INSTALLED ON EACH SCRUBBER, ONE AT THE THROAT INLET
OF THE VENTURI AND ONE AT THE THROAT. THE PLANT REPORTED THAT PH CONTROL WAS STILL A PROBLEM.
SOME PROBLEMS MERE BEING ENCOUNTERED WITH THE PH PROBES DUE TO THE CONSTANT FLOW OF LARGE
AMOUNTS OF SOLIDS, AND SOLIDS DEPOSITS ON THE PROBES.
105
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
NEKOOSA PAPERS* INC.; ASHOOWN* ARKANSAS (CONTINUED)
2ND QUARTER-1978 NO MAJOR PROBLEMS OCCURRED DURING THE REPORT PERIOD. IN JUNE A PARTICULATE
COMPLIANCE TEST MAS RUN. PARTICULATE EMISSIONS MERE 0.05 LB/MM BTU AGAINST THE O.t LB/MM BTU
REGULATION. CAUSTIC SCRUBBING SOLUTION IS CYCLED TO THE SCRUBBER FROM THE PULP BLEACH PLANT
AT 400 GPM. THE BOILER OPERATED 2153 HOURS AT 40* TO 60S CAPACITY. DURING THAT PERIOD THE SCRUBBER
DEMONSTRATED 100* OPERABILITY.
3RD OUARTER-197B DURING THIS REPORT PERIOD THE ONLY PROBLEM THAT MAS REPORTED NA8 A RECYCLE
PUMP FAILURE CAUSING UNE SCRUBBER TO BE DOWN FOR APPROXIMATELY l.S DAYS. HOWEVER* DUE TO THE
PARALLEL ARRANGEMENT OF THE SCRUBBING TRAINS AND LON OPERATING LEVEL OF THE BOILER (40 • 60S), THE
TOTAL FLUE GAS FLOH WAS ROUTED THROUGH THE REMAINING SCRUBBER TRAIN. THE BOILER HAS REPORTED
TO OPERATE 24 HOURS PER DAY DURING THIS PERIOD.
«TH QUARTER-197B DUE TO THE PARALLEL ARRANGEMENT OF THE SCRUBBER MODULES AND LOM BOILER LOADS.
SCRUBBER-RELATED BOILER DOWNTIME IS RARE. THE ENTIRE VOLUME OF FLUE GAS CAN BE ROUTED TO ONE OF THE
SCRUBBERS WHEN THE OTHER NEEDS MAINTENANCE WORK. HOWEVER* THE PLANT IS CURRENTLY UNDERGOING EXPAN-
SION WHICH WILL REQUIRE BOILER LOADS OF BOS TO 90S. THIS WILL MEAN THAT THE ENTIRE VOLUME OF GAS
WILL NOT BE ABLE TO BE ROUTED THROUGH ONE MODULE AND PLANT PERSONNEL REPORTED THAT THEY EXPECT MORE
BOILER DOWNTIME DUE TO F6D PROBLEMS OR AT LEAST REDUCED OPERATING LOADS.
DURING THIS QUARTER* THE LINING OF ONE OF THE SEPARATORS WAS PATCHED. THE LINING HAD BEEN
CHIPPING OFF CAUSING THE MILD STEEL SHELL TO CORRODE. CORROSION LEAKS IN THE SEPARATOR WERE ALSO
REPAIRED. THE BOILER HAS NUT SHUT OOWN. PLANS HAVE BEEN MADE TO RELINE THE SEPARATORS WITH AN AS
YET UNDETERMINED LINING MATERIAL IN THE SPRING.
PURCHASED CAUSTIC (I70U-J6UW/UAY) WAS USED 3 TO 4 WEEKS THIS QUARTER SINCE THE PUMP THAT
DELIVERS THE UN-SITE CAUSTIC FROM THE PULP BLEACHING OPERATION BROKE OOMN DUE TO A MECHANICAL
FAILURE. NO SCRUBBER DOWNTIME RESULTED.
PH PROBES ARE CLEANED TWICE WEEKLY. AN AVAILABILITY OF iOOS WAS DEMONSTRATED BY THE FGD SYSTEM.
1ST OUARTER-19T9 THERE WERE NU MAJOK FGO SYSTEM RELATED PROBLEMS REPORTED DURING THE PERIOD.
THE SYSTEM WAS DOWN FOH ABOUT ONE WEEK DUE TO EXPANSION WORK ANO PROBLEMS WITH THE PULVERIZERS
AND BUCKET ELEVATORS. DURING THIS TIME A SWITCH WAS MADE FROM COAL TO OIL AND GAS. THERE WERE
PROBLEMS WITH FROZEN COAL AT WHICH TIME SCREENED COAL WAS BOUGHT AND BURNED. THIS HAD NO EFFECT
ON FOD OPERATIONS. THE PLANT HAS BEGUN TO BURN SOME BARK. THfc PLANT EXPANSION IS EXPECTED TO BE
COMPLETED IN DECEMBER 1979. THERE ARE CURRENTLY NO PLANS TO EXPAND FGO SYSTEM CAPACITY AS IT IS
PRESENTLY RUNNING AT 50 TO 60S OF FULL CAPACITY.
THE SYSTEM IS STILL EXPERIENCING DIFFICULTY WITH PH PROBE PLUGGING. IT REQUIRES CLEANING WITH
106
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STATUS TO APRIL I97S
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
NEKUOS* PAPERS, INC.! ASHDOWN, ARKANSAS (CONTINUED)
HIGH PRESSURE AIR AND HATER ONCE PER SHIFT.
NEXT QUARTER THERE MILL BE A MAJOR SCRU8SEK OVERHAUL, AT WHICH TIME THE FLAKED GLASS LINING
MILL BE REPLACED BY 317L SS. THE BRICK LINING IN THE THROAT IS EXPECTED TO BE REPLACED BY A
NEH ONE.
THE FGO SYSTEM DEMONSTRATED lOOt AVAILABILITY THIS QUARTER.
107
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OP SEPARATE FGO UNITS
NUMBER OP BOILERS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEM / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
NORTHERN OHIO SUGAR COMPANY
FREEMUNT, OHIO
COAL (IX SULFUR)
10,000 SCFM (TOTAL - i BOILERS)
140*000 Lb/HR STEAM (TOTAL - 2 BOILERS)
2
2
GREAT WESTERN SUGAR
SODIUM HYDROXIDE SCRUBBING
RETROFIT
OCTOBER, 1975
OPERATIONAL
MASTENATER TREATMENT AND DISCHARGE TO CITY SEWER
SEE SECTION 13 FUR DETAILED ECONOMIC INFORMATION
BACKGROUNU INFORMATION
THE FGD SYSTEM CURRENTLY OPERATING AT THE FREEMONT, UHIO PLANT OF GREAT ME3TERN SUGAR
HAS BEEN DESIGNED FOR BOTH 802 AND PARTICULATE CONTROL. THE SYSTEM CONSISTS OF A VARIABLE THROAT
VENTURI SCRUBBER MITH A SINGLE PASS, THREE STAGE CHEVKON MIST ELIMINATOR.
A BLEED-OFF STREAM OF SCRUBBER EFFLUENT IS CONTINUOUSLY DISCHARGED TO A HOLDING POND FON
TREATMENT.
REFER TO FIbURE l«-29 IN StCUuN 14 FOR A UETAILEI) PNOCESS FLO* UlAGRAM OF THIS SYSTEM.
108
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STATUS 10 APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOK UPEKAllUNAL FGD SYSTEMS ON INOUSTKIAL BUlLtKS
INSTALLATION NAME
INSTALLATION LOCATION
SOUfcCE CHARACTEHIST1CS
SOURCE BATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILEK8 BEING CONTROLLED
SOURCE CAPACIU
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEH / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PAKTICULATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
PFI2EH, INC.
EAS1 ST. LOUIS, ILLINOIS
COAL 13.bX SULFUR)
10,000 SCFM UUTAL 3 OOILERSJ
i
i.
20 M* lEUUIVALEwT)
IFOR iHiSi REPOKT, UNLESS SlATfcD OTHERWISE, 2000 SCFM ~ 1 EQUIVALENT MW.
THIS IS BECAUSE GAS FLU* RATE IS THE PRIMARY FACTOR I» MODULE SIZING.)
JN-hUUSE DESIGN
LIME SCRUBBING
RETKUFIT
SEPTEMBER, 19TO
OPERATIONAL
99X tiOOO PPM SU2 ol INLET)
Va\ C1«S LH/HR ASH «i INLET)
SO GPM
DEMA1EREO SLURRY TO LANDFILL
SEE SECTION 13 FOK DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE IRON OXIDE PIGMENT PLANT OF PFIZERt INC. IN EAST ST. LOUIS, ILL. THREE BOILERS ARE USED
TO PROVIDE PROCESS STEAM. THE THREE BOILERS HAVE STEAM OUTPUTS Of 10,000, 30,000 AND 100.000 LB/HR
NlTH CORRESPONDING HEAT INPUTS OF 20 MM bTU/HR, SOMM BTU/HX, AND ISO MM BTU/HH. THE TftO SMALLER
80ILER3 HAVE TRAVELLING GRATE STOKERS WHILE THE LARGE BOILER HAS A SPREADER STOKER. THE FUEL USEO
[
IN THESE BOILERS IS ILLINOIS BITUMINOUS COAL WITH ABOUT 3.5* SULFUR, 8-12X ASH, AND A HEATING VALUE
OF 11,WOO BTU/Lti. THE COAL IS WASHED AND SIZED TO 1 1/4 IN X 0 IN. THE UNCONTROLLED S02 EMISSIONS
FOR THE THREE BOILERS ARE 128, 320, AND 9bO LB/HR (TOTAL OF 140B LB/HR)* WHILE THE PARTICULATE
EMISSIONS ARE 14, 16, AND 115 LB/HR (TOTAL OF 145 LB/HR}. THE CORRESPONDING ALLOWABLE EMISSIONS
ARE 3br 90, AND 270 LB/HR (TOTAL OF 396 LB/HR) FOR 302, AND 12, 15.5, AND 21 LB/HH (TOTAL OF
/
49 LB/HR) FOR PARTICIPATES.
IN LATE 1-J74, PFIZER SELECTED THE NLA-L£WIS ABSOKBER FOR A LIME FGO SYSTEM (SEE OPERATING
HISTORY FOR DETAILS ON DESIGN MODIFICATIONS PERFORMED BY PFIZEH, INC.). THE NLA-LEWIS SCRUBBER
IS A HORIZONTAL, ROTATING CYLINDER MOUNTED ON TRUNNIONS ANO SLOPED UPWARD ABOUT 1/2 DEGREE TO
PROVIDE GRAVITY FLOW OF THE LIME SLURKY COUNTERCURHENT TO THE GAS FLOW. THE SHELL CONTAINS
RINGS OF FILTER BOXES INTERLACED WITH LOOSELY HUNG CHAINS. THE LIME SLURRY CASCADES OVER THE
CHAINS THUS PROVIDING AN IMMENSE DHUHLET AREA Irt ADDITION TO THE WETTED CHAIN SURFACE FOR CONTACT
KITH THE FLUE GAS. 1HE CHAINS ALSO SCOUR THE 1NTEHNAL SURFACE TO PREVENT SCALING.
109
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STATUS TU APRIL 1979
SECTION 9 (CONTINUED;
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
PFIZER, INC.; EAST ST. LOUIS, ILLINOIS (CONTINUED)
THE FLUE GAS FROM ALL THE THREE BOILERS (74,000 ACFM ol 2SO F) ARE MANIFOLDED INTO THE SCRUBBER
(11 FT OIA X d7 FT LONG) WHICH CONSISTS OF DRYING (7 FT), SCRUBBING (35 FT), HIST ELIMINATING,
(7 FT), AND DROPOUT Clb FT) ZONES. FRESH QUICKLIME (9JX CAO, 3/8 IN X 0 IN) IS ADDED ALONG HITH
MAKEUP MATER TO THE SLAKEH. THE FEED PUMP SUPPLIES ABOUT 50 GPM OF LIME SLURRY (10 NT.Z), HHILE
THE DISCHARGE FLO* RATE IS ABOUT 25 GPM OF CAS03/S04 SLURRY (30 WT.X). EACH BOILER HAS AN
1.0. FAN, AND THE SCRUBBER HAS ONE I.D. FAN. THERE IS A CYCLONIC MIST ELIMINATOR CONTAINING
IMPINGEMENT TUBES DOWNSTREAM OF THE SCRUBBER 1.0. FAN. THE PRESSURE DROP ACROSS THE SCRUBBER IS
£ 1/2 INCHES OF WATER. THE SCRUBBER DISCHARGE PH IS CONTROLLED AT 6.0 OR ABOVE. THE INTERNAL
SLURRY POOL CONTAINS BETWEEN 3000 10 4000 GALLONS OF SLURRY. AT 2 2/3 RPM, THE LIFTER BOXES
GIVE AN EFFECTIVE INTERNAL L/G RATIO OF 66 GAL/1000 ACF. TYPICAL 302 AND PARTICIPATE REMOVAL
EFFICIENCIES ARE 9bX (1408 LB/HR a INLET) AND 75X (145 LB/HR 9 INLET). THE WASTE SLURRY IS MIXED
NITH SOME FRESH LIME, UTILIZED IN NEUTRALIZING 01HER MASTENATER STREAMS FROM THE PLANT AND
FILTERED. THE FILTRATE IS DISPOSED OF, AND THE SLUDGE IS LANDFILLEO.
THE BOILER I.D. FANS, INLET DUCTWORK, THE SCRUBBER INTERNALS AND SHELL, AND THE SLAKER ARE
MADE OF CARBON STEEL. THE SCRUBBER I.D. FAN, OUTLET DUCTWORK AND THE STACK ARE 316 33. THE
IMPINGEMENT TUBES IN THE MIST ELIMINATOR ARE PVC CPOLYVINYL CHLORIDE); AND THE SLURRY FEED PUMP
IS RUBBER-LINED.
OPERATING HISTORY
J975-197B THE NLA-Lfc«IS SCRUBBER "AS SELECTED IN LATE 1974 BASED ON ITS RELATIVELY LOW ENERGY
REQUIREMENTS, SIMPLICITY, AND FREEDOM FKOM PLUGGING. PFIZER LOCATED AN IDLE DOLOMITE KILN (11 FT
OIA X 67 FT LONG) AMD FILLED IT NITH THE NLA-LEWIS CHAIN SYSTEM. IN ADDITION, PFIZER
INCORPORATED A DRYING SECTION BEFORE THE MET SCRUBBER TO OEWATErt THE WASTE SLUDGE PRODUCT BY
CONTACT NITH THE INCOMING FLUt GAS. THIS CONCEPT OFFERS A PRODUCT SUITABLE FOR LANDFILL. THE
SCRUBBER NAS INSTALLED TO HANDLE THE FLUE GAS FROM THE LARGE BOILER (ISO MILLION BTU/HR) SUPPLIED
BY ERIE CITY.
THE SCRUBBING SECTION CONTAINED ABOUT FIVE TONS OF CHAIN. THE DRYING SECTION CONTAINED A80UT
FIVE TONS OF CHAIN AND A NEUTRALIZING PORTION FREE OF CHAINS. ALL THE SCRUBBING EBUIPMENT NAS OF
MILD STEEL, EXCEPT FOR A FEW 1EST CHAINS. TESTS ON THIS CONFIGURATION INDICATED EXCELLENT 802
REMOVAL* bUT INADEQUATE PARTICULATE CAPTURE. THE PARTICIPATE EMISSIONS (42 LB/HR) HERE STILL
TWICE THE ALLOWABLE LIMIT OF 21 LB/HR.
IN OROEH TO IMPROVE THE PAMTICULATE REMOVAL, THE SCRUBBING SECTION NAS SHIFTED TO THE CENTER
OF THE KILN IN EARLY 1977 AND HEAVIER LOW ALLOY (AISI «8620) CHAINS MERE INSTALLED* A MIST
ELIMINATOR SECTION OF IMPINGEMENT ZONE AND A DROPOUT ZONE WERE ADDED DOWNSTREAM OF THE SCRUBBING
SECTION. THE DRYING CHAINS WERE REMOVED AND THE SCRUBBER WAS OPERATED NITH A NET DISCHARGE. NITH
THESE DESIGN CHANGES, PARTICULATE EMISSIONS WERE REDUCED TO 26 LB/HR, 5 LB/HR SHORT OF THE EPA
110
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
PFIZER. INC.) EAST ST. LOUIS, ILLINOIS (CONTINUED)
REOUIREMtNT. 302 REMOVAL WAS INCREASED TO 97X. THE PH OF THE SPENT SLURRY HAS RELATIVELY
STABLE AT 6.0. AT THIS SET POINT, THE LIME CONSUMPTION WAS 1000 L8/HR FOR 302 REMOVAL OF
990 LB/HR (960 LB/HR at INLET).
IN 1976f IT WAS DECIDED TO ROUTE THE FLUE GASES FROM THE TnO SMALL BOILERS TO THE SCRUBBER.
IT HAS EXPECTED THAT THE ADDED GAS FLOW AND THE CORRESPONDING INCREASE IN PRESSURE DROP MOULD
ENHENCE PARTICULATE REMOVAL. AN ENLARGED SCRUBBER l.D. FAN, OUTLET DUCT, AND STACK OF 316 S8 WERE
ADDED! AS WELL AS THE MIST ELIMINATOR BEFORE THE STACK. THE DRYING SECTION OF THE SCRUBBER WAS
REACTIVATED WITH 30 TONS OF LOW ALLOY CHAINS. IN THE FINAL CONFIGURATION, WHICH IS DESCRIBED IN _
THE BACKGROUND SECTION, THE OPERATIONS WERE RELATIVELY SIMPLE AND UNSOPHISTICATED RESULTING IN
VERY HIGH (>96X) AVAILABILITY VALUES.
4TH OUARTfcR-197« EMISSION TES1S HERE CONDUCTED DURING THIS QUARTER, AND FINAL EPA APPROVAL WAS
GRANTED FOR COMPLIANCE OF BOTH 302 AND PARTICULATE EMISSION STANDARDS.
WITH DRY DISCHARGE, THE LIME FEED IS PROPORTIONED TO COAL FEED, AND BIASED MANUALLY
TO COMPENSATE FOH OTHER CHANGES. WITH LIQUID DISCHARGE, THE CURRENT MODE OF OPERATION, THE LIME
FEED HATE IS ADJUSTED MANUALLY TO KEEP THE DISCHARGE PH AT 6.0.
THE SYSTEM RELIABILITY WAS 96X.
1ST OUARTER-1979 THE PVC IMPINGEMENT TUBES IN THE MIST ELIMINATOR HAVE SHOWN CREEP FATIGUE.
TO REDUCE THE LOAD UN THESE TUBES, ADDITIONAL CHAINS ARE INSTALLED IN THE MIST ELIMINATOR SECTION
INSIDE THE SCRUBBER. THE LOW ALLOY CHAINS IN THE SCRUBBING SECTION HAVE EXPERIENCED SOME
CORROSION. THE PH CONTROL WILL BE IMPROVED (MINIMUM DISCHARGE PH OF 6.0) TO AVOID FURTHER
CORROSION. A VARIABLE. SPEED KILN URIVE WILL Bt ADDED TU THE SCRUBBER TO PERMIT BETTER CONTROL OF
THE DRIED PRODUCT MOISTURE.
A RELIABILITY OF 951 WAS REPORTED. THE DOWNTIME WAS REUUINED MAINLY FOR THE INSPECTION OF THE
MIST tLIMINATUH AND SCRUBBER INTERNALS.
Ill
-------
STATUS TU APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGU SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SUUKCt CHARACTERISTICS
SOURCE KAllub
NUMBER OF SEPARATE FGD UMTS
NUMBER OF HUILERS BEING CONTROLLED
SOURCE CAPACIIY
CONTROL SYSTEM VENDUR
CONTROL PRUCEbS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE UK dY-PRUDUCT DISPOSAL
CONTROL SYSTEM COST
REICHHOLD CHEMICALS, INC.
PENSACULA, FLUR1UA
wuuo a OIL (2X SULFUK)
80,000 SCFM (TOTAL • i BOILERS)
170,000 ACFM a 530 F (TOTAL - 2 BOILERS)
200,000 LB/HR STEAM (TOTAL)
40 hn (EQOIVALENT); TUTAL - & BOILERS.
(FOK THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM * 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
NEPTUNE AIRPOL, INC.
SODIUM CARdONATE SCRUBBING
RETROFIT
JUNE, 1975
OPERATIONAL
NOT AVAILABLE
NASTEMATEtt TREATMENT AND DISCHARGE TO TAILINGS POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
REICHHULO CHEMICALS, INC. LOCATED IN PENSACOLA, FLORIDA OPERATES A T«0-bOILER STEAK PLANT
WHICH GENERATES A TOTAL OF QO,OuO SCFM AT MAXIMUM LOAD. THE OIL ANO "000 FIRED BOILERS INSTALLED
IN 1973, ARE RATED FOR 100,QUO LB/HH STEAM EACH WITH TOTAL HEAT INPUT 300 MILLION BTU/HK.
EMISSIONS ARE CONTROLLED BY AN AIRPOL AIR QUALITY CONTROL SYSTEM CONSISTING OF A VENTURI
SCRUBBER ANO SEPARATOR IN WHICH PARTICIPATE ANO S02 REMOVAL OCCUR SIMULTANEOUSLY. SULFUR DIOXIDE
REMOVAL TAKES PLACE BY THE USt OF SUDIUM CARBONATE FGO TECHNOLOGY. EACH SCHOBBER HANDLES 65,000
ACFM OF FLUE GAS AT 530 F. THE TOTAL INSTALLED COST OF BOTH THE SCRUBBERS WITH STUB STACKS (ATOP
THE SCRUBBER) WAS i«J7U,000 IN 1973. THE VENTUHI SCRUBBERS (b FT OIA X 16 FT HIGH) AND SEPARATORS
(11.75 FT OIA X ?b FT HIGH) ARE CONSTRUCTED OF 304 SS ANO CARBON STEEL RESPECTIVELY. THE STUB
STACKS (6.5 FT UIA X 31 F1 HIGH) AND FANS (UPSTREAM UF THE SCRUBBERS) ARE CARBON STEEL.
PRESSURE DROP ACRUSS THE VENTORI VARIES 17-24 IN H.G.
OPERATING HISTORY
NO INFORMATION HAS BEEN MADE AVAILABLE BY THE PLANT PERSONNELON OPERATING EXPERIENCE.
112
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STATUS TU APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPEKA11UNAL FGD SYSTEMS ON INDUSTRIAL &OUERS
INSTALLATION NAME
INSTALLATION LUCAUUN
SOURCE CHARACTERISTICS
SOURCE HATING
NUMBER UF SEPARATE I-GD UNITS
NUMBER UF BUILEKS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUO&E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
RICKENBACKER AIR FORCE BASE
COLUMBUS, OHIO
COAL li.bX SULFUK)
55,000 SCFM (TUTAL - 7 BOILERS)
277,OUU LB/HR STEAM
1
7
27 MW (EQUIVALENT); TOTAL - 7 BOILERS
(FOR THIS KEPURT, UNLESS STATED OTHERWISE. £000 SCFM = 1 EQUIVALENT MW.
THIS IS BECAUSE UAS f-LUM HATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
RESEARCH-COTTRELL/BAHCO
LIMESTONE SCRUBBING
RETROFII
MARCH, 1976
OPERATIONAL
901+ (DESIGN)
ACTUAL REMOVAL is MUM LONER DUE TO EASING OF REGULATIONS.
98X
OPEN LOOP - 2.b GPM/MW (MAX)
NON-FIXATED SLUKKY TO LINED POND
UNSTAttlLIZED CAS03/S04 SLUDGE TO LINED POND
SEE SECTION 13 FUR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
UN MARCH 11, 1976 THE FIRST U.S. INSTALLATION OF THE SftEDISH BANCO SULFUR DIOXIDE REMOVAL SYSTEM
DAS PLACED IN SERVICE AT RICKENBACKER AIR FORCE BASE IN COLUMBUS, OHIO. THE SYSTEM. MANUFACTURED
BY A.6. BAHCO VENTILATION OF ENKOP1NG, SWEDEN, DISTRIBUTED EXCLUSIVELY IN THE UNITED STATES BY
RESEARCH/COTTRELLt HAS ORIGINALLY INSTALLED Al RICKENBACKEH TO HANDLE THE FLUE GAS FROM SEVEN
Jl MM BTU/HR STOKER-TYPE COAL FIRED BOILERS INSTALLED BETnEEN 1954 AND 1956. IN JUNE 1977, A NEW
»0 MM BTU/HR BOILER CAME INTO SERVICE. THIS UNIT REPLACED i. OF THE OLDER BOILERS, AND A THIRD MAS
PLACED ON STAND-BY. THE BOILERS ALL FIRE A HIGH SULFUR 13.61) COAL.
THE RICKENBACKER EMISSION CONTROL SYSTEM CONSISTS ESSENTIALLY OF A MECHANICAL COLLECTOR, 2-STAGE
BACHO SCRUBBER TOWER, LIMESTONE STORAGE AND HANDLING SYSTEM, CLARIFIER, BOOSTER FAN AMD ASSOCIATED
OUCT-HORK, PUMPS, CONTROLS, AND A SLUDGE DISPOSAL POND.
SOLID PARTICULATE ANO SULFUK DIOXIDE-LADEN FLUE GAS TAKEN f-KUM EACH OF THE EXISTING SIX
STACKS IS FED THROUGH A COMMON HEADER AND INTO A MECHANICAL COLLECTOR WHERE PRIMARY PARTICULATE
REMOVAL TAKES PLACE. THE MECHANICAL COLLECTOR HAS A DESIGN REMOVAL EFFICIENCY OF 70 PERCENT AND
MAS INSTALLED PRIMARILY TO REDUCE FAN WEAK. THE PARTIALLY CLEANED GAS THEN FLUhS INTO THE BACHO
113
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FSD SYSTEMS ON INDUSTRIAL BOILERS
RICKENBACKER AIR FORCE BASE I COLUMBUS* OHIO (CONTINUED)
TOMER WHERE ADDITIONAL PARTICULATE AND PRIMARY SULFUR DIOXIDE REMOVAL TAKES PLACE.
THE BACHO SCRUBBING VESSEL IS A VERTICAL TOWER CONSISTING OF TWO SCRUBBING STAGES. CAS FLOWS
THROUGH THE TONER WHERE IT IS CONTACTED WITH A LIMESTONE SLURRY. AFTER PASSING THROUGH THE
FIRST SCRUBBING STAGE, ENTRAINED MOISTURE IS REMOVED BY A CYCLONIC TYPE MIST ELIMINATOR. THE
GAS THEN PASSES THROUGH A SECOND SCRUBBING STAGE AND A SECOND CYCLONIC MIST ELIMINATOR. THE
CLEANED GAS IS DISCHARGED TO THE ATMOSPHERE THROUGH A STUB STACK ATOP THE ABSORBER TOMER.
FINE MESH LIMESTONE IS EMPLOYED A3 THE REAGENT IN THE SCRUBBING SYSTEM. THE SCRUBBING SLURRY IS
PUMPED TO THE ABSORBER WHERE IT IS CONTACTED WITH THE FLUE GAS IN A COUNTERCURRENT FASHION,
THE SPENT SCRUBBING SOLUTION IS DISCHARGED TO THE THICKENER WHERE THE WASTE SOLIDS SETTLE OUT.
THICKENER OVERFLOW IS RETURNED TO THE MIX/HOLD TANK. THICKENER UNDERFLOW IS DISCHARGED TO A 5-
ACRE HYPALON-LINED DISPOSAL POND. THIS POND IS LOCATED APPROXIMATELY 400 FEET FROM THE ABSORBER
TOWER. CLEAR WATER FROM THE POND IS RETURNED TO THE PROCESS AS MAKE-UP WATER IN THE SLURRY TANK.
REFER TO FIGURE 14-31 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
MAR. 76 THROUGH OCT. 76 THE INITIAL OPERATION PROCEEDED IN AN OPEN-WATER-LOOP MODE BECAUSE THE
THICKENER WAS NOT VET COMPLEIELY INSTALLED. SULFUR DIOXIDE INLET CONCENTRATIONS WERE IN THE 1600 TO
2000 PPM RANGE. HIGH OXYGEN CONCENTRATIONS ALSO EXISTED IN THE FLUE GAS BECAUSE THESE OLDER* IN-
EFFICIENT BOILERS OPERATE AT 150 TO 160 PERCENT EXCESS AIR RATES. 8ULFER DIOXIDE REMOVAL EFFICIENCY
HAS IN THE LOW 90 PERCENT PLUS MANGE. EARLY PROBLEMS WERE PRIMARILY OF A MECHANICAL NATURE USUALLY
ASSOCIATED WITH START-UP. THE MAJOH START-UP PROBLEMS WERE AS FOLLOWS!
UP PROBLEMS HEHE AS FOLLONSI
1. ELECTRICAL CIRCUITS AND SYSTEM CONTROL PANEL.
Z. PUMP MALFUNCTION-SPARE PARTS SHIPMENT DELAY.
3. SEDIMENTATION BUILDUP IN THE SCRUBBER VESSEL (THIS WAS DUE PRIMARILY TO OPERATION AT
HIGHER THAN DESIGN SULIDS CONCENTRATION IN THE SCRUBBING SOLUTION BECAUSE THE THICKENER
HAS NOT YET IN SERVICE PLUS GRIT GETTING THROUGH THE LIME SLAKER GRIT REMOVAL STEP).
4. FAMILIARIZATION OF THE OPERATING STAFF WITH THE MECHANICS OF THE PROCESS.
b. I.D. BOOSTER FAN PROBLEMS. ADDITIONAL BRACING* AND EPOXY GROUTING WAS REQUIRED TO STOP
THE ELEVATED FAN CONCRETE SUPPORT FROM VIBRATING WHILE THE FAN WAS OPERATING.
NOV. 76 THROUGH JUN. 77 DOWNTIME WAS LESS THAN 51. OPERATING PROBLEMS WERE MECHANICAL- AND
CONTROL- RATHER THAN PROCESS-RELATED. FAN-RELATED PROBLEMS ACCOUNTED FOR OVER 75* OF THE ACTUAL
DOWN-TIME. THIS RESULTED FROM EXCESSIVE FAN VIBRATIONS CAUSED BY BEARING, SUPPORT, AND INSTRUMENT-
ATION DIFFICULTIES. IN APRIL 1977, THE FAN WHEEL DEVELOPED A CRACK IN THE RIM ATTRIBUTED TO
FATIGUE FROM RESONANT VIBRATION. THE FAN MAS SENT BACK TO THE MANUFACTURER, AMERICAN STANDARD, MHO
114
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGU SYSTEMS ON INDUSTRIAL BOILERS
RICKENBACKER Alk FORCE BASE; COLUMBUS* OHIO (CONTINUED)
MADE THE KtUUIRtD MODIFICATIONS. THE ORIGINAL FAN WAS RADIAL BLADE WITH RIMS, AMD A MAJOR MODIFI-
CATION HAS CHOPPING THE RIMS OFF, THtREBY REDUCING THE DIAMETER. THE FAN HAS RETURNED IN EARLY MAY
AND THE VIBRATION PROBLEM HAS SOLVED. OTHER OPERATIONS HERE RELATIVELY PROBLEM-FREE. THERE HERE
NO CORROSION, EHOSION, SCALING, OR PLUGGING PROBLEMS. THE SYSTEM BEGAN RUNNING ON LIMESTONE IN
APRIL, AS PART UF THE EPA TEST PROGRAM. LIMESTONE PERFORMED WtLL, YIELDING ADEQUATE REMOVAL.
ON JUNE 3R0, THb STEAM PLANT WAS SHUTDOWN FOR THE TIE-IN OF THE NEW NO. 8 BOILER. TIE IN WAS COM-
PLETED IN JUNE.
AUG. 77 THE ARMS BROKE OFF IN THE 25-FOOT DIAMETER THICKENER TANK, CAUSING A 30 DAY DOWNTIME.
SEP. 77 A MAKE-UP WATER BOOSTER PUMP HAD TO BE REPLACED.
OCT. 77 THb MOTOk DRIVE ON THE SLAKER BELT HAD TO BE REPAIRED. ALTHOUGH THE SLAKER IS NO LONGER
USED WITH THE LIMESTONE REAGENT, THE BELT IS USED TO CONVEY THE LIMESTONE TO THE DISSOLVING TANK.
1ST UUARFLH-197B IT WAS DISCOVERED THAT WITH A 3TOICHIOMETHIC RATIO OF 0.75 THE REQUIRED DEGREE
OF SU2 REMOVAL CAN BE ACHIEVED. THE CURRENT REGULATION LIMITS EMISSIONS TO 2.2 LBS/MM BTU HEAT
INPUT. DURING THE JANUARY BLIZZARD, SOME FREEZE-UP PROBLEMS WERE ENCOUNTERED.
DURING JANUARY THE BOILERS OPERATED 744 HOURS AND THE FGD SYSTEM OPERATED 596 HOURS YIELDING OPER-
ABIL1TY AND AVAILABILITY INDEX VALUES OF BOX. ALL DOWNTIME WAS ATTRIBUTABLE TO FREEZE-UPS DURING
BLIZZARD CONDITIONS. DURING FEBRUARY, THE BOILERS OPERATED 672 HOURS AND THE CONTROL SYSTEM OPERA-
TED 168 HOUMS. HOWEVER THE FGO SYSTEM WAS AVAILABLE 551 HOURS. THEREFORE THE OPERABILITY INDEX MAS
2SX WHILE 1HE AVAILABILITY WAS 8£X. THE ABSORBER LINES HERE THAwEO OUT FEBRUARY b, BUT DURING
FEBRUARY, THE GOVERNOR OF OHIO TEMPORARILY SHELVED POLLUTION CONTROL REGOLATIONS. THEREFORE THE
FGD SYSTEM WAS NOT OPERATED ALTHOUGH IT WAS AVAILABLE t-OK OPERATION. THE SYSTEM WAS SHUTDOWN ON
FEBRUARY 13 AND DID NUT OPERATE DURING MARCH.
2ND bUARTER-1976 SYSTEM WAS RESTARTED APRIL 10 AND WAS REPORTED TO HAVE RUN WITH A 100X OPERA-
6ILITY INDEX VALUfc FOR THE REMAINING PERIOD. PLANT REPORTED THAT ALL PREVIOUS PROBLEMS HAVE
BEEN CORRECIEO. DURING THE LAST PORTION OF THt 2ND QUARTER THE BOILER LOAD DROPPED TO ITS SUMMER
LEVEL, ABOUT 30 MM oTU/HR, AS OPPOSED (U THE MAXIMUM COLD SEASON LOAD OF 150 MM BTU/HR.
3RD QUAHT6R-1970 THE SYSTEM OPERATED WITH AN AVAILABILITY INDEX OF OVER 99.5X FOR THE
PERIOD. THE SCHUbBER WAS CLEANED AND INSPECTED DURING A 5-DAY BOILER MAINTENANCE OUTAGE AND
FOUND TO BE RELATIVELY FREE OF CORROSION AND SCALING. THE SYSTEM WAS OBTAINING ABOUT 75X 302
REMOVAL, WHICH WAS SUFFICIENT TO MEET THE REGULATION. WHILE THE BOILER IS OPERATING AT ITS REDUCED
SUMMER LOAD, FRESh MAKE-UP AIR IS BEING MIXED WITH THE FLOE GAS ENIERING THE F.D. FAN TO MAINTAIN
FULL GAS PRESSURE AND VELUCITY THROUGH THE ABSORBER.
115
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS UN INDUSTRIAL BOILERS
RICKENBACKER AIR FORCE BASE; COLUMBUS, OHIO (CONTINUED)
4TH OUARTER-1978 THE FGD SYSTEM EXPERIENCED 3b HOURS UF DOWNTIME DURING THE PERIOD FOR AN OVERALL
AVAILABILITY INDEX OF 96.HI. MUST OF THE DOWNTIME HAS CAUSED BY A BROKEN HELD ON THE FAN
HOUSING. THE NUCLEAR DENSITY CONTROL VALVE ON THE CLAKIFIER UNDERFLOW DEVELOPED PROBLEMS AND HAS
REPAIRED bY THE MANUFACTURER. THE SCRUBBER OPERATOR REPORTED THAT SHUTDOWN/STARTUP IS A SMOOTH
PROCEDURE. A CLEANOUT/MAINTENANCE SHUTDOWN IS TENTATIVELY SCHEDULED FOR LATE WINTER.
1ST OUARTER-1979 THE FGD SYSTEM DEMONSTRATED AN AVAILABILITY OF ABOUT 9S.6X DURING THE REPORT
PERIOD. PLUGGING OF THE FIRS1 STAGE LEVEL TANK LINE CAUSED A 4-DAY OUTAGE IN EARLY MARCH. DUE TO
COMPLIANCE TESTS BEING CONDUCTED* THE SYSTEM HAS BEEN OPERATING AT A HIGHER LIMESTONE FEED STOICHIO-
METRY AND ACHIEVING 802 REMOVAL EFFICIENCIES AS HIGH AS 80-65 PERCENT. THE HIGH LIMESTONE FEED RATE
MAT HAVE CAUSED THE PLUGGING PROBLEM. PLANS ARE BEING MAOE TU TEST THE SYSTEM WITH PEBBLE LIME.
THE CLEANOUT/MAINTENANCE SHUTDOWN ORIGINALLY SCHEDULED FUR LATE WINTEK HAS BEEN POSTPONED UNTIL JUNE
AND HILL ACCOMPANY AN 6 TO 10 DAYS BOILER INSPECTION.
116
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STATUS 1U APRIL 1979
SECTION 9 (CONTINUED)
PtRFORMANCt DESCRIPTION FUR OPERATIONAL FGl> SYSTEMS UM INDUSTRIAL BOlLtRS
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS bEING CONTROLLED
80URCt CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP UA1E
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR 6Y-PHOOUCT DISPOSAL
CONTROL SYSTEM COS I
TEXACO INCORPORATED
SAN ARUOf CALIFORNIA
OIL It.7* SULFUR)
317,UUO SCFM tFUIAL - 2-J HOILERS)
22,000 ACFM a, bOU f, FOR EACH Oh 22 FGD SYSTEMS
60,000 ACFM « 600 F, FOR EACH OF t F6D SYSTEMS
10,000 ACFM 4 600 f, FOR EACH OF 5 SYSTEMS
29
29
173 MA (EQUIVALENT)) 1S60 MILLION BTU/HRi TOTAL - 29 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM * 1 EQUIVALENT MN.
THIS IS BECAUSE GAS FLO* RATE IS THE PRIMARY FACTOR IN MODULE SIZ7N6.)
CE1LCOTE
SODIUM HYUKUXIUt SCRUBBING
RETROFIT
NOVEMBER, 1973
OPERATIONAL
73X 11000 PPM i INLET)
WASTEOATER TREATMENT
HALF UF THE SCRUBBER UNDERFLOW IS TREATED AND RECYCLED AS
BOILER FEEDWATEM; THE OTHER HALF tots TO NASTENATER
DISPOSAL MELLS.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
TEXACO USCS SEVERAL OIL-FIRED BOILERS AT THE SAN AROU, CALIFORNIA SITE. THE STEAM IS INJECTED
INTO OIL MELLS iu FACILITATE OIL FLOW. NINE (so MILLION BTU/HR EACH) OUT OF A TOTAL 36 STEAM
GENERATORS MILL HAVE OUCON FGO SYSTEMS. THE NINE UNITS WITH OUCON SYSTEMS ARE REPORTED SEPARATELY
REPORT. THE UTHER 29 GENERATORS ARE IN THREE DIFFERENT SIZES: T«0, EACH o 160 MILLION BTU/HRr
25 EACH » bU MILLION BTU/HR, AND FIVE, EACH d 20 MILLION UTU/HR. THE FUEL OIL HAS A TYPICAL SULFUft
CONTENT OF 1.7X.
THE FLUE GASES (80,000 ACFM FROM THE LARGE, 22.000 ACFM FROM THE INTERMEDIATE, AND 10,000 ACFM
FROM THE SMALL GENERATORS <* 600 F) ARE SCRUBBED BY FGO SYSTEMS SUPPLIED BY CEILCOTE COMPANY IN
NOVEMBER 1973. EACH BOILER IS FOLLOWED BY A UUENCHING CHAMBER AND A SCRUBBER. THE SCRUBBERS, WHICH
ARE HORIZONTAL TOnERS PACKED «ITH i IN. TELLER1TE PACKINGS, ARE OF SIZES: IS FT LONG X IS FT HIDE X
20 FT HIGH (2 LARGE UNITS), IS FT LONG X 15 FT MICE X 9.S FT HIGH (22 INTERMEDIATE UNITS), AND THE
GAS FLOWS ACROSS THE HORIZONTAL SCRUBBER WHEREAS THE LIQUID IS SPRAYED PRIMARILY IN A CROSS-CURRENT
MODE. THE ABSORBER SECTION IS FOLLOWED BY A SHORTER PACKED DEPTH WHICH SERVES AS A MIST ELIMINATOR
117
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STATUS TO APRIL 1979
SECTION S (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
TEXACO INCORPORATED* SAN ARDO, CALIFORNIA (CONTINUED)
(M-E). THE SCRUBBING LIQUOR IS A MIXTURE OF NATURAL WATER AND SOX NAOH SOLUTION. THE TYPICAL
LIOUID MASS FLUX VALUES ARE 2000-3000 LBS/HR FT2. A L/fi RATIO OF 11 GAL/1000 SCF IS USED AND PH AT
THE INLET IS B.O. THE FLUE GASES ENTER THE QUENCHERS AT 600 F WITH 1000 PPM 302 AND LEAVE THE M-E'S
AT 160 F WITH LESS THAN 2B3 PPM 302. THE SPENT LIQUOR IS SPLIT INTO TWO STREAMS, ONE RECYCLED AS
BOILER FEED WATER AFTER REMOVING FLYASH AND SOFTENING, THE OTHER IS DISPOSED OF IN WASTE-WATER
DISPOSAL WELLS.
THE ABSORBER MODULES, DOWNSTREAM DUCTWORK, STACK AND THE I.D. FAN ARE MADE OF FRP, WHEREAS THE
PACKING IS POLYPROPYLENE. THE QUENCHER SECTION IS 316 SS, WHEREAS THE SPENT LIQUOR PIPING, CAUSTIC
TANKS, AND THE CAUSTIC FEED LINES ARE MILD STEEL.
REFER TO FIGURE 14-37 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
THE MAJOR OPERATIONAL PROBLEM AREAS ARE!
1. THE QUENCHER SECTION HAS SUFFERED SEVERE CORROSION DUE TO ACID ATTACK.
2. FRP LINER DETERIORATES DUE TO MECHANICAL ABRASION DURING CLEANING OPERATIONS. IT NEEDS
OCCASIONAL RESURFACING.
3. THE PACKED BEOS ARE FREQUENTLY PLUGGED BY FLVA3H. THE OIL IN THE NATURAL LIQUOR HAS CAUSED
FOULING OF THE PACKED BEDS.
4. OCCASIONAL OVERINJECTION OF CAUSTIC HAS RESULTED IN PLUGGING OF SPRAY NOZZLES BY SCALE.
1ST QUARTER-197B DUE TO THE LOW 302 REMOVAL AND MICH MAINTENANCE COST OF THE ABOVE DESIGN, TEXACO
HAS UNDERTAKEN A TEST PROGRAM WH'ICH, IF 8UCCESFUL, MILL PHASE OUT THE PRESENT SCRUBBERS BY THE END
OF 1479. FOR MORE INFORMATION ON THE PROGRAM SEE THE OTHER TEXACO, SAN ARDO BACKGROUND INFORMATION
ENTRY IN SECTION 10 OF THIS REPORT.
2ND QUARTER-197B THE AVAILABILITY OF EACH FGD SYSTEM WAS APPROXIMATELY 94X. ON AN AVERAGEi ONE
SYSTEM WAS SHUTDOWN TWO DAYS A MONTH FOR MAINTENANCE.
3RD QUARTER-1970 THERE WAS NO MAJOR DOWNTIME DUE TO EQUIPMENT OR PROCESS FAILURE. THE SCRUBBERS
WERE DOWN' FOR SCHEDULED MAINTENANCE FOR ABOUT a HOURS PER MONTH REQUIRING ABOUT 24-MAN-HOUR3 PER
UNIT. GENERALLY DURING THIS REGULAR MAINTENANCE PERIOD THE PACKING IS REPLACED AND THE INTERNALS
INSPECTED AND CLEANED. TEXACO IS CONSIDERING CONVERTING FROM NAOH TO NA2C03 AS THE REAGENT. NO
TIMETABLE HAS BEEN ESTABLISHED FOR SUCH A TRANSITION.
4TH OUARTER-197* OPERATIONAL PROBLEMS OF CORROSION IN THE QUENCHER, AND ABRASION AND PLUGGING IN
ABSORBER CONTINUED. THE ABSORBERS ARE MOUNTED ATOP THE GENERATORS WITH ONLY 1 OR Z FT CLEARANCE.
-------
STATUS TO APRIL 197*
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
TEXACO INCORPORATED; SAN ARDO, CALIFORNIA (CONTINUED)
HENCE, THE HEAT LOSSES FROM THE RADIATION SECTION WEAKEN THE FRP SHELL OF THE ABSORBERS. IN THIS
OUAKTtK, EACH SCRUBBER HAS SHUT DOWN FOR MAINTENANCE FOR AN AVERAGE TIME OF 109 HOURS.
1ST OUAK1ER-1979 THE SCRUBBERS CONTINUED TO OPERATE THROUGH THIS PERIOD WITH HIGH MAINTENANCE
REQUIREMENTS. TYPICALLY* A SCRUBBER NOULD BE BROUGHT OFF THE LINE AS THE PRESSURE DROP INCREASED
BEYOND 1U IN. w.G. AND THE 802 REMOVAL EFFICIENCY FALLS BELOW 70X. THE INTERNALS WOULD BE CLEANED
AND SOMt 1ELLERETTE PACKING RINGS MOULD BE REPLACED. ON AN AVERAGE A SCRUBBER MOULD BE OONN FOR
tHO DAYS EVERY MONTH FOR MAINTENANCE. THIS PLANT HAD OPERATED 3ft CEILCOTE SCRUBBERS, BUT 9 ARE
BEING DISCONTINUED DUE TO POOR S02 REMOVAL AND HIGH MAINTENANCE COSTS. THESE 9 UNITS ARE BEING
REPLACED BY 3 OUCON SCRUBBERS.
119
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUN OPERATIONAL FliU SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS btlNG CONTKOLLEO
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-OP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PART1COLATE REMOVAL EFFICIENCY
SLU06E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
1EXASGOLF
GRANGER. WYOMING
COAL (U.75X SULFUR)
110,000 SCFM (TOTAL - 2 BOILERS)
600,000 LB/HR STEAM (TOTAL)
2
2
70 MM (EQUIVALENT); TOTAL - I BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM = 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
SHEMCO INC.
SODIUM CARBONATE SCRUBBING
NEW
SEPTEMBER. 1976
OPERATIONAL
90X (660 PPM a INLET)
99.jt (HOT-SIDE ESP IN/PRECEDING MECHANICAL COLLECTOR)
HASUNATEk TREATMENT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
TEXASGULF INC. HAS BEEN OPERATING A MEW SODA ASH PLANT (1 MM TONS/YR) AT GRANGER, WYOMING, SINCE
SEPTEMBER 1976. TWO BOILERS GENERATE A TOTAL OF 600,000 LBS/HR SATURATED STEAM at 300 PSIG.
ONIT EFFICIENCY IS 85X WHEN BURNING WYOMING SUB-BITUMINOUS COAL, WHICH HAS 13.97X MOISTURE, 6.43X
ASM, 0.7bt SULFUR, AND A HEATING VALUE OF IS 10,424 BTU/LB ON AN AS-RECEIVED BASIS. EACH BOILER
BURNS APPROXIMATELY 25,000 LB/HR OF THE COAL.
AFTER FLUE GASES LEAVE EACH BOILER, (156,150 ACFM d ibO F) IHEY PASS THROUGH A MECHANICAL
COLLECTOR, ESP, ECONOMIZER, AND WET SCRUBBER. (THE ECONOMIZER IS LOCATED AFTER THE PRECIPITATOR
BECAUSE THE ASH FROM WESTERN COAL IS COLLECTED MORE EFFICIENTLY WHEN THE GAS IS HOT). THE CYCLONE
AND ESP TOGETHER HAVE A PARTICULATE REMOVAL EFFICIENCY OF 99.3X. THE SCRUBBING UNITS, INSTALLED
DOWNSTREAM OF THE ECONOMIZER, w£K£ SUPPLIED BY SwEMCO IN SEPTEMBER 1976. THE SYSTEM CONSISTS OF
A QUENCHER, A SIEVE TRAY ABSORBER (15 FT DIA X 20.5 FT HIGH) AND A BYPASS. THE ENGINEERING WORK
WAS DUNE BY A.G. MCKEE * CO. FLUE 6AS IS SPRAY-COOLED FROM 350 F TO 125 F AS IT ENTERS THE
QUENCHER WITH 19 PVC NOZZLES ON FIBERGLASS HEADERS AND IS DIRECTED INTO THE CIRCULATING LIQUOR
IN THE RESERVOIR. THE GAS BUBBLES UP THROUGH THE LIUUUR, ENTERS THE ADJACENT ABSORBER, TRAVELS
UP THROUGH TWO SIEVE TRAYS, AND A MESH TYPE MIST ELIMINATOR UF TEFLON AT THE TOP. SCRUBBING
LIQUOR (700 GPM TO THE ABSORBER, 300 GPM TO THE QUENCHER) IS REC1HCULATED FROM THE SCRUBBER PUMP
TANK WHICH RECEIVES THE SCRUBBER EFFLUENT (1023 GPM). PH VALUE IS MAINTAINED Al 6.3. A CONSTANT
120
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
TEXASGULFl GRANGER, WYOMING (CONTINUED)
BLEED-OFF (350 TO 487 Lfl/MIN) CONTAINING 8X OF SODIUM SALTS IS PURGED TO A HOLDING POND FOR EVAPORA-
TION. THE CLARIFIED MAKEUP MATER (60 TO 93 GPM) IS USED FOK M-E MASHING (IS GPM) AND QUENCHER SPRAT
(45 TO 66 GPM). MAKEUP SODA ASH 301 BY WEIGHT. IS FED FROM A LIQUOR HEAD TANK TO THE SCRUBBER PUMP
TANK AT A MINIMUM RATE OF 56 LS/MIN AND MAX. RATE OF 119 LB/MIN.
EACH A8SORBER IS DIVIDED VERTICALLY INTO TWO SECTIONS, ONE OF WHICH HAS A DAMPER AT THE TOP.
THIS PERMITS CURTAILMENT OF GAS FLOW THROUGH HALF OF THE UNITS AT LOW LOADS. THE ABSORBER,
THEREFORE, CAN OPERATE AT THE DESIGN EFFICIENCY MHEN THE BOILER PRODUCES FROM 25X TO 100X OF ITS
RATED OUTPUT. THE ABSORBER BYPASS ALLOWS UP TO 25X OF THE INCOMING HOT FLUE GAS TO BE DIVERTED.
TYPICALLY, TEXASGULF USES THE BYPASS TO KEEP THE FLUE GAS IN THE STACK 10 F WARMER THAN THAT AT THE
SCRUBBER OUTLET. THE ABSORBERS ARE MADE OF CARBON STEEL nITH FLAKED GLASS LINING AND THE TKAYS ARE
OF INCONEL 625. THE HECIRCULATION TANKS ARE MADE OF FRP AND THE STACK (7.5 FT 10 X 150 FT HEIGHT)
IS DOUBLEWALLEDr INSULATED STEEL TYPE WITH FLAKED GLASS COATING BY CEILCOTE COMPANY.
REFER TO FIGURE 14-38 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
THE THROAT IN ONE OF THE QUENCHERS WAS REPLACED BY THAT OF INCONEL 625 BECAUSE OF CORROSION
PROBLEMS.
1ST QUARTER-1978 THE OUTLET DUCTWORK, WHICH WAS CORRODED DUE TO THE ACID CONDENSATE, WAS TO BE
REPLACED. THE SYSTEM OPERATED WITHOUT ANY MAJOR PROBLEMS.
2ND OUARTER-1978 DURING A MAJOR ELECTRICAL TURNAROUND, THE SCRUBBER MODULES WERE CLEANED AND
REPAIRED, SLUDGE FROM THE TRAYS WAS REMOVED AND THE OUTLET DUCTWORK WAS REPLACED BY 304 S3. THE S02
MEASURING INSTRUMENTS WERE BEING UPGRADED BY LEAK SIEGLEU, THE SUPPLIER.
3RD QUARTEH-1978 DURING THE REPORT PERIOD, THE BOILER AND FGD SYSTEM WERE OOnN TWICE FOR
SCHEDULED INSPECTION OUTAGES. DOWNTIME WAS 4 DAYS FOR ONE MODULE AND 2 DAYS FOR THE OTHER. SOME
MINOR PLUGGING WAS OBSERVED DURING THE INSPECTION PERIODS.
4TH QUARTER-19/a DURING THIS PERIOD, OUTAGE OCCURRED UN NO. 2 BOILER FUR A DAY IN OCTOBER. IN
NOVEMBER, THE NO. 2 BOILER WAS DOWN FOR SCHEDULED INSPECTION FOR 2.5 DAYS. DURING THIS TIME, THE
TRAYS AND INTERIOR OF THE SCRUBBER WERE CLEANED. SOME OF THE PIPING LEADING TO TRAYS WAS REPLACED.
SOME OF THE PLUGGED NOZZLES IN THE QUENCHER WERE EITHER CLEANED OR REPLACED. THE RELIABILITY INDEX
VALUE FOR BOTH SCRUBBERS WAS ABOUT 100S.
121
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STATUS TO APRIL 1979
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
TEXASGULF? CHANGES, NYOMING (CONTINUED)
1ST QUARTER-1979 DURING THE PERIOD, BOTH BOILERS HERE OOMN FOR ONE DAY EACH IN MARCH FOR
SCHEDULED MAINTENANCE. ON THESE DAYS, THE ABSORBER DRAIN LINES NERE EXTENDED. THESE LINES (10 IN
OIA, INCONEL 625) HERE NOT IMMERSED PROPERLY IN THE RECIHCULATION TANK LIQUOR. HENCE, SOME OF THE
FLUE SAS MOULD BYPASS INTO THE RECIRCULATION TANK WITH THE DROP OF LIQUID LEVEL IN QUENCHER.
IN ADDITION, A NEM INSTRUMENTATION STRATEGY NILL BE INCORPORATED SHORTLY. SO FAR, THE
RECIRCULATION PH HAS BEEN MEASURED BY ANALYZING SAMPLES TAKEN ONCE EVERY S HOURS. THE NEW SCHEME
HILL HAVE INDICATOR/CONTROLLERS FOR BOTH DENSITY AND PH OF RECIRCULATION LIQUOR. THE APPROXIMATE
SET POINTS MILL BE 1.08 AND 6.5 RESPECTIVELY. DENSITY NILL BE THE PRIMARY PARAMETER CONTROLLING THE
FLO* OF MAKEUP NA4C03 LIQUOR. ONCE THE DENSITY IS STABILIZED, THE PH CONTROLLER NILL SUPERSEDE THE
DENSITY CONTROLLER IN ADJUSTING THE MAKEUP LIQUOR- FLON RATE.
THE RELIABILITY VALUES FOR BOTH THE SCRUBBERS WERE 100* FOR THE PERIOD.
-------
STATUS TO APRIL 1979
SECTION 10
OI-SIS* iNFUrtftAllUN FOK UNO!-* CUNSTKUCIION FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
IHSTALLATIUN LOCATION
SUUKCt CHAKACTEKISUCS
SUUMC6
NUMBtK (Jf SEPARATt FSJ UNITS
NUMH6R OF DUILEMS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VtNUOK
CUNIHUL PKOUSS
N£« / RtTHOFIT
START-UP OAIE
CONTROL SYSTEM STATUS
SU2 REMOVAL EFFICItNCiT
PARTICULATE REMOVAL EFFICIENCY
SLUDGE UR dY-PRUDUtT UlSPOSAL
CUNTRUL SYSTEM COST
ARCU/POLYMERS, INC.
MONACA, PENNSYLVANIA
COAL (3.US 9ULFOR)
30b,000 SCFM CTUTAL - 3 BOILERS)
900,000 LB/HR STEAM it 700 PSIG AND 700 F.
3
3
152 Hw (fcl)UIVALENT)» TOTAL - 3 BOILERS
(FOR TnIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM * 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
RETROFIT
JUNE, 1900
CONSTRUCTION
90X (l.dOO PPM H INLET)
99.SX
OEftATERED SLUKRY TU LANDFILL
FLYASH ADDITION TO OtNATEKEO CA303/CA804 FILTER CAKE,
THEN TO LANDFILL.
SEE SECTION 13 FON DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AMCO/PULYMERb, UEAVER VALLEY PLANT LOCATED NEAM hUNACA, PENNSYLVANIA, AftARDEO A CONTRACT
IN JUNE 1970 TO FMC TO INSTALL THREE FOUR-STAGE DISC CONTACTOR SCRUBBERS. THE SYSTEM
MILL UTILIZt THE FMC DOUBLE ALKALI PROCESS WITH 1HE SCRUBBERS SHARING A COMMON REGENERATION UNIT.
THREE BOILEKS GENERATE PROCESS STEAM USED TO OPERATE A TURBINE NHICH GENERATES 1« TU 20
KVA (CAPACITY 3& KVA). THE STtAM HATE FOR EACH BOILER IS 300,000 LB/HR i 700 PSIG AND 700 F.
TOTAL HEAT INPUT IS 1100 MM BTO/HR. PULVERISED COAL (3.0k SULFUR) IS THE FUEL USED NITH AN ASH
.CONTENT OF IbX. IT HAS A HEAT VALUE OF 12,000 8TU/L8 <* 4-6X MOISTURE CONTENT. THE COST FOR THE
COAL IS SU.04/TON.
KOPPERS ESP'S PRLCLEAN THE FLUE GAS BEFORE II ENTERS THE SCRUBBERS AT A RATE OF IbSrOOO ACFM
(EACH) 4 400 F. THE INLET CONCENTRATION OF PAM1CULATES TO THE ESP'S IS 5 GR/SCF. GAS ENTERING THE
SCRUBBERS NlLL HAVE AN 302 CONCENTRATION OF APPROXIMATELY 1800 PPM. THE SCRUBBERS (17 FT OIA X 62
FT HEIGHT) KITH 4 DISCS AND DONUTS (EACH) MILL BE CONSTRUCTED OF CARBON STEEL HITh FLAKE GLASS
LINING (CEILCOTE) AND THE MIST ELIMINATORS (1 FOR EACH SCRUBBER) ARE SINGLE STAGE CHEVRON PAD
TYPE CONSTRUCTED OF PVC PLASTIC WITH PROVISIONS FOR A SECOND STAGE. EACH SCRUBBER WILL EXHAUST THE
TREATED FLUE « 13S F TU INDIVIDUAL INSULATED STACKS LINED WITH FRP. ASSOCIATED HITH EACH STACK IS A
123
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STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOH UNDER CONSTRUCTION FGD SYSTfcMS ON INDUSTRIAL BOILERS
ARCO/POLYMEKS* INC.; MONACA, PENNSYLVANIA (CONTINUED)
RCHEATER USING STEAM HEATED AMblENT A Ik KITH A HEHEAT OF iS H. THE SCNUBBEK MILL HANDLE IOOX OF THE
FLUE CASES WITH BY-PASS ONLY AVAILABLE FOR EMERGENCIES. THE L/C RATIO FOR THE SCRUBBERS IS APPROXI-
MATELY 10. THE MESTINGHOuSE P.O. FANS "ILL BE OF CARBON STEEL AND PUMPS OF RUBBER-LIMED CARBON
STEEL. THE DUCTING LEADING TO AND FROM THE SCRUBBERS MILL BE OF FIBERGLASS LINED (CEILCOTE) CARBON
STEEL AND F«P, RESPECTIVELY.
CALCIUM SULFATE WASTE GENERATED AT A KATE OF 17*500 LB/HR KITH 55* SOLIDS CONTENT *ILL BE
HAULED BY TRUCK TO A DISPOSAL SITE.
REFER TO FIGURE 14-2 IN SECTION 10 FOR A DETAILED PROCESS FLON DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1978 CONSTRUCTION IS TO BEGIN IN SEPTEMBER 1978.
«TH OUARTER-197B CONSTRUCTION OF THE PLANNED FGD SYSTEM STARTED IN SEPTEMBER 1976.
1ST OUARTER-1979 THE CONSTRUCTION OF THE PLANNED FGO SYSTEM STILL IN EARLY STAGES, CONTINUES
A3 SCHEDULED.
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STATUS 10 APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LUCAT1UN
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UMTS
NUMBER OF TOILERS bEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENUUK
CONTROL PROCESS
MEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
HATER MAKE-UP
3LUOSE OR bY-PROOUCF DISPOSAL
CONTROL SYSTEM COST
CHEVNON U.S.A. INC.
BAKEhSUELD, CALIFORNIA
OIL (1.1* SULFUR)
146,000 SCFM (TOTAL - 12 BOILERS)
ISG.OOO ACFM a 500 F, FUR EACH OF 2 FGO SYSTEMS
2
12
73 MM (EUUIVALtfcl)T 1UTAL - 12 bOlLEMS
600 KM Blu/HR (TOTAL » 12 BOILtKS) 6 BOILtRS/FGD SYSTEM)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2UOO SCFM x 1 EQUIVALENT MM.
THIS IS BECAUSE GAS KLUnt KATE IS THE PRIMARY FAC10R IN MODULE SIZING.)
KOCH ENGINEERING
SODIUM CAttbONATE SCRUBBING
RETROFIT
JULY, 1979
CONSTRUCTION
90Z (660 PHM ol INLET)
12 - 13 GPM
NASTEftATEK TREATMENT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
CHEVRON U.S.A. HAS AN OIL SITE AT BAKERSFIELO, CALIFORNIA. THERE ARE ABOUT SO STEAM GENERATORS
HHICH BURN 1.1X CftUOE OIL. EACH GENERATOR IS RATED AT SO MM EtTU/HR. THE STEAM IS USED FOR ENHANCED
OIL RECOVERY FROM THE OIL NELLS.
A CONTRACT HAS AHAROEU TO KOCH ENGINEERING TO CONSTUCT TftO MORE FGD SYSTEMS. THE DESIGN MILL BE
SIMILAR TO EXISTING NA2C03 SCRUBBING UNITS. REFER TO SECTION 9 OF THIS REPORT FOR UETAILS ON THESE
F6D SYSTEMS.
OPERATING HISTORY
4TH OUARTER-1978. THE FGD SYSTEMS ARE UNDER DESIGN. THE CONSTRUCTION MILL START IN JANUARY
1979. THE START-UP IS STILL EXPECTED TO BE APRIL, 1979.
1ST OUARTER-1979 CONSTRUCTION HAS STARTED ON 30TH THE FGD SYSTEMS DURING THIS PERIOD. SOME
DELAYS IN DELIVERY OF STEAM GENERATORS AND ANCILLARY EQUIPMENT HAVE PUSHED THE EXPECTED STARTUP TO
JULY 1979.
125
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STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INT-URMAUON FOR UNDER CONSTRUCTION FUO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOOMCC CHARACTERISTICS
SOOMCE KATlNb
NOMBER Qf SEPARATE KiU ONUS
NUMBER OF BOILERS BEING CONTROLLED
SOOMCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEH / R6THUFIT
START-OP OATfc
CONTROL SYSTEM STATUS
SU2 HEMUVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
bRISSOM AIR FORCE BASE
BUNKtrt HILL, INDIANA
COAL (3.UX - J.bX SULFUR)
ja.OOO SCKh (IOTAL - i BOILERS)
1
3
16 M(N (EUUIVALENT)i TOTAL - 1 BOILERS
(FUR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM * 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLO* RATE 13 THE PRIMARY FACTO* IN MODULE SIZING.)
NEPTONE AIRPOLi INC.
DOUBLE ALKALI (CONCENTRATED)
1 NEM i RETRO
NOVEMBER, 1479
CONSTRUCTION
DEwAIERED SLURRY 10 LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT GR1SSOM AIR FORCE BASE NEAR BUNKER HILL, INDIANA, THE AIR FORCE HAS INITIATED A PROJECT MHICH
INCLUDES THE ERECTION OF A NEM 6S.OOO Ltf/HR COAL-FIREO BOILEH AND AN FGD SYSTEM FOR THE NEH UNIT AND
TWO EXISTING 40*000 Ld/riR COAL-FIRED UNITS. THE NAVY IS THE MILITARY CONSTRUCTION AGENT FOR THE
PROJECT AND ARNOLD M. DIAMOND HAS THE OVERALL CONSTRUCTION CONTRACT. COAL FOR THE BOILERS IS
TYPICALLY SOUInER* INDIANA. nIGH SULFUR COAL MllH A SULFUR CONTENT OF 3-3.5 PEfcCtNT AND AN AVERAGE
HEATING VALUE OF 11,500 BlU/Ld. THE BOILERS NORMALLY OPERATE wITH ABOUT 40X EXCESS AIR.
CONSTRUCTION HAS BEGUN 0.1 A N£« CONCENTRATED DOUBLE ALKALI FGO SYSTEM SUPPLIED BY AIRPOL
INDUSTRIES. THE SYSTEM *ILL HAVE A GUARANTEED MAXIMUM su« OUTLET CONCENTRATION OF
1.8 LB/MILLION UTU AND A MAXIMUM PARTICULAR CONCENTKATIUN OF 0.171 LB/MILLION BTU. FLUE GAS FROM
EACH BOILER MILL PASS IriROUGri A MECHANICAL COLLECTOR. THE GAS FROM ALL THREE BOILERS HILL THEN BE
MANIFOLOEO TOGETHER ANO PASS THROUGH TWO PARALLEL ABSORBER TRAINS. EACH CAPABLE OF HANDLING SOS
OF THt FLUE GAS. THE MAXIMUM FLOW RATE IS 00.473 ACFM 4 4faJ F.
THE AIRPOL SYSTEM CONSISTS OF i PARALLEL Jib S3 VENTURI 3CRUBdERS> EACH FOLLOWED BY A
CYCLONIC SEPARATOR AND STUB STACK. THERE IS A COMMON RECIRCULAT10N TANK MADE OF 316 STAINLESS
STEEL AND TNU 600 GPM RUBBER-LINED RECIRCULAUON PUMPS. THE L/G RATIO IS IS GALLONS/1000 ACFi
KITH A SLURRY INLET TEMPERATURE OF 13b F AND A PH OF BETrtEEN S ANO 7. RECIRCULAT1UN PIPES MILL
«E MADE OF FRP.
A 100-eOU GPM BLEED STREAM FROM THE RECIRCULATION TANK GOES TO A 316 SS LIME REACTION TANK
HHERE THE 30DIUM SULFITE/SULFATE IS REACTED WITH SLAKED LIME PRODUCING CALCIUM SULFATE ANO
126
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STATUS TO APRIL 1979
SECTION 10 (CONTINUED]
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS
GKISSOM A1H FORCE (JASE» BUNKER HILL* INDIANA (CONTINUED)
REGENERATING THE SODIUM HYDROXIDE. FROM THE REACTION TANK THE MIXED SLURRY FLONS TO A THICKENER/
CLAMIFIEK, WHERE INSOLUBLE CALCIUM COMPOUNDS ARE SEPARATED FROM THE CLEAR OVERFLOW CONTAINING THE
REGENERATED NAOri. THE CLARIFIES uVERFLOw IS RETURNED TO THE ABSORBER* WHILE THE UNDERFLOW IS
RtACTtO ONCE AGAIN KITH LIME IN A PIPELINE MIXER TO PRECIPITATE ANY RESIDUAL SULFITE AS SULFATE.
THE SLUH*Y IS THEN FILTERED IN A ROTARY FILTER* AND THE FILTRATE IS RETURNED TO THE REACTION TANK.
THE FILTER CAKE WILL BE LANOFILLED. THE TANKS MILL BE MADE OF 316 S3 AND THE PIPING OF FRP. THE
LIME STORAGE TANK AND SLAKER MILL BE CARBON STEEL.
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STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDE* CONSTRUCTION FUO SYSTEMS ON INDUSTRIAL BOILERS
INLAND CONTAINER CORPORATION
NEW JOHNSONVILLE, TENNESSEE
MOOOX5PENT LIvlUOR l<3.0» SULFUR)
194,000 SCFM (t BOILER)
256>000 ACFM a 400 F.
I
1
7? MM (EQUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM s 1 EQUIVALENT MN.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
NhPTUNE AIRHOL INC.
AMMONIA SCRUBBING
RETROFIT
MAY, 1979
CONSTRUCTION
90S (OES1GN)
95.71 (DESIGN)
CLOSED LOOP - UNTREATED SCRUBBING LIUUOR KECYCLEO
AMMONIUM SULFITE/BISULFITE RECYCLED TO PULP PROCESS
RECOVERED SOLUTION USED AS MAKE-UP TO COOKING LIQUOR
IN THE PULP MILL.
SEE SECTION 13 FOR OETAILEO ECONOMIC INFORMATION
INSTALLATION
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO ONlfS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULAR H6MOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
BACKGROUND INFORMATION
THE INLAND CONTAINER CORPORATION IN NEW JOHNSONVILLE, TENNESSEE* IS A MANUFACTURER OF MEDIUM
GRADE CORRUGATED PAPER. THE MILL HAS A 8ABCOCK & MlLCOX BOILER FIRING SPENT LIUUOR AND 90S WOOD
NASTE (<3.0X SULFUR) AT A RATING OF 300,000 LB/rIK STEAM MlTH 542 MILLION BTU/HR HEAT INPUT.
AN AIRPOL DESIGNED AMMONIA SCRUBBING SYSTEM "ILL BE UStU TO CONTHOL SO* AND PARTICULATE
EMISSIONS. A VENTURI SCRUBBER AND SEPARATOR/ABSORBER COMBINATION MILL HANDLE A FLUE GAS VOLUME
OF 250,000 ACFM 4 400 F NllH 24S MOISTURE CONTENT. THE VENTURI SCRUBBER 18.75 FT DIA X 24 FT
HEIGHT) AND SEPARATOR/ABSORBER (21 FT DIA X 66 FT HIGH) «ITH A MIST ELIMINATOR WILL BE CONSTRUCTED
OF 316L SS. THE PRESSURE DROP ACROSS THE VENTURI MILL BE 20 IN M.G. THE L/G RATIOS FOR THE VENTURI
SCRUBBER ANO SEPARATOR/ABSORBER MILL BE 10 AND S GAL/1000 ACF RESPECTIVELY. STUB STACK (10.75 FT
OIA X 43 FT HEIGHT) AND RECIRCULATION TANK MILL BE 316L SS WHILE FO FAN MILL BE CANBON STEEL.
THE COST OF THE VENTURI SCRUBBER, SEPARATOR AND STUB STACK IN 1970 DOLLARS IS $350,000.
128
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STATUS TO APRIL 1979
SECTION 10 (CONTINUE)
DESIGN INFORMATION F UK UNDER CONSTRUCTION FGD SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LUCAUUN
SOURCE CHARACTERISTICS
SOUKCfe RATING
NUMBER OF SEPARATE F(JO UMTb
NUMBER UF dUILEKS BEING CONlftClLLEL)
SOURCE CAPACITY
CONTROL SYSfE* VENOUK
CONTROL PROCESS
nlEN / RETKUFiT
START-UP DATE
CONTROL SYSTEM STATUS
SU
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STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BOILERS
MOBIL OIL COMPANY; BUTTONNILLOH* CALIFORNIA (CONTINUED)
OPERATING HISTORY
«TH QUARTER-197B THE START-UP DATE HAS BEEN EXTENDED TO FEBRUARY OF 1979, DUE TO DELAYS IN
AWARDING SEPARATE CONTRACTS FOR PIPING AND OTHER WORK.
1ST OUARTER-1979 CONSTRUCTION HORK IS IN THE FINAL PHASES ON THE 7 FGD SYSTEMS. STARTUP IS
NOW PROJECTED TO BE EARLY APRIL 1979.
130
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STATUS TO APRIL 1979
SECTION >0 (CONTINUED)
DESIGN INFORMATION FOR ONOER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBfcK Of-' SEPARATE FGU UNITS
NUMBER OF bUILERS bfclNG CONIKULLEU
SOURCE CAPACITY
CONTROL SYSTfch VENUUR
CONTROL PROCESS
MEN / RETROFIT
START-UP OATt
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
CONTROL SYSTEM CUST
PHILLIP MOKRIS, INC.
CHESTERFIELD, VIRGINIA
CUAL II.HI SULFUR OESIG.M)
39,000 SCFM (TOTAL - 1 BOILER)
bb.OOO ACFM o> i50F, 2(10,0(10 LB/HR STEAM
1
1
20 Mw (EQUIVALENT); 237 MM BTU/Hk
(FOR THIS REPuKl, UNLESS STATED OTHERWISE,
-------
STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BOILERS
PHILLIP MORRIS^ INC.I CHESTERFIELD. VIRGINIA (CONTINUED)
MADE OF FRP AND THE NOZZLES 16 PER STAGE) AkE 316 STAINLESS STEEL. ALL PUMPS ARE RUBBER-LINED.
RECIRCULATION LINES ARE 316 38 AND THE MIST ELIMINATOR IS POLYPROPYLENE.
REFER TO FIGURE 14-30 IN SECTION 14 FOR A DETAILED PROCESS FLOrt DIAGRAM OF THIS SYSTEM.
132
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STATUS TO APKIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FUR UNOEK CONSTRUCTION FliD SYSThMS ON INDUSTRIAL UUILEHS
INSTALLATION NAME
INSTALLATION LUCAIIUN
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER UF SEPARATE FGO UNITS
NUMBER UF BOILERS hEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
SANTA FE ENERGY COkP.
BAKERSFIELU, CALIFORNIA
OIL (1.5X SULFUR)
70,000 SCFM (1U1AL - 8 BOILERS)
310 MM BTU/HH (TOTAL - a BOILERS)
133,«00 ACFM 01 bbO F U01AL - « BUILER3)
1
B
35 MW (EQUIVALENT)I TOTAL - a STEAM GENERATORS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 8000 SCFM « 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLUM RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEW
MAY, 1979
CONSTRUCTION
9bX (710 PPM a) INLET)
71 UPM
DEWATERED SLURRY TO LANDFILL
SEt SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
SANTA FE ENERGY CORP., FORMERLY CHANSLON WESTERN OIL co,, AS AN ENHANCED OIL RECOVERY SITE NEAR
BAKEKSFIELO, CALIFORNIA. THE OIL PRODUCTION INVOLVES INJECTION OF STEAM IN THE UlL WELLS, DECANTA-
TION OF OIL FROM OIL-WATER MIXTURE, AND PURIFICATION OF UlL IF NECESSARY. THE CRUDE OIL PRODUCED BY
THIS PROCESS HAS APPROXIMATELY l.bX SULFUR. A PART OF THE OIL PRODUCED IS USED AS A FUEL FOR THE
BOILERS WHICH GENERATE THE NECESSARY PROCESS STEAM. THERE ARE SEVERAL BOILERS UN THE SITE, MANY OF
rtHICH ARE RATED AT SO MM BTU/HR. THE BOILERS ARE CLASSIFIED AS "STEAM GENERATORS" BECAUSE OF THEIR
SIZE, PORTABLE NATURE, AND LONtR DUALITY OF STEAM (80S) PRODUCED.
EIGHT OF THE STEAM GENERATORS, MITH A TOTAL HEAT OUTPUT UF 310 MM BTU/HR, ARE BEING CONSTRUCTED
ALONG WITH A NEW, FMC DOUBLE-ALKALI ICUNCENIRATEO) FGO SYSTEM. THE FLUE GASES FROM THE EIGHT STEAM
GENERATORS ARE MANIFOLDED TOGETHER (133,400 ACFM d 550 F), AND PASS THROUGH A PH£SATUhATOK AND AN
A6SOMBER (IS FT DIA X 35 FT HIGH) WITH FOUR OISC-AND-DONUT TRAYS. THE RECIRCULATION LIUUOR PH IS
MAINTAINED AT 6.S, AND A L/G RATIO OF 8-10 GAL/1000 SCF IS USED. THE FLUE GASES PASS THROUGH A
CHEVRON MIST ELIMINATOR TO A STACK. A CONSTANT BLEED-OFF STREAM (60 GPM) IS TAKEN 10 THE REACTION
TANK NHERE IT REACTS WITH LIME SLURRY TO REGENERATE SODIUM HYDROXIDE. THE CALCIUM SULFIU/SULFATE
SLURRY IS SENT TO THE THICKENER, VACUUM FILTER AND LANDFILL.
REFER TO FIGURE 14-32 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM UF THIS SYSTEM.
133
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STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGO SYSTEMS-ON INDUSTRIAL BOILERS
SANTA FE ENERGY CORP.I flAKERSFI£LD» CALIFORNIA (CONTINUED)
OPERATING HISTORY
3RD OUARTER-1978 THE PLANT IS HEARING COMPLETION OF CONSTRUCTION. THE COMMISIONING ACTIVITIES
MILL BE UNDERWAY SOON.
«TH QUARTER-1978 CONSTRUCTION MORK HAS BEEN HELD UP PRIMARILY DUE TO DELAYS IN SHIPMENT OF
ELECTRIC CONNECTIONS AND EQUIPMENT.
1ST QUARTER-1979 THE FGO SYSTEM CONSTRUCTION IS EXPECTED TO 96 COMPLETED BY THE END OF THIS
QUARTER EXCEPT FOR THE INSTALLATION OF MANIFOLDED DUCTMORK. STARTUP OF THE GENERATORS MAY FURTHER
OELAY THE FGD STARTUP DATE.
134
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STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION. FOR UNDER CONSTRUCTION KGU SYSTEMS Urt INDUSTRIAL BUILtRS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
suuHCt RATING
NUMBER Of SEPARATE KGU UNITS
NUMBER OF BOILERS HElUG CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP JATE
CONTROL SYSTEM STAtUS
902 REMOVAL EFFICIENCY
SLUDGE OH BY-PRODUCT OISPUSAL
CONTROL SYSTErt CUSI
ST. JOE ZINC CO.
MUNACA, PENNSYLVANIA
CUAL (2.iX - «.SX SULFUR)
ia2,000 SCFM (TOTAL - 1 BOILER)
243,000 ACFM » 300 F.
1
t
bU Hn CELECTWIC PQrtEKI NOMINAL PEAK CAPACITY)
IFOR THIS REPORT, UNLESS STAIEO OTHERWISE. 2000 SCFM s 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOM «AtE IS THE PRIMARY FACTOR IN MUOULE SUING.)
ttUHEAU OF HlntS
CITHAIt PROCESS
WETHOF1T
APKILr 1979
CONSTRUCTIUN
90»»
REGENERAttLt - ELEMENTAL SULFUK PRODUCT
SEE SECTION 13 FOK OETAILEO ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN THE SUMMER UF 19/7, CUN3UUCT ION bEGAN AT MONACA, PA. ON A CITRATE PROCESS ItJUkEAU OF MINES)
F6D SYSTEM FOR UNt OF I HE TnO 60-Mrt (NOMINAL PtAK CAPACITY) bUILEHS UF THE GEORGE F. NEATON POHEA
PLANT USED UY ST. JOE ZINC CO. TO GENERATE ELECTRICITY FOR A 2INC SMELTER. ST. JOE HAS A RECIPROCAL
AGREEMENT MlTrt THE LOCAL UTILITY COMPANY, QUUUESNE LIGHT, MHEREdY ST. JOE CAN SELL UP TO 2S-MW OF
ITS TOTAL 120-MM CAPACITY TU UUUUESNE. IN RETURNi ST. JOE CAN BUY SUFFICIENT POWER TU MAINTAIN
ELECTRO-SMELTING OPERATIONS IN THE EVENT OF AN EMERGENCY. THIS FGO SYSTEM IS THE FIRST SMALL COM-
MERCIAL si/t EXPERIMENTAL CITRATE CONTROL SYSTEM BEING BUILT FOR REMOVING SULFUR OIOXIOE FROM
CUAL-F1RE1) HUMER PLANT STACK GAS.
UNDER A S12.7 MILLION CUST-SHARING AGREEMENT BETWEEN THE BUREAU AND ST. JOE, COSTS FOR TESTING
THE CITRATE PROCESS FOR A FULL YEAR ARE BEING SHARED ABOUT bU-bO. THE CITRATE PROCESS MAS DEVELOPED
BY THE oUREAU IN THE ISbv'S TO HELP CURB SULFUR DIOXIOE EMISSIONS FROM dASE METAL SHELTERS.
THE CITRATE PROCESS DERIVES ITS NAME FROM THE MATER SOLUTION OF SODIUM CITRATE AND CITRIC ACID
USED AS A BUFFERING AGENT UURING SU2 ABSORPTION FROM THE FLUE UAb. THE ST. JOE PLANT IS DESIGNED
TO TREAT 231.000 ACFH « 300 F FLUE GAS GENERATED BY FIRING PULVERIZED COAL POSSESSING 2.5-4.SX
SULFUR. 1SX ASH AND AN HHV OF APPROXIMATELY 12,500 BTU/LB. THE PLANT MILL MEET THE PENNSYLVANIA AIR
DUALITY REGULATION UF 0.69b LBS OF S02 PER MILLION BTU HEAT INPUT TO THE BOILER.
THE DEMONSTRATION PLANT, DESIGNED WITH A bOZ TURNDUwN RATIO, UTILIZES A SINGLE PROCESS TRAIN
CONSISTING UF GAS COOLING AND SU2 ABSORPTION, SULFUR PRECIPITATION, SULFUR RECOVERY, SODIUM SULFATE
135
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STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTKUCT10N FGD SYSTEMS ON INDUSTRIAL BOILERS
ST. JOE ZINC CO.; MUNACA, PENNSYLVANIA (CONTINUED)
REMOVAL* AND H2S GENERATION UNIT OPEKA1IONS. FLUE GAS FROM AN EXISTING PRECIP1TATOK ENTERS AN
EOUCTOR TYPE VENTURI SCRUBBER* THROUGH AN F.D. FAN WHERE. IT is COOLED FROM 300 F TO 120 F BY BOTH
HUMIDIFICATION AND SENSIBLE COOLING. A BLEED STREAM IS TAKEN FROM THE VENTUKI RECYCLE STREAM TO
PREVENT BUILD-UP OF ASH AND ACIDS. THIS STREAM FLOWS THROUGH A PACKED COLUMN COUNTERCURRENT TO A
STREAM OF AIR WHERE 802 IS STRIPPED FROM THE LIQUID AND RECYCLED TU THE SCRUBBER. THE STRIPPED
LIQUID IS DISCHARGED TO AN AGITATOR TANK WHERE IT IS NEUTRALIZED WITH LIME. FROM THERE* IT IS PUMP-
ED TO THE EXISTING ASH POND.
THE COOLED* CLEANED FLUE GAS THEN ENTERS A PACKED AbSOKBEH (26 FT DIA X 65 FT HI6H) MADE OF
FLAKE-GLASS LINED, CARBON STEEL, WHERE IT FLOWS UPWARD COUNTERCURRENT TO THE DESCENDING CITRATE
SOLUTION. MORE THAN 90X OF THE S02 IS REMOVED FROM THE FLUE GAS, MAINLY AS SULFUROUS ACID, IN THE
PRESENCE OF THE CITRATE BUFFER SOLUTION. CITRATE SOLUTION LEAVING THE ABSORBER FLOWS IN SERIES
THROUGH TWO TANDEM REACTORS IN THE SULFUR RECOVERY SECTION. THE CITRATE RECYCLE STREAM FROM THE
REGENERATION SECTION IS COOLED FROM HI F TO 123 f BY HEAT EXCHANGE WITH RIVER WATER BEFORE ENTERING
THE ABSORBER.
SULFUR IS FORMED 8Y CONTACTING THE S02-RICH SOLUTION WITH AN H2S-C02 GAS FROM THE HYDROGEN
SULFIDE GENERATING UNIT. OFF-GAS WHICH IS MAINLY COS WITH SMALL QUALITIES OF H2S, CS2, AND COS FROM
THE REACTOR SYSTEM IS SENT TO THE BOILER FIREBOX FOR INCINERATION VIA A SURGE DRUM. CRYSTALLINE
SULFUR IS FORMED IN THE REACTORS AND SULFUR SLUKRY FLUWS TO A DIGESTER WHERE A SMALL STREAM OF
S02-RICH SOLUTION FROM THE ABSORBER IS REACTED WITH ANY DISSOLVED OR ENTRAINED H2S IN THE SLURRY
ENTERING THE DIGESTER. FROM THE DIGESTED THE SLURRY FLUWS TU THE SULFUR FLUTATIUN TANK. SEPARA-
TION OF THE SULFUR FROM THE BULK OF THE SOLUTION IS ACCOMPLISHED BY FLOTATION WITH AIR. SULFUR
FROTH, CONCENTRATED TO ABOUT 101 SOLIDS, IS SEPARATED FROM THE TOP OF THE SOLUTION AND FLOWS TO THE
SULFUR SLUKRY TANK.
REGENERATED CITRATE SOLUTION IS DRAWN FROM THE BUT10M OF THE FLOTATION TANK AND RETURNED TO THE
ABSORBER. SULFUR IS SEPARATED FROM THE REMAINING SOLUTION BY HEATING THE SLUKRY TO ABOUT 200 F WITH
STEAM lit A SHELL-AND-TUdE EXCHANGER. THE MULTEN SULFUR AND TMt CITRATE SOLUTION AfcE SEPARATED BY
GRAVITY IN A PRESSURUEO, STEAM-JACKETED DECANTER VESSEL. THE MULTEN SULFUK IS DISCHARGED
CONTINUOUSLY FROM iHt BOTTOM t»Y INTERFACE LEVEL CONTROL AND FLOWS '0 A HEA1ED STORAGE TANK. THE
CITRATE SOLUTION LEAVES THE TUP OF THE DECANTER AND RETURNS TU THE F1HST REACTOR.
SODIUM SULFATE OECAHYORAIE, PRODUCED BY THE NEUTRALIZATION UF CAUSTIC WITH A SMALL AMOUNT OF
GENERATED SULFUHIC ACID, IS REMOVED FROM CITKATE SOLUTION BY VACUUM CRYSTALLIZATION.
GENERATION OF H2S GAS IS ACCUMPLIShtU USINb RECOVERED ELEMENTAL SULFUR, A GASEOUS REDUCTANT
(METHANE) AND TUHblNE EXTRACTION STEAM AS CUNSUMPTIVt FEED STOCKS IN A FIXED-BED CATALYTIC REACTOR.
REFER TO FIGUKE J«-3« IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTOKY
136
-------
STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION F6D SYSTEMS UN INDUSTRIAL BOILERS
ST. JOE ZINC CO.? MONACA. PENNSYLVANIA (CONTINUED)
3RD OUARTER-1978 ALL MAJOR EQUIPMENT HAS BEEN INSTALLED; INSTALLATION OF PIPING AND WIRING IS IN
PROGRESS.
4TH OUARTER-1976 THE PLANT REPORTED THAT INSTALLATION OF PIPING AND MIKING IS STILL IN PROGRESS.
START-UP HAS BEEN RESCHEDULED FOR MARCH 1979.
1ST OUARTER-1979 INSTALLATION OF PIPING AND WIRING IS 65X COMPLETE. SEVERE HEATHER CONDITIONS
HAVE DELAYED THE START-UP OPERATIONS TO THE END OF APRIL 1979.
137
-------
STATUS TO APKIL 1 FT DIA X £0 FT HtltMTJ WILL TKEAI
-------
STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS UN INDUSTRIAL BOILERS
STRATHMORE PAPEK COMPANY> wORONOCOi MASSACHUSETTS (CONTINUED)
FABRIC FILTER MILL HAVE A COAL 1AR EPOXY LINING.
THE DRY WASTE GENERATED FROM THE SYSTEM WILL BE TRUCKED TO A DUMPING AREA.
OPERATING HISTORY
1ST QUARTER 1979 CONSTRUCTION HAS BEGUN FOR THE DRY SCRUBBING SYSTEM* SLATED FOR STARTUP
IN MAY 1979.
139
-------
STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION F60 SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
80UKCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEH / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COS1
SUN PRODUCTION COMPANY
FELLOWS, CALIFORNIA
OIL (1.4X SULFUR)
6>000 SCFM 112,000 ACFM a) 570 F)
1
1
C-E NA1CO
SODIUM HYDROXIDE SCRUBBING
RETROFIT
MAY, 1979
CONSTRUCTION
BbX 1600 PPM at INLET)
4 GPW
HOLDING POND FUR EVAPORATION
1 GPM BLEEDUFF 10 DISPOSAL POND
SEE SECTION 13 FUR DETAILED ECONOMIC INFORMATION
bACKGROUND INFORMATION
SUN PRODUCTION COMPANY HAS AN ENHANCED OIL RECOVERY SITE NtAR FELLOWS* CALIFORNIA. SEVERAL
STEAM GENERATORS ARE USED TO PRODUCE TMt PROCESS STEAM REQUIRED FOR THE OPERATION. A PART OF OIL,
NH1CH HAS A 1.4 PERCENT SULFUR, IS USED AS FUEL.
C-E NATCO HAS BEEN AWARDED A CONTRACT TO INSTALL AN FGl> SYSTEM ON ONE 25 MM BTU/HOUR STEAM GENE-
RATOR. NO FGO SYSTEM TREATS 12,000 ACFM FLUE GAS AT bTO F. THE FLUt GAS IS CONTACTED WITH ONE SET
OF SPRAYS (ISO GPM) IN THE BOT1UM UF THE ABSORBER CO.5' DIAMtTtrt X 3b Fl HIGH). PH OF b.b IS MAIN-
TAINED IN THE FIRST STAGE. THE bAS *HICH PASSES UP A TRAY WITH A CEMRAL OOwNCOMER, IS FURTHER
CONTACTED WITH A SECOND SET OF SPKAYS (150 GPM). A CHEVRON MIST ELIMINATOR (INCOLOY 825) LEADS INTO
A STUB STACK. THE EXCESS LlttUOK FKOM THE TRAY OVERFLOWS 10 Tht FIRSJ STAGE. PH IS MAINTAINED AT
7.b IN THE SECOND STAGE. MAKEUP SODIUM HYDROXIDE SULU1ION (O.Ob GPM) IS ADDED TO THE SECOND STAGE
BY A POSITIVE DISPLACEMENT PUMP WHILE FRESH MAKEUP WATER (4 GPM) IS ADDED TO THE FIKST STAGE. A
BLEEOOFF (1 GPM) STREAM IS TAKEN TO WASTE DISPOSAL FROM THE FIRM SIAGE MEC1RCOLATION LINE.
THE ABSORBER, RECIRCULAT10N PUMPS AND PIPING, AND THE SPRAY HEADERS ARE ilbL SS. THE CAUSTIC
FEED PUMP AND THE PIPING AND 1 HE INLE1 OUCTWORK IS C.S.
REFER TO FIGURE 14-JS IN SECTION 14 FUR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
4TH aUARTER-197»
OPERATING HISTORY
THE SYSTEM WAS UNDER CONSTRUCTION. THE STARTUP WAS EXPECTED BY APRIL 1979.
140
-------
STATUS TO APRIL 1974
SECTION 10 (CONTINUED)
DESISN INFORMATION FOR UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS
SUN PRODUCTION COMPANY; FELLOWS, CALIFORNIA (CONTINUED)
1ST OUARTER-1979 THE SYSTEM IS SCHEDULED FOR START-UP ON MAY 1ST, PENDING PERMIT APPROVAL* THIS
REPRESENTS A ONE-MONTH DELAY WITH RESPECT TO THE INITIAL TIMETABLE. THE DECISION TO DELAY HAS MADE
BECAUSE IT IS PREFERABLE TO BE INVOLVED WITH ONLY ONE START-UP AT ANY GIVEN TIME. THE C-E NATCO
UNIT AT THE SUN OILDALE SITE WILL START-UP FIRST. AT FELLOWS, THE EQUIPMENT IS FABRICATED AND
ON-SITE, BUT IS NOT YET INSTALLED. CONSTRUCTION IS ESTIMATED TO BE 6SX COMPLETE. NO MAJOR
CONSTRUCTION PROBLEMS HAVE BEEN ENCOUNTERED TO DATE.
ALTHOUGH THIS IS A FULL-SCALE UNIT, IT WILL ALSO SERVE AS A TEST UNIT FUR POSSIBLE FUTURE FGD
OPERATIONS WHICH ARE EXPECTED TO START-UP IN I960, WHICH HAVE NOT YET BEEN EVALUATED.
Kit
-------
STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUM6ER OF BGILEhS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
SUN PRODUCTION COMPANY
01LOALE, CALIFORNIA
OIL (1.2X SULFUR)
6,000 SCFM (12,000 ACFM o) 570 F)
Z
I
C-E NATCO
SODIUM HYDROXIDE SCRUBBING
RETROFIT
APRIL, 1979
CONSTRUCTION
«5X (700 PPM » INLET)
4 GPM
HOLDING POND FOR EVAPORATION
1 GPM 6LEEDOFF TO DISPOSAL POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
SUN PRODUCTION CO. HAS AN ENHANCED OIL RECOVERY SITE NEAR OILOALE, CALIFORNIA. SEVERAL SMALL
GENERATORS ARE USED TO PRODUCE THE PROCESS STEAM REQUIRED FOR THE OPERATION. A PART OF THE OIL,
WHICH HAS 1.2 PERCENT SULFUR, IS USED AS FUEL.
C-t NATCO HAS BEEN AWARDED A CONTRACT TO INSTALL AN FGD SYSTEM ON ONE 2b MM BTU/HOUR STEAM GEN-
ERATOR. NO FGD SYSTEM TREATS 12,000 ACFM FLUE GAS AT 570 F. THE FLUE GAS IS CONTACTED WITH ONE
SET UF SPRAYS (150 BPM) IN THE BOTTOM OF THE ABSORBER (4.5 FT DIAMETER X 35 FT HIGH). PH OF 6.5 IS
MAINTAINED IN THE FIRST STAGE. THE GAS, WHICH PASSES UP A TRAY WITH A CENTRAL OOMNCOMER, IS FURTHER
CONTACTED WITH A SECOND SET OF SPRAYS (150 GPM). THE GAS PASSES UP A CHEVRON MIST ELIMINATOR
(INCOLOY 825) INTO A STUB STACK. THE EXCESS LIUUOR FROM THE TRAY OVERFLOWS TO THE FIRST STAGE.
A PH OF 7.5 IS MAINTAINED IN THE SECOND STAGE. MAKEUP SODIUM HYDROXIDE SOLUTION (0.05 GPM) IS ADDED
TO THE SECOND STAGE BY A POSITIVE DISPLACEMENT PUMP WHILE FRESH MAKEUP HATER (4 GPM) IS ADDED TO THE
FIRST STAGE. A BLEED OFF (1 GPM) STREAM IS TAKEN TO WASTE DISPOSAL FROM THE FIRST STAGE
RECIRCULAUON LINE.
THE AbSORBER, RECIRCULATION PUMPS AND PIPING, AND SPRAY HEADERS ARE 316L S3. THE CAUSTIC FEED
PUMP AND THE PIPING AND THE INLET DUCTWORK ARE C.S CARBON STEEL.
REFER TO FIGURE 14-35 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
142
-------
STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION F6D SYSTEMS ON INDUSTRIAL BOILERS
SUN PRODUCTION COMPANY) OILDALEr CALIFORNIA (CONTINUED}
1ST OUARTER-1979 THE SYSTEM IS STILL SCHEDULED FOR START-UP APRIL 1ST, PENDING PERMIT APPROVAL.
THE EQUIPMENT IS FABRICATED AND UN-SITE* BUT IS NOT YET INSTALLED. CONSTRUCTION IS ESTIMATED TO BE
bSX COMPLETE. NO MAJOR CONSTRUCTION PROBLEMS HAVE BEEN ENCOUNTERED TO DATE.
ALTHOUGH THIS IS A FULL-SCALE UNIT, IT HILL ALSO SERVE AS A TEST UNIT FOR POSSIBLE FUTURE FCD
OPERATIONS WHICH ARE EXPECTED TO START-UP IN 19ftO, BUT WHICH HAVE NOT YET BEEN EVALUATED.
143
-------
STATUS TO APRIL 1479
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNOER CONSTRUCT IO« FGD SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER UF SEPARATE KM UNITS
NUMbER OF BUILEKS BtlNG CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR aY-PROOUCI U1SPUSAL
CONTROL SYSTEM COST
TEXACO INCUHPURAtEU
SAN AKDU, CALIFORNIA
OIL 11.7X SULFUK)
99,000 SCFM (TOTAL - 4 BOILERS)
2£,UOO ACFM ,> bOU Ft FOrt EACH OF 9 BOILERS.
3
9
49 HK (EQUIVALENT); 4SU MILLION 8TU/HR (TOTAL - 9 BUILEKS)
(FOR THIS NEPUKl, UNLESS STATED OTHERWISE. 2UOO SCFM = 1 EQUIVALENT M*.
THIS IS bECAUSk GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
DUCbN COMPANY
SUOIUM CAKHONATE SC«UoBlNG
RETMOFII
MARCH. 1979
CONSTrtUCriON
9bt (IOUU PPM oi INLET)
SCRUBBER EFFLUtNl OISPUSEO OF IH hASTE HELLS
SEE SECTION 13 FOK OLTAILED ECONOMIC INFORMATION
bACKGNUUNO INFORMATION
TEXACO HAS CHOSEN TO PHASE OUT THE EXISTING CEILCOTE SCRUBBER SYSTEMS AT SAN ARDO OIL FIELDS DUE
TO L0« S02 REMOVAL AND ilSh MAINTAINENCE COST. A MAJOR PrtObLEM OF 7h£ PRESENT DESIGN HAS BEEN
SCRUBBER FOULING BECAUSE OF HIGH ASH CONTENT IN THE FLUE GAS. AS THE FIRST STEP OF THE PHASE-OUT
PR06KAH, 9 UF THE PRESENT CEILCUTE SCRUBBERS UN THE bO MM BTU/HK STEAK GENERATORS MILL bE REPLACED
BY 3 DUCON CO. SCRUbbERS HEADEMED IN PARALLEL. START»UP OF THE NEN EbUIPCENT IS SCHEDULED FOR MARCH
1979. THE NEXT STEP OF TH£ PHASE-OUT PROGRAM IS DEPENDENT UN TMt PERFORMANCE OF THE DUCON SYSTEM.
(FOR INFORMATION ON THE CEILCOTE DESIGN SEE THE TEXACO, SAN AKDU ENTRY IN SECTION 9 OF THIS REPORT).
EACH OUCON SCRUBBING UNIT MILL CONSIST OF A VENTUKI FUR PAKTICULA1E REMOVAL FOLLOWED BY A HORIZ-
ONTAL J-STAGE SPRAY ABSORBER ( 6UU F MILL BE HANDLED BY t»Cn SCRUbdEK. FURIHERMORE, EACH TRAIN CAN
TREAT SOS OF THE LOAD AND CAN BE ISOLATED FROM THE FLUE GAS FLOW. IT IS HOPED THAT THIS SYSTEM DE-
SUN KILL YIELD SIGNIFICANTLY HIGHER AVAILABILITIES THAN THE DESIGN CURRENTLY IN USE.
THE DUCON ABSORBER MODULE IS CONSTRUCTED OF FIBERGLASS. THE VENTURI IS INCONEL 625. THE
144
-------
STATUS TO APRIL 1979
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BOILERS
TEXACO INCORPORATED; SAN ARDOr CALIFORNIA (CONTINUED)
OVERALL DIMENSIONS OF THE SYSTEM AKE 12 FEET X 23 FEET X 25 FEET. THE SPRAY NOZZLES MILL BE NYLON
Oft STAINLESS STEEL. BOTH THE ABSORBER AND VENTURI RECYCLE PUMPS ARE MANUFACTURED dY GALLIGER. THEY
ARE RUBBER-LINED AND SIZED 800 AND 1200 GPM RESPECTIVELY AT 40 HP. THERE ARE 2 GARDEN CITY FANS PER
UNIT RATED AT 100 HP EACH. DUCON HAS GUARANTEED 9bX 302 REMOVAL EFFICIENCY.
REFER TO FIGURE 14-36 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTER-1978 TEXACO HAS TAKEN DELIVERY ON ONE DUCUN SYSTEM. DELIVERY ON THE OTHER UNITS IS
EXPECTED SOON. THE UNITS ARE SCHEDULED TO START-UP WITH A NAOH SYSTEM. CONSIDERATION IS BEING
GIVEN TO FUTURE CONVERSION TO NA2C03.
4TH OUARTER-1976 CONSTRUCTION IS PROGRESSING AS SCHEDULED ANO THE SYSTEMS MILL BE SODIUM
CARBONATE SCRUBBING. THE THREE FGO SYSTEMS ARE ON THE PLANT SITE. THE SYSTEMS ARE SCHEDULED TO BE
ONSTREAM IN MARCH 1979.
1ST OUAKTER-1979 THE CONSTRUCTION WORK CONTINUED DURING THIS PERIOD. MOST OF THE EQUIPMENT HAS
BEEN ERECTED. DELAYS IN DUCTWORK FABRICATION ANO LAYOUT HAVE PUSHED THE START-UP DATE To
MAY 1979.
145
-------
STATUS TO APRIL 1979
SECTION 11
DESIGN INFORMATION hOK PLANNED FGO SYSTEMS ON INOUSTHIAL BOILERS
INSIALLATION NAME C.A.M.(CARBIDE-AMOCO-MONSAN10)
INSTALLATION LOCAIIUN HOUSTON, TEXAS
SOUHCt CHAKACTEK1STICS FUEL NOT YET SELECTED
SUUKCE RATING 1,200,000 SCF* 13 BOILERS)
NUKriEK OF StPAHATE Fbl) UMTS 3
NUMbfcH UF KUILEKS BEING CONTROLLED 3
sconce CAPACITY 6So MM (EQUIVALENT); i BOILER
(FOK THIS REPOK1, UNLESS SlATfcD OTHERWISE, 2000 SCFM * I EQUIVALENT MM.
THIS IS BECAUSE CAS FLOW KATE IS THE PRIMARY FACTO** IN MODULE SIZING.)
CUNTHUL SYSUM VENDOR VENDOR NUT YET SELECTED
CONTROL PROCESS DOU0LE ALKALI
NEW / RETKOFIT MEM
START-UP DATE 1964
CONTROL SYSTEM STATUS PLANNED-CONSIDERING S02 CONTROL
302 KE*OVAL EFFICIENCY NOT DETERMINED
SLUOSt UR BY-PHODUCT DISPOSAL DISPOSAL TECHN1UUE NO) KNOWN
BACKGROUND INFORMATION
UN10* CARBIDE, AMOCO AND MONSANTO HAVE ENTERED IN A JOINT VENTURE (C.A.M.) TO ERECT A COCENERA-
TION FACILITY NEAR HOUSTON, TEXAS. THE CAM PLANT NlLL CONSIST OF THREE BOILERS NITH TOTAL CAPACITY
OF 6100 MILLION BTU/HOUR. THE CAM PLANT MILL BE DESIGNED 10 GENERATE s.s MILLION LAS/HOUR STEAM
(6RU8SJ OUT (if WHICH 6 MILLION LBS/HOUR Slt'AM MILL 8E PROVIDED FOR PROCESS USE BY TfcXAS
CITY PLANTS OF THE THKEE COMPANIES. AS A COGENERAIION PLANT, CAM MILL ALSO PROVIDE STEAM FOR
COMMUNITY PUBLIC SERVICE COMPANY TO GENERATE ABOUT 100-M* OF ELECTRICITY FOR THE AREA. CAM
WILL ALSO SAVE ENERGY til OPERA)ING AT A 7S« FUEL EFFICIENCY COMPARED TO THE 3SS FOR THE
CONVENTIONAL ELECTRIC UTILITY PLANTS.
THE TYPt 01- COAL OR LIGNITE TO BE USED IS NOT FINALIZED. HOWEVER, IT IS CERTAIN THAT AN FCD
SYSTEM MILL BE RfcilUlHEU. STARTUP FOR THE FACILITY IS SCHEDULED FOR 1984.
OPERATING HISTORY
3RD UUAR!ER-197(t THE SYSTEM IS STILL IN THE VERY EARLY STAGES OF DEVELOPMENT. STEARNS-ROGERS
HAS ttt-EN CONTRACTED TO OU PRIMARY ENGINEERING AND AID IN THE CHOICE OF AN FGO SYSTEM AND VENDOR.
AS OF THIS REPORT PERIOD, COAL TYPE HAS NOT BEEN CHOSEN AND A CONTROL SYSTEM OR SYSTEM VENDOR HAS
NOT BEEN SELECTED.
4TH UUARTER-197B THE SYSTEM IS NOH UNDERGOING DETAILED DESIGN ENGINEERING AND PLANNING AND IS
SCHEDULED FOR FINAL REV It* BY THt THREE COMPANIES. IF APPROVED BY ALL THREE PARTNER COMPANIES*
CONSTRUCTION MILL START IN 2ND ttUAHTER 1960 WITH COMPLETION UF THE PROJECT SCHEDULED FOR 3RD QUARTER
146
-------
STATUS TO APRIL 1979
SECTION 11 (CONTINUED)
DESIGN INFORMATION FOR PLANNED FGO SYSTEMS ON INDUSTRIAL BOILERS
C.A.M.(CARBIOE-AMOCO-MONSANTO); HOUSTON, TEXAS (CONTINUED)
1964. THE SELECTION OF CONTROL SYS1EM IS EXPECTED BY THE ENU OF THE NEXT QUARTER.
1ST QUARTER-1979 THE SYSTEM IS IN PLANNING STAGE AND STILL UNDER REVIEh BY THE THREE COMPANIES.
THE CONTROL PROCESS HAS BEEN SELECTED TO BE OOU8LE ALKALI. THERE MILL BE SIX MODULES IN PARALLEL,
TREATING FLUE GAS FROM THREE BOILERS. ONLY FOUR MODULES MILL BE REQUIRED FOR FULL LOAD OPERATION.
REGENERATION SECTION MILL HAVE 10UX REDUNDANCY.
147
-------
STATUS 10 APRIL 1979
SECTION 11 (CONTINUED)
DESIGN INFORMATION fUK PLANNED FGO SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARAUIErtlSTICS
SOURCE RAIll.U
NUMBEH UF SEPARATE FGO UNITS
NUMBER OF BOILERS bEING CONTROLLED
SOURCE. CAPACITY
CONTROL SYSTtM VfcNDUK
CONTROL PROCESS
NEW / RETROFIT
START-UP UATE
CONTROL SYSTEM STATUS
SU2 REMOVAL EFFICIENCY
SLUDGE OH bY-HROUUCT DISPOSAL
CARBORUNDUM ABRASIVES
BUFFALO, NEn YORK
COAL (a.ex SULFUR)
30,000 3CFM (TOTAL - i. HJILERS)
160,000 LBS/HK STEAM (TOTAL - 2 BOILERS)
1
2
Ib MK (EQUIVALENT)
IFOH THIS RtPUHT, UNLESS STATED OTHENMlSE* £000 SCFM * 1 EQUIVALENT MM.
THIS is aecAusE GAS fLOm HATE is THE PRIMARY FACTOR IN MODULE SIZING.)
CARBORUNDUM tNVIR. SYS. LTD.
LIME SCHUBHING
RETHOFI1
I960
PLANNEO-CONTHACf AWARDED
9bX
WASTEHATEH TREATMENT
BACKGROUND INFUKMATION
AT THE CARHOkUNDUM ABRASIVES PLANT IN BUFFALO, NEh YORK THERE ARE 4 CUAL-FIREO BOILERS BUMMING
2.2X SULFUR COAL AllH AN AVERAGE HEA) VALUE OF 13,000 BTU/LB. IrtO OF THESE BOILERS ARE IDENTICAL
AND HAVE A TOTAL STEAM GENEHATINU CAPACITY OF 160.000 LB/HR.
THE FLUE CASES FRUM THE TWO bOILERS WILL BE CONTROLLED BY A VENTURI SCRUBBER (« FT INLET, 13 IN
THROAT, 13 Fl HIGH) FOLLOWED BY A 6-STAGE SPRAY TOttER (6.5 FT OlA X 36 FT HIGn). THE FliO SYSTEM HAS
DESIGNED bY CARBORUNDUM ENVIRONMENTAL SYSTEMS LTD., AM) WILL HANULE 40,000 ACFM, OR 10WX OF THE FLUE
6AS FROM BOTH BOILERS. LlME nILL HE USED AS 1HE SCRUBBING MEDIUM AND THE DESIGN S02 REMOVAL
EFFICIENCY IS 9bl. THE SPRAY TONER IS DESIGNED TO OPEKATt AT 125 F NITH AN L/G RATIO OF
60 GAL/1000 ACF. THE MAXIMUM LIUU1D FLUW RATE IS 3000 GKM. MAKE-UP NATEH MILL BE FED TO THE TOP
OF THE ABSORBER AT A KATE OF 4!> GPM, WHILE A 30 6PM BLEED STREAM MILL FLO* FROM THE RECIRCULATION
TANK DIRECTLY TO AN EXISTING TERTIARY NASTE TREATMENT FACILITY.
REFER TU FIGURE 14-4 IN SECTION 14 FOR A DETAILED PROCESS FLOM DIAGRAM OF THIS SYSTEM.
PARTICULAR REMOVAL OPERATING HISTORY
THE VENTURI AND ABSORBER MODULE MERE INSTALLED IN 197b. THE VENTORI HAS PUT INTO SERVICE FOR
PARTICULATE REMOVAL AT THAT TIME USING MATER AS THE SCRUBBING MEDIUM. THE HIGH CHLORIDE CONTENT OF
THE FLUE GAS HAS CAUSED SERIOUS CORROSION PROBLEMS. EFFLUENT FROM THE VENTURI HAS A PH OF 2.6,
THE 31t»L SS VENTURI WILL BE REPLACED WITH A HASTELLOY-C UNIT BEFORE START-UP FOR S02 REMOVAL. THE
ABSORBER, ALSO OF 316L SS IS BEING USED AS A SEPARATOR AND IS ALSO BADLY CORRODED. AN FRP UNIT WILL
148
-------
STATUS TO APRIL 1979
SECTION 11 (CONTINUED)
DESIGN INFORMATION FOR PLANNED FGO SYSTEMS ON INDUSTRIAL UOILERS
CARBORUNDUM ABRASIVES! BUFFALO, NEW YORK (CONTINUED)
BE INSTALLED TO REPLACE IT AND WILL INCLUDE A 3-PASS CHEVRON MIST ELIMINATOR, ALSO MADE OF FRP. AN
ACID-RESISTANT COATING MAS RECENTLY APPLIED TO THE STACK LINER. COMPLETION OF THESE MODIFICATIONS,
AND START-UP FOR 302 REMOVAL ARE SCHEDULED FOR 1980.
149
-------
STATUS TU APRIL 1979
SEC I ION 11 (CONTINUED)
OE&lbN INFORMATION FUR PLANNED F6U SYSTEMS ON INDUSTRIAL BOILERS
INS I ALLATIUN NAME
INSTALLATION LUCAIION
SOUKCE CMAkACTfcKlSTILS
SOURCE RATlNb
NUMBtH OF SEPARATE f&O ONITS
NUMBtK uF BOILtKS BelMG CONlMOLLfcU
SOUKCt CAPACITY
CONTROL SYSTEM VENUUK
CONTHOL PROCESS
Nt* / RETROFIT
STAHT-UP DATE
CONTHOL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUUSE OR bY-PRUUUCT DISPOSAL
CATERP1LLAN TKACIUK CO.
MAPLfcTUN, ILLINOIS
COAL li.il. SULFUR)
lOSrOUU SCfM (TOTAL - 2 BOILERS)
80,000 ACFM « 3SV K. FOM EACH OF 2 fGD SYSTEMS.
500,000 Ld/HR SI£AM (TOTAL - Z BOlLERSJ
52 Hn (EOUlVALbNT)} TOTAL - i BOILERS.
IFOM THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM • 1 EQUIVALENT MX.
THIS IS BECAUSE GAS FLbn NATE IS THt PRIMARY FACTOR IN MODULE SIZIN6.)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEn
JANUARY, 1980
2 SYSTEMS MILL START UP IN 1979-1980 HEATINS SEASON.
PLANNEU-CONTMACT AnAKOEO
90S (2000 PPM *l INLET)
DEMATERED SLURHY TO LANOF1LL
60+X SOLIDS (CAS04) SLUDGE DIRECILY TO LANDFILL.
BACKGROUND INFORMATION
AT THE MAPLETON, ILLINOIS PLANT, CATERPILLAR TRACTOR IS INSTALLING TNO NEM BOILERS WHICH MILL
8E COMPLETED BY THE kAMLY 19BO'S. EACH BOILER IS HA1ED AT 250,000 LB/HH STEAM AND KILL HAVE A
SEPAHATE FliU SYSTEM. CATthPlLLAK HAS AMAADED THE CONTRACT TO FMC ENVIORNMEMAL EUUIPMENT TO PROVIDE
CONCENTRATED DUAL ALKALI FGD SYSTEMS FOR THESE. TftO BOILERS. THE SCRUBBERS MILL SHARE SCRUBBING
LI4UO* REGENERATION ANO SLUOGt HANOLING FACILITIES. FOR MOKE INFORMATION, REFER TO THE CATERPILLAR
HAPLELTON ENTRY IN SECTION 10 OF THIS REPORT.
ISO
-------
STATUS TO APRIL 197S
SECTION 11 (CUNliNUED)
DESIGN INFORMATION FUR PLANrttQ FGU SYSTEMS UN INDUSTRIAL BUlLERb
INSTALLATION NAME
INSTALLATION LOCATIUN
SOURCE CHARACTERISTICS
SOURCE HATING
NUMBER UF SEPARATE FbO UNITS
NUMBER OF &OILERS Hcl.vG CONTROLLED
SOURCE CAPACITY
CONTMOL SYSTEM VENOUK
CONTROL PHOCKSS
MEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUDGE UK BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CELANESfc CORPORATION
CUMBERLAND, MARYLAHU
COAL (1.0-d.O* SULFUK)
bO,700 SCFM 11 BUILEK)
67,000 ACFM <* «50 F
1
1
£5 Mn IEUUIVALENT)
(FOR THIS REPORT, UNLESS STATED OTHERWISE* i!0«0 SCFM • 1 EQUIVALENT MM.
THIS IS HECAUSt GAS FLOW RATE IS THE PRIMARY FACTOR IN MUOULE SIZING.}
HMtELABHATOK-KKYfc/ftUCHHELL INT
OMV LIMfc SCHUbSlNG
KETKOFII
OECEMBEH, 1979
PLANNEU-CUKIKACT AWAKOEO
AS!
DRY WASTE IS TRUCKED TO A DUMPING AKEA
CAPITAL COS! IS S1.2b MILLIOM IN 1979 DOLLARS. IT INCLUDES
PUNCHASEU CU3T UF tUUlPMtNT, 3ILOS, INTERNAL UUCfBOHK,
SLAKERS AND PUMPS. IF OOES NUT INCLUDE OTHER DUCTNORK,
INSTALLATION, FOUNDATION, ELECTRICAL, ID FAN, ASH HANDLING
SYSTEMS AND STACK.
BACKGROUND INFORMATION
CELANESE CUWPORATION HAS AWARDED A CONTRACT TO HHEELAURA f Uh-FiJYE/ROCKNELL INTtHNAT IOIHAL TO SET
UP A PARTICIPATE AND Su
-------
STATUS TO APRIL 1979
SECTION 11 (CONTINUED)
OE8I6N INFORMATION FOK PLANNED FGD SYSTEMS ON INDUSTRIAL BOILERS
CELANE3E CORPORATION; CUM8EKLANO, MARYLAND (CONTINUED)
CONSTRUCTION OF THE CONTROL SYSTEM WILL START IN JUNE 1979 AND START-UP IS EXPECTED TO OCCUR BY
THE END OF 1979.
152
-------
STATUS TO APRIL 1979
SECTION 11 (CONTINUED)
OtblbH INFORMATION FOR PLANNED FGD SYSTEMS DM INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMUER OF SEPARATE FbO UNITS
NUMHER UF &OILER8 BfcluG CONTROLLED
SOUKCt CAPACITY
CONTROL SYSTEM VENDUK
CONTROL PROCESS
Nfcw / RETROFIT
S1AKT-UP DATE
CONTROL SYSTEM STATUS
502 REMOVAL EI-FILlt^CY
SLUOGE OH BY-PWOUUC1 DISPOSAL
DUPOM, INC.
ATHtNS> btUKUIA
COAL 11.bX SULFUK)
280>000 5CFM (10TAL - 3 BOILERS;
1,dUO,000 LU/HK SlbAH (TOTAL - 3 BOILERS)
1
3
14U MM (EQOlVALEfcT)
IFUH THIS MbPOrtT, UNLESS STATED OTHERWISE, £000 3CFM = 1 EQUIVALENT MN.
THIS IS BECAUSE GAS FLOW KATE IS THE PRIMARY FACTOK IN MODULE SIZING.)
VENUOK NOT YET StLECTED
DOUBLE ALKALI
nEn
DECEfBtK, 198b
PLANNED-CONSIDERING so? CONTROL
90X
OEMATEHEl) SLUrtriY TO LANDFILL
HACKGKUUNO INFOHHATIDN
DUPOMT HAS ANNOUNCED PLANS FOR A CHEMICAL PLANT NEAR ATHENS, GEORGIA. THE PLANT MILL HAVE
THHEE COAL-FINED UOILERS WITH A TOTAL CAPACITY OF ONE MILLION LB/HR OF STEAMJ AND A TOTAL HEAT
INPUT UF AttuuT i
-------
STATUS TO APRIL 1979
SECTION 11 (CONTINUED)
OESIbH INFORMATION FUH PLANNED FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE LHARACTERIST1CS
SOURCE HATING
NUMBER OF SEPARATE FGO ONITS
NUMBER UF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP OATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
3LUOCE OR BY-PRODUCT DISPOSAL
SHELL OIL COMPANY
BAKtRSFlELO* CALIFORNIA
OIL 11.U SULFUR)
99,000 SCFM (TOTAL - 8 BOILERS)
400 MM flTU/MH, (50 MM BTU PER HOILEHJ
I
a
SO MM (EUU1VALENT)
(FOR THIS HEPCKT, UNLESS STATED OTHEHNlSE> 2000 SCFM * 1 EQUIVALENT MM.
THIS IS BECAUSE bAS FLOM MATE IS THt PRIMARY FACTOR IN MODULE SIZING.)
VENOOM NOT YET SELECTED
PROCESS NOT YET SELECTED
NEft
PLANNED-CONSIDERING 502 CONlROL
90X 15/5 PPM SOi « INLET)
DISPOSAL TECHNIQUE NUT KNUwN
BACKGROUND INFORMATION
SHELL OIL IS CONSIDERING IMPLEMENTING FGD TECHNOLOGY 10 CONTROL EMISSIONS FROM 6 SMALL OIL-
FIRED 11.U SULFUR) STtAM GtNtKAToKS. NO PrtOCtsS OR START-UP OATE HAVE AS YEI BEEN SPECIFIED. AN
SOZ REMOVAL EFFICIENCY OF 94X MILL BE REQUIRED.
154
-------
STATUS TU APRIL 1979
SECTION 11 ICUNTIiMUED)
UESlbN INFORMATION FUrt PLANNED FUO SYSTEMS UN INDUSTRIAL bUILfcKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CMAHACTEKISTICS
SOURCE RATING
NUMBER OF StPAKAIt FGD UNITS
NUMBER UF bUlLtRS BEING CUNlkULLED
SOUkCt CAPACITY
CWvTHOL SYSTEM VENOUH
CONTKOL FHUCtSS
Nfctv / RfcTROUT
STAKT-UH DATE
CONTKUL SYSFtM SUIUS
S0£ KEMUVAL tFFlCItivCY
SLUUGE. OK HY-PKUDUCI DISPOSAL
SHELL OIL COMPANY
TAFlt CALIFORNIA
OIL ll.lt SULFUk)
85,000 SCFM ITOTAL
1
BOILERS)
IB M* lEUOIVALENT); 100 MM BTO/HR; TOTAL - £ BOILERS
(FOH THIS HEPUKT, UNLESS STATED UlHtRMSE, 2000 SCFM = 1 EQUIVALENT MM.
THIS IS BECAUSt GAS FLOW KAlE IS THE PRIMARY FACTUR IN MODULE SIZING.)
VENOOH N01 Ytl SELECTED
PKOCESS NUT YET SELECTED
NEW
PLANNED-CONSIDERING S02 CON1NUL
4«X I37b PPM SU2 ol INLET)
DISPObAL TECHNIUUE NUT KNOWN
BACKGROUND ^INFORMATION
SHELL OIL IS CONblUEMING IMPLEMENTING FUD TECHNOLOGY TU CONTROL EMISSIONS FKOM 2 SMALL OIL-
FlhEU 11.11 SULFUR) STEAM bENERATUKS. NO PROCESS OR START-UP DATE HAVE AS YET BEEN SPECIFIED. AN
502 REMOVAL EFFICIENCY UF 9
-------
STATUS TO APKIL 1979
SECTION 11 (CONTINUED)
OESIG'M INFORMATION FUR PLANNtO FliU SYSTEMS ON 1NUUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
BOUNCE CHARACTERISTICS
SOURCE RATINU
NUMBER OF SEPAHATK FGU UNITS
NOMBER OF BOILERS HE1NG CONTWULLEU
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUDGE OH BY-PRODUCT DISPOSAL
TENNtCO OIL CO.
GREEN HIVERr WYOMING
COAL 11.5X SULFUR. MAXIMUM)
140,000 3CFM (TOTAL - H HUILERS)
'i. FGU SYSTEMS. EACH TREATING 120,000 ACFM a) ISO F.
2
i
7U Min IEQUIVALENI) ; 640 MM dTU/HR (TOTAL - 2 BOlLtRS).
(FOR THIS REPORT. UNLESS STATED OTHERWISE. 20UU 3CFM = I EQUIVALENT MW.
THIS IS BECAUSE GAS FLOW HAlE IS THE PRIMARY FACTOR IN MODULE SIZING.)
VENDOR NOT YET SELECTEO
SODIUM CARBONAU SCHUUUINU
NEW
JANUARY. 1902
PLANwEU-RE'QUeSUNG/EVALUA TING BIDS
90X 10.2 L8/MM BTU a) OUTLET)
HOLDING PUND FOR EVAPORATION
bACKGHOUNO INFORMATION
TENNECU OIL COMPANY HAS ANNOUNCED PLANS FOR A SDOA ASH PLAN! IN GREEN KIVER, WYOMING.
THE DESIGN AND CONSTRUCTION COMPANY WILL BE BROWN AND HOOT. INC. THE PLANT MILL HAVE TWO JOOrOOO
cB'HR BOILERS. WHICH WILL BURN ' r.-SULFUH WYOMING COAL (1.5X SULFUR. MAXIMUM, 1U.OUU HTU/LB,
141 MOISTURE* b* »un;.
THE FLUE GASES FROM EACH BOILER 1120,000 ACFM al 45U F) HILL BE TREATED BY AN FttD SYSTEM USING
SODIUM CARBONATE SCRUBBING. THE SYSTEMS WILL BE UILT NEW ANU GO ONSTREAM IN EARLY-19B2 AT THE
SAME TIME AS THE SUUA ASH PLANT.
1ST QUARTER-1979
QUARTER.
OPERATING HISTORY
BIOS ARE CURRENTLY BEING EVALUATED. A VENDOR IS EXPECTED TO BE SELECTED NEXT
156
-------
STATUS 10 APHIL 19T9
SECTION 11 (CONTINUED)
DESIGN I^FURMAMUN FUH PLANNtl) f GO SYSTEMS OH liVIJOSTRIAL dUlLERS
INSTALLATION NAME
INSTALLATION LutAllUN
SOURCE CHARACTERISTICS
SOURCE. HATING
NUMBER OF SEPARATE FliU UNI TS
NUHrtER OF BOILERS BtlNti CONTROLLED
SOURCE CAPACITY
•VtSTtKN CURKtCriONAL IU3T.
CUNTHUL SYSTEM VENDOR
CONTROL PROCESS
NE* / RETROFIT
START-UP UATt
CONTROL SYSTEM STATUS
SOi! REMOVAL EI-FICItlXtY
SLUOGt UW BY-PkUDUCT
CUAL U.5X
1U.OOO SCFt4 (1UUL - 1
£0,000 ACFM a) 600F
1
30,000 Lb/HK STfcAM
b Mvi ItUUIVALENT) , io MM BTU/HH
IFUK THIS WtPUKT, UNLtSS 3TA7td OTHtRMSE, 2UUU SCFM a 1 EQUIVALENT Nn.
THIS IS HECAU36 liAS FLUA HATE IS iMt PHlMAKf FACIUR IK MODULE SIZING.)
pnrt>HUKbn ENV.&EiMGY. SYSTEMS
SULF-K
HdMUVAL
KETROFIT
JANUAKY,
PLANNtU-CUIvTHACT ANAKUtD
till 12UUO PPM dl INLET)
bUX MOX KtMUVAL (2UU PPH « INLfclJ
E - ELEMfcMTAL SULFUK PHUDUCT
bACK(ikUUNU INFUHMATIUN
THE HESTtRN CUKhtCTJONAL 1MST1TUIZUN IN P1T1SBUNGM, PA. HAS T*fO IDENTICAL COAL-FIKEO BOILERS*
EACH HAUU AT 3U|UUU LB/nH SltftM. UNt BOIL EH IS ALrtAYS UK 9UHU»tiY AhD THE OPEKAlING 60IUEH BUKN3
HISH aULFUH (3.SS »J PENNSYLVANIA bHUM I NOUS COAL.
THt FGO SYSTtM, USINU SULF-X CONCUHHfcNT UXIUES kEMUVAL CSCUftE) PHUCE8S, MILL BE HETHOFITTEU bf
PITTSdUWGM ENVIMONMEM1AL AND ENkHbY SYSTEHS, INC. THt PROCESS HAS DEMONS!KATtO 802 AND NCK HEHOVAL
CAPAblLITIES UN A I-MW aOlLER AT THE U.S. AHMY PUAEM PLANT AT FOKT BENJAMIN, HAftKISUNf PA. THIS
PROCESS USES 1HUN SULF1UE (FES) SLUkRY AS AN ABSOHBENT ViHlCH HfcftCTS WITH SU
-------
STATUS TO APRIL 1979
SECTION 11 (CONTINUED)
DESIGN INFORMATION FOR PLANNED FGD SYSTEMS ON INDUSTRIAL BOILERS
WESTERN CORRECTIONAL INST.f PITTSBURGH* PENNSYLVANIA (CONTINUED)
AND THE NO. THE OFF-GAS FROM THE KtOUCTING KILN IS PASSED THRUU6H A CtCLUNt TO REMOVE
SOME OF THE PARTICULATES AND THEN IS COOLED TO CONDENSE APPROXIMATELY 60X OF THE SULFUR
AS A LIQUID BYPRODUCT. THE REGENERATED FES IS TAKEN TO A RESLURRYING TANK WHERE
THE FILTRATE FROM THE VACUUM FILTER, THICKENER OVERFLOW AND MAKEUP FES SLURRY ARE ADDED. THE FCS
SLURRY FROM THE RESLURRYING TANK IS TRANSPORTED TO THE ABSORBER.
THE FLUE GAS (20,000 ACFM d 600 F) NlLL CONTAIN 2000 PPM S02 AND 200 PPM NO WHICH MILL BE
REDUCED TO LEVELS OF 200 PPM AND 60 PPM RESPECTIVELY. THE ABSORBER (5 FT DIA X 30 FT HEIGHT) HILL
HAVE FOUR KOCH ENGINEERING FLEXITRAYS AND A FLEXIMESH MIST ELIMINATOR. THERE MILL BE TWO FANS IN
THE F60 SYSTEM ONt FAN UPSTREAM OF THE SPRAY TOMER AND THE OTHER DOWNSTREAM OF THE ABSORBER. THE
ABSORBER AND MIST ELIMINATOR WILL BE CONSTRUCTED OF 316L SS WHILE THE REGENERATION SECTION MILL BE
PRIMARILY CARBON STEEL.
OPERATING HISTORY
4TH OUARTER-1976 THE SYSTEM IS IN THE DESIGN PHASE. THE ABSORBER SECTION ONLY OF THE FGD SYSTEM
WILL BE STARTED UP IN MAY 1979 AND TESTED FOR A SHORT DURATION. THE REGENERATION LOOP WILL BE
COMPLETED BY LATE FALL OF 1979.
1ST OUARTER-1979 THE DESIGN OF ABSORPTION SECTION IS COMPLETE. DESIGN OF REGENERATION SECTION
WILL BE OVER BY MID-MAY 1979. PRELIMINARY TESTING FOR ABSORPTION SECTION MILL BE PERFORMED IN
SEPTEMBER 1979. THE STARTUP IS NOW SCHEDULED FOR JANUARY I960.
ise
-------
MAT US TU APRIL 1979
SECTION 12
UESCR1PIION UF INDUSTRIAL UOlLEh F60 SYSItMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE MATING
NUMBER UF SEPARATE FliO UNITS
NUMBER UF BOILERS bEING CONTROLLED
SUUKCe CAPACITY
CONTROL SYSTEM VENOOK
CONTROL PROCESS
NEw / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUDGE OK BY-PRODUCT DISPOSAL
CONTROL SYSTEM CUS1
nUNlit. INC.
CAlRUf ILLINOIS
CUAL (31 SULFUK)
44,000 SCFM (TOTAL • 2 BOILERS)
81,400 ACFM a> S£0 F
1
e
ii Mn IEQUIVALENT); TOTAL • 2 BOILERS
160,OOU LbS/HK STEAM ITUTAL)
(FOM THIS RE HURT, UNLESS STATED OTHERWISE, 2U(/0 SCFM - 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLUW kATE IS THE HRIMAWY FACTOR IN MODULE SIZING.)
DttAVU CUNP./NAT'L LIht ASS'N
LlMt SCKUBBING
RETROFIT
SEPTEMBER, 1977
INDEFINITELY SHUT uuniM
941 (2700 PPM INLET)
DEwATEKED SLURRY TU LANUFILL
SEE SECTION 13 FUR DElAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BUNGE PURCHASED THIS LIME SCRUBBING SYSTEM FOR TESTING PURPOSES. THE LEWIS SCRUBBER, WHICH IS
A HORIZONTAL ROTARY VESSEL MlTH INTERNAL CHAINS. PERFORMED VERY MELL DURING THE TESr C94 PERCENT S02
REMOVAL). PRESENTLY, BUNGE IS USING LOW SULFUR COAL (0.9 PERCENT) AND HAS NO PLANS TO RESTART
F60 OPERATIONS.
159
-------
STATUS TO APRIL 1979
SECTION 12 (CONTINUED)
UtSCKIHTlUN UF INDUSTRIAL dOILER FGO SYSTtMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCAlluN
SOURCE CHARACTERISTICS
SOUHCt RATING
NUMbEH OF SEPARUTt FGU UNITS
NUMOEK Of bUILEKS BEING CUNTKOLLED
SOUHCt CAPACITY
CONTROL SYSTEM VENDOR
CONTHUL PROCESS
N£» / rttlrtOFIT
STAKT-UP UATE
CONTROL SYSTEM STATUS
808 REMOVAL tFFlCIENCY
PARTICULAR REMOVAL EFFICIENCY
SLUU6E OK BY-PRUUUCT DISPOSAL
CONTROL SYSTEM COST
HAHM1S MINING CO.
SPMUCE PINE, NOKTH CAROLINA
CUAL (0.6* SULFUR)
4,000 SCFM (TOTAL - 2 BOILERS)
Z
z
i MM (EQUIVALENT); TUTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM B 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOM KATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
W.W. SLY MANUFACTURING CO.
HATER SCRUBBING (NA,NH3 OPTN.)
RETROFIT
1973
INDEFINITELY SHUT
96X
DISPOSAL TECHNIQUE NOT KNOHN
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACK6KOUND INFORMATION
THE FGD SYSTEM AT THE HARRIS MINING COMPANY LOCATED AT SPRUCE PINE, NORTH CAROLINA REMOVES FLY»
ASH AND SULFUR DIOXIDE FROM THE FLUE GAS OF A COAL FIMED BOILEK. THE SCRUBBER IS A M.N. SLY
1MPINGENT TYPE SCRUBbEh CONSTRUCTED OF 304 STAINLESS STEEL. THE BOILElTlS RATED 1.9 MM
(EQUIVALENT £00 bOILER HO«SEPO«tK). COAL COMPOSITION IS TYPICALLY 0.6X SULFUR AND S* ASH. PRIMARY
INTEREST IN FLUE GAS SCRUBBING IS IN FLYASH REMOVAL AND NO TESTS FOR SULFUR DIOXIDE REMOVAL EFFI-
CIENCY HAVE BEEN MAUE.
ZND QUARTEH-1977
OPERATING HISTORY
NO OPERATIONAL PROBLEMS HAVE BEEN REPORTED.
1ST QUARTEK-lV7t> THIS PLANT HAS BEEN MOVED TU THE INACTIVE SYSTEMS FILE UNTIL SUCH TIME AS ACTUAL
FGD OPERATIONS BEGIN. fME SCRUBBER IS EQUIPPED NITH ALKALI ADDITION CAPABILITY, BUT NITH
THE LOM SULFUR COAL CURRENTLY BEING FIrtEO, NO ALKALI ADDITION OR PH CONTROL IS OCCURRING.
2ND QUARTER-197B
3MO.QUARTEK-197B
PLANT REPORTED NO CHANGE.
PLANT REPORTED NO CHANGE.
160
-------
STATUS TO APRIL 1979
SECTION 12 (CONTINUED)
DESCRIPTION OF INDUSTRIAL BOILER FGU SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE MATING
NUMBER OF SEPARATE f-GO UNITS
NUMBER OF BOILERS rttING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOe REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
NORTHERN OHIO SUGAR COMPANY
FINDLAY, OHIO
CUAL (1.2* SULFUR, AVERAGE)
65.830 SCFM (TOTAL - 2 BOILERS)
100,000 LB5/HK STEAM (TOTAL - Z BOILERS)
2
2
33 MN (EUUIVALENT), TOTAL - 2 BOILERS
(FOR THIS REPORT, UNLESS STATED OTHERhlSE, 2000 SCFM s 1 EUUIVALENT MM.
THIS IS BECAUSE GAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SUING.)
GREAT WESTERN SUGAR
SODIUM CARBONATE SCRUBBING
RETROFIT
OCTOBER, 1970
TERMINATED
76* (600 PPM oi INLET)
90Z
WASTtMATER TREATMENT AND DISCHARGE TO CITY SEDER
BLEED-OFF STREAM TO HOLDING TANK
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE NORTHERN OHIO SUSAR'tOMPANTnuS TERMINATED ALL SUGW PRODUCTION OPERATIONS AT FINOLAY OHIO.
THE PLANT IS NOW OPEN ONLY AS A SHIPPING AND RECEIVING STATION. THE SCRUBBER OPERATED DURING THE
1975, 1976, AND 1977 SUGAR PRODUCTION SEASONS BEFORE THE SHUTDOWN OCCURRED.
REFER TO FIGORE 14-20 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
161
-------
STATUS TO APRIL 1979
SECTION It (CONTINUED)
DESCRIPTION OF INDUSTRIAL dUILEK FGO SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE HATING
NUMBER OF SEPAKA1E FUU UNITS
NUMBER OF BOILERS BEING CONIKOLLEO
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP UATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE RtMUVAL EFFICIENCY
SLUUbE UR BY-PRUOUCT DISPOSAL
CONTROL SYSTEM COST
SHELLER GLOBE CURP.
NORFOLK, VIRGINIA
COAL (< l.OX SULFUR)
8,000 SCFM (TOTAL - 1 BOILER)
1
1
4 MN (EQUIVALENT)! TUTAL - 1 BOILER
(FOR THIS REPORT, UNLESS STATED OTHERWISE, 2000 SCFM * I EQUIVALENT MN.
THIS IS BECAUSE liAS FLOW RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
W.W. SLY MANUFACTURING CO.
SUDIUM HYDROXIDE SCRUBBING
RETROFIT
INDEFINITELY SHUT DOWN
NUT OETERHINEU
NOT DETERMINED
OVERFLOW TO SEwEH/SLUOGE TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN NORFOLK, VIRGINIA, SHELLER GLOBE CORPORATION OPERATES THE MITCHELL SMITH DIVISION PLANT,
HHENE THE PRIMARY PRODUCT IS CORK RUBBER GASKET MATERIAL. PROCESS (AUTOCLAVE) AND HEATING STEAM
ARE SUPPLIED BY A BOILER RATED AT 350 BOILER HP (ABOUT 3.5 Mrt EQUIVALENT). STEAM CONDITIONS ARE
US PSI AT 32i F. THE 6U1LEK MAS ORIGINALLY ERECTED IN 1939, BUT UNOEftftENT A COMPLETE OVERHAUL IN
1977. BOILER TUBES, REFRACTORY BRICK, GRATE, AND SOOT BLOrtERS «ERE REPLACED DURING THE OVERHAUL.
THE BOILER FIRES COAL SUPPLIED BY GENERAL COAL - NOMINAL SIZE IS 1.25 X 0.25 INCHES. COAL
CHARACTERISTICS ARE AS FULLOKSJ HHV«i3,«oo BTU/LB, ASH«b», AND SULFUR is LESS THAN u.
THE EMISSIONS CONTROL SYSTEM AT SHELLER GLOBE CONSISTS OF A w.w. SLY SINGLE-STAGE IMPINJET
SCRUBBER (*170) WHICH REMOVES PARTICULATE AND 802 FROM THE FLOt GAS. THE SYSTEM USES A NAOH MAKE-UP
PRIMARILY FOR CORROSION CONTROL BUT 302 CONTROL IS AN ADDITIONAL BENEFIT. RECYCLE TANK SUPERNATANT
IS PH NEUTRALIZED AND IS DISCHARGED TO CITY 8EMEHS WHILE FLY ASH AND SEDIMENT ARE SETTLED, SCRAPED
OUT AND HAULED TO A SANITARY LANDFILL.
THE SCRUBBER MODULE IS CONSTRUCTED OF 316L S3 (10 FT OIA X 15 FT HIGH). THE FLOE GAS RATE ENTE-
RING THE SCRUBBER IS 19,400 CFM » 450 F. THE DUCTING ENTERING AND EXITING THE SCRUBBER IS MADE OF
3/8' C.S. AND COHTEN STEEL RESPECTIVELY. THE tt.M. SLY FAN 4BOILER ID) IS MADE OF CARBON STEEL.
THE RECYCLE TANK IS CONSTRUCTED OF UNLINEO STEEL (20 FT X 10 FT X 8 FT) AND THE PIPING IS OF PVC.
CHEMICALS ARE PURCHASED FROM THE CHEMICAL TREATMENT CO. WHO ALSO OPERATE THE SCRUBBING SYSTEM.
REFER TO FIGURE 14-33 IN SECTION 14 FOR A DETAILED PROCESS FLON DIAGRAM OF THIS SYSTEM.
162
-------
STATUS TO APRIL 1979
SECTION 12 (CONTINUED)
DESCRIPTION OF INDUSTRIAL BOILER FGO SYSTEMS NOT OPERATING
SHELLED ULU6E CORP.; NORFOLK, VIRGINIA (CONTINUED)
OPERATING HISTORY
UPON INITIAL STARTUP NO CAUSTIC WAS INTRODUCED TO THE SYSTEM AND MITHIN A FEN MONTHS THE INTER-
NALS OF Trie MODULI: AND THE STEEL PIPING SYSTEM HERE CORRODED BEYOND USE. THIS NECESSITATED REPLACE-
MENT OF Tht INTERNALS, SUBSTITUTION OF STEEL PIPE HITH PVCr AND ADDITION OF NAOH TO THE SCRUBBING
LIQUOR.
2ND QUANTER-1978 DURING THE REPORT PERIOD THE UNIT UNDERWENT A VIRGINIA EPA CERTIFICATION
INSPECTION, AND WAS FOUND TO BE IN COMPLIANCE. NO SCRUBBER-RELATED PROBLEMS HAVE OCCURRED.
3RD QUAHTEH-1970 BOILER OPERATION WAS ESTIMATED TO BE AT 601 CAPACITY 24 HR8 PER DAY, t DAYS PER
MEEK. NO SCRUBBER-RELATED PROBLEMS HAVE BEEN REPORTED. PLANT PERSONNEL ARE CON8IDERIN6 REPLACEMENT
OF THE PRtSENT SYSTEM DUt TO REAR ON THE EQUIPMENT.
4TH QUAKTEK-1970 MO SCRUBBER RELATED PROBLEMS HERE REPORTED DURING THIS PERIOD. AT PRESENT, THE
USE OF FRESH NAOH HAS BEEN DISCONTINUED*
163
-------
STATUS TO APRIL 1979
SECTION 12 (CONTINUED)
DESCRIPTION OF INDUSTRIAL BU1LEK FGU SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOUKCE CHARACIEKISTICS
30UHCE MATING
NUMbER OF SEPARATE FGU UNITS
NUMbER OF BOILERS bEING CON1NOLLEU
SOURCE CAPACITY
CONTHOL SYSTEM VENDOR
CONTROL PROCESS
NEW / HETHOF1T
START-UP DATE
CONTROL SYSTEM STATUS
SOe REMOVAL EFFICIENCY
HATEk MAKE-UP
SLU06E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
THANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
FUEL OIL (2X MAX. SULFUR)
50,000 ACFM
I
1
20 Mh lEUUIVALfcNI)
IFON THIS REPORT, UNLtSS STATED UTHtRHlSE, 2000 SCFM s 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLOn RATE IS THE PRIMARY FACTO* IN MOOULE SUING.)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
NEW
MARCH, 197*
INDEFINITELY SHUT DOWN
BOX-65X 1610 Ld/MR ol INLET)
48 SHM; OPEN LUOP
WASTEHATER TREATMENT AND DISCHARGE TO RIVER
NAaSUJ/S04 L1UUOH UISCHAMGEO TO A HOLDING POND
SEE SECTION 13 FUN DETAILED ECONOMIC INFORMA1ION
BACKGROUND INFORMATIUN
THE FGO OPERATIONS HAVE BEEN TERMINATED FUN AN INDEFINITE PERIOD. THt PLANT BURNS NUMBER b
FUEL OIL AND THE SULFUH DIOXIDE EMISSIONS ARC SOX OF THE EXI3ITING REGULATIONS. THE bOlLER IS
RATED AT 20 MN (EOUIVALENT) AND PRODUCES IbO.OOO L8S/HK STEAM. WHEN OPERATIONAL, THE SCRUBBER
SYSTEM HAD A FLUE GAS VOLUME OF bu.000 ACFM AT 140 DEGREES F. SYSTEM START-UP OCCURRED IN MARCH
1975 AND SCRUBBER OPERATIONS MERE TERMINATED LATER IN THE SAME YEAR. THERE ARE CURRENTLY NO PLANS
TO INITIATE OPERATIONS.
164
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STATUS TO APRIL 1979
SECTION 14 (CONTINUED)
OtSCRlPIlON UP INDUSTRIAL BOILER FGD SYSTEMS NUT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHAKACTEKISUCS
SOURCE HATING
NUMBER OF SEPAKATE FGO UNITS
NUMBER (if olIILtRS rifcING CONTkULLtD
SOURCE CAPACITY
CONTROL SYSTEM VENDOK
CONTROL PROCESS
NEW / RETROFIT
START-UP OATE
CONTROL SYSTEM STATUS
SU2 REMOVAL EFFICIENCY
PARTICOLATb HEMUVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR HY-PRUDUCT DISPOSAL
CONTROL SYSTEM COST
U.S. bYPSUM CORP.
OAKMONT, PENNSYLVANIA
COAL
19,300 SCFH CTOTAL - * BOILERS)
1
4
10 MM (EQUIVALENT)
(FUR THIS REPORT, UNLESS STATED OTHERWISE. £000 SCFM s 1 EQUIVALENT MM.
THIS IS BECAUSE GAS FLU* RATE IS THE PRIMARY FACTOR IN MODULE SIZING.)
NEPTUNE AIKPOL, l*C.
DOUBLE ALKALI (DILUTE)
NtW
NEVER STARTED-UP
SUFFICIENT TO MEET REGULATION
MEETS CODE
10 (iPM (CLOSED LOOP)
DEWATEREO SLURRY TO LANDFILL
SLUDGE TO POMU FOR DRYING. THEN TO LANDFILL.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AN AIRPOL DOUBLE ALKALI SCRUBBING SYSTEM IS UN-SITE, INSTALLED, AND READY FOR OPERATIONS.
HUNeVER, OS GYPSUM DECIDED NUT TO INITIATE PRODUCTION AT THIS FACILITY FOR ECONOMIC REASONS. A
CHECK OURIN6 THE 4TH UUARTER 1970 REPORT PERIOD REVEALED THAT THERE ARE STILL NO PLANS TO USE THIS
FACILITY.
IbS
-------
STATUS TO APRIL 1979
SECTION 13
INDUSTRIAL BOILER FGD COSTS
VENDOR
COMPANY PROCESS COST
LOCATION STATUS ........................
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATIN6
ALYESKA PIPELINE SERVICE CO. FMC ENVIRONMENTAL EQUIPMENT
VALOEZi ALASKA SODIUM HYDROXIDE SCRUBBING
50,000 OPERATIONAL
6/77
PLANT PERSONNEL HAVE NUT SEPARATED OUT FGD SYSTEM
COSTS FROM OVERALL PROJECT COSTS NOR DO THEY KEEP
OPERATING COSTS FOR THE F6D SYSTEM.
ARCO/POLVMERS, INC. FMC ENVIRONMENTAL EQUIPMENT Sll*600,000. IZ,400,000.
MONACA, PENNSYLVANIA DOUBLE ALKALI (CONCENTRATED)
305,000 CONSTRUCTION
6/60
THE CAPITAL COST REPRESENTS THE TOTAL COST OF THE
ENTIRE FCD SYSTEM INCLUDING INSTALLTION, DUCTWORK*
STACK, PIPING, ENGINEERING, START-UP, TE8TIN6,
INSTRUMENTATION, OVERHEADS AND HASTE DISPOSAL
FACILITIES IN MID-1979 DOLLARS, THE PROJECTED
OPERATING COST IS IS/TON OF COAL.
BELRI06E OIL CO. C-E NATCO 1185*000.
MCKITTRICK, CALIFORNIA SODIUM HYDROXIDE SCRUBBING
12,000 OPERATIONAL
1/79
THIS IB THE REPORTED CAPITAL COST IN 1976 DOLLARS.
BSLRIOGE OIL CO. HEATER TECHNOLOGY S106,000. S79,000.
MCKITTHICK, CALIFORNIA SODIUM HYDROXIDE SCRUBBING
18,000 OPERATIONAL
6/76
THE CAPITAL COST INCLUDES THE COSTS OF SCRUBBER,
RECYCLE TANK, STACK, OEMISTEH, PIPING, DUCTWORK,
ELECTRICITY, INSTRUMENTATION IN MID-1976 DOLLARS.
IT DOES NOT INCLUDE CAUSTIC TANK, PUMP* FEEDLINES,
HASTE DISPOSAL FACILITIES AND MATED AND ELECTRICAL
CONNECTIONS. THE OPERATING COST IS BASED ON 92S
AVAILABILITY THROUGH A YEAR. IT INCLUDE* COST OF
CAUSTIC (6.6 GAL/HOUfO, ELECTRICITY, MATER AND
LABOR ZN LATE 1976 UOLLAKS, IT DOES NOT INCLUDE
INDIRECT COSTS AND NABTfc DISPOSAL.
166
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGD COSTS
COMPANY
LOCATION
CAPACITY ISCFM)
VENDOR
PROCESS
STATOS
START-UP DATE
COST
CAPITAL
OPERATING
8ELRIUGE OIL CO.
MCKITTR1CK, CALIFORNIA
ie,ooo
THERMOTICS INC. $175,000.
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
7/7B
THE CAPITAL COST INCLUDES THE TOTAL INSTALLED COST
OF THE ENTIRE FGD SYSTEM IN MID-1978 DOLLARS. IT
DOES NOT INCLUDE HASTE DISPOSAL FACILITIES AND
MATER AND ELECTRICAL CONNECTIONS. THE OPERATING
COST IS BASED ON 92X AVAILABILITY THROUGH A YEAR.
IT INCLUDES COST OF THE CAUSTIC (6.9 GAL/HOUH),
ELECTRICITY, MATER AND LABOR IN LATE ma DOLLARS.
IT DOES NOT INCLUDE INDIRECT COSTS AND HASTE
DISPOSAL.
$60,500.
BUNGE, INC.
CAIRO, ILLINOIS
44,000
ORAVO COKP./NAT'L LIME ASS'N
LIME SCRUBBING
INDEFINITELY SHUT DOWN
9/77
•1,000,000.
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
COST OF THE FGD SYSTEM, ENGINEERING, START-UP, AND
TESTING IN 1977 DOLLARS.
CANTON TEXTILES
CANTON, GEORGIA
FMC ENVIRONMENTAL EQUIPMENT $138,000.
CAUSTIC NASTE STREAM
OPERATIONAL
b/74
THE CAPITAL COST REPRESENTS THE TOTAL COST FOR THE
INSTALLED SYSTEM, IN 1974 DOLLARS.
134*000,
CATERPILLAR IRftCTOrt CO.
CAST PEONIA, ILLINOIS
210,000
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
OPERATIONAL
4/76
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGO SYSTEMS.
167
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGD COSTS
VENDOR
COMPANY PROCESS COST
LOCATION STATUS
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
CATERPILLAR TRACTOR CO. ZURN INDUSTRIES
JOLIETr ILLINOIS DOUBLE ALKALI (DILUTE)
67*000 OPERATIONAL
9/74
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGD SYSTEMS.
CATERPILLAR TRACTOR CU. FMC ENVIRONMENTAL EQUIPMENT
MAPLETON, ILLINOIS DOUBLE ALKALI (CONCENTRATED)
131,000 OPERATIONAL
3/79
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGO SYSTEMS.
CATERPILLAR TRACTOR CO. ZURN INDUSTRIES
MORTON, ILLINOIS DOUBLE ALKALI (DILUTE)
38,000 OPERATIONAL
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGD SYSTEMS.
CATERPILLAR TRACTOK CO. FMC ENVIRONMENTAL EQUIPMENT
MOSSVlLLEr ILLINOIS DOUBLE ALKALI (CONCENTRATED)
140.000 OPEHAT1UMAL
10/75
NO ECONOMIC INFORMATION HAS BEEN SUPPLUO FOR THE
CATERPILLAR FGD SYSTEMS.
166
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGO COSTS
VENDOR
COMPANY PROCESS COST
LOCATION STATUS ........................
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
CHEVRON U.S.A. INC. KOCH ENGINEERING $8,800.000. $930,000.
BAKERSFIELD, CALIFORNIA SODIUM CARBONATE SCRUBBING
248,000 OPERATIONAL
7/78
THE CAPITAL COST IS IN 1978 DOLLARS. THIS REPRE-
SENTS THE TOTAL INSTALLED COST OF THE F6D SYSTEM
INCLUDING SITE PREPERATION. THE OPERATING COST
INCLUDES ELECTRICITY, SODA ASH, AND MAINTENANCE
(LABOR AND MATERIALS). THIS CORRESPONDS TO A 340
DAY YEAR AND APPROXIMATELY S900/DAY PER SCRUBBER
IN 1978.
CHEVRON U.S.A. INC. KOCH ENGINEERING
BAKERSFIELD, CALIFORNIA SODIUM CARBONATE SCRUBBING
146,000 CONSTRUCTION
7/79
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CHEVRON FGD SYSTEMS.
DOUBLE BARREL OIL CO. C-E NATCO
BAKERSFIELD, CALIFORNIA SODIUM HYDROXIDE SCRUBBING
1Z,000 OPERATIONAL
6/76
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
DOUBLE BARREL OIL FGD SYSTEMS.
FIRESTONE TIRE AND RUBBER CO. FMC ENVIRONMENTAL EQUIPMENT $163,000. $60,000.
POTTSTOMN, PENNSYLVANIA DOUBLE ALKALI (CONCENTRATED)
8070 OPERATIONAL
1/75
THE CAPITAL COST INCLUDES EQUIPMENT, ENGINEERING
AND STARTUP. THE COST DOES NOT INCLUDE LABOR AND
MATERIALS FOR ELECTRICAL SYSTEM, PIPING, OK STRUC-
TURAL AND FOUNDATIONS ERECTION IN 1974 DOLLARS.
THE OPERATING COST INCLUDES CHEMICALS, LABOR,
ELECTRICITY, DISPOSAL, MATERIALS, AMD LAB WOHK FOR
1977.
169
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BUILEH FUO COSTS
VENDOR
COMPANY PROCESS COST
LOCA1ION STATUS ........................
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
FMC (SODA ASH PLANT) FMC ENVIRONMENTAL EQUIPMENT S10,OOU,OUO,
6REEN RIVER, WYOMING SODIUM CARBONATE SCRUBBING
446,000 OPERATIONAL
5/76
THIS TOTAL CAPITAL COST. IN 197* DOLLARS,
INCLUDES ESP AND F&D PURCHASE AND INSTALLATION
COSTS.
GENERAL MOTORS CORPORATION ENTOLETER, INC, $668,000.
DAYTON, OHIO SODIUM HYDROXIDE SCRUBBING
36,000 OPERATIONAL
9/74
THE CAPITAL COST IS THE TOTAL INSTALLED COST FOR
THE TWO FGD SYSTEMS, IN 1974 DOLLARS.
GENERAL MOTORS CORPORATION GM ENVIRONMENTAL S3,200,000. 9644,000,
PARMA, OHIO DOUBLE ALKALI (DILUTE)
138,400 OPERATIONAL
3/74
THE OPERATING COST REPRESENTS S11.70/TON COAL.
GENERAL MOTORS CORPORATION GM ENVIRONMENTAL 5600,000,
PONTIAC, MICHIGAN SODIUH HYDROXIDE SCRUBBING
107,300 OPERATIONAL
4/76
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
COST IN 1972 DOLLARS.
GENERAL MOTORS CORPORATION A.O. LITTLE $773,000. 1172,000,
ST. LUU1S, MISSOURI SODIUM HYDROXIDE SCRUBBING
64,000 OPERATIONAL
1972
THE CAPITAL COST IS IN 1973 DOLLARS. THE OPERAT-
ING COST INCLUDES MAINTENANCE MATERIALS, LABOR AND
170
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGD COSTS
COMPANY
LOCATION
CAPACITY C5CFM)
VENDOR
PROCESS
STATUS
STAKT-UP DATE
COST
CAPITAL
OPERATING
GENERAL MOTORS CORPORATION
TONONANbAr NEW YORK
92,000
FMC ENVIRONMENTAL EQUIPMENT
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
6/75
THE CAPITAL COST IS IN 1974 DOLLARS.
GEORGIA-PACIFIC PAPtR CO.
CROSSEIlr ARKANSAS
2*0,ODD
NEPTUNE AIRPUL, INC*
CAUSTIC WASTE STREAM
OPERATIONAL
7/75
»Z75,000.
THE CAPITAL COST REPRESENTS THE ABSORBER COST ONLY
AND IS IN 1974 DOLLARS.
GETTY OIL COMPANY
BAKERSFItLU, CALIFORNIA
72,000
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
OPERATIONAL
t/77
$400,000,
•390,000,
THE CAPITAL COST INCLUDES THE ABSORBER MODULE,
SODA ASH TANK, PUMPS, AND PIPING IN 1977 DOLLARS.
IT DUES NOT INCLUDE THE STACK, DUCTING, ENGINEER-
ING, OR OVERHEADS. THE OPERATING COST 19 EQUIV-
ALENT TO S0.16/MM BTU, INCLUDES THE COST FOR
SODA ASH, ELECTRICITY, AND SCRUBBER MAINTENANCE,
AND REPRESENTS A SOU-DAY YEAR.
fcETTY OIL COMPANY
BAKERSFULU, CALIFORNIA
891,000
IN-HOUSE UESIGN
SODIUM CARBONATE SCRUBBING
OPERATIONAL
15,400,000.
•9,820,000.
THE CAPITAL COST INCLUDES COST OH SCRUBBER, FAN,
UUCTlNb, TANKS, PUMPS, PIPINtt, ELECTRICAL, AND
INSTALLATION IN 1976 DOLLARS FOR 6 SCRUBBER SYSTEM
THE UPbRATING COST INCLUDES ELECTRICITY, SCRUBBER
MAINTENANCE, AND SODA ASH FON 9 SYSTEMS. IT IS
BASED ON A J40-DAV YEAR.
171
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTK1AL bOILER FGO COSTS
COMPANY
LOCATION
CAPACITY (SCFM)
VENDOR
PROCESS
STATUS
START-UP DATE
COST
CAPITAL
OPERATING
6ETTY OIL COMPANY
ORCUTT, CALIFORNIA
5000
IN-HOUSE DESIGN
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
6/77
6REAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
420,000
NEPTUNE AIRPOL, INC.
CAUSTIC MSTE STREAM
OPERATIONAL
1975
$1,800,000.
THE CAPITAL COST IS THE TOTAL INSTALLED COST FOR
THE TWO SCRUBBER MODULES IN 1974 DOLLARS.
6RISSOM AIR FORCE BASE
BUNKER HILL, INDIANA
32,000
NEPTUNE AIRHUL, INC.
DOUBLE ALKALI (CONCENTKATED)
CONSTRUCTION
11/79
11,610,000.
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
F6D SYSTEM COST AND IS BROKEN OUWN BY CONSTRUCTION
DEPARTMENT AS FOLLOWS! ELECTRICAL ftORK-S195,000?
CIVIL "OrtK-S229,600| MECHANICAL «URK"«l,184,930.
HARRIS MINING CO.
SPRUCE PINF, NURTH CAROLINA
4,000
W.H. SLY MANUI-ACTUKIHG CU.
MATER SCRUBBING (NA,*HJ UPTN.)
INDEFINITELY SHUT DUM.N
1973
»31,000.
THE CAPITAL COST IS THE TOTAL INSTALLED COST IN
1973 OULLAKS.
INLAND CONTAINER CORPORATION
NEW JOHNSONVILLE, IENNES3EE
154,000
NEPTUNE AIRPUL INC.
AMMONIA SCRUBBING
CONSTKUCTiON
5/79
THE CAPITAL COST IS IHt HURChASED COST OF
VENTUKl SCRUdBEK, SEPARATOR AND SIUB STACK ONLY
172
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGO COSTS
COMPANY
LOCATION
CAPACITY (SCFM)
VENDOR
PROCESS
STATUS
START-UP DATE
COST
CAPITAL OPERATING
ITT RAYONIER, INC.
FERNANOINA BEACH, FLORIDA
176,000
NEPTUNE AIRPOL, INC.
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
1975
SbOO.OOO.
THE CAPITAL COST IS FOR 2 SCRUBBERS, DUCTWORK,
AND STACKS IN 1975 DOLLARS.
KERR-MC6EE CHEMICAL CORP.
TRONA, CALIFORNIA
490,000
COMBUSTION EQUIPMENT ASSOC.
SODIUM CARBONATE SCRUBBING
OPERATIONAL
6/76
16,000,000.
KERR-MCGEE SPENT SI.5 MILLION IN A PILOT PLANT FOR
SEVERAL YEARS BEFORE AND DURING CONSTRUCTION OF
THE NEW FACILITY, OUT OF THE S200 MILLION PROJECT
COST, S16 MILLION OF THAT IS FOR POWER PLANT AND
•6 MILLION IS FOR THE BOILER RELATED POLLUTION
CONTROL COSTS.
MEAD PAPERBOARD CO.
STEVENSON, ALABAMA
100,000
NEPTUNE AIRPOL, INC. 9173,000.
SODIUM CARBONATE SCRUBBING
OPERATIONAL
1975
THE CAPITAL COST REPRESENTS THE ORIGINAL EQUIPMENT
AND INSTALLATION COST IN 1974. SINCE THEN, EXTEN-
SIVE MODIFICATIONS HAVE BEEN REQUIRED. ANOTHER
1173,000 WAS SPENT FOR REPAIRS AND UPGRADING IN
1976. OVER THE SCRUBBER PLANT LIFE, AN ADDITIONAL
1136,000 HAS BEEN SPENT, INCLUDING:* 35,000 (RUB-
dER LINERS), 954,000 (STAINLESS STEEL LINERS), AND
447,000 (GENERAL REPAIRS).
THE OPERATING COST INCLUDES S40,000/YH FOR
OPERATING LABOR, »40,000/YR FOR MAINTENANCE
LABOR, AND 1760,000/YR FOR REAGENT (6526 TONS).
S640,000,
MINN-DAK FARMER'S CO-OPERATIVE
MAHPETON, NORTH DAKOTA
164,000
KOCH ENGINEERING
AMMONIA SCRUBBING
OPERATIONAL
6/77
1300,000,
THE CAPITAL COST REPRESENTS THE TOTAL EQUIPMENT
COST IN 1977 DOLLARS.
173
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGD COSTS
VENDOR
COMPANY PKOCfcSS COST
LOCATION STATUS ........................
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
MOBIL OIL COMPANY HEATER TECHNOLOGY 1500,000.
BUTTONNILLOW, CALIFORNIA SUOIUM CARBONATE SCRUBBING
80.500 CONSTRUCTION
«/79
THE CAPITAL COST INCLUDES ABSORBER MODULES, RE-
CYCLE TANKS, STACK, OEMISTERS, PUMPS, AND PIPING
IN 1976 DOLLARS. IT DOES NOT INCLUDE CAUSTIC
TANK, FEED PUMPSi OR FEED PIPES.
MOBIL OIL COMPANY IN-HOUSE DESIGN (2,900,000. SI,390,000.
SAN AROO, CALIFORNIA SODIUM HYDROXIDE SCRUBBING
17b,000 OPERATIONAL
1974
THE CAPITAL COST REPRESENTS EQUIPMENT, INSTAL-
LATION, PIPING, DUCTHORK, STACK, WATER TREATMENT
FACILITY, AND INSTRUMENTATION IN 197* DOLLARS.
THE OPERATING COST INCLUDES ELECTRICITY, CAUSTIC,
LABOR* AND MAINTENANCE. II DOES NOT INCLUDE IN-
DIRECT (FIXED) COSTS. THE AVERAGE OPERATING COST
FOR THE 22 SMALLER SYSTEMS IS S38,OOU/YR EACH, AND
FOR THE 8 LARGER SYSTEMS IS S65,000/YR EACH.
NEKOOSA PAPERS* INC. NEPTUNE AIRPOL, INC. 1290,000. 1207*000,
ASHOOWN, ARKANSAS CAUSTIC SCRUBBING
211*000 OPERATIONAL
2/76
THE CAPITAL COST REPRESENTS THE EQUIPMENT COST IN
197!) DOLLARS.
NORTHERN OHIO SUGAR COMPANY GREAT WESTERN SUGAR 1423,000. $30*100.
FINDLAY, OHIO SODIUM CARBONATE SCRUBBING
65,250 TERMINATED
10/71
THE CAPITAL COST IS THE 10TAL INSTALLED COST OF
THE FGI) SYSTEM IN 1974 DOLLARS. THE OPERATING
COST INCLUDES ELECT8ICIIY, MAINTENANCE* LABOR* AND
MATERIALS.
174
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGO COSTS
VENDUR
COMPANY PROCESS COST
LOCATION STATUS ........................
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
NORTHERN OHIO SU6AH COMPANY GREAT WESTERN SUGAR
FRE.EMONT, OHIO SODIUM HYDROXIDE SCRUBBING
40,000 OPERATIONAL
10/75
NO COST INFORMATION HAS BEEN SUPPLIED FOR THE
FREEMONT FGO SYSTEM.
PFIZER, INC. IN-HOUSE DESIGN *1,800,000. $500,000,
EAST ST. LOUIS, ILLINOIS LIME SCRUBBING
40,000 OPERATIONAL
9/76
THE CAPITAL COST IS THE TOTAL INSTALLED COST OF
THE FGO SYSTEM IN OCTOBER 197S DOLLARS. THIS IN-
CLUDES ALL THE DIRECT AND INOIHECT COSTS OF THE
PROJECT. THE OPERATING COST IS THE DIRECT ANNUAL
OPERATING COSTS IN OCTOBER 1976 DOLLARS. THESE
INCLUDE LIME (»170,000), WASTE DISPOSAL
(1160(000), ELECTRICITY, WATER, AND MAINTENANCE
(MATERIAL AND LABOR). THE TOTAL OPERATING COSTS
ARE PROJECTED TO BE S .04/MM BTU INCLUDING ALL THE
INDIRECT COSTS. FOR A CAPACITY FACTOR OF 96X
(0900 HOURS OF OPERATION/YR 9 FULL LOAD), THIS
HILL CORRESPOND TO S740,000/YR.
PHILLIP MONRIS, INC. FLAKT, INC.
CHESTERFIELD, VIRGINIA SODIUM CARBONATE SCRUBBING
39,000 CONSTRUCTION
6/79
NO COST INFORMATION is AS YET AVAILABLE.
REICMHOLU CHEMICALS, INC. NEPTUNE AIRPUL, INC. SZ70.000.
PEN3ACOLA, FLORIDA SODIUM CARBONATE SCRUBBING
60,000 OPERATIONAL
6/75
THE CAPITAL COST REPRESENTS ONLY THE INSTALLED
COST OF SCRUBBER AND STUb STACK IN 1973 DOLLARS.
175
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGO COSTS
VENDOR
COMPANY PROCESS COS1
LOCATION STATUS ——— ——————
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
RICKENBACKER AIR FORCE BASE RESEAHCH-COTTRELL/BAHCO S2,£00,000. $207,000.
COLUMBUS, OHIO LIMESTONE SCRUBBING
55,000 OPERATIONAL
3/76
THE CAPITAL COST INCLUDES ADJACENT ELECTRICAL SUB-
STATION, SLUDGE DISPOSAL, EXTERNAL FLUES, AND
OTHER ATYPICAL EUUIPMENT IN 1975 DOLLARS. THE OP-
ERATING COST REPRESENTS THE OVERALL 1977 COST FOR
35,000 TONS OF COAL. DURING THE 1977 U.S.E.P.A.
DEMONSTRATION TEST, OPERATING COSTS MERE S5.61/TON
OF COAL. THESE COSTS INCLUDE OPERATING AND MAIN-
TENANCE, LABOR, POftER, MATER, MAINTENANCE PARTS,
AND SLUDGE DISPOSAL, BUT DOES NOT INCLUDE DEPRE-
CIATION.
SANTA FE ENERGY COHP. FMC ENVIRONMENTAL EQUIPMENT SlfbOO,000.
BAKERSFIELO, CALIFORNIA DOUBLE ALKALI ICUMCbNTHATEO)
70,000 CONSTRUCTION
5/79
THE CAPITAL COST INCLUDES THE SCRUBBER, LIQUOR
REGENERATION EQUIPMENT, AND DUCTWORK IN 1978
DOLLARS.
SHELLER GLOBE CORP. W.*. SLY MANUFACTURING CO. $80,000.
NORFOLK, VIRGINIA SODIUM HYDROXIDE SCRUBBING
6,000 INDEFINITELY SHUT DOWN
1975
THE CAPITAL COST IS THE ESTIMATED REPLACEMENT COST
IN 1976. AN ESTIMATED MAINTENANCE COST OF tlbO/HO
4AS REPORTED C<> MAW-OAYS/MO).
ST. JOE ZINC CO. BUKbAO UF MINES $12,700,000.
MONACA, PENNSYLVANIA CITKATt PROCESS
148,000 CONSTRUCTIUN
4/79
THE CAPITAL COST IS IN 1977 DOLLARS ANU IS BEING
JOINTLY FUNDED BY ST. JOE ZINC, THE US EPA, AND
THE U.S. BUREAU OF MINES.
176
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGD COSTS
VENDOR
COMPANY PROCESS COST
LOCATION STATUS ........................
CAPACITY (SCFH) START-UP DATE CAPITAL OPERATING
STRATHMORE PAPER COMPANY MIKROPUL CORPORATION SI,400,QUO. $162,000.
NOftONOCO, MASSACHUSETTS OKI LIME SCRUBBING
22,000 CONSTRUCTION
5/79
THE CAPITAL COST IS TOTAL INSTALLED COST OF
THE ENTIRE FGD SYSTEM IN 1979 DOLLARS. THE
ESTIMATED OPERATING COST INCLUDES ONLY DIRECT
COSTS OF RAM MATERIALS, MATER AND ELECTRICITY.
SUN PRODUCTION COMPANY C-E NATCO SlOOrOOO. 835,000.
FELLOKS, CALIFORNIA SODIUM HYDROXIDE SCRUBBING
6,000 CONSTRUCTION
5/79
THE CAPITAL COST IS THE TOTAL INSTALLED COST
OF THE FGD SYSTEM IN 1979 DOLLARS. THE ESTIMATED
OPERATING COST INCLUDES ONLY DIRECT COSTS OF RAM
MATERIALS (50 LB/HR OF 50 X CAUSTIC, 4 GPM MAKEUP
MATER), AND ELECTRICITY (16 HP).
SUN PRODUCTION COMPANY C-E NATCO 3100,000. $35,000.
OILDALEr CALIFORNIA SODIUM HYDROXIDE SCRUBBING
6,000 CONSTRUCTION
4/79
THE CAPITAL COST 16 THE TOTAL INSTALLED COST
OF THE FGD SYSTEM IN 1979 DOLLARS. THE ESTIMATED
OPERATING COS! INCLUDES ONLY DIRECT COSTS OF RAW
MATERIALS (50 LB/HR OF SOX CAUSTIC, 4 GPM MAKEUP
MATEK), AND ELECTRICITY (16 HP).
TEXACO INCORPORATED CEILCOTE
SAN ARDO, CALIFORNIA SODIUM HYDROXIDE SCRUBBING
347,000 OPERATIONAL
11/73
NO ECONOMIC INFORMATION HAS AS YET BEEN PROVIDED
BY TEXACO.
177
-------
STATUS TO APRIL 1979
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FGO COSTS
VENDOR
COMPANY PROCESS COST
LOCATION STATUS ........................
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
TEXACO INCORPORATED OUCON COMPANY
SAN AROO, CALIFORNIA SODIUM CARBONATE SCRUBBING
99,000 CONSTRUCTION
3/79
NO ECONOMIC INFORMATION HAS AS YET BEEN PROVIDED
BY TEXACO.
TEXASGULF SNEMCO INC. 1250,000.
GRANGER* WYOMING SODIUM CARBONATE SCRUBBING
140,000 OPERATIONAL
9/7b
THE CAPITAL COST IS FOR TWO SCRUBBING UNITS ONLY
AND IS IN 1976 DOLLARS.
TRANSCO TEXTILES, INC. FMC ENVIRONMENTAL EQUIPMENT
AUGUSTA, GEORGIA SODIUM CARBONATE SCRUBBING
50,000 INDEFINITELY SHUT DOWN
3/75
NO ECONOMIC INFORMATION WAS MADE AVAILABLE.
U.S. GYPSUM CORP. NEPTUNE AIRPOL, INC.
OAKMONT, PENNSYLVANIA DOUBLE ALKALI (DILUTE)
19,300 NEVER SIAKTfcO-UF-
NO ECONOMIC INFORMATION HAS MADE AVAILABLE.
178
-------
SECTION 14
PROCESS DIAGRAMS FOR
INDUSTRIAL BOILER FGD SYSTEMS
LIST OF FIGURES
NO. PAGE
14-1 ALYESKA PIPELINE SERVICE CO. 181
14-2 ARCO/POLYMERS, INC. 182
14-3 CANTON TEXTILES 183
14-4 CARBORUNDUM ABRASIVES 184
14-5 CATERPILLAR TRACTOR CO., EAST PEORIA 185
14-6 CATERPILLAR TRACTOR CO., JOLIET 187
14-7 CATERPILLAR TRACTOR CO., MORTON 189
14-8 CATERPILLAR TRACTOR CO., MOSSVILLE 191
14-9 CHEVRON U.S.A. INC. 192
14-10 FIRESTONE TIRE AND RUBBER CO. 193
14-11 FMC (SODA ASH PLANT) 194
14-12 GENERAL MOTORS CORPORATION, DAYTON 195
14-13 GENERAL MOTORS CORPORATION, PARMA 196
14-14 GENERAL MOTORS CORPORATION, PONTIAC 197
14-15 GENERAL MOTORS CORPORATION, TONOWANDA 198
14-16 GEORGIA-PACIFIC PAPER CO. 199
14-17 GETTY OIL COMPANY, BAKERSFIELD, (FMC) 200
14-18 GETTY OIL COMPANY, BAKERSFIELD, (IN-HOUSE DESIGN)201
14-19 GETTY OIL COMPANY, ORCUTT 202
179
-------
LIST OF FIGURES (Continued)
NO. PAGE
14-20 GREAT SOUTHERN PAPER COMPANY 203
14-21 ITT RAYONIER, INC. 204
14-22 KERR-MCGEE CHEMICAL CORPORATION 205
14-23 MEAD PAPERBOARD COMPANY 206
14-24 MINN-DAK FARMER'S COOP. 207
14-25 MOBIL OIL COMPANY, BUTTONWILLOW 208
14-26 MOBILE OIL CORPORATION, SAN ARDO 209
14-27 NEKOOSA PAPERS, INC. 210
14-28 NORTHERN OHIO SUGAR COMPANY, FINDLAY 211
14-29 NORTHERN OHIO SUGAR COMPANY, FREEMONT 212
14-30 PHILLIP MORRIS, INC. 213
14-31 RICKENBACKER AIR FORCE BASE 214
14-32 SANTA FE ENERGY CORPORATION 215
14-33 SHELLER GLOBE CORPORATION 216
14-34 ST. JOE ZINC CO. 217
14-35 SUN PRODUCTION 219
14-36 TEXACO, INC., SAN ARDO 220
14-37 TEXACO, INC., SAN ARDO 221
14-38 TEXASGULF 222
180
-------
GO
nwr
HC1
Al
KMT
jaBDQESS
Kt
-------
H1
00
NJ
H«Tf«
Figure 14-2. Arco/Polymers, Inc.,
Monaca, Pennsylvania.
EQUIPMCin LIST
EQNO.
Al
F1
Ml
PI
P2
RF1
SSI
Tl
T2
T3
T4
TS
NAME
ABSORBER
F.D. FAN
MIST ELIMINATOR
RECIRCULATION
PUMP
REGENERATION
PUMP
ROTARY VACUUM
FILTER
SODA ASH SLURRIZER
RECIRCULATION
TANK
LINE REACTOR
THICKENER
SURGE TANK
LINE SLAKER
SIZE. FEET
17 DIA. X 62 HIGH
372 HP
MATERIAL
FLAKE GLASS LINED C.S.
C.S.
PVC
RUBBER-LINED C.S.
RUBBER-LINED C.S.
NO.
3
3
3
3
2
2
3
3
1
US SIRLAM NO.
IAU. Ib/hr a 1000
tclm i 1000
PMIICUUTCS. Ib/hr
SO;. Ib/hr
I1NPCMTUU. *F
HjO. Ib/hr
02. i
U0>. Ib/hr
VtLOCITI. ft/itc
(T)
"
-------
CO
Q> " FLUE GAS IN
FRESH WATER SAFETY SHOWER fcl |
i MAKE-UP
LIZATION BASIN
^h
» A T
ft
r
JOI
_jaf J
-TTOVERF4
J ki.._ _1-
<
1
jn[
T2
iERtU
M £
r
• ,1
$
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fvtt
I
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r?
1
1
&
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1ST)]
JJ
SI
^— z;
im
-n
Tl
1 SLUICE GATE
f)
— ~- EXHAUST
•>.
•^
\
0 CP
&
TO ATMOSPHERE
,__TO DUST COLLECTOR
r^FOR ASH SLUICING
IYPASS
TO WASTE TREATMENT PLANT
Figure 14-3. Canton Textiles,
Canton , Georgia .
EQUIPMENT LIST
EQ NO.
n
PI
n
P3
P4
P5
SI
ST1
Tl
T2
T3
VI
NAME
F.O. FAN
MAKE-UP PUMP
MAKE-UP PUMP
MAKE-UP PUMP
RECIRCULATION
PUMP
BLEED-OFF
PUMP
SEPARATOR
STACK
RECIRCULATION
TANK
DYE RETENTION
BASIN
DYE COLLECTION
MANHOLE
VENTURI
SIZE. FEET
30 HP
8 OIA. X 12 HIGH
14.980 GAL.
MATERIAL
FIBERGLASS
FIBERGLASS
F.R.P.
CONCRETE
316 LSS
NO.
1
1
1
1
1
1
1
1
1
1
1
1
GAS STREAM NO.
RATE. Ib/hr » 1000
tctm * 1000
PMTICULATES. Ib/hr
SO?, Ib/hr
TEMPERATURE. *F
H20. Ib/hr
02. *
K0», )b/hr
VELOCITY, ft/sec
(T)
42
295.2
124.2
430
@
2">.5
J7.3
qp
0 LIQUID STREAM NO.
RATE. Ib/hr x 100
9f»
TOTAL SOLIDS. I
P«
TEMPERATURE. *F
H20. Ib/hr
SULFITE. ag/l
SULFATE. mtl\
CHLORIDE, ag/l
SPECIFIC GRAVITY
(|)
qp
7.5
Cj)
1-291
L0.4—
1.2. C
(S)
201
9
0-M1
1S2
(^
tl)
%
fy
>-201
8.0
9
1$
^
OJ)
-------
CO
**.
nut CAS IN
*•*—I®
(2)
®
n
f
f
Tl
_0i
J
MME-UP »TER
r~er
TO ON-SITE
TREA
TKNT
Figure 14-4. Carborundum Abrasives,
Buffalo, New York.
EQUIPMENT LIST
EQHO.
A1
F1
F2
PI
P2
P3
P4
Tl
T2
¥1
NAME
ABSORBER
F.D. FAN
1.0. FAN
ABSORBER
RECYCLE PUMPS
VENTURI
RECYCLE PUMPS
BLEED-OFF
PUMP
MAKE-UP PUMP
RECIRCULATION
TANK
MAKE-UP TANK
VENTURI
SUE, FEET
8.5 DIA. x 38 HIGH
306PM
45 GPM
4 INLET x 13 HIGH
13 IN. THROAT
MATERIAL
316L SS
316L SS, HASTALLOY U
LINING
NO.
1
1
1
2
1
1
1
1
I
I
GAS STUAH NO.
RAH. >b/hr K 1000
ttlm * 1000
PARTJCULAUS. Ib/hr
SO?, Ib/hr
ItMPERATUM. *f
H20. 16/hr
0?. i
HOa. Ib/hr
¥UOCII«. ft/sec
(Y)
45.8
535.6
350
(£»
31.1
26.8
125
(3)
0 LIQUID STHLAM MO.
MK. Ib/hr x 100
9P"
TOTAL SOLIDS. X
PH
TEMPERATURE. *f
HjO. Ib/hr
SULFITE. Kj/1
SULFATE. ag/l
CHLORIOC. «s/l
SPECIFIC GSAV1T*
(j)
2.8
®
(p
<•>
1000
-------
TO STACK
EQUIPMENT LIST
CO
Oi
FILTER
CAKE
EXHAUST
Figure 14-5. Caterpillar Tractor Co., East Peoria.
EQNO.
n
Ftl
LSI
ME1
PI
n
n
P4
PS
P6
Rl
RF1
SI
SSI
Tl
T2
T3
T4
¥1
NAME
F.D. FAN
FILTRATE
RECEIVER
LIME SILO
MIST ELIMINATOR
RECIRCULATION
PUMPS
LIME REACTOR
PUMPS
FEED MATER
PUMPS
UNDERFLOW PUMPS
REGENERATED
LIQUOR PUMP
VACUUM PUMP
REHEATER
ROTARY FILTER
SEPARATOR
SODA ASH SILO
RECIRCULATION
TANK
LIME REACTOR
TANK
THICKENER
SURGE TANK
VENTURI
SIZE. FEET
700 HP
13.5 DIA. X 9 HIGH
.7 HIGH
75 HP. 1300 6PM
75 HP. 1300 6PN
5569 L8/HR
20 OIA. X 20 HIGH
13.5 OIA. X 7 HIGH
10 OIA. X 10 HIGH
13.5 OIA. X 9 HIGH
3.7 LONG X 1.8 HIDE
X 21.5 HIGH
MATERIAL
MILD STEEL
SS
INCOLOY
RUBBER-LINED C.I.
RUBBER-LINED C.I.
MILD STEEL
SS
MILD STEEL
MILD STEEL
316 SS
NO.
4
1
1
4
6
4
4
1
4
1
4
1
4
1
1
1
4
-------
GAS STRUM NO.
HATE. Ib/hr x 1000
•eta x 1000
rARTICULATCS. Ib/hr
SOj. Jb/hr
TEMPERATURE. *F
HjO. Ib/hr
02. I
HO*. Ib/hr
mOClTT. ft/sec
(I)
80
1040
350
(|)
104
Q)
(?) LIQUID STREW NO.
RATt. Ib/hr x 100
9P»
TOTAL SOLIDS. X
pH
TEMPERATURE, f
HjO. Ib/hr
SULFITE. •)/)
star ATE. 09/1
CHUWIOE. •)/!
SPECIFIC GRAVITY
(?)
©
2.3
(?)
CO
(*)
(^
2«.S
(fj
(^
^
171.2
to
@>
0
o
181
e
®
®
®
a
^
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@
Q
(9
@
$
id
Figure 14-5. (continued)
-------
EQUIPMENT LIST
00
-J
-LMDHU
Figure 14-6. Caterpillar Tractor Co.,
Joliet, Illinois.
(continued)
EQM.
Al
Fl
LSI
NE1
PI
n
n
P4
PS
P6
P7
PS
SSI
Tl
n
n
T4
T5
T6
vn
VF2
VR1
VR2
NANE
ABSORBER
F.D. FAN
LIME STORAGE
TANK
HIST
aiNINATOR
BLEED-OFF PUMPS
LIME Mil TANK
PUMPS
SODA ASK MIX
TANK PUMPS
FEED MATER PUMPS
SLUDGE PUMP
SLUDGE PUMP
FILTRATE PUMPS
VACUUM PUMPS
SODA ASH STORAGE
TANK
PRIMARY LINE
NIX TANK
SECONDARY LINE
NIX TANK
SODA ASH
MX TANK
SURGE TANK
THICKENER
CLARIFIER
VACUUM FILTER
VACUUM FILTER
SPARE
VACUUM RECEIVER
VACUUM RECEIVER
SPARE
SIZE. FEET
MO HP
.7 HIGH
50.000 GAL
MATERIAL
316 S.S.
STEEL
C.S.
316 LSS
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.
MET SURFACES
904 SS
MET SURFACES
304 SS
C.S.
C.S.
NO.
2
2
1
2
4
2
2
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
-------
CO
CO
GAS STRUM HO.
•ATE. Ib/hr * 1UOO
•eta * 1000
PARTICIPATES. Ib/hr
SO;. Ib/hr
TEMPERATURE. *F
H20. Ib/hr
02. *
HO,. Ib/hr
VELOCITY, ft/sec
LIQUID STREMI HO.
fcAtE. tb/hr » 100
9P»
TOTAL SOLIDS. 1
PH
TEMPERATURE. *F
H20. Ib/hr
SULFITE. ag/l
SULfATE. ag/l
CHLORIDE, ag/l
SPECIFIC GRAVITY
(J)
57.5
145.1
ISO
®
(?)
41.0
22.9
32.1
110
0
52.0
65
(7)
46.0
241.1
150
(J) LIQUID STREAM MO.
RATE. Ib/hr * 100
11.2 gp*
15.0 TOTAL SOLIDS. S
21.5 pM
125 TEMPERATURE. ^F
HzO. Ib/hr
SULFITE. ag/l
SULFATE. -9/1
CHLORIDE, ag/1
SPECIFIC GRAVITY
$
)D
.6
®
12.0
O
12.0
^|
12.0
©
$
12.0
©
$
12.0
CO
®
(•)
Q
3
a
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3
9
©
$
^
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12.0
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9
15-20
e
o
15-2«
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Figure 14-6. (continued)
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Figure 14-7. Caterpillar Tractor Co., »
Morton, Illinois.
n
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(continued) »n
w?
in
Ott
•ME
MHOOOU
F.O. rm
sn^ter
miT EmlMTW
cm wm twr
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son MM snow
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LIQUID STKAN HO.
MTE. Ib/kr k 100
«•
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TEMKMTUtt. *f
NJO. lb/kr
SUUITE. ag/l
SU.FAU. «|/I
CMLMIOC. Bg/1
SKCIf 1C CMVITI
(1)
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179
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1.01
6
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12S
12.0
70
MO
912OI
1.00
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99140
1.01
$
611
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12.0
70
560
9120(
l.OO
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210
2
134
1SOO
99*40
1.01
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10
2.0
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1000
1.00
(•)
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70
$
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11S1
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1.04
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0
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^
Figure 14-7. (continued)
-------
EQUIPMENT LIST
EQNO.
TO STACK "I" LINE STORAGE
,Jl
_r~/2> "*' Kjucxnin
~A-Ai
*r~~>
y\ ® P)
- 'Q -^
PI 1 ™
Tl 1 p3
1l
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f
TZ
© FROM LINE SODA SOFTNER
—
HATER *l&
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©
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74
0
T
^-,
1
1
gure 14-8. Caterpillar Tractor
Mossville, Illinois.
j
19
"Cr
^
RfJ
OjjM^ FILTER
)cfx ^CAtt TO
Ol DISPOSAL
^1 1 J=k CVUAItCT
Ml 1 *Gf s~j I.«™J[J1
IFRI! g
^-^ PS
Co.,
n
FR1
ME1
ME2
HI
PI
P2
N
PS
P6
RF1
SI
Tl
T2
n
T4
VI
NAME
F.D. FAN
FILTRATE
RECEIVER
MIST aiNINATOR
MIST ELIMINATOR
REHEATER
RECIRCULATION
PUMP
BLEED-OFF PUMP
fAltCTVf pigMp
CAUSTIC PUMP
FILTRATE PUMP
EXHAUST PUMP
UNOERFUM PUMP
ROTARY FILTER
SEPARATOR
RECIRCULATION
TANK
LINE NIX TANK
THICKENER
SURGE TANK
VARIABLE THROAT
VENTURI
SIZE. FEET
250. 250. 700. 800 HI
.8 HIGH
MATERIAL
INCOLOY
316 SS
316 LSS
NO.
4
1
4
1
4
3
4
4
4
Steam flow characteristics for Boiler No. 2 are from a
SO. emissions, January 21, 1977.
final report o;i particulatc and
GAS STREAM W.
RATE. Ib/hr K 1000
•Cta x 1000
MRTICULATES. Ib/hr
SOz. Ib/hr
TEMPERATURE. *F
HzO. Ib/hr
02. «
HOx. Ib/hr
VELOCITY, ft/sec
(T)
40
604.8
440.1
413
(p
28.4
10.5
23.4
159
(3)
©
LIQUID STREAM HO.
RATE. Ib/hr *. 100
9P»
TOTAL SOLIDS, f
pH
TEMPERATURE. *F
HzO. Ib/hr
SULFITE. *9/l
SULFATE. ng/1
CHLORIDE. •?/)
SPECIFIC GRAVITT
©
®
34S
f.4»
n»
24.2
86.9
1.111
CO
2.°
(?)
6.48
Ijn
24.2
B6.9
1.1)1
®
<$
.2
fy
B.3
($
K|
8.4
120
13.7
70.8
1.108
fy
130
0^
130
&
W
u
«J
23.5
CO*
^
-------
10
to
TO
BYPASS
STACK
iTO ATMOSPHERE
AND
SEALS
TO WASTE
DISPOSAL
SITE
Figure 14-9» Chevron U.S.A. Inc.,
Bakersfield, California.
EQUIPMENT LIST
EQ NO.
A1
Fl
PI
P2
P3
SI
ST1
Tl
T2
NAME
ABSORBER
F.D. FAN
RECIRCULATION
PUMP
MAKE-UP LIQUOR
PUMP
MAKE-UP UATER
PUMP
SODA ASH SILO
STACK
MAKE-UP TANK
BLEED STORAGE
TANK
SIZE. FEET
16.5 DIA. X
33 HIGH
75 HP
8 DIA. X
20 HIGH
MATERIAL
316L SS
C.S.
31 6L SS
NO.
3
6
6
3
3
3
3
GAS SIRUM NO.
RAH, Ib/hr * 1000
•Cta « 1000
PARTICULARS. lb/hr
S
-------
i TO STACK
Figure 14-10. Firestone Tire and Rubber Co.,
Pottstown, Pennsylvania.
EQUIPMENT LIST
CQ NO.
Fl
LSI
PI
P2
RM
SI
SSI
Tl
T2
T3
T4
VI
NAME
F.D. FAN
LIME STORAGE
TANK
REC1RCULATION
PUHP
LIME REACTOR
PUHP
ROTARY FILTER
SEPARATOR
SODA ASH
STORAGE
RECIRCULAT10N
TANK
LIME REACTOR
THICKENER
SURGE TANK
DUAL THROAT
VENTURI
SIZE, FEET
4.67 OIA x 7.17 HIGH
.5-1.25 THROAT LENGTH
MATERIAL
RUBBER-LINED
CAST IRON
RUBBER-LINED
CAST IRON
316L S.S.
316L S.S.
316L S.S.
C.S.
C.S.
C.S.
3161 S.S.
NO.
1
1
1
1
1
1
1
1
1
1
1
1
GAS STRUM NO.
RATE. Ib/hr » 1000
tclm x 1000
PAR1ICULATES. Ib/hr
SO?. Ib/hr
UHPCRATURE. "F
H20. Ib/hr
02. i
NO.. Ib/hr
VELOCITY, ft/sec
(V)
13
450
Jt>0
100
Cp
10
11.7
34.2
130
Q)
(T) LIQUID STREAM NO.
RATE, Ib/hr * 100
9pm
T01AL SOLIDS, 1
pH
TEHCLRATURE, "F
H;0. Ib/hr
SULF1TE. mg/1
SULFATE, mg/1
CHLORIOf. ing/I
SPECIFIC GRAVITY
(5)
@
110
CD
.081
OP
(?)
d>
fy
($
iQi
^
<0i
i.a
55
1$
-------
KN1STER IMSH HATER
<3>
aUE GAS IN
—&
® „
A
.af1^
L<£
<: <;'<; <;
X"
XT
XT
"V
~x
~^
Al
^
DEMSTER
T- ®
"
id
HASH HATER
©
FLUE GAS IN
^-TT
=*" L
.1
® Jii
A
U/SiT^
J®.
f £ f f
\"V
^<~~/
xr^v
A1
^ ®
__P1
TO IIASTE POND
RIVER HATER —,P3 Q
PWCCSS JIASTEMATtR /-^__ ~
SOOA ASHiLIQUOR *»
vo
it*
(Z>
P2
©
P2
Figure 14-11. FMC (Soda Ash Plant),
Green River, Wyoming.
EQUIPMENT LIST
EQNO.
A1
Fl
ME1
HI
PI
P2
P3
P4
PS
T1
NAME
ABSORBER
F.O. FAN
MIST ELIMINATOR
REHEATER
RECIROJLATION
PUMP
MAKE-UP PUMP
RIVER HATER
MAKE-UP PUMP
PROCESS MASTEUATER
MAKE-UP PIMP
SODA-ASH LIQUOR
PUMP
MAKE-UP TANK
SIZE. FEET
26.5 OIA. X 73 HIGH
193,000 SCFM
6000 GPM
MATERIAL
C.S.. CEILCOTE 103
RUBBER-LINED C.I.
NO.
2
2
2
2
2
2
1
1
1
GAS SlttAN NO.
RAH. U/hr » 1000
•eta « 1000
PMTICULATIS, lb/ftr
SO*. lb/hr
TtMPCMTURC. *F
HjO. Ib/hr
02.*
HO,. Ib/fcr
ULOCITY. ft/sec
QP
231
320
(J)
176
135
Q>
99
320
0 LIQUID STREAM NO.
RATC. Ib/hr » 100
279 9P»
TOTAL SOLIDS. S
PH
200 TEHPCRATURt. *F
H20. Ib/hr
SULFITE. ag/l
SULFATE. ag/l
CHLORIDE, ag/l
SPECIFIC GRAVITY
(5)
6800
(6)
qp
IUV<
(8)
(9)
'^
^
($
0
d>
fy
-------
WSMOt
nsna
vo
U1
Figure 14-12. General Motors Corporation,
Dayton, Ohio.
EQUIPMENT LIST
EQNO.
Al
F1
PI
P2
P3
Tl
T2
Tl
NAME
ADSORBER
F.O. FAN
RECIRCULATION
PUMP
CAUSTIC PUMP
BLEED-OFF
PUMP
RECIRCULATION
TANK
CAUSTIC TANK
BLEED-OrF
TANK
SIZE, FEET
C DIA. * 10 HIGH
35.000 SCFM.
9 IN. H.C.
200 CPU. 25 HEAD
806PM
SO 6PM
7.5 DIA. x 12 HIGH
9 DIA. x ID HIGH
t OIA. » t.l HICN
MATERIAL
nci ss
C.S.
OUBKR-LIMEO C.S.
C.S.
DUUER.LINEOC.S.
lid ss
C.S.
iidss
NO.
2
2
1
1
2
1
1
1
CAS STREAM M.
UTE. Ik/kr • 1000
acte • 1000
PAITICUUTES. th/hr
SO;. Ik/kr
TENPEMTUtC. *f
HjO. U/kr
02. t
N0«. Ib/fcr
VUOCITV. ft/scc
(i)
45
SS.3
111.5
400
^
JS.t
• .1
16.4
125
&
® LIQUID STBEAN M.
9P>
TOTAL SOLIDS. I
PH
TEMPEMTUU. *F
HjO. Ib/kr
SULFITE. ag/1
SULFATE. ag/l
CMLDtlOC. ag/l
SPECIFIC CWWITT
<&>
SA
«)
200
7.0
(n
SO
fo)
(•)
^
ft
-y
»
IS
-------
Figure 14-13. General Motors Corporation;
M Parma, Ohio
EQUIPMENT LIST
EQNO.
A1
F1
HI
PI
P2
P3
P4
PS
m
LSI
SSI
Tl
T2
T7
Ti
T5
T6
NAME
ABSORBER
F.D. FAN
REHEATER
RECIRCULATION
PUMP
RECIRCULATION
PUMP
UNDERFLW PUMP
UNDERFLOW PUMP
FILTRATE PIMP
ROTARY VACUUM
FILTER
LINE STORAGE
SODA ASH
STORAGE
CHEMICAL NIX
TANK
CHEMICAL NIX
TANK
CLARIFIER *1
OARIFIER 12
FILTRATE TANK
RECIRCULATION
TANK
SIZE, FEET
10.5 DIA. x 22.5 HIGH
200 HP. 12 IN. H.6.
2-750 GPM
2-550 GPM
700 GPM
100 GPM
25 GPM
300 GPM
500 SQ. FT. AREA
90 TON
35 TON
5000 GAL
5000 GAL
60 DIA. x 14 HIGH
60 DIA. x 14 NIGH
4 DIA. x 7 HIGH
2-3700 GAL
2-3000 GAL
MATERIAL
3161 SS
C.S.
C.S..
RUBBER-LINED
RUBBER-LINED
RUBBER-LINED
RUBBER-LINED
RUBBER-LINED
C.S.. POLYPROPYLENE
CLOTH
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.. TAR
COATING
NO.
4
4
4
4
3
2
2
2
2
2
1
1
2
1
1
1
4
GAS STRUM NO.
RAH. Ib/hr a IUOO
Ktm > 1000
CAHIICU.AUS. Ib/hr
JO?. Ib/hr
TCNPUATURE. *F
MjO. Ik/ftr
02. I
BO,. Ib/hr
VUOCITI. ft/sec
(V)
58. t
73.2
2*f-
397
S50
(?)
JS.S
60.1
41. S
152
($
0 LIQUID STRUM NO.
MTC. Ib/hr a 100
9P»
TOTAL SOLIDS. %
P«
TtMPEMTURE. *F
H]O. Ib/hr .
suinu. .9/1
SUUATE. ag/l
CHLORIDE. •(/!
SPCCIFIC GMVITT
^
^
C')
C')
<$
^
^
^
1200
(|
|f)
15-21
ft
4*
to
44'
4*
^
so
y '
1
-------
FLUE B>S III 0>
C3
VD
® g TO MKTflHTn
PI
Figure 14-14. General Motors Corporation,
Pontiac, Michigan.
CDUIMUT LIST
EO NO.
Al
n"
PI
P2
P3
N
PS
N
Tl
T2 -
MANE
ARSORKR
I.D. FAM
RECIRCULATION
PIMP
IMOCRFUM
PIMP
RECIKULATION
PIMP
RECIRCULATION
PIMP
MAKE-UP PIMP
MAKE-UP PIMP
MUMS IBM
CLARiriER
SIZE. FEET
12 DIA. x 21. S HIGH
MATERIAL
3ISLSS
NO.
I
t
CAS STRUM NO.
•ATE. Ib/hr » 1000
•eta « 1000
PARTICIPATES. Ib/hr
SO?. Ib/hr
TENPERATURE. *f
NjO. Ib/hr
02. i
HO,. Ib/hr
VELOCITT. ft/sec
(Y)
91
• S.5
160
OP
75
28.2
360
(3)
@ LIQUID STRUM MO.
RATE. Ib/hr • 100
«•
TOTAL SOLIDS. S
PH
TEMPERATURE. *F
HjO. lb/br
SULFITE. ag/1
SULFATE. ag/l
CHLORIDE, ag/1
SPECIFIC GRAVITY
CD
@
Q)
(R)
$
10-20
5.0
^
405
^
325
^
SO
^
50
^
^
^
4
-------
10
CO
MNunac
Figure 14-15. General Motors Corporation, Tonowand*,
New York.
EQUIPMENT LIST
CQ NO.
F1
n
n
P3
P4
PS
re
»7
SI
ST1
Tl
T2
T3
T4
TS
T*
VI
NAME
i.o. FAN
RECIRCULATION
PUMPS
OVERFLOW PIMP
CHEMICAL FEED
PIMPS
SCRUMER BLOU-
DOM PIMPS
HASTE TREATMENT
TRANSFER PIMPS
CAUSTIC FEED
PUMPS
ma -UP PUMP
SEPARATOR
STACK
RECYCLE TANK
OVERFLOU TANK
CHEMICAL FEED
TANK
AERATION MIXER
HOLDINCTANK
CAUSTIC STORACC
TANK
VARIARU 1NRMT
vonwu
SIZE. FEET
MATERIAL
116LSS
S.S.
muss
NO.
4
t
1
1
2
Z
\
\
4
I
4
1
1
1
1
1
4
MS STREAM •.
RATE. Ib/hr * 1000
M«fc« 1000
PAtTICULATES. Ik/tar
SOJ. U/kr
TDKM1UC. *T
NIO. Wfcr
•2. *
•V. IWkr
VOOCTTT. ft/MC
©
3*.«
1M.O
257.3
ISO
$
3«.0
194. q
210.I
4 100
•!•
10.4 1DTM. SOLIDS, f
21. • pH
TEMPERATURE. T
HjO. Ib/kr
SULFITE. •)/!
SULFATE. «9/I
CHLORIDE, ^/l
SPECIFIC CMVITV
Q
«.A
qp
C.A
(J)
7.n
(t)
7«2
7.0
(')
721
7.0
^
IS-101
<1.0
Q>
<1.0
<^)
-------
rasTwx
vo
vo
-W MMX MTtl
mr mu MOCESS
Figure 14-16. Georgia-Pacific Paper Co.
Crossett, Arkansas.
MUtMOn LIST
COM.
n
ri
si
Tl
VI
HMC
F.O. FM
•CCIKUUT10H
NNP
SCMMTQft
•ECIKUUTION
TAW
vomfti
SIZE. FttT
50006IH
24 s SS HIGH
».» HIDE tt JO NIGN
MKTEtlM.
3MU.MBI.UW>
304SS. FIKKLASS
LINO)
J04SS
KMSS
w.
1
1
1
1
1
CAS STUAHNO.
MfE. W»r » 10M
Mta« 10I»
MIIKUUTES. IWhr
SO}. U/hr
TEHKMTURf. f
M20. U/kr
02. 1
MW. tb/kr
tlLOCITY. ft/iec
<0
320
765
1094
110
(|)
SO
10*-
164
W
®
LIQUID SIMM NO.
RATE. Ib/hr » 100
9P"
lOTM. SOIIDS. S
pH
TEM>EMTW£. *F
HjO. Ib/hr
SULF1TE. ma/\
SULfATE. ag/l
CMLORIK. og/l
SPECIFIC GIUVITT
(|)
®
5000
cp
2100
(g)
2000
7.5
®
^
0
($
^
^
^
^
$
'•
-------
IO
o
o
HAKE UP
MATER
Figure 14-17
Getty Oil Company.
Bakersfield, California
FMC Environmental Eqmnt,
EQUIPMENT LIST
EQNO.
Al
F1
ME1
PI
Tl
T2
NAME
ABSORBER
F.O. FAN
HIST ELIMINATOR
RECIRCULATION
PUMP
DISPOSAL TANK
SODA ASH
MIX TANK
SUE. FEET
13.5 OIA. X 35 HIGH
42.000 GAL
MATERIAL
31 6L SS
INCONEL
1/4" C.S.
NO.
1
1
1
1
1
1
CAS STKAN NO.
WTt. Ib/Nr x I00»
•eta R 1000
PMTICUIATCS. Ik/kr
J0|. Ik/kr
TENPCM1UK. *F
NlO. Ik/kr
t?. I
•Ok. Ik/kr
niocuf. U/MC
V?
130
500
®
•I.«
1)0
<$
(J) liqUID STMAN NO.
Wit. Ib/hr x 100
IP-
TOTAL SOLIDS. S
*
TCNPtNATME. *F
HjO. Ib/hr
SUiriTE. •«/)
SW.FATE. «9/l
CMLORIOC. mt/\
SPECIFIC HAVITT
©
10
(*)
1000
«.l
(J)
Ci)
(i)
V
-------
ME1
Fl
nuc ""(ET1
(AS
1 1U 3
A
1 ,
1
Al
^n
©
0
rs ®
&?
P2
Figure 14-18 . Getty
PI
Oil
SODA ASH
CAUSTIC
TO
DISPOSAL^
®
Company ,
Bakersfield, California
In-House Design
to
o
M
•
EQUIPMENT LIST
EQ. NO.
Al
Fl
ME1
PI
P2
P3
Tl
T2
NAME
ABSORBER
F.D. FAN
NIST ELIMINATOR
RECIRCULATION
PUMP
BLEED-OFF PUMP
ALKALI FEED
PUMP
DISPOSAL TANK
ALKALI MIX
TANK
SIZE. FEET
18 DIA. X 33 HIGH
500 HP. 11 IN. HG
40 HP. 1000JJPM
40 HP. 1-2 GPM
20 DIA. X 20 HIGH
42,000 GAL.
MATERIAL
316L SS
C.S.
C.S.. RUBBER-
LINED
316L SS. RUBBER-
STATOR
C.S.. RUBBER-
LINED
C.S.
NO.
9
9
9
9
9
9
9
GAS STREAM NO.
RATE. Ib/hr x 1000
•cfn x 1000
PARTICULATES, Ib/hr
SO*. Ib/hr
TEMPERATURE, *F
HjO, Ib/hr
OZ. t
NO,. Ib/hr
VELOCITY, ft/sec
(T)
200
500
qp
127
150
QP
(?) LIQUID STREAM NO.
RATE. Ib/hr « 100
9P"
TOTAL SOLIDS. X
pH
TEMPERATURE, *F
HzO. Ib/hr
SULFITE. ng/1
SULFATE. 019/1
CHLORIDE, mg/l
SPECIFIC GRAVITY
©
10
QP
lonn
"•*-«
1.15
Cj)
CJP
19)
W
fy
150
V
($
Oil
03)
®
-------
10
o
to
TO ATKKPM.U
f\
n
CAUSTIC
Figure 14-19. Getty Oil Company,
Orcutt, California.
EQUIPMENT LIST
EQ. NO.
Al
Fl
HC1
PI
P2
Tl
T2
NAME
ABSORBER
F.D. FAN
HYOROCLONE
PUMP
CAUSTIC FEED
PUMP
DISPOSAL TANK
CAUSTIC MIX
TANK
SIZE. FEET
4 DIA. X 10 HIGH
42.000 GAL
MATERIAL
316L SS
C.S.
316L SS
1/4" C.S.
NO.
1
1
1
1
1
1
1
CAS STREAM NO.
•ATE. Ib/hr x 1000
•CfB X 1000
PARTICIPATES. Ib/hr
SO?. H>/hr
TEMPERATURE. *F
HzO. Ib/hr
02. 1
NOx. Ib/hr .
VaOCITY. ft/sec
(1)
20
son
(?)
12
ISO
(3)
0 LIQUID STREAM NO.
RATE. Ib/br x 100
9P*
TOTAL SOLIDS. %
P«
TEMPERATURE. *F
HzO. Ib/br
SULFITE. Mg/1
SULFATE. ag/1
CHLORIDE. *g/l
SPECIFIC GRAVITY
©
2
(§)
6.8
(7)
QP
®
(^
^
^
^
^
(^
K^
•
^
-------
EIMUIST TO A1MSPMCH
to
o
TO AWOSFKK
CAIKTIC RBI OQIIWMI.mil
*-TO ASH TOM)
Figure 14-20. Great Southern Paper Co.
Cedar Springs, Georgia.
EQUIPMENT LIST
EQNO.
Fl
PI
P2
51
ST1
Tl
72
VI
NAME
P.O. FAN
RECIRCULAT10N
PUMP
ASH PUMP SLUDGE
SEPARATOR
(RADIAL VANE)
STUB STACK
RECIRCULATION
TANK
HOLD TANK
VENTURI
SIZE. FEET
900 HP. 900 RPM
150 HP, 2400 6PM
5006PM
24 DIA. X 45 HIGH
200 FT.
18 DIA. X 15 HIGH
MATERIAL
ALLOY LINED STEEL
RUBBER LINED C.I.
RUBBER LINED C.I.
S.S.
s.s.
S.S.
316 LSS
NO.
4
3
2
2
2
1
1
2
CAS STREAM W.
RATE. Ib/hr 11 1000
Kfa « 1000
rARIICULAIES. Ib/hr
SO?. Ib/kr
TEMPERATURE. *F
MJO. Ib/hr
oz. *
NO*. Ib/hr
VELOCITT. ft/MC
(T)
ISO
6900
2500
425
®
211
•5
250
11O
(1)
0 LIQUID STROM MO.
RATE. Ib/kr « 100
9P"
TOTAL SOLIDS. I
PH
TEMPERATURE. *F
HjO. Ib/hr
SULFITE. •!/!
SULFATE. B9/1
CHLORIDE. •»/!
SMCIFIC UAVIIV
©
$
"»So
(j)
(8)
1200
2-5
(9)
1600
3-5
^
1600
2-5
^
600
to
-------
MAKE-UP MATtR ,
FLUE
-to
-TO STACK
51
_JIII IU
WSTDHTER TREATKNT
o Figure 14-21. ITT Rayonier, Inc.
*• Fernandina Beach, Florida.
EQUIPMENT LIST
CO M.
Fl
PI
SI
T1
«1
HMC
P.O. FAR
RECIMULATIW
PUMP
SEPARATOR
RECIRCuUTHM
TANK
VARIABLE THROAT
VENTURI
SIZC. FEET
103S HP
75 HP
16.S OIA. i 38 HICH
MATERIAL
31CSS
316L SS
31CL SS
HO.
2
2
2
1
2
CAS STREAK M.
RATE. Ib/hr • 1000
•eta « 1000
PARTICULATES. lk/hr
SOZ. Ib/hr
TEKHRATURE. f
H20. lk/hr
02. X
ROk. Ik/br
mociTv. rtysK
(T)
its
1300
1132.1
«0
@
140
1340
9*1.0
460
(3)
30
169.9
0 LIQUID STREAM M.
RATE. Ib/hr « 100
9P>
30 TOTAL SOLIDS. I
144.2 PM
TEMPERATURE.^
MjO. Ib/hr
SULFITE. ag/1
SULFATE. >9/1
CHLORIOE. ••/!
SPECIFIC OIAVITV
(D
100
$
1470
(j)
ISO
(jp
1620
$
<$
<^
^
^
^
^
^
^
-------
-» TO STACK
to
o
Ul
aUEGAS HI
Figure 14-22. Kerr-McGee Chemical Corp. ,
Trona, California.
EQUIPMENT LIST
EQ NO.
Al
n
HI
PI
re
Tl
MANE
ABSORBER
F.D. FAN
REHEATER
RECIRCULATION
PUMP
ALKALI FEED
PIMP
BURUTE TANK
SIZE. FEET
30 DIA. x 35 HIGH
50*F REHEAT
1256PM
MATERIAL
C.S.. FIAKEGLASS
LINED. 317L SS
TRAYS
C.S.
C.S.
C.S.. RUBBER-LINED
NO.
2
2
2
2
2
2
CAS STKM M>.
UTE. Ib/kr K 1000
•eta « 1000
PARTICULATES. Ib/hr
SO;. Ik/kr
TENPEMTUK. f
HZO. IWHr
02. S
•Ox. Ib/kr
VELOCmr. ft/tec
(p
361
320
®
29*
175
(3)
0 LIQUID STREMt HO.
MTE. Ib/kr « 100
91"
TOTAL SOLIDS. X
pH
TEWEMTURE. *F
HjO. Ib/hr
SULFITE. ng/1
SULFATE. •)/!
CHLORIDE. •!/!
SPECIFIC CWVITT
(p
<8»
(?)
*-2"i
<$>
125
ft. 5
t?)
6.5
$
(fj
«9
o^
"^
(^
^
©
1
-------
STACK
FLUE
GAS
IN
PULP HILL
MAKE-UP
tttTER
to
o
Figure 14-23. Mead Paperboard Co.
Stevenson , Alabama •
EQUIPMENT LIST
EQ. NO.
A1
Fl
PI
P2
Tl
T2
NAME
ABSORBER
F.D. FAN
RECIRCULATION
PUMP
CAUSTIC PUMP
RECIRCULATION
TANK
SODIUM CARBONATE
TANK
SIZE, FEET
MATERIAL
316 SS
C.S.
FIBERGLASS
NO.
1
1
1
1
1
1
MS SIMM IB.
MTC. Ib/hr a 1000
•eta > 1000
rAITICULMES. Ib/hr
S0j. lk/hr
TENPEMTME. T
HjO. lk/hr
02. I
Mfc. W
waocin. rt/stc
(T)
17S
450
TOTAL SOLIDS. S
pH
TEPPEMTURC.^F
MjO. Ib/hr
SULFITf . •!/!
SULFATE. ag/l
CHLORIM. >9/l
SPECIFIC CMVITT
9
3000
MM?
$
6nn
(7)
20-2!
/ .n-
8.'
®
•
20-2!
C?)
^
1"
<$
0^1
d>
HI*
d$
oji
-------
10
o
AMMONIA-LADEN
PROCESS HATER
?J AMMONIA-LADEN
PROCESS HATER
UASTEHATER
TREATMENT
AND
STORAGE
Figure 14-24. Minn-Dak Farmer's Coop.
Wakpeton, North Dakota,
EQUIPWNT LIST
EQ NO.
Fl
Ml
PI
Tl
VI
MK
F.O. FAN
HIST
U1MINATOR
RECIRCULATION
PUMP
RECIRCULATION
TANK
VARIABLE THROAT
VEHTUR1
SIZE. FEET
75 HP 3000 6PN
10 x 10 x 10
MATERIAL
316SS
CONCRETE PIT.
TAR LINED
31 (L SS
NO.
2
2
2
2
2
GAS STREAM NO.
RATE. Ib/hr x 1000
acta x 1000
PARTICULATES. Ib/hr
SO?. Ib/hr
TEMPERATURE. *F
HpO. Ib/hr
02. »
HOx. Ib/hr
VELOCITY. ft/sec
CO
125
245. 4
767
0 LIQUID STREAM. NO.
RATE. Ib/hr x 100
(f)
Id
0$
-------
TO ATOHSPHERE
O
00
fWl fiAS
i
u
|N 1 1
i
HASTE DISPOSAL <§>
POND
\
r
i
-»f\
\
s^ ^>
r 5Ei
»1 -< ® c-, f 1
/ * LJ
r
1&~ORA,N
2 14-25. Mobil
Oil
California
Company, Buttonwillow,
•
EQUIPMENT LIST
EQ NO.
Al
ME1
PI
P2
Tl
NAME
ABSORBER
MIST ELIMINATOR
RECIRCULAT10N
PUMP
CAUSTIC FEED
CAUSTIC STORAGE
TANK
SIZE, FEET
MATERIAL
C.S.. EPOXY COATED
FRP
316 SS
NO.
7
7
7
7
7
GAS STRUM NO.
RATE. Ib/hr x 1000
*cf« x 1000
PARTICULATES. Ib/hr
S02. Ib/hr
TEMPERATURE. *F
HjO. Ib/hr
02. I
NO*. Ib/hr
VELOCITY, ft/sec
(T)
11.4
30
ss«
Cp
4.5
(T)
0 LIQUID STREAM NO.
RATE. Ib/hr x 100
9P"
TOTAL SOLIDS. S
pH
TEMPERATURE. "F
H;0. tb/hr
SULFITE. ng/1
SULfATE. nig/I
CHLORIDE. "9/1
SPECIFIC GRAVITY
©
dD
(7)
C!P
15
C9)
•
^
05
HD
(Q)
(Hi
dsi
®
-------
S
NCI
auc CAS iifl>^
_CIMIUST
J®~»
Bill
Al
***
TO ATM!
MOE
® ,^_ CAUSTIC AM) ALKALIK
ff^OIl FIELD HUTOHTO
~- HASTOMTE* DISPOSAL ZOIC
--
Figure 14-26. Mobil Oil Corp., San Ardo/
California.
to
0
*° US STREAM M.
(T)
ff)
CD
(?) LIQUID STREAM NO.
d)
(QUIPKn LIS1 STSTCH 1
(OM.
Al
Fl
•1
n
n
STl
MM
AISOMMS
I.D. FANS
HIST UINIMTOI
KCIKUUTUM
FUNK
NM£-VP PIMPS
STACK
sin. rut
4 OIA. « tO NICK
NATUIAL
SMCU 31H SS
TKATi 311 SS
C.S.. 3IIL SSLMIIKS
01 CASIMS
3IM. SS, LIKD MITN
•MRTMtt-IC t9On BftlM
nMHlU|>|li ft3f|Ml ••••••I
FIKMUSS
M.
20
to
20
It
(QVIMW IIST STOW t
MiO.
Al
ft
Ml
n
n
STl
MM
AISOIKRS
1.0. FAtt
HIST UmUATOI
KCIKUUTION
PUMPS
NAtt-UP PIMPS
STACKS
Sill. FltT NATU1AI
I.I OIA. 1 n MM
»
CU 31ft SS
TMtS 311 SS
C.S.. 31N. SS LIMMS
MCASMCS
SIM. SS. HMD MITH
PKNOLIC (PUT NUM
FIKMUSS
M.
0
•
•
0
0
•
(D (D CD
CD
10
(DOG
<& @ 03 ®
US STREAM M.
RATE. Ib/hr « 1000
•eta i 1000
MRTICULAIES. Ib/hr
S02. Ib/hr
TEMPUATURE. *F
N20. Ib/hr
02. ft
Nft«. Ib/hr
MLOCITI. ft/Mt
(^)
8
(8
470
(I)
£.8
(3)
t?) LIQUID STREAM NO.
RATE. Ib/br i 100
gp"
TOTAL SOLIDS. S
pH
TEMPERATURE. *f
HjO. Ib/hr
SULFITE. «9/l
SULFATE. «9/l
CHLORIDE, ag/l
SPECIFIC CRAVITV
^
75
(»)
^
ro
CO
^
4)
4?
^
«
STREAM FLOW CMAI
n
Msmi
0^
ucmi
91 1
V
ITICS
4r*
—
GAS STtlAN NO.
NATE. Ib/hr * 1000
•cto M 1000
PUTICULATES. Ib/hr
SO?. Ib/hr
TENPENATIME. *F
MJO. Ih/hr
02. 1
NO,. Ib/br
VEIOCITI. ft/tM
CO
18
153
470
6.0
(8)
6.0
OP
8.0
<$
^
(|2)
n
4?
mown
n
V
lOHCMAI
IR mti
OJJ
ucrni
[Ml
4£
ITICS.
dj)
-------
10STKI
10
M
o
Figure 14-27,
Nekoosa Papers, Inc.
Ashdown, Arkansas.
EOjUimENT LIST
EQNO.
n
n
n
n
si
n
n
n
MK
F.O. FM
KCIKUUTION
NMP
•LEED-OFFNNP
mamr MMP
SEPARATOR
RECIKUUTIM
TMK
NUE-VPTMUC
VARUULE THROAT
VERTUR1
SIZE. FEE1
2200 «m
300 6TM
10 OIA. I
IS NUN
HtTERIM.
NILD STEEL
FLAKED GUSS
iniM
MUD STEEL
MDLUED
n.
2
2
2
2
2
2
1
2
MS S1MMIM.
•Ml. Ik/kr • MM
•ctaM 1000
MITICHUtTES. Ifc/fcr
SOf. Ik/kr
TIMKM1UK. *F
"It, M/hr
•2. •
•tj. Ih/kr.
•aocm. ft/Me
0
125
2112
12S»
3SS
^
27
12*
(3)
© Liquio SIOUN •.
OP"
TOTAL SOLIDS. S
f*
TOTEMTUH. *T
HzO. Ik/kr
SULFITE. •!/!
SULFATE. B|/|
OUUK. ••/!
SKC1FIC COMI1V
2.1
SB
C.fl
"^
7.2
4M
If
^
tt
o
(A
•S"
7JT
IT
•
-------
EXHAUST
TO
ATMOSPHERE
OEMISTER
WASH
MATER
TO HOLDING
POND v
Figure 14-28. Northern Ohio Sugar Co.,
Findley, Ohio.
EQUIPMENT LIST
CO NO.
n
HE)
PI
PZ
P3
ST1
Tl
V}
NAME
F.D. FAN
HIST ELIMINATOR
RECIRCULAT10N
PUMP
HAKE -UP PUMP
UASTEMATER PUMP
STACK
RECIttCULATION
TANK
VARIABLE THROAT
VENTUR1
SIZE. FEET
7.5 OIA
MATERIAL
SHILI-316L SS
31 6L SS
NO.
2
1
1
T
CAS SIKt AH NO.
RATE. Ib/ltr * 10UU
«cfn > 1000
PARTICIPATES. iD/hr
SO?. It/nr
UNPERAIURE . °F
njli. Tb/hr
o:.
l.0». iD/hr
VlLOCm. ft/ sec
(;o
120
2t.J. 1
MS
t?)
(.). )
$
0 IIQOID STREAM NO.
RATE. ID/hr » luO
9P"
TOTAL SOLIDS. I
pH
TENPlRAIURE.^'f
HjO. Ib/hr
SULflTt. 119/1
SUIFATE. H9/I •
CHLORIDE. MQ/I
SPECIFIC GRAVITY
<$)
16)
r.nn
(V)
ion
^
inn
^
un
&
^
(To
<$
^
6
-------
—•- TO
I
Figure 14-29. Northern Ohio Sugar Co.,
Freemont, Ohio.
HOLDING
EQUIPKHT LIST
EQ n.
FI
MCI
PI
P2
P3
ST1
T1
VI
HME
r.o. FAN
MIST ELIMINATOR
RECIRCULAT1M
PUMP
MAKE-UP PIMP
MASTEUATER PIMP
STACK
REC1RCULAT10N
TANK
VARIABLE THROAT
VEMTM1
SIZE. FEET
MATERIAL
•0.
2
1
I
1
1
GAS STREAM NO.
RATE. Ib/hr a 1000
ICfB H 1000
PADIICULAIES. Ib/kr
SO?. Ib/hr
TEMPERATURE. *f
HJO. Ib/hr
02. »
ROm. Ib/hr
VELOCIII. ft/sec
(T)
(?)
(3)
0 LIQUID STREAM NO.
RATE. Ib/hr » 100
9P>
TOTAL SOLIDS. S
PH
TEMPERAIURE. *F
HzO. Ib/hr
SULFITE. *9/1
SULFATE. «J/1
CHLORIDE. »9/l
SPECIFIC CMVITV
©
(£)
(J)
0
o
(^
ft
<$
^
-
-------
•TO STACK
ro
M
U)
SOU* ASH
DISPOSAL
Figure 14-30. Phillip Morris, Inc.
Chesterfield, Virginia.
EQUIPKHT LIST
EO n.
Al
F1
HI
NE1
PI
n
n
01
Tl
T2
RME
MSOR8ER
F.O. FAH
REHEATER
HIST aiWHATOR
RECIRCULATION
PUMP
MAKE-UP PM>
BLEED-OFF PUMP
PREQUCHCHER
SODA ASH TAHK
AERATOR
SIZE. FEET
9 DIA I 35 NIGH
1000 GPN
6 SHI
12 OIA I 22 HIGH
MATERIAL
FRP
POLYPROPYLENE
RUBBER-LIMED
MBER-LMEO
RUHER-LIHED
C.S.
HO.
1
1
1
1
2
2
2
1
1
1
CAS SIMAH NO.
•AH. Ib/hr > 1000
•eta ii 1000
PART1CULAIES. tb/kr
SO?. Ib/hr
TEHPERATUU. *F
HjO. Ib/hr
02. X
HO.. Ib/hr
•ILOC1TV. ft/uc
(T)
IS
1%0
10
^
40
110
10
(3)
ISO
0 LIQUID SHUN HO.
RATE. Ib/hr » luO
9P«
TOTAL SOLIDS. I
PH
IEHPERA1URE. *F
HjO. Ib/hr
SULflTE. *9/l
SULFAIE. ag/l
CHLORIDE, ag/l
SPECIFIC CRAVIIT
(S)
1000
6.S
110
$
7.5
(?)
Q
tj)
^
5-11
*.S
$
<$
«
Q
9
$
o
o
-------
N>
HUE
Figure 14-31. Rickenbacker Air Force Base.
Columbus, Ohio.
EQUIPNUT LIST
CQ NO.
Al
F1
LSI
MCI
PI
n
P3
ST1
11
T2
T3
T4
NAME
ABSORBER
F.D. FAN
LINE STORAGE
MECHANICAL
COLLECTOR
REC1RCULAT10N
PUMP
RECIRCULATION
PUMP
UNDERFLOW PUMP
STACK
LIME MIX TANK
2ND STAGE LEVEL
TANK
1ST STAGE LEVEL
TANK
CLMIFIEI
S12E. FEET
12 01 A, i 61 HIGH
600 HP
12 DtA. i 60 HIGH
(120 TONS)
S.S DIA. * 20 HIGH
KDIA.
MATERIAL
316L SS
3/16"
A-36 STEEL
RUBBER-LINED
RUBBER-LINED
RUBBER-LINED
FRP
316L SS
MOW
HO.
1
1
1
1
1
1
1
1
1
1
1
1
GAS STREAM NO.
RAH. Ib/hr * 1UOO
•eta « 1000
PARTICULATES. Ib/hr
SO?. Ib/hr
TEMPERATURE. *F
N?0. Ib/hr
02. '•
MO.. Ib/hr
VELOCITY. ft/Me
(i)
108
577. S
619.1
475
(£)
11.6
64.0
9/l
SULFATE. mt/\
CHLORIDE, ag/1
SPECIFIC GM«m
$
$
(£
$
12.0
c.o
$
$
0
4.8
®
<40
fl^
ft
S.S
^
1$
(j>
U|)
8.5
0
-------
to
M
(Ji
Figure 14-32
Santa Fe Energy Corp.,
Bakersfield, California,
EQUIPMENT LIST
EQNO.
AI
n
NE1
PI
P2
P3
P4
PS
K
P7
P8
RF1
T1
T2
T3
T4
NAME
ABSORBER
F.O. FAN
MIST aiNINATOR
RECIRCULATION PUMP
BLEED-OFF PUMP
MAKE-UP LIQUOR
PUMP
SODA ASH MAKE-UP
PIMP
LINE REACTOR PUMP
CLARIFIED EFFLUENT
PUMP
MAKE-UP HATER PUMP
MAKE-UP MATER PUMP
ROTARY FILTER
SODA ASH MAKE-UP
RECIRCULATION TANK
LIME REACTOR
THICKENER
SIZE. FEET
IS DIA. X
35 HIGH
MATERIAL
316L SS
C.S.
NO.
1
8
1
1
1
1
1
1
GAS STRCAN NO.
RATE. Ib/hr » 1000
•cf« * 1000
PARTICULARS. Ib/hr
SO;. Ib/hr
UNrtRAIURf. *F
HjO. Ib/hr
0?. I
MO,. Ib/hr
VUOCITT. ft/tec
(Y)
113.4
493.5
550
()P
19.7
@
0 LIQUID STREAM NO.
RATE. Ib/hr x 100
9P"
TOTAL SOLIDS. X
PH
TEMPERATURE. *F
H20. Ib/hr
SULFITE. •)/!
SULFATE. »9/l
CHLORIDE. *g/l
SPECIFIC GRAVITY
^
CJ)
^
^
71
^
^
q)
^
0
^
Ifil
ft
(ft
-------
STACK
N>
M
0*
TO CITY SjjWERS
LANDFILL
Figure 14-33.
Sheller Globe Corp.
Norfolk, Virginia.
EQUIPMENT LIST
EQ NO.
Al
Fl
PI
P2
T1
T2
T3
NAME
ABSORBER
F.D. FAN
RECIRCULATION
PUMP
BLEED-OFF PUMP
RECIRCULATION
TANK
CLARIFIER
REAGENT MAKEUP
TANK
SIZE. FEET
10 DIA. X IS HIGH
20 x 10 x 8 HIGH
MATERIAL
3161 SS
C.S.
BRONZE
C.S.
NO.
1
1
1
1
CAS SIRUM HO.
•ATE. Ib/hr • IUOO
Kim * 1000
PMIKULAKS. Ib/kr
SO?, Ib/kr
I(MȣM!uAC. *f
HjO. Ib/kr
02. *
HO,. Ib/kr
WLOCIIV. ft/tec
(T)
^
^
0 LIQUID SIMM NO.
HATE. Ib/kr » 100
*« '
TOTAL SOLIDS. S
PH
TUVIRATUU. *f
NzO. Ib/kr
SULFIU. >9/I
SULffcte. «g/l
CHLMIOE^Bi/l
SPECIFIC GMVITV
Cp
<$
•(J)
(*)
^
q>
(f>
^
0
•^
^
u>
V
-------
MM.
KTMW.
STUH-
Hl
XM*A/\/\
-frUNMKT TO AINUMCK
«
sit
10 IIITLI«
MTU
Figure 14-34. St. Joe Zinc Co.
Monaca, Penhsylvania,
(continued)
m
M
nn«ii» *»
MM! Ml
MM)
lOUKIHCfCU
no cmm stuniti
UUMIUMTW
IM Muirmiwr
no ctnm
MUIIIB NM>
snu
itsuni
Mm wcimuMi
•ucra
Mm wciriuiHi
(ITMRnWVMB
cnmuna
out urn
sin. nn
M I.*. • M MM
IM.OOO wn. IMO »
HI ni. i
i« 0*. » m. i ir
«M> M. luni. tMI
ll»n>
M CM. M Ml. M »
MSM. U»ni. J»»
«»
it cm. n PSI. ».i v
M ««. » KI. ) »
4.IM SWM. «f-USY
M l.t. • IN MM
It 1.1. I M MM
MM I.I. I M.CIMM.
If.D 1.1. I W.M MM,
is 1.1. • n
M.MW
Ml.*. IIS
• moMrr
St l.». • M MS*
M.N»M. •
S I A I >.« M
M
MM*. I«
C.S.
•anun
MMO
CIST I
•snutrc
MtltUMC
I
I
cinsran.
CMTsnn
C.I. SKU.
MtTIUOlM
c-p»
C.S..
t.ua
I.J..
C.S..
UM*
t.s..
tua
c.s..
c.s.. i/r
MH
C.S.
MI
c.s.
nan as. «c»
-------
6AS STRUM NO.
KATE. Ib/br * 1000
•eta x 1000
PARTICULATES, Ib/kr
SO?. Ib/br
TEMPERATURE. *F
H20. Ib/hr
02. »
HO*. Ib/kr
VELOCITY. ft/MC
LiqUlO STRUM HO.
M1E. Ib/kr n 100
V*
TOTAL SOLIDS. X
*
TfMKMTURC. *F
NJO. Ib/kr
SULFITE. «9/l
SU.FAU. «9/l
CM.OK1DE. ag/1
SHCIFIC UMKITf
fj)
234
300
0)
(?)
ISC
120
o
$
$
1300
131
0 LIQUID ST«AH NO.
RATE. Ib/kr * 100
tt»
TOTAL SOLIDS. S
*
TEMPERATURE. *F
HjO. Ib/kr
SULFITE. B9/1
SULFATE. ag/l
CHLORIDE. «9/l
SPECIFIC CMVITV
($
120
ID
1300
131
®
o
<8>
@
130
10
C')
@
«4
131
(jj)
®
130
2«n
$
1CAOO
112
$
100
a
2*0
6
12. t
$l»
^
$
IS
ID
^
4.S
^
0
4200
4.S
123
®
0
4.S
d
$
0
-------
VO
STl
FLUE GAS IN-
-SPENT SOLUTION
TO DISPOSAL
Figure 14-35. Sun Production Company,
Oildale, California;
Fellows, California.
EQUIPMENT LIST
EQ. NO.
Al
ME!
PI
P2
P3
ST1
Tl
NAME
ABSORBER
HIST ELIMINATOR
CIRCULATION PUMP
CIRCULATION PUMP
CAUSTIC PUMP
STUB STACK
CAUSTIC TANK
SIZE. FEET
4.6 DIA. X 35 HIGH
MATERIAL
316L SS
INCOLOY 825
31 6L SS
31 6L SS
CS
31 6L SS
CS
NO.
1
1
1
1
1
1
1
GAS STREAM NO.
RATE. Ib/hr x 1000
tcfm x 1000
PARTICULATES. Ib/hr
SO?, Ib/hr
TEMPERATURE, 'f
H20. Ib/hr
02. %
NQx. Ib/hr
VELOCITY, ft/sec
(?)
12
50
570
^
O
fy
(8>
O
O
-------
MAKE-UP , , SOOIUN
HATER CARBONATE
©
to
K)
O
J
FLUE
GAS
IN
<3>
A
\/
faA_
1 T3 1
J J ig
/ ^ f rrr f til rf f f ' t t f rf fl
J
1 Al
ol
1.
ff T2
\
^) ( .
_O^ Tl
®
\ ^
V"® ^xTO STACK
/ M
f rt
Ofro ~T^-^
f HASTE
DISPOSAL
Figure 14-36. Texaco Inc
California
. , San Ardo>
•
Ducon Company
EQNO.
Al
Fl
ME1
PI
P2
Tl
T2
T3
VI
NAME
ABSORBER
1.0. FAN
MIST ELIMINATOR
RECIRCULATION
PUMP
RECIRCULATION
PUMP
ABSORBER
RECYCLE TANK
VENTURI
RECYCLE TANK
CARBONATE
MIX TANK
VENTURI
SIZE. FEET
30 X 20 X 11 LONG
200 HP
40 HP, 1200 GPM
40 HP, 800 GPM
9 LONG
MATERIAL
FIBERGLASS St
C.S.. PHENOL!
COATED
C.S.. RUBBER-
.5., RUBBER-
FRP
FRP
C.S.
INCONEL 62S
GAS STREAM NO.
MATE. Ib/hr * 1000
•eta x 1000
PARTICIPATES. Ib/hr
SOz. Ib/hr
TEHPEMTUM. T
HzO. Ib/hr
02. X
NOk. Ib/hr
UIOCITT. ft/stc
(T)
117
600
(p
TO
1(0
(D
(T)
LIQUID STREAM NO.
RATE. Ib/hr i 100
9P"
TOTAL SOLIDS. I
pH
TEMPERATURE. T
HjO. Ib/hr
SULFITE. ng/1
SULFATE. ng/1
CHLORIDE. -9/1
SPECIFIC GRAVITY
cp
(§)
(j)
d)
OP
^
^
1200
<^
Ifi)
800
IB
031
^
^
-------
|N,OH SOLUTION
FLUE GAS IN
d?i
<0i
-------
FUiCtt H
—£
TBMSTE
Figure 14-38. Texasgulf,
Granger, Wyoming.
EQUIPMENT LIST
EQNO.
A1
n
Ml
NCI
PI
Ql
Tl
n
n
NAME
ABSORBER
F.O. FAN
REHEATER
NIST
ELIMINATOR
RECIRCULATION
MNP
QUENCHER
LIQUOR HEAD
TMK
RECIRCULATION
TANK
HEAD TANK
SIZE. FEET
IS DIA. X 20.5 HIGH
.8 HIGH
2400 SW. 30 HP
7.2 DIA.
8 DIA. I 10 HIGH
MATERIAL
FLAKED GLASS LINED C.S.
INCONEL 625 TRAYS
C.S.
TEFLON
RUBBER LINED C.S.
INCONELttS
FRP
NO.
2
2
2
2
4
2
2
2
2
to
to
to
MS STREAM M.
MK, Ib/fcr I 1000
Kta I 1000
rMHCUUHS. Ib/hr
SO?. Ib/hr
TEMPERATURE, 'f
H20, Ib/hr
02. I
Mb. Ib/hr
VCLOCITI. ft/MC
LIQUID STUM HO.
»•
IOTM. SOLIDS. S
»«
ICNPtRAIUU. *F
NjO. Ib/hr
SULflTE. ag/l
SULF«K. «j/l
CMLMIOC. ag/l
snciric CMvnr
©
ISt.l
3SO
^
100
$
121. t
120
4*
IS
®
&
CD
ID
60-tl
LIQUID
-------
STATUS TO APRIL 1979
SECTION IS
FUEL SULFUR CONTENT OF INDUSTRIAL BOILER F6D SYSTEMS
COMPANY
LOCATION
CAPACITY (SCFH)
SULFUR
CONTENT
STATUS
PROCESS
VENDOR
NUMBER
OF FGO
SYSTEMS
NUMBER
OF BOILERS
CONTROLLED
COAL (LESS THAN IX SULFUR)
CANTON TEXTILES ,8X
CANTON, GEORGIA
25.000
GENERAL MOTORS CORPORATION .71 - 2.OX
DAYTON, OHIO
36,000
GENERAL MOTORS CORPORATION .84*
PONTIAC. MICHIGAN
107,300
HARRIS MINING CO. .8X
SPRUCE PINE, NORTH CAROLINA
4,000
TEXASGULF .75X
GRANGER, WYOMING
140,000
OPERATIONAL
CAUSTIC WASTE STREAM
FMC ENVIRONMENTAL EQUIPMENT
OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
ENTOLETER, INC.
OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
GM ENVIRONMENTAL
INDEFINITELY SHUT DOWN
WATER SCRUBBING (NA,NH3 OPTN.)
W.W. SLY MANUFACTURING CO.
OPERATIONAL
SODIUM CARBONATE SCRUBBING
SWEMCO INC.
COAL (I TO 2X SULFUR)
CELANESE CORPORATION l.OX - 2.OX
CUMBERLAND, MARYLAND
50,700
DUPONT, INC. t.SX
ATHENS, GEORGIA
280,000
FMC (SODA ASH PLANT) l.OX
GREEN RIVER, WYOMING
446,000
GENERAL MOTORS CORPORATION 1.2X
TONOWANOA, NEW YORK
92,000
MINN-OAK FARMER'S CO-OPERATIVE i.ox
WAHPETON, NORTH DAKOTA
164,000
NtKUOSA PAPtRS, INC. l.OX - 1.5X
ASHUOWN, ARKANSAS
211,000
NORTHERN OHIO SUGAR COMPANY 1.2X
FINOLAY, OHIO
65,230
NURIHEHW OHIO SUGAR COMPANY i.ox
FKEEMONT, OHIO
40,000
PHILLIP MORRIS, INC. 1.4X
CHESTERFIELD, VIRGINIA
39,000
TENNF.Cn OIL CO. 1.5X
GREEN RIVER, WYOMING
140,000
PLANNED-CONTRACT AWARDED
DRY LIME SCRUBBING
WHEELABRATOR-FftYE/ROCKWELL INT
PLANNED-CONSIDERING 302 CONTROL
DOUBLE ALKALI
VENDOR NOT YET SELECTED
OPERATIONAL
SODIUM CARBONATE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
OPERATIONAL
AMMONIA SCRUBBING
KOCH ENGINEERING
OPERATIONAL
CAUSTIC SCRUBBING
NEPTUNE AIRPOLi INC.
TERMINATED
SODIUM CARBONATE SCRUBBING
GREAT WESTERN SUGAR
OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
GREAT WESTERN SUGAR
CUNSTKUCTION
SODIUM CARBONATE SCRUBBING
FLAKT, INC.
PLANNED-REQUEST ING/EVALUATING BIOS
SODIUM CARBONATE SCRUBBING
VENDOR NOT YET SELECTED
223
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STATUS TO APRIL 1979
SECTION IS (CONTINUED)
FUEL SULFUR CONTENT OF INDUSTRIAL BOILER FGO SYSTEMS
COMPANY
LOCATION
CAPACITY (SCFM)
SULFUR
CONTENT
STATUS
PROCESS
VENDOR
NUMBER
OF F6D
SYSTEMS
NUMBER
OF BOILERS
CONTROLLED
COAL (a TO 3X SULFUR)
ARCO/POLYMERS, INC. 3.OX
MONACAf PENNSYLVANIA
305,000
SUN6E, INC. 3.OX
CAIRO, ILLINOIS
44,000
CARBORUNDUM ABRASIVES 2.21
BUFFALO, NEW YORK
30,000
FIRESTONE TIRE AND RUBBER CO. 2.5X - 3.OX
POTTSTOWN, PENNSYLVANIA
0070
GENERAL MOTORS CORPORATION 2.5X
PARMA, OHIO
128,400
ST. JOE ZINC CO. Z.5X - 4.5X
MONACA, PENNSYLVANIA
142,000
CONSTRUCTION
DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
INDEFINITELY SHUT DOhN
LIME SCRUBBING
DRAVO CORP./NAT'L LIME ASS'N
PLANNED-CONTRACT AWARDED
LIME SCRUBBING
CARBORUNDUM ENVIR. SYS. LTD.
OPERATIONAL
DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
OPERATIONAL
DOUBLE ALKALI (DILUTE)
GM ENVIRONMENTAL
CONSTRUCTION
CITRATE PROCESS
BUREAU OF MINES
COAL(6REATER THAN 3X SULFUR)
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
210,000
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
67,000
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
131,000
CATERPILLAR TRACTOR cy.
MAPLETON, ILLINOIS
105,000
CATERPILLAR TRACTOR CO.
NORTON, ILLINOIS
36,000
CATERPILLAR TKACTOR CO.
MOSSVILLE, ILLINOIS
140,000
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
64,000
GRISSOM AIR FORCE BASE
BUNKER HILL, INDIANA
32,000
3.ex OPERATIONAL
DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
3.2X OPERATIONAL
DOUBLE ALKALI (DILUTE)
ZURN INDUSTRIES
3.2X OPERATIONAL
DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
3.2X PLANNED-CONTRACT AWARDED
DOUBLE ALKALI (CONCENTRATED)
FHC ENVIRONMENTAL EQUIPMENT
3.2X OPERATIONAL
DOUBLE ALKALI (DILUTE)
?URN INOUSTRIhS
3.2X OPERATIONAL
OOIJBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
3.2X OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
A.O. LITTLE
3.OX • 3.5X CONSTRUCTION
DOUBLE ALKALI (CONCENTRATED)
NEPTUNE AIRPOL, INC.
224
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STATUS TO APRIL 1979
SECTION 15 (CONTINUED)
FUEL SULFUR CONTENT OF INDUSTRIAL BOILER FGD SYSTEMS
COMPANY
LOCATION
CAPACITY (SCFM)
SULFUR
CONTENT
STATUS
PROCESS
VENDOR
NUMBER NUMBER
OF FGD OF BOILERS
SYSTEMS CONTROLLED
COAL(6REATEK THAN 3X SULFUR)
PFIZER, INC. 3.51
EAST ST. LOUIS, ILLINOIS
40,000
RICKENBACKER AIR FORCE BASE s.fcx
COLUMBUS, OHIO
55,000
WESTERN CORRECTIONAL INST. 3.5*
PITTSBURGH, PENNSYLVANIA
10,000
OPERATIONAL
LIME SCRUBBING
IN-HOUSE DESIGN
OPERATIONAL
LIMESTONE SCRUBBING
RESEARCH-COTTRELL/BAHCO
PLANNED-CONTRACT AWARDED
SULF-X SCORE PROCESS
PITTSBURGH ENV.SENGY. SYSTEMS
OIL (LESS THAN IX SULFUR)
ALYESKA PIPELINE SERVICE co. .03* - .ix
VALOEZ, ALASKA
50,000
SHELLER GLOBE CORP. <1.0t
NORFOLK, VIRGINIA
8,000
OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
INDEFINITELY SHUT OOMN
SODIUM HYDROXIDE SCRUBBING
N.N. SLY MANUFACTURING CO.
OIL (1 TO
SULFUR)
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
18,000
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
12,000
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
12,000
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
248,000
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
146,000
DOUBLE BARREL OIL CO.
8AKERSFIELO, CALIFORNIA
12,000
BETTY OIL COMPANY
BAKERSFIELO, CALIFORNIA
891,000
SETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
72,000
"EAO PAPERBOARD CO.
1TEVENSON, ALABAMA
100,000
1.1* OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
HEATER TECHNOLOGY
1.1* OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
C-E NATCO
I.IX OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
THERMOTICS INC.
1.1* OPERATIONAL
SODIUM CARBONATE SCRUBBING
KOCH ENGINEERING
1.1X CONSTRUCTION
SODIUM CARBONATE SCRUBBING
KOCH ENGINEERING
1.1X OPERATIONAL
SODIUM HYDROXIDE SCRUBBING
C-E NATCO
1.1X OPERATIONAL
SODIUM CARBONATE SCRUBBING
IN-HOUSE DESIGN
1.1X OPERATIONAL
SODIUM CARBONATE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
1.5* - 3.0* OPERATIONAL
SODIUM CARBONATE SCRUBBING
NEPTUNE AIRPOL, INC.
12
61
225
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STATUS TO APRIL 1979
SECTION 15 (CONTINUED)
FUEL SULFUR CONTENT OF INDUSTRIAL BOILER FGD SYSTEMS
COMPANY
LOCATION
CAPACITY (SCFH)
OIL (1 TO 2X SULFUR)
MOBIL OIL COMPANY
BUTTONMILLOM* CALIFORNIA
80,500
SANTA FE ENERGY CORP.
BAKER3FIELD, CALIFORNIA
70*000
SHELL OIL COMPANY
BAKERSFIELOr CALIFORNIA
99,000
SHELL OIL COMPANY
TAFTi CALIFORNIA
25
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3TATU3 TO APRIL
SECTION 15 (CONTINUED)
FUEL SULFUK CONTENT OF INDUSTRIAL BOILER FGD SYSTEMS
COMPANY STATUS NUMBER NUMBER
LOCATION SULFUR PROCESS OF FGO OF BOILERS
CAPACITY (SCFM) CONTENT VENDOR SYSTEMS CONTROLLED
MIXTURE OF FUELS (2 TO JX SULFUR)
ITT RAYONIER, INC. i.OX • 2.5X OPERATIONAL 2 4
FERNANDINA BEACH, FLORIDA SODIUM HYDROXIDE SCRUBBING
176,000 NEPTUNE AIRPOL. INC.
MIXTURE OF FUELS (GREATER THAN 3X SULFUR)
INLAND CONTAINER CORPORATION <3,OX CONSTRUCTION 1 1
MEM JOHNSONVILLE, TENNESSEE AMMONIA SCRUBBING
154,000 NEPTUNE AIRPOL INC.
227
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO. ,
EPA-600/7-79-067b
2.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
EPA INDUSTRIAL BOILER FGD SURVEY: First
Quarter 1979
6. REPORT DATE
April 1979
6. PERFORMING ORGANIZATION CODE
7. AUTHORIS)
^ TutUe ^ A Patkar f s t Kothar i , D. Osterhout ,
M.Heffling, and M. Eckstein
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, OH 45246
10. PROGRAM ELEMENT NO.
EHE624
11. CONTRACT/GRANT NO.
68-02-2603, Task 45
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
Task Final; 1-3/79
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTES ffiRL-RTP project officer R. M. McAdams is no longer with EPA;
for .details contact II. Dt Stern, MD-61, 919/541-2915. Earlier related reports are
7Wl> AV« A^« k^bWA AA • JLTJ
7-78-052 series.
s. ABSTRACT
rep0rt gives detailed technical information concerning application of
flue gas desulfurization (FGD) systems to Indus trial boilers. Design and operation
data is presented for 164 FGD control systems (125 of them operational), designed to
control SO2 emissions from 304 industrial boilers at 58 plants. With a 1978 capacity
of 8. 8 million scfm, an average of more than seven new FGD systems have been put
on line each year since 1972. Information in the report was obtained by a survey of
plant personnel, control system vendors, regulatory agencies, and consulting engin-
eering firms . The data is given in two types of tables : one gives summary informa-
tion; the other, detailed information. Summary tables present information as a func-
tion of control process , control system vendor , disposal technique , operational sta-
tus, startup date, and flue gas capacity. Detailed information includes: control sys-
tem design, economics, operating experience, problems and solutions, waste dis-
posal techniques, and maintenance practices.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Pollution
Flue Gases
Desulfurization
Boilers
Waste Disposal
Maintenance
Pulping
Chemical Industry
Pollution Control
Stationary Sources
Industrial Boilers
13B
21B
07A,07D
13A
15E
11H
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
236
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
228
. GOVERNMENT PRINTING OFFICE:! 9 79 -6kQ -013/ k2kO REGIONNO.4
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