SUMMARY REPORT - FLUE GAS DESULFURIZATION. SYSTEMS - NOVEMBER - DECEMBER 1976
TnBLL PAGE
1 SUMARY LIST OF FGD SYSTEMS 3
2 STATUS OF FGD SYSTEMS 9
3 PLKFOKMAKCL DESCRIPTION FUR OPERATIONAL FGD SYSTEMS 37
H NUMBER AIMD TOTAL MW UF FGL SYSTEMS 195
5 SUGARY oF FbU SYSTEMS BY COMPANY 199
fo SUMMARY OF FGU SYSTEMS BY VENDOR 203
7 SUK'-'AKY UF NEW AND RETROFIT FGD SYSTEMS BY PROCESS 209
6 SUGARY OF OPERATING FbU SYSTEMS BY PROCESS AND GENERATING UNITS 213
9 SUMMARY UF SLUUGE DISPOSAL PRACTICES FOR OPERATIONAL FGu SYSTEMS 217
lffr' SUGARY UF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS 221
11 SUMMARY OF OPERATIONAL FGD SYSTEhS 227
12 SUMf'.AKY OF FGU SYSTEMS UIVDER CONSTRUCTION 231
13 SUMARY CF PLANNED FbD SYSTEMS 237
IH SUMMARY LIST OF FGD SYSTEMS IN ThE EARLY PLANNING STAGES
15 STATUS Op FGD SYSTEMS IN THE EARLY PLANNING STAGES
FbD SYSTLM OPERATIONS THAT HAVE BEEN TERMINATED OR SHUT DOWN INDEFINITELY APPENDIX A
FGD ECONOMICS APPENDIX B
FGU PROCESS FLOW OIAbRAMS APPENDIX C
DEFINITIONS APPENDIX D
PREPARED BY
PEDCO-ENVIRONMENTAL INC.
H495I CHESTER ROAD
CINCINNATI, OHIO
DIVISION OF
ENFORCEMENT
PREPARED FOR
STATIONARY SOURCE
AND
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
U.S. ENVIRONMENTAL PROTECTION AGENCY
RESEARCH TRIANGLE PARK,
NORTH CAROLNA 27711
CONTRACT NO. 68-02-1321
TASK NO. 28
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TABLE 1
SUMMARY LIST OF FGD SYSTEMS
PEDCO-ENVIRONMENTAL
-------
PEOCO ENVIRONMENTAL
-------
TABLE 1
SUMMARY LIST OF FGD SYSTEMS
FGO STATUS REPORT 12/76
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
RE6
CLASS
1 ALABAMA ELECTRIC COOP
2 ALABAMA ELECTRIC COOP
3 ALLEGHENY POWER SYSTEM
4 ALLEGHENY POWER SYSTEM
5 ARIZONA ELECTRIC POWER COOP
6 ARIZONA ELECTRIC POWER COOP
7 ARIZONA PUbLlC SERVICE
8 AKIZONA PUBLIC SERVICE
9 ARIZONA PUBLIC SERVICE
10 AKIZONA PUBLIC SERVICE
11 ARIZONA PUbLlC SERVICE
12 BASIN ELECTRIC POWER COOP
13 BASIN ELECTRIC POWtR COOP
14 BASIN ELECTRIC POWER COOP
15 faASIN ELECTRIC POWER COOP
16 BASIN ELECTRIC POWER COOP
17 BIG RIVERS ELECTRIC COOP CORP.
18 BRAZOS ELECTRIC POWER COOP
19 CENTRAL ILLINOIS LIGHT CO.
20 CENTHAL ILLINOIS LIGHT CO.
21 CENTRAL ILLINOIS LIGHT CO.
22 CENTRAL ILLINOIS PUBLIC SERV
23 CINCINNATI GAS 8 ELECTRIC CO,
24 COLORADO UTE ELECTRICAL ASSN.
25 COLORADO UTE ELECTRICAL ASSN.
26 COLUMBUS & SOUTHERN OHIO ELEC.
27 COLUMBUS & SOUTHERN OHIO ELEC.
28 COLUMBUS & SOUTHERN OHIO ELEC.
29 COLUMBUS & SOUTHERN OHIO ELEC.
30 COMMONWEALTH EDISON
31 COMMONWEALTH EDISON
32 DETROIT EDISON
33 GUflUESNE LIGHT
34 OUQUESNE LIGHT
35 EASTERN KENTUCKY POWER COOP
TOMBIGBEE NO. 2
TOMBIGBEE NO. 3
PLEASANTS NO. I
PLEASANTS NO. 2
APACHE NO 2
APACHE NO 3
ChOLLA NO 1
CHOLLA NO 2
FOUR CORNERS NO. «f
FOUK CORNERS NO. SA
FOUR CORNERS NO. SB
ANTELOPE VALLEY NO. 1
ANTELOPE VALLEY NO. 2
MISSOURI BASIN NO 1
MISSOURI BASIN NO 2
MISSOURI BASIN NO 3
RLIU STEAM STATION NO. 2
ATACOSA MCMULLEN NO. 1
DUCK CREEK NO. 1A
DUCK CREEK NO. IB
DUCK CREEK NO.2
NEWTON NO.l
EAST BEND NO 2
CRAIG STATION NO.l
CRAIG STATION NO.2
CONESVILLE NO 5
CONESVILLE NO 6
POSTON NO. 5
POSTON NO. 6
POuJtRTON NO. 51
WILL COUNTY NO 1
ST. CLAIR NO 6
ELRAMA POWER STATION
PHILLIPS POWER STATION
SPUKLOCK GENERATING PLANT
JACKSON ALABAMA
JACKSON ALABAMA
BELLMONT W VIRGINIA
BELLMONT W VIRGINIA
COCHISE ARIZONA
COCHISE ARIZONA
JOSEPH CITY ARIZONA
JOSEPH CITY AKIZONA
FARMINGTON NEW MEXICO
FARMINGTON NEW MEXICO
FARMINGTON NEW MEXICO
BEULAH NORTH DAKOTA
BEULAH NORTH DAKOTA
WHEATLAND WYOMING
WHEATLAND WYOMING
WHEATLAND WYOMING
SEBREL KENTUCKY
SAN MIGUEL TEXAS
CANTON ILLINOIS
CANTON ILLINOIS
CANTON ILLINOIS
NEUTON ILLINOIS
RABBIT HASH KENTUCKY
CRAIG COLORADO
CRAIG COLORADO
CONL'SVILLE OHIO
CONESVILLE OHIO
ATHENS OHIO
ATHENS OHIO
PEKIN ILLINOIS
ROMEOVILLE ILLINOIS
BELLE RIVER MICHIGAN
ELRAMA PENNSYLVANIA
SOUTH HEIGHT PENNSYLVANIA
NO.2 MAYSVILLE KENTUCKY
1. OPERATIONAL UNITS 4.
2. UNITS UNDER CONSTRUCTION 5.
3. PLANNED - CONTRACT AWARDED 6.
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
CONSIDERING ONLY FGD SYSTEMS
3-78
3-79
3-79
3.80
6-78
6-79
10-73
6-77
0- 0
2-76
0- 0
0-81
0-64
4-80
10-80
6-63
12-79
12-79
9-76
8-78
1-62
7-76
1-81
3-79
3-79
2-77
1-78
0-81
0-83
12-79
2-72
5-76
10-75
7-73
3-80
2
2
2
2
2
2
1
2
6
1
6
6
6
3
3
6
2
3
1
2
6
2
6
6
6
2
3
6
6
3
1
1
1
1
6
A
A
A
A
B
B
B
B
B
B
B
8
B
B
B
6
A
E
A
A
A
A
A
B
B
B
B
B
B
C
C
C
B
B
A
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
PEDCO ENVIRONMENTAL
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TABLE 1
SUMMARY LIST OF FGD SYSTEMS
F6D STATUS REPORT 12/76
I.D. NUMBER ANQ COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
RE6
CLASS
36 GENERAL MOTORS
37 GULF POWER CO.
38 INDIANAPOLIS POWER & LIGHT CO.
39 INDIANAPOLIS POWER & LIGHT CO.
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TABLE 1
SUMMARY LIST OF FGD SYSTEMS
FGD STATUS REPORT 12/76
I.D. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
71 NEVADA POWER
72 NEVADA POWER
73 NEW ENGLAND ELEC SYSTEM
7
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TABLE 1
SUMMARY LIST OF FGO SYSTEMS
FGO STATUS REPORT 12/76
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
RES
CLASS
106 SOUTHERN CALIFORNIA EDISON
107 SOUTHERN ILLINOIS POWER COOP
106 SOUTHERN INDIANA GAS&ELECTRIC
109 SOUTHERN MISSISSIPPI ELECTRIC
110 SOUTHERN MISSISSIPPI ELECTRIC
111 SPRINGFIELD CITY UTILITIES
112 TENNESSEE VALLEY AUTHORITY
113 TENNESSEE VALLEY AUTHORITY
lit TENNESSEE VALLEY AUTHORITY
115 TEXAS UTILITIES CO.
116 TEXAS UTILITIES CO.
117 TEXAS UTILITIES CO.
116 TEXAS UTILITIES CO.
119 TEXAS UTILITIES CO.
120 UIJITED POWER ASSOCIATION
121 UNITED POWER ASSOCIATION
122 UTAH POWEK i LIGHT CO.
123 UTAH POWER & LIGHT CO.
12<* WISCONSIN POWEK & LIGHT CO.
MOHAVE NO. 2
SOUTHERN ILLINOIS POWER PT.
A.B. BROWN .JO.l
R.O. MORROW NO.l
R.D. MORROW NO.2
SOUTHWEST NO. 1
SHAWNEE N0.10A
SHAWNEE N0.10B
WIDOWS CREEK NO 6
MARTIN LAKE NO. 1
MARTIN LAKE NO. 2
MARTIN LAKE NO. 3
MAKTIN LAKE NO. H
MONTICELLO NO.3
COAL CREEK NO. 1
COAL CREEK NO. 2
EfiEKY NO.l
HUNTINGTON NO.l
COLUMBIA NO. 2
LAUGHLIN NEVADA
MARION ILLINOIS
WEST FRANKLIN INDIANA
HATTIESBURG MISSISSIPPI
HATTIESBURG MISSISSIPPI
SPRINGFIELD MISSOURI
PADUCAH KENTUCKY
PADUCAH KENTUCKY
BRIDGEPORT ALABAMA
TATUM TEXAS
TATUM TEXAS
TATUM TEXAS
TATUM TEXAS
MT. PLEASANT TEXAS
UNDERWOOD NORTH DAKOTA
UNDERWOOD NORTH DAKOTA
EMEKY COUNTY UTAH
PRICE UTAH
PORTAGE WISCONSIN
6-77
1-78
H-79
11-77
6-78
2-77
«f-72
«»-72
3-77
1-77
10-77
12-78
12-79
10-77
11-78
11-79
6-78
6-77
1-80
6
3
3
2
2
2
1
1
2
2
2
3
3
2
3
3
3
2
5
E
A
A
A
A
A
C
C
C
A
A
A
A
A
A
A
A
A
A
1. OPERATIONAL UNITS «».
2. UNITS UNDER CONSTRUCTION 5.
3. PLANNED - CONTRACT AWARDED 6.
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
CONSIDERING ONLY FGO SYSTEMS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT To STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT To STATE STANDARD THAT IS EQUAL To OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
PEDCO ENVIRONMENTAL
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TABLE 2
STATUS OF FGD SYSTEMS
PEDCO-ENVIRONMENTAL
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10 PEUCO ENVIRONMENTAL
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING 12/76
POWER STATION
CURRENT MONTH
I.D. NUMBER 1
ALABAMA ELECTRIC COOP
TOMBIGBEE NO. 2
225 MW - NEW
COAL O.b- 1.5 PERCENT SULFUR
PEABOOY ENGINEERING
LIMESTONE. SCRUBBING
STARTUP 3/7«
PEABOOY ENGINEERING HAS BEEN AWARDED THE CONTRACT FOR THE INSTALLATION
OF A LIMESTONE SCRUBBING SYSTEM ON THIS UNIT. A HIGH-EFFICIENCY ESP WILL
BE INSTALLED UPSTREAM OF THE SCRUBBING SYSTEM TO PROVIDE PRIMARY
PARTICULATE CONTROL. THE FGD SYSTEM CONTAINS TWO SCRUBBING TRAINS.
TREATING APPROXIMATELY 70 PERCENT OF THE FLUE GAS FOR REMOVAL OF SULFUR
DIOXIDE. STACK GAS REHEAT WILL NOT BE REQUIRED. DURING THE REPORT PERIOD*
WORK ON THE CONSTRUCTION OF THIS UNIT CONTINUED. SITE PREPARATION
AMU FOUNDATION WORK HAVE BEEN COMPLETED.EQUIPMENT ERECTION IS PROCEEDING.
I.D. NUMBER 2
ALABAMA ELECTRIC COOP
TOMBIGBEE NO. 3
225 fW - NEW
COAL 0.5- 1.5 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/79
PEABODY ENGINEERING HAS BEEN AWARDED THE CONTRACT FOK THE INSTALLATION
OF A LIMESTONE SCRUBBING SYSTEM ON THIS UNIT. A HIGH-EFFICIENCY ESp WILL
BE INSTALLED UPSTREAM OF THE SCRUBBING SYSTEM TO PROVIDE PRIMARY
PARTICULATE CONTROL. THE FGO SYSTEM CONTAINS TWO SCRUBBING TRAINS.
TREATING APPROXIMATELY 70 PERCENT OF THE FLUE GAS FOK REMOVAL OF SULFUR
DIOXIDE. STACK GAS REHEAT WILL NOT BE REQUIRED. DURING THE REPORT PERIOD.
WORK ON THE CONSTRUCTION OF THIS UNIT CONTINUED. SITE PREPARATION AND
FOUNDATION WORK HAVE BEEN COMPLETED. EQUIPMENT ERECTION IS PROCEEDING.
I.D. NUMBER 3
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 1
625 MW - NEW
COAL H.5 PERCENT SULFUR (MAX)
BABCOCK AND WlLCOX
LIME SCRUBBING
STARTUP 3/79
THE THREE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM ARE INSTALLING AN EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED
UNIT WHICH INCLUDES A HIGH EFFICIENCY ESP UPSTREAM OF FOUR SPRAY TOWERS
FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 99.5 AND 90 PERCENT
RESPECTIVELY. THE DRAVO CO. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS AND CONSTRUCTORS. SLUDGE
DISPOSAL PLANS ARE NOW BEING EVALUATED ANU FINALIZED.
1.0. NUMBER «»
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 2
625 MW - NEW
COAL t.5 PERCENT SULFUR (MAX)
BABCOCK AND WlLCOX
LIME SCRUBBING
STARTUP 3/60
THE THREE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM ARE INSTALLING AN EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED
UNIT WHICH INCLUDES A HIGH EFFICIENCY ESP UPSTREAM OF FOUR SPRAY TOWERS
FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 99.5 AND 90 PERCENT.
RESPECTIVELY. THE DRAVO CO. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS AND CONSTRUCTORS. SLUDGE
DISPOSAL PLANS ARE NOW BEING EVALUATED AND FINALIZED.
I.D. NUMBER 5
ARIZONA ELECTRIC POWER COOP
APACHE NO 2
200 KW - NEW
COAL 0.5- O.fl PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/7fl
THE CONTRACT FOR THE INSTALLATION OF A WET LIMESTONE SCRUBBING SYSTEM HAS
BEEN AWARDED BY THE UTILITY TO RESEARCH-COTTRELL. CONSTRUCTION OF THE
SYSTEM IS NOW IN PROGRESS. SITE PREPARATION AND FOUNDATION WORK IS
NEARING COMPLETION. THE CONCRETE FOR THE SCRUBBING TOWER HAS ALREADY
BEEN POURED. THE EMISSION CONTROL SYSTEM WILL CONSIST OF A HIGH-
EFFICIENCY ESP INSTALLED UPSTREAM OF TWO PACKED TOWERS. GUARANTEED S02
ANO PARTICULATE REMOVAL EFFICIENCIES ARE 85 AND 99.4 PERCENT.
RESPECTIVELY. THE A-E UESIGN FIRM IS BURNS & MCDONNELL.
1)
PEOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 12/76
CURRENT MONTH
1.0. NUMBER 6
ARIZONA ELECTRIC POWER COOP
APACHE NO 3
200 MW - NEW
COAL 0.5- O.fl PERCENT SULFUR
RESEARCH COTTKELL
LIMESTONE SCRUBBING
STARTUP 6/79
THE CONTRACT FOR THE INSTALLATION OF A WET LIMESTONE SCRUBBING SYSTEM HAS
BEEN AWARDED BY THE UTILITY TO RESEARCH-COTTRELL. CONSTRUCTION OF THE
SYSTEM IS NOW IN PROGRESS. SITE PREPARATION AND FOUNDATION WORK IS
NEARING COMPLETION. THE CONCRETE FOR THE SCRUBBING TOWER HAS ALREADY
BEEN POURED. THE EMISSION CONTROL SYSTEM WILL CONSIST OF A HIGH-
EFFICIENCY ESP INSTALLED UPSTREAM OF TWO PACKED TOWERS, GUARANTEED S02
AND PARTICULAR REMOVAL EFFICIENCIES ARE 85 AND 99.1 PERCENT,
RESPECTIVELY. THL A-E. FIRM IS BURNS & MCDONNELL,
1.0. NUMBER 7
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
115 MW - RETROFIT
COAL 0.
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COMPANY
POWER STATION
TABLE 2
STATUS OF F6D SYSTEMS DURING
12/76
CURRENT MONTH
I.D. NUMBER 11
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 58
595 MW - RETROFIT
COAL 0.7 - 0.75S SULFUR (AVG)
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THE BALANCE OF FLUE GAS FROM THE 755-HW NO.5 UNIT WILL BE CONTROLLED
PENDING THE OUTCOME OF TESTS CURRENTLY BEING CONDUCTED ON THE PROTOTYPE
PROTOTYPE WEIR HORIZONTAL SCRUBBING MODULE INSTALLED ON THIS UNIT.
TEST RESULTS ON THE PROTOTYPE'S PERFORMANCE WILL BE PUBLISHED IN
FEBRUARY 1977. A DECISION CONCERNING SULFUR DIOXIDE CONTROLS
FOR THIS UNIT HAS NOT YET BEEN FINALIZED.
I.D. NUMBER 12
BASIN ELECTRIC POWER COOP
ANTELOPL VALLEY NO. 1
«*50 Mta - NEW
LIGNITE 1.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
THE UTILITY IS CURRENTLY INVESTIGATING VARIOUS FGD PROCESSES FOR TWO
COAL-FIRED UNITS AT THIS NEW STATION WHICH WILL BE LOCATED IN MERCER
COUNTY. NEAR BEULAHt NORTH DAKOTA. THIS NEW FACILITY WILL BE KNOWN AS
THE ANTELOPE VALLEY STATION AND WILL BE REQUIRED TO COMPLY WITH AIR
EMISSION STANDARDS VIA THE BEST AVAILABLE TECHNOLOGY. START-UP IS NOW
SCHEDULED FOR 1961.
I.D. NUMBER 13
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY NO. 2
450 MW - NEW
LIGNITE 1.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/8H
THE UTILITY IS CURRENTLY INVESTIGATING VARIOUS FGD PROCESSES FOR TWO
COAL-FIRED UNITS AT THIS NEW STATION WHICH WILL BE LOCATED IN MERCER
COUNTY,NEAR BEULAH.NORTH DAKOTA. THIS NEW FACILITY WILL BE KNOWN AS
THE ANTELOPE VALLEY STATION AND WILL BE REQUIRED TO COMPLY WITH AIR
EMISSION STANDARDS VIA THE BEST AVAILABLE TECHNOLOGY• START-UP IS NOW
SCHEDULED FOR
I.D. NUMBER If
BASIN ELECTRIC POWER COOP
MISSOURI BASIN NO 1
550 MW - NEW
LIGNITE 0.6 PERCENT SULFUR
RESEARCH COTTREUL
LIMESTONE SCRUBBING
STARTUP M/80
BECAUSE OF THE STRICT STATE OF WYOMING EMISSION STANDARDS OF 0.2 LBS.
OF S02 PER MILLION BTU HEAT INPUT* LOl' SULFUR COAL ALONE WILL NOT MEET
STANDARDS. DURING THE REPORT PERIOD THE UTILITY AWARDED A CONTRACT
TO RESEARCH COTTRELL FOR THE INSTALLATION OF A LIMESTONE SCRUBBING
SYSTEM ON THIS UNIT. THE UNIT IS DESIGNED TO FIRE LIGNITE HAVING A
HEAT CONTENT OF 6000 BTU/LB AND ASH AND SULFUR CONTENTS OF
7.0 AND 0.6 PERCENT* RESPECTIVELY. THE A-E DESIGN FIKM IS
BURNS a MCDONNELL.
I.D. NUMBER 15
BASIN ELECTRIC POWER COOP
MISSOURI BASIN NO 2
550 MW - NEW
COAL
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 10/80
BECAUSE OF THE STKICT STATE OF WYOMING EMISSION STANDARDS OF 0.2 LBS*
OF S02 PER MILLION BTU HEAT INPUT* LOW SULFUR ALONE WILL NOT MEET
STANDARDS. DURING THE REPORT PERIOD THE UTILITY AWARDED A CONTRACT
TO RESEARCH COTTKELL FOR THE INSTALLATION OF A LIMESTONE SCRUBBING
SYSTEM ON THIS UNIT. THE UNIT IS DESIGNED TO FIRE LIGNITE HAVING A
HEAT CONTENT OF 6000 BTU/LB AND ASH AND SULFUR CONTENTS OF
7.0 AND 0.6 PERCENT* RESPECTIVELY. THE A-E DESIGN FIKH IS
BURNS & MCDONNELL.
PEDCO CNVXRONRCNTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FSO SYSTEMS DURING 12/76
CURRENT MONTH
1.0. NUMBER 16
BASIN ELECTRIC POWER COOP
MISSOURI BASIN NO 3
550 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/83
BECAUSE OF THE STRICT STATE OF WYOMING EMISSION STANDARDS OF 0*2 LBS.
S02 PER MILLION BTU HEAT INPUT, LOW SULFUR COAL ALONE WILL NOT MEET
STANDARDS. THE UTILITY IS CURRENTLY INVESTIGATING VARIOUS FGD PROCESSES
FOR THE NO.3 UNIT AT THE MISSOURI BASIN STATION.
I.D. NUMBER 17
BIG RIVERS ELECTRIC COOP CORP,
REID STEAM STATION NO. 2
250 MM - NEW
COAL 3.5-1.0 PERCENT SULFUR
AMERICAN AIM FILTER
LIME SCRUBBING
STARTUP 12/79
THE UTILITY HAS AWARDED A CONTRACT TO THE AMERICAN AIR FILTER COMPANY
FOR THE INSTALLATION OF AN EMISSION CONTROL SYSTEM ON THIS NEW COAL-FIRED
UNIT LOCATED IN SEBREE. KENTUCKY. AAF WILL DESIGN,FABRICATE AND INSTALL
AN ESP AND TWO SPRAY TOWERS FOR THE CONTROL OF PARTICULATES AND SULFUR
DIOXIDE.DESIGN REMOVAL EFFICIENCIES ARE 99.6 AND 90 PERCENT RESPECTIVELY.
THE BOILER, WHICH IS CURRENTLY UNDER CONSTRUCTION, WILL FIRE HIGH SULFUR
WESTERN KENTUCKY COAL (3.5 TO <».5 PERCENT) AND COMPLY WITH NEW SOURCE
PERFORMANCE STANDARDS.CONSTRUCTION OF THE CONTROL SYSTEM IS NOW UNDERWAY,
I.D. NUMBER 16
BRAZOS ELECTRIC POWER COOP
ATACOSA MCKULLEN NO. 1
HOO MW . NEW
LIGNITE 1.67 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 12/79
BAbCOCK AND WILCOX HAS BEEN AWARDED THE CONTRACT FOR THE INSTALLATION OF
THIS ENTIRE MEw SYSTEM. THE. EMISSION CONTROL EQUIPMENT FOR THE COAL-FIRED
RADIANT BOILER WILL CONSIST OF ELECTROSTATIC PRECIPITATORS UPSTiHEAM OF
THE LIMESTONE SCRUBBING MODULES. THE SCRUBBER FLUE GAS CAPACITY IS
NOMINALLY DESIGNED TO LXCELD 1.5 MILLION ACFM. THE OLSIGN S02 REMOVAL
EFFICIENCY IS 66 PERCENT FOR <»tOO PPM S02 INLET. LIGNITE COAL WILL BE
FIKED Iivl THE BOILER. THE SCRUBBING WASTES WILL BE DISPOSED IN AN OFF-
SITE MINEFILL. THE CONSULTING A-E FIRM IS TIPPETT AND GEE.
I.D. NUMBER 19
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO. 1A
100 MW - NEW
COAL 2.5 - 3.0 PERCENT SULFUR
RILEY STOKER / ENVlRONEERING
LIMESTONE SCRUBBING
STARTUP 9/76
THE INSTALLATION OF THIS SINGLE 100-MW SCRUBBER MODULE WAS COMPLETED IN
JULY AND START-UP OPERATIOIJS FOLLOWED, DEBUGGING OPERATIONS HAVE BEEN
PROCEEDING ON AN INTLRhlTTLwT BASIS BECAUSE OF CONSTRUCTION-RELATED
PROBLEMS. THE SYSTEM WAS SHUTDOWN FOR A SHORT PERIOD OF TIME TO CORRECT
THLSE PROBLEMS. RE-START COMMENCED ON SEPTEMBER 9. OPERATION OF THE
MOuULE DURLMG THE PERIOD FOLLOWING START-UP HAS BEEN INTERMITTENT BECAUSE
OF McCHAMCAL AND CHEMICAL-RELATED PROBLEMS. THIS HAS PROMPTED THE
UTILITY TO SHUTDOWN THE MODULE UNTIL FULL-SCALE START-UP DATE OF S/78.
I.D. NUMBER 20
CENTRAL ILLINOIS LIGHT CO.
DUCK CRELK NO. IB
300 MW - NEW
COAL 2.5 - 3,0 PERCENT SULFUR
RILEY STOKER / ENVlRONEERING
LIMESTONE SCRUBBING
STARTUP 8/78
A CONTRACT HAS BEEN AWARDED BY THE UTILITY TO THE RILEY STOKER CORP. FOR
THE OESIGN, FABRICATION AND INSTALLATION OF THREE ADDITIONAL SCRUBBER
MODULES FOR THE BALANCE OF THIS UNIT. THE THREE MODULES HILL COMPLETE A
FOUR MODULE SULFUK DIOXIDE SCRUBBING SYSTEM, THE FIRST OF WHICH WAS
PLACED IN SERVICE ON SEPTEMBER 9,1976. THE EMISSION CONTROL SYSTEM FOR
THIS UNIT WILL CONSIST OF A HIGH-EFFICIENCY ESP UPSTREAM OF FOUR VENTRI-
SORBER SCRUBBER MODULES. DESIGN PARTICULATE AND SULFUR DIOXIDE REMOVAL
EFFICIENCIES AKE 99.8 AND 75 PERCENT.RESPECTIVELY.
PCOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING 12/76
CURRENT MONTH
I.D. NUMBER 21
CENTRAL ILLINOIS LIGHT CO.
3UCK CREEK NO.2
400 MW - NEW
COAL 2.5-3.0 PERCENT SULFUR
AlOT SELECTED
.IMESTONE SCRUBBING
iTARTUP 1/82
THE PROPOSED LIMESTONE SCRUBBING SYSTEM FOR THIS NEW COAL-FIRED
UNIT IS SCHEDULED TO COMMENCE OPERATIONS IN JANUARY 1962. THE
UTILITY HAS NOT YET SELECTED A SYSTEM SUPPLIER. A DECISION CONCERNING
THE. STATUS OF THE bOILLR AND CONTROL STRATEGY WILL BE
ANNOUNCED IN LATE 1977.
I.D. NUMBER 22
:ENTRAL ILLINOIS PUBLIC SERV
JEWTON NO.l
575 MW - NEW
:OAL 2.8-3.2 PERCENT SULFUR
•JUELL/ENVIROTECH
OOU3LE ALKALI SCRUBBING
•STARTUP 7/78
A CONTRACT HAS BEEN AWARDED BY CIPSCO TO BUELL/ENVIROTECH FOR THE
INSTALLATION OF AN EMISSION CONTROL SYSTEM ON UNIT N0.lt A COAL-FIRED
57b-MW POWER BOILER LOCATED IN NEWTONtILLINOIS. THE KEY COMPONENTS OF THE
EMISSION CONTROL SYSTEM INCLUDE* A HIGH-EFFICIENCY ESP, FOUR SCRUBBER-
ABSORBER TRAINS. THREE THICKENERS. TWO EXPERIMENTAL REHEAT SYSTEMS, AND
THKEE HORIZONTAL EXTRACTION FILTERS FOR SLUUGE DENATURING. DESIGN PLANS
CALL FOR COMPLETE WATER RECOVERY WITH ZERO EFFLUENT DISCHARGE. DESIGN
PART1CULATE AND S02 REMOVAL EFFICIENCIES ARE 99.5 ANU 95 S,RESPECTIVELY.
t.D. NUMbER 23
CINCINNATI GAS & ELECTRIC CO.
'CAST 8ENO NO 2
600 MW - NEW
COAL
HOT SELECTED
NOT SELECTED
STARTUP 1/81
BIO REQUEST AND EVALUATION IS SCHEDULED TO COMMENCE SHORTLY.
CONSTRUCTION AND OPERATING PERMITS ARt BEING PROCURED. A COAL
SOURCE AND SUPPLY HAS NOT BEEN FINALIZED. COMMERCIAL
START-UP DATE HAS BEEN DELAYED ONE TEAR TO JANUARY 1981.
THL A-E DESIGN FIRM IS SARGENT AND LUNDY.
C.D. NUMBER 2«*
COLORADO UTE ELECTRICAL ASSN.
CRAIG STATION NO.l
450 MW - NEW
COAL 0.45 PERCENT SULFUR
HOT SELECTED
LIME/LIMESTONE SCRUBBING
iJTARTUP 3/79
THIS NEW STATION IS A MINE MOUTH FACILITY CONTAINING TWO COAL-FIRED
POWER GENERATING UNITS. THESE UNITS WILL FIRE COLORADO LOW-SULFUR SUB-
BITUMINOUS COAL HAVING A HEAT CONTENT OF 9100 TO 10300 BTU/LB AND ASH
ANU SULFUR CONTENTS OF 10 TO 12 PERCENT AND 0.45 PERCENT, RESPECTIVELY.
THE UTILITY IS NOW INVESTIGATING VARIOUS CONTROL STRATEGIES WHICH WILL
PROBABLY INCLUDE HOT-SIDE ESP'S UPSTREAM OF WET CALCIUM-BASED SCRUBBERS.
REQUIRED PARTICULATE AND SULFUR DIOXIDE REMOVAL EFFICIENCIES ARE 99.8
AND 05 PERCENT, RESPECTIVELY. FGD START-UP IS SCHEDULED FOR SPRING 1979.
I.D. NUMBER 25
COLORADO UTE ELECTRICAL ASSN.
CRAIG STATION NO.2
450 MW - NEW
COAL 0.45 PERCENT SULFUR
MOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP 3/79
THIS NEW STATION IS A MINE MOUTH FACILITY CONTAINING TWO COAL-FIRED
POWER GENERATING UNITS. THESE UMTS WILL FIRE COLORADO LOW-SULFUR SUB-
BITUMINOUS COAL HAVING A HEAT CONTENT OF 9100 TO 10300 BTU/LB AND ASH
AND SULFUR CONTENTS OF 10 TO 12 PERCENT AND 0.45 PERCENT, RESPECTIVELY,
THL UTILITY IS NOW INVESTIGATING VAKIOUS CONTROL STRATEGIES WHICH WILL
PROBABLY INCLUDE HOT-SIOE ESP'S UPSTREAM OF WET CALCIUh-BASEO SCRUBBERS.
REQUIRED PARTICULATE AND SULFUR DIOXIDL REMOVAL EFFICIENCIES ARE 99.8
ANU 65 PERCENT, RESPECTIVELY. FGD STAKT-UP IS SCHEDULED FOK SPKING 1979.
15
PEDCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
12/76
CURRENT MONTH
1.0. NUMBER 26
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE NO 5
400 MM - NEW
COAL <».5 - <».9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
STARTUP 2/77
THE CONSTRUCTION OF THE BOILER AND ESP HAVE BEEN COMPLETED. THE UNIT WAS
PUT IN SERVICE IN SEPTEMBER AND HAS CONTINUED TO OPERATE WITH THE ESP
IN THE FLUE GAS PATH. OPERATION OF THE A-SIOE SCRUBBING TRAIN HAS BEEN
DELAYED BY A FIRE WHICH ORIGINATED INSIDE THE MODULE, RESULTING IN A
PROJECTED MINIMUM DELAY PERIOD OF Six MONTHS. THE UTILITY IS NOW
CONDUCTING AIR AhO WATER TESTS ON THE B-SIDE MODULE IN PREPARATION
OF A FEBRUARY START-UP. THE DRAVO CORP. is SUPPLYING THIOSORBIC LIME. THE
MINE MOUTH PLANT FIRES A HIGH SULFUR, HIGH ASH OHIO BITUMINOUS COAL.
I.D. NUMbER 27
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE NO 6
tOO MM • NEW
COAL <».5 - 1.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
STARTUP 1/78
THE UTILITY SIGNED LONG-TEKM CONTRACTS WITH DRAVO FOR THE PURCHASE OF
THIOSORBIC LIME AND KITH IUCS FOR THE PURCHASE OF SLUDGE FIXATIVES. CON-
STRUCTION ON THIS UNIT IS CURRENTLY SCHEDULED FOR 1977 WITH COMPLETION
EXPECTED BY JANUARY 1978. SIMILAR TO CONESVILLE NO.5, THIS MINE MOUTH
PLANT WILL 3UhN COAL WITH 17 PERCENT ASH CONTENT AND f.5 TO H.9 PtRCENT
SULFUR CONTENT. AN ELECTROSTATIC PKtClPITATOR WILL BE INSTALLED UPSTREAM
OF THE F&O SYSTEM. THE A-E DESIGN FIRM IS BLACK AND VEATCH.
I.D. NUMBER 28
COLUMBUS & SOUTHERN OHIO ELEC.
POSTON NO. 5
375 MW - NEW
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
THIS UNIT WILL BURN HIGH SULFUR OHIO COAL (APPROXIMATELY 2.5 PERCENT
SULFUR CONTENT). THE DESIGN OF THE EMISSION CONTROL STRATEGY HAS
NOT YET BEEN FINALIZED.
I.D. NUMBER 29
COLUMBUS S SOUTHERN OHIO ELEC.
POSTON NO. 6
375 MW - NEW
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/83
THIS UNIT WILL BURN HIGH SULFUR COAL (APPROXIMATELY 2.5 PERCENT
SULFUR CONTENT). THE DESIGN OF THE EMISSION CONTROL STRATEGY
FOR THIS UNIT HAS NOT YET BEEN FINALIZED.
I.D. NUMbER 30
COMMONWEALTH EDISON
POWERTON NO. 51
<*25 MW.- RETROFIT
COAL 3.6 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 12/79
THE CONTRACT FOR THIS FGO SYSTEM HAS BEEN AWARDED TO UNIVERSAL OIL
PRODUCTS. THE PROCESS IS A CLOSED-LOOP WET LIMESTONE SCRUBBING SYSTEM
WHICH WILL BE BACKFITTED TO BOILER 51, ONE OF TWO IDENTICAL BOILERS
SUPPLYING STEAM TO AN 650 MW TURBINE-GENERATOR. THE FGD SYSTEM IS DE-
SIGNED TO TREAT FLUE GAS RESULTING FROM THE COMBUSTION OF HIGH SULFUR
COAL <3.6 PERCENT SULFUR* 8.3 PERCENT ASH* 17.3 PERCENT MOISTURE* 10,500
BTU/LB.) AND ME.ET S02 EMISSION STANDARDS OF 1.8 LB. S02/MM BTU. THE
TOTAL INSTALLED CAPITAL COST OF THE FGO SYSTEM IS ESTIMATED AT S50MM.
PCOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING 12/76
CURRENT MONTH
I.D..NUMBER 31
COMMONWEALTH EDISON
WILL COUNTY NO 1
167 MW - RETROFIT
COAL 4.0 PERCENT SULFUR
BA&COCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 2/72
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS FULL SCALE DEMONSTRATION SCRUBBING SYSTEM HAS BEEN IN SERVICE SINCE
FEBRUARY 1972. THE FGD SYSTEM INCLUDES TWO SCRUBBING TRAINS FOR THE
CONTROL OF PARTICULARS AND SULFUR DIOXIDE. MODULE AVAILABILITY*
OPERABILITY, RELlABILITYt AND UTILIZATION INDEX VALUES FOR THE PERIOD
ARt POSTED IN TABLE THREE. THE BOILER FIRED BOTH LOW SULFUR
WESTERN COAL AND HIGH SULFUR ILLINOIS COAL DURING SEPARATE MONTHS.
THE FlXATIOu AND HAULAWAY OF SCRUBBtR WASTES CONTINUED DURING THE PERIOD,
I.D. NUMBER 32
DETROIT EDISON
ST. CLAIK NO 6
163 MW - RETROFIT
COAL 3.7 PERCENT SULFUR
PEABOOY ENGINEERING
LIMESTONL SCRUBBING
STARTUP 5/76
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
A 30-DAY VENDOR QUALIFICATION RUN AND A WEEK-LONG FINAL ACCEPTANCE TEST
WEHE SUCCESSFULLY COMPLETED DUKING THE SPRING OF 1976. THE UTILITY IS
NOW IN THE PROCESS OF CONDUCTING A MINIMUM TWO-MONTH INTERNAL DEMONSTRA-
TION PROGRAM DURING WHICH THE SCRUBBERS WILL OPERATE IN THE S02-REMOVAL
MODE. THIS PROGHAM IS BEING CONDUCTED PRIMARILY BY PLANT PERSONNEL.
FOLLOWING COMPLETION OF THE S02 PROGRAM. THE VENTURI SCRUBBERS WILL
REMAIN IN THE FLUE GAS PATH, OPERATING IN THE PARTICULATE-REMOVAL MODE.
I.D. NUMBER 33
UUBUESNE LIGHT
ELRAMA POWER STATION
510 MW - RETROFIT
COAL 1.0 - 2.8 PERCENT SULFUR
CHEMICO
LIKE SCRUBBING
STARTUP 10/75
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SCRUBBING SYSTEM•WHICH CONSISTS OF FIVE SINGLE-STAGE MODULES,WAS
INITIALLY PLACED IN SERVICE OCTOBER 26,1975. INITIAL OPERATION PROCEEDED
WITH FLUE GAS FROM ONE BOILER BEING TREATED BY FIVE SCRUBBING VESSELS.
DUKING THE REPORT PERIOD OPERATIONS PROCEEDED WITH TWO BOILERS COUPLED
INTO THE S-MODULE SCRUBBING SYSTEM. ONE SINGLE-STAGE SCRUBBING MODULE
OPERATED WITH Two RUBBER-LINED RECYCLE PUMPS IN SERVICE. THE SCRUBBING
WASTES ARE CHEMICALLY FIXATED BY THE IUCS METHOD AND LANOFILLED.
I.D. NUMBER 34
DUQUESNE LIGHT
PHILLIPS POWER STATION
410 MW - RETROFIT
COAL 1.0- 2.6 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 7/73
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SCRUBBING SYSTEM HAS BEEN IN SERVICE SINCE JULY 1973. THE UTILITY
REPORTED THAT OPERATIONS DURING THE REPORT PERIOD WERE CONDUCTED WITH
BOILER NOS. 2 THrtOUGH 6 COUPLED INTO THE SCRUBBING SYSTEM. BOILER NO.l
REMAINED OUT OF SLrtVICE FOR OVERHAUL AND REPAIRS. THE IUCS INTERIM
SCKUBBER SLUDGE PROCESSING PLANT IS NOW OPERATIONAL AT THE PLANT SITE.
THE CHEMICALLY FIXED SLUDGE IS BEING DISPOSED IN AN OFF-SITE
LANDFILL AREA.
I.D. NUMBER 35
EASTERN KENTUCKY POWER COOP
SPURLOCK GENERATING PLANT NO.2
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 3/80
THE SPURLOCK GENERATING PLANT IS LOCATED APPROXIMATELY 3-MILES WEST OF
MAYSVILLEiKENTUCKY. TWO NEW COAL-FIRED UNITS ARE SCHEDULED FOR THIS
STATION. UNIT NO.l IS SCHEDULED FOR OPERATION IN MAY 1977. UNIT NO.2,
WHICH WILL HAVE TO MEET NSPS, IS IN THE PLANNING STAGE. PARTlCULATES WILL
BE CONTROLLED BY A 99.5 PERCENT EFFICIENT ESP. OESULFURIZATION MAY BE
REGUIRED IF THE UTILITY CANNOT SECURE A LONG-TERM CONTRACT FOR THE
PURCHASE OF LOW SULFUR COAL. A DECISION WILL BE MADE SOMETIME IN THE
EARLT PART OF 1977.
17
PEOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS DURING
12/76
CURRENT MONTH
1.0. NUMBER 36
GENERAL MOTORS
CHEVROLET PARMA 1 2 3 & H
32 MW - RETROFIT
COAL 2.5 PERCEMT SULFUR
KOCH/GENERAL MOTORS
DOUBLE ALKALI SCRUBBING
STARTUP 3/7H
REFER TO BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THESE 4-COAL FIRED STOKER BOILERS
CONSISTS OF MECHANICAL COLLECTORS INSTALLED UPSTREAM OF A DILUTE DOUBLE
ALKALI SCRUBBING SYSTEM. THE FGO SYSTEM HAS BEEN IN SERVICE SINCE MARCH
197
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 12/76
CURRENT MONTH
I.D. NUMBER HI
KANSAS CITY POWER & LIGHT
HAWTHORN NO 4
100 MW - RETROFIT
COAL 0.6- 3.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION *WET SCRUB
STARTUP 8/72
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS INJECTION AND TAIL-END WET SCRUBBING SYSTEM WAS DESIGNED AND IN.
STALLED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE AUGUST 1972.
FGO SYSTEM OPERATIONS DURING 1976 HAVE PROCEEDED ON AN INTERMITTENT
BASIS. PROBLEMS ENCOUNTERED HAVE INCLUDED PLUGGING IN THE MARBLE BCD
AND REHEAT TUBE BUNDLES, DRAFT LOSSES THROUGH THE DUCTWORK AND PUMP
FAILURES. THE UTILITY IS NOW CONVERTING THIS SYSTEM FROM LIMESTONE
INJECTION TO LIME INJECTION AND TAIL-END WET SCRUBBING.
I.D. NUMBER 42
KANSAS CITY POWER & LIGHT
LA CYGNE NO 1
620 MW - NEW
COAL 5.0 PERCENT SuLFUR
BAfaCOCK * WILCOX
LIMESTONE SCRUBBING
STARTUP 2/73
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS 7-MOOULE FGa SYSTEM HAS BEEN IN OPEKATION SINCE FEBRUARY 1973.
THE ANNUAL SYSTEM OPERABILITY INDEX VALUE AVERAGED IN EXCESS OF
76 PERCENT FOR 1974. ANNUAL AVERAGE AVAILABILITY INDEX VALUES FOR
1975 AND 1976 EXCEEDED at PERCENT AND 91 PERCENT,RESPECTIVELY.
THE NO.l UNIT WAS IN SERVICE THROUGHOUT THE REPORT PERIOD,
ACHIEVING AVERAGE AVAILABILITY INDEX VALUES OF 94 AND 90 PERCENT FOR
THt MONTHS OF NOVEMBER AND DECEMBER, RESPECTIVELY.
I.D. NUMBER 43
KANSAS POWER * LIGHT
JEFFERY NO. 1
660 MW - NEW
COAL 0.32 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/78
THE UTILITY HAS PURCHASED AN AIR QUALITY CONTROL SYSTEM FROM COMBUSTION
ENGINEERING FOR PARTICULATE AND S02 REMOVAL. THE SYSTEM WILL CONSIST OF
AN ESP DOWNSTREAM OF THE AIR HEATER PLUS ID FANS AND SPRAY TOWERS. AN
OVERFIRE AIR SYSTEM AT THE TANGENTIAL FIRED PULVERIZED BURNERS WILL CON-
TROL THE NOX EMISSIONS. THE CLEANED GASES WILL BE VENTED TO A 600 FOOT
STACK. THE CONSTRUCTION OF THIS NEW INSTALLATION IS PROCEEDING
ACCORDING TO SCHEDULE. THIS UNIT WILL FIRE 250 TONS/HR OF WYOMING
COAL WITH A HEAT CONTENT OF 8000 BTU/LB, 0.3* SULFUR AND 6X ASH.
I.D. NUMBER 44
KANSAS POWER & LIGHT
JEFFERY NO. 2
6tiO MW - NEW
COAL 0.32 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/79
THE UTILITY HAS PURCHASED AN AIR QUALITY CONTROL SYSTEM FROM COMBUSTION
ENGINEERING FOR PAKTICULATE AND S02 REMOVAL. THE SYSTEM WILL CONSIST OF
AN ESP DOWNSTREAM OF THE AIR HEATER PLUS ID FANS AND SPRAY TOWERS. AN
OVERFIRE AIR SYSTEM AT THE TANGENTIAL FIRED PULVERIZED BURNERS WILL CON-
TROL THE NOX EMISSIONS. THE CLEANED GASES WILL BE VENTED TO A 600 FOOT
STACK. THE CONSTRUCTION OF THIS NE*I INSTALLATION IS PROCEEDING
ACCORDING TO SCHEDULE. THIS UNIT HILL 250 TONS/HR OF WYOMING
COAL HAVING A HEAT CONTENT OF UOOO BTU/LB, 0.3Si SULFUR ANO 68 ASH.
I.D. NUMBER 45
KANSAS POWER & LIGHT
LAWRENCE NO 4
125 MW - RETROFIT
COAL 0.5 PERCENT SULFUR
COKBUSTION ENGINEERING
LIMESTONE INJECTION *W£T SCRUB
STARTUP 12/68
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE ORIGINAL FGD SYSTEM FOR THIS UNIT WAS PLACED IN SERVICE DECEMBER
I960. IN ACHIEVING AN OPTIMUM MODE OF OPERATION, THE PHYSICAL SCRUBBER
PLANT WAS CONSUMED, REQUIRING REPLACEMENT WITH A NEW VENTUKl ROD
SCRUBBER AND SPRAY TOWER ABSORBER SYSTEM SUPPLIED BY COMBUSTION
ENGINEERING.INSTALLATION OF THE NEW SYSTEM IS COMPLETE.INITIAL OPERATION
SHOULD COMMENCE IN THE EARLY PART OF 1977. THE UNIT WAS DOWN THROUGH*
OUT THE KEPOHT PERIOD BECAUSE OF A SCHEDULED TURBINE OVERHAUL.
19
PEOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS QURINS 12/76
CURRENT MONTH
1.0. NUMBER if 6
KANSAS POWER X LIGHT
LAWRENCE NO 5
400 MU - NEW
COAL 0.5 PERCENT SULFUR
•COMBUSTION ENGINEERING
LIMESTONE INJECTION &WET SCRUB
STARTUP 11/71
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE ORIGINAL FGD SYSTEM FOR THIS UNIT WAS PLACED IN SERVICE NOVEMBER 1971
RENTLY BURNING LOW SULFUR WYOMING COAL. THE OPERATION OF THE SCRUBBER HAS
IN ACHIEVING AN OPTIMUM MODE OF OPERATION, THE PHYSICAL SCRUBBER PLANT
WAS CONSUMEOi REQUIRING REPLACEMENT WITH TWO NEW VENTURI ROD
SCRUBBERS AND SPRAY TOWER ABSORBERS SUPPLIED BY COMBUSTION ENGINEERING.
IS PROCEEDING ON POURING OF THE FOUNDATION AND ERECTION OF THE
STRUCTURAL STF.E.L. THE BOILER IS IN SERVICE, FIRING FUEL OIL.
I.D. NUMBER i»7
KENTUCKY UTILITIES
GREEN RIVER UNITS 1 AND
6t MW - RETROFIT
COAL 3.6 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 9/75
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT,
BOILERS 1, 2, AND 3 ARE EXISTING UNITS WHICH HAVE BEEN FITTED WITH
MECHANICAL COLLECTORS AND A WET LIME SCRUBBER-ABSORBER MODULE FOR
THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. THE SCRUBBER
MODULE WAS ORIGINALLY PLACED IN THE FLUE 6AS PATH SEPT. 9, 1975.
100,100,100, AND y"4 PERCENT RESPECTIVELY FOR THE MONTH OF OCTOBER.
AN ANNUAL OPERABILITY INDEX VALUE OF 87 PERCENT.
I.D. NUMBER
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 12/76
CURRENT MONTH
'I.D. NUMBER 51
'LOUISVILLE GAS & ELECTRIC
'CANE RUN NO 6
277 MW - RETROFIT
'COAL 3.5 - 4.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI SCRUBBING
STARTUP 2/79
THE CONTRACT FOR THIS FULL-SCALE DEMONSTRATION SCRUBBING SYSTEM HAS BEEN
AWARDED TO A.D.LITTLE/COMBUSTION EQUIPMENT ASSOC. FOR THE INSTALLATION
OF A DOUBLE ALKALI SCRUBBER. THE FEDERAL EPA WILL SUBSIDIZE A MAXIMUM
Sif.5 MM FOR OPERATION* RESEARCH AND DEVELOPMENTt AND REPORT WRITING FOR
A ONE-YEAR PERIOD FOLLOWING THE FIRST THREE MONTHS OF OPERATION(NOTE*THIS
SUBSIDY WILL NOT BE APPLIED FOR ANY CAPITAL EXPENDITURES). ENGINEERING
DESIGN WORK IS NOW UNUEKWAY. START-UP IS SCHEDULED FOK FEBRUARY 1.1979.
I.D. NUMBER 52
LOUISVILLE GAS i ELECTRIC
MILL CREEK NO 1
330 MW - RETROFIT
COAL 3.5- 4.0 PERCENT SULFUR
NOT SELECTED
LIME: SCRUBBING
STARTUP 1/82
A COMPLIANCE SCHEDULE HAS BEEN SUBMITTED TO THE JEFFERSON COUNTY AIR POL-
LUTION CONTROL DISTRICT WITH 1/82 ESTABLISHED AS THE STARTUP DATE FOR AN
FGO SYSTEM.
'I.D. NUMBER 53
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 2
330 MW - RETROFIT
COAL 3.5- 4.0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 1/el
A COMPLIANCE SCHEDULE HAS BEEN SUBMITTED TO THE JEFFERSON COUNTY AIR POL-
LUTION CONTROL DISTRICT WITH 1/81 ESTABLISHED AS THE STARTUP DATE FOR AN
FGO SYSTEM.
I.D. NUMBER 54
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 3
425 MW - NEW
COAL 3.5- 4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 7/77
THE UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGO EQUIPMENT ON THIS POWER GENERATING UNIT BY
JULY 1.1977. THIS NEW FACILITY WILL BE REQUIRED TO MEET FEDERAL NSpS FOR
THE LIMITATION OF S02 EMISSIONS. CONTRACT HAS BEEN AWARDED TO AMERICAN
AIR FILTER. THE SYSTEM WILL OPERATE ON A CLOSED WATER LOOP AND THE SLUDGE
WILL BE STABILIZED. CONSTRUCTION HAS BEGUN ON THE FGD SYSTEM.
I.D. NUMBER 55
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 4
425 MW - NEW
COAL 3.5- 4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 7/79
THE UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGD EQUIPMENT ON THIS POWER GENERATING UNIT BY
JULY 1.1979. THIS NEW FACILITY WILL BE REQUIRED TO MEET FEDERAL NSPS FOR
THE LIMITATION OF S02 EMISSIONS. THE CONTRACT HAS BEEN AWARDED TO
AMERICAN AIR FILTER FOR A LIME SCRUBBING SYSTEM.
21
PEDCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 12/76
CURRENT MONTH
1.0. NUMBER 56
LOUISVILLE GAS & ELECTRIC
PADDYS RUN NO 6
65 MW - RETROFIT
COAL 3.5-i».0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 1/73
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SCRUBBING SYSTEM WAS DESIGNED BY COMBUSTION ENGINEERING AND PLACED
IN SERVICE IN APRIL 1973. PADDYS RUN NO.6 IS A PEAK-LOAD UNIT THAT
OPERATES ONLY DURING DEMAND PERIODS. THE UNIT WAS OPERATIONAL DURING
THE REPORT PERIOD. BEING AVAILABLE TO THE BOILER ON 99 PERCENT BASIS.
SCKUbBER OPERATIONS WERE CONDUCTED ON CARBIDE LIME SLURRY DURING THE
PERIOD. THE EPA-SUBSIUI2EO SCRUBBER/SLUDGE STUDY CALLS FOR A HIGH
CALCIUM VIRGIN LIME RUN TO COMMENCE ON MARCH 1, 1977.
I.D. NUMBER 57
MINNESOTA POWER AND LIGHT CO.
CLAY BOSWELL STATION N0.«t
500 MW - NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
MOT SELECTED
STARTUP 0/80
THE UTILITY IS CURRENTLY REQUIESTING AND EVALUATING BIDS FOR THE INSTAL-
LATION OF A SCRUBBING SYSTEM ON THIS NEW COAL-FIRED UNIT PLANNED FOR
COMMERCIAL SERVICE IN THE SPRING OF 19BO. THIS NEW UNIT WILL FIRE LOW
SULFUR SUBBITUMNOUS COLSThIP COAL. THE UTILITY IS CONSIDERING DRY
COLLECTION AND MET SCRUBBING STRATEGIES (ESP AND SCRUBBERS) AND TWO-
STAGE WET SCRUBBING STKATEGIES (SCRUBBER-ABSORBERS) FOR THE
REMOVAL OF PARTICULATES AND SULFUR DIOXIDE. A FINAL DECISION WILL
BE ANNOUNCED BY THE UTILITY SHORTLY.
I.D. NUMBER 58
HINNKOTA POWER COOPERATIVE
MILTON R. YOUNG NO. 2
t50 MW - NEW
LIGNITE - 6.500 BTu. 0.755 S
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 8/77
THE CONTRACT FOR THIS LIME/ALKALINE FLYASH SCRUBBING SYSTEM HAS BEEN
AWARDED TO ADL/COMBUSTION EQUIPMENT ASSOCIATES. THE EMISSION CONTROL
SYSTEM FOR THIS UNIT CONSISTS OF A HIGH-EFFICIENCY ESP UPSTREAM OF TWO
SPRAY TOWERS. DESIGN PARTICULATE ANU SULFUR DIOXIDE REMOVAL EFFICIENCIES
ARE 99.6 AND 75 PERCENT.RESPECTIVELY. SITE PREPARATION AND FOUNDATION
WORK HAS BEEN COMPLETED. ALL EQUIPMENT FABRICATION HAS BEEN COMPLETED.
EQUIPMENT ERECTION IS NOW IN PROGRESS. ALL HVAC AND ELECTRICAL CONTRACTS
FOR THE SCRUBBER AND ANCILLARY EQUIPMENT HAVE BEEN AWARDED.
I.D. NUMBER 59
MONTANA POWER CO.
COLSTRIP NO 1
360 MW - NEW
COAL 0.6 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 10/75
THE COLSTRIP PLANT IS A MINE MOUTH INSTALLATION. CONSTRUCTION ON THIS
UNIT WAS COMPLETED BEHIND SCHEDULE. THE FGD SYSTEM STARTED UP IN LATE
1975 AND PROCEEDED THROUGH A SHAKEDOWN AND DEBUGGING OPERATION PHASE. THE
UNIT HAS BEEN OPERATING AT FULL COMMERCIAL CAPACITY. THE SCRUBBING
SYSTEM DESIGN INCORPORATES THE VENTURI WET SCRUBBERS FOR PARTICULATE
AND SULFUR DIOXIDE REMOVAL. FLUE GAS CANNOT BE BYPASSED AROUND THE
SCRUBBING SYSTEM. INFORMATION AND OPERATING DATA WERE NOT
AVAILABLE BY THE UTILITY DURING THE REPORT PERIOD.
I.D. NUMBER 60
MONTANA POWER CO.
COLSTRIP NO 2
360 MW - NEW
COAL 0.6 PERCENT SULFUR
ADL/COMBUSTION EOUjp ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/76
THE COLSTRIP PLANT IS A MINE MOUTH FACILITY. CONSTRUCTION OF THE FGD
SYSTEM HAS BEEN COMPLETED. TURBINE KOLL AND SYSTEM CHECKOUT HAVE BEEN
COMPLETED. INITIAL OPERATION OF THE SCRUBBING SYSTEM COMMENCED IN
JULY 1976. THIS UNIT IS IDENTICAL TO THE NO.l SYSTEM DESIGN IN THAT
THREE SCRUBBER MODULES ARE INSTALLED FOR PARTICULATE AND SULFUR DIOXIDE
REMOVAL. FLUE GAS CONNOT BE BY-PASSED AROUND THE SCRUBBING SYSTEM.
INFORMATION AND OPERATING DATA WERE NOT MADE AVAILABLE BY THE UTILITY
DURING THE REPORT PERIOD,
22
PEDCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS DURING
12/76
CURRENT MONTH
I.D. NUMBER 61
MONTANA POWER CO.
COLSTRIP NO.3'
700 MW - NEW
COAL 0.7 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/SO
THE UTILITY ANNOUNCED DURING THE REPORT PERIOD THAT A CONTRACT FOR
THE INSTALLATION OF TWO ADDITIONAL LIME/ALKALINE FLYASH SCRUBBING
SYSTEMS HAS BEEN AWARDED TO AD LITTLE/COMBUSTION EOUlPfiENT ASSOCIATES.
THESE SYSTEMS WILL BE INSTALLED ON UNITS NOS. 3 AND H OF THE COLSTRIP
POWER STATION. COLSTRIP UNITS 1 AND 2 ARE BOTH EQUIPPED WITH OPERATIONAL
LIME/ALKALINE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL OF PARTICULATES
AND SULFUR DIOXIDE. ENGINEERING WORK FOrt THE NEW SYSTEMS IS NOW UNDERWAY.
THIS CONTRACT IS EXPECTED TO EXCEED $50 MM.
I.D. NUMBER 62
MONTANA POWER CO.
COLSTRIP N0.<»
700 MW - MEW
COAL 0.7 PERCENT SULFUR
ADL/COMBUSTIO.M EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/61
THE UTILITY ANNOUNCED DURING THE REPORT PERIOD THAT A CONTRACT FOR
THE INSTALLATION OF TWO ADDITIONAL LIME/ALKALINE FUYASH SCRUBBING
SYSTEMS HAS BEEN AWAHULD TO AD LITTLE/COMBUSTION EQUIPMENT ASSOCIATES.
THESE SYSTEMS WILL BE INSTALLED ON UNITS NOS. 3 AND "» OF THE COLSTRIP
POwER STATION. COLSTRIP UNITS 1 AND 2 ARE BOTH EQUIPPED WITH OPERATIONAL
LIME/ALKALINE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL OF PARTICULATES
AND SULFUR DIOXIDE. ENGINEERING WORK FOR THE NEW SYSTEMS IS NOW UNDERWAY.
THIS CONTRACT IS EXPECTED TO EXCEED $50 MM.
I.D. NUMBER 63
NEVADA POWER
HARRY ALLEN STATION NO. 1
500 MW - NEW
COAL
NOT SELECTED
HOT SELECTED
STARTUP
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
I.D. NUMBER 6t
NEVADA POWER
HARRY ALLEN STATION NO. 2
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/BH
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
I.D. NUMBER 65
NEVADA POWER
HARRY ALLEN STATION NO. 3
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/85
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
PEOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS- OF FGD SYSTEMS DURING
12/76
CURRENT MONTH
' 1.0. NUMBER 66
NEVADA POWER
HARRY ALLEN STATION NO.
500 Mh - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/86
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
1.0. NUMBER 67
NEVADA POWER
REID GARDNER NO 1
125 HW - RETROFIT
COAL 0.5- 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CAKBOMATE SCRUBBING
STARTUP
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A TWIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A
SINGLE-STAGE PERFORATED-PLATE WASHING TOWER. THE SCRUBBING TRAIN
WAS FIRST PLACED IN OPERATION IN APRIL 197H. THE SYSTEM WAS IN SERVICE
THROUGHOUT THE REPORT PERIOD. LOGGING SERVICE TIMES OF 508 HOURS AND
599 HOURS FOR THE MONTHS OF NOVEMBER AND DECEMBER. RESPECTIVELY.
68
1I.D. NUMbER
NEVADA POWER
REID GARDNER NO 2
125 Mw - RETROFIT
COAL 0.5- 1.0 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CAKBUNATE SCRUBBING
STARTUP H/7H
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A TWIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A
SINGLE-STAGE PERFORATED-PLATE WASHING TOWER. THE SCRUBBING TRAIN WAS
FIRST PLACED IN THE GAS PATH IN APRIL 1974. SYSTEM OPERATION DURING THE
REPOKT PERIOD WAS INTERMITTENT BECAUSE OF SCRUBBER AND BOILER-RELATED
PROBLEMS.
'I.D. NUMBER 69
NEVADA POWER
REID GARDNER NO 5
1 125 Kw - NEW
COAL 0.5- 1.0 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP 7/76
REFEK TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS UNIT IS A NEW COAL-FIRED BOILER THAT IS EQUIPPED WITH SODIUM
CAKBONATE-BASED(TRONA)SCRUBBING SYSTEM WHICH INCORPORATES A TWIN
VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A SINGLE-STAGE PERFORATED-
PLATE WASHING TOWEK FOR THE CONTROL OF PARTICULATES AND SULFUR
DIOXIDE. THE BOILER COMMENCED OPERATIONS IN APRIL 1976 AND THE
SCRUBBER WAS PLACED IN SERVICE THREE MONTHS LATER. THE SYSTEM
WAS IN SERVICE THROUGHOUT THE REPORT PERIOD.
'I.D. NUMBER 70
NEVADA POWER
REID GARDNER NO H
125 MW - NEW
• COAL 0-5- l.Q PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP O/ 0
NEVADA POWER COMPANY HAS SIGNED A LETTER OF INTENT WITH COMBUSTION EQUIP-
MENT ASSOCIATES FOR THL CONSTRUCTION OF AN FGD SYSTEM ON REID GARDNER NO.
«». HOWEVER. CONSTRUCTION OF THE BOILER HAS BEEN INDEFINITELY POSTPONED.
PCDtO ,
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
12/76
CURRENT MONTH
1.0. NUMBER 71
NEVADA POWER
WARNER VALLEY STATION NO. 1
250 MU - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/62
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM.
I.D. NUMBER 72
NEVADA POWER
WARNER VALLEY STATION NO.
250 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/83
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM.
I.D. NUMBER 73
NEW ENGLAND ELEC SYSTEM
BRAYTON POINT NO.3
650 MW - RETROFIT
COAL 3.0 PERCENT SULFUR
NOT SELECTED
REGENERABLE NOT SELECTED
STARTUP O/ 0
THE UTILITY IS CURRENTLY INVESTIGATING VARIOUS ADVANCED REGENERABLE
FLUE GAS DESULFURIZATION SYSTEMS WHICH OFFER A BREAKTHROUGH IN
OPERATING COSTS AND PRODUCE ELEMENTAL SULFUR AS AN END
PRODUCT. THE UTILITY IS CURRENTLY INVOLVED IN BENCH AND LABORATORY
SCALE INVESTIGATIONS OF SULFUR RECOVERY. THE NO. 3 UNIT IS CURRENTLY
OPERATIONAL. FIRING LOW SULFUR FUEL OIL.
I.D. NUMBER 7*t
NIAGARA MOHAWK POWER COOP.
CHARLES K. HUNTLEY NO. 6
100 MW - RETROFIT
COAL 2.5-«u5 PERCENT SULFUR
ATOMICS INTERNATIONAL
AQUEOUS CARBONATE SCRUBBING
STARTUP 6/78
THE EMPIRE STATE ELECTRIC ENERGY RESEARCH CORP.
BY THE EPA TO NEGOTIATE FOR THE INSTALLATION OF
SCRUBBING SYSTEM UTILIZING SULFUR RECOVERY. THE
SITE IS THE C.R. HUNTLEY STATION OF THE NIAGRA
NEAR BUFFALO, NEW YORK. THE PROCESS BEING GIVEN
THE AQUEOUS CABONATE SCRUBBING PROCESS OFFERED
THE DESIGN COAL SPECIFICATIONS CALL FOR 2.5 TO
TO BE BUhNED WITH AN S02 REMOVAL EFFICIENCY OF
HAS BEEN GIVEN PERMISSION
A 100-MW DEMONSTRATION
DESIGNATED INSTALLATION
MOHAWK POWER COOP LOCATED
PRIMARY CONSIDERATION IS
BY ATOMICS INTERNATIONAL.
«*.5 PERCENT SULFUR COAL
90 PERCENT OR 200 PPM.
I.D. NUMBER 75
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 7
190 MW - RETROFIT
COAL 3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/0
CONSIDERING A LIME OR LIMESTONE SCRUBBING UNIT. ALSO WAITING FOR PER-
FORMANCE OF WELLMAfc LORD/ALLIED CHEMICAL UNIT UNDER CONSTRUCTION AT THEIR
D.N.MITCHELL NO.11 UNIT. LOW SULFUR COAL MAY BE EMPLOYED TO COMPLY WITH
S02 EMISSION REGULATIONS.
25
PEDCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS DURING 12/76
CURRENT MONTH
I.D. NUMBER 76
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 8
400 MW - RETROFIT
COAL 3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
CONSIDERING A LIME OR LIMESTONE SCRUBBING UNIT. ALSO WAITING FOR PERFOR-
MANCE OF WELLMAN LORD/ALLIED CHEMICAL UNIT UNDER CONSTRUCTION AT THEIR
0. H. MITCHELL NO. 11 UNIT. LOW SULFUR COAL MAY BE BURNED TO COMPLY WITH
S02 EMISSION REGULATIONS.
I.D. NUMBER 77
NORTHERN INDIANA PUBLIC SERVIC
D.H. MITCHELL NO.ll
115 MW - RETROFIT
COAL 3.2- 3.5 PERCENT SULFUR
DAVY POWERGAS/ALLIEO CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 0/77
THIS FGO SYSTEM IS AN INTEGRATION OF THE WELLMAN-LORO S02 RECOVERY PRO-
CESS OF DAVY POWE.RGAS AND ALLIED CHEMICAL'S S02 TO SULFUR REDUCTION
PROCESS. DAVY POWERGAS IS THE ENGINEER AND CONSTRUCTOR OF THE FGD
FACILITY AND ALLIED CHEMICAL IS THE SYSTEM OPERATOR AND PRODUCT MARKETERt
AT THE PRESENT TIME. INITIATIATION OF OPERATIONS OF THE S02 RECOVERY
SYSTEM HAVE BEEN OE-LAYfcO BY BOILER UNAVAILABILITY. START-UP OF SYSTEM
OPERATIONS IS INDEFINITE. ALL PROGRAM PARTICIPANTS ARE ANALYZING
VARIOUS STRATEGIES TO MINIMIZE THE LENGTH OF THE DELAY PERIOD.
I.D. NUMBER 78
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.l
710 Mfci - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/76
REFEK TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
A PRELIMINARY WATLR/AIR SYSTEM CHECKOUT WAS SUCCESSFULLY COMPLETED BY
THE UTILITY AND INITIAL OPERATIONS COMMENCED ON MARCH 16, 1976. FULL
COMMERCIAL OPERATION OF THE SYSTEM BEGAN ON MAY 1. 1976. THE SCRUBBING
SYSTEM FOR THIS UNIT CONSISTS OF 12 MODULES. EACH SCRUBBING MODULE
INCORPORATES A VENTURI-ROD SECTION AND A MARBLE BED ABSORBER FOR PAR-
TICULATE AND SULFUR DIOXIDE REMOVAL. SYSTEM DESIGN CALLS FOR 11 MODULES
TO BE IN OPERATION FOR FULL LOAD CAPACITY.
I.D. NUMBER 79
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.2
. 680 MW - NEW
COAL 0.8 PERCENT SuLFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 5/77
THL CONSTRUCTION Of- THIS NEW POWER-GENERATING UNIT IS VIRTUALLY COMPLETE.
THE EARLY STAGES OF SYSTEM CHECKOUT IS NOW IN PROGRESS. BOILOUT AND
STLAM BLOWOUT HAVE BEEN COMPLETED. GAS HAS BEEN PASSED THROUGH THE
SCKUiiBER MODULES. TUKBINE KOLL HAS BEEN SCHEDULED FOR THE LAST WEEK
IN JANUARY 1977. THE DESIGN OF THE EMISSION CONTROL SYSTEM FOR THIS UNIT
is IDENTICAL TO THE SYSTLM NOW OPERATIONAL ON THE NO. i UNIT. THE SYSTEM
DOES NOT INCLUDE FLUE GAS BY-PASS CAPABILITY. NECESSITATING THE
SIMULTANEOUS START-UP OF BOTH THE BOILER AND SCRUBBING SYSTEM.
I.D. NUMBER 80
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.3
860 MW - NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 5/81
NSP HAS ANNOUNCED THAT TWO ADDITIONAL COAL-FIRED POWER.GENERATING UNITS
ARE SCHEDULED TO BE INSTALLED AT THEIR SHERBURNE COUNTY GENERATING
STATION IN BECKER, MINNESOTA. COMMERCIAL OPERATION DATES ARE NOW
SCHEDULED FOR MAY 1961 AND MAY 1983. EACH UNIT IS NOMINALLY RATED AT
860 MW. THE BOILERS WILL BE DESIGNED TO FIRE MONTANA LOW-SULFUR SUB-
BITUMINOUS COAL WITH A HEAT CONTENT OF 6300 BTU/LB AND ASH AND SULFUR
CONTENTS OF 9.0 AMU 0.6 PERCENT, RESPECTIVELY. THE UTILITY IS CONSIDERING
TWO-STAGE SCRUBBERS FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE.
PEOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS DURING 12/76
CURRENT MONTH
I.D. NUMBER al
NORTHERN STATES POWER CO.
SHERbURNE COUNTY STATION N0.«»
860 MM - NEW
:OAL o.s PERCENT SULFUR
MOT SELECTED
*OT SELECTED
STARTUP 5/83
NSP HAS ANNOUNCED THAT TWO ADDITIONAL COAL-FIRED POWER-GENERATING UNITS
ARE SCHEDULED TO BE INSTALLED AT THEIR SHERBURNE COUNTY GENERATING
STATION IN BECKER, MINNESOTA. COMMERCIAL OPERATION DATES ARE NOW
SCHEDULED FOR MAY 1981 AND MAY 1985. EACH UNIT IS NOMINALLY RATED AT
860 MW. THE BOILERS WILL BE DESIGNED TO FIRE MONTANA LOW-SULFUR SUB-
BITUMINOUS COAL WITH A HEAT CONTENT OF 8300 BTU/LB AND ASH AND SULFUR.
CONTENTS OF 9.0 AND 0.6 PERCENT, RESPECTIVELY. THE UTILITY IS CONSIDERING
TWO-STAGE SCRUBBERS FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE.
I.D. NUMBER 82
OTTER TAIL POWER COMPANY
COYOTE STATION NO.l
HOO MW - NEW
LIGNITE 0.9 PERCENT SULFUR
UOT SELECTED
NOT SELECTED
STARTUP 0/81
THIS NEW COAL-FIRED STATION IS JOINTLY OWNED BY FIVE UTILITIES. OTTER
TAIL POWER IS THL MAJOR OWNER AND CONSTRUCTOR. MONTANA-DAKOTA UTILITIES
IS THE FACILITY OPERATOR. THIS PLANI4ED UNIT WILL FIRE LOW SULFUR LIGNITE
FROM THE MERCER COUNTY AREA. THE UTILITY IS NOW INVESTIGATING VARIOUS
EMISSION CONTROL STRATEGIES TO MEET PARTICULATE AND SULFUR DIOXIDE
COOES. SULFUR DIOXIDE REMOVAL STRATEGIES BEING CONSIDERED AT THE PRESENT
INCLUDE BOTH WET AND DRY REMOVAL PROCESSES.
:i.D. NUMbER 83
PACIFIC PUWER AND LIGHT CO.
JIM BRIDGER NO. *t
509 MW - MEW
COAL 0.56 PERCENT SULFUR(AVG.)
UNIVERSAL OIL PRODUCTS
SODIUM CARBONATE SCRUBBING
STARTUP 9/79
THE PACIFIC POWEK & LIGHT CO. AND IDAHO POWER CO. HAVE ANNOUNCED THAT THE
PLANS FOR AN EMISSION CONTROL STRATEGY FOR THEIR NEW POWER GENERATING
UNIT AT THE JIM BRIDGER PLANT HAVE BEEN FINALIZED. UNIT NO.f WILL FIRE A
LOW SULFUR (0.56 PERCENT) SUBBITUMINOUS COAL AND HAS A NET RATING OF 509
MW. PARTICULATES AND SULFUR DIOXIDE WILL BE CONTROLLED BY A ELECTROSTATIC
PRECIPITATOR UPSTREAM OF A SODIUM-BASED WET SCRUBBING SYSTEM. THE FGD
CONTRACT HAS BEEN AWARDED TO UOP FOR THREE ABSORPTION TRAINS DESIGNED TO
REMOVE 91 PERCENT OF THE S02 TO MEET THE STRICT WYOMING EMISSION COOES.
7.D. NUMBER 84
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 1
835 MW - NEW
COAL <*.7 PERCENT SULFUR
C.HEMICO
LIME SCRUBBING
J.TARTUP n/je>
HEFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS EMISSION CONTROL SYSTEM IS CAPABLE OF REMOVING FLYASH AND S02 FROM
3.35 MM ACFM OF FLUE GAS VIA WET LIME SCRUbBItJG. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASE OF OPERATION BEGAN FOR PART OF THE SYSTEM IN DECEMBER
1975. FULL COMMERCIAL OPERATION COMMENCED IN APRIL 1976. TO DATE, ALL 6
OF THE SCRUBBING TRAINS HAVE BEEN SUCCESSFULLY PUT INTO OPERATION.
THE AVAILABILITY INDEX VALUE FOR THE ENTIRE SCRUBBING SYSTEM HAS
BEEN IN THE MID 90 PERCENT RANGE SINCE COMMERCIAL START-UP.
I.D. NUMBER 85
PENNSYLVANIA POWER CO.
tRUCE MANSFIELD NO. 2
835 MW - NEW
COAL H.7 PERCENT SULFUR
cHEMico
LIME SCRUBBING
STARTUP H/77
THE FGO SYSTEM FOR THIS INSTALLATION WILL BE A CHEMICO WET LIME SCRUBBING
SYSTEM CAPABLE OF REMOVING PARTICULATE MATTER AND S02 FROM THE FLUE GAS.
THIS SYSTEM IS CURRENTLY UNDER CONSTRUCTION. LONG DELAYS HAVE BEEN EN-
COUNTERED IN MATERIAL DELIVERIES. THE FGD SYSTEM STAKTUP DATE IS NOW
SCHEDULED FOR APRIL 1977. THE DESIGN, ARRANGEMENT AND OPERATION OF THIS
SCRUBBING SYSTEM WILL BE IDENTICAL TO THE NO.l UNIT CURRENTLY OPERATIONAL
AT THIS STATION
27
PEDCO ENVIRONMENTAL
-------
COMPANY
, • I -I
POWER STATION
TABLE: 2
STATUS OF F6D SYSTEMS DURING 12/76
CURRENT MONTH
I.D. NUMBER 86
'PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 3
635 MW - NEW
COAL H.7 PERCENT SULFUR
PULLMAN KELLOGG
LIME SCRUBBING
STARTUP H/79
THE PULLMAN KELLOGG DIVISION OF PULLMAN INCORPORATED HAS BEEN
AWARDED A CONTRACT IN EXCESS $50 MILLION BY THE CAPCO CONSORTIUM
FOR THE INSTALLATION OF SULFUR DIOXIDE SCRUBBER ON THIS 035 MW COAL-
FIREU POWER-GENERATING UNIT. THE EMISSION CONTROL SYSTEM FOR THIS
UNIT WILL CONSIST OF ESP«S FOR PARTICULATE CONTROL UPSTREAM OF
5 WEIK HORIZONTAL CROSSFLOW WET SCRUBBING MODULES EMPLOYING A
THIOSORBIC LIME SCRUBBING SOLUTION FOR THE REMOVAL OF SULFUR
DIOXIDE. CONSTRUCTION OF THE BOILER IS CURRENTLY IN PROGRESS.
1.0. NUMBER 87
'PHILADELPHIA ELECTRIC CO.
CROfiBY
150 MW - RETROFIT
COAL 2-<» PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 6/60
THt. UTILITY PLANS TO RETROFIT ONE OF THE TWO BOILERS AT CROMBY WITH AN
FGO SYSTEM. HOUEVEK, A FINAL DECISION HAS NOT BEEN MADE. THE PROCESS
BEING GIVEN PRIME CONSIDERATION IS MAGNESIUM OXIDE SCRUBBING DESIGNED
JOINTLY BY UNITED ENGINEERS AND PHILADELPHIA ELECTRIC. ENGINEERING
DESIGN WORK IS SCHEDULED TO COMMENCE IN 1977. TENATIVE FGD SYSTEM
START-UP IS SCHEDULED FOR JUNE I960.
I.D. NUMBER 86
PHILADELPHIA ELECTRIC CO.
EODYSTONE NO 1A
120 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 9/75
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE S02 SCRUBBING OPERATIONS HAVE BEEN TEMPORARILY DISCONTINUED AT THIS
STATION BECAUSE THE REGENERATION FACILITY AT THE OLIN CHEMICAL SULpURIC
ACID PLANT HAS PERMANENTLY CEASED OPERATIONS. THE UTILITY IS NOW RELO-
CATING THE REGENERATION FACILITY TO THE ESSEX CHEMICAL PLANT LOCATED
IN NEWARK, NEW JERSEY. RESUMPTION OF S02 SCRUBBING OPERATIONS IS NOW
SCHEDULED FOR MAY OF 1977. TO DATE* THE MAGNESIUM OXIDE SCRUBBING UNIT
HAS BEEN IN SERVICE FOR ONLY A SHORT PERIOD OF TIME DURING LATE 1975.
I.D. NUMBER 89
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO IB
240 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP t>/80
THE INSTALLATION OF S02 SCRUBBERS ON THE BALANCE OF THE FLUE GAS FROM
THIS UNIT WILL FOLLOW PENDING THE OUTCOME OF THE PERFORMANCE OF THE
SCRUBBING UNIT WHICH HAS BEEN INSTALLED AND INTERMITTENTLY OPERATIONAL
ON THE EODYSTONE fJO.l UNIT. CURRENTLY. 3 WET PARTICULATE SCRUBBERS ARE
IN SERVICE ON THIS UNIT. THE UTILITY REPORTS THAT'PROBLEMS WITH THE
SCRUBBER BOOSTER FANS HAVE HOPEFULLY BEEN SOLVED AND WILL BE RETURNED
TO SERVICE WHEN THE UNIT RETURNS TO OPERATION FOLLOWING AN EXTENDED
SCHEDULED SHUTDOWN FOR OVERHAUL AND REPAIR.
I.D. NUMBER 90
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. 2
336 MW - RETROFIT
COAL 2.«t PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 6/60
THE UTILITY IS AWAITING PERFORMANCE RESULTS FROM THE EXISTING MAGOx
SCRUBBER INSTALLED Ofv UNIT UO.l AT THIS STATION BEFORE PROCEEDING
WITH THE DESIGN OF AN FGU SYSTEM FOR THIS COAL-FIRED BOILER. THE PROCESS
BEING GIVEN PRIME CONSIDERATION IS MAGNESIUM OXIDE SCRUBBING DESIGNED
JOINTLY BY UNITED ENGINEERS AND PHILADELPHIA ELECTRIC. ENGINEERING
DESIGN WORK IS SCHEDULED TO COMMENCE IN 1977. TENATIVE FGD SYSTEM
START-UP IS SCHEDULED FOR JUNE 1980.
28
PEDCO ENVIRONMENTAL
-------
January 31, 1977
PEDCo- ENVIRONMENTAL
SUITE 13 • ATKINSON SQUARE
CINCINNATI. OHIO 45246
513 /771-433O
Enclosed is a copy of the November-December report on the
Status of Flue Gas Desulfurization Systems in the United
States. This report is prepared every other month by PEDCo-
Environmental, Inc., under a contract to the Industrial
Environmental Research Laboratory/RTF and the Division of
Stationary Source Enforcement of the U.S. Environmental
Protection Agency. Table I, listed below, summarizes the
current status of these systems.
Table I
NUMBER AND TOTAL MW OF FGD SYSTEMS
Status
Operational
Under construction
Planning
Contract awarded
Letter of intent
Requesting/evaluating bids
Considering only FGD systems
TOTAL
No. of
units
30
31
20
2
4
37
124
MW
6,476
13,309
9,981
365
2,327
16,726
49,184
Table II, gives the categorized breakdown for FGD units,
comparing the December report totals with those of the
October report.
Table III summarizes the individual units that changed
status during the report period.
BRANCH OFFICES
Suite 110. Crown Canter
Kansas City, Mo. 64108
Suite 107-B Profenlonal Village
Chapel Hill, N.C. 27514
-------
Table II
NUMBER AND TOTAL MW OF FGD SYSTEMS
DECEMBER REPORT PERIOD VERSUS OCTOBER REPORT PERIOD
Status
Operational
Under constructio:
Planning
Total
November-December
1976
No. of
units
30
\ 31
63
124
MW
6,476
13,309
29,399
49,184
September-October
1976
No. of
units
30
24
67
121
MW
6,476
9,869
30,589
46,934
The performance of the operating systems is summarized in
Table IV. Other activity highlights during the months of
November and December are outlined below:
Allegheny Power System reported that construction is under-
way at the utility's Pleasants1 Units No. 1 and 2, in Bell-
mont. West Virginia. Construction is currently in the
foundation phase and a 1000-foot stack shell has been erected,
The flue gas from these two 625-MW units will be scrubbed by
Babcock and Wilcox spray towers utilizing a recirculating
thiosorbic lime slurry. APS and Babcock and Wilcox are
currently in the process of analyzing data from a recently
completed 5000-acfm pilot study which simulated conditions
that will apply to full-scale installations. This data will
be utilized to ascertain optimal scrubber operating condi-
tions. Pleasants1 Units No. 1 and 2 are scheduled for
start-up in March 1979, and March 1980, respectively.
Arizona Public Service reported the following items in
connection with the utility's FGD installations:
Cholla No. 1 remained in service throughout the report
period. The average system reliability index values
for the months of November and December were 99.7 and
99.7 percent, respectively.
-------
Construction of Cholla No. 2 is still in progress and
on schedule. Start-up is scheduled for June 1978.
The experimental horizontal module at the Four Corners
plant operated during the month of November, the test
program was concluded December 6, 1976, and the scrubber
unit has been dismantled. A summary report on the test
results is expected in March 1977.
Basin Electric Power Cooperative reported that it has award-
ed a contract to Research-Cottrell for limestone scrubbing
systems at the utility's Missouri Basin Units No. 1 and 2,
in Wheatland, Wyoming. Both of these 550-MW units will fire
low-sulfur western coal, with a sulfur content of 0.8 per-
cent. Babcock and Wilcox will provide the pulverized-coal,
dry-bottom boilers. These units are scheduled for start-up
in April and October of 1980. The units will have to comply
with the Wyoming emissions regulation of 0.2 Ib S02/MM Btu.
The Big Rivers Rural Electric Power Cooperative reported
that construction has begun on the Reid Steam Station, Unit
No. 2, a new 250-MW coal-fired unit, in Sebree, Kentucky.
The FGD system contract awarded to American Air Filter was
announced last report period. Construction is currently in
the foundation-pouring phase with start-up scheduled for
late 1979. The unit will be burning western Kentucky coal
with a sulfur content varying from 2.5 to 5.0 percent.
The Central Illinois Light Co. announced that scrubbing
operations have been temporarily terminated at the first of
four limestone scrubbing modules scheduled for its Duck
Creek Station, Unit No. 1. The Ventri-Sorber scrubber
module had been.operating intermittently since mid-summer of
1976, and it was reported that the primary problem has been
scale build-up in the mist eliminator. The unit operated 16
days in October, 1 day in November, and in December, Duck
Creek No. 1 was switched to low-sulfur eastern Kentucky
coal, with a sulfur content of 0.6 percent. Scrubbing
operations will not be restarted until the remaining three
scrubbing modules, controlling emissions from 300-MW of
generating capacity, have been installed. Start-up for
these three modules is scheduled for August 1, 1978. The
clarifying system and ball mill, and the major part of the
instrumentation for these modules has been installed.
Columbus and Southern Ohio Electric Co. reported that a
major fire, causing 2.1 million dollars damage, occurred at
the utility's Conesville Station in the A-side module on
Unit No. 5. All scrubber internals were destroyed and the
-------
utility estimates repairs to the module will last through
June 1977. The Conesville Unit No. 5 has two scrubbing
modules, each capable of handling 60 percent of the flue gas
flow. Air and water testing of the undamaged B-side module
are scheduled to commence in January 1977. Construction has
not yet begun on the Conesville No. 6 Unit. Scheduled
start-up date is January 1978.
Commonwealth Edison reported that both scrubbing trains at
Will County were in service during the months of October and
November. The availability index values reported for the A-
side and B-side trains were 28 and 76 percent, respectively,
in October and 20 and 72 percent, respectively, in November.
Simultaneous module service time for the same months were 0
and 47 hours, respectively. Because of the low volume of
sludge produced during November, accumulated sludge in the
recirculation ponds was retrieved, stabilized with lime and
fly ash and transported to the off-site disposal area.
The Detroit Edison Company reported that the St. Clair No. 6
SO2 scrubber demonstration program continued during the
report period. The utility reported availability index
values of 80 and 51 percent for November and December,
respectively. Solids build-up on the I.D. fan was removed
by sandblasting and a decision was made to complete modifi-
cations such as fan rebalancing and wash system redesign
after the S02 demonstration program is completed. The
program is currently scheduled for completion by February
1977. Following the completion of the sulfur dioxide re-
moval program, the scrubbing system will continue to operate
in the particulate-removal mode only.
Duquesne Light reported the following items in connection
with the utility's FGD installations:
Elrama continued with flue gas from two boilers being
treated by five single-stage scrubbing vessels. Also,
the utility is conducting an evaluation of rubber-lined
recycle pumps which have been installed on one of the
vessels.
Phillips operation continued with Boilers No. 2 through
6 coupled into the scrubbing system. The No. 1 boiler
remains shutdown. The interim IUCS sludge stabiliza-
tion facility was installed and started up in December.
A contract with Dravo for the purchase of magnesium
lime was finalized and the new lime will be added to
the system when the third and final thickener is cou-
pled into the system.
-------
General Motors reported that the double alkali scrubbing
system at the Chevrolet Parma Steam Plant was operational
during the report period. The FGD system operability index
values for the months of November and December were 60 and
22 percent, respectively. Two of the four available boilers
operated during the period. During the latter part of
November and early December, the scrubber was taken off-line
to resolve solids deposition in the mix tank, effected by
the modification of some piping arrangements. A year-end
plant shutdown December 23, further reduced operability,
because the local U.A.W. contract specifies that the scrub-
ber may only be operated by union personnel.
Chiyoda International reported that on November 1, Southern
Services finished its evaluation of the CT-101 FGD prototype
unit. A report on the test program and its results will be
published in the spring of 1977. Gulf Power is continuing
scrubber operations for an unspecified time period in 1977,
in order to accumulate more data. The unit's availability
index values for the months of November and December were
99.5 and 99.6 percent, respectively. Three short periods of
forced scrubber outage occurred as a result of very minor
problems. In December, a demonstration was successfully
completed, using 125 tons of synthetic gypsum to make wall
board.
Indianapolis Power and Light Co. announced during the report
period that a new 530-MW, coal-fired power generating unit
is being planned for their Petersburg Generating Station..
This new unit will fire high sulfur bituminous coal with an
average heat content of 11,000 Btu/lb and ash and sulfur
contents of 10 percent and 3.5 percent, respectively. The
utility is considering various scrubbing strategies for the
control of sulfur dioxide, giving primary considerations to
wet limestone scrubbing. Commercial operation is scheduled
for April 1982. The utility also reported that construction
is 50 percent completed at the Petersburg Unit no. 3, 530-MW
boiler and FGD system. Initial electrical work has begun
and the rubber lining within the scrubber is currently being
installed.
The Kansas City Power and Light Co. reported the following
items concerning FGD at the utility's LaCygne and Hawthorn
Power Stations:
The seven scrubbing modules controlling emissions from
the 820-MW, coal-fired LaCygne Unit No. 1 performed
well during the report period, with average availa-
bilities of 94 and 90 percent for the months of Novem-
-------
her and December, respectively. The utility reported
that no major scrubber problems occurred during Novem-
ber. During December, module A experienced venturi
recycle pump problems, and module C had the number of
reheat bundles doubled from four to eight.
Major modifications to the scrubbing systems installed
on the No. 3 and No. 4 units of the Hawthorn Station
are continuing. The existing systems installed on each
boiler include a limestone-injection and dual-module
tail-end wet scrubbing system. These systems are now
being converted to lime-based tail-end wet scrubbing
systems. Operation of both systems during the report
period was limited because of the ongoing modifica-
tions. The A-module on Unit No. 4 was in service
during the month of November, logging an operability
index value of 91 percent. All modification work is
expected to be completed during the first quarter of
1977.
Kansas Power and Light Co. reported the following items con-
cerning FGD at the utility's Jeffrey and Lawrence Power Sta-
tions:
Construction is progressing on schedule at the Jeffrey
Power Generating Station, Units No. 1 and 2. These two
units will function as base-load units, each having a
generating capacity of 680 MW. Each unit will fire 250
T/hr of low-sulfur coal, with a sulfur content of 0.3
percent and a heating value of 8000 Btu/lb. Jeffrey
Units No. 1 and 2 are scheduled for start-up in June
1978, and June 1979, respectively.
The utility reported that Lawrence Power Station Units
No. 4 and 5 are still in the process of being changed
over from boiler limestone injection to wet scrubbing
systems designed and installed by Combustion Engi-
neering. C-E will be demonstrating a fully-automated
scrubbing system on the 400-MW No. 5 unit. This sulfur
dioxide control system will consist of two large scrub-
bing modules, each handling 50 percent of the boiler
flue gas. On this unit, the foundation and structural
steelwork are in, and some breeching has been installed.
C-E is currently working out the logic circuitry for
this fully-automated control system. The No. 4 unit,
rated at 125 MW, is near to a scrubber system start-up
date. Start-up was delayed by scheduled turbine over-
haul work in the fourth quarter of 1976. Units No. 4
and 5 will fire 50 and 140 T/hr, respectively, of
pulverized coal with a sulfur content of 0.5 percent
sulfur and a heating value of 10,000 Btu/lb.
-------
Kentucky Utilities reported that the Green River FGD system
achieved operability index values of 100 and 99.6 percent
for the months of November and December, respectively. The
scrubber system was by-passed during part of the December
period for a check of scrubber internals and replacement of
balls in the mobile bed contactor.
The Key West Utility Board reported modifications and re-
pairs to the scrubbing system at the Stock Island generating
plant were delayed because replacement parts had not yet
been delivered. The utility is planning a test period for
the first half of 1977. The FGD system will then be shut
down because it is not required to meet regulations.
Louisville Gas and Electric reported the following items in
regards to the utility's FGD installations:
The utility reported that the Cane Run Unit No. 4
scrubber system utilized carbide lime for scrubbing
during the months of November and December. The oper-
ability index values were 95 and 90 percent, respec-
tively.
The construction of Cane Run Unit No. 5 is proceeding
on schedule. Total installed capital cost of the sys-
tem is estimated to be 12 million dollars for the
capacity.
The EPA-subsidized scrubber/sludge characterization
study at Paddy's Run No. 6 unit was operational during
November and December with an availability index value
of 99.5 percent for the two-month period. The scrubber
operated with carbide lime during the report period.
The high-calcium virgin lime operation has been delayed
until approximately March 1, 1977, because of the
current emergency power situation.
Minnkota Power Cooperative reported that all additional
contracts for heating, ventilation, air conditioning, elec-
trical, and ancillary equipment for the Milton R. Young No.
2 FGD system have been awarded. In addition, construction
is ongoing and the utility is currently anticipating that it
will be ready for FGD system testing when the new 450-MW
unit is started-up in May 1977.
-------
Nevada Power reported the following items regarding the
utility's FGD installations:
Reid Gardner No. 1 was in service throughout the report
period. The system availability index values for the
months of November and December wer 86.5 and 92.7
percent, respectively. One forced scrubber outage
occurred during November because of a screw conveyor
failure, resulting in an inability to mix the chemical
absorbent. Two forced scrubber outages occurred during
December because of chemical depletion and a plugged
sensing line, respectively.
Reid Gardner No. 2 demonstrated an availability index
value of 52 percent during November. During a boiler
outage to repair a condenser tube leak and bottom ash
nozzle, the scrubber's guillotine dampers were badly
damaged, and the scrubber remained out of service
during the month of December.
Reid Gardner No. 3 was not in operation during the
first half of November due to repairs of leaks in the
venturi scrubber box. The system was restarted Novem-
ber 19, and experienced one further forced outage
during the month, because of a screw conveyor malfunc-
tion, preventing chemical mixing. During the month of
December, one minor scrubber outage occurred, because
of repairs to the I.D. fan expansion joint. The avail-
ability index values for the months of November and
December were 28.5 and 99.1 percent, respectively.
Northern Indiana Public Service Co. announced that during
the report period the Mitchell No. 11 unit was brought down
for a scheduled annual boiler overhaul. The demonstration
Wellman-Lord SC>2 recovery system was awaiting completion of
the overhaul for initiation of its first extended period of
operation in an integrated mode. Boiler unavailability of
the Mitchell No. 11 unit has resulted in an indefinite
period of delay of the demonstration S02 recovery program.
All participants in the program are now considering and
analyzing various alternatives that can minimize the delay
of the S02 recovery system start-up.
Northern States Power reported the following items con-
cerning the utility's FGD activity:
Sherburne No. 1 remained in service throughout the
period achieving total system availability index values
of 93.0 and 94.7 percent for the months of November and
-------
December, respectively. Modification to the duplex
strainer system is continuing with work about one-third
complete. The utility is currently conducting a full-
load evaluation study, analyzing system operation on 10
scrubber modules in contrast to the designed 11 modules.
Construction on Sherburne No. 2 is proceeding ahead of
schedule, with turbine roll now scheduled for mid-Janu-
ary. The projected start-up date is now March 1, 1977.
The utility is now officially considering FGD for both
the No. 3 and No. 4 units at the Sherburne County
Generating Station. Bid request and evaluation will
start shortly. Each of these Babcock and Wilcox
boilers will have a nominal 860-MW rating, and will
fire a sub-bituminous coal with a heating value of 8300
Btu/lb and sulfur and ash contents of 0.8 and 9.0,
respectively. Particulate and SC^ emissions for each
unit will be controlled by a two-stage scrubbing de-
sign, and the design specifications will call for NSPS
performance (though particulate control will be more
complete, in order to comply with opacity require-
ments) . Units No. 3 and No. 4 are scheduled for start-
up in May 1981, and May 1983, respectively.
The Pennsylvania Power Co. reported that the Bruce Mansfield
No. 1 scrubbing system was available 100 percent during the
report period. Limited service time during the month of"
November was caused by boiler-related problems.
Philadelphia Electric Co. reported that the 150-MW Cromby
unit is scheduled for a retrofit FGD unit to start-up in
June 1980. Engineering design work is scheduled to commence
in 1977. The plant will be subject to emissions regulations
more stringent than Federal NSPS. MgO scrubbing operations
at the utility's Eddystone No. 1 unit are scheduled for re-
start in May 1977. The utility is completing the relocation
of regeneration facilities to the Essex Chemical Plant in
Newark, New Jersey. The No. 1 power generating unit has
been out of service since late November because of modifica-
tions to the booster fans. Start-up of Eddystone No. IB
scrubbing operations is now scheduled for June 1980.
Engineering design work for the Eddystone No. 2 scrubbing
system is scheduled to commence in 1977, with system start-
up scheduled for June 1980.
Research-Cottrell reported that the Bahco wet lime scrubbing
system installed at the Rickenbacker AFB in Columbus, Ohio
did not operate during November because of completion of
-------
repairs to the I.D. fan housing. The system operated during
the entire month of December with S02 removal efficiency
varying from 85 to 90 percent. Lime feed was regulated on a
manual basis because of a mulfunctioning slaker. The new
stoker boiler has not yet been placed in commercial opera-
tion, primarily because of problems related to the particu-
larly severe weather conditions.
South Carolina Public Service reported that construction is
progressing on schedule at its Winyah No. 2 Power Station in
Georgetown, South Carolina. This new, coal-fired, 280-MW
unit will fire 1 percent sulfur coal and SC>2 emissions will
be controlled by a Babcock and Wilcox limestone scrubbing
system. Start-up is scheduled for May 1, 1977.
Southern Indiana Gas and Electric Co. announced that in
December it awarded a contract to FMC for the installation
of a double-alkali scrubbing system on A.B. Brown Unit No.
1, a new 250-MW coal-fired unit. The sodium-calcium (soda
ash/lime) system will generate a filter cake which will be
disposed in a landfill. The system is currently under
construction. A contract for the upstream ESP has not yet
been awarded. Full commercial operation is scheduled for
January 1979.
Springfield City Utilities reported that the 200-MW South-
west No. 1 unit in Springfield, Missouri, did not start-up
as scheduled in December 1976. The delay has been caused
primarily by electrical wiring problems, and the boiler
operation has been undergoing problems in the combustion
control and coal-handling system. The experimental sludge
disposal strategy consists of stabilization with cement and
transport to an on-site landfill. Scheduled start-up date
is now projected for February 1977.
The Bechtel Corporation reported that experimental work is
continuing at the Shawnee TVA/EPA/Alkali Scrubbing Test
Facility. From mid-October through early December an inten-
sive flue gas characterization testing program was conducted
on the venturi/spray tower system with lime slurry. For the
remainder of December the venturi/spray tower system was
down for modifications for two-stage oxidation testing.
During November, the TCA unit was operated with fly ash-
laden flue gas using lime slurry without added magnesium
oxide. SC>2 removal was about 80 percent. In late November,
fly ash-free limestone tests without magnesium oxide addi-
tion were begun on the TCA system. At the same stoichiom-
etry, the pH of the fly ash free slurry was 8.2 to 8.3 as
compared with 8.0 in previous runs with fly ash.
-------
Utah Power and Light Co. announced that a contract has been
awarded to Chemico for the installation of a S02 control
system at its Emery Unit No. 1, in Emery County, Utah. The
Chemico scrubbing system will be preceded by an upstream
Buell/Envirotech ESP for primary particulate control. S02
emissions from this 400-MW unit will be controlled by a wet
lime, open-water-loop scrubbing system, removing SC>2 with a
design efficiency of 80 percent. Sludge will be mixed with
fly ash and disposed on-site. Start-up is scheduled for
June 1978. At the utility's Huntington Power Station,
equipment is now arriving and construction of the scrubbing
system will commence shortly. System start-up is scheduled
for June 1977.
-------
TABLE III
SUMMARY OF CHANGES
FGD STATUS REPORT, NOVEMBER-DECEMBER, 1976
FGD status report
10/31/76
Allegheny Power System
Pleasants No 4 i
Pleasants No. 2
Basin Electric Power Coop.
Missouri Basin No. 1
Missouri Basin No. 2
Big Rivers Rural Electric Coop.
Reid No. 2
Central Illinois Light Co.
Duck Creek No. IB
Indianapolis Power and Light Co.
Petersburg No. 4
Kansas Power and Light Co.
Jeffrey No. 1
Jeffrey No. 2
Northern States Power Co.
Sherburne No. 3
Sherburne No. 4
South Carolina Public Service
Co.
'•"inyah No. 2
Southern Indiana Gas and
Electric Co.
A.B. Brown No. 1
Utah Power and Light
E-.ery No. 1
12/31/76
Operational
No.
30
30
MW
6,476
6,476
Under
construction
No.
24
+1
+1
+1
+1
•H
+1
+1
31
MW
9,869
625
625
250
300
680
680
280
13,309
Contract
awarded
No.
23
-1
-1
-H
+1
-1
-1
-1
-1
-1
+ 1
-n
20
MW
11,671
625
625
550
550
250
300
680
680
280
250
400
9,981
Letter of
intent
No.
3
-1
2
MW
765
400
365
Requesting/
evaluating
bids
No.
7
-1
-1
-1
4
MW
3,677
550
550
230
2,327
Considering
FGD
No.
34
+1
+ 1
+1
37
MW
14,476
530
860
860
16,726
Total
No.
121
124
MW
46,934
49,184
-------
TABLE IV. PERFORMANCE OF OPERATIONAL UNITS
DURING THE REPORT PERIOD
Flint
Choi la
Four Corner*
Duck Creak 1A
Hill County 1
St. Clair
Elrarna
Phillip*
Parma
Scholi -
Chiyoda
Hawthorn 3
Hawthorn 4
La Cygn*
Lawrence 4
Lawrence 5
Green River
1*2
Stock I aland
Cane Run
Paaay ' • kun
Coletrlp 1
Colctrlp 2
Reid Gardner 1
Reid Gardner 2
Reid Gardner 3
Sherburne 1
Bruce
Mansfield 1
Eddy (tone 1A
valmont 5
Rickenbacker
Shawnee 10A
Shawnee 10B
Total (30)
PCD lyaten
deeign
capacity
111
1«0
100
167
163
510 .
410
32
23
140
100
•20
125
400
64
37
ITS
6*
360
360
125
125
125
710
835
120
50
20
10
10
6.459
PCD unit
on-line
during
period*
US
160
100
16T
163
200
37$
16
23
100
620
64
178
64
125
12S
125
710
20
10
10
3,671
No
information
for thia
period
360
360
(35
1,355
Shut down
throughout
period
110
3$
16
140
12S
400
37
120
50
1,233
FGD ay a ten
avell-
ability(%)««
46
•0
s»
»4
100
8«
$2
99
93
pee.
SI
99
90
71
91
28
95
FGD ayatem
opara-
bility(t)**
Nov.
40
99
46
100
95
99
81
58
97
100
0*0.
99
97
90
99
96
•a
100
rco eyatem
reliability
(»)••
-HOT: —
41
99
98
84
51
99
D«c.
99
87
98
29
FGD syatem
utilization
(»)*•
NOV •
38
99
98.
71
50
97
her.
99
70
87
29
ThU category include* the flu* gaa capacity being handled by the FOO ayatern at leaat part of the tin* during the
report period.
The percent figure* Hated en average value* for all the ayaten ccrubblng train* during the period in question.
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 12/76
CURRENT MONTH
1.0. NUMBER 91
POTOMAC ELECTRIC & POWER
OlCKERSOfj NO.l
190 MW - RETROFIT
COAL
CHEMICO
NOT SELECTED
STARTUP 0/78
THE UTILITY HAS AWARDED A CONTRACT TO CHEMICO AIR POLLUTION FOR THE
INSTALLATION OF A WET SCRUBBING SYSTEM ON THIS UNIT. THE SCRUBBER
CONSISTS OF A SINGLE MODULE DOUBLE VENTURI THROAT UNIT. THE FIRST
VENTURI STAGE IS DESIGNED FOR REMOVAL OF PARTICULATE MATTER ONLY. THE
SECOND VENTURI STAGE WILL BE INSTALLED FOR FUTURE CONSIDERATIONS IF
THE UTILITY ELECTS TO SCRUB SULFUR UIOXIDE. THE DESIGN ALLOWS CON-
SIDERATION FOR EITHER A REGENERATIVE OR NON-REGENERATIVE FGD SYSTEM.
I.D. NUMBER 92
POTOMAC ELECTRIC & POWER
DICKEKSON NO.2
190 MW - RETROFIT
COAL
CHEMICO
NOT SELECTED
STARTUP 0/78
THE UTILITY HAS AWARDED A CONTRACT TO CHEMICO AIR POLLUTION FOR THE
INSTALLATION OF A WET SCRUBBING SYSTEM ON THIS UNIT. THE SCRUBBER
CONSISTS OF A SINGLE MODULE DOUBLE VENTURI THROAT UNIT. THE FIRST
VENTURI STAGE IS DESIGNED FOR REMOVAL OF PARTICULATE MATTER ONLY. THE
SECOND VENTURI STAGE WILL BE INSTALLED FOR FUTURE CONSIDERATIONS IF
THE UTILITY ELECTS TO SCRUB SULFUR DIOXIDE. THE DESIGN ALLOWS CON-
SIDERATION FOR EITHER A REGENERATIVE OR NON-REGENERATIVE FGD SYSTEM.
1.0. NUMBER 93
PUBLIC SERVICE CO OF COLORADO
VALMONT NO. 5
so MW - 'RETROFIT
COAL 0.72 PERCENT SULFUR
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
STARTUP 10/7f
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 19-74. THE FGD SYSTEM CURRENTLY
OPERATIONAL AT THIS STATION IS AN EXPERIMENTAL UNITt ORIGINALLY DESIGNED
BY UNIVERSAL OIL PRODUCTS FOR PARTICULATE REMOVAL ONLY. ONE OF THE TWO
PARALLEL SCRUBBING MODULES WAS CONVERTED TO LIMESTONE SCRUBBING FOR
EXPERIMENTAL PURPOSES ONLY.
I.D. NUMBER 9f
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 1
375 MW - NEW
COAL 0.8 PERCENT SULFUR
DAVY POWERGAS/ALHED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 7/77
THE CONSTRUCTION OF THIS SYSTEM IS NOW UNDERWAY. THIS FGD SYSTEM IS AN
INTEGRATIOiM OF THE WELLMAN LORD S02 RECOVERY PROCESS OF DAVY POWERGAS
AND ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR PROCESS. DAVY POWERGAS IS
THE DESIGN ENGINEERING FIRM. STEARNS AND ROGER IS THE SYSTEM CONSTRUCTOR.
THE UTILITY WILL BE THE SYSTEM OPERATORS. A HOT SIDE ELECTROSTATIC
PRECIPITATOR WILL BE INSTALLED UPSTREAM OF THE SCRUBBING UNIT. FOUR
ABSORBER TOWERS WILL BE INSTALLED FOR EACH UNIT. THREE WILL CARRY THE
FULL LOAD. MOLTEN SULFUR WILL BE STORED ON THE PLANT SITE.
I.D. NUMBER 95
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 2
340 MW - RETROFIT
COAL 0.8 PERCENT SULFUR
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 7/77
THE CONSTRUCTION OF THIS SYSTEM IS NOW UNDERWAY. THIS FGD SYSTEM IS AN
INTEGRATION OF THE WELLMAN LORD S02 RECOVERY PROCESS OF DAVY POWERGAS
ANU ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR PROCESS. DAVY POWERGAS IS
THE DESIGN ENGINEERING FIRM. STEARNS AND ROGER IS THE SYSTEM CONSTRUCTOR.
THE UTILITY WILL BE THE SYSTEM OPERATORS. A HOT SIDE ELECTROSTATIC
PRECIPITATOR UlLL BE INSTALLED UPSTREAM OF THE SCRUBBING UNIT. FOUR
ABSORBER TOWERS WILL BE INSTALLED FOR EACH UNIT. THREE MODULES WILL CARRY
THE FULL LOAD. MOLTEN SULFUR WILL BE STORED ON THE PLANT SITE.
29
PEOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 12/76
CURRENT MONTH
I.D. NUMBER 96
PUBLIC SERVICE CO OF NEW HEX,
SAN JUAN NO. 3
500 MW - NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
REGENERABLE NOT SELECTED
STARTUP 5/81
THE UTILITY HAS PLACED A HOLD ON FURTHER ENGINEERING DESIGN WORK AT THE
PRESENT TIME. THE PROJECTED START-UP DATE FOR BOTH UNITS 3 AND «» IS
MAY 1981. THE KELLMAN LORD AND OTHEK SULFUR DIOXIDE RECOVERY PROCESSES
ARE NOW UNDER CONSIDERATION BY THE UTILITY. AN ESP WILL BE PROVIDED
UPSTREAM OF THE FGD SYSTEM FOR PRIMARY PARTICULATE CONTROL.
I.D. NUMBER 97
PUBLIC SERVICE CO OF NEW MEX,
SAN JUAN NO. 4
500 MW - NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
REGENERABLE NOT SELECTED
STARTUP 5/61
THE UTILITY HAS PLACED A HOLD ON FURTHER ENGINEERING DESIGN WORK AT THE
PRESENT TIME. THE PROJECTED START-UP DATE FOR BOTH UNITS 3 AND <* IS
MAY 1981. THE WELLMAN LORD AND OTHER SULFUR DIOXIDE RECOVERY PROCESSES
ARE NOW UNDER CONSIDERATION BY THE UTILITY. AN ESP WILL BE PROVIDED
UPSTREAM OF THE FGO SYSTEM FOR PRIMARY PARTICULATE CONTROL.
I.D. NUMBER 98
PUBLIC SERVICE OF INDIANA
GIBSON NO. 3
650 MW - NEW
COAL 3.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/78
THE UTILITY HAS COMPLETED THE EVALUATION OF BID SPECIFICATIONS
SUBMITTED FOR FGD SYSTEMS FOR BOTH UNITS 3 AND <* AT THIS STATION.
NO DECISION HAS YET BEEN MADE.
I.D. NUMBER 99
PUBLIC SERVICE: OF INDIANA
GIBSON NO.
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F6D SYSTEMS DURING 12/76
CURRENT MONTH
I.D. NUMBER 101
SALT RIVER PROJECT
CORONADO NO.l
3bO MW - NEW
COAL 1.0 PERCENT SULFUR (MAX)
PULLMAN KELLOGG
LIMESTONE SCRUBBING
STARTUP H/T3
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. 80 PERCENT OF THE
GAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
THE UTILITY ANNOUNCED THAT A CONTRACT HAS BEEN AWARDED TO PULLMAN/KELLOGG
FOR THE INSTALLATION OF TWO WEIR HORIZONTAL CROSSFLOW SCRUBBING MODULES.
THE SCRUBBING REAGENT WILL BE LIMESTONE. THE CONTRACT FOR THE ESP HAS
BEEN AWARDED TO JOY/WESTERN PRECIPITATION DIVISION. THE CONSULTING
ENGINEERING AND CONSTRUCTION FIRM IS BECHTEL.
I.D. NUMBER 102
SALT RIVER PROJECT
CORONADO NO.2
350 MW - NEW
COAL 1.0 PERCENT SULFUR (MAX)
PULLMAN KELLOGG
LIMESTONE SCRUBBING
STARTUP «*/80
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. 80 PERCENT OF THE
GAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
THE UTILITY ANNOUNCED THAT A CONTRACT HAS BEEN AWARDED TO PULLMAN/KELLOGG
FOR THE INSTALLATION OF TWO WEIR HORIZONTAL CROSSFLOW SCRUBBING MODULES*
THE CONTRACT FOR THE ELECTROSTATIC PRECIPITATOR HAS BEEN AWARDED
TO JOY/WESTLRN PRECIPITATION DIVISION. THE SULFUR DIOXIDE SCRUBBING
REAGENT is LIMESTONE. THE CONSULTING ENGINEERING AND CONSTRUCTION
FIRM IS BECHTEL.
I.D. NUMBER 103
SALT RIVER PROJECT
CORONADO MO. 3
350 HW - NEW
COAL 1.0 PERCENT SULFUR(MAY)
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 0/67
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. 80 PERCENT OF THE
GAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
THE UTILITY IS CURRENTLY CONSIDERING THE INSTALLATION OF TWO HORIZONTAL
CROSSFLOW SCRUBBING MODULES EMPLOYING A LIMESTONE SCRUBBING SOLUTION
TO REMOVE S02 FROM THE FLUE GAS. SCHEDULED COMMERCIAL OPERATION
DATE IS 1987. PLANS FOR AN EMISSION CONTROL SYSTEM HAVE NOT
BEEN FINALIZED.
I.D. NUMBER 10«t
SOUTH CAROLINA PUBLIC SERVICE
WINYAH NO. 2
280 MW > NEW
COAL 1.0 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 5/77
THIS NEW COAL-FIRED POWER BOILER WILL FIRE 1.0 PERCENT SULFUR COAL.
PRIMARY PARTICULATE CONTROL WILL BE PROVIDED BY A HIGH-EFFICIENCY ESP
(99.4 PERCENT). 50 PERCENT OF THE FLUE GAS FROM THIS 280-MW NOMINALLY
RATED UNIT WILL BE SCRUBBED TO MEET NSPS. THE CONTRACT FOR THIS WET
LIMESTONE SCRUBBING SYSTEM HAS BEEN AWARDED TO BABCOCK AND WILLCOX. THE
GUARANTEED SULFUR DIOXIDE REMOVAL EFFICIENCY IS 69 PERCENT. SCRUBBING
WASTES WILL BE DISPOSED IN AN ON-SlTE UNLINED SLUDGE POND. THE UNIT
IS NOW UNDER CONSTRUCTION.
I.D. NUMBER 105
SOUTHERN CALIFORNIA EDISON
MOHAVE NO IB
620 MW - RETROFIT
COAL 0.5- 0.6 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP 6/77
THE TOTAL CAPACITY OF BOILER IS 790 MW. EXISTING EXPERIMENTAL FGD MODULE
WILL TREAT ONLY 170 MW. FINAL SELECTION OF THE PROCESS HAS BEEN POST-
PONED. SEE MOHAVL 1A.
31
PEDCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING 12/76
CURRENT MONTH
1.0. NUMBER 106
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2
790 MW - RETROFIT
COAL 0.5 TO 0.8 % SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STAKTUP 6/77
A PROTOTYPE 170 MW LIME SCRUBBING SYSTEM (HORIZONTAL MODULE) ON THIS UNIT
WAS OPERATED FROM NOVEMBER 1973 UNTIL FEBRUARY 1975* AVAILABILITY FOR THE
PERIOD l/16/7«* TO 2/9/75 AVERAGED 73.5S. THIS SYSTEM IS TO BE REINSTALL-
ED AT THE FOUR CORNERS PLANT* OPERATED BY ARIZONA PUBLIC SERVICE.
I.D. NUMBER 107
SOUTHERN ILLINOIS POWER COOP
SOUTHERN ILLINOIS POWER PT. «
18f MW - NEW
COAL
BABCOCK i WILCOX
LIMESTONE SCRUBBING
STARTUP 1/78
THE CONTRACT FOR THIS LIMESTONE SCRUBBING SYSTEM HAS BEEN AWARDED TO
BABCOCK AND WILCOX. THE FGD SYSTEM WILL CONSIST OF 2 SCRUBBING MODULES,
TREATING THE FLUE GAS FROM A COAL-FIRED BOILER. HAVING A NOMINAL DESIGN
CAPACITY OF 691»500 ACFM AT 290F. THE DESIGN S02 REMOVAL EFFICIENCY IS
89.4 PERCENT, BASED UPON AN INLET OF 3,326 PPM OF S02. THE CONSULTING
ENGINEERING FIKM FOR THIS PROJECT IS BURNS & MCDONNELL.
1.0. NUMBER 108
SOUTHERN INDIANA GAS4ELECTRIC
A.B. BROWN NO.l
250 MM - NEW
COAL 3.75 PERCENT SULFUR
FMC CORPORATION
DOUBLE ALKALI SCRUBBING
STAKTUP <*/79
THIS NEW COAL-FIRED POWER-GENERATING UNIT IS PART OF A NEW POWER
GENERATING STATION LOCATED IN WEST FRANKLIN,INDIANA. THE UNIT
WILL FIRE HIGH SULFUR(3.75 PERCENT) INDIANA COAL AND MUST
COMPLY WITH NSPS. THE UNIT'S EMISSION CONTROL SYSTEM WILL CONSIST
OF AN ESP FOR PARTICULATE REMOVAL AND AN FGD SYSTEM FOR SULFUR
DIUXIDE REMOVAL. THE UTILITY HAS AWARDED A CONTRACT To THE FMC
CORPORATION FOR THE INSTALLATION OF A DOUBLE ALKALI SCRUBBING
SYSTEM UTILIZING SODA ASH AND LIME, START-UP IS SCHEDULED FOR 0«»/79t
I.D. NUMBER 109
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW NO.l
180 MW - NEW
COAL 1.0 PERCENT SULFUR
RILEY STOKER / ENVlRONEERING
LIMESTONE SCRUBBING
STARTUP 11/77
THIS NEW COAL-FIRED UNIT WILL FIRE 1.0 PERCENT SULFUR COAL. A CONTRACT
HAS BEEN AWARDED TO RILEY STOKER/ENVIRONEERING FOR THE INSTALLATION OF
A WET LIMESTONE SCRUBBING SYSTEM. PARTICULATES WILL BE CONTROLLED BY A
HIGH-EFFICIENCY ESP UPSTREAM OF THE SCRUBBING SYSTEM. DESIGN SULFUR
DIOXIDE AND PARTICULATE REMOVAL EFFICIENCIES ARE 85 AND 99.6 PERCENT,
RESPECTIVELY. SCRUBBER SLUDGE WILL BE STABILIZED WITH FLYASH AND DISPOSED
ON THE PLANT SITL. CONSTRUCTION OF THE SCRUBBING SYSTEM IS NOW IN
PROGRESS. ERECTION OF THE ABSORBER TOWERS HAS BEEN COMPLETED.
I.D. NUMBER 110
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW NO.2
ISO MW - NEW
COAL 1.0 PERCENT SULFUR
RILEY STOKER / ENVlRONEERING
LIMESTONE SCRUBBING
STARTUP 6/78
THIS NEW COAL-FIRED UNIT WILL FIRE 1.0 PERCENT SULFUK COAL. A CONTRACT
HAS UEEN AWARDED TO RILEY STOKER/ENVIRONEERING FOR THE INSTALLATION OF
A WET LIMESTONE SCRUBBING SYSTEM. PARTICULATES WILL BE CONTROLLED BY A
HIGH-EFFICIENCY ESP UPSTREAM OF THE SCRUBBING SYSTEM. DESIGN SULFUR
DIOXIDE AMD PARTICULATE REMOVAL EFFICIENCIES ARE 85 AND 99.6 PERCENTt
RESPECTIVELY. SCRUBBER SLUDGE WILL BE STABILIZED WITH FLYASH AND DISPOSED
ON THE PLANT SITE. ERECTION OF THE ABSORBER TOWERS IS NOW IN PROGRESS.
32
PEDCO ENVIRONMENTAL
-------
COMPANY
TABLE 2
STATUS OF FGO SYSTEMS DURING 12/76
POWER STATION
CURRENT MONTH
1.0. NUMBER 111
SPRINGFIELD CITY UTILITIES
SOUTHWEST NO. 1
200 MW -NEW
COAL 3.5 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 2/77
THE BOILER AND ELECTROSTATIC PREClPITATOR ARE NOW OPERATIONAL* THE
SCRUBBERS ARE BEING BYPASSED UNTIL CONSTRUCTION is COMPLETED. THE
MAJORITY OF THE CONSTRUCTION ON THE SCRUBBING SYSTEM HAS BEEN COMPLETED.
INITIAL OPERATION OF THE SCRUBBING SYSTEM WILL COMMENCE ON FEB It 1976.
COMMERCIAL OPERATION WILL FOLLOW 60 DAYS LATER. INSTALLATION OF THE
SYSTEM HAS BEEN HAMPERED BY SOME WIRING PROBLEMS IN THE SCRUBBING AND
SLUDGE TREATMENT EQUIPMENT. PARTICULATES WILL BE CONTROLLED BY A HIGH-
EFFICIENCY ESP INSTALLED UPSTREAM OF THE SCRUBbER MODULES.
1.0. NUMBER 112
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10A
10 MU - RETROFIT
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
STARTUP
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS OUR INS 12/7(6
CURRENT MONTH
1.0. NUMBER 116
TEXAS UTILITIES CO.
MARTIN LAKE NO. 2
793 MW - NEW
COAL 1*0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 10/77
THE CONTRACT FOR THIS F6D SYSTEM WAS AWARDED TO RESEARCH-COTTRELL. THIS
NEW FACILITY IS NOW UNDER CONSTRUCTION. THE FGD SYSTEM STARTUP DATE IS
NOW SCHEDULED FOR OCTOBER 1977.
1.0. NUMBER 117
TEXAS UTILITIES CO.
MARTIN LAKE NO. 3
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 12/76
THE CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO RESEARCH-COTTRELL.
THE BOILER IS NOW BEING ERECTED. START-UP IS SCHEDULED FOR DECEMBER
1978.
I.D. NUMBER 118
TEXAS UTILITIES CO.
MARTIN LAKE NO. t
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 12/79
THE CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO RESEARCH-COTTRELL.
THE BOILER IS NOW BEING ERECTED. START-UP IS SCHEDULED FOR DECEMBER
1978.
I.D. NUMBER 119
TEXAS UTILITIES CO.
MONTICELLO NO.3
750 HW - NLW
LIGNITE 1.0 PERCENT SULFUR
CHEMICO
LIMESTONE SCRUBBING
STARTUP 10/77
THIS NEW STEAM BOILER WILL FIRE LOW SULFUR (0.8 TO 1.0 PERCENT SULFUR)
TEXAS LIGNITE. THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF
A HIGH EFFICIENCY ESP UPSTREAM OF LIMESTONE SPRAY TOWERS. THE CONTRACT
FOR THIS SCRUBBING SYSTEM HAS BEEN AWARDED TO CHEMICO FOR THE INSTAL-
LATION OF THE SPHAY TOwERS. THE ESP IS A COLD-SIDE UNIT SUPPLIED BY POL-
LUTION CONTKOL-WALTHER. DESIGN PARTICULATE AND SULFUK DIOXIDE REMOVAL
EFFICIENCY WILL ENABLE THIS UNIT TO MEET NEW SOURCE PERFORMANCE STANDARDS
I.D. NUMBER 120
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
5
-------
COMPANV
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING 12/76
CURRENT MONTH
1.0. NUMBER 121
UNITED POWER ASSOCIATION
COAL CREEK NO. 2
545 MW - NEW
LI6NITE - 0.63 PERCENT SULFUR
COMBUSTION ENGINEERING
LIKE SCRUBBING
STARTUP 11/79
THE CONTRACT FOR THIS SCRUBBING SYSTEM HAS BEEN AWARDED TO COMBUSTION
ENGINEERING FOR THE INSTALLATION OF LIME FGD SYSTEMS ON UNITS NOS.l AND
2 AT THIS STATION. THE SCRUBBING SYSTEM FOR EACH BOILER WILL CONSIST OF
4 SPAY TOWER ABSOBER MODULES FOK REMOVING S02 FROM THE FLUE GAS.
ELECTROSTATIC PRECIPITATORS WILL BE INSTALLED UPSTREAM OF EACH SCRUBBING
SYSTEM. FULL COMMERCIAL START-UP DATES FOR UNITS 1 AND 2 ARE 11/78 AND
11/79 RESPECTIVELY. INITIAL OPERATIONS WILL COMMENCE THE PRECEDING
AUGUST FOR E\CH UNIT. F&D CONSTRUCTION IS SCHEDULED TO COMMENCE On/78.
1.0. NUMBER 122
UTAH POWER & LIGHT CO.
EMERY NO.l
400 MM . NEW
COAL 0.5 PERCENT SULFUR
CHEMICO
LIME: SCRUBBING
STARTUP 6/76
A CONTRACT HAS BEEN AWARDED TO THE CHEMICO AIR POLLUTION DIVISION FOR
A PEBBLE LIME WET SCRUBBING SYSTEM ON THIS NEW UNIT. THE SCRUBBING
SYSTEM IS DESIGNED TO OPERATE IN AN OPEN WATER LOOP MODE WITH AN S02
REMOVAL EFFICIENCY OF 60 PERCENT FOR LOW SULFUR UTAH COAL. PRIMARY
PAKTICULATE CONTROL WILL BE PROVIDED BY AN ESP UPSTREAM OF THE SCRUBBERS.
THE SCRUBBER SLUDGE WILL BE STABILIZED WITH FLYASH AND DISPOSED ON THE
PLANT SITE. THE A-E DESIGN FIRM FOR THIS PROJECT IS STEARNS-ROGER.
I.D. NUMBER 123
UTAH POWER & LIGHT CO.
HUNTINGTON NO.l
<415 MW - NEW
COAL 0.5 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 6/77
A CONTRACT HAS BEEN AWARDED TO CHEMICO AIR POLLUTION DIVISION FOR
A LIME SCRUBBING SYSTEM ON THIS NEW UNIT. MATERIALS ARE NOW ARRIVING AT
THE PLANT SITE. SITE PREPARATION AND CONSTRUCTION IS NOW UNDERWAY. THE
STATE OF UTAH REGULATIONS REQUIRE THE BEST AVAILABLE AND MOST COST
EFFECTIVE TECHNOLOGY FOR SULFUR DIOXIDE REMOVAL. PRIMARY PARTICULATE
REMOVAL WILL BE PROVIDED BY AN ESP INSTALLED UPSTREAM OF THE WET
SCRUBBING SYSTEM. THE A-E DESIGN FIRM FOR THIS PROJECT IS STEARNS-ROGER.
I.D. NUMBER 124
WISCONSIN POWER & LIGHT CO.
COLUMBIA NO. 2
527 MW - NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP 1/80
THE UTILITY IS NOW REQUESTING/EVALUATING BIDS FOR A NEW COAL-FIRED UNIT
CURRENTLY UNDER CONSTRUCTION AT THEIR COLUMBIA STATION LOCATED IN PORTAGE
WISCONSIN. START-UP OF THE BOILER IS SCHEDULED FOR MARCH 1978. START-UP
OF THE SCRUBBING SYSTEM IS PROJECTED FOR JANUARY 1980. THE UNIT WILL
COMPLY WITH STANDARDS DURING THE INTERIM BY BURNING LOW SULFUR BELAIR
COAL. THE SCRUBBERS ARE BEING DESIGNED TO TREAT 50 PERCENT OF THE FLUE
GAS RESULTING FROM THE COMBUSTION OF LOW SULFUR COLSTRlP COAL. THE RE-
MAINING 50 PERCENT WILL BE BYPASSED FOR REHEAT.
35
PEDCO ENVIRONMENTAL
-------
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
37 PEDCO-ENVIRONMENTAL
-------
PCOCO
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
JOSEPH CITY ARIZONA
115 MU
FUEL CHARACTERISTICS COAL 0.
-------
BACKGROUND INFORMATION
ON
THE CHOLLA POWER PLANT
THE CHOLLA POWER STATION* LOCATED NEAR JOSEPH CITY, ARIZONA, HAS ONE 115-MW COAL-FIRED BOILER IN SERVICE AND TWO 250 MW UNITS
UNDER CONSTRUCTION. CHOLLA NO. 1 IS A DRY-BOTTOM PULVERIZED-COAL-FIRED UNIT DESIGNED BY COMBUSTION ENGINEERING. THE AVERAGE
CHARACTERISTICS OF THE COAL BURNED DURING THE COURSE OF 1975 ARE* HEAT CONTENT OF 10*150 BTU/LB* ASH CONTENT OF 13.US PERCENT*
SULFUR CONTENT OF 0.52 PERCENT* CHLORIDE OF 0.04 PERCENT (MAX.)* AND MOISTURE CONTENT OF 14.77 PERCENT.
THE FGD SYSTEM AT THE CHOLLA PLANT WAS MANUFACTURED BY RESEARCH-COTTRELL AND INSTALLATION WAS COMPLETED ON DECEMBER 3, 1973.
THE DESIGN COMBINED SULFUR UIOXIDE REMOVAL EFFICIENCY (FOR BOTH MODULES A AND B) IS 58.5 PERCENT. THE SYSTEM CONSISTS OF TWO
PARALLEL TRAINS (MODULES A AND B). EACH TRAIN IS DESIGNED FOR 240,000 ACFM THROUGHPUT AT 276 F, AND HANDLES APPROXIMATELY 50
PERCENT OF THE BOILER'S FLUE GAS LOAD. THE A SIDE CONSISTS OF A VARIABLE THROAT FLOODED DISC SCRUBBER FOS FOLLOWED BY A PACKED
TOWER (HUNTERS PACKING). THE B-SIDE IS SIMILAR IN DESIGN. HOWEVER, THE TOWER IS NOT PACKED AND LIMESTONE SLURRY IS NOT CIRCU-
LATED THROUGH IT. EITHER ONE OR BOTH OF THE SCRUBBERS CAN BE BYPASSED. GAS LEAKAGE AROUND EACH TRAIN IS ESTIMATED TO BE ABOUT
4.5 PERCENT OF THE GAS BEING TREATED. THE TOWER PACKING, WHICH IS APPROXIMATELY 2-FEET THICK, IS CONSTRUCTED OF POLYPROPYLENE
CORRUGATED SHEETS JOINED TOGETHER IN CRISS-CROSS PATTERNS SIMILAR TO HONEYCOMBS. THE TOWER DEMISTERS ARE ALSO CONSTRUCTED OF
POLYPROPYLENE, AND THE REHEATERS ARE SHELL AND TUBE TYPE CONSISTING OF THREE TUBE BUNDLES PER UNIT.
LIMESTONE FOR THE FGO SYSTEM IS PURCHASED IN GROUND FORM SUITABLE FOR SLURRYING. THE MAIN SOURCE OF SUPPLY IS THE SUPERIOR
CO. LOCATED NEAR PHOENIX, ARIZONA. THIS GRADE OF LIMESTONE IS GENERALLY KNOWN AS *RED WALL* LIMESTONE AND IS CONSIDERED A VERY
HIGH QUALITY GRADE. CHEMICAL SPECIFICATIONS ARE* MINIMUM CALCIUM OXIDE CONTENT, 52 PERCENT* MINIMUM CALCIUM CARBONATE CONTENT,
95 PERCENT* MAXIMUM MAGNESIUM OXIDE CONTENT, 2 PERCENT* MAXIMUM MAGNESIUM CARBONATE CONTENT, 0.5 PERCENT* MAXIMUM SILICA CONTENT,
1 PERCENT.
THE PLANT HAS NO SLUDGE TREATMENT OR FIXATION SYSTEMS. THE SLUDGE IS PUMPED TO THE FLY ASH POND ON AN INTERMITTENT BASIS
THROUGH A COMMON PIPING SYSTEM WITH THE FLY ASH. NO POND WATER IS RECYCLED TO THE FGO SYSTEM (SOLAR EVAPORATION POND), A GENERAL
PROCESS FLOW DIAGRAM OF THE CHOLLA FGO SYSTEM IS PRESENTED IN FIGURE 1, APPENDIX C.
-------
CHOLLA POWER PLANT (CONTINUED)
PROBLEMS AND SOLUTIONS
DECEMBERt 1973 TO APRIL 2, 197H - BECAUSE OF A DIFFERENCE IN SIZE OF THE MAIN DUCT AND THE REHEATER TRANSITION DUCT* THE GAS
FLOW PRODUCED HARMONIC VIBRATIONS IN THE REHEATER. THE VIBRATIONS WERE PARTIALLY DAMPED BY INSTALLATION OF BAFFLES. ONE OF THE
REHEATER TUBE BUNDLES WAS BADLY CORRODED BY ACID THAT CONDENSED IN THE UNINSULATED DUCT UPSTREAM OF THE REHEATERS. THE TUBE
BUNDLE WAS REPLACED* AND A BAFFLE WAS INSTALLED TO DIVERT CONDENSED ACID FROM REHEATER TUBES. ALSO* THE DUCT UPSTREAM OF THE
REHEATER MAS INSULATED. THE ACID CONDENSATION OCCURRED ONLY IN THE MODULE WITH NO TOWER PACKING AND HENCE LOW SULFUR DIOXIDE
REMOVAL EFFICIENCY.
ANOTHER PROBLEM RESULTED BECAUSE OF SOLIDS BUILDUP IN THE FOS STUFFING GLAND BOX AND ON TOP OF THE SPRAY DOME. ALSO, SOME
LINES PLUGGED* PARTICULARLY WHEN THE SYSTEM OPERATED AT LOW FLOW RATES. SOLIDS SETTLED OUT IN STANDBY PUMPS, AND EXCESSIVE FAN
VIBRATIONS OCCURRED BECAUSE OF ACCUMULATION OF SCALE BUILDUP WHEN THE UNIT WAS IDLE. TO SOLVE THESE PROBLEMS, PACKING GLAND
POSITION WAS REVERSED (INSTALLED UPSIDE DOWN), THE FAN WAS SANDBLASTED, THE PIPING WAS MODIFIED TO ELIMINATE STAGNANT POCKETS, AND
PUMPS WERE FLUSHED IMMEDIATELY AFTER REMOVAL FROM SERVICE.
OPERATION OF THE SYSTEM THROUGHOUT 1975 AND 1976 RESULTED IN THE DEVELOPMENT OF SOME ADDITIONAL PROBLEM AREAS, INCLUDING*
SIGNIFICANT CORROSION ATTACK IN THE VESSEL WAULS OF THE j-LOOOED-OISC PARTICULATE SCRUBBER MODULE* ACID CORROSION IN THE B-SIDE
REHEATER HOUSING* SCALE BUILDUP IN THE PIPE OUTLET AT THE SLUDGE/FLY ASH EVAPORATION POND* PLUGGING IN THE SCRUBBER TOWER PACKING
AND MIST ELIMINATOR* EROSION IN THE PUMPS* CORROSION IN THE BOILER EXHAUST ELBOW OF THE DUCTWORK LEADING FROM THE SCRUBBERS TO THE
STACK.
»1 PEDCO ENVIRONMENTAL
-------
FGO SYSTEM RELIABILITY
CHOLLA UNIT NO. 1
RELIABILITY (X)
MONTH MODULE A MODULES COMMENTS
JAN. 74 97 90
FEB. 74 100 94
MAR. 74 100 66
APR. 74 66 57
MAY 74 96 99
JUN. 74 100 100
JUL. 74 97 92
AU6. 74 97 97
SEP. 74 95 99
OCT. 74 63 66 ANNUAL BOILER AND FGD SYSTEM OVERHAUL.
NOV. 74 100 96
DEC. 74 100 100
JAN. 75 98 99
FEB. 75 96 99
MAR. 75
APR. 75 88 65
MAY 75 46 40 MODULES WERE BOTH OFF-LINE FOR MOST OF MONTH FOR SCHEDULED REPAIRS AND CLEANING.
JUN. 75 100 100 SUBSTANTIAL PLUGGING OF PACKING AND MIST ELIMINATORS WAS OBSERVED.
NO PROBLEM REPORTED.
JUL. 75 97 98 MODULES WERE SHUT DOWN TO CLEAN FLOW RESTRICTIONS IN FLOODED-DISC RECIRCULATION
LINES.
AUG. 75 95 100 MODULE A WAS DOWN FOR INSPECTION ONE TIME.
-------
FGO SYSTEM RELIABILITY
CHOLLA UNIT NO. 1 (CONTINUED)
RELIABILITY (X)
MONTH MODULE A MODULE B COMMENTS
SEP. 75 98 97 MINOR OUTAGE DUE TO FLOOOEO-OISC LINES.
OCT. 75 6
-------
F6D SYSTEM RELIABILITY
CHOLLA UNIT NO. 1 I CONTINUED)
RELIABILITY <»>
MONTH NODULE A MODULE B COMMENTS
JUL. 76 100 98 DURING THE JULY-AUGUST PERIOD THE UTILITY REPORTED THAT REPAIRS TO THE COATIN6 IN THE
AUG. 76 100 100 ELBOW OF THE SCRUBBER EXHAUST DUCT WERE COMPLETED. A MALFUNCTIONING SELENOID VALVE
IN THE DEMISTER WASH SYSTEM OF THE B-SIDE TRAIN PREVENTING INADEQUATE WASHING OF
THE DEMISTER, RESULTED IN A MINOR SCRUBBER OUTAGE. THE BOILER WAS IN SERVICE THE
SEP. 76 100 100 THE ENTIRE MONTH. THE A-SIOE WAS IN SERVICE 720 HR.t THE B-SIDE 676 HOURS. NO
SIGNIFICANT PROBLEMS WERE REPORTED.
OCT. 76 56 56 THE BOILER WAS IN SERVICE 417 HOURS DURING THE MONTH. A-SlOE AND B-SIDE OPERATIONAL
HOURS WERE 415 AND 277 RESPECTIVELY.
NOV. 76 96 98 DURING THE MONTH THE BOILER A-SIDE AND B-SIDE TRAINS WERE IN SERVICE 720t 682 AND 556
HOURS, RESPECTIVELY. TWO MINOR FORCED SCRUBBER OUTAGES OCCURRED DURING THE PERIOD
BECAUSE A REHEATER STEAM LEAK AND INLET GAS DAMPER ADJUSTMENTS TO BOTH THE A-SIOE AND
B-SIDE SCRUBBING TRAINS.
DEC. 76 96 100 BOILER, A-SIDE, AND B-SIDE OPERATION HOURS FOR THE MONTH WERE 714, 742 AND 498 HOURS,
RESPECTIVELY. ONE OUTAGE WAS REPORTED BECAUSE OF AN ADDITIONAL ADJUSTMENT TO THE
A-SIDE GAS INLET DAMPER.
PCDCO ENVIRONMENTAl.
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTEKISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
10
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 5A
FARMINGTON NEW MEXICO
160 MW
COAL 0.7 PERCENT SULFUR
SO. CALIFORNIA EDISON
LIME SCRUBBING
RETROFIT
2/76
OPERATIONAL
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
PENDING THE OUTCOME OF TESTS WHICH HAVE JUST BEEN COMPLETED ON THE
MOVED FROM THE MOHAVE TEST SITE AND REASSEMBLED AT THE FOUR CORNERS
STATION OF ARIZONA PUBLIC SERVICE. THE EXPERIMENTAL MODULE IS DESIGNED
TO TREAT APPROXIMATELY 20 PERCENT OF THE FLUE GAS FLOW FROM UNIT NO. 5
WHICH HAS A NET GENERATING CAPACITY, OF 75S-MW. THE S02 TEST PROGRAM
COMMENCED FEB. 1976 AND WAS COMPLETED ON DEC. 6, 1976. UPON CONCLUSION OF
THE PROGRAM, THE MODULE WAS DISASSEMBLED. RESULTS WILL BE PUBLISHED
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
FOUR CORNERS NO. 5A - EXPERIMENTAL HORIZONTAL SCRUBBER
THE FOUR CORNERS POWER STATION, LOCATED NEAR FARMINGTON, NEW MEXICO, IS JOINTLY OWNED BY THE ARIZONA PUBLIC SERVICE COMPANY
AND THE SOUTHERN CALIFORNIA EDISON COMPANY. THIS STATION CONTAINS FIVE COAL-FIRED BOILERS WITH AN EQUIVALENT ELECTRIC POWER
GENERATING CAPACITY OF 2233-MW. ONLY UNIT NO. 5 IS RETROFITTED WITH AN FGD SYSTEM.
UNIT NO. 5 IS A COAL-FIRED BOILER CAPABLE OF GENERATING 5»«»H6»000 LBS. OF STEAM, WHICH IS EQUIVALENT TO 800-MW OF NET ELEC-
TRICAL POWER. THIS UNIT WAS FIRST PLACED IN COMMERCIAL OPERATION JULY 1970. APPROXIMATELY 20 PERCENT OF THE FLUE GAS GENERATED BY
THIS BOILER IS BEING SCRUBBED INITIALLY IN ORDER TO ESTABLISH WHAT SULFUR DIOXIDE AND PARTICULATE REMOVAL EFFICIENCIES CAN BE
OBTAINED.
THE FGO SYSTEM WHICH HAS BEEN RETROFITTED ON UNIT NO. s is THE WEIR HORIZONTAL CROSSFLOW SPRAY SCRUBBER WHICH WAS FORMERLY
INSTALLED AND OPERATED IN A TEST PROGRAM AT THE MOHAVE GENERATING STATION OF THE SOUTHERN CALIFORNIA EDISON COMPANY(SEE MOHAVE NO.
2A IN APPENDIX A OF THIS REPORT).
DURING THE MOHAVE TEST PROGRAM THE HORIZONTAL MODULE WAS OPERATIONAL FROM NOVEMBER 1« 1973, TO JANUARY 16,1974, FOR SHAKEDOWN
PURPOSES. OVER THE COURSE OF THE ACTUAL TEST PROGRAM* WHICH EXTENDED FROM JANUARY 16, 197H, TO FEBRUARY 9, 1975* THE PROTOTYPE
UNIT OPERATED A TOTAL OF 5,927 HOURS IN VARIOUS TEST MODES. FOLLOWING COMPLETION OF TESTS, THE MODULE WAS SHUT DOWN, DISMANTLED*
TRANSPORTED, AND REASSEMBLED AT THE FOUR CORNERS GENERATING STATION OF ARIZONA PUBLIC SERVICE FOR FURTHER TESTING.
THE HORIZONTAL MODULE IS A FOUR-STAGE SCRUBBING CHAMBER WITH THE FOLLOWING DIMENSIONS* LENGTH - US FEET* WIDTH - 26 FEET*
HEIGHT - 15 FEET. THE MODULE ITSELF IS A HOLLOW CHAMBER CONSISTING OF FOUR STAGES OF CROSSFLOW SPRAY NOZZLES. EACH STAGE CONTAINS
A ROW OF 36 EXTERNALLY-MOUNTED NOZZLES. THE SLURRY IS CYCLED THROUGH THE SCRUBBER IN A COUNjERCURRENT MANNER AT A RATE OF 36,000
GPM/STAGE. FRESH LIME SLURRY IS SPRAYED ACROSS THE FLUE GAS AT THE FOURTH STAGE, WHICH IS THE DISCHARGE END OF THE SCRUBBING
CHAMBER. THE SCRUBBING SOLUTION IS THEN COLLECTED AND RECYCLED SUCCESSIVELY TO THE THIRD,SECOND,AND FIRST STAGES OF THE SCRUBBING
MODULE. THIS ALLOWS FOR COMPLETE DEPLETION OF ANY EXCESS ALKALINITY AND INSURES THAT FRESH SLURRY IS CONTACTING GAS HAVING THE
LOWEST SUFLUR DIOXIDE CONCENTRATION. THE LI8UID RECIRCULATION RATE CAN BE ADJUSTED OVER A WIDE RANGE. THE MODULE IS DESIGNED TO
TREAT A MAXIMUM FLUE GAS CAPACITY OF
-------
FOUR CORNERS NO. 5A (CONTINUEED)
SCRUBBING SYSTEM TO A THICKENER AND THE UNDERFLOW IS PUMPED TO AN ON-SITE SETTLING POND. WATER IS RETURNED TO THE PROCESS FOR
FURTHER USE.
A CUTAWAY VIEW OF THE WEIR SCRUBBING CHAMBER IS PRESENTED IN FIGURE 2 OF APPENDIX C.
PEOCO ENVIRONMENTAL
-------
FOUR CORNERS NO. 5A
PERIOD
MONTH/YEAR
FEB. 76
MAR. 76
APR. 76
HAY 76
JUN. 75
JUL. 76
AUG. 76
SEP. 76
OCT. 76
NOV. 76
DEC, 76
OPERATING HOURS
BOILER F60 SYSTEM
COMMENTS
INSTALLATION OF THE MODULE AT THE FOUR CORNERS GENERATING STATION WAS
COMPLETED AND THE MODULE WAS PLACED IN-SERVICE FEBRUARY 17. 1976.
FOR INITIAL OPERATION.
THE SYSTEM WAS TAKEN DOWN IN MID-APRIL FOR A SCHEDULED BOILER OVERHAUL,
SYSTEM RESTART IS SCHEDULED FOR JULY 1976.
THE SYSTEM HAS REMAINED OUT OF SERVICE SINCE MID-APRIL 1976 BECAUSE OF AN
EXTENSIVE OVERHAUL TO THE NO, 5 BOILER PLUS THE DEVELOPMENT OF PROBLEMS
WITH THE SCRUBBER MODULE'S REHEATER UNIT.
THE PROTOTYPE WAS IN SERVICE THROUGHOUT THE MONTH OF NOVEMBER. ON DEC.6 THE TEST
PROGRAM WAS CONCLUDED AND THE UNIT HAS SINCE BEEN DISMANTLED. APS IS NOW IN THE
PROCESS OF ANALYZING THE OPERATING DATA ACCUMULATED DURING THE TEST PERIOD. A
REPORT ADDRESSING THE RESULTS OF THE PROGRAM WILL BE PUBLISHED IN FEBRUARY 1977.
PEOCO ENVIRONMENT M_
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
19
CENTRAL ILLINOIS LI6HT CO.
DUCK CKEEK NO. 1A
CANTON ILLINOIS
100 MW
FUEL CHARACTERISTICS COAL 2.5 - 3.0 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICULATES
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
NEW
9/76
OPERATIONAL
99.6 PERCENT
S02
75 PERCENT
WATEK MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
UNSTABILI2ED* SLUDGE DISPOSED IN LINED POND
UNIT COST
$80/KW CAPITAL (ESTIMATED)
OPERATIONAL
EXPERIENCE
THE INSTALLATION OF THIS SINGLE 100-MW SCRUBBER NODULE WAS COMPLETED IN
JULY AND START-UP OPERATIONS FOLLOWED. DEBUGGING OPERATIONS HAVE BEEN
PROCEEDING ON AN INTERMITTENT BASIS BECAUSE OF CONSTRUCTION-RELATED
PROBLEMS. THE SYSTEM WAS SHUTDOWN FOR A SHORT PERIOD OF TIME TO CORRECT
THESE PROBLEMS. RE-START COMMENCED ON SEPTEMBER 9. OPERATION OF THE
MODULE DURING THE PERIOD FOLLOWING START-UP HAS BEEN INTERMITTENT BECAUSE
OF MECHANICAL ANO CHEMICAL-RELATED PROBLEMS. THIS HAS PROMPTED THE
UTILITY TO SHUTDOWN THE MODULE UNTIL FULL-SCALE START-UP DATE OF 6/7S.
PEOCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
31
COMMONWEALTH EDISON
WILL COUNTY NO 1
ROMEOVILLE ILLINOIS
167 HW
COAL 4.0 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
RETROFIT
2/72
OPERATIONAL
98 PERCENT
S02
62 PERCENT
WATER MAKE UP
OPEN LOOP
SLUU6E DISPOSAL
STABILIZED SLUDGE DISPOSED IN HAULAWAY TO LANUFILL
UNIT COST
S113/KW CAPITAL * 13 HILLS PERKWH OPERATING
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS FULL SCALE DEMONSTRATION SCRUBBING SYSTEM HAS BEEN IN SERVICE SINCE
FEBRUARY 1972. THE FGD SYSTEM INCLUDES TWO SCRUBBING TRAINS FOR THE
CONTROL OF PARTICULATES AND SULFUR DIOXIDE. MODULE AVAILABILITY.
OPERABILITY, RELIABILITY, AND UTILIZATION INDEX VALUES FOR THE PERIOD
ARE POSTED IN TABLE THRLE. THE BOILER FIRED BOTH LOW SULFUR
WESTERN COAL AND HIGH SULFUR ILLINOIS COAL DURING SEPARATE MONTHS.
THE FIXATION AHO HAULAWAY OF SCRUBBER WASTES CONTINUED DURING THE PERIOD.
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
WILL COUNTY NO. 1
IN 1970t COMMONWEALTH EDISON CONTRACTED WITH THE BECHTEL CORPORATION TO INVESTIGATE THE SULFUR REMOVAL SYSTEMS THEN AVAILABLE
HAVING A SUFFICIENT DEGREE OF DEVELOPMENT TO WARRANT LARGE-SCALE INSTALLATION ON WILL COUNTY STATION'S UNIT NO. I. AFTER DECIDING
ON A WET SCRUBBER SYSTEM USING LIME OR LIMESTONE* BECHTEL PREPARED A SPECIFICATION AND RELEASED IT FOR BID. FROM NINE BIDDERS THAT
WERE SOLICITED, SEVEN PROPOSALS WERE RECEIVED. AFTER DETAILED STUDY AND BIO EVALUATION WITH SPECIAL CONSIDERATION OF THE PROJECT
SCHEDULE, BABCOCK AND WILCOX WAS AUTHORIZED IN SEPTEMBER 1970 TO BEGIN DETAILED ENGINEERING FOR A LIMESTONE SLURRY SYSTEM. COM-
PLETION DEADLINE FOR THE PROJECT WAS DECEMBER 31, 1971< A DEADLINE ESTABLISHED BY THE ILLINOIS COMMERCE COMMISSION AS PART OF A
RATE CASE.
THE BABCOCK AND WILCOX PROCESS WAS GUARANTEED TO REMOVE 96 PERCENT OF THE FLY ASH AND 76 PERCENT OF THE SULFUR DIOXIDE. THESE
EFFICIENCIES WERE BASED ON A DuST INLET LOADING OF 1.355 GRAINS PER STANDARD CUBIC FOOT AT 70 F AND ON BURNING OF ILLINOIS COAL
CONTAINING H PERCENT SULFUR.
THE WILL COUNTY POWER STATION IS LOCATED NEAR ROMEOVlLLEt ILLINOIS. THE PLANT HAS FOUR ELECTRIC POWER GENERATING UNITS WITH A
TOTAL RATED CAPACITY OF Il«t7 MW. ONLY UNIT NO. 1 IS RETROFITTED WITH AN FGD SYSTEM.
UNIT NO. i is A WET-BOTTOM COAL-FIRED BOILER PRODUCING 167 MW OF ELECTRICITY. THE BOILER WAS MANUFACTURED BY BABCOCK AND
WILCOX AND WAS INSTALLED IN 1955. THE PLANT NOW BURNS A LOW-SULFUR (1.3 PERCENT) WESTERN COAL AND A HIGH-SULFUR (4.0 PERCENT)
ILLINOIS COAL.
THE WET LIMESTONE FGD SYSTEM AT WILL COUNTY WAS PLACED IN SERVICE ON FEBRUARY 23, 1972. THE SYSTEM CONSISTS OF TWO F60
MODULLS (IDENTIFIED AS A AND B)« LIMESTONE HANDLING AND MILLING FACILITIES, AND A SLUDGE TREATEMENT AND STABILIZATION UNIT. A
PROCESS FLOW DIAGRAM OF THE FGO SYSTEM IS GIVEN IN FIGURE
-------
WILL COUNTY (CONTINUED)
SLUDGE FROM THE SYSTEM IS SENT TO A CLARIFICR. THE OVERFLOW IS RETURNED TO THE PROCESS** THE UNDERFLOW IS STABILIZED BY MIXING
IT WITH LI PIE AND FLY ASH. APPROXIMATELY 200 POUNDS OF LIME AND HOO POUNDS OF FLY ASH ARE USED PER TON OF DRY SOLIDS OF SLUDGE.
THE STABILIZED SLUDGE IS STABILIZED IN AND TRANSPORTED BY CONCRETE MIXING TRUCKS FOR ULTIMATE DISPOSAL IN AN OFF-SITE DISPOSAL
AREA.
PROBLEMS AND SOLUTIONS
1972 - DEMISTER PLUGGING WAS A CONSTANT PROBLEM,MAINLY BECAUSE OF HEAVY LIMESTONE ACCUMULATIONS ON THE BOTTOM Of THE DEMISTER
AND PARTLY BECAUSE OF LOW WASHWATER PRESSURE CAUSED BY LEAKS IN THE POND KETURN BYPASS. BECAUSE OF THESE PROBLEMS MODULES A AND B
WERE OUT OF SERVICE FOR SEVERAL DAYS EACH MONTH DURING MARCH, APRIL. JUNE. AND JULY 1972. THE MODULES WERE ALSO OUT OF SERVICE
FROM SEPTEMBER 26 TO NOVEMBER 21* 1973* BECAUSE THE BOILER WAS DOWN.
IN ORDER TO SOLVE THE DEMISTER PROBLEM* THE SLURRY NOZZLES WERE LOWERED AND THE SLURRY CIRCULATION SYSTEM WAS LEFT OUT OF
SERVICE TO KEEP THE DEMISTER CLEAN. SINCE THE SITUATION DID NOT IMPROVE, THE DEMISTER ELEMENTS WERE HAND-WASHED. THIS SOLVED THE
PROBLEM PARTIALLY* BUT CAUSED DIFFICULTY WITH THE VENTURI NOZZLES BECAUSE BROKEN ELEMENTS FROM THE DEMISTER GOT INTO THE SLURRY
SYSTEM.
AT HIGH GAS FLOW RATES, THE REHEATER OF MODULE B VIBRATED EXCESSIVELY. THEREFORE, MODULE B WAS TAKEN OUT OF SERVICE IN APRIL
TO ALLOW REHEATER MODIFICATIONS, WHICH INCLUDED REBRACING OF THE REHEATER TUBES AND INSTALLATION OF A BAFFLE PLATE TO REDUCE THE
VIBRATIONS.
OTHER REASONS FOR OUTAGES WERE EROSION AND PLUGGING OF SPRAY NOZZLES, INTERNAL AND EXTERNAL BUILDUP OF DEPOSITS ON VENTURI
NOZZLES, CORROSION, SULFITE BLINDING PROBLEMS, AND FAN VIBRATIONS.
1973 - DEMISTER PLUGGING CONTINUED. FURTHERMORE, THE OEMISTER ON MODULE B BROKE LOOSE FROM ITS MOUNTINGS AND THE RESULTANT
CARRYOVER OF WASH-WATER PLUGGED THE REHEATER. THIS REHEATER ALSO LEAKED BECAUSE OF CHLORIDE PITTING CORROSION. MODULE A WAS DOWN
FROM APRIL 24 TO MAY 2
-------
WILL COUNTY (CONTINUED)
MONTH OF JANUARY 197*.
1975 - ENTERING 1975 NODULE A WAS OPERATIONAL AND NODULE B WAS STILL UNDERGOING MODIFICATION* IN THE FIRST QUARTER OF 1975
THERE WERE EIGHT A-MODULE OUTAGES* ONLY ONE WAS A FORCED OUTAGE. DUE TO THE SPLITTING OF A SLURRY VENTURI SUPPLY HOSE. MOBULE B
WAS RETURNED TO SERVICE ON MAY 20, 1975. THE UTILITY DECIDED TO OPERATE THE SCRUBBER ON ILLINOIS HIGH-SULFUR COAL. WHEN THIS
OPERATION BEGAN, A MULTITUDE OF PROBLEMS OCCURRED* LOWER PARTICULATE REMOVAL EFFICIENCIES* HIGH SLURRY CARRYOVERS* DEMISTER
PLUGGING, REHEATER COIL FOULING AND LEAKS. MODULE A WAS TAKEN OUT OF SERVICE IN MID-JUNE FOR THE REMAINDER OF 1975. BY MID-
SEPTEMBER 1975 MODULE B WAS TAKEN OUT OF SERVICE OWING TO MASSIVE SCALING IN THE ABSORBER SYSTEM. FINALLY* UNIT NO. 1 WAS SHUT
DOWN FOR OVERHAUL OF THE BOILER. TURBINE* AND SCRUBBER IN MID-OCTOBER* THIS OUTAGE LASTED MORE THAN «* MONTHS.
PERFORMANCE FACTORS FOR EACH MODULE AND THE CORRESPONDING COMMENTS FOR THE REPORT PERIOD ARE PRESENTED IN THE FOLLOWING TABLE
93 PEDCO ENVIRONMENTAL
-------
PERIOD OPERABILITY («)
MONTH/YEAR MODULE A MODULE B
MAR. 72
APR. 72
MAY 72
JUN. 72
JUL. 72
AUG. 72
SEP. 72
OCT. 72
70
79
35
32
31
21
30
FGD SYSTEM OPERABILITY
WILL COUNTY UNIT NO. 1
COMMENTS
MODULE A DOWN FOR REPAIR AND MODIFICATION OF DEMISTER WASH PIPING ASSEMBLY.
MODULE B WAS REMOVED FROM SERVICE EVERY 2 OR 3 DAYS TO HAND-WASH THE DEMISTER. OTHER
PROBLEMS WERE VIBRATION OF KEHEATER TUBE BUNDLE, RAPID EROSION OF SCRUBBER SPRAY
NOZZLESt PLUGGING OF VENTURI NOZZLES.
MODULE A OUT OF SERVICE FOR 6 DAYS BECAUSE OF NEAR-RUPTURE OF A VENTURI PIPE
EXPANSION JOINT. HEAVY BUILDUP OF SOLIDS ON OEMISTER. MODULE B OUT OF SERVICE MOST
OF THE TIME FOR SIMILAR REPAIR OF VENTURI PIPE EXPANSION JOINT, AND FOR MODIFICATION
OF REHEATER UNIT AND DEMISTEK WASH SYSTEM.
A TWO WEEK OUTAGE OF MODULE B TO REBRACE THE REHEATER UNIT* TO INSTALL UNDERSPRAY
NOZZLES ON OEMISTERi AND TO INSTALL HEAVIER SCREENS IN THE SUMP. REHEATER PLUGGING
CAUSED ADDITIONAL OUTAGES.
BOTH MODULES WERE OUT OF SERVICE OWING TO HIGH DIFFERENTIAL PRESSURE ACROSS THE
DEMISTERS. LEAKAGE OF POND RETURN BYPASS VALVE CAUSED DEMISTER PLUGGING. ALSO
DURING THIS PERIOD. THE RUBBER LINING OF SCRUBBER A WAS REPAIRED.
PLUGGING OF VENTURI NOZZLES AND DEMISTER CAUSED SHUTDOWN OF MODULE A FOR 2 DAYS FOR
REPAIRS. MODULE B WAS OUT OF SERVICE FOR 22 DAYS FOR CLEANING OF THE DEMISTER AND
REHEATER UNIT, INSTALLATION OF OVERHEAD SPRAY NOZZLES, AND REPLACEMENT OF SECTIONS OF
THE OEMISTER. THE BOILER WAS DOWN FOR TWODAYS FOR REPAIR OF THE GENERATOR.
BOILER DOWN SEPT. 1-5 BECAUSE OF NO DEMAND. I.D. FAN PROBLEM CAUSED UNSTABLE OPERA-
TION OF THE BOILER MOST OF THE MONTH. MODULE A WAS DOWN FOR MODIFICATION OF REHEATER
UNIT AND REPAIR OF RECIRCULATION TANK SCREENS.
BOILER AND SCRUBBERS WERE DOWN. PRINCIPAL MODIFICATIONS INCLUDED INSTALLATION OF
REHEATEK «AFFLE PLATES TO DAMPEN VIBRATIONS AND INSTALLATION OF AN EXPERIMENTAL
PEOCO ENVIRONMENTAL
-------
PERIOD
MONTH/YEAR
NOV. 72
DEC. 72
JAN. 73
FEB. 73
MAR. 73
APR. 73
OPERABILITY (X)
MODULE A MODULE B
OCT. 73
NOV. 73
DEC. 73
0
22
0
22
65
32
51
0
30
0
2
-------
PERIOD OPERABILITY
MONTH/YEAR MODULE A HOOULE B
JAN. 74
FEB. 7*
MAR. 7
-------
PERIOD
MONTH/YEAR
NOV. 74
DEC. 7H
JAN. 75
FEB. 75
OPERABILITY
-------
WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
MAR. 75 A
SYSTEM PERFORMANCE FACTORS (K)
AVAILABILITY OPERABIHTY RELIABILITY UTILIZATION
93
81
APR. 75
37
-------
WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION
JUN. 75
A
B
6
-------
WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS (XI
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
AUG. 75
100
92
76
SEP. 75
63
63
OUT. 75
100
26
COMMENTS
SULFUR COAL WAS BURNED DURING THE FIRST (3) WEEKS
AND HIGH SULFUR ILLINOIS COAL WAS BURNED DURING TH
THE LAST WEEK OF THE MONTH.
MODULE A REMAINED OUT OF SERVICE ALL MONTH. MODULE
B WAS SHUT DOWN SEVEN TIMES DURING THE MONTH, FOUR
OF WHICH WERE DUE TO »NO DEMAND.* HIGH SULFUR PILE
COAL WAS BURNED IN THE UNIT DURING THE MONTH,
RESULTING IN A SUBSTANTIAL INCREASE IN SLUDGE PRO-
DUCTION AND FORCING A 6-DAY. 10 HR/DAY, SLUDGE
DISPOSAL OPERATION. SLUQGE STABILIZATION IS
CONTINUING.
MODULE A REMAINED OUT OF SERVICE ALL MONTH BECAUSE
OF DELAY ON THE NEW REHEATER ORDER. MODULE B WAS
DOWN THREE TIMES BECAUSE OF MASSIVE ABSORBER SCALE
DEMISTER AND 1.0. BOOSTER FAN CLEANING, BALANCING
I.D. BOOSTER FAN, AND PLUGGING OF ABSORBER PUMP
SCREEN. TOTAL OUTAGE TIME WAS 238 HOURS, HO
MINUTES FOR CUEANOUT AND FAN BALANCING. HIGH
SULFUR COAL WAS BURNED IN THE BOILER WHEN THE
SCRUBBER WAS IN THE GAS PATH.
ON OCTOBER 11• OVERHAUL BEGAN ON THE WILL COUNTY
UNIT NO. 1 BOILER, TURBINE,AND SCRUBBER. MODULE B
EXPERIENCED TWO MINOR OUTAGES DURING THE 11-DAY
PERIOD PRIOR TO THE OVERHAUL. MODULE A REMAINED
60
PEDCO ENVIRONMENTAL
-------
WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD NODULE
MONTH/YEAR
NOV. 75
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPERABXLITY RELIABILITY UTILIZATION
TURBINE« BOILER, AND SCRUBBER OVERHAUL
DEC. 75
TURBINE. BOILER AND SCRUBBER OVERHAUL
JAN. 76
FEB. 76
MAR. 76
TURBINE* BOILER AND SCRUBBER OVERHAUL
TURBINE* BOILER AND SCRUBBER OVERHAUL
A
B
30
9
45
20
21
8
19
8
COMMENTS
OUT OF SERVICE PENDING DELIVERY OF THE NEW RE-
HEATER
THE SCHEDULED OVERHAUL OF THE BOILER* TURBINE* AND
SCRUBBER MODULES CONTINUED* MAJOR MAINTENANCE
AREAS INCLUDED MODULE REHEATERS* POND RETURN PUMP*
VENTURI SPRAY NOZZLES* VENTURI AND ABSORBER
MODULES* PUMP VALVES* AND SUMPS.
MODULE B REHEATER WAS RETURNED FROM MANUFACTURER
AFTER REPAIRS AND REVISIONS. SCRUBBER REHEATERS
COULD BE INSTALLED AND OPERATING BY THE END OF
JANUARY.
THE UNIT REMAINED OUT OF SERVICE FOR COMPLETION OF
THE BOILER* TURBINE* AND SCRUBBER OVERHAUL THAT
BEGAN ON OCTOBER 11* 1975. SYSTEM RESTART IS NOW
SCHEDULED FOR MID-MARCH 1976.
UNIT NO. i RETURNED TO SERVICE IN MARCH FOLLOWING
THE EXTENDED MAJOR BOILER* TURBINE AND SCRUBBER
OVERHAUL. THE A-SIDE WAS PUT INTO THE GAS PATH
ON MARCH 22 AND REMAINED AVAILABLE FOR SERVICE THE
REST OF THE MONTH. THE B-SIDE REMAINED OUT OF
SERVICE UNTIL MARCH 29 BECAUSE OF DELAYS IN THE
INSTALLATION OF A REPAIRED REHEATER. HIGH SULFUR
ILLINOIS WAS BURNED IN THE BOILER DURING THE MONTH
PEOCO ENVIRONMENTAL
-------
WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
APR. 76
A
B
A X B*
23
51
20
«f9
20
20
19
19
HAY 76
87
85
76
COMMENTS
DURING THE MONTH OF APRIL THE A-SIDE INCURRED PUMP
LINER FAILURES WHEN AN ISOLATION VALVE BROKE AND
FELL INTO THE VENTURI RECYCLE PUMP. B-SIOE OUTAGES
DURING THE MONTH RESULTED FROM REHEATER TUBEBUNDLE
LEAKS* PLUGGED ABSORBER TANK SCREEN* AND VENTURI
PUMP LINER FAILURE. HIGH SULFUR COAL (3.5 PERCENT
SULFUR) WAS BURNED IN THE BOILER THROUGHOUT THE
MONTH. IN ADDITION! THE UTILITY INITIATED A
TESTING AND EVALUATION PROGRAM DURING THE MONTH.
THIS PROGRAM IS DESIGNED TO PROVIDE DATA AND
INFORMATION CONCERNING CHEMISTRY AND RELATED
OPERATING CHARACTERISTICS.
THE A-SIDE WAS DOWN THE ENTIRE MONTH AWAITING A
PARTS SHIPMENT (VENTURI PUMP LINERS). MODULE B
ENCOUNTERED FOUR FORCED SCRUBBER OUTAGES. THREE
OF THESE OUTAGES WERE MECHANICAL PROBLEMS* DUE
TO A VENTURI HOSE LEAK, PLUGGED ABSORBER TANK
SCREEN, AND A FOULED I.D. BOOSTER FAN. HIGH
SULFUR ILLINOIS COAL WAS BURNED IN THE BOILER
DURING THE MONTH. THE SLUDGE WAS STABILIZED WITH
LIME AND FLY ASH AND HAUuED TO AN OFF-SITE
DISPOSAL AREA.
PEOCO ENVIRONMENTAL
-------
WILL COUNTY UNIT NO. X (CONTINUED)
PERIOD MODULE
MONTH/YEAR
JUN. 76
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
A
B
A & B*
50
63
44
85
37
42
01
36
70
31
JUL. 76
A
B
20
86
0
90
0
64
0
72
AUG. 76
A
B
A 1 B*
98
65
57
61
17
96
54
38
41
11
COMMENTS
SIDE-A WAS RETURNED TO SERVICE JUNE 9 FOLLOWING
THE INSTALLATION OF A NEW VENTURI PUMP LINER.
FOUR FORCED SCRUBBER OUTAGES WERE REPORTED-
TWO BECAUSE OF NO DEMAND, ONE FOR A BYPASS-
DAMPER FAILURE AND ONE FOR 1.0. BOOSTER FAN
FOULING. THE B-SIDE ENCOUNTERED SEVERAL FORCED
SCRUBBER OUTAGE - TWO DUE TO NO DEMAND AND
SEVERAL SHORT TRIPS BECAUSE OF SCALING AND
PLUGGING IN THE VENTURI TANK SCREEN. HIGH SULFUR
ILLINOIS COAL WAS BURNED IN THE BOILER DURING
THE MONTH. SLUDGE FIXATION AND HAULAWAY TO A
DISPOSAL SITE CONTINUED.
THE A-SIOE REMAINED OUT OF SERVICE THE ENTIRE
MONTH BECAUSE OF REPAIRS TO A DAMAGED ABSORBER
PUMP AND POND THICKENER SLUDGE OVERLOADING. THE
B-SIDE ENCOUNTERED FOUR FORCED SCRUBBER OUTAGES*
TWICE FOR NO DEMAND* ONCE TO BALANCE THE I.D.
BOOSTER FANS, AND ONCE TO WASH THE I.D. BOOSTER
FANS.
THE A-SIOE REMAINED OUT OF SERVICE SO PERCENT OF
OF THE TIME DURING THE MONTH TO AVOID POND
THICKENER OVERLOADING. FOUR SCRUBBER OUTAGES
WERE REPORTED* ONE BECAUSE OF NO DEMAND AND THREE
BECAUSE OF MINOR PROBLEMS. THE B-SIDE ENCOUNTERED
PEOCO ENVIRONMENTAL
-------
WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
SEP. 76
A
B
A & B*
H2
79
29
76
5
25
7H
60
COMMENTS
THREE NO-DEMAND OUTAGESt TWO BECAUSE OF LOSS OF
CHEMICAL CONTROL. ONCE FOR FOULING AND ONCE FOR
SPENT SLURRY VALVE REPAIRS. EXPERIMENTATION WITH
THE SYSTEM'S PROCESS CHEMISTRY, BY LOWERING THE
PH SET POINT FROM 5.t TO 5.1, WAS CONDUCTED BY THE
UTILITY DURING THIS PERIOD. THIS VARIATION IN
OPERATION WAS BELIEVED To HAVE CAUSED THE MAS-
SIVE GYPSUM SCALING IN BOTH MODULES WHICH OCCURRED
DURING THE PERIOD. THE PH SET POINT WAS RETURNED
BACK TO THE 5.4 VALUE. HIGH SULFUR ILLINOIS COAL
WAS BURNED IN THE BOILER DURING THE MONTH. SLUDGE
STABILIZATION PRACTICES CONTINUED.
FIVE OUTAGE PERIODS WERE REPORTED DURING THE MONTH
FOR THE A-SIOE, THREE OF WHICH RESULTED FROM
FORCED SCRUBBER OUTAGES. PROBLEMS WERE REPORTED
WITH LOW FLOW TRIPS IN THE VENTURI, NOZZLE FOULING
CLEANING AND INSPECTION OF THE RECIRCULATION TANK,
PUMPS AND VALVES, AND A PUMP MOTOR FAILURE. THE
B-SIDE ENCOUNTERED FOUR FORCED SCRUBBER OUTAGES*
TWO BECAUSE OF SPENT SLURRY VALVE TROUBLE* ONE LOW
VENTURI FLOW TRIP AND ONCE BECAUSE OF LOSS OF
CHEMICAL CONTROL. HIGH SULFUR ILLINOIS COAL
BURNING WAS CONTINUED IN THE BOILER DURING THE
MONTH.
PEDCO ENVIRONMENTAL
-------
WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR'
OCT. 76
MOV. 76
SYSTEM PERFORMANCE FACTORS
-------
TABLE S
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
32
DETROIT EDISON
ST. CLAIR NO 6
BELLE RIVER MICHIGAN
163 MW
COAL 3.7 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
RETROFIT
5/76
OPERATIONAL
99,7 PERCENT
S02
90 PERCENT
WATEK MAKE UP
OPEN LOOP 1.07GPM/MW
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
UNSTABILIZED SLUUGE DISPOSED IN LINED POND
$92 / KW CAPITAL * 2.f MILLS/ KUH OPERATING
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
A 30-DAY VENDOR QUALIFICATION RUN AND A WEEK-LONG FINAL ACCEPTANCE TEST
WERE SUCCESSFULLY COMPLETED DURING THE SPRING OF 1976. THE UTILITY IS
NOW IN THE PROCESS OF CONDUCTING A MINIMUM TWO-MONTH INTERNAL DEMONSTRA-
TION PROGRAM DURING WHICH THE. SCRUBBERS WILL OPERATE IN THE S02-REMOVAL
MODE. THIS PROGRAM IS BEING CONDUCTED PRIMARILY BY PLANT PERSONNEL.
FOLLOWING COMPLETION OF THE S02 PROGRAM. THE VENTURI SCRUBBERS WILL
REMAIN IN THE FLUE GAS PATH, OPERATING IN THE PARTICULATE-KEMOVAL MODE.
66
PEDCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
ST. CLAIR NO. 6
THE ST. CLAIR POWER PLANT OF THE DETROIT EDISON COMPANY IS LOCATED ON THE ST. CLAIR RIVER IN BELLE RIVER* MICHIGAN. APPROXI-
MATELY <»5 MILES NORTHEAST OF DOWNTOWN DETROIT. THIS PLANT CONTAINS 7 FOSSIL-FUEL-FIRED GENERATING UNITS WHICH HAVE A TOTAL NET
GENERATING CAPACITY OF 1775-MW. UNIT NO. 6 IS A COAL-FIRED TWO-STAGE SUPERHEATER UNIT, CONTAINING TWO SEPARATE BOILER BOXES KNOWN
AS THE SOUTH BOILER AND THE NORTH BOILER. THE TOTAL NE.T GENERATING CAPACITY OF THE NO. 6 UNIT IS 325 MW. THE SUPERHEATER WAS
MANUFACTURED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE IN 1961. BOTH THE NORTH BOILER AND THE SOUTH BOILER ARE EQUIPPED
WITH EMISSION CONTROL SYSTEMS. THE UNIT CURRENTLY OPERATES AT EXCESS AIR RATES OF 115 TO 120 PERCENT.
THE ST.CLAIR NO.6 BOILER FIRES EXCLUSIVELY A LOW SULFUR WESTERN SUBBITUMINOUS COAL ORIGINATING FROM THE DECKER COMPANY'S
OIETZ MINE LOCATED IN SOUTHERN MONTANA. THE AVERAGE CHARACTERISTICS OF THIS COAL ARE* HEAT CONTENT 9500 TO 9600 8TU/t_B*SULFUR CON-
TENT OF 0.3 TO 0.«* PERCENT* ASH CONTENT OF 4.0 PERCENT* AND A TOTAL MOISTURE CONTENT OF 22.0 TO 2H.O PERCENT.
THE EMISSION CONTROL SYSTEM INSTALLED ON THE NORTH BOILER CONSISTS OF MECHANICAL COLLECTORS AND AN ELECTROSTATIC PRECIPITATOR
(ESP) INSTALLED UPSTREAM OF A WET SCRUBBING SYSTEM. THE MECHANICAL COLLECTORS AND ESP ARE PROVIDED FOR PRIMARY PARTICULATE CONTROL
THE WET SCRUBBING SYSTEM PROVIDES ADDITIONAL PARTICULATE REMOVAL AND PRIMARY SULFUR DIOXIDE CONTROL.
THE FLUE GAS DESULFURIZATION (FGD) CONSISTS OF TWO PEABODY-LURGI VENTURI SCRUBBER AND SPRAY TOWER ABSORBER MODULES WITH A
TOTAL FLUE GAS CAPACITY OF 193,500 ACFM AT 270 F. THIS VOLUME IS EQUIVALENT TO APPROXIMATELY 50 PERCENT OF THE TOTAL FLUE GAS
FROM THE NO. 6 UNIT. THE DESIGN FLOW RATE PER SCRUBBING TRAIN IS 246*700 ACFM AT 270 F. FLUE GAS CAN BE BYPASSED AROUND THE
SCRUBBING SYSTEM. 6.6 MW OF ELECTRICAL POWER ARE CONSUMED BY THE SCRUBBING OPERATIONS. THIS FGO SYSTEM IS AN EXPERIMENTAL
DEMONSTRATION UNIT DESIGNED AND INSTALLED BY PEABODY ENGINEERED SYSTEMS IN COOPERATION WITH THE DETROIT EDISON COMPANY. EACH
SCRUBBING TRAIN WHICH ALSO INCLUDES A CLEAR WATER TRAY AND RADIAL VANE MIST ELIMINATOR. A COMMON RECYCLE TANK, INDUCED DRAFT FAN*
OIL-FIRED HOT-AIR-INJECTION REHEAT SYSTEM AND A 10.8-ACRE CLAY-LINED SETTLING POND. DESIGN REMOVAL EFFICIENCY OF THIS EMISSION
CONTROL SYSTEM IS 99.7 PERCENT FOR PARTICULATES AND 90 PERCENT FOR SULFUR DIOXIDE BASED UPON HIGH SULFUR EASTERN COAL. A DIAGRAM
OF ONE OF THE TWO PARALLEL SCRUBBING TRAINS IS PRESENTED IN FIGURE 5 OF APPENDIX C.
67 PEOCO ENVIRONMENTAL
-------
F60 SYSTEM PERFORMANCE
ST. CLAIR NO. 6
PERIOD COMMENTS
NOV. 7«t INSTALLATION OF THE FGD SYSTEM WAS ESSENTIALLY COMPLETED BY THIS TIME. A FAULTY INSTRUMENT PANEL WHICH WAS
DEC. 7 AND LASTED 27 HOURS. THE RUN WAS TERMINATED BECAUSE OF A
REHEATER THERMOCOUPLE FAILURE. A SUBSEQUENT INSPECTION OF THE SCRUBBING SYSTEM REVEALED NO APPARENT ABNOR-
MALITIES OR MALFUNCTIONS.
SEP. 75
OCT. 75 A THIRD HOT FLUE GAS RUN OF
-------
F60 SYSTEM PERFORMANCE (CONTINUED)
ST. CLAIR NO. 6
PERIOD COMMENTS
NOV. 75
DEC. 75 A FOURTH FLUE 6AS RUN OF 23 DAYS DURATION HAS TERMINATED DUE TO EXCESSIVE VIBRATION IN THE 1.0. BOOSTER FAN.
ONE OTHER SCRUBBER-RELATED OUTAGE OCCURRED WHEN THE PACKING OF ONE OF THE SCRUBBER RECIRCULATION PUMPS REQUIRE
MAINTENANCE. S02 REMOVAL DURING THIS PERIOD WAS 90 PERCENT AND PARTICIPATE OUTLET LOADING WAS 0.1 LB/1000 LBS
OF FLUE GAS FOR 1 TO 3 PERCENT SULFUR COAL.
JAN. 76
FEB. 76
MAR. 76
APR. 76 THE 30-DAY VENDOR QUALIFICATION RUN AND FINAL ACCEPTANCE TESTS WERE COMPLETED BY MAY 29. THE QUALIFICATION
MAY 76 RUN WAS CONDUCTED ON A *HANDS OFF* BASIS USING PLANT PERSONNEL EXCLUSIVELY. THE SYSTEM WAS IN SERVICE 100
PERCENT OF THE TIME THE BOILER WAS OPERATIONAL. THE FINAL ACCEPTANCE TEST CONSISTED OF SIX 4-HR. TEST RUNS
CONDUCTED IN THE SPACE OF ONE WEEK. THE S02 REMOVAL EFFICIENCY FOR HIGH SULFUR COAL WAS 90.9 PERCENT.
PARTICULATE REMOVAL ALSO EXCEEDED DESIGN LEVELS. NO MAJOR MECHANICAL OR CHEMICAL-RELATED PROBLEMS WERE
ENCOUNTERED.
JUN. 76
JUL. 76
AUG. 76 THE UTILITY IS NOW PREPARING TO CONDUCT A 2 MONTH MINIMUM INTERNAL SCRUBBER DEMONSTRATION PROGRAM TO ACQUIRE
OPERATING DATA AND INFORMATION. FOLLOWING THE COMPLETION OF THIS PROGRAM THE BOILERS WILL FIRE LOW SULFUR
DECKER COAL (0.3 TO O.«f PERCENT) TO MEET S02 EMISSION REGULATIONS. THE SCRUBBERS WILL CONTINUE TO OPERATE IN
THE PARTICULATE REMOVAL MODE.
SEP. 76 THE INTERNAL SQ2 SCRUBBING DEMONSTRATION PROGRAM COMMENCED ON OCTOBER 1«*. THE SCRUBBERS OPERATED CONTINUOUSLY
OCT. 76 FOR 10 DAYS. OPERATION WAS INTERRUPTED BY A FORCED SCRUBBER OUTAGE RESULTING FROM SCALE AND SOLIDS CARRYOVER
FROM THE WASH TRAY AND MIST ELIMINATOR TO THE SCRUBBER I.D. BOOSTER FAN ASSEMBLYt CAUSING VIBRATION AND
BALANCE PROBLEMS. THE SCRUBBING SYSTEM WAS TAKEN OUT OF THE GAS PATH THE FAN WAS CLEANED OUT AND REBALANCED.
THE UTILITY PLANS TO MODIFY THE COMPONENT'S WASH SYSTEM FOR GREATER FLOW CAPABILITY AFTER COMPLETION
69 PEOCO ENVIRONMENTAL
-------
OF THE so2 SCRUBBING PROGRAM. OECO ALSO PLANS TO CONTINUE PARTICULATE SCRUBBING FOLLOWING THE
TERMINATION OF THE S02 PROGRAM BY UNCOUPLING THE SPRAY TOWERS AND MAINTAINING THE PEABODY-LURGI
VENTURI SCRUBBERS IN THE FLUE GAS STREAM. SOME LIMESTONE MAY HAVE TO BE ADDED TO THE PARTICULATE SCRUBBING
SOLUTION IN ORDER TO PREVENT LOW PH SWINGS AND MINIMIZE THE POSSIBILITY OF ACID CORROSION DAMAGE TO THE
INTERNAL COMPONENTS.
NOV. 76 FOLLOWING THE COMPLETION OF SAND BLASTING OPERATIONS TO SCRUBBER'S I.D. BOOSTER FAN FOR REMOVAL OF SOLIDS
BUILD UP, OPERATIONS RESUMED ON NOVEMBER 7 AND CONTINUED THROUGHOUT THE MONTH. THE SYSTEM'S AVAILABILITY
INDEX FOR THE MONTH WAS 60 PERCENT, THE MAJORITY OF THE OUTAGE TIME WAS CONSUMED PROCURING SAND BLASTING
SERVICES. THE OPERATION ITSELF REQUIRED ONLY B HOURS.
DEC. 76 THE S02 DEMONSTRATION PROGRAM CONTINUED THROUGHOUT DECEMBER. THE SYSTEMS'S AVAILABILITY INDEX FOR THE PERIOD
WAS 51 PERCENT. SCRUBBER OUTAGES RESULTED FROM MALFUNCTIONS OF THE LIMESTONE FEEDER, THE DENSE SLURRY TRAVERSE
PUMP, THE DENSE SLURRY TANK AGITATORS* AND PLUGGING OF THE PH SAMPLE LINE,
70 PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
33
DUQUESNE LIGHT
ELRAMA POWER STATION
ELRAMA PENNSYLVANIA
510 MW
FUEL CHARACTERISTICS COAL 1.0 - 2.8 PERCENT SULFUR
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
CHEMICO
LIME SCRUBBING
RETROFIT
10/75
OPERATIONAL
S02
83 PERCENT FOR 2X SULFUR COAL
WATER HAKE UP
OPEN LOOP
SLUDGE DISPOSAL
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
S93/KW CAPITAL * 6.0 MILLS/KWHOPERATING COSTS(BOTH STATIONS)
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SCRUBBING SYSTEM,WHICH CONSISTS OF FIVE SINGLE-STAGE MODULES,WAS
INITIALLY PLACED IN SERVICE OCTOBER 26,1975. INITIAL OPERATION PROCEEDED
WITH FLUE GAS FROM ONE BOILER BEING TREATED BY FIVE SCRUBBING VESSELS.
DURING THE REPORT PERIOD OPERATIONS PROCEEDED WITH TWO BOILERS COUPLED
INTO THE 5-MODULE SCRUBBING SYSTEM.-ONt SINGLE-STAGE SCRUBBING MODULE
OPERATED WITH TWO RUBBER-LINED RECYCLE PUMPS IN SERVICE. THE SCRUBBING
WASTES ARE CHEMICALLY FIXATED BY THE IUCS METHOD AND LANDFILLED.
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
ELRAMA POWER STATION
DUOUESNE LIGHT COMPANY. AN INVESTOR-OWNED ELECTRIC UTILITY, SERVES ABOUT ONE-HALF MILLION CUSTOMERS IN SOUTHWESTERN
PENNSYLVANIA AND HAS A NET GENERATING CAPABILITY OF APPROXIMATELY 2500 MW. THIS CAPABILITY IS GENERATED BY COMBUSTION TURBINES IN
SIMPLE AND COMBINED-CYCLE MODES, BY NUCLEAR PLANTS, AND BY COAL-FIRED POWER STATIONS. THE COMPANY IS SOLE OWNER AND OPERATOR OF
THREE COAL-FIRED STATIONS, TWO OF WHICH HAVE BEEN RETROFITTED WITH WET SCRUBBERS USING LIME AS A REAGENT. .
THE SCRUBBER FACILITY AT THE
-------
PERIOD
OCT. 75
TO
JAN. 76
FEB. 76
MAR. 76
APR. 76
HAY 76
JUN. 76
JUL. 76
AUG. 76
OPERATING HOURS
BOILER SCRUBBER VESSELS
1169 1508 976 838
SEP. 76
ELRAMA POliER STATION
COMMENTS
ONE BOILER WAS CONNECTED TO THE SCRUBBER SYSTEM ON OCTOBER 26t 1975.
A SECOND BOILER WAS CONNECTED ON FEBRUARY 4« 1976. FOUR OF THE
SCRUBBER VESSELS HAVE BEEN IN SERVICE IN VARIOUS COMBINATIONS. THE
SERVICE HOURS TO JANUARY 31t 1974 ARE POSTED IN THE ACCOMPANYING
TABLE. THE FIFTH VESSEL HAS NOT BEEN IN SERVICE BECAUSE IT IS BEING
REVISED FOR TRIAL INSTALLATION OF RUBBER-LINED RECYCLE PUMPS.
THE SYSTEM OPERATED DURING THE REPORT PERIOD WITH 2 BOILERS COUPLED
INTO THE SCRUBBING SYSTEM. REVISIONS TO THE FIFTH SCRUBBING VESSEL
HAVE BEEN COMPLETED AND OPERATIONS ARE PROCEEDING WITH TWO RUBBER-
LINED RECYCLE PUMPS.
THE SYSTEM IS STILL OPERATING WITH TWO BOILERS COUPLED INTO THE
SCRUBBING SYSTEM. THE FIFTH SCRUBBING VESSEL WAS TAKEN OUT OF SERVICE
FOR REPAIRS AND MODIFICATIONS REQUIRED FOR THE RUBBER-LINED RECYCLE
PUMPS. THE UTILITY IS CURRENTLY CONDUCTING A PERFORMANCE TEST ON
THE SCRUBBING SYSTEM IN THE TWO BOILER OPERATION MODE. THE IUCS
SLUDGE FIXATION METHOD IS STILL CONTINUING AT THIS FACILITY.
THE FIFTH SCRUBBING VESSEL EMPLOYING TWO RUBBER-LINED RECYCLE PUMPS
WAS OPERATIONAL FOR A SHORT PERIOD OF TIME DURING THE REPORTING
MONTHS. TWO BOILERS REMAIN COUPLED INTO THE SCRUBBING SYSTEM. THE
CONSTRUCTION OF ADDITIONAL EQUIPMENT AT THIS FACILITY IS CONTINUING*
ADDITIONAL LIME STORAGE SILOS AND A THICKENER WILL BE REQUIRED
FOR FULL SCALE OPERATION. THE UTILITY HAS SIGNED A LETTER OF INTENT
WITH IUCS FOR A LONG-TERM SLUDGE FIXATION SYSTEM. HIGH CALCIUM LIME
IS STILL BEING EMPLOYED IN THE SCRUBBING SYSTEM.
OPERATIONS AT THIS STATION DURING THE REPORT PERIOD PROCEEDED WITH
73
PEDCO ENVIRONMENTAL
-------
PERIOD
OCT. 76
BOILER SCRUBBER VESSELS
OPERATING HOURS
NOV. 76
DEC. 76
ELRAMA POWER STATION (CONTINUED)
COMMENTS
TWO BOILERS COUPLED INTO THE 5-HODULE SCRUBBING SYSTEM. THE STH
SCRUBBING VESSEL WAS OPERATIONAL DURING THE REPORT PERIOD WITH THE
RUBBER-LINED RECYCLE PUMPS IN SERVICE. TESTS WERE CONDUCTED DURING
THE PERIOD TO DETERMINE PARTICULATE AND «02 REMOVAL EFFICIENCIES. S02
REMOVAL EFFICIENCY WAS 50 PERCENT. PARTICULATE EMISSIONS WERE BEING
REDUCED WELL BELOW THE 0.1 LB/MM BTU STANDARD (ACTUAL RESULTS* O.OH
LB/MM BTU). THESE RESULTS WEKC BASED ON 2 BOILERS COUPLED INTO THE 5
SCRUBBING MODULES WHILE BURNING MEDIUM SULFUK U.O TO 2.6 PERCENT)
COAL. THE MECHANICAL COLLECTORS AND ESP'S WERE IN SERVICE DURING
THE TESTS. OPERATIONS ARE STILL PROCEEDING ON AN OPEN-WATER-LOOP
BASIS. PART OF THE THICKENER OVERFLOW IS STILL BEING DIVERTED TO THE
ASH POND AND NOT RECYCLED BACK TO THE PROCESS, BECAUSE BOTH THE
BEAVER VALLEY AND BRUCE MANSFIELD STATIONS ARE FULLY OPERATIONAL,
THIS STATION HAS BEEN RELEGATED TO PEAK LOAD OPERATIONS. GENERAL LOAD
OPERATIONS ARE FULL LOAD CAPACITY IN THE DAYTIME AND 50 TO 60 PERCENT
LOAD REDUCTION AT NIGHT.
THE SCRUBBER REMAINED IN SERVICE THROUGHOUT THE RPPORT PERIOD WITH
TWO BOILERS COUPLED INTO THE SCRUBBING SYSTEM. RECYCLE PUMP EVALUA-
TION IS BEING CONDUCTED BY THE UTILITY AT BOTH THE PHILLIPS AND
ELRAMA STATIONS. OBSERVATIONS OF THE RUBBER-LINED RECYCLE PUMPS
INDICATE SOME SEVERE ABRASION AND GOUGING HAVE OCCURRED AFTER 1000
HOURS OF SREVICE TIME.
PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
3
-------
BACKGROUND INFORMATION
ON
PHILLIPS POWER STATION
THE PHILLIPS POWER STATION IS LOCATED ON THE OHIO RIVER ABOUT 20 MILES NORTHWEST OF PITTSBURGH. THE POWER STATION CONSISTS
OP SIX COAL-FIRED BOILERS HAVING A NET GENERATING CAPABILITY'OF 307 MW. THE RESULTANT FLUE GASES ARE DISCHARGED TO A COMMON
HEADER. TO WHICH THE FGD MODULES ARE CONNECTED THROUGH ISOLATION VALVES. THE BOILERS ARE CURRENTLY BURNING COAL WITH A HEATING
VALUE OF 11.350 BTU PER POUND AND SULFUR AND ASH CONTENTS OF 2.2 AND 18.2 PERCENT, RESPECTIVELY.
THE FGD SYSTEM, WHICH SUPPLEMENTS THE EXISTING MECHANICAL AND ELECTROSTATIC DUST COLLECTORS, CONSISTS OF FOUR TRAINS OF WET
VENTURI-TYPE SCRUBBERS, INSTALLED AT A COST OF APPROXIMATELY S103/KW. GIBBS & HILL, INC.. WAS ENGAGED AS THE A-E FIRM FOR THE
ENTIRE PROJECT* BATTERY LIMITS OF THE CHEMICO CORPORATION ARE CONFINED TO THE SCRUBBERS AND ASSOCIATED PUMPS AND CONTROLS BETWEEN
THE INLET HOT GAS DUCT MANIFOLD AND THE EXIT WET GAS HEADER (INCLUDING THE REHEATER, EXCLUDING THE NEW ID FANS>.
THE FOUR TRAINS ARE LOCATED DOWNSTREAM OF EXISTING MECHANICAL COLLECTORS AND ESP'S INSTALLED IN SERIES ON EACH OF THE SIX
PULVERIZED-COAL-F1RED BOILERS. THREE OF THE TRAINS ARE SINGLE-STAGE VENTURI SCRUBBERS ORIGINALLY INTENDED FOR PARTICULATE REMOVAL.
THE FOURTH TRAIN IS A DUAL-STAGE VENTURI SCRUBBER-ABSORBER AND IS THE PROTOTYPE FOR DETERMINING THE FEASIBILITY OF TWO-STAGE
SCRUBBING FOR COMPLIANCE WITH SULFUR DIOXIDE EMISSION LIMITS. A DIAGRAM OF THE SCRUBBER-ABSORBER TRAIN INSTALLED AT THE PHILLIPS
STATION IS PRESENTED IN FIGURE 6 OF APPENDIX C.
EACH TRAIN IS EQUIPPED WITH A NEW WET-TYPE ID FAN. A NEW COMMON DUCT DIRECTS GAS STREAMS FROM AIR BOILERS TO THE SCRUBBER
SYSTEM. WHERE THEY CAN BE SENT TO ANY OR ALL OF THE TRAINS. THE SCRUBBED GAS IS EXHAUSTED THROUGH A COMMON DUCT AND AN OIL-FIRED
REHEATER TO A NEW GROUND-SUPPORTED STACK, WHICH CONTAINS AN INNER ACID-RESISTANT BRICK STACK.
SLAKED QUICKLIME IS ADDED TO THE LOWER CONE OF EACH OF THE SCRUBBER VESSELS TO NEUTRALIZE THE RECIRCULATING LIQUOR, WHICH, IN
SINGLE-STAGE SCRUBBING WITH HIGH-CALCIUM LIME, REACTS WITH APPROXIMATELY 50 PERCENT OF THE SULFUR DIOXIDE IN THE FLUE GAS. A
LIQUOR BLEED FLOW OF APPROXIMATELY
-------
PHILLIPS POWER STATION NCONTINUEO)
DROPLETS ARE REMOVED BEFORE THE 6AS LEAVES THE SCRUBBER.
STARTUP OF A PORTION OF THE PHILLIPS SCRUBBER SYSTEM BEGAN JULY 1973. SEVERAL PROBLEMS THEN DEVELOPED IN THE FORM OF EROSION
OF FANS AND THE LIME FEED SYSTEM, CAUSING OUTAGES OF THE SCRUBBER SYSTEM. AFTER AN EXTENDED OUTAGE* THE SCRUBBER SYSTEM WAS
RETURNED TO SERVICE IN MARCH 197t. THE SYSTEM HAS BEEN OPERATING CONTINUOUSLY SINCE THAT TIME WITH VARIOUS NUMBERS OF BOILERS
CONNECTED TO THE SCRUBBER SYSTEM AND SCRUBBER TRAINS IN SERVICE.
DETERMINATION OF THE AVAILABILITY OF THE PHILLIPS SYSTEM HAS BEEN DIFFICULT. UNTIL ALL BOILERS WERE CONNECTED TO THE SCRUB*
BERS, THERE WAS AT LEAST ONE SPAKE TRAIN AND AS MUCH AS 100 PERCENT SPARE SCRUBBER CAPACITY. THEREFORE , HAVING A TRAIN OUT OF
SERVICE FOR MAINTENANCE DID NOT REDUCE THE CAPABILITY OF THE SCRUBBER SYSTEM. UNTIL ALL SIX BOILERS WERE CONNECTED. MEANINGFUL
AVAILABILITY FACTORS COULD NOT BE COMPUTED. ON MARCH 17, 1975, THE SIXTH BOILER WAS CONNECTED* AND ALL FOUR SCRUBBER TRAINS WERE
REQUIRED TO BE IN SERVICE. OPERATION IN THAT MODE CONTINUED UNTIL AUGUST «», 1975, WHEN THE NO. 6 BOILER WAS REMOVED FROM THE
SCRUBBER SYSTEM BECAUSE THE PH LEVEL COULD NOT BE MAINTAINED AND DEPOSITS BECAME UNMANAGEABLE TO THE POINT THAT SCRUBBER OUTAGES
WERE REDUCING GENERATING CAPABILITY OF THE STATION.
77 PEDCO ENVIRONMENTAL
-------
PHILLIPS POWER STATION
OPERATING HOURS
BOILER SCRUBBER-ABSORBER
MONTH 1234 5 6 101 201 301 401 COMMENTS
FOURTH FGD TRAIN AND SIXTH BOILER WERE TIED IN ON
MARCH 17, 1975. PARTICIPATE TESTS IN MAY SHOWED
JUL. 75 63 64«t 70S 349 60S 643 400 180 531 723 OUTLET LOADINGS OF 0.01 LB/MILLION BTU. THE TWO-
STAGE TRAIN HAS BEEN OUT OF SERVICE FROM JUNE 19
FOR GENERAL CLEANING AND REPAIR OF A LEAK IN THE
FIRST-STAGE SCRUBBER.
AUG. 75 354 701 454 457 517 445 478 682 323 319 SCRUBBER UNAVAILABILITY FORCED RETURNING BOILER
NO, 6 TO THE SCRUBBER BYPASS GAS PATH TO PREVENT
LOSS OF BOILER CAPACITY. PLUGGING AND MAINTENANCE
PROBLEMS HAVE BEEN ENCOUNTERED. EVALUATION OF
VARIOUS RECYCLE PUMPS IS CONTINUING.
SEP. 75 463 287 669 503 672 525 57 561 685 536 IN OCTOBER 1975, PHILLIPS INITIATED THIOSORBIC
OCT. 75 547 575 620 604 681 687 607 207 505 487 LIME SCRUBBING IN THEIR SINGLE-STAGE MODULES ON AN
EXPERIMENTAL BASIS. THE PURPOSE IS TO STUDY
COMPLIANCE FEASIBILITY. S02 REMOVAL EFFICIENCY*
AND QUALITY OF THE SLUDGE GENERATED BY THE SINGLE-
STAGE MODULES.
NOV. 75 16 720 688 70 720 593 626 720 0 75 THE UTILITY CONCLUDED THE THIOSORBIC LIME TESTING
DEC. 75 172 660 709 0 689 547 360 661 182 386 PROGRAM IN MID-DECEMBER. FOUR BOILERS WERE COUPLED
TO THE SCRUBBING SYSTEM DURING THE RUN. THE
UTILITY IS NOW ANALYZING THE DATA GENERATED DURING
THE TEST PROGRAM. THE SCRUBBERS HAVE BEEN PUT
BACK ON REGULAR LIME. NO UNUSUAL PROBLEMS WERE
ENCOUNTERED DURING THE TEST RUN.
JAN. 76 222 722 639 0 662 661 277 536 101 707 THE 2.5-MONTH TEST PROGRAM WITH THIOSORBIC LIME
78 PEOCO ENVIRONMENTAL
-------
PHILLIPS POWER STATION (CONTINUED)
OPERATING HOURS
BOILER SCRUBBER-ABSORBER
MONTH 1234 5 6 101 201 301 401 COMMENTS
INCLUDED 1612 SERVICE HOURS ON ONE TRAIN AND 1309
HOURS ON ANOTHER TRAIN. RESULTS INDICATE THAT
THE REQUIRED DEGREE OF So2 REMOVAL (83 PERCENT)
CAN BE OBTAINED WITH AN MGO CONTENT OF 8-10
PERCENT IN THE LIME WITH SINGLE-STAGE SCRUBBING.
FEB. 76
-------
PHILLIPS POWER STATION (CONTINUED)
MONTH
BOILER
Z 3
OPERATING HOURS
SCRUBBER-ABSORBER
101 201 301 101
JUL. 76
AUG. 76
COMMENTS
SCHEDULED TURBINE OVERHAUL TO UNIT NO. 6. THE
SCRUBBING SYSTEM WAS SHUT DOWN ON JUNE 27 FOR A
SCHEDULED FOUR WEEK REPAIR PERIOD. THE MAJORITY
OF THE WORK WILL BE CONCENTRATED ON THE STACK*
ASSOCIATED DUCTWORKt AND BOILER DAMPERS. ALSO,
THE UTILITY IS PROCEEDING WITH THE INSTALLATION OF
3 ADDITIONAL LIME STORAGE SILOS AND A THIRD
THICKENER.
THE 4-WEEK SYSTEM OVERHAUL WAS COMPLETED JULY 25.
DURING THIS PERIOD, THE FOLLOWING REPAIRS AND
MODIFICATIONS WERE MADE*
REPAIR OF THE TURNING VANES TO THE SCRUBBER
DEMISTER.
REPAIR OF THE EXPANSION JOINT SEAL WHERE THE
DUCTWORK TIES INTO THE MAIN STACK.
REPAIR OF STEEL BANDS AROUND INNER STACK
STRUCTURE.
OVERHAUL OF 1.0. FANS.
REPAIR OF BOILER EXIT DAMPERS.
REPAIR LEAKAGE OF THE ACID-BRICK LINING IN
THE MAIN STACK.
THE THREE ADDITIONAL LIME STORAGE SILOS AND THE
FOUNDATION FOR THE ADDITIONAL 75-FOOT DIAMETER
THICKENER HAVE BEEN INSTALLED. THE UTILITY
HAS SIGNED A LETTER-OF-INTENT WITH IUCS FOR A
60
PEOCO ENVIRONMENTAL
-------
PHILLIPS POWER STATION (CONTINUED)
MONTH
SEP. 76
OCT. 76
BOILER
2 3
OPERATING HOURS
SCRUBBER-ABSORBER
101 201 301 401
TOTAL SCRUBBER HOURS* 23*274
TOTAL BOILER HOURS* 63*642
TOTAL SCRUBBER OUTA&E TIME* s*soo
TOTAL SCRUBBER AVAILABILITY HOURS* 23*274
AVERAGE HU LOAD/ SCRUBBER OPERATION HOUR* 243
TOTAL OPERABILITT INDEX* 28 PERCENT
COMMENTS
LONG-TERM SLUDGE TREATMENT SYSTEM.
BOILER NOS. 2-6 WERE COUPLED INTO THE SCRUBBING
SYSTEM. BOILER NO. 1 IS DOWN FOR OVERHAUL AND
REPAIRS. THE IUCS INTERIM SLUDGE PROCESSING
PLANT IS UNDER CONSTRUCTION AND WILL BE IN SERVICE
BY DECEMBER 1976. THE TEMPORARY FACILITIES WILL
PROCESS THE THICKENER UNDERFLOW AND PONDED
SLUDGE UNTIL THE POND IS DEPLETED OF SLUDGE AND
THE PERMANENT FACILITY HAS BEEN INSTALLED.
SCRUBBING OPERATIONS ARE STILL PROCEEDING IN AN
OPEN-WATER-LOOP MODE WITH PART OF THE THICKENER
OVERFLOW BEING DIVERTED TO THE ASH POND.
BECAUSE BOTH THE BEAVER VALLEY AND BRUCE MANSFIELD
STATIONS ARE FULLY OPERATIONAL* THIS STATION HAS
BEEN RELEGATED TO PEAK LOAD OPERATIONS. GENERAL
LOAD OPERATIONS ARE FULL LOAD CAPACITY IN THE
DAYTIME AND SO TO 67 PERCENT LOAD REDUCTION AT
NIGHT.
THE FIGURES IN THE LEFT-HAND COLUMNS HAVE BEEN
COMPILED BY THE UTILITY FOR SYSTEM OPERATIONS FOR
THE PERIOD FOLLOWING START-UP IN JULY 1973 INCLUSIVE
TO OCTOBER 1976. THE TOTAL SCRUBBER HOURS VALUE IN-
CLUDE OPERATION TIME WHEN ONE OR MORE OF THE MODULES
WERE IN SERVICE. TOTAL BOILER AND UNAVAILITY VALUES
APPLY FOR ALL THE CORRESPONDING UNITS. THE TOTAL
61
PEOCO ENVIRONMENTAL
-------
PHILLIPS POWER STATION (CONTINUED)
BOILER
OPERATING HOURS
SCRUBBER-ABSORBER
NOV. 76
DEC. 76
SCRUBBER AVAILABILITY INDEX INCLUDES THE TIME WHEN
ONE OR MORE MODULES WERE AVAILABLE FOR SERVICE.
THE UTILITY REPORTS THAT BOILERS 2-6 REMAINED
COUPLED INTO THE SCRUBBING SYSTEM DURING THE REPORT
PERIOD. THE INTERIM UICS FIXATION FACILITY WAS IN-
STALLED AND COMMENCED OPERATIONS IN DECEMBER. THE
UTILITY REPORTS THAT THE VENTURI SCRUBBERS ARE STILL
DEVELOPING LARGE AMOUNTS OF SCALE ON THE INTERNALS.
RESULTING IN TWICE NORMAL PRESSURE DROPS. THE RECYCLE
PUMP EVALUATION HAS BEEN IN PROGRESS. APPROXIMATELY
2500 TO 2800 HOURS OF OPERATION TIME HAVE BEEN AC-
CUMULATED ON THE VARIOUS UNITS WITH NO FAILURES OR
APPRECIABLE WEAR OBSERVED. THE ADDITIONAL OEWATERING
AND REAGENT PREPARATION EQUIPMENT IS NOW BEING IN-
STALLED. THE CONTRACT HAS BEEN AWARDED TO DRAVO TO
PROVIDE THIOSORBIC LIME FOR THIS SCRUBBING SYSTEM.
PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
36
GENERAL MOTORS
CHEVROLET PARMA 1234*
PARMA OHIO
32 MM
COAL 2.5 PERCENT SULFUR
KOCH/GENERAL MOTORS
DOUBLE ALKALI SCRUBBING
RETROFIT
3/7t
OPERATIONAL
60 PERCENT
S02
90 PERCENT
WATER MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
S3.2 MILLION CAPITAL * S11.70 PER TON OF COAL ANNUALIZEO
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THESE f-COAL FIRED STOKER BOILERS
CONSISTS OF MECHANICAL COLLECTORS INSTALLED UPSTREAM OF A DILUTE DOUBLE
ALKALI SCRUBBING SYSTEM. THE FGD SYSTEM HAS BEEN IN SERVICE SINCE MARCH
197H. SYSTEM OPERABILITY INDEX VALUES FOR THE MONTHS OF NOVEMBER AND
DECEMBER WERE 60 PERCENT AND 22 PERCENT, RESPECTIVELY. THE ANNUAL
SYSTEM OPERABILITY INDEX VALUE FOR 1976 AVERAGED 6<* PERCENT.
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE CHEVROLET PARMA STEAM PLANT
THE CHEVROLET PARMA PLANT OF GENERAL MOTORS IS LOCATED NEAR CLEVELANDt OHIO. THE PLANT HAS FOUR SPREADER-STOKER BOILERS
FIRED BY TRAVELING GRATES. CAPABLE OF PRODUCING A TOTAL OF 320,000 LB/HR OF STEAM OR APPROXIMATELY 32 MU OF EQUIVALENT ELECTRICAL
CAPACITY. THE COAL FIRED IN THESE UNITS ORIGINATES PRIMARILY FROM THE SOUTHEASTERN PORTION OF OHIO AND HAS THE FOLLOWING AVERAGE
CHARACTERISTICS* HEAT CONTENT OF XI,300 TO 13,900 BTU/LB* SULFUR CONTENT OF 1.7 TO 2.7 PERCENT* ASH CONTENT OF 6.a TO m.6
PERCENT* AND A TOTAL MOISTURE CONTENT OF 0.9 TO 7.8 PERCENT.
THE POWER BOILERS HAVE BEEN FITTED WITH AN EMISSION CONTROL SYSTEM CONSISTING OF MECHANICAL COLLECTORS UPSTREAM OF A DILUTE
DOUBLE ALKALI SCRUBBING SYSTEM. THE FGD SYSTEM SCRUBBING MODULES WERE SUPPLIED BY KOCH ENGINEERING. INSTALLATION WAS COMPLETED
ON FEBRUARY 26, 197t. THE SYSTEM CONSISTS OF FOUR SCRUBBERS OPERATING IN PARALLEL. EACH SCRUBBER CONTAINS THREE BUBBLE-CAP
ABSORPTION TRAYS AND A MESH MIST ELIMINATOR.
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 SULFlTE AND SULFATE SOLIDS, WHICH ARE SEPARATED OUT OF THE SOLUTION. NEXT, SODA ASH IS
AODED 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 FORMEU IS THEN RECYCLED BACK TO THE SCRUBBER FOR ADDITIONAL SULFUR DIOXIDE REMOVAL. THE
CALCIUM SALT AND FLY ASH SLUDGE WHICH RESULTS IS DEWATERED AND HAULED AWAY BY TRUCK TO AN OFF-SITE LANDFILL.
PROBLEMS 'AND SOLUTIONS
THE SYSTEM WAs STARTED UP ON FEBRUARY 26, 197t AND BY APRIL 31 IT HAD OPERATED FOR 62
-------
CHEVROLET PARMA (CONTINUED>
SIGN OR ABRASION IN THE PUMPS OR PIPING.
THE SYSTEM WAS SHUT DOWN FROM MAY 1 TO MAY 28f 1974* BECAUSE OF UNEXPECTED BUILDUP OF SOLIDS IN THE CLARIFIERt WITH SUBSE-
QUENT OVERFLOW INTO THE SCRUBBER. THE PROBLEM WAS SOLVED BY 1) USING A POLYMERIC FLOCCULATION AGENT TO ATTAIN BETTER SETTLING AND
2) WITHDRAWING SLUDGE FROM THE CLARIFIER AT MORE FREQUENT INTERVALS. SYSTEM AVAILABILITY TO THE BOILER WAS 67 PERCENT IN APRIL
197«H LESS THAN 10 PERCENT IN MAYt AND 100 PERCENT IN JUNE, JULY. AND AUGUST AFTER THE SYSTEM WAS RESTARTED. PLUGGING BY GYPSUM
DEPOSITS IN THE OVERFLOW LINE BETWEEN THE CLARIFIERS AND IN THE LINE FROM CLARIFIER NO. 2 TO THE MIX TANKS WAS CORRECTED BY
RELOCATING A CHEMICAL FEED LINE AND REPLACING SOME PIPING. THE SYSTEM WAS DOWN THROUGHOUT JULY AND AUGUST FOR REPLACEMENT OF
GRAVITY FLOW LINES WITH AN OPEN FLUME THAT CAN BE EASILY CLEANED. ADDITIONAL MODIFICATIONS TO THE DESIGN AND OPERATION OF THE FGD
SYSTEM HAVE CONTINUED. THE OPERABILITY INOEX FOR THE FGD SYSTEM HAS INCREASED SIGNIFICANTLY THROUGHOUT THE COURSE OF 1976. THE
MAJOR PROBLEM AND SOLUTION AREAS, PLUS MODIFICATIONS IMPLEMENTED TO THE SYSTEM ARE HIGHLIGHTED BELOW IN THE SYSTEM PERFORMANCE
TABLE. A PROCESS FLOW DIAGRAM OF THE DOUBLE ALKALI UNIT IS PRESENTED IN FIGURE 7 OF APPENDIX C.
65 PEOCO ENVIRONMENTAL
-------
CHEVROLET PARMA
MONTH
JUN. 75
BOILER
1 2
OPERATION HOURS
F60 SYSTEM
2 3
OPERABILITY (X>
234
JUL. 75
AUG. 75
SEP. 75
OCT. 75
NOV. 75
DEC. 75
2331*
16«»8*
79
2135
1250
59
COMMENTS
RECENT OPERATION HAS BEEN INTERMITTENT.
TESTS HAVE BEEN CONDUCTED FOR ANALYSIS
OF PARTICIPATE LOADING AT THE BOILER
OUTLET. THE SYSTEM WAS RESTARTED IN MAY
BUT WAS SHUT DOWN BECAUSE OF A PLUGGED
CHEMICAL FEED LINE TO CLARIFIER. AFTER
RESTART* AROUND JUNE 10t THE SYSTEM WAS
SHUT DOWN BECAUSE OF SIMILAR PLUGGING IN
ANOTHER PART OF THE LINE. UNIT RAN FOR
ABOUT 2 WEEKS IN JUNE.
FGD SYSTEM WAS DOWN IN JULY AND AUGUST
FOR REPLACEMENT OF GRAVITY FLOW LINES
WITH AN OPEN FLUME.
FGD SYSTEM RESTARTED SEPTEMBER 8t AND
OPERATED DURING THIS PERIOD AT AN
AVAILABILITY FACTOR OF 80 PERCENT.
NOTE THE FIGURES GIVEN FOR SEPTEMBER
AND OCTOBER REPRESENT THE OPERATION
HOURS FROM SEPTEMBER a TO NOVEMBER 9
THE FGD SYSTEM OPERATED DURING THE
REPORT PERIOD EXCEPT FOR A SCHEDULED
HOLIDAY SHUTDOWN FROM DECEMBER 23 TO
JANUARY Hi 1976. BECAUSE OF PROBLEMS
WITH SOLIDS AND SOLIDS CARRYOVER* G.M.
PEOCO ENVIRONMENTAL
-------
CHEVROLET PARMA
MONTH
BOILER
2
OPERATION HOURS
F60 SYSTEM
Z 3
OPERABILITY (*)
234
JAN. 76
FEB. 76
2997
1196
NAR. 76
1379
240
APR.
1064
647
78
MAY 76
JUN. 76
1149
924
1042
616
91
86
87
COMMENTS
CONDUCTED STREAM TESTS DURING DECEMBER
TO DETERMINE WHETHER SOLIDS CARRYOVER
IS DUE TO A HIGH SOLIDS RECIRCULATION
RATE. THE FGD SYSTEM WAS DOWN MOST OF
DECEMBER BECAUSE OF THESE TESTS* WHICH
CAUSED THE LOW OPERABILITY FACTOR.
G.M. HAS FOUND SOLIDS CONCENTRATION IN
THE CLARIFIER TOO HIGH FOR EFFICIENT
SYSTEM OPERATION.A.D.LITTLE IS SCHEDULED
TO CONDUCT TESTS ON THE SYSTEM IN APRIL
AS PART OF AN EPA EVALUTATlON PROGRAM.
THE LOW OPERABILITY INDEX DURING THE
MONTH OF MARCH RESULTED FROM EXTENSIVE
MODIFICATIONS PERFORMED ON THE SYSTEM BY
6.M. DURING THIS PERIOD THE SCRUBBER
BLOWDOWN AND SCRUBBER FLOW INDICATION
SYSTEM WAS REVISED.
FROM APRIL 19 TO THE END OF THE MONTH
THE SYSTEM WAS OPERABLE 100X. DURING
THIS PERIOD ALL SYSTEM MODIFICATIONS
WERE COMPLETEP. AND ALL MAJOR PROBLEM
AREAS CORRECTED.
NO MAJOR PROBLEMS WERE ENCOUNTERED
DURING THE REPORTING PERIOD.
ONE SYSTEM UPSET OCCURRED DURING THE
PCDCO ENVIRONMENTAL
-------
CHEVROLET PARMA (CONTINUED)
OPERATION HOURS
BOILER F6D SYSTEM OPERABILITY («)
MONTH 12 3
-------
CHEVROLET PARMA (CONTINUED)
OPERATION HOURS
BOILER F60 SYSTEM OPERABILITY (X)
MONTH 123H1231123H COMMENTS
INITIAL PART OF THE MONTH. A NUMBER OF
PROBLEMS WERE ENCOUNTERED* FORCING A SHUT-
DOWN THROUGHOUT THE REMAINDER OF THE MONTH,
THESE INCLUDED*
SOLIDS DEPOSITION AND PLUGGING OF THE
CHEMICAL TANKS AND REACTORS. REQUIRING
SHUTDOWN AND CLEANOUT.
AGITATOR PROBLEMS.
BOILER PROBLEMS.
REPLACEMENT OF DEMISTER PADS.
OCT. 76 117* 73* 63 THE SYSTEM WAS RETURNED TO SERVICE THE SECOND
WEEK IN OCTOBER* TWO BOILERS AND THEIR
CORRESPONDING SCRUBBERS WERE PUT BACK IN THE
GAS STREAM. PROBLEMS ENCOUNTERED STEMMED
PRIMARILY FROM A MECHANICAL COLLECTOR MAL-
FUNCTION*RESULTING IN EXCESSIVE DUST LOADINGS
IN THE MODULES AND EVENTUALLY CAUSING WIDE-
SPREAD PLUGGING OF THE LOWER BUBBLE-CAPE
TRAYS. SHUTDOWN AND CLEANOUT Op THE 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*
INSTALLATION Op A GREAT LAKES PH MONITOR
69 PEUCO ENVIRONMENTAL
-------
MONTH
BOILER
1 2
OPERATION HOURS
FGD SYSTEM
2 3
CHEVROLET PARMA (CONTINUED)
OPERABILITY (X)
23*
NOV. 76
DEC. 76
1321
1559
787
349
60
22
COMMENTS
AND CONTROL UNIT FOR THE REGULATION OF
LIME FEED TO THE REGENERATION REACTOR-
CLARIFIER UNIT. THIS UNIT EMPLOYS A
DIGITAL READOUT AND IS SCHEDULED FOR
OPERATION SOMETIME IN NOVEMBER.
SUPERIOR CRYSTAL GROWTH OF THE CALCIUM
SULFITE/SULFATE SALTS HAS RESULTED BY
RUNNING A SEEDING LINE BACK TO THE
REACTOR-CLAKIFIER UNIT.
THE FGO FIGURES REPORTED FOR THE MONTH OF
DECEMBER ARE SOMEWHAT DISTORTED BECAUSE UAW
PERSONNEL CAN ONLY OPERATE THE SYSTEM AND
THEREFORE THE SCRUBBERS COULD NOT BE OPERATED
DURING THE CHRISTMAS HOLIDAY PERIOD. DURING THE
LATTER PART OF NOVEMBER AND EARLY DECEMBER
PERIOD THE SCRUBBERS WERE TAKEN OUT OF THE FLUE
GAS PATH BECAUSE OF CONTINUED SOLIDS BUILD UP
IN THE MIX TANK. IN ADDITION, SOME PIPING AR-
RANGEMENTS WERE MODIFIED AND THE GEAR REDUCER
IN THE MIX TANK HAD TO BE REPLACED.
90
PEOCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
37
GULF POWER CO.
SCHOLZ NOS. IB 4 28
CHATTAHOOCHEE FLORIDA
23 MW
COAL 5.0 PERCENT SULFUR (MAX)
CHIYODA INTERNATIONAL
THOROUGHBRED 101
RETROFIT
3/75
OPERATIONAL
99.7 PERCENT
90 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
OPEN LOOP
UNSTABILIZED SLUDGE DISPOSED IN DRY GYPSUM POND
UNIT COST
OPERATIONAL
EXPERIENCE
S3 MILLION CAPITAL COST
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS PROTOTYPE DEMONSTRATION UNIT WAS FIRST PUT INTO THE FLUE GAS PATH
ON FEBRUARY 11.1976. THE OPERABILITY INDEX FOR OPERATIONS DURING 1975
WAS 60 PERCENT. THE UNIT WAS IN SERVICE THROUGHOUT THE REPORT MONTHS,
ACHIEVING OPERABILITY INDEX VALUES OF 99.5 AND 99.6 PERCENT,RESPECTIVELY.
THE ANNUAL AVERAGE OPERABILITY INDEX VALUE FOR 1976 OPERATIONS WAS 64
PERCENTJFOR 9 MONTHS OF OPERATION). THE PROTOTYPE FGD UNIT IS
SCHEDULED TO CONTINUE OPERATIONS THROUGHOUT THE COMING YEAR.
91
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
SCHOLZ UNITS 1 AND 2 - CHIYOOA
THE SCHOLZ POWER PLANT IS LOCATED IN CHATTAHOOCHEE, FLORIDA* ABOUT SO MILES WEST OF TALLAHASSEE. THE F6D SYSTEM WAS DESIGNED
BY CHIYOOA INTERNATIONAL CORP. FOR TESTING AND PROCESS DEMONSTRATION ON A COAL-FIRED APPLICATION. THE PROCESS IS USED IN JAPAN
EXCLUSIVELY ON OIL-FIRED AND GAS-FIRED BOILERS, AND TAIL GAS FROM CLAUS UNITS.
THE SYSTEM AT SCHOLZ CAN HANDLE ONE-HALF THE LOAD (53,000 SCFM) FROM EITHER OF THE
-------
SCHOLZ IB AND 2B - CHIYODA
TOTAL
MONTH HOURS
FEB. 75 672
APR. 75 720
HAY 75 744
JUN. 75 720
JUt. 75 744
AUG. 75 744
SEP. 75 720
OCT. 75 744
NOV. 75 720
UNIT OPERATING HOURS
BOILER FGO SYSTEM
672
720 200
744 100
FGO SYSTEM PERFORMANCE (X)
OPERABILITY UTILIZATION
28
13
26
13
685
744
685
624
100
84
95
84
720
0
337
46
46
744
720
744
720
100
100
000
100
COMMENTS
THIS IS A PILOT PLANT SIZE DEMONSTRATION UNIT.
1973. INITIAL SHAKEDOWN AND DEBUGGING OPERATIONS
COMMENCED ON FEBRUARY 11, 1975. PROBLEMS
ENCOUNTERED INCLUDED CRACKS IN THE FRP LINING AT
THE OXIDIZING TOWER. STARTUP OCCURRED IN MARCH
1975. AFTER INITIAL OPERATION FOR BREAK-IN TESTS,
THE UNIT WAS SHUT DOWN FOR INTERNAL INSPECTION.
RELIABILITY TESTS THEN FOLLOWED IN JULY 1975.
CHEMICAL PERFORMANCE WAS SATISFACTORY. EMISSION
TESTS HAVE NOT BEEN PERFORMED. SOME PUMP AND
INSTRUMENT FAILURES HAVE OCCURRED.
A 100 PERCENT OPERABILITY FACTOR WAS REGISTERED
FOR THE MONTH OF JUNE. DURING THE MONTH OF JULY
ONE CENTRIFUGE BECAME UNBALANCED, REQUIRING THE
SPARE TO BE PLACED IN SERVICE.
DURING THE MONTH OF AUGUST BOTH CENTRIFUGES BECAME
UNBALANCED REQUIRING A FORCED OUTAGE WHICH
EXTENDED TO MID-SEPTEMBER. UNIT OPERATED AT A
95 PERCENT SQ2 REMOVAL EFFICIENCY DURING THIS
PERIOD. GULF POWER IS ATTEMPTING TO UPGRADE THIS
VALUE TO A HIGHER EFFICIENCY LEVEL.
WASTE WATER DISCHARGE FROM THIS UNIT STILL A
PROBLEM AREA.
OUTAGE TIME WAS LESS THAN ONE HOUR DURING NOVEMBER
93
PEOCO ENVIRONMENTAL
-------
SCHOLZ IB AND 2B - CHIYOOA (CONTINUED)
MONTH
TOTAL
HOURS
DEC. 75
JAN. 76
FEB. 76
MAR. 76
APR. 76
MAY 76
JUN. 76
696
720
UNIT OPERATING HOURS
BOILER FGD SYSTEM
FGO SYSTEM PERFORMANCE (X)
OPERABILITY UTILIZATION
680
690
726
-------
SCHOLZ IB AND 2B - CHIYQOA (CONTINUED)
MONTH
TOTAL
HOURS
UNIT OPERATING HOURS
BOILER F60 SYSTEM
F6D SYSTEM PERFORMANCE (X)
OPERABILITY UTILIZATION
JUL. 76
AUG. 76
192
66
66
COMMENTS
THE REPORT PERIOD. SYSTEM RESTART IS
SCHEDULED FOR THE END OF JULY.
THE PROTOTYPE UNIT REMAINED OUT OF SERVICE
MAY. JUNE AND JULY TO REPAIR THE FIRE-DAMAGED
AREAS. THE SYSTEM WAS PUT BACK IN OPERATION
IN AUGUST. THE SYSTEM WAS AGAIN BROUGHT DOWN
DURING THE MONTH TO COMPLETE ADDITIONAL REPAIRS
WHICH WENT UNDETECTED DURING THE PREVIOUS
OUTAGE. 2
-------
SCHOL2 IB AND 2B - CHIYOOA (CONTINUED)
UNIT OPERATING HOURS
TOTAL FGD SYSTEM PERFORMANCE (X)
MONTH HOURS BOILER FGO SYSTEM AVAILABILITY OPERABILITY RELIABILITY UTILIZATION COMMENTS
SEP. 76 780 720 496 99 69 99 69 TOTAL FORCED OUTAGE TIME DURING
THE MONTH AMOUNTED TO 5.1 HOURS.
OCT. 76 744 744 357 70 48 62 48 TOTAL DOWN TIME DURING THE MONTH
AMOUNTED TO 386.9 HOURS. OF THIS
TOTAL 1.1 HOUR WAS ATTRIBUTED To A
FORCED SCRUBBER OUTAGE* 218 HOURS
WAS REQUIRED TO REPAIR EXPECTED
DAMAGES INCURRED IN THE PRE
SCRUB3ER RESULTING FROM OPERA-
TIONS IN THE WATER SAVINGS PROGRAM.
SPECIFICALLY« THE LINING WAS
SUFFERING FROM EXTENSIVE CORROSION
DAMAGE BECAUSE OF HIGH ACID
CONCENTRATIONS WHICH DEVELOPED
IN THE PKESCRUBBER SCRUBBER SOLU-
TION. THIS OUTAGE WAS SCHEDULED
FOR INSPECTION, REPAIR, AND
PROVIDE DESIGN DATA FOR FUTURE
UNITS. S02 REMOVAL EFFICIENCY
STILL RESIDES IN THE 85-95
PERCENT RANGE.
NOV. 76 720 720 717 99 99 99 99 A TOTAL OF THREE FORCED SCRUBBER
DEC. 76 744 744 741 99 99 99 99 OUTAGE TIME TOTALLING 6.5 MRS WAS
REPORTED BY THE SYSTEM SUPPLIER
FOR OPERATIONS DURING THE PERIOD.
96 PEDCO ENVIRONMENTAL
-------
SCHOLZ IB AND 2B - CHIYODA (CONTINUED) COMMENTS (CONTINUED)
PROBLEMS INCLUDED A MALFUNCTION
GRID VANE. AM OPERATOR CAUSED
THE OTHER OUTAGE.
97 PEOCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL. FGD SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS COAL 0.6- 3.0 PERCENT SULFUR
40
KANSAS CITY POWER ft LIGHT
HAWTHORN NO 3
KANSAS CITY MISSOURI
nw
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
COMBUSTION ENGINEERING
LIMESTONE INJECTION 2UET SCRUB
RETROFIT
11/72
OPERATIONAL
99 PERCENT
S02
70 PERCENT
WATER MAKE UP
OPEN LOOP 6.0 GPM/MW
SLUUGE DISPOSAL
UNSTABILIZED SLUUGE DISPOSED IN UNLINED POND
UNIT COST
S19/KW CAPITAL*2.5 MILS/KWH OP
OPERATIONAL
EXPERIENCE
KEFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS INJECTION ANU TAIL-END WtT SCRUBBING SYSTEM WAS DESIGNED AN£> IN-
STALLED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE NOVEMBER 1972.
OPERATION OF THIS SCRUBBING SYSTEM DURING 1976 HAS BEEN INTERMITTENT.
A NUfiUL'R OF MAJOR MODIFICATIONS ARE BEING PERFORMED TO THE SYSTEM SY THE
UTILITY.MAJOR CHANGES HAVE INCLUDED*CONVERSIOM FROM A LIMESTONE TO A LIME
INJECTION SYSTEM. OEMISTER WASH SYSTEM MODIFICATIONS. SCRUBBER BED SPRAY
SYSTEM MODIFICATIONS. AND MODIFICATIONS TO THE GAS DAMPER ARRANGEMENT.
98
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE HAWTHORN POWER STATION* UNIT NO. 3
THE HAWTHORN POWER STATION is LOCATED ON THE NORTH BANK OF THE MISSOURI RIVER IN EAST KANSAS CITY, MISSOURI. THE PLANT HAS
FIVE ELECTRIC GENERATING UNITS WITH A TOTAL RATED CAPACITY OF 980 MW. ONLY UNITS 3 AND H ARE RETROFITTED WITH FGD SySTEMS.
BOILER 3 IS A DRY-BOTTOM PULVERIZED-COAL-FIKED UNIT, MANUFACTURED BY COMBUSTION ENGINEERING AND INSTALLED IN EARLY 1950.
THE PLANT BURNS TWO GRADES OF COAL* THE COAL WITH HIGHER ASH CONTENT TYPICALLY CONTAINS it PERCENT ASH AND z PERCENT SULFUR.
WITH A HEAT CONTENT OF 11,400 bTU/LB* THE LOWER ASH COAL HAS 11 PERCENT ASH, 0.6 PERCENT SULFUR, AND A HEAT CONTENT OF 9600
BUT/LB.
THE FGD SYSTEM OPERATES ON LIMESTONE FURNACE INJECTION FOLLOWED BY A FLUE GAS WET-SCRUBBING SYSTEM IN WHICH BOTH THE SULFUR
DIOXIDE AND THE FURNACE-CALCINED LIMESTONE ARE SCRUBBED AND ALLOWED TO REACT IN A REACTION TANK.
THE FGD SYSTEM CONSISTS OF TWO IDENTICAL MODULES, EACH CAPABLE OF TREATING 500.000 ACFM OF FLUE GAS AT 300 F. BYPASSING OF
THE MODULES IS POSSIBLE THROUGH A SYSTEM OF DUCTWORK AND DAMPERS AROUND EACH MODULE, EACH MODULE CONSISTS OF A GLASS MARBLE BED,
A CHEVRON-TYPE FIBERGLASS DEMISTER, AND A FINNED TUBE REHEATER. THE DEMISTER WASH SYSTEM USES A SET OF EIGHT WATER LANCES THAT
TURN ON AUTOMATICALLY TO WASH MUD FROM THE DEMISTERS WHENEVER THE DAMPERS CLOSE.
THE SPENT LIMESTONE SLURRY FROM THE MODULES IS DISCHARGED INTO A CLARIFIER TANK, AND THE UNDERFLOW IS PUMPED, UNSTABILIZEO,
TO A 160-ACRE UNLlNED POND, WHICH IS ALSO USED FOR DISPOSAL OF FLY ASH FROM THE OTHER BOILERS. A PROCESS FLOW DIAGRAM OF THE
LIMESTONE INJECTIOfc AND TAIL-END WET LIME SCRUBBING SYSTEM INSTALLED ON THIS UNIT IS PRESENTED IN FIGURE 9 OF APPENDIX C.
PROBLEMS AND SOLUTIONS
THE MAJOR PROBLEMS ENCOUNTERED WITH THE TWO FGD SYSTEMS ON UNITS 3 AND
-------
HAWTHORN NO. 3
OPERATING HOURS F&O OPERABILITY IS)
MONTH BOILER MODULE 3A MODULE 3B MODULE A MODULE B COMMENTS
JUL. 75 56
-------
HAWTHORN NO. 3 (CONTINUED)
OPERATING HOURS FGD OPERABILITY (X)
MONTH BOILER MODULE 3A MODULE 38 MODULE A MODULE B COMMENTS
MAR. 76 0 0 00 0 RECONVERSION OF MODULE SB'S SPRAY SYSTEM ARRANGE-
MENT HAS BEEN COMPLETED.
APR. 76 0 0 00 0 ALSOt THE BYPASS SYSTEM HAS BEEN MODIFIED AND
CHANGED TO A SLIDE-GATE DAMPER ARRANGEMENT.
MAY 76 0 0 0 0 0 THE SYSTEM WAS SHUT DOWN DURING THE MONTH DUE TO
THE CONTINUATION OF MANPOWER SHORTAGE PROBLEMS.
THE UTILITY DID PERFORM SOME CLEANING AND REPAIRS
DURING THE MONTH.
JUN. 76 505 196 220 39
-------
HAWTHORN NO. 3 (CONTINUED)
OPERATING HOURS FGO OPERABILITY (X)
MONTH BOILER MODULE 3A MODULE HA
GO A SERIES OF TESTS TO INSURE COMPLIANCE WITH
CITY AND FEDERAL REGULATIONS.
102 PEOCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F60 VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
11
KANSAS CITY POWER £ LIGHT
HAWTHORN NO H
KANSAS CITY MISSOURI
100 MW
COAL 0.6- 3.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION *WET SCRUB
RETROFIT
6/72
OPERATIONAL
99 PERCENT
S02
70 PERCENT
WATEK MAKE UP
SLUUGE DISPOSAL
OPEN LOOP 8.0 GPM/MW
UNSTABILIZED SLUUGE DISPOSED IN UNLINEO POND
UNIT COST
OPERATIONAL
EXPERIENCE
S19/KW CAPITAL*2.2 MILS/KUH OP
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS INJECTION AND TAIL-END WET SCRUBBING SYSTEM WAS DESIGNED AND IN-
STALLED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE AUGUST 1972.
FGD SYSTEM OPERATIONS DURING 1976 HAVE PROCEEDED ON AN INTERMITTENT
BASIS. PROBLEMS ENCOUNTERED HAVE INCLUDED PLUGGING IN THE MARBLE BED
AND REHEAT TUBE BUNDLES, DRAFT LOSSES THROUGH THE DUCTWORK AND PUMP
FAILURES. THE UTILITY IS NOW CONVERTING THIS SYSTEM FROM LIMESTONE
INJECTION TO LIME INJECTION AND TAIL-END WET SCRUBBING.
103
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE HAWTHORN POEER STATION* UNIT NO.
-------
HAWTHORN NO.
-------
HAWTHORN NO. H
OPERATING HOURS FGD OPERABILITY (X)
MONTH BOILER MODULE HA MODULE US MODULE A MODULE B COMMENTS
JUL. 75 516 41 12fl B 25 MARBLE BED PLUGGING AND STRAINER PROBLEMS ON BOTH
MODULES.
AUG. 75 16^ 212 LOST HALF OF BOILER DUE TO NO. HB I.D. FAN OUTAGE.
BOTH FGD MODULES WERE SHUT DOWN TO ENSURE AGAINST
THE LOSS OF THE ENTIRE UNIT. NEW CHEMISTRY -
ATTEMPTING TO RUN AT 100* SLOWDOWN AND NEAR 0
PERCENT SOLIDS. EMPHASIS ON PARTICULATE CONTROL.
MAINTAINING PH AT 5 WITHOUT LIMESTONE INJECTION.
SEP. 75 395 206 210 52 53 SCRUBBER MODULES WERE RETURNED TO SERVICE ON
SEPT. 21 AFTER REPLACEMENT OF THE ORIGINAL I.D.
FAN ON MODULE
-------
HAWTHORN NO. H (CONTINUED)
OPERATING HOURS FGD OPERAblLITY (X)
MONTH BOILER MODULE HA MODULE HB MODULE A MODULE B COMMENTS
MOV. 75 720 0 713 0 99 MODULE HA WAS SHUT DOWN DURING THE REPORT PERIOD
BECAUSE OF LOSS OF DRAFT THROUGH THE DUCTWORK
FROM THE ECONOMIZER TO THE AIR PREHEATER. THE
REHEATER PLUGGED FREQUENTLY UNTIL THE SYSTEM WAS
SHUT DOWN.
DEC. 75 6*0 0 103 0 16 BOILER OUTAGE OF 5 DAYS WAS DUE TO A SCHEDULED
OVERHAUL.
JAN. 76 0 0 0 00 THE SYSTEM WAS DOWN ALL MONTH BECAUSE OF FROZEN
EQUIPMENT AND LINES* MANPOWER WAS ASSIGNED TO A
BOILER AND TURBINE OVERHAUL ON ANOTHER UNIT.
FEB. 76 579 0 450 0 76 MODULE HA WAS SHUT DOWN THE ENTIRE MONTH BECAUSE
OF CONTINUING LOSS OF DRAFT THROUGH THE DUCTWORK
FROM THE ECONOMIZER TO THE AIR PREHEATER. MARBLE
BED PLUGGING AND LOSS OF A RECYCLE PUMP OCCURRED
ON MODULE HB,
MAR. 76 706 0 2H 0 3.H DURING THE REPORT PERIOD THE UNIT'S BYPASS SEALS
APR. 76 550 231 220 H2 HO WERE REPLACED WITH SLIDE-GATE DAMPERS.
MAY 76 365 99 99 27 27 THE UTILITY REPORTS THE B-SIDE REHEATER IS STILL
JUN. 76 H60 29H 23 65 5 EXPERIENCING PLUGGING PROBLEMS. ONE SECTION OF
THE REHEAT TUBE BUNDLES HAS BEEN REMOVED IN
ORDER TO FACILITATE CLEANING AND MAINTENANCE.
JUL. 76 CURRENTLY? THE UTILITY IS IN THE PROCESS OF
AUG. 76 MODIFYING THE SCRUBBING SYSTEM FROM A LIMESTONE
INJECTION AND TAIL END BASED SYSTEM TO A LIME
107 PEOCO ENVIRONMENTAL
-------
HAWTHORN NO.
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 12/76
IDENTIFICATION NO,
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
42
KANSAS CITY POWER & LIGHT
LA CYGNE NO 1
LA CYGNE KANSAS
820 MW
COAL 5,0 PERCENT SULFUR
BABCOCK 2 UILCOX
LIMESTONE SCRUBBING
NEW
2/73
OPERATIONAL
98 PERCENT
S02
76 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
OPEN LOOP 1.4 GPM/MW
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
S52/KW CAPITAL * 0.94 MILLS/ KWH OPERATING COSTS
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT,
THIS 7-MODULE FGD SYSTEM HAS BEEN IN OPERATION SINCE FEBRUARY 1973,
THE ANNUAL SYSTEM OPERABILITY INDEX VALUE AVERAGED IN EXCESS OF
76 PERCENT FOR 1974. ANNUAL AVERAGE AVAILABILITY INDEX VALUES FOR
1975 AND 1976 EXCEEDED 8
-------
BACKGROUND INFORMATION
ON
LA CYGNE UNIT NO. 1
THE LA CYGNE: POWER STATION OF KANSAS CITY POWER AND LIGHT COMPANY BEGAN COMMERCIAL OPERATION ON JUNE i, 1973, AS A JOINT
PROJECT OF KANSAS GAS AND ELECTREC COMPANY AND KANSAS CITY POWER & LIGHT COMPANY. THE STATION IS LOCATED ABOUT 55 MILES SOUTH OF
KANSAS CITY, IN LINN COUNTY, KANSAS.
ELECTRIC POWER GENERATING FACILITIES CONSIST OF ONE 620 MW COAL-FIRED BASE-LOAD BOILER WITH ASSOCIATED STEAM TURBINES AND
ELECTRIC GENERATORS. THE PLANT HAS THREE OIL-FIRED BOILERS, USED PRIMARILY FOR STARTUP OF THE LARGE UNIT. THEIR COMBINED
CAPACITY IS EQUIVALENT TO 28 MW.
THE BOILER AT LA CYGNE, DESIGNED BY BABCOCK AND WlLCOX, IS A DRY-BOTTOM, PULVERIZED-COAL-FIRED CYCLONE UNIT. THE COAL
BURNED IS LOW-GRADE. SUBBlTUMlNOUS, WITH AN AS-FIRED HEATING VALUE OF 9000 TO 9700 BTU/L8 AND ASH AND SULFUR CONTENTS OF 25
PERCENT AND 5 PERCENT, RESPECTIVELY. POLLUTION CONTROL EQUIPMENT ON THIS BOILER CONSISTS OF SEVEN SCRUBBING MODULES, FOR THE
CONTROL OF PARTICULATE AND SULFUR DIOXIDE EMISSIONS. THIS SCRUBBING SYSTEM WAS DESIGNED AND CONSTRUCTED BY BABCOCK AND WILCOX AS
AN INTEGRAL PART OF THE POWER GENERATING FACILITIES. BYPASSING OF THE BOILER'S FLUE GAS AROUND THE FGD SYSTEM IS NOT POSSIBLE.
A PROCESS FLOW DIAGRAM OF THE LA CYGNE AIR QUALITY CONTROL SYSTEM AND RELATED MAJOR EQUIPMENT IS PRESENTED IN FIGURE 10.
PROBLEMS AND SOLUTIONS
THE FGD INSTALLATION HAS BEEN PLAGUED WITH NUMEROUS PROBLEMS SINCE THE FIRST TRIAL OPERATION ON DECEMBER 26, 1972. SOME OF
THESE PROBLEMS, SUCH AS VIBRATIONS OF THE INDUCED-DRAFT FANS AND THEIR SENSITIVITY TO IMBALANCE, OCCURRED EVEN BEFORE THE BOILER
WAS FIREC. AS THESE FABRICATION PROBLEMS WERE CORRECTED AND THE FGD SYSTEM WENT INTO OPERATION, TWO OTHER TYPES OF PROBLEMS
APPEARED. THE FIRST TYPE, ASSOCIATED WITH THE WET LIMESTONE PROCESS, INCLUDED PLUGGING OF THE DEMISTER AND STRAINERS, WEARING OF
SPRAY NOZZLES, AND CORROSION OF REHEATER TUBES. PROBLEMS OF THE SECOND TYPE MAY BE UNIQUE TO THE LA CYGNE INSTALLATION IN THAT
THEY CONCERN THE EFFECT OF THE SCRUBBED FLY ASH ON VISCOSITY AND FLOW CHARACTERISTICS OF THE RECIRCULATED SLURRY, WHICH RESTRICTED
THE MOBILITY OF THE BALLS IN THE ORIGINAL TCA TOWER. THE FLY ASH CONTENT OF THE FUUE GAS (DUE TO LACK OF PRIMARY PARTICULATE
CONTROLS) IS LARGELY RESPONSIBLE FOR BOTH TYPES OF PROBLEMS. SEVERAL MODIFICATIONS HAVE BEEN MADE* THE ORIGINAL TURBULENT
CONTACT ABSORBER'S FLOATING BED WAS REPLACED WITH SIEVE TRAYS NEXT, IN ORDER ALSO TO REDUCE THE EROSIVE EFFECT OF FLY ASH AND
LARGE-SCALE PARTICLES AND TO EXTEND THE LIFE OF THE LIMESTONE SLURRY SPRAY NOZZLES ON THE VENTURI SCRUBBERS, A HYOROCLONE WAS
INSTALLED IN THE SLURRY RECIRCULATION LINE OF EACH MODULE TO CENTRIFUGALLY SEPARATE AND REMOVE THESE PARTICLES FROM THE SYSTEM.
THE CORROSION ASSOCIATED WITH CONDENSATION OF ACID VAPORS FROM THE GAS ON THE REHEATER TUBE BUNDLES WAS CONTROLLED BY
110 PEDCO ENVIRONMENTAL
-------
LA CYGNE NO. 1 (CONTINUED)
INJECTION OF SLIP STREAMS OF HOT AIR FROM THE BOILER'S COMBUSTION AIR HEATER INTO THE SCRUBBED FLUE GASES AT THE INLET TO THE
REHEATER UNITS. THIS PRACTICE HAS REDUCED THE MAXIMUM GENERATING CAPACITY OF THE BOILER BY LIMITING THE AIR AVAILABLE FOR COAL
COMBUSTION.
BECAUSE THE FGD SYSTEM INCLUDES NO SPARE MODULES AND IT CANNOT BE BYPASSED. OUTPUT OF THE BOILER is TOTALLY CONTROLLED BY
PERFORMANCE AND AVAILABILITY OF THE FGD MODULES. PRESENT PROCEDURES CALL FOR CLEANING ONE MODULE EACH NIGHT ON A ROTATIONAL
SCHEDULE AND KEEPING ALL MODULES AVAILABLE DURING THE DAYTIME PEAK PERIODS. CLEANOUTS REQUIRE THREE MEN FOR A PERIOD OF 10 TO 12
HOURS. RECENT MODIFICATIONS BY THE UTILITY ON THE SCRUBBER INSTALLATION HAVE RESULTED IN PLANS FOR PROLONGED OPERATIONAL PERIODS,
WITH MODULES STAYING ON-LINE CONTINUOUSLY FOR PERIODS UP TO 3 WEEKS. THIS PREVENTATIVE MAINTENANCE AND CLEANOUT SCHEDULE HAS* TO
DATE. NOT YET BEEN ADOPTED.
THE UTILITY IS CURRENTLY PLANNING ADDITIONAL SYSTEM MODIFICATIONS. INCLUDING THE INSTALLATION OF AN EIGHTH SCRUBBING MODULE
SCHEDULED TO BE IN SERVICE THE SUMP.ER OF 1977. THE ADDITIONAL MODULE IS ESTIMATED TO COST APPROXIMATELY $5.2 MILLION AND WILL
ENABLE THE PLANT To INCREASE ITS MAXIMUM CONTINOUS GENERATING CAPACITY FROM THE CURRENT 700 MM LEVEL TO 800 MW. THE ORIGINAL
AIR QUALITY CONTROL SYSTEM DESIGN ALLOTTED ADDITIONAL SPACE FOR JUST SUCH A SYSTEM EXPANSION. OTHER SYSTEM MODIFICATIONS INCLUDE*
CHANGING THE I.D. FANS IN ORDER TO MINIMIZE OR ELIMINATE A FAN PARALLELING PROBLEM* CONTINUATION OF EXPERIMENTS AND MINOR CHANGES
IN ORDER TO IMPROVE SYSTEM MECHANICAL EFFICIENCY AND DECREASE OPERATING EXPENSES.
Ill PEDCO ENVIRONMENTAL
-------
FGO SYSTEM AVAILABILITY
LA CYGNE UNIT NO. 1
PERCENT AVAILABLITY-BY MODULE
MONTH BOILER HOURS
JAN.
FEB.
MAR.
APR.
MAY
JUN.
JUL.
AUG.
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
MAR.
APR.
MAY.
JUN.
JUL.
AUG.
74
74
74
74
74
74
74
74
74
7
-------
FGD SYSTEM AVAILABILITY (CONTINUED)
LA CYGNE UMT NO. 1
PERCENT AVAILABLITY-BY MODULE
MONTH BOILER HOURS A B C 0 E F G AVERAGE COMMENTS
SEP. 75 610 78 64 84 65 79 76 74 80 SYSTEM SHUTDOWN OCT. 16, 1975 OWING TO
PROBLEMS WITH GENERATOR AND 1.0. AIR FAN.
SYSTEM REMAINED INOPERATIVE THROUGHOUT THE
MONTH.
OCT. 75 231 66 77 46 74 72 73 65 68 AVAILABILITY FIGURES FOR OCTOBER AND
NOV. 75 346 93 90 80 93 96 89 94 91 NOVEMBER 00 NOT INCLUDE THE OUTAGE TIME FROM
DEC. 75 597 91 67 81 65 87 69 84 86 OCTOBER 16 TO NOVEMBER 13. BOILER OUTAGES
OF 80, 50, AND U HOURS, TOTALING 141 HOURS,
OCCURRED DURING DECEMBER.
JAN. 76 616 66 85 91 72 84 52 64 63
FEB. 76 594 94 90 66 91 92 93 95 92
MAR. 76 643 92 90 88 93 94 91 91 91
APR. 76 BOILER OVERHAUL THE SYSTEM WAS SHUT DOWN ON APRIL 6 FOR A
SCHEDULED BOILER AIR PREHEATER AND STACK
BREECHING OVERHAUL. DURING THIS OUTAGE SOME
MAINTENANCE WAS PERFORMED ON THE SCRUBBER
DUCTWORK, PRIMARILY BECAUSE OF CORROSION
PROBLEMS.
MAY 76 436 96 92 93 96 69 95 96 94 THE SCHEDULED UNIT OUTAGE ENDED MAY 10 WHEN
THE SYSTEM WAS RESTARTED. DURING THE
REMAINDER OF THE MONTH FOUR UNIT OUTAGES
WERE ENCOUNTERED, TOTALING OVER 70 HOURS.
113 PEDCO ENVIRONMENTAL
-------
FGD SYSTEM AVAILABILITY (CONTINUED)
LA CYGNE UNIT NO. 1
MONTH BOILER HOURS A
JUN. 76 99
JUL. 76 96
PERCENT AVAILABLITY-BY MODULE
B C D E F 6
95
95
93
93
93
93
91
AVERAGE
93
AUG. 76
93
92
92
90
88
92
SEP. 76
OCT. 76
TURBINE REPAIR
TURBINE REPAIR
COMMENTS
FOUR FORCED MINOR SCRUBBER OUTAGES OCCURED
DURING THE MONTH, RESULTING IN A TOTAL
AVERAGE SYSTEM AVAILABILITY OF 93.33 PERCENT.
THE UNIT RECORDED ITS LARGEST MU-HOUR MONTH
SINCE INITIATION OF COMMERCIAL OPERATION.
TWO MINOR SCRUBBER OUTAGES OCCURRED DURING
THE MONTH.
THE SYSTEM WAS TAKEN OUT OF SERVICE AUGUST
2<» FOR REPAIR OF A TURBINE BLADE. THE
UTILITY TOOK ADVANATAGE OF THIS OUTAGE
PERIOD TO PROCEED WITH COATING THE STACK
INNER STRUCTURE WITH PLASTITE H005. THE
AUGUST AVAILABILITY FIGURES DO NOT INCLUDE
THIS OUTAGE TIME.
UNIT NO. 1 REMAINED OUT OF SERVICE ALL OF
SEPTEMBER AND THE FIRST THREE WEEKS OF
OCTOBER BECAUSE OF COMPLETION TO TURBINE
BLADE REPAIRS WHICH COMMENCED ON AUGUST 2H.
THE SYSTEM WAS RETURNED TO SERVICE ON
OCTOBER 20. OPERATION WAS INTERMITTENT
PENDING TURBINE BLADE REBALANCING AND RE-
ESTABLISHMENT OF NORMAL OPERATING CONDITIONS.
11*
PEOCO ENVIRONMENTAL
-------
F60 SYSTEM AVAILABILITY (CONTINUED)
LA CYGNE UNIT NO. 1
PERCENT AVAILABILITY - BY MODULE
MONTH
NOV. 76
DEC. 76
BOILER HOURS
627
706
A
95
87
B
93
89
C
94
81
D
95
94
E
94
94
F
93
95
e
94
91
AVERAGE
94
90
COMMENTS
DURING THE MONTH OF DECEMBER THE UTILITY
CONDUCTED SOME MINOR REPAIR AND MODIFICATION
WORK ON THE AGCS, SPECIFICALLY A-MODULE
EXPERIENCED SOME VENTURI RECYCLE PUMP
PROBLEMS AND THE C-MODULE'S REHEAT STEAM
TUBE BUNDLES WERE INCREASED IN NUMBER FROM
115
PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
HS
KANSAS POWER & LIGHT
LAWRENCE NO «f
LAWRENCE KANSAS
125 MW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION SUET SCRUB
RETROFIT
12/66
OPERATIONAL
99 PERCENT
S02
75 PERCENT
WATER MAKE UP
SLUUGE DISPOSAL
OPEN LOOP
GPM/MW
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE ORIGINAL FliD SYSTEM FOR THIS UNIT WAS PLACED IN SERVICE DECEMBER
1568. IN ACHIEVING AN OPTIMUM MODE OF OPERATION, THE PHYSICAL SCRUBBER
PLANT WAS CONSUMED* REQUIRING REPLACEMENT WITH A NEW VENTUHI ROD
SCRUBBER AND SPRAY TOWER ABSORBER SYSTEM SUPPLIED BY COMBUSTION
ENGINEERING.INSTALLATION OF THE NEW SYSTEM IS COMPLETE.INITIAL OPERATION
SHOULD COMMENCE IN THE EARLY PART OF 1977* THE UNIT WAS DOWN THROUGH-
OUT THE REPORT PERIOD BECAUSE OF A SCHEDULED TURBINE OVERHAUL.
116
PEDCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE LAWRENCE POWER STATION* UNIT NO. H
LAWRENCE POWER STATION'S UNIT NO. H IS A CYCLIC LOAD STEAM BOILER EQUIPPED TO BURN COAL, NATURAL GAS SUPPLEMENTED WITH OIL,
OR COMBINATIONS OF THESE THREE FUELS. THE BOILER WAS BUILT BY COMBUSTION ENGINEERING AND PLACED IN SERVICE IN 1959. GENERATING
CAPACITY VARIES FROM 125 MW TO 143 MW WITH THE TYPE OF FUEL BEING BURNED. RETROFITTING WITH AN FGD SYSTEM IN NOVEMBER 1968
INTRODUCED ADDITIONAL PRESSURE DROP IN THE FLUE GAS SYSTEM AND REDUCED BOILER CAPACITY TO 115 MW.
THE COAL NOW BURr4£D AT THE. LAWRENCE POWER PLANT IS A LOW-SULFUR SOUTHEAST WYOMING COAL, HAVING AN AVERAGE HEATING VALUE OF
10,000 BTU/LB AND SULFUR AND ASH CONTENTS OF 0.5 AND 11 PERCENT RESPECTIVELY.
THE ORIGINAL SCRUBBING SYSTEM INCLUDED TWO MODULES, EACH SIZED TO HANDLE 150,000 SCFM OF FLUE GAS. EACH MODULE CONTAINS A
SINGLE-STAGE MARBLE BED SCRUBBER FOLLOWED BY A CHEVRON DEMISTER AND INDIRECT STEAM REHEATER. ORIGINALLY* BOTH MODULES WERE
FITTED WITH BYPASS DUCTS AND HYDRAULIC SEAL DAMPERS, WHICH WERE LATER REMOVED BECAUSE OF EXTENSIVE CORROSION AND PLUGGING.
THE PLANT HAS FACILITIES FOR STORING AND HILLING THE LIMESTONE, WHICH CONTAINS 93 PERCENT CALCIUM CARBONATE, 6 PERCENT
SILICA, AND 1 PERCENT MAGNESIUM CARBONATE.
SPENT SLURRY DISCHARGED FROM THE ORIGINAL SYSTEMS FITTED ON UNITS 4 AND 5 WERE SENT TO THREE INTERCONNECTED UNLINEO DISPOSAL
PONDS WITH CAPACITIES OF 16, 26, AND 4 ACRES, RESPECTIVELY. KANSAS RIVER WATER (MAKE-UP) WAS ADDED TO THE LATTER POND. THE
SUPERNATANT FROM THIS POND WAS RECYCLED. THE UNSTABILIZEO SLUDGE SOLIDIFIED AND SET-UP IN THE DISCHARGE PONDS.
PROBLEMS AND SOLUTIONS
PROBLEMS WITH THE FGD SYSTEM ON BOILER NO. 4 HAVE INCLUDED BUILDUP AND PLUGGING OF THE INLET DUCT WHERE HOT GASES ENTER THE
SCRUBBERS, EROSION OF SCRUBBERS WALLS, CORROSION OF SCRUBBERS INTERNALS, BUILDUP ON ID FAN ROTORS, AND PLUGGING OF DRAIN LINES,
MARBLE BEOS, AND DEMISTERS. LOW S02 REMOVAL WAS CAUSED BY OVERBURNING OF THE LIMESTONE AND DROPOUT OF THE LIME WITH THE ASH IN
THE BOTTOM OF THE SCRUBBER.
THE SCRUBBERS WERE MODIFIED IN 1969 BY RAISING THE DEMISTER AND ADDING SOOT BLOWERS IN THE INLET DUCT AND REHEATER TO REDUCE
PLUGGING. NEW SPRAY NOZZLES WERE ALSO INSTALLED. REHEATER PLUGGING WAS ELIMINATED BY REPLACING COPPER REHEAT COILS WITH A
CARBON STEEL UNIT HAVING WIDELY SPACED FINS.
MAJOR MODIFICATIONS IN 1970 WERE SANDBLASTING AND COATING OF THE INTERIOR OF THE SCRUBBERS, REPLACEMENT OF ALL INTERNAL
STEEL PIPES WITH PLASTIC AND FIBERGLASS, AND REPLACEMENT OF STAINLESS STEEL DEMISTERS WITH FIBERGLASS. SINCE DEMISTER PLUGGING
WAS NOT COMPLETELY ELIMINATED* THE UNIT WAS WASHED MANUALLY EVERY NIGHT TO MAINTAIN THE REQUIRED OUTPUT.
117 PEDCO ENVIRONMENTAL
-------
LAWRENCE UNIT NO. <* (CONTINUED)
THE MODIFICATIONS IN THE SUMMER OF 1972 ON THE TWO FGD MODULES INCLUDED ENLARGEMENT OF THE CRYSTALLIZATION TANK. AND
INSTALLATION OF NEW PLASTIC SPRAY NOZZLES, NEW SLURRY PUMPS ANU STRAINERS? AND NEW MULTIPLE MIXERS IN THE TANK.
PROBLEMS THAT REMAINED INCLUDED CORROSION, INEFFICIENT DAMPERS, EXPANSION JOINT FAILURE, DEMISTER FOULING, RAPID EROSION
OF THE SLURRY PUMP, AND VALVE FAILURE. OPERATION OF THE FGD SYSTEM SINCE THE FALL OF 1973 HAS BEEN THE MOST SUCCESSFUL TO DATE.
OPERATION OF THE SCRUBBER SYSTEM ON THE WYOMING COAL HAS PROVED TO BE MORE EFFICIENT AND ECONOMICAL THAN EARLIER OPERATIONS
BECAUSE A LESSER DEGREE OF S02 REMOVAL IS KEOUIREO FOR COMPLIANCE. THE SCRUBBER SYSTEM IS STILL OPERATING IN THE HIGH-SOLIDS
MODE AS AN S02 AND PARTICULATE REMOVAL SYSTEM. NORMAL MANUAL CLEANING REQUIREMENTS HAVE BEEN REDUCED TO TWO H-HOUR SHIFTS PER
SCRUBBER PER WEEK.
IN 197
-------
LAURENCE NO. 4
MONTH
JUL. 75
AUG. 75
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN. 76
FEB. 76
MAR. 76
APR. 76
MAY 76
JUN. 76
JUL. 76
AUG. 76
BOILER
OPERATING HOURS
MODULE A MODULE B
AVAILABILITY
MODULE A MODULE B
NOT LOGGED
NOT LOGGED
NOT LOGGED
NOT LOGGED
COMMENTS
THE FGD SYSTEM HAS OPERATED SATISFACTORILY FOR OVER A YEAR.
AVAILABILITY IS REPORTED TO BE ADEQUATE FOR THE OPERATION
OF THIS STATION. STATION LOAD IS REDUCED TO 50 PERCENT>
EVEKY NIGHT. THEREFORE, ONE OF THE MODULES CAN BE TAKEN
OFF-LINE NIGHTLY FOR CLEANING OR REPAIR. WYOMING COAL (>0.5
PERCENT SULFUR) IS BEING BURNED IN THE BOILER. SOME
NATURAL GAS HAS BEEN BURNED SINCE JUNE 20.
BURNED COAL 100 PERCENT OF TIME. EACH MODULE SHUT DOWN
ONCE PER WEEK FOR INSPECTION AND CLEAN-UP. NO BOILER
OUTAGES OCCURRED DURING THE JULY-AUGUST PERIOD.
PRESENT PROJECTIONS BY THE UTILITY CALL FOR THIS UNIT TO BE
AVAILABLE 330 DAYS DURING 1976. THE FUEL CONSUMPTION WILL
BE 80 PERCENT COALt 12 PERCENT NATURAL GAS, AND 6 PERCENT
FUEL OIL. THE UTILITY IS REPLACING THIS SCRUBBER SYSTEM
WITH A VENTURI-ROD FOLLOWED BY A SPRAY TOWER.
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
119
PEDCO ENVIRONMENTAL
-------
LAURENCE NO.
MONTH BOILER
SEP. 76
OCT. 76
NOV. 76
DEC. 76
OPERATING HOURS
MODULE A MODULE 8
AVAILABILITY
MODULE A MODULE B
TURBINE OVERHAUL AND REPAIR
COMMENTS
THE UTILITY REPORTS THAT THE UNIT REMAINED OUT OF SERVICE
THROUGHOUT THE REPORT PERIOD AS A SCHEDULED TURBINE
OVERHAUL, WHICH COMMENCED IN MID-SEPTEMBER* CONTINUED. THE
NEW EMISSION CONTROL SYSTEM, CONSISTING OF AN ESP FOLLOWED
BY A ROD SECTION AND SPRAY TOWER SCRUBBING SYSTEM, HAS
BEEN INSTALLED ON THIS UNIT. INITIAL OPERATION OF THE
SYSTEM WILL COMMENCE FOLLOWING COMPLETION OF THE TURBINE
OVERHAUL. THE UNIT WILL CONTINUE TO FIRE LOW SULFUR
WYOMING COAL (0.5& SULFUR* 10,000 BTU/LB).
120
PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCLSS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KANSAS POWER & LI6HT
LAWRENCE NO 5
LAWRENCE KANSAS
100 HW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION iWET SCRUB
NEW
11/71
OPERATIONAL
99 PERCENT
S02
65 PERCENT
hlATEK MAKE UP
OPEN LOOP 3.0 GPM/MW
SLUDGE DISPOSAL
UNSTABILIZED SLUDGE DISPOSED IN UNLINEO POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE ORIGINAL FttD SYSTEM FOR THIS UNIT WAS PLACED IN SERVICE NOVEMBER 1971
RENTLY BURNING LOW SULFUR WYOMING COAL. THE OPERATION OF THE SCRUBBER HAS
IN ACHIEVING AN OPTIMUM MODE OF OPERATION. THE PHYSICAL SCRUBBER PLANT
WAS CONSUMED! REQUIRING REPLACEMENT WITH TWO NEW VENTURI ROD
SCRUBBERS AND SPRAY TOWER ABSORBERS SUPPLIED BY COMBUSTION ENGINEERING.
IS PROCEEDING ON POURING OF THE FOUNDATION AND ERECTION OF THE
STRUCTURAL STEEL. THE BOILER IS IN SERVICE. FIRING FUEL OIL.
121
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE LAWRENCE POWER STATION* UNIT NO. 5
UNIT NO. 5 AT LAWRENCE POWER STATION IS A CYCLIC-LOAD STEAM BOILER EQUIPPED TO BURN COAL. NATURAL GAS SUPPLEMENTED WITH OILt
OR COMBINATIONS OF THESE FUELS. THE BOILERt PLACED IN SERVICE IN 1971t HAS A RATED CAPACITY OF <»00 MW WHEN BURNING COAL AND
NATURAL GAS.
THE COAL NOW BURNED AT THE LAURENCE POWER PLANT IS A LOW-SULFUR SOUTHEAST WYOMING COAL, HAVING AN AVERAGE HEATING VALUE OF
10,000 BTU/LB AND SULFUR AND ASH CONTENTS OF 0.5 AND 11 PERCENT RESPECTIVELY.
THE BOILER'S ORIGINAL FGD SYSTEM WAS SUPPLIED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE IN 1971. ORIGINAL EQUIPMENT
INCLUDED 6 IDENTICAL MODULES WITH A CAPACITY OF 150,000 SCFM/MODULE. EACH MODULE CONSISTS OF A SINGLE-STAGE MARBLE BED SCRUBBER
FOLLOWED BY A CHEVRON-TYPE DEMISTER AND INDIRECT STEAM REHEATER. ALL THE MODULES ARE FITTED WITH BY-PASS DUCTS AND HYDRAULIC
SEAL DAMPERS. THE PLANT INCLUDES FACILITIES FOR STORING AND MILLING LIMESTONE (COMPOSITION* 93 PERCENT CALCIUM CARBONATE* 6
PERCENT SILICA, AND 1 PERCENT MAGNESIUM CARBONATE).
SPENT SLURRY FROM THE UNIT ALONG WITH THE SLURRY FROM UNIT NO.
-------
LAWRENCE UNIT NO. 5 (CONTINUED)
THE UTILITY HAS RE-EVALUATED THE FUTUKE OF SCRUBBING APPLICATION ON THIS POWER-GENERATING UNIT. THE UTILITY IS NOW
FOLLOWING A COURSE SIMILAR TO THAT OF UNIT *, CONVERTING THE MARBLE BED SCRUBBERS To A TWO TRAIN ROD AND SPRAY TOWER SCRUBBING
SYSTEM. AUOITIONAL DATA AND INFORMATION ON THE DEVELOPMENT OF FGU TECHNOLOGY FOR THIS UNIT IS PRESENTED IN THE PERFORMANCE
TABLE BELOW
123 PEOCO ENVIRONMENTAL
-------
MONTHS
OPERATING HOURS
BOILER FGO MODULES
JUL. 75
AUG. 75
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN. 76
FEB. 76
MAR. 76
APR. 76
MAY 76
JUN. 76
JUL. 76
AUG. 76
SEP. 76
OCT. 76
NOT LOGGED
NOT LOGGED
NOT LOGGED
NOT LOGGED
NOT LOGGED
LAWRENCE NO. 5
COMMENTS
WYOMING COAL IS BEING BURNED IN THIS UNIT. FGO SYSTEM AVAILABILITY IS REPORTED TO BE
ADEQUATE FOR OPERATION OF THIS STATION. SINCE STATION LOAD IS REDUCED TO 50 PERCENT
EVERY NIGHT. AS MANY AS FOUR MODULES CAN BE SHUT DOWN FOR CLEANING AND REPAIR EACH
EVENING.
FGD UNITS WERE OFF-LINE MOST OF JUNE FOR MAJOR REBUILDING OF THE SPRAY SYSTEMS IN ALL
MODULES. SOME OIL WAS BURNED TO ALLOW BYPASSING OF THE REPAIR.
OIL AND GAS WERE BURNED IN JULY AND AUGUST. NO FGD OPERATION.
GAS AND OIL BURNED ON A PART-TIME BASIS DURING SEPTEMBER AND OCTOBER. BOILER OUTAGE
WAS DUE TO INSPECTION, TURBINE REPAIR, AND REPLACEMENT OF THE SLURRY TANK SCREEN.
PROJECTIONS BY THE UTILITY FOR THIS UNIT CALL FOR 330 DAYS OF OPERATION IN 1976 WITH
FUEL CONSUMPTION BEING 60 PERCENT COAL, 25 PERCENT FUEL OIL, AND 15 PERCENT NATURAL
GAS. LIKE UNIT 4, THIS UNIT MAY BE CONVERTED TO A VENTRI-ROD AND SPRAY TOWER
SCRUBBING SYSTEM*
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
PEOCO ENVIRONMENTAL
-------
LAWRENCE NO.5(CONTINUED)
MONTHS
NOV. 76
DEC. 76
OPERATING HOURS
BOIL£R FGD MODULES
COMMENTS
THE UTILITY REPORTS THAT THE INSTALLATION OF THE NEW ROD AND SPRAY TOWER SCRUBBING
SYSTEM IS NOW IN PROGRESS. THE SYSTEM WILL INCLUDE TWO SCRUBBING TRAINS, EACH
HANDLING 50 PERCENT OF THE FLUE GAS CAPACITY. FOUNDATION AND STRUCTURAL STEEL
ERECTION HAS BEEN COMPLETED. SOME OF THE BREECHING HAS BEEN INSTALLED. THE FGO
SYSTEM WILL OPERATE ON A FULLY AUTOMATED BASIS. KP&L REPORTS THAT C-E HAS
ENCOUNTERED SOME PROBLEMS WORKING OUT AND FINE-TUNING SOME OF THE LOGIC CIRCUITS.
THE BOILER HAS BEEN FIRING NO.2 FUEL OIL WHILE THE NEW SCRUBBING SYSTEM IS BEING
INSTALLED. THE SYSTEM WILL TREAT FLUE GAS RESULTING FROM THE BURNING OF LOW SULFUR
(0.5 PERCENT) WYOMING COAL.
125
PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP OATE
FGD STATUS
EFFICIENCY,
PARTICIPATES
H7
KENTUCKY UTILITIES
GRC-N RIVER UNITS 1 AND 2
CENTRAL CITY KENTUCKY
6
-------
BACKGROUND INFORMATION
ON
GREEN RIVER POWER STATION
THE GREEN RIVER POWER STATION IS WHOLLY OWNED AND OPERATED BY THE KENTUCKY UTILITIES COMPANY AND SITUATED ON THE GREEN RIVER,
NEAR CENTRAL CITY IN MUHLENBERG COUNTY, KENTUCKY. THE STATION CONSISTS OF TWO TURBINE GENERATORS AND FOUR COAL-FIRED BOILERS.
AS THE RESULT OF A CONTRACT AWARDED BY KENTUCKY UTILITIES (KU) TO AMERICAN AIR FILTER (AAF), A TAIL.END WET LIME SCRUBBING
SYSTEM WAS DESIGNED AND INSTALLED ON BOILERS 1, 2, AND 3 AT THE GREEN RIVER POWER STATION.
THE FLUE GAS oESULFURIZATION (FGD) AND PARTICIPATE REMOVAL SYSTEM CONSISTS OF ONE SCRUBBER MODULE DESIGNED TO HANDLE A
MAXIMUM OF 360,000 ACFM OF FLUE GAS AT 300 F. THE BLOW-THROUGH SCRUBBER MODULE CONTAINS A VARIABLE-THROAT FLOODED-ELBOW VENTURI
FOR FLY ASH REMOVAL AND A MOBILE BED CONTACTOR FOR SULFUR DIOXIDE REMOVAL. ENTRAINED WATER DROPLETS ARE REMOVED VIA A CENTRIFUGAL
OEMISTER BEFORE DISCHARGE TO A LOCAL STACK. THE SLURRY RECYCLE/DISCHARGE SYSTEM CONSISTS OF ONE COMMON ACID RESISTENT TANK WITH
TWO PARTITIONS MAKING A TOTAL OF THREE COMPARTMENTS. COMPLETION OF CHEMICAL REACTIONS, RECIRCULATION OF SOLUTION AND WASTES
DISCHARGE ARC CONTROLLED AND MONITORED HERE. MECHANICAL COLLECTORS ARE PROVIDED UPSTREAM OF THE WET SCRUBBING SYSTEM FOR PRIMARY
PARTICULATE MATTER REMOVAL.
BOILERS 1, 2, AND 3 ARE PULVERIZED COAL-FIRED UNITS SERVICING TWO TURBINES, EACH RATED AT 32 MW (GROSS). THE FUEL BURNED IN
THESE UNITS IS PRIMARILY A HIGH SULFUR WESTERN KENTUCKY COAL (10,797 BTU/LB.t 3.6 TO t.O PERCENT SULFUR, 13 TO 1H PERCENT ASH).
THE FGD SYSTEM CAN BE BYPASSES THROUGH A SERIES OF DUCTWORK AND GUILLOTINE DAMPERS.
A TURNKEY CONTRACT FOR THIS PROJECT WAS AWARDED TO AAF IN JUNE 1973. CONSTRUCTION AND INSTALLATION OF THE SYSTEM WAS COM-
PLETED BY MID-SEPTEMBER 1975. FOLLOWING GENERAL ELECTRICAL AND MECHANICAL DEBUGGING, WHICH INCLUDED OPERATION OF THE AGITATORS
AND PUMPS, THE UNIT WAS PUT IN SERVICE ON AIR AND WATER ONLY IN AUGUST 1975. DURING THIS OPERATION PERIOD, THE FLOW OF GAS AND
LIQUID* OPERATION OF DAMPERS, AND SPRAY PATTERNS WERE MONITORED AND CALIBRATED. NEXT, THE SYSTEM WAS OPERATED ON AIR AND WATER
UNDER NORMAL PROCESS CONDITIONS. THE PURPOSE OF THIS PHASE OF OPERATION WAS TO DETECT ANY EARLY FAILURES OF A MECHANICAL NATURE
PRIOR TO THE INITIAL FLUE GAS RUN.
THE FLUE GAS RUN COMMENCED THE MORNING OF SEPTEMBER 13, 1975. INITIAL OPERATION PROCEEDED ON A HALF-LOAD BASIS BECAUSE ONE
OF THE TURBINE GENERATORS WAS OUT OF SERVICE FOR OVERHAUL AND REPAIRS. IN ADDITION, OPERATION OF THE SCRUBBING SYSTEM WAS CON-
DUCTED ON AN OPEN-WATER-LOOP BASIS. THIS MODE OF OPERATION (HALF LOAD, OPEN LOOP) CONTINUED INTO THE FIRST QUARTER OF 1976. IN
MARCH, THE SYSTEM BEGAN OPERATION AT FULL LOAD CAPACITY IN A CLOSED-WATER-LOOP MODE. GUARANTEED SULFUR DIOXIDE REMOVAL EFFICIENCY
IS 60 PERCENT FOR 3.6 PERCENT SULFUR COAL HAVING A HEATING VALUE EQUAL TO OR GREATER THAN 11*000 BTU/LB.
127 PEDCO ENVIRONMENTAL
-------
GREEN RIVER POWER STATION (CONTINUED)
ADDITIONAL INFORMATION ON THE OPERATION OF THIS SYSTEM IS PRESENTED IN THE PERFORMANCE TABLE THAT FOLLOWS. A GENERAL PROGRESS
FLOW DIAGRAM IS PRESENTED IS FIGURE 12 OF APPENDIX C.
128 PEDCO ENVIRONMENTAL
-------
TOTAL
PERIOD PERIOD
DEC. 75 7«m
AVAILABILITY = 7HX
RELIABILITY = 76X
OPERABILITY = 65X
UTILIZATION = 35X
JAM. 76 7
-------
F6D SYSTEM AVAILABILITY (CONTINUED)
GREEN RIVEK NOS. 1 AND 2
TOTAL BOILER
RIOD PERIOD HR OPERATION HR
APR. 76 720
AVAILABILITY = 90%
RELIABILITY = 100*
OPERABILITY = 100%
UTILIZATION = 778
HAY 76 7HH
AVAILABILITY = 61%
RELIABILITY = 100%
OPERABILITY = 100%
UTILIZATION = 61%
JUN. 76 720
AVAILABILITY = 100%
RELIABILITY = 99%
OPERABILITY = 99%
UTILIZATION = 82*
JUL. 76 7nt
AVAILABILITY = 90%
RELIABILITY = 99S
OPERABILITY = 98%
UTILIZATION = 72%
AUG. 76 7HH
AVAILABILITY = 97%
552
MODULE
AVAILABILITY HR
6<»8
NOt riR. MODULE
CALLED UPON
TO OPERATE
552
HR. MODULE
OPERATE
552
COMMENTS
THE UTILITY MADE A PRIOR COMMITMENT
TO RUN AT 100 PWRCENT OPERABILITY
DURING THE MONTH OF APRIL.
H56
606
-------
TOTAL
PERIOD PERIOD (HK)
RELIABILITY = 97*
OPERABILITY = 97*
UTILIZATION = 97S
SEP. 76 720
AVAILABILITY = 86*
RELIABILITY = 100%
OPERABILITY = 100*
UTILIZATION = 79*
OCT. 76
AVAILABILITY = 100JS
RELIABILITY = 1005
OPERABILITY = 100%
UTILIZATION = 9>»S
NOV. 76 720
AVAILABILITY = 100%
OPERABILITY = 100*
RELIABILITY = 98S
UTILIZATION = 98*
OtC. 76 7<»'»
AVAILABILITY = 73*
OPERABIHTY = 97*
RELIABILITY = 67*
UTILIZATION = 70*
FGD SYSTEM AVAILABILITY {CONTINUED)
GREEN RIVEK NOS. 1 AND 2
BOILER
OPERATION (HR)
MODULE
AVAILABILITY (HK)
NO. HR. MODULE
CALLED UPON
TO OPERATE
HR. MODULE
OPERATE
571
617
571
571
699
699
699
701*
536
720
539
70«t
591
704
517
COMMENTS
BECAUSE OF VIBRATION IN THE SCRUB-
BER BOOSTER I.D. FAN, NECESSITATING
SYSTEM SHUTDOWN AND REPAIR.
HALF-LOAD OPERATIONS WERE CONDUCTED
THROUGHOUT THE PERIOD BECAUSE OF
BEARING PROBLEMS TO ONE OF THE TWO
TURBINE GENERATING UNITS. SOME
MINOR FAN PROBLEMS, WHICH DID NOT
REQUIRE ANY FORCED OUTAGE TIME,
WERE ENCOUNTERED DURING THE PERIOD.
DURING THE PERIOD SOME FLUE GAS WAS
BY-PASSED AROUND THE SYSTEM WHILE
THE UTILITY CINDUCTED A CHECKOUT OF
THE SCRUBBER INTERNALS AND REPLACED
SOME OF THE PACKING SPHERES IN THE
MOBILE BED.
131
PEDCO ENVIRONMENTAL
-------
TABLE: 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 12/74
IDENTIFICATION NO.
UTILITY NAME
UNIT MAKE
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP UATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
KEY WEST UTILITY BOARD
STOC . ISLAND PLANT
KEY WEST FLORIDA
37 HU
OIL Z.H PERCENT SULFUR
2URN AIR SYSTEMS
LIMESTONE SCRUBBING
NEW
10/72
OPERATIONAL
90 PERCENT
85 PERCENT-ESTIMATED
WATEK MAKE UP
SLUUCiE DISPOSAL
OPEN LOOP 2.7 GPM/MW
UNSTABILIZED SLUUGE DISPOSED IN UNLINED POND
UNIT COST
* 21.6/KW CAPITAL COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS f3££N OPERATIONAL SINCE OCTOBER 1972. THE F3D SYSTEM HAS
BEEN OUT OF SERVICE SINCE JANUARY 28,1975. MODIFICATIONS AND REPAIRS ARE
CURRENTLY IN PROGRESS. SYSTEM RESTART IS STILL INDEFINITE. A CHECKOUT
OF ALL SYSTEM MOTORS AND PUMPS MUST BE COMPLETED BEFORE STARTUP CAN
COMMENCE. DURING THE REPORT PERIOD THE UNIT DlO NOT OPERATE BECAUSE OF
REPAIRS TO BOILER TUBES THAT FAILED. RESTART IS SCHEDULED SHORTLY.
132
PEDCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
STOCK ISLAND PLANT
THE UTILITY BOARD OF THE CITY OF KEY WEST OWNS AND OPERATES A NEW 37-MW OIL-FIRED POWER BOILER. INSTALLED AT THEIR STOCK
ISLAND PLANT WHICH IS LOCATED DIRECTLY ADJACENT TO THE ISLAND CITY OF KEY WEST. THE BOILER IS AN ERIE CITY BALANCED.DRAFT OIL-
FIRED UNIT THAT IS NOMINALLY RATED AT 37 MW AND CAN ACHIEVE <*2 MW AT FULL PERFORMANCE. THE UNIT FIRES NO. 6 RESIDUAL FUEL OIL
FROM VENEZUELA UlTh SULFUR AND ASH CONTENTS OF 2.75 AND 0.05 PERCENT, RESPECTIVELY. THE UNIT'S GROSS HEAT RATE IS 11,360
BTU/KWH. INITIAL OPERATION OF THE UNIT COMMENCED IN NOVEMBER 1972.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A MULTIPLE TUBE MECHANICAL OUST COLLECTOR INSTALLED UPSTREAM OF TWO
SULFUR DIOXIDE WET SCRUBBERS DESIGNED AND INSTALLED BY ZURN AIR INDUSTRIES. THIS IS A DEMONSTRATION FACILITY (EPA FUNDED)
EMPLOYING LIMESTONE IN A SEAwATER SOLUTION FOR THE REMOVAL OF SULFUR DIOXIDE FROM THE BOILER FLUE GAS STREAM. NO PROVISIONS FOR
STACK GAS REHEAT EXIST AT THE FACILITY.
THE LIMESTONE ABSORBENT IS OBTAINED FROM CORAL DREDGED FROM THE OCEAN. THE CORAL CONSISTS PRIMARILY OF CAC03 WITH LITTLE OR
NO MGC03. THE CORAL IS GROUND TO A FINE POWDER IN A HAMMERMILL CRUSHER TO 90 PERCENT MINUS 325 MESH AND SLURRIED IN SEAWATER.
ZURN DUSTRAXToRS ARE EMPLOYED FOR THE REMOVAL OF SULFUR DIOXIDE AND RESIDUAL PARTICULATES FROM THE BOILER FLUE GAS. THE TWO
SCRUBBER MODULES ARE DESIGNED TO HANDLE A COMBINED TOTAL OF 126,950 CFM AT ISO F. FLUE GASES FROM THE BOILER ARE DRAWN THROUGH AN
INDUCED DRAFT FAN AND FORCED EITHER THROUGH THE BYPASS DUCT OR THROUGH ONE OR BOTH SCRUBBEKS VIA THREE SETS OF DAMPERS BETWEEN THE
.INDUCED-DRAFT FAN AND THE STACK. BEFORE ENTERING THE SCRUBBING SYSTEM THE GAS IS COOLED FROM 360 F TO 160 F BY SEAWATER SPRAYS.
THIS COOLING PROTECTS THE FIBERGLASS COMPONENTS OF THE SCRUBBER MODULES. A PRESSURE DROP OF 12 TO 1H INCHES WATER GAUGE IS THE
NORrtAL OPERATING RANGE FOR THE SCRUBBERS. THE SPENT SCRUBBING SLURRY IS BLED OFF TO TWO ON-SITE SETTLING PONDS WITH A RETENTION
CAPACITY OF 21 DAYS. THE SLUDGE SETTLES OUT AND CLARIFIED WATER IS DISCHARGED BACK INTO THE SEA BY AN OVERFLOW PIPE AND SEEPAGE.
THE PARTICULATE AND SULFUR DIOXIDE REMOVAL EFFICIENCIES OF THE EMISSION CONTROL SYSTEM ARE 6
-------
STOCK ISLAND (CONTINUED)
SYSTEM PERFORMANCE
STAKT-UP OF THE SCRUBBING SYSTEM OCCURRED IN AUGUST 1973. ENSUING OPERATION HAS PROCEEDED ON AN INTERMITTENT BASIS. THE
MAJOR PROBLEM AREAS ENCOUNTERED HAVE INCLUDED*
SEVERE CORROSION OF GAS QUENCH DUCT AND DAMPER SEALING FANS ON INLET AND OUTLET OF SCRUBBERS.
PLUGGING AT THE BOTTOM OF SCRUBBER TUBES.
LIQUID LEVEL CONTROL FAILURES IN THE SCRUBBER MODULES.
POOR LIMESTONE UTILIZATION (APPROXIMATELY 20 PERCENT).
INDUCED DRAFT FAN REPAIRS.
REPLACEMENT OF INTERNAL STAINLESS STEEL PARTS WITH MONEL COMPONENTS,
BOILER FOUNDATION AND BOILER TUBE PROBLEMS.
LIMESTONE SUPPLY SHORTAGES.
ADDITIONAL INFORMATION AND DETAILS ON THE PROGRESS OF THIS INSTALLATION ARE PRESENTED IN THE PERFORMANCE TABLE BELOW. A
PROCESS FLOW DIAGRAM IS PRESENTED IN FIGURE 13 OF APPENDIX C.
134 PEOCO ENVIRONMENTAL
-------
STOCK ISLAND (CONTINUED)
OPERATING HOURS FGD SYSTEM
MONTH BOILER FGD SYSTEM AVAILABILITY COMMENTS
FGD SYSTEM WAS SHUT DOWN ON JANUARY 2fl, 1975, BECAUSE OF DAMAGED
DUCTWORK BAFFLES. SPRAY TREES AND OTHER STAINLESS STEEL PARTS HAVE
BEEN RREPLACEO WITH MONEL.
JUL. 75 FGD SYSTEM IS STILL OUT OF SERVICE BUT IS SCHEDULED FOR RESTART IN
EARLY OCTOBER.
AUG. 75 BOILER HAS BEEN DOWN SINCE AUGUST 90 FOR REPAIRS OF THE INDUCED-DRAFT
FAN.
SEP. 75 FGD SYSTEM IS STILL OUT OF SERVICE. DATE OF SYSTEM RESTART IS
INOEFINTE.
OCT. 75
NOV. 75 FGD SYSTEM IS STILL OUT OF SERVICE. THE UTILITY IS REPLACING DAMPERS
DEC. 75 AND VARIOUS SYSTEM PARTS. DATE OF SYSTEM RESTART IS STILL INDEFINITE.
JAN. 76 REPAIRS TO OUTLET DAMPER ARE COMPLETE. ALL HOLES IN THE HOPPER WALL
FEB. 76 AND DUCTWORK HAVE BEEN PATCHED. NEW SpRAY TREES HAVE BEEN INSTALLED.
THE SYSTEM WILL NOT BE PLACED IN SERVICE UNTIL A THOROUGH CHECKOUT
OF ALL THE PUMPS AND MOTORS IS FIRST COMPLETED.
MAR. 76 THE FGD SYSTEM RESTART HAS BEEN DELAYED BECAUSE OF BOILER-RELATED
APR. 76 PROBLEMS. DATE OF SYSTEM RESTART IS STILL INDEFINITE.
HAY 76 THE UTILITY REPORTED THAT REPAIRS AND MODIFICATIONS ARE WEARING
COMPLETION.
JUN. 76 SYSTEM RESTART IS EXPECTED SHORTLY.
135 PEOCO ENVIRONMENTAL
-------
STOCK ISLAND (CONTINUED)
OPERATING HOURS FGD SYSTEM
MONTH BOILER FGU SYSTEM AVAILABILITY COMMENTS
JUL. 76 ALL MODIFICATIONS TO THE SCRUBBING SYSTEM WHICH CAN BE MADE AT THE
AUG. 76 PRESENT TIME HAVE BEEN COMPLETED. THE SCRUBBING SYSTEM HAS BEEN
SEALED OFF FROM THE BOILER BY A METAL PARTITION WHILE THE MODIFICA-
TIONS WERE IN PROGRESS. FINAL MODIFICATIONS CAN BE COMPLETED ONLY
WHEN THE SCRUBBING SYSTEM AND BOILER HAVE BEEN INTEGRATED INTO ONE
UNIT, WHICH WILL REQUIRE BRINGING THE BOILER DOWN. THE UNIT IS
CONTINUING TO FIRE 2.1-2.4 PERCENT SULFUR FUEL OIL.
SEP. 76 THE BOILER HAS BEEN TAKEN OUT OF SERVICE BECAUSE OF TUBE FAILURES.
OCT. 76 THE METAL PARTITION BETWEEN THE SCRUBBING SYSTEM AND BOILER HAS
BEEN REMOVED. A SHAKE-DOWN AND TEST RUN ON WATER WILL BE CONDUCTED
SHORTLY.
NOV. 76 THE UTILITY REPORTED NO CHANGE IN STATUS, REPLACEMENT PARTS HAVE
DEC. 76 JUST REACHED THE PLANT. TENATTIVE RESTART DATE IS FEB. 1. 1977.
136 PEOCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
LOUISVILLE GAS & ELECTRIC
CANE RUN NO
-------
BACKGROUND INFORMATION
ON
CANE RUN NO. 4
THE CANE RUN POWER STATION IS OPERATED BY THE LOUISVILLE GAS AND ELECTRIC COMPANY AND LOCATED IN LOUISVILLE* KENTUCKY. THE
PLANT CONSISTS OF SIX ELECTRIC POWER STEAM GENERATING UNITS HAVING A TOTAL STEAM TURBINE NET GENERATING CAPACITY OF 992-MW.
UNIT NO. H IS A COAL-FIRED STEAM GENERATING BOILER WITH A CONTINUOUS NET GENERATING CAPACITY OF 17S-MW. THE UNIT HAS A
MAXIMUM POWER GENERATION CAPACITY OF 190-MW. THE UNIT HEAT RATE IS 10,030 BTU/KWH. THE BOILER IS CURRENTLY BURNING COAL WITH A
GROSS HEATING VALUE OF 11,500 BTU/LB AND AVERAGE SULFUR AND ASH CONTENTS OF 3.5-H.O PERCENT AND 11.0-12.0 PERCENT, RESPECTIVELY.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF AN ELECTROSTATIC PRECIPITATOR (ESP) UPSTREAM OF A WET SCRUBBING SYSTEM.
THE ESP PROVIDES PRIMARY PARTICULATE CONTROL WHILE THE WET SCRUBBING SYSTEM PROVIDES ADDITIONAL PARTICULATE REMOVAL AND PRIMARY
SULFUR DIOXIDE CONTROL.
THE FLUE GAS DESULFURIZATION (FGD) SYSTEM CONSISTS OF TWO IDENTICAL PARALLEL SCRUBBING TRAINS DESIGNED AND INSTALLED BY THE
AMERICAN AIR FILTER (AAF) COMPANY. THE WET SCRUBBING SYSTEM UTILIZES A SLURRY OF CARBIDE LIME FOR SULFUR DIOXIDE REMOVAL FROM THE
FLUE GAS. THE CARBIDE LIME IS A WASTE BY-PRODUCT OBTAINED FROM A NEARBY ACETYLENE MANUFACTURING PLANT. THE HYDRATED LIME CON-
TAIfJS 90.0 TO 92.0 PERCENT CALCIUM HYDROXIDE, 2.0 TO 2.5 PERCENT SILICA, 3.0 TO 8.0 PERCENT CALCIUM CARBONATE, AND 0.1 PERCENT
MAGNESIUM OXIDE.
EACH SCRUBBING TRAIN IS EQUIPPED WITH A GUILLOTINE-TYPE BY-PASS DAMPER ALLOWING BY-PASSING OF THE GAS AROUND THE SCRUBBERS.
EACH SCRUBBING TRAIN CONTAINS THE FOLLOWING MAJOR PIECES OF EQUIPMENT* 1.0. BOOSTER FAN, QUENCH SECTION, FLOODED ELBOW, MOBILE
BED CONTACTOR, CENTRIFUGAL OEMISTER, AND A 3-SECTION REACTANT TANK SYSTEM. THE WASTE DISPOSAL SYSTEM CONSISTS OF A 75-FOOT
DIAMETER THICKENER FOR LIQUID-SOLIDS SEPARATION AND A FLY ASH POND FOR ULTIMATE DISPOSAL OF THE THICKENER UNDERFLOW. THE SCRUB-
BING WASTES ARE STABILIZED WITH FLY ASH AND WATER IS RECYCLED BACK TO THE PROCESS. THE SYSTEM DOES NOT USE A STACK GAS REHEAT
SYSTEM. A WET STACK. WHICH IS THE EXISTING STACK LINED WITH CARBOLYNE, OBVIATES THE NECESSITY OF REHEAT.
138 PEOCO ENVIRONMENTAL
-------
F60 SYSTEM PERFORMANCE
CANE RUN UNIT NO.
-------
FSO SYSTEM PERFORMANCE
CANE RUN UNIT NO. H
PERFORMANCE FACTORS (X)
PERIOD HOURS BOILER (HR) SCRUBBERS (HR) OPERABILITY UTILIZATION COMMENTS
OF THE SYSTEM, AS A FUNCTION OF SERVICE TiME VERSUS
OUTAGE TIME, HAS BEEN VERY GOOD.
NOV. 76 720 95 THE SYSTEM INCURRED NO MAJOR PROBLEMS OR UPSETS
DEC. 76 711 90 DURING THE REPORT PERIOD. CARBIDE LIME SLURRY IS
EMPLOYED AS THE SULFUR DIOXIDE ABSORBENT.
1UO PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICULATES
56
LOUISVILLE 6AS & ELECTRIC
PADDYS RUN NO 6
LOUISVILLE KENTUCKY
65 MM
COAL 3.5-1.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
RETROFIT
H/73
OPERATIONAL
99 PERCENT DESIGN
S02
80 PERCENT (DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
OPEN LOOP 0*7 GPM/MU
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
S57/KW CAPITAL
2.5 MILLS/KWH OPERATING
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SCRUBBING SYSTEM UAS DESIGNED BY COMBUSTION ENGINEERING AND PLACED
IN SERVICE IN APRIL 1973. PADDYS RUN NO.6 IS A PEAK-LOAD UNIT THAT
OPERATES ONLY DURING DEMAND PERIODS. THE UNIT WAS OPERATIONAL DURING
THE REPORT PERIOD* BEING AVAILABLE TO THE BOILER ON 99 PERCENT BASIS.
SCRUBBER OPERATIONS WERE CONDUCTED ON CARBIDE LIME SLURRY DURING THE
PERIOD. THE EPA-SUBSIOIZED SCRUBBER/SLUDGE STUDY CALLS FOR A HIGH
CALCIUM VIRGIN LIME RUN TO COMMENCE ON MARCH It 1977.
PEDCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
PADDY'S RUN POWER STATION
PADDY'S RUN POWER STATION IS LOCATED IN LOUISVILLE, KENTUCKY. THE PLANT HAS SIX ELECTRIC POWER GENERATING UNITS WITH A TOTAL
RATED CAPACITY OF 320 MW. UNIT NO. 6 IS RETROFITTED WITH A CARBIDE LIME-BASE FGD SYSTEM.
UNIT NO. 6 IS A PEAK LOAD COAL-FIRED BOILER, MANUFACTURED BY FOSTER WHEELER AND INSTALLED IN 1950. THIS UNIT FIRES COAL WITH
A GROSS HEATING VALUE OF 11,500 BTU/LB AND AVERAGE SULFUR AND ASH CONTENTS OF 3.7 PERCENT AND 13 PERCENT, RESPECTIVELY.
THE FGD SYSTEM CONSISTS OF TWO MODULES. EACH HANDLES 175,000 ACFM OF sso F FLUE GAS. EACH MODULE is MADE UP OF TWO STAGES
OF 3-INCH MARBLE BEDS, FOLLOWED BY A TWO-STAGE CHEVRON-TYPE OEMISTER. THE GAS IS REHEATED BY DIRECT COMBUSTION OF NATURAL GAS.
SCRUBBING SYSTEM PROVIDING PRIMARY CONTROL OF PARTICIPATE EMISSIONS. THIS UNIT OPERATES WITH A 99.1 PERCENT PARTICULATE REMOVAL
EFFICIENCY. PARTICULATE LOADING AT THE ESP OUTLET IS 0.05 GR/SCF
PARTICULATE LOADING AT THE ESP OUTLET IS 0.05 GR/SCF.
THE SYSTEM UTILIZES A SLURRY OF CARBIDE LIME AS THE SULFUR DIOXIDE ABSORBENT. THE CARBIDE LIME, A WASTE BY-PRODUCT OBTAINED
FROM A NEARBY ACETYLENE MANUFACTURING PLANT CONTAINS 90 TO 92.0 PERCENT CALCIUM HYDROXIDE, 2.0 TO 2.5 PERCENT SILICA, 3.0 TO 6.0
PERCENT CALCIUM CARBONATE, AND 0.1 PERCENT MAGNESIUM OXIDE.
THE UNIT OPERATES ON A CLOSED-LOOP MODE* THE SULFUR DIOXIDE IS ABSORBED IN THE MARBLE BED BY A SLURRY OF CALCIUM SULFITE TO
FORM A MIXTURE OF CALCIUM SULFITE/BISULFITE. EFFLUENT FROM THE MARBLE-BED TOWER IS CONVERTED IN THE REACTION TANK TO CALCIUM
SULFITE BY THE ADDITION OF CALCIUM HYDROXIDE. HALF OF THE REACTION TANK EFFLUENT IS RETURNED TO THE ABSORBER TOWERS WHILE THE
OTHER HALF IS FED TO A CLARIFILR TANK. THE CALCIUM SULFITE CRYSTALS PRECIPITATE WITH THE AID OF A FLOCCuLANT. WHICH IS ADDED AT
THE RATE OF H TO 7 PPM. THE OVERFLOW is RETURNED TO THE REACTION TANK. THE UNDERFLOW, CONTAINING 22 TO 2«t PERCENT SOLIDS, is
STABILIZED BY MIXING IT WITH LIME. APPROXIMATELY 60 TO 100 POUNDS OF LIME ARC USED PER TON OF DRY SOLIDS OF SLUDGE. THE FIXED
SLUDGE IS TRANSPORTED BY TRUCKS TO A 10-ACKE OFF-SITE LANDFILL AREA.
DURING THE INITIAL 45 DAYS OF OPERATION ONLY ONE ABSORBER WAS PLACED IN SERVICE, ALLOWING OPERATORS TO OBSERVE THE EQUIPMENT
AND TO DETERMINE ANY NEEDED MODIFICATIONS. BEGINNING MAY 19, 1974, THE SYSTEM WAS SHUT DOWN FOR A MONTH FOR MODIFICATIONS, THE
MOST SIGNIFICANT BEING INSTALLATION OF EQUIPMENT FOR INJECTING A FLOCCULATING AGENT INTO THE CLARIFIER TANK. DURING THE PERIOD
JUNE 19 TO JULY 11, INCONSISTENT SIZING OF SLURRY ADDITIVE MATERIAL AS RECEIVED CAUSED MALFUNCTION OF THE ADDITIVE CONTROL VALVES
AND UNDUE PLUGGING OF SLURRY LINE STRAINERS. THESE PROBLEMS WERE CORRECTED BY INSTALLATION OF A DISINTEGRATOR IN THE SLURRY
PEOCO ENVIRONMENTAL
-------
PADDY'S NUN (CONTINUED)
MODIFICATION HADE WAS LOWERING THE SLURRY PH TO REMOVE SULFITE SCALE FORMATION ON THE UPPER BED PERFORATED SUPPORT PLATE AND ON
MODIFICATION MADE WAS LOWERING OF THE SLURRY PH TO REMOVE SULFITE SCALING FORMED ON THE UPPER BED PERFORATED SUPPORT PLANT AND ON
THE MARBLES*
PEOCO ENVIRONMENTAL
-------
MONTH
APR. 75
MAY 73
JUN, 73
JUL. 73
AUG. 73
SEP. 73
OCT. 73
OCT9 73
NOV. 73
OEC. 73
JAN. 74
THROUGH
JUL. 7«
OPERABILITY (X)
MODULE A MODULE B
18 56
11
21
53
21
65
72
35
104
7fl
0
F60 SYSTEM OPERABILITY
PADDY'S RUN UNIT NO. 6
COMMENTS
MODULES WERE OPERATED ONE AT A TIME, WITH FREQUENT SHUTDOWNS FOR INSPECTION OF EQUIPMENT AND
MINOR REPAIRS.
SINGLE-MODULE OPERATION CONTINUED THROUGH MAY 19, WHEN THE UNIT WAS SHUT DOWN FOR MODIFICA-
TIONS. THE MOST SIGNIFICANT MODIFICATION WAS INSTALLATION OF EQUIPMENT FOR INJECTION OF A
FLOCCULATING AGENT INTO THE CLARIFIER TANK.
OPERATION MAS INTERMITTENT FROM JUNE 19 TO JULY 11 BECAUSE OF MECHANICAL PROBLEMS WITH THE
SLURRY PUMPS.
DURING A SCHEDULED OUTAGE FROM JULY 12 THROUGH AUGUST 1« SEVERAL REPAIRS WERE MADE TO THE LINE
SLURRY MAKEUP SYSTEM. A DISINTEGRATOR UNIT WAS INSTALLED TO REDUCE PLUGGING OF STRAINERS AND
SLURRY CONTROL VALVES.
THE OPERATION WAS CONTINUOUS FROM AUGUST 2 TO AUGUST 18 EXCEPT FOR A BRIEF SHUTDOWN DUE TO A
BOILER-RELATED PROBLEM. FROM AUGUST 19 TO SEPTEMBER 5t THE SYSTEM WAS SHUT DOWN TO REPLACE THE
CLARIFIER'S UNDERFLOW LINE WITH ONE OF LARGER DIAMETER AND TO INSTALL ADDITIONAL PUMP CAPACITY
IN THE CLARIFIER«S OVERFLOW SYSTEM.
THE UNIT OPERATED CONTINUOUSLY BETWEEN SEPTEMBER 6 AND SEPTEMBER 20 EXCEPT FOR A 7-HOUR SHUT-
DOWN TO REPAIR A MARBLE BED SUPPORT PLATE. THE UNIT WAS SHUT DOWN THE REMAINDER OF THE MONTH
THE FGO SYSTEM REMAINED IN SERVICE TO DEC. 20 AFTER WHICH THE BOILER AND THE SCRUBBER MODULES
THE FbQ SYSTEM WAS IN SERVICE THROUGH DECEMBER 20 AFTER WHICH THE BOILER (AND THE SCRUBBERS)
WERE SHUT DOWN BECAUSE 0F *No DEMAND* (THIS IS A PEAKING-LOAD BOILER).
BOILER SHUT DOWN BECAUSE OF *NO DEMAND**
PEDCO ENVIRONMENTAL
-------
MONTH
AUG. 7«*
SEP. 7«t
OCT. 7«»
NOV. 7H
THROUGH
AUG. 75
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN. 76
FEB. 76
OPERABILITY (X)
MODULE A MODULE B
50
0
100
NO DEMAND
77
0
100
100
100
100
100
100
90
100
90
100 100
NO DEMAND
FGO SYSTEM OPERABILITY
PADDY'S RUN UNIT NO. 6
COMMENTS
UNIT HAS BEEN ON AND OFF FREQUENTLY DUE TO FLUCTUATION IN POWER DEMAND.
BOILER IS DOWN BECAUSE OF *NO DEMAND.*
BOILER TURNED ON SPECIFICALLY TO PERFORM LIMESTONE TESTS ON FGD SYSTEM.
BOILER IS DOWN BECAUSE OF *NO DEMAND.*
BOILEK AND FGD SYSTEM OPERATIONAL ALL OF SEPTEMBER AND FIRST TWO WEEKS IN OCTOBER. SYSTEM
OUTAGE DURING THE LAST TWO WEEKS OF OCTOBER WAS DUE PRIMARILY TO BREECHING IN THE BOILER
SECTION. OPERABILITY FOR BOTH MODULES DURING THE OPERATIONAL PERIOD WAS 100 PERCENT (BASED
UPON LG&E«S PEAK LOAD DETERMINATION). S02 REMOVAL WAS REPORTED TO BE OyER 98 PERCENT.
BOILER AND SCRUBBER SYSTEM RAN MOST OF THE REPORT PERIOD ON A MONDAY-THROUGH-FRIDAY BASIS.. TWO
MINOR OUTAGES IN DECEMBER WERE DUE TO MALFUNCTION AND REPAIR OF THE DUAL STRAINER SWITCH SHAFT
IN THE BOTTOM OF THE SCRUBBER MODULE.
502 REMOVAL EFFICIENCY WAS REPORTED TO BE 99 PERCENT DURING JANUARY. THE SYSTEM WAS SHUT DOWN
IN EARLY FEBRUARY IN PREPARATION FOR AN EPA SCRUBBER/SLUDGE STUDY SCHEDULED FOR JUNE OR JULY.
THE SCRUBBER WILL NOT BE OPERATED UNTIL THE START OF THE STUDY PROGRAM UNLESS THE BOILER IS
REQUIRED FOR PEAKING POWER DEMANDS. HIGHLIGHTS OF THE SCRUBBER/SLUDGE STUDY PROGRAM ARE AS
FOLLOWS*
6 MONTH DURATION.
ONE SCHEDULED SHUTDOWN FOR TEST MODIFICATIONS.
1*5
.REDCO ENVIRONMENTAL
-------
MONTH
MAR. 76
APR. 76
KAY 76
JUN. 76
JUL. 76
AUG. 76
SEP. 76
OCT. 76
NOV. 76
DEC. Tfr
OPEKABILITY (X)
MODULE A MODULE B
NO DEMAND
NO DEMAND
100 10&
100 100
190
100
180
100
NO DEMAND
99
99
99
99
FGD SYSTEM OPERABILITY
PADDY'S RUN UNIT NO. 6
COMMENTS
DELIBERATE HIGH CHLORIDE CONCENTRATION OPERATION.
MGO INNOCULATION.
EXTENSIVE SLUDGE STUDY* FIXATION* LEACHATES. SEASONAL VARIATIONS.
THE UNIT DID NOT OPERATE DURING THE REPORT PERIOD IN ANTICIPATION OF THE EPA SCRUBBER/SLUDGE
STUDY. THE UTILITY IS NOW COMPLETING SYSTEM MODIFICATIONS FOR THE OPERATION OF THE TEST
PROGRAM. THIS PEAK LOAD UNIT WAS OPERATED PART OF THE TIME DURING THE REPORT PERIOD (APPROXI-
MATELY 2 WEEKS IN MAY AND 2 WEEKS IN JUNE). THE SCRUBBER WAS AVAILABLE TO THE BOILER 100
PERCENT OF THE TIME. S02 REMOVAL EFFICIENCY WAS 98 TO 99 PERCENT DURING THIS OPERATING SEG-
MENT. THE EPA-SPONSORED SCRUBBER/SLUDGE STUDY IS NOW SCHEDULED TO COMMENCE SEPTEMBER 1* 1976.
THE UNIT WAS OPERATIONAL PART OF THE TIME DURING THE JULY-AUGUST PERIOD. THE SCRUBBING SYSTEM
WAS AVAILABLE TO THE BOILER ON A 100 PERCENT BASIS* NO MAJOR SCRUBBER-RELATED PROBLEMS W£RE
ENCOUNTERED.
THE UNIT DID NOT OPERATE THROUGHOUT SEPTEMBER AND THE FIRST 3 WEEKS OF OCTOBER.
THE EPA-FUNDED SCRUBBER/SLUDGE STUDY PROGRAM COMMENCED OCTOBER 25. THE INITIAL PHASE OF
THE PROGRAM CALLS FOR OPERATIONS TO PROCEED FOR A 20 TO- 30-OAY PERIOD WITH CARBIDE LIME
SCRUBBING ABSORBENT. FOLLOWING COMPLETION OF THIS RUN* THE UNIT WILL BE SHUT DOWN AND
MODIFICATIONS WILL BE INCORPORATED INTO THE SYSTEM FOR OPERATION WITH COMMERCIAL GRADE (HIGH
CALCIUMI LIME.
THC ufoiT WAS IN SERVICE DURING* THE REPORT PERIOD. THE SCRUBBING SYSTEM OPERATED 99.5 PERCENT
Of THE TIME THE BOILER WAS IN SERVICE. CARBIDE LIME WAS EMPLOYED AS THE 502 ABSORBENT. THE
HI6++ CALCIUM {VIRGIN) LIME RUN, SCHEDULED AS PART OF THE SCRUBBER/SLUDGE STUDY* WILL COMMENCE
OW MARCH It 1977.
1*6
PEOCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
59
MONTANA POWER CO.
COLCTRIP NO 1
COLSTRIP MONTANA
360 MU
COAL 0.8 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
NEW
10/75
OPERATIONAL
99 PERCENT
S02
60 PERCENT
UATEK MAKE UP
SLUDGE DISPOSAL
UNIT COST
CLOSED LOOP
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
$50/Kh CAPITAL
OPERATIONAL
EXPERIENCE
THE COLSTKIP PLANT IS A MINE MOUTH INSTALLATION. CONSTRUCTION ON THIS
UNIT WAS COMPLETED BEHIND SCHEDULE. THE FGD SYSTEM STARTED UP IN LATE
1975 AND PROCEEDED THROUGH A SHAKEDOWN AND DEBUGGING OPERATION PHASE. THE
UMT HAS BEEN OPERATING AT FULL COMMERCIAL CAPACITY. THE SCRUBBING
SYSTEM DESIGN INCORPORATES THE VENTURI WET SCRUBBERS FOR PARTICULATE
AND SULFUR DIOXIDE REMOVAL. FLUE GAS CANNOT BE BYPASSED AROUND THE
SCRUBBING SYSTEM. INFORMATION AND OPERATING DATA WERE NOT MADE
AVAILABLE BY THE UTILITY DURING THE REPORT PERIOD.
PEOCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 12/76
IDENTIFICATION NO.
UtILffY NAME
UN ft NAM£
UNIT LOCATION
UNIT RATIN6
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
PARfiCULATES
60F
MONTANA POWER CO.
COL^fRIP W0 2
COLSTRIP MONTANA
36$ MW
Cm 6<& WttCENt SULFUtf
AOL/COMBUST ION- EQUIP ASSOCIATE,
LIHE/AtKACfNE FLYASH SCRUBS INS
NEW
7/76
OPERATIONAL
99 PERCENT
SO?
WATER HAKE- UP
SLUDGE
UNiT COST
OPER'A'fKJNA'L
EXPERIENCE
CLOSES LOOP1
SLUDGE DISPOSED IN UNLlNtD POND
CAPltAtr
C^fcS-fRlP PLANT IS A MINE MOUTH FA(iIL*Ty. CONSTRUCTION OF THE FGO
H*& B6.EM COMPLETED« TURrflNE ROLL AND &YSTEH CHECI OUT HAVE BEEN
iNitlM OP£R^fl6N OF THE SCRUBBINS SYSTEM COMMENCED IN
i*t"6. fHIS UNlf iS IDENTICAL TO fn£ NO.i SYSTEM OESlSN IN THAT
SCWJB6ER HODULES ARE INSTALLED I^OR PARTICULATE AND SULFUR DIOXIDE
REMOVAL. FLUE GAS CONAOT BE BY-PASSED AROUND THE SCRUBBING SYSTEM.
ANO OPEPfAflWS DATA MfRC NflPt MADE AVAILABLE BY THE UTILITY
THE REPORT PERIOo.
ins
PCDCO £NVIRONMEJVTAt
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
67
NEVADA POWER
RE III- GARDNER NO 1
nOAPA NEVADA
125 MW
COAL 0.5- 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
RETROFIT
OPERATIONAL
99 PERCENT
S02
85 PERCENT
WATER HAKE UP
SLUU6E DISPOSAL
OPEN LOOP 1.52 GPH/MW
UNSTABILIZLD SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
CAPITAL (197
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTlCULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
68
NEVADA POWER
REIL' GARDNER NO 2
nOAPA NEVADA
125 MU
COAL 0.5- 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
RETROFIT
OPERATIONAL
99 PERCENT
85 PERCENT
OPEN LOOP 1.52 GPH/MW
UNSTABILIZED SLUoGE DISPOSED IN UNLINEQ PONo
OOLLAKSJ* JC600 «600ANNUALlZEO
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SODIUH CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MOGULS CONTAINING A TwIN VARIABLE-THKOAT VENTURI SCRUBBER FOLLOWED BY A
SIN9l£«STAGE PERFORATED-PLATE WASHING TOWER* THE SCRUBBING TRAIN WAS
FIRST PLACED IN THE GAS PATH IN APRIL i974. SYSTEM OPERATION DURING THE
REPORT PERIOD WAS INTERMITTENT BECAUSE OF SCRUBBER AND BOILER-RELATED
PROBLEMS.
150
PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
69
NEVADA POWER
REI- GARDNER NO 3
MOAPA NEVADA
125 MM
COAL 0.5- 1.0 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
NEW
7/76
OPERATIONAL
99 PERCENT
S02
WATER MAKE UP
SLUUGE DISPOSAL
85 PERCENT
OPEN LOOP 1.52 GPM/MW
UNSTABILIZED SLUDGE DISPOSED IN UNLINED PONO
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS UNIT IS A NEW COAL-FIREO BOILER THAT IS EQUIPPED WITH SODIUM
CARBONATE-8ASED(TRONA>SCRUBBIN6 SYSTEM WHICH INCORPORATES A TWIN
VAKIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A SINGLE-STAGE PERFORATED-
PLATE WASHING TOWER FOR THE CONTROL OF PARTICULATES AND SULFUR
DIOXIDE. THE BOILER COMMENCED OPERATIONS IN APRIL 1976 AND THE
SCRUBBER WAS PLACED IN SERVICE THREE MONTHS LATER. THE SYSTEM
WAS IN SERVICE THROUGHOUT THE REPORT PERIOD*
151
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
RE.ID GARDNER UNITS 1. 2, AND 3
THE REID GARDNER POyER STATION IS LOCATED NEAR NOAPA, NEVADA, ABOUT 50 MILES NORTH OF LAS VEGAS. THE STATION HAS, THREE
ELECTRIC POWER GENERATING UNITS, (REID GARDNER 1, 2, AND 3) EACH RATED AT 125 MW. UNITS 1 AND 2 ARE RETROFITTED WITH SODIUM
CARBONATE-BASED F&D SYSTEMS. UNIT NO. 3 IS A NEW INSTALLATION, ALSO EQUIPPED WITH A SODIUM CARBONATE BASED FGO SYSTEM. THE COAL
BURNED AT THE PLANT HAS AN AVERAGE GROSS HEATING VALUE OF 12,450 BTU/LB* AND ASH AND SULFUR CONTENTS OF 6 AND 0.5 PERCENT RESPEC-
TIVELY.
THE FGD SYSTEMS INSTALLED ON REID GARDNER UNITS 1,2, AND 3 WERE DESIGNED AND INSTALLED BY COMBUSTION EQUIPMENT ASSOCIATES IN
ASSOCIATION WITH A.D. LITTLE. THE SYSTEMS FOR UNITS 1 AND 2 WERE PLACED IN SERVICE IN APRIL 197 STORAGE AND SAND REMOVAL SERVES ALL THE FGD MODULES AT THE REID
GARDNER PLANT. SULFUR DIOXIDE REMOVAL EFFICIENCY is REPORTED TO BE as PERCENT. PRIMARY PARTICULATE REMOVAL is ACCOMPLISHED BY 75
PERCENT EFFICIENT MERCHANICAL COLLECTORS INSTALLED UPSTREAM OF THE WET SCRUBBERS, THE TOTAL PARTICULATE REMOVAL EFFICIENCY OF THE
.MECHANICAL COLLECTION AND WET SCRUBBING SYSTEM EXCEEDS THE 99 PERCENT LEVEL.
IN THIS SODIUM CARBONATE PROCESS, HOT FLUE GAS FROM THE BOILER PASSES FIRST THROUGH THE MECHANICAL COLLECTORS WHERE PRIMARY
PARTICULATE REMOVAL TAKES PLACE. PRESSURE is THEN BOOSTED BY AN INDUCED DRAFT FAN BEFORE THE GAS STREAM SPLITS AS IT ENTERS THE
TWIM-THROAT VENTURI SCRUBBER. THE HOT FLUE GAS is QUENCHED BY A SHOWER OF CIRCULATED SODIUM BASE LIQUOR* THE GAS THEN ENTERS THE
WASH TRAY AND BUBBLES THROUGH THE RADIAL-VANE MIST ELIMINATOR, WHERE TH£ REMAINING LIQUID DROPLETS CARRIED OVER WITH THE GAS ARE
TRAPPED AND REMOVED.
EFFLUENT FROM THE FGO SYSTEM IS FROM TWO SOURCES* THE SLIP STREAM OF SPENT LIQUOR DISCHARGED FROM THE RECIRCULATION TANK,
AND THE ALKALINE CLARIFIES UNDERFLOW, WHICH SERVES TO NEUTRALIZE THE PH OF THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE
t
SLUDGE SETTLING PONOS. THE SPENT LIQUOR IS PUMPED INTO ONE OF TWO SETTLING PONDS. THE OVERFLOW FROM THIS POND IS PUMPED TO A
LARGER 4&-ACRE PONbt WHERE THE BRINE IS EVAPORATED. THE F6D SYSTEM OPERATES ON AN OPEN WATER LOOP WITH NO LIQUOR RECYCLED TO THE
152 PEDCO ENVIRONMENTAL
-------
REID GARDNER UNITS It 2, AND 3 (CONTINUED)
MODULES FROM THE PONDS.
ADDITIONAL INFORMATION CONCERNING THE PERFORMANCE OF THE SCRUBBERS INSTALLED AT THE REID GARDNER STATION, INCLUDING PROBLEMS,
SOLUTIONS, AND MODIFICATIONS, ARE PRESENTED IN THE FOLLOWING TABLES. IN ADDITION, A GENERAL PROCESS FLOW DIAGRAM OF THE SODIUM
CARBONATE SCRUBBING SYSTEM IS PRESENTED IN FIGURE 15 OF APPENDIX C.
153 PEDCO ENVIRONMENTAL
-------
REID GARDNER 1
PERIOD
MAR. 75
APR. 75
NAY 75
JUN. 75
BOILER
TOTAL OPERATION
(HR.) (HR.)
HR.
CALLED
AVAILABILITY UPON TO
(HR.) OPERATE
OPERATION
(HR.)
JUL. 75
AUG. 75
SEP. 75 720 716
OPERABILITY = 76%
UTILIZATION s 78S
OCT. 75 7
-------
REIO GARDNER 1 (CONTINUED)
PERIOD
BOILER
TOTAL OPERATION
(HR.) (HR.)
JAN. 76 744 6«f7
AVAILABILITY = 81X
OPERABILITY = 29X
RELIABILITY = 57X
UTILIZATION = 25X
FEB. 76 696 66H
AVAILABILITY = 91%
OPERABILITY = 78X
RELIABILITY = 89X
UTILIZATION = 75X
MAR. 76 7
-------
REID GARDNER 1 (CONTINUED)
bOlLCR
TOTAL OPERATION
(HR.) CHR.)
PERIOD
HAT 76
JUN. 76
JUL. 76
AUG. 76 7HH
AVAILABILITY = 97*
OPERABILITY s 75*
RELIABILITY = 9**
UTILIZATION s H9*
SEP. 76 720
AVAILABILITY »9S»
OPERABILITY 4 97*
RELIABILITY s 99K
UTILIZATION = 89X
OCT. 76 7H1
AVAILABILITY »96*
OPERABILITY = 96*
RELIABILITY « 98)1
UTILIZATION * »7»
*79
656
670
HR.
CALLED
AVAILABILITY UPON TO
(HR.) OPERATE
OPERATION
(HK.)
719
366
360
683
676
639
726
661
6«8
COMMENTS
THE NO. 1 UNIT WAS SHUT DOWN THE ENTIRE MONTH FOR A SCHEDULED
TURBINE OVERHAUL AND BURNER LINE CONDUIT REPLACEMENT.
THE NO. I UNIT REMAINED OUT OF SERVICE THROUGHOUT THE MONTH FOR
COMPLETION OF THE TURBINE AND BOILER OVERHAUL WHICH COMMENCED THE
PRECEDING MONTH.
TWO FORCED SCRUBBER OUTAGES OCCURRED DURING THE MONTH ATTRIBUTED
TO PLUGGING IN THE TRAY RECYCLE TANK AND THICKENER TANK. TOTAL
BOILER OUTAGE TIME FOR THE MONTH EXCEEDED 265 HOURS.
TWO FORCED SCRUBBER OUTAGES WERE REPORTED BT THE UTILITY FOR THE
MONTH, THESE MINOR OUTAGES WERE CAUSED BY PLUGGING IN THE
VENTURI SPRAY HEADERS AND AN I.D. FAN MALFUNCTION* TOTAL FORCED
OUTAGE TIME AMOUNTED TO 36.8* HOURS.
SCRUBBER OUTAGE fIME WAS REQUIRED FOR INSTALLATION OF A NEW CAR-
BONATE FEED LINE* IN ADDITION, A MINOR SCRUBBER TRIP WAS CAUSED
BY PLUGGING IN THE SCRUBBER EFFLUENT SUCTION LINE.
156
PEOCO ENVIRONMENTAL
-------
REID GARDNER 1 (CONTINUED)
BOILER
TOTAL OPERATION
PERIOD HR. HR.
NOV. 76 720 631*5
AVAILABILITY - 87*
RELIABILITY = 8t*
OPERABILITY = SIX
UTILIZATION = 71*
DEC. 76 7«»*» 677.H
AVAILABILITY = 93*
RELIABILITY = 92*
OPERABILITY = 88*
UTILIZATION = SOX
AVAILABILITY
HR.
623
HR.
CALLLO
UPON TO
OPERATE
605
OPERATION
HR.
SOS
690
652.5
599
COMMENTS
ONE FORCED SCRUBBER OUTAGE OCCURRED DURING THE REPORT PERIOD
BECAUSE OF A SCREW CONVEYOR FAILURE, RESULTING IN AN
INABILITY TO MIX THE CHEMICAL ABSORBENT.
TWO FORCED SCRUBBER OUTAGES OCCURRED DURING DECEMBER BECAUSE
OF CHEMICAL DEPLETION AND A PLUGGED SENSING LINE.
157
PEDCO ENVIRONMENTAL
-------
REID GARDNER 2
PERIOD
FEB. 75
MAR. 75
APR. 75
MAY 75
JUM. 75
BOILER
TOTAL OPERATION
-------
BOILER
TOTAL OPERATION
PERIOD (HR.) (HR.)
OPERABILITY = 66*
UTILIZATION = 62*
FEB. 76 696 675
AVAILABILITY = 6*»*
RELIABILITY = 66*
OPERABILITY = 86*
UTILIZATION = 83*
MAR. 76 7t
-------
REID GARDNER 2 (CONTINUED)
BOILER
TOTAL OPERATION
PERIOD (HR.) IHR.)
JUU. 76 74* 516
AVAILABILITY = 91S
RELIABILITY = 96*
OPERABILITY = 61*
UTILIZATION = 57*
AUG. 76 7ft 709
AVAILABILITY = 95*
RELIABILITY = 9
-------
REID GARDNER 2 {CONTINUED)
BOILER
TOTAL OPERATION
HR. HR.
NOV. 76 720 621
AVAILABILITY = 52*
RELIABILITY = SIX
OPERABILITY = 58X
UTILIZATION s SOX
DEC. 76 744 275
AVAILABILITY = OX
RELIABILITY s OX
OPERABILITY = OX
UTILIZATION s OX
HK.
CALLEOO
AVAILABILITY UPON TO
HR. OPERATE
709
OPERATION
HR.
363
DURING A BOILER OUTAGE TO REPAIR A CONDENSER TUBE LEAK AND
BOTTOM ASH NOZZLE, THE SCRUBBER'S GUILLOTINE DAMPERS WERE BADLY
DAMAGED, AND THE SCRUBBER REMAINED OUT OF SERVICE DURING THE
MONTH OF DECEMBER.
161
PEDCO ENVIRONMENTAL
-------
REID GARDNER 3
BOILER
TOTAL OPERATION
PERIOD (HR.) (HR.I
JUL* 76 7** 692
AVAILABILITY =
-------
REID GARDNER 3 (CONTINUED)
BOILER
TOTAL OPERATION AVAILABILITY
PERIOD HR. HR.
NOV. 76 720 264
AVAILABILITY = 28X
RELIABILITY = 29*
OPCRABILITY = 80X
UTILIZATION = 29%
DEC. 76 7«»»» 7«»«»
AVAILABILITY = 99X
.RELIABILITY = 99X
OPERABLIITY = 97S
UTILIZATION = 97X
HR.
205
HR.
CALLED
UPON TO
OPERATE
727
737
728
OPERATION
HR.
212
721
COMMENTS
THE SCRUBBER SYSTEM WAS NOT IN OPERATION THE FIRST HALF OF
NOVEMBER DUE TO REPAIRS OF LEAKS IN THE VENTURI SCRUBBER BOX.
THE SYSTEM WAS RESTARTED NOV. 19, AND EXPERIENCED ONE FURTHER
FORCED OUTAGE, BECAUSE OF A SCREW CONVEYOR MALFUNCTION, PRE-
VENTING CHEMICAL MIXING.
DURING THE MONTH, ONE MINOR SCRUBBER OUTAGE, OCCURRED, BECAUSE OF
REPAIRS TO THE I.D. FAN EXPANSION JOINT.
163
PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY.
PARTICULATES
S02
78
NORTHERN STATES POWER CO.
SHERBUKNE COUNTY STATION NO.l
BECKER MINNESOTA
710 NW
COAL O.fi PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
NEb
3/76
OPERATIONAL
99 PERCENT GUARANTEE
SO PERCENT GUARANTEE
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
OPEN LOOP 1.13 GPM/MW
UNSTA8ILIZEQ SLUDGE DISPOSED IN LINED POND
$60 MILLION CAPITAL FOR UNITS 1 AND 3,
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT.
A PRELIMINARY WATEH/A1H SYSTEM CHECKOUT WAS SUCCESSFULLY COMPLETED BY
THE UTILITY AND INITIAL OPERATIONS COMMENCED ON MARCH 16, 1976. FULL
COMMERCIAL OPERATION OF THE SYSTEM BEGAN ON MAY 1, 1976. THE SCRUBBING
SYSTEM FOR THIS UNIT CONSISTS OF 12 MODULES. EACH SCRUBBING MODULE
INCORPORATES A VENTURI<-KOD SECTION AND A MARBLE BED ABSORBER FOR PAR-
TICULATE AND SULFUR DIOXIDE REMOVAL. SYSTEM DESIGN CALLS FOR 11 MODULES
TO BE IN OPERATION FOR FULL LOAD CAPACITY.
164
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
SHERBURNE COUNTY GENERATING PLANT
THE SHERBURNE COUNTY GENERATING PLANT OF THE NORTHERN STATES POWER COMPANY IS LOCATED ON THE MISSISSIPPI RIVER IN SHERBURNE
COUNTY. NEAR BECKER. MINNESOTA. THIS NEW POWER GENERATING PLANT CURRENTLY HAS ONE COAL-FIRED UNIT OPERATIONAL,ONE UNDER CONSTRUC-
TION* AND TWO IN THE EARLY PLANNING STAGES. UNIT NO. 1 IS RATED AT 710-NW AND FIRES MONTANA COLSTRlP COAL WITH A HEATING VALUE OF
8300 BTU/LBt AND SULFUR AND ASH CONTENTS OF 0.8 AND 9.0 PERCENT, RESPECTIVELY. IN ORDER TO MEET PARTICULATE AND SULFUR DIOXIDE
EMISSION STANDARDS WHICH ARE MORE STRINGENT THAN NEW SOURCE PERFORMANCE STANDARDS. THE UNIT WAS FITTtO WITH A SCRUBBING SYSTEM FOR
SIMULTANEOUS PARTICULATE AND SULFUR DIOXIDE REMOVAL.
THE NORTHERN STATES POWER CO., SHERBUHNE NO. 1 SCKUbBER DESIGN IS BASED UPON THE RESULTS OF A PILOT PLANT TEST PROGRAM CON-
DUCTED AT COMBUSTION ENGINEERING'S (CE) KREISINGER DEVELOPMENT LABORATORY AND A PROTOTYPE SCRUBBER PROGRAM CONDUCTED JOINTLY BY
COMBUSTION ENGINEERING AND NORTHERN STATES POWER AT THE UTILITY'S BLACK DOG STATION. THE SCRUBBING SYSTEM IS COMPRISED OF A FIRST
STAGE FIXED-ROD VENTURI SCRUBBER FOR PARTICULATE REMOVAL AND A MARBLE BED ABSORBER TO COMPLETE PARTICULATE REMOVAL AND ACHIEVE THE
NECESSARY SULFUR DIOXIDE REMOVAL. THE SCRUBBING SYSTEM HAS BEEN GUARANTEED TO REMOVE 99 PERCENT OF THE PARTICULATE MATTER ENTERING
THE SCRUBBING SYSTEM. OR MAINTAIN AN EMISSION 0.04 GR/DSCF, WHICHEVER OUTLET VALUE IS GREATER. THE SULFUR DIOXIDE DESIGN REMOVAL
EFFICIENCY IS BASED UPON THE REMOVAL OF 50 PERCENT OF THE SULFUR IN THE FUEL (MAXIMUM FUEL SULFUR CONTENT OF 1.2 PERCENT) OR
MAINTAIN AN EMISSION OF 200 PPM. WHICHEVER OUTLET VALUE IS GREATER.
THE GENERAL SCENARIO OF THE SHERBURNE NO. 1 SCRUBBING SYSTEM CONSISTS OF 12 SCRUBBING MODULES, 11 OF WHICH ARE REQUIRED FOR
FULL LOAD CAPACITY. EACH MODULE HAS A RATED FLUE GAS CAPACITY OF 200,000 TO 220,000 ACFM AT 135 F. AN AGITATED REACTION TANK IS
LOCATED AT THE BOTTOM OF EACH SCRUBBER MODULE. THE PURPOSE OF THE REACTION TANK IS TO ALLOW COMPLETION OF SULFUR DIOXIDE FORMA-
TION TO SULFITE, PROVIDE FORCED OXIDATION OF SULFITE TO SULFATE, AND FACILITATE PRECIPITATION OF CALCIUM SULFATE SOLIDS. IN
FORCED OXIDATION, AIR IS BUBBLED INTO THE REACTION TANK, OXIDIZING SULFITE TO SULFATE. THE SULFATE FORMED IS PRECIPITATED IN THE
REACTION TANK BY ADDITION OF GYPSUM SEED CRYSTALS. A BLEED LINE PROVIDES THE NECESSARY SOLIDS REMOVAL TO A 160-FOOT DIAMETER
CLARIFIER. HERE THE WASTE SOLIDS (FLY ASH, CALCIUM CARBONATE., AND CALCIUM SULFATE) SETTLE OUT AND THE CLARIFIED WATER IS RETURNED
TO THE PROCESS.
THE CLEANED FLUE GAS THEN PASSES THROUGH A DOUBLE ROW, TWO-PASS CHEVRON MIST ELIMINATOR. REHEAT ( T = HO ) IS ADDED TO THE
GAS STREAM TO PROVIDE PROTECTION TO THE DOWNSTREAM DUCTWORK, I.D. FAN, AND PLUME CONTROL BEFORE FINAL DISCHARGE TO THE ATMOSPHERE.
THE CLARIFIER UNDERFLOW IS PUMPED TO AN 16-INCH CLAY-LINED SETTLING POND WHICH IS H5-FEET DEEP AND 62 ACRES IN AREA. THE WATER IS
165 PEDCO ENVIRONMENTAL
-------
SHERBURNE COUNTY (CONTINUEDI
RECYCLED FROM THE POND BACK TO THE PROCESS. A GENERAL FLOW DIAGRAM OF THE SHERBURNE SCRUBBER ARRANGEMENT IS PROVIDED IN FIGURE
16 OF APPENDIX C.
INITIAL OPERATION OF THE SYSTEM COMMENCED MARCH 16, 197&. FULL COMMERCIAL OPERATION COMMENCED MAY it 1976. PROBLEMS ENCOUN-
TERED DURING INITIAL STARTUP OPERATIONS HAVE INCLUDED THE USUAL MECHANICAL PROBLEMS ASSOCIATED WITH A NEW SYSTEM AND SOME PLUGGING
IN THE SCKUBBER INTERVALS. SPECIFICALLY, PROBLEMS HAVE BEEN ENCOUNTERED IN THE SPRAY SYSTEM, REQUIRING THE DESIGN OF THE NOZZLES
TO BE CHANGED FROM PLASTIC AND RUBBER COMPONENTS TO CERAMIC SPINNER-VANE COMPONENTS. ALSO, SOME PLUGGING PROBLEMS HAVE BEEN,
ENCOUNTERED IN THE SPRAY HEADERS, PRIMARY CONTACTOR, AND MARBLE BED. THIS HAS STEMMED LARGELY FROM THE MALFUNCTION OF. THE STRAINER
SYSTEM BECAUSE OF POOR NOZZLE CONFIGURATIONS. NSP IS CURRENTLY MAKING MODIFICATIONS IN THIS AREA.
166 PEDCO ENVIRONMENTAL
-------
SHERBURNE NO
BOILER OPERATION TIME AND MODULE OPERABILITY
BOILER
PERIOD HR.
MAR. 76
APR. 76
MAY 76
JUN. 76
101 102 103 104 105 106 107 106 109 110 111 112
JUL. 76
AUG. 76
COMMENTS
A PRELIMINARY SYSTEM CHECKOUT BY PASSING WATER AND
AIR THROUGH THE SYSTEM WAS SUCCESSFULLY COMPLETED.
THE SYSTEM WAS INITIALLY PLACED IN SERVICE MARCH
16. 1976. FIRST COMMERCIAL OPERATION COMMENCED
MAY 1. 1976. THIS IS AN INTERMEDIATE LOAD UNIT,
OPERATING AT OR NEAR FULL CAPACITY DURING THE DAY
AND 35 PERCENT CAPACITY AT NIGHT. MODIFICATIONS
ARE PROCEEDING ON THE SPRAY SYSTEM, SPRAY NOZZLES,
AND STRAINER SYSTEM.
DEVELOPMENTAL WORK IS CONTINUING ON THIS SCRUBBING
SYSTEM. SINCE JULY 1, THE NO. 1 UNIT HAS BEEN
GENERATING 95 TO 98 PERCENT THE NUMBER OF MW-HOURS
THAT HAVE BEEN REQUIRED. THE NO. 1 UNIT IS AN
INTERMEDIATE LOAD UNIT WHICH OPERATES AT FULL
CAPACITY 15-16 HOURS/DAY AND ONE-THIRD CAPACITY
THE REMAINDER. PLUGGING IN THE SLURRY NOZZLES IS
STILL A PROBLEM. A QUARTER-INCH PARTICLE IN
THE FEED SOLUTION WILL PLUG UP THE FEED NOZZLES.
NSP is NOW PLANNING TO MODIFY THE DUPLEX STRAINER
SYSTEM TO ALLEVIATE THIS PROBLEM. IN ADDITION,
THE DEPOSITION OF SOFT SOLIDS IS STILL CONTINUING
IN THE DEMISTERS AND REHEATERS. HARD SCALE
GYPSUM FORMATION ON THE VESSEL WALLS HAS LEVELED
OFF. A CREW OF 70 PEOPLE IS REQUIRED TO MAINTAIN
167
PEDCO ENVIRONMENTAL
-------
SHERBURNE NO. 1 (CONTINUED)
BOILER OPERATION TIME AND NODULE OPERABILXTY
BOILER
PERIOD HR. 101 102 10} 10H 105 106 107 106 109 110 111 112
SEP. 76 566 87 90 93 76 76
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
TOTAL SYSTEM OPERABILITY = 100.0 PERCENT
OCT. 76 606 97 8H 96 96 93
TOTAL SYSTEM AVAILABILITY = 93 PERCENT
TOTAL SYSTEM OPERABILITY s 100 PERCENT
79 85
79
85 80 92 96
30 7H 76 91 81 100
67
COMMENTS
SCRUBBER OPERATIONS. THE PREVENTIVE MAINTENANCE
AND CLEANING PROCEDURES NOW EMPLOYED FOR THE
SCRUBBING SYSTEM CALLS FOR 3 TO 4 MODULES TO BE
TAKEN OUT OF SERVICE EACH NIGHT. THEREFORE*
EACH MODULE IS CLEANED OuT ONCE EVERY THREE DAYS.
THE TOTAL SYSTEM AVAILABILITY INDEX IS DEFINED AS
THE AMOUNT OF TIME 11 MODULES ARE AVAILABLE TO THE
UNIT, THUS ALLOWING FULL LOAD CAPACITY CAPABILITY.
TOTAL SYSTEM OPERABILITY HAS TO BE 100 PERCENT
SINCE THE SCRUBBERS CANNOT BE BYPASSES TO OPERATE
THE BOILER. NSP IS NOW IN THE PROCESS OF MODIFYING
THE SYSTEM'S STRAINER DESIGN. THE DUPLEX UNITS
ARE GOING TO BE RETIRED AND REPLACED WITH IN-THE-
TANK SCREENS AND SOOT BLOWERS, BOTH LOCATED AT
THE SUCTION SIDE OF THE RECYCLE PUMP. CARBON
STEEL FIN TUBE REHEAT BUNDLES ARE ALSO AN AREA OF
CONCERN. MULTIPLE FAILURES IN FOUR UNITS HAVE
BEEN EXPERIENCED.
168
PEOCO ENVIRONMENTAL
-------
SHERBURNE NO.l (CONTINUED)
BOILER OPERATION TIME AND MODULE. AVAILABILITY
BOILER
PERIOD HR. 101 102 103 104 105 106 107 108 109 110 111 112
NOV. 76 720 83 80 87 79 92
TOTAL SYSTEM AVAILABILITY = 93 PERCENT
TOTAL SYSTEM OPERABILITY = 100 PERCENT
DEC. 76 722 88 6H 87 60 71
TOTAL SYSTEM AVAILABILITY s 95 PERCENT
TOTAL SYSTEM OPERABILITY = 100 PERCENT
80 93 89 69 78 73 93
97 91
95
91 88 73 75
COMMENTS
THE MODIFICATION OF THE DUPLEX STRAINER SYSTEM
IS ONGOING, CURRENTLY APPROXIMATELY ONE-THIRD
COMPLETED ON THE NO. 1 UNIT. THE UTILITY IS
NOW CONDUCTING A FULL-LOAD EVALUATION STUOYt
ANALYZING SYSTEM OPERATION ON 10 MODULES VS.
THE DESIGNED 11 MODULES. THE UNIT IS CURRENTLY
HAVING DIFFICULTY COMPLYING WITH THE 20 PERCENT
OPACITY REGUALTION, DUE TO THE EXTREMELY FINE
FLY ASH BEING EMITTED (70 PERCENT LESS THAN
ONE MICRON.)
169
PEDCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGQ STATUS
EFFICIENCY,
PARTICULATES
84
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 1
SHIPPINGPORT PENNSYLVANIA
635 MM
COAL t.7 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
NEW
H/76
OPERATIONAL
99.8 PERCENT
S02
92 PERCENT GUARANTEE
WATER MAKE UP
SLUUGE DISPOSAL
CLOSED LOOP
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
S133/KW CAPITAL * 2.7 MILLS/ KWH ANNUALIZED
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS EMISSION CONTROL SYSTEM IS CAPABLE OF REMOVING FLYASH AND S02 FROM
3.35 MM ACFrt OF FLUE GAS VIA MET LIME SCRUBBING. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASE OF OPERATION BEGAN FOR PART OF THE SYSTEM IN DECEMBER
1975. FULL COMMERCIAL OPERATION COMMENCED IN APKIL 1976. TO DATE, ALL 6
OF THE SCRUBBING TRAINS HAVE BEEN SUCCESSFULLY PUT INTO OPERATION.
THE AVAILABILITY INDEX VALUE FOR THE ENTIRE SCRUBBING SYSTEM HAS
BEEN IN THE MID 90 PERCENT RANGE SINCE COMMERCIAL START-UP.
170
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
BRUCE MANSFIELD UNIT NO. 1
THE BRUCE MANSFIELD PLANT IS A 2700-MH, THREE-UNIT, COAL-FIRED FACILITY LOCATED ON THE OHIO RIVER IN THE BOROUGH OF SHIPPING
PORT* PENNSYLVANIA. THIS NEW FACILITY IS BEING BUILT BY PENNSYLVANIA POWER CO., WHICH IS ACTING ON ITS OWN BEHALF AND AS AGENT FOR
THE OTHER PARTICIPATING COMPANIES* THE CLEVELAND ELECTRIC ILLUMINATING CO., DUQUESNE LIGHT CO., OHIO EDISON CO., AND TOLEDO EDISON
CO.
BRUCE MANSFIELD NO. 1 IS A COAL-FIRED, ONCE-THROUGH, SUPERCRITICAL STEAM GENERATOR WHICH FIRES 333 TONS/HR OF COAL GENERATING
APPROXIMATELY 6.5 MM LB/HR OF STEAM AT 3*765 PSIG, 1005 F/1005 F. THE EMISSION CONTROL EQUIPMENT REQUIRED FOR THIS UNIT IS
DESIGNED TO MEET STATE EMISSION REGULATIONS OF 0.6 LBS SULFUR DIOXIDE/MM BTU OF HEAT INPUT AND 0.0175 GR/SCF OF PARTICULATE WHEN
BURNING 11,900 BTU/L8 COAL HAVING AVERAGE ASH AND SULFUR CONTENTS OF 12.5 AND t.7 PERCENT. RESPECTIVELY.
IN LATE 1970. AN INTENSIVE INVESTIGATION OF MORE THAN 30 POTENTIAL DESULFURIZATION SYSTEMS WAS INITIATED* THE SYSTEM ULTI-
MATELY CHOSEN FOR THE REMOVAL OF FLY ASH AND SULFUR DIOXIDE WAS THE VENTURI WET-SCRUBBING SYSTEM* MANUFACTURED BY CHEMICO AIR
POLLUTION CONTROL CO., UTILIZING THE DRAVO CORPORATION'S THIOSORBIC LIME AS THE SCRUB8ING-ABSORBENT.
THE DESIGN FEATURES OF THE SCRUBBING SYSTEM DICTATES EACH SCRUBBING TRAIN CONSIST OF A SCRUBBING VESSEL (VARIABLE-THROAT
VENTURI), A 9000-HR I.Q. FAN, AND AN ABSORBER VESSEL (FIXED-THROAT VENTURI). THERE ARE SIX SCRUBBER TRAINS PER UNIT, FIVE OF WHICH
ARE REQUIRED TO HANDLE THE FLUE GAS FLOW FROM THE BOILER AT FULL LOAD (3.35 MM ACFM AT 285 F). THE SCRUBBER/ABSORBER TRAINS ARE
ARRANGED IN TWO GROUPS OF THREE. THE TREATED FLUE GAS, WHICH HAS PASSED THROUGH THE SCRUBBING SYSTEM, IS DUCTED THROUGH A COMMON
REHEAT CHAMBER ANU THEN EXHAUSTED UP THE 950-FT. STACK.
THE ADJUSTABLE VENTURI THROAT SCRUBBING MODULE REMOVES NEARLY ALL OF THE FLY ASH CONTAINED ZN THE FLUE GAS. THE ABSORBER
MODULE, WHICH IS A FIXED-THROAT VENTURI, REMOVES THE REMAINING FLY ASH. SULFUR DIOXIDE IS ABSORBED IN BOTH THE SCRUBBER AND
ABSORBER e»Y DROPLETS OF LIME SLURRY. CONTAINING 2 TO 6 PERCENT MAGNESIUM OXIDE,
THE SCRUBBER-RECYCLE BLEED IS COMBINED WITH A FLY ASH SLURRY FROM THE BOILER AND DISCHARGED TO A 200-FOOT-DZAMETER THICKENER.
SLUDGE FROM THE THICKENER IS THEN PUMPED TO A WASTE DISPOSAL SYSTEM WHERE IT IS MIXED WITH A STABILIZING AGENT (CALCILOX) AND THEN
PUMPED APPROXIMATELY 7 MILES TO THE LITTLE BLUE RUN RAVINE FOR LAND FILL.
A SIMPLIFIED PROCESS FLOW DIAGRAM IS PRESENTED IN FIGURE 17 OF APPENDIX C.
PEOCO ENVIRONMENTAL
-------
MONTH
BRUCE MANSFtELD NO. 1
BOILER
OPERATING HOURS
FGD MODULES
COMMENTS
DEC. 75
JAN. 76
FEB. 76
MAR. 76
APR. 76
506
210
MAY 76 595 209 615
TOTAL SYSTEM AVAILABILITY s. 60*
TOTAL SYSTEM OPERABILITY s 108*
TOTAL SYSTEM RELIABILITY a 100*
TOTAL SYSTEM UTILIZATION = 60*
JUN.76 72Q 711 660
TOTAL SYSTEM AVAILABILITY s 100K
TOTAL SYSTEM OPCRABILITY * 1003
TOTAL SYSTEM RELIABILITY « 100*
TOTAL SYSTEM UTILIZATION e 100*
JUU. 76 672.« 537 S9fl
TOTAL SYSTEM AVAILABILITY s 968
TOTAL SYSTEM OPERABILITY s 100*
TOTAL $YSJC« RELIABILITY * 100*
TOTAL SYSTEM UTILIZATION s 90S
2147
24Q6
2H27
1576 2659
3430
2920
701
674
705
578
606
637
662
661
INITIAL OPERATION (SHAKEDOWN AND DEBUGGING) FOR PART OF THE
SYSTEM COMMENCED IN DECEMBER 1975.
THE INSTALLATION BEGAN FULL COMMERCIAL OPERATION IN APRIL.
THE SCRUBBING SYSTEM IS CURRENTLY HANDLING FLUE GAS AT A
TOTAL EQUIVALENT CAPACITY OF 840 TO 850-MU (GROSS). THE
TOTAL MODULE BY MODULE OPERATION HOURS LOGGED TO-OATE ARE
POSTED IN THE ACCOMPANYING TABLE.
THE LAST SCRUBBING TRAIN WAS PLACED IN SERVICE DURING THE
MONTH. SERVICE TIME TOTALS FOR ALL 6 SCRUBBER-ABSORBER
TRAINS THROUGH MAY ARE POSTED IN THE ACCOMPANYING TABLE
ALONG WITH THE PERFORMANCE INDEX VALUES.
THE VALUES IN THE ACCOMPANYING TABLE ARE THE BOILER HOURS
AND THE MODULAR OPERATING HOURS.
172
PEOCO ENVIRONMENTAL
-------
BRUCE MANSFIELD NO. 1 (CONTINUED)
OPERATING HOURS
MONTH BOILER FGD MODULES COMMENTS
A B C 0 £ F
AUG. 76 705.3 672 620 655 535 500 668
TOTAL SYSTEM AVAILABILITY = 95X
TOTAL SYSTEM OPCRABILITY = 100X
TOTAL SYSTEM RELIABILITY = 100*
TOTAL SYSTEM UTILIZATION = 95X
SEP. 76 720 706 617 693 695 596 H6H
TOTAL SYSTEM AVAILABILITY = 1008
TOTAL SYSTEM OPERABILITY = 100%
TOTAL SYSTEM RELIABILITY = 10OK
TOTAL SYSTEM UTILIZATION = 100X
OCT. 76 739 710 549 631 619 691 691
TOTAL SYSTEM AVAILABILITY = 99X
TOTAL SYSTEM OPERABILITY = 10OX
TOTAL SYSTEM RELIABILITY = 100X
TOTAL SYSTEM UTILIZATION = 99X
NOV. 76 277 270 278 282 113 159 2t6
TOTAL SYSTEM AVAILABILITY = 100X
TOTAL SYSTEM OPERABILITY = 100 X
TOTAL SYSTEM RELIABILITY = 100 X
TOTAL SYSTEM UTILIZATION = 38X
DEC. 76 722 58«» 726 68* 433 622 626
TOTAL SYSTEM AVAILABILITY = 100 X
TOTAL SYSTEM OPERABILITY = 100 X
TOTAL SYSTEM RELIABILITY = 100 X
TOTAL SYSTEM UTILIZATION =97X
173 PEOCO ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
80
PHILADELPHIA ELECTRIC CO.
EBCYSTONE NO 1A
EDOYSTONE PENNSYLVANIA
120 MU
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/75
OPERATIONAL
99.9 PERCENT
S02
WATER MAKE UP
SLUObE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
90 PERCENT
CLOSED LOOP 1.1 GPM/MW
$17 MILLION CAPITAL
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE &02 SCRUBBING OPERATIONS HAVE BEEN TEMPORARILY DISCONTINUED AT THIS
STATION BECAUSE THE REGENERATION FACILITY AT THE OLIN CHEMICAL SULFURIC
ACID PLANT HAS PERMANENTLY CEASED OPERATIONS. THE UTILITY IS NOW RELO-
CATING THE REGENERATION FACILITY TO THE ESSEX CHEMICAL PLANT LOCATED
IN NEWARKi NEW JERSEY, RESUMPTION OF $02 SCRUBBING OPERATIONS js NOW
SCHEDULED FOR MAY OF 1977. To DATE. THE MAGNESIUM OXIDE SCRUBBING UNIT
HAS BEEN IN SERVICE FOR ONLY A SHORT PERIOD OF TIME DURING LATE 1975,
17*
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
EDDYSTONE NO. 1
THE EDDYSTONE STATION OF THE PHILADELPHIA ELECTRIC COMPANY (PECO) IS LOCATED ON THE DELAWARE RIVER IN EODYSTONE,PENNSYLVANIA.
ABOUT 11 MILES SOUTHWEST OF THE CENTER OF PHILADELPHIA. THE PLANT IS APPROXIMATELY FIVE MILES WEST OF ONE OF THE MAIN RUNWAYS OF
THE PHILADELPHIA INTERNATIONAL AIRPORT.
THE STATION HAS FOUR GENERATORS WITH A TOTAL NET GENERATING CAPACITY OF 1370 MW. UNITS 1 AND 2 BURN COAL WITH AN AVERAGE
GROSS HEATING VALUE OF 12.100 BTU/LB AND ASH AND SULFUR CONTENTS OF 12 PERCENT AND 2.3 PERCENT, RESPECTIVELY. STEAM CONDITIONS ARE
5.000 PSI AND 1150 F. THESE ARE THE HIGHEST UTILITY PLANT OPERATING PRESSURE AND TEMPERATURE CONDITIONS IN THE UNITED STATES.
UNITS 1 AND 2 ARE BASE-LOAD UMTS. UNITS 3 AND
-------
EODYSTONE (CONTINUED)
THE MAGNESIUM OXIDE REGENERATION FACILITY HAS BEEN OPERATED TO PROCESS ALL MAGNESIUM SULFITE MATERIAL SENT TO IT FROM EDDY-
STONE. THIS OPERATION WAS USUALLY ON A BATCH BASIS DUE TO THE UPS AND DOWNS AT THE EDDYSTONE SCRUBBER.
THE SULFUR DIOXIDE SCRUBBING SYSTEM WAS TEMPORARILY SHUT DOWN DECEMBER 31t 1975i BECAUSE THE ACID PLANT REGENERATION FACILITY
AT THE OLIN CHEMICAL SULFURIC ACID PLANT IN PAULSBORO, NEW JERSEY PERMANENTLY CEASED OPERATIONS. THE UTILITY IS NOW IN THE PROCESS
OF RELOCATING THE REGENERATION FACILITY-TO THE ESSEX CHEMICAL PLANT LOCATED IN NEWARKt NEW JERSEY. THE RELOCATION OF THIS FACILITY
WILL PROBABLY PROLONG THE SULFUR DIOXIDE DEVELOPMENTAL SCHEDULE BY APPROXIMATELY ONE YEAR. THE WET PARTlCULATE SCRUBBERS ARE.
CONTINUING TO OPERATE AT THE EOOYSTONE PLANT.
THE PARTlCULATE AND SULFUR DIOXIDE REMOVAL SYSTEM INSTALLED ON THE EODYSTONE NO. 1 UNIT IS THE FIRST PHASE OF A TWO-PHASE
PROJECT. FOLLOWING SUCCESSFUL DEVELOPMENT OF THIS SYSTEM WITH MORE CONTINUOUS OPERATION, IT WILL BE INCORPORATED INTO THE DESIGN
FOR THE COMPLETE SULFUR DIOXIDE REMOVAL ON EODYSTONE NO. 2 AND ONE OF THE TWO EXISTING UNITS AT THE CROMBY STATION.
ADDITIONAL INFORMATION AND DATA CONCERNING THE OPERATION OF THE PARTlCULATE AND SULFUR DIOXIDE SCRUBBERS INSTALLED AT TH.IS
PLANT ARE PROVIDED IN THE PERFORMANCE TABLE.
176 PEOCO ENVIRONMENTAL
-------
F60 SYSTEM PERFORMANCE
EODYSTONE NO. 1
COMMENTS
NOV. 7H THE SCRUBBING SYSTEM AT THIS PLANT CONSISTS OF THREE PARALLEL SCRUBBING TRAINS INCORPORATING 3 WET PARTICULATE SCRUBBERS
DEC. 7<» AND ONE S02 ABSORBER MODULE. THERE WAS A BKIEF OPERATING PERIOD ON THE PARTICULATE SCRUBBERS FROM MID-NOVEMBER 197«t TO
JAN. 75 MARCH 1975. PROBLEMS ENCOUNTERED CENTERED AROUND THE SCRUBBER BOOSTER FANS AND THE FLUE GAS AND LIQUID CONDITIONS.
FEB. 75 THE B-SIDE BOOSTER FAN DEVELOPED HIGH SHAFT VIBRATION WHEN STARTED FOR THE FIRST TIME. THIS PROBLEM WAS DESIGN-RELATEOt
MAR. 75 INVOLVING AN EXCESSIVE CLEARANCE AREA BETWEEN THE SHAFT AND THE WHEEL HUB. ALSO, EXTENSIVE CORROSION DEVELOPED IN THE
APR. 75 C-SIDE PARTICULATE SCRUBBER INTERNALS. THIS WAS CAUSED BY LOW SCRUBBING SOLUTION PH LEVELS AND CHLORIDE LEVELS AS HIGH
MAY 75 AS 2000 PPM. THESE CONDITIONS COUPLED WITH THE THERMAL SHOCK OF A HOT START PROCEDURE CAUSED THE CORROSION. THIS
JUN. 75 PROBLEM WAS AMELIORATED BY CAUSTIC ADDITION* HIGHER SLOWDOWN AND EMPLOYING A COLO START PROCEDURE. AT APPROXIMATELY
THIS TIME, A CHECKOUT OF SQ2 SYSTEM WAS CONDUCTED. BLISTERING AND PEELING OF THE POLYURETHANE COATINGS WERE DETECTED
AND CORRECTED BY RECOATING WITH FLAKE GLASS.
JUL. 75 THE C-SIDE: PARTICULATE SCRUBBER RESTARTED ON JULY 23. 1975, THE TWO REMAINING TRAINS. B-SIDE AND A-SIOE, WERE PUT INTO
AUG. 75 OPERATION ON AUGUST 15 AND OCTOBER 2, RESPECTIVELY. THE S02 ABSORBER MODULE IN THE C-SIDE SCRUBBING TRAIN WAS INITIALLY
SEP. 75 PLACED IN SERVICE OCTOBER 2. 1975. THE OLIN CHEMICAL MGO REGENERATION FACILITY FIRST PROCESSED MAGNESIUM SULFITE FROM
OCT. 75 THE EDDYSTONE SCRUBBER ON OCTOBER 28, 1975. THE C-SIDE PARTICULATE SCRUBBER OPERATED A TOTAL OF 2831 HOURS THROUGH
NOV. 75 JANUARY 31. 1976, FOR AN AVAILABILITY OF 70 PERCENT. THHE B-SIDE TRAIN HAS OPERATED A TOTAL OF 1933 HOURS THROUGH
DEC. 75 JANUARY 31. 1976 FOR AN AVAILABILITY OF 55 PERCENT. THE A-SIDE TRAIN OPERATED A TOTAL OF 626 HOURS THROUGH JANUARY 31.
JAN. 76 1976, FOR AN AVAILABILITY OF 2H PERCENT. THE C-SIDE S02 ABSORBER WAS IN SERVICE A TOTAL OF 556 HOURS THROUGH DECEMBER
31, 1975, WITH AN AVAILABILITY OF 33 PERCENT SINCE STARTUP. PROBLEMS ENCOUNTERED IN THE OPERATION OF THE THREE SCRUBBING
TRAINS INCLUDED* UNDER-DESIGNED RECIRCULATION PUMPS, MALFUNCTION OF THE FLUE GAS BY-PASS DAMPER DRIVE UNITS AND
FAILURE OF THE DOUBLE-BRICK REFRACTORY LINING IN THE REHEAT COMBUSTION CHAMBER.
FEB. 76 OPERATION OF THE SQ2 SCRUBBING SYSTEM AT EDDYSTONE WAS TEMPORARILY HALTED BECAUSE THE ACID PLANT REGENERATION FACILITY
MAR. 76 AT THE OLIN CHEMICAL SULFURIC ACID PLANT IN PAULSBORO, NEW JERSEY PERMANENTLY CEASED OPERATIONS. THE UTILITY IS NOW
APR. 76 INVESTIGATING ALTERNATIVE REGENERATION SITES. A MINIMUM PERIOD OF SIX MONTHS WILL BE REQUIRED FOR RELOCATION ONCE A
177 PEOCO ENVIRONMENTAL
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FGO SYSTEM PERFORMANCE (CONTINUED)
EODYSTONE NO. 1
COMMENTS
HAY 76 CHOICE Is MADE. THE UTILITY ANNOUNCED PLANS FOR RELOCATION OF THE REGENERATION FACILITY AT THE ESSEX CHEMICAL PLANT IN
NEWARK. NEW JERSEY.
JUN. 76 RESUMPTION OF S02 SCRUBBING OPERATIONS IS PRESENTLY SCHEDULED FOR DECEMBER 1976. THE RELOCATION OF THE REGENERATION
JUL. 76 FACILITY IS NOW IN PROGRESS. THE PARTlCULATE SCRUBBERS ARE OPERATIONAL. THE C-SIDE BOOSTER FAN HAS DEVELOPED A
AUG. 76 MATERIALS FAILURE BETWEEN THE HUB AND SHAFT (IDENTICAL TO THE B-SIDE UNIT MENTIONED ABOVE).
SEP. 76 ALL THREE BOOSTER FANS HAVE NOW DEVELOPED THE MATERIALS FAILURE BETWEEN THE HUB AND SHAFT (AS IDENTIFIED IN THE ABOVE
OCT. 76 FOR THE B-SIDE UNIT). THESE UNITS HAVE BEEN RETURNED TO THE MANUFACTURER FOR MODIFICATIONS AND REPAIRS. CURRENTLY, ONE
OF THE PARTICULATE SCRUBBERS is IN THE FLUE GAS STREAM. TO DATE. ALL THREE OF THE WET PANICULATE SCRUBBERS HAVE NOT
SEEN ANY APPRECIABLE SIMULTANEOUS SERVICE TIME.
NOV. 76 MGO SCRUBBING OPERATIONS ARE NOW SCHEDULED TO RESTART IN HAY 1977. REGENERATION FACILITY RELOCATION IS BEING COM-
DEC. 76 PLETED, AND MODIFICATIONS TO THE ID BOOSTER FANS CURRENTLY BEING EFFECTED CONSIST OF CONVERSION FROM A SHRINK FIT
TO A SLIP FIT. THESE MODIFICATIONS ARE EXPECTED TO ELIMINATE RECURRING VIBRATION PROBLEMS.
176 PEDCO ENVIRONMENTAL
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
93
PUBLIC SERVICE CO OF COLORADO
VAL.10NT NO. 5
VALNONT COLORADO
SO MU
FUEL CHARACTERISTICS COAL 0.72 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY*
PARTICULATES
S02
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
RETROFIT
10/7H
OPERATIONAL
95 PERCENT
65 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
CLOSED LOOP
UNSTABILIZED SLUDGE DISPOSED IN LINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 197*. THE FGt SYSTEM CURRENTLY
OPERATIONAL AT THIS STATION IS AN EXPERIMENTAL UNIT. ORIGINALLY DESIGNED
BY UNIVERSAL OIL PRODUCTS FOR PARTICULATE REMOVAL ONLY. ONE OF THE THO
PARALLEL SCRUBBING MODULES WAS CONVERTED TO LIMESTONE SCRUBBING FOR
EXPERIMENTAL PURPOSES ONLY.
179
PCOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
VALMONT NO. 5
THE VALMONT POWER STATION OF THE PUBLIC SERVICE COMPANY OF COLORADO IS LOCATED IN VALMONT, COLORADO, APPROXIMATELY 20 MILES
NORTH OF DENVER. VALMONT NO. & IS A COAL-FIRED UNIT BURNS THAT FIRES GAS A FEW MONTHS DURING THE YEAR. THE COAL GENERALLY
EMPLOYED FOR THIS UNIT IS WYOMING ROSEBUD, WHICH HAS AN AVERAGE GROSS HEATING VALUE OF 10.760 BUT/LB WITH ASH CONTENT IN THE & TO
7 PERCENT RANGE ANQ SULFUR CONTENT LESS THAN 1 PERCENT.
THE FGD SYSTEM BEING TESTED AT THIS STATION is AN EXPERIMENTAL UNIT ORIGINALLY DESIGNED BY UNIVERSAL OIL PRODUCTS FOR PARTIC-
ULATE REMOVAL ONLY. THIS TCA UNIT CONSISTS OF TWO PARALLEL MODULES WITH A COMBINED CAPABILITY OF TREATING APPROXIMATELY 50
PERCENT OF THE TOTAL FLUE GAS LOAD OR THE EQUIVALENT OF APPROXIMATELY 100 MW GENERATING CAPACITY (50 MW PER MODULE). THIS SYSTEM
WAS COMPLETED AND OPERATIONAL IN 1971 AND RAN UNTIL OCTOBER 1971. PARTICIPATE REMOVAL EFFICIENCY WAS MEASURED AT 95 PERCENT,
SULFUR DIOXIDE REMOVAL EFFICIENCY WAS <*S PERCENT, AND AVAILABILITY WAS APPROXIMATELY 70 PERCENT. FREQUENT SCRUBBER OUTAGES WERE
CAUSED PRIMARILY BY SUPERSATURATED CALCIUM SULFATE IN THE SCRUBBING LIQUOR. TO MINIMIZE CLEANOUTS AND RECTIFY SCALING PROBLEMS*
A PH CONTROL PROGRAM WAS IMPLEMENTED FOR ONE OF THE SCRUBBING MODULES WITH ADDITION OF LIMESTONE TO THE SCRUBBING LIQUOR. THIS
MODIFICATION WAS EXPECTED TO MINIMIZE SCALING, DECREASE SCRUBBER OUTAGES FOR CLEANOUTS* AND INCREASE AVAILABILITY. THE EXPECTED
RESULTS DID MOT MATERIALIZE. SCALE BUILDUP CONTINUED AND AVAILABILITY DECREASED. TESTS DURING THE PH CONTROL PROGRAM SHOWED
PARTICULATE REMOVAL EFFICIENCY AT 95 PERCENT* SULFUK DIOXIDE REMOVAL EFFICIENCY INCREASED TO 85 PERCENT* AND AVAILABILITY DROPPED
TO 70 PERCENT. THE UNSTABILIZED SLUDGE GENERATED DURING THIS OPERATION WAS PUMPED TO A LINED POND. THE OPERATIONAL DATA GENER-
ATED FROM THE LIMESTONE MODIFICATION PROGRAM ARC PRELIMINARY* BASED UPON A 4.5 MONTH TESTING PROGRAM.
160 PEOCO ENVIRONMENTAL
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VALMONT NO. S
MONTH
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN. 76
FEB. 76
MAR. 76
APR. 76
MAY 76
JUN. 76
JUL. 76
AUG. 76
SEP. 76
OCT. 76
OPERATING HOURS
BOILER FGO SYSTEM
FGD SYSTEM
OPEKABILITY (X)
NOV. 76
DEC. 76
COMMENTS
THIS FACILITY HAS BEEN INACTIVE SINCE SEPTEMBER 1« 1975. BECAUSE OF A
TURBINE GENERATOR FAILURE. THE UNIT IS SCHEDULED TO GO ON LINE AGAIN
IN DECEMBER 1975. THIS UNIT IS STILL INACTIVE BECAUSE OF A BOILER
OVERHAUL. THE SCRUBBER/ABSORBER TRAIN IS AVAILABLE AND WILL BE COUPLED
INTO THE SYSTEM WHEN THE BOILER GOES BACK ON-LINE.
THE BOILER OVERHAUL HAS BEEN COMPLETED. THE UNIT IS AVAILABLE IN THE
PARTICULATE REMOVAL MODE ONLY* THE UTILITY IS SUSPENDING RESUMPTION
OF THE LIMESTONE MODIFICATION OPERATION FOR AN INDEFINITE PERIOD.
THE EXPERIMENTAL LIMESTONE SCRUBBING PROGRAM WAS INACTIVE DURING THE
REPORT PERIOD. RESUMPTION OF THE PROGRAM IS CONSIDERED INDEFINITE AT
THE PRESENT TIME.THE EXPERIMENTAL LIMESTONE SCRUBBING PROGRAM REMAINED
INACTIVE DURING THE REPORT PERIOD. PRESENT PLANS CALL FOR THE RESUMP-
TION OF THIS PROGRAM SOMETIME IN THE FALL OF 1976. THE TCA UNIT IS
NOW OPERATIONAL IN THE PARTICULATE REMOVAL MODE. THE NO. 5 UNIT FIRES
A COMBINATION OF COAL AND NATURAL GAS MEETING CURRENT STATE AIR
EMISSION STANDARDS.
NO CHANGE IN STATUS. THE RESUMPTION OF THE EXPERIMENTAL LIMESTONE
ADDITIONAL AND S02 REMOVAL PROGRAM IS STILL INDEFINITE. THE TCA
MODULES ARE CONTINUING TO OPERATE IN THE PARTICULATE REMOVAL MODE.
CARRYOVER INTO THE RECIRCULATION SYSTEM IS STILL A PROBLEM AREA.
THE LOW PH SCRUBBER ENVIRONMENT HAS CAUSED A MATERIALS PROBLEM,
NECESSITATING REPLACEMENT OF 304 SS PARTS WITH 316 SS.
THE UTILITY HAD NO CHANGE IN STATUS TO ANNOUNCE FOR THE
CURRENT REPORT PERIOD.
161
PEDCO ENVIRONMENTAL
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TABLE: 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCtSS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICULATES
100
RICKENBACKER AFB
RICKENBACKER
COLUMBUS OHIO
20 MW
COAL 3.6 PERCENT. SULFUR
RESEARCH COTTRELL
LIME SCRUBBING
RETROFIT
3/76
OPERATIONAL
99 PERCENT
S02
90 PERCENT
WATER MAKE UJ*
SLUDGE DISPOSAL
OPEN LOOP 2.50 GPrt/MW MAY
UNSTABILIZED SLUDGE DISPOSED IN LINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
H10/KW CAPITAL
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE SCRUBBING SYSTEM WAS FIRST PLACED IN SERVICE MAKCH 11, 1976.
THE SYSTEM SUPPLIER REPORTED THAT THE SYSTEM REMAINED OUT OF SERVICE
THROUGHOUT THE MONTH OF NOVEMBER FOR COMPLETION OF REPAIRS TO
THE SCRUBBER FAN THRUST BEARING. THE SCRUBBEK WAS PUT BACK IN THE
GAS STREAM AND REMAINED IN SERVICE THROUGHOUT THE MONTH. A NEW
STOKER BOILER* WHICH WILL REPLACE TWO OF THE OLDER UNITS, IS NOW
BEING INSTALLED AT THIS FACILITY.
162
PEOCO ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
RICKENBACKER AIR FORCE BASE
IN 1971 RESEARCH-COTTRELL CONCLUDED AN AGREEMENT WITH A.B. BANCO VENTILATION, ENKOPING, SWEDEN. THIS CONTRACTUAL ARRANGEMENT
ALLOWS RESEARCH-COTTRELL TO BE THE EXCLUSIVE LICENSEE OF THE BAHCO SULFUR DIOXIDE SCRUBBING PROCESS IN THE UNITED STATES. TO
OATEi THERE ARE 19 SULFUR DIOXIDE BAHCO SCRUBBING SYSTEMS IN THE VARIOUS STAGES OF DEVELOPMENT THROUGHOUT THE WORLD. THE FIRST
u.s. BAHCO INSTALLATION HANDLES SEVEN STOKER-TYPE COAL-FIRED BOILERS AT THE RICKENBACKCR AIR FORCE BASE IN COLUMBUS* OHIO. THE
BOILERS ARE OLDER UNITS. THREE WERE FIRST PLACED IN SERVICE IN 1952 AND THE REMAINING H CAME ON LINE IN 1954. THE UMTS FIRE A
HIGH SULFUR COAL, 3.6 PERCENT SULFUR, AT HIGH COMBUSTION AIR RATESi 150 TO 160 PERCENT EXCESS AIR.
THE RICKENBACKER EMISSION CONTROL SYSTEM CONSISTS ESSENTIALLY OF A MECHANICAL COLLECTOR, BAHCO SCRUBBER TOWER, LIME. STORAGE
AND HANDLING SYSTEM, CLARIFIERt BOOSTER FAN AND ASSOCIATED DUCTWORK. PUMPS, CONTROLS, AND A SLUDGE DISPOSAL POND.
SOLID PARTICULATE AND SULFUR DIOXIDE-LADEN FLUE GAS TAKEN FROM EACH OF THE EXISTING SEVEN 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 WAS INSTALLED PRIMARILY TO REDUCE FAN WEAR. THE PARTLY CLEANED GAS THEN FLOWS TO THE FAN AND
INTO THE BAHCO TOWER WHERE ADDITIONAL PARTICULATE AND PRIMARY SULFUR DIOXIDE REMOVAL TAKES PLACE.
THE BAHCO SCRUBBING VESSEL IS A VERTICAL TOWER CONSISTING OF TWO SCRUBBING STAGES. GAS FLOWS THROUGH THE TOWER WHERE IS IS
CONTACTED WITH A LIME SLURRY SOLUTION. 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 TYPE MIST ELIMINATOR.
THE CLEANED GAS IS DISCHARGED TO THE ATMOSPHERE THROUGH A STACK MOUNTED DIRECTLY TO THE TOWER.
PEBBLE LIME IS EMPLOYED AS THE REAGENT IN THE SCRUBBING SYSTEM AND IS PREPARED BY SLAKING AND DISSOLUTION IN A MIX/HOLD .TANK.
THE SCRUBBING SLURRY IS THEN 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 APPROXI-
MATELY HOO FEET FROM THE SCRUBBING TOWER. CLEAR WATER FROM THE POND IS RETURNED TO PROCESS AS SLAKING WATER. A SIMPLIFIED
PROCESS FLO*. DIAGRAM OF THE RESEARCH COTTRELL/BAHCO WET LIME SCRUBBING SYSTEM IS PRESENTED IN FIGURE 19 OF APPENDIX C.
OPERATING HISTORY
PEDCO ENVIRONMENTAL
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RICKENBACKER AFB (CONTINUED)
THE: SYSTEM WAS INITIALLY PLACED IN SEKVICE MARCH n, 1976. INITIAL OPERATION PROCEEDED IN AN OPEN WATER LOOP nooE BECAUSE
TH£ THICKENER WAS NOT YET COMPLETELY INSTALLED. SULFUR DIOXIDE INLET CONCENTRATIONS WERE IN THE 1600 TO 2000 PPM RANGE. HIGH
OXYGEN CONCENTRATIONS ALSO EXIST IN THE FLUE GAS BECAUSE THESE OLDERi INEFFICIENT BOILERS OPERATE AT 150 TO 160 PERCENT EXCESS AIR
RATES. SULFUR DIOXIDE REMOVAL EFFICIENCY HAS BEEN IN THE LOW 90 PERCENT PLUS RANGE. LIME UTILIZATION HAS BEEN VERY GOOD.
PROBLEMS ENCOUNTERED TO DATE HAVE BEEN PRIMARILY OF A MECHANICAL NATURE USUALLY ASSOCIATED WITH STARTUP. THE MAJOR PROBLEMS ARE
ITEMIZED BELOW.
ELECTRICAL CIRCUITS ANt> SYSTEff CONTROL PANEL.
PUMP MALFUNCTION - SPARE PARTS SHIPMENT DELAY.
SEDIMENTATION BUILDUP IN THE SCRUBBER VESSEL (THIS WAS DUE PRIMARILY TO OPERATION AT HIGHER THAN DESIGN SOLIDS CON-
CENTRATION IN THE SCRUBBING SOLUTION BECAUSE THE THICKENER WAS NOT YET IN SERVICE PLUS GRIT GETTING THROUGH THE LIME
SLAKER GRIT REMOVAL STEP).
FAMILIARIZATION OF THE- OPERATING STAFF WITH THE MECHANICS OF THE PROCESS.
I.D. BOOSTER FAN PROBLEMS. ADDITIONAL BRACING. AND EPOXY GROUTING WAS REQUIRED TO STOP THE ELEVATED FAN
CONCRETE SUPPORT FRO* VIBRATING WHILE THE FAN WAS OPERATING. A THRUST BEARING FAILURE IN THIS UWIT
HAS ALSO BEEN ENCOUNTERED.
A NEW COAL-FIRED STOKER-TYPE BOILER (RILEY STOKER. 60 MM BTU/HR. HEAT CAPACITY). IS NOW BEING INSTALLED AT THIS FACILITY. THE
INSTALLATION OF THIS NEW UltIT WILL RESULT IN THE TERMINATION OF OPERATIONS FOR THE NO. 1 AND 2 UNITS AND STANDBY SERVICE FOR THE
NO. 3 UNIT. THESE ARE THE THREE OLDER UMTS (MANUFACTURED AND INSTALLED IN 1952) WHICH ARE OPERATING AT HIGH EXCESS AIR RATES AND
CORRESPONDING LOW THERMAL EFFICIENCIES. THE OVERALL RESULT SHOULD BE A STABILIZATION OF FLUE GAS CONDITIONS, INCREASED SCRUBBER
EFFICIENCY. AND REDUCTION OF CAftBOW FlNCS CARRYOVER STEMWIN& FRGff THE INEFFICIENT COMBUSTION CONDITIONS IN THESE OLDER UWITS.
THE BAHCO FGD CONTROL SYSTEIt Ola NO? OPERATE DURING NOVEMBER BECAUSE OF COMPLETION OF REPAIRS TO THE 1.0. FAN HOUSING.
THE STSTEK OPERATED DURING THE- ENTIRE MOWtH OF DECEMBER WITH S02 REMOVAL EFFICIENCY VARYING FROM 85 TO 90 PERCENT. LIME FEED
HAQ TO PROCEED ON ft MANUAL BASIS BECAUSE OF A MALFUNCTIONING SLftKER. THE NEW STOKER BOILER HAS NOT YET BEEN PLACED IN COMMERCIAL
OPERATION, PRIMARILY BECAUSE 6F PRGStEMS RELATED TO SEVERE WEATHER CONTITIONS.
PEDCO ENVIRONMENTAL
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY.
PARTICULATES
S02
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
112
TENNESSEE VALLEY AUTHORITY
SHAWNEE NO.IDA
PADUCAH KENTUCKY
10 HW
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
RETROFIT
H/72
OPERATIONAL
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
TURBULENT CONTACT ABSORBER(TCA) LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN
OPERATIONAL SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA.
TVA IS THE CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN
FRANCISCO IS THE MAJOR CONTRACTOR* TEST DIRECTOR, AND REPORT WRITER.
185
PEDCO ENVIRONMENTAL
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 12/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
113
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10B
PAOUCAH KENTUCKY
10 MW
COAL 2.9 PERCENT .SULFUR
GHEMICO
LIME/LIMESTONE SCRUBBING
RETROFIT
4/72
OPERATIONAL
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
VENTURI/SPKAY TOWER LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN OPERATIONAL
SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA. TVA IS THE
CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN FRANCISCO IS
THE MAJOR CONTRACTOR,TEST DIRECTOR, AND REPORT WRITER.
PEOCO ENVIRONMENTAL
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BACKGROUND
ON
SHAWNEE NOS. 10A, lOBt AND IOC
IN JUNE I966t THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE LIME AND LIMESTONE SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND
PARTICIPATES FROM COAL-FIRED BOILER FLUE GASES. THE PROGRAM WAS CARRIED OUT IN A TEST FACILITY INCORPORATED INTO THE FLUE GAS
DUCTWORK OF UNIT NQ. 10, A COAL-FIRED BOILER AT THE TVA SHAWNEE POWER STATION* PADUCAH, KENTUCKY. TVA IS THE CONSTRUCTOR AND
FACILITY OPERATOR* BtCHTEL CORP. IS THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE, TREATING PART OF THE FLUE GAS FROM THE
BOILER. EACH SCRUBBER TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30,000 ACFM OR THE EQUIVALENT OF APPROXIMATELY 10 MW OF POWER
PLANT GENERATING CAPACITY.
THREE PARALLEL WET SCRUBBER SYSTEMS WERE SELECTED FOR THE TEST PROJECT* D A VENTURI WITH A SPRAY TOWER AFTER ABSORBER* 2> A
TURBULENT CONTACT ABSORBER (TCA) AND 3) A MARBLE-BED ABSORBER. THE VENTURI SYSTEM, MANUFACTURED BY CHEMICAL CONSTRUCTION CO.,
CONTAINS AN ADJUSTABLE THROAT THAT PERMITS CONTROL AND VARIATION OF PRESSURE DROP UNDER A WIDE RANGE OF FLOW CONDITIONS. THE TCA
UNIT, MANUFACTURED BY UNIVERSAL OIL PRODUCTS, INCORPORATES A FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT ARE FREE TO MOVE
BETWEEN RETURNING GRIDS. THE MARBLE-BED ABSORBER, SUPPLIED BY COMBUSTION ENGINEERING CO,t USES A PACKING OF 3/4-INCH GLASS MARBLE
SPHERES AND A TURBULENT LAYER OF LIQUID AND GAS ABOVE THE MARBLE LAYER TO ENHANCE MASS TRANSFER.
IN JUNE 1974, THE EPA BEGAN A 3-YEAR ADVANCED TEST PROGRAM AT THE SHAWNEE FACILITY WITH THESE MAJOR GOALS* (1) CONTINUA-
TION OF LONG-TERM TESTING, WITH EMPHASIS PLACED UPON THE RELIABLE OPERATION OF MIST ELIMINATION SYSTEMS AT INCREASED GAS VELOCITY,
(2) INVESTIGATION OF ADVANCED PROCESS AND EQUIPMENT DESIGN VARIATIONS FOR IMPROVING SYSTEM RELIABILITY AND PROCESS ECONOMICS, AND
(3) LONG-TERM RELIABILITY TESTING ON PROMISING PROCESS AND EQUIPMENT DESIGN VARIATIONS.
THE TWO PARALLEL SCRUBBING SYSTEMS OPERATING DURING THE ADVANCED PROGRAM ARE THE VENTURI/SPRAY TOWER SYSTEM AND THE TCA UNIT.
GENERAL PROCESS FLOW DIAGRAMS OF THE TWO PROTOTYPE UNITS ARE PROVIDED IN FIGURES 20 AND 21 OF APPENDIX C. OPERATION OF THE
MARBLE-BED ABSORBER UNIT HAS BECN PERMANENTLY DISCONTINUED.
EACH OF THE SCRUBBING SYSTEMS CONTAINS ITS OWN SLURRY HANDLING FACILITIES AND CAN TREAT APPROXIMATELY 30,000 ACFM OF GAS AT
300 F CONTAINING 1600 TO 4000 PPN OF SULFUR DIOXIDE AND 2 TO * GRAINS/SCF OF PARTICULARS. BOILER NO. 1 NORMALLY BURNS A HIGH-
SULFUR BITUMINOUS COAL.
167 PEDCO ENVIRONMENTAL
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SHAWNEE NOS. IDA, 108t AND IOC (CONTINUED)
FROM JUNE 197H TO JANUAKY, 1976. MIST ELIMINATION AND LIMESTONE UTILIZATION TESTS WERE CONDUCTED AT THE SHAWNEE FACILITY.
DURING THIS TEST PERIOD THE VENTURI/SPRAT TOWER SYSTEM WAS OPERATED ON BOTH LIME AND LIMESTONE AND THE TCA SYSTEM WITH LIMESTONE,
TESTING WAS PERFORMED UNDER A CLOSED-WATER-LOOP OPERATION MODE. DURING THIS PERIOD THE SLURRY SOLIDS CONTAINED APPROXIMATELY 40
TO 50 PERCENT WEIGHT FLY ASH BECAUSE OF RELATIVELY HIGH GAS INLET PARTICULATE LOADING. THIS TESTING PROGRAM IS SCHEDULED TO RUN
THROUGH TO JUNE 1977.
ADDITIONAL INFORMATION AND DATA CONCERNING THE DETAILS OF THE ADVANCED TEST PROGRAM ARE PRESENTED IN THE PERFORMANCE TABLE
THAT FOLLOWS.
168 PEDCO ENVIRONMENTAL
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SHAWNEE MOS. 10A AND 10B
FGO SYSTEM OPERATING HOURS
TEST RUN PERIOD IDA 10B COMMENTS
SEP. 75 THIS EXPERIMENTAL ERA-FUNDED OPERATION IS PROCEEDING WITH THE TEST PROGRAM. TWO
OCT. 75 ABSORBER MODULES ARE CURRENTLY OPERATIONAL (10 MW EACH)* THE MARBLE-BED ABSORBER
IS STILL INOPERATIVE (SINCE -JULY 1973)* CURRENT EXPERIMENTS ARE RELATED TO MIST
ELIMINATOR SECTION.
NOV. 75 RECENT TESTING AT SHAWNEE HAS SHOWN THAT THE CHEVRON MIST ELIMINATORS IN BOTH THE
DEC. 75 SPRAY TOWER AND THE TCA CAN BE KEPT FREE OF SOLIDS BUILDUP AT HIGH ALKALI UTILIZATION
GREATER THAN 90 PERCENT, USING ONLY INTERMITTENT WASHING WITH AVAILABLE RAW WATER.
THIS HIGH UTILIZATION IS NORMALLY ACHIEVED WITH LIME* IT HAS BEEN ACHIEVED WITH
LIMESTONE AT REDUCED SCRUBBER INLET SLURRY PH (ABOUT 5.2) AND WITH THREE EFFLUENT
TANKS IN SERIES TO SIMULATE A PLUG-FLOW REACTOR.
TESTING IS CONTINUING TO DETERMINE THE EFFECTS OF PROCESS VARIABLES ON MIST ELIMINA-
TOR PERFORMANCE AND ON LIMESTONE UTILIZATION. FUTURE PLANS INCLUDE* (1) FACTORIAL
TESTING WITH LIME AND LIMESTONE TO DETERMINE THE EFFECTS OF PROCESS VARIABLES ON S02
REMOVAL AND (2) TESTING THE OXIDATION OF SLUDGE TO GYPSUM IN THE VENTURI/SPRAY TOWER
SYSTEM USING AIR SPARGING OF AN ACIDIFIED SLURRY BLEED STREAM.
JAN. 76 THE ADVANCED TEST PROGRAM IS CONTINUING. HIGHLIGHTS OF THE PROGRAM ARE AS FOLLOWS*
EVALUATE SCRUBBER OPERABILITY DURING VARIABLE LOAD OPERATION.
CONTINUE LONG-TERM RELIABILITY TESTING.
INVESTIGATE METHODS FOR IMPROVING WASTE SOLIDS SEPARATION.
CONTINUE SLUDGE OXIDATION AND SLUDGE FIXATION STUDY PROGRAMS.
EVALUATE SYSTEM PERFORMANCE AT REDUCED FLY ASH LOADINGS.
DETERMINE THE PRACTICAL UPPER LIMITS OF S02 REMOVAL EFFICIENCY.
EVALUATE AOOITITION OF MAGNESIUM ION TO THE SCRUBBING SLURRY.
CHARACTERIZE ALL STACK GAS EMISSION COMPONENTS.
EVALUATE MATERIALS OF CONSTRUCTION OF ALL SCRUBBER AND PLANT-RELATED
COMPONENTS.
169 PEDCO ENVIRONMENTAL
-------
SHAWNEE NOS. IDA AND 10B (CONTINUED)
FGD SYSTEM OPERATING HOURS
TEST RUN PERIOD IOA IOB COMMENTS
DEVELOP A COMPUTER PROGRAM FOR DESIGN AND COST ANALYSIS OF FULL-SCALE
LIME/LIMESTONE SYSTEM.
MAR. 76 BECHTEL REPORTED THAT THE FACTORIAL TEST PROGRAM, EVALUATING THE PERFORMANCE
APR. 76 OF THE LIME/LIMESTONE SCRUBBING SYSTEMS WITH AND WITHOUT MAGNESIUM ADDITION
HAS BEEN COMPLETED. CURRENTLY, TESTING IS PROCEEDING ON THE EVALUATION OF
SYSTEM PERFORMANCE AS A FUNCTION OF LOU RESIDENCE TIMES (1.5 TO 5.0 MINUTES)
IN THE RECYCLE TANKS. IN ADDITION, A FLY ASH-FREE DUCT IS BEING INSTALLED
AT THE TEST FACILITY, THUS ENABLING EVALUATION OF SYSTEM PERFORMANCE IN THE
ABSENCE OF FLY ASH.
MAY 76 THE TEST DIRECTOR, BECHTEL, PROVIDED THE FOLLOWING INPUT CONCERNING THE
JUN. 76 OPERATION OF THE EXPERIMENTAL SCRUBBING SYSTEMS DURING THE REPORT PERIOD*
THE EFFECT OF MGO ADDITION WAS EXPLORED IN BOTH SCRUBBER SYSTEMS. RESULTS
INDICATE MAGNESIUM ION IN THE SCRUBBER SLURRY LIQUOR ENCHANCES S02 REMOVAL
AND CAN DEPRESS SULFATE SUPERSATURATION. IT WAS FOUND THAT THE MAGNESIUM
ION CONCENTRATION HAD TO EXCEED THE EQUIVALENT CHLORIDE ION CONCENTRATION
TO HAVE AN EFFECT ON S02 REMOVAL.
IN THE TCA UNIT, WITH LIMESTONE SLURRY* S02 REMOVAL WAS INCREASED FROM 75
TO 95 PERCENT BY INCREASING THE MAGNESIUM ION CONCENTRATION TO 9,000 PPM IN
EXCESS OF EQUIVALENT CHLORIDE ION. TO ACHIEVE THIS CONCENTRATION LEVEL,
MAGNESIUM OXIDE WAS ADDED AT A RATE EQUAL TO 6 PERCENT BY WEIGHT OF THE
LIMESTONE ADDITION RATE.
IN THE VENTURI/SPRAY TOWER SYSTEMS, WITH LIME SLURRY, S02 REMOVAL WAS
INCREASED FROM 75 TO 90 PERCENT BY INCREASING MAGNESIUM ION CONCENTRATION
TO 2.000 PPM IN EXCESS OF EQUIVALENT CHLORIDE ION. THE MAGNESIUM OXIDE
ADDITION RATE WAS 2 PERCENT BY WEIGHT OF THE LIME ADDITION RATE.
190 PEOCO ENVIRONMENTAL
-------
SHAWNEE NOS. IDA AND 108 (CONTINUED)
F6D SYSTEM OPERATING HOURS
TEST RUN PERIOD IDA 10B COMMENTS
BOTH SCRUBBING SYSTEMS OPERATED IN THE SUBSATURATED SULFATE MODE WHEN
MAGNESIUM OXIDE WAS ADDED. INLET S02 CONCENTRATIONS DURING THE TESTS
AVERAGE APPROXIMATELY 3,000 PPM DURING THESE TESTS.
FOLLOWING THE TEST BLOCKS MENTIONED ABOVE, BOTH SCRUBBERS ARE OPERATING
WITH LIME SLURRY SCRUBBING SOLUTIONS, THE TCA SYSTEM ON FLUE GAS CONTAINING
FLY ASH AND THE VENTURI/SPRAY TOWER SYSTEM ON FLY ASH-FREE FLUE GAS.
JUL. 76 EXPERIMENTAL OPERATION OF THE EPA/TVA ALKALI SCRUBBING TEST FACILITY CONTINUED
AUG. 76 DURING THE REPORT PERIOD. BECHTELt THE TEST DIRECTOR, PROVIDED THE FOLLOWING
INPUT CONCERNING THE OPERATION OF THE PROTOTYPE TEST UNITS.
VENTURI/SPRAY TOWER SYSTEM* THIS SYSTEM OPERATED ON FLY ASH-FREE FLUE GAS
USING A LIME SLURRY SCRUBBING SOLUTION. NO SIGNIFICANT DIFFERENCES IN S02
REMOVAL, GYPSUM SATURATION AND SU|_FITE OXIDATION WERE DETECTED (VERSUS FLY
ASH-LADEN FLUE GAS). ONE DIFFERENCE NOTED WAS THE FILTER CAKE SOLIDS
CONTENT WHICH WAS APPROXIMATELY 10 PERCENT LOWER FOR THE FLY ASH-FREE
SLUDGE (40 TO 50 PERCENT SOLIDS) VERSUS THE FLY ASH-LADEN SLUDGE (50 TO 60
PERCENT SOLIDS). IN ADDITION, OPERATION IN A LOW RESIDENCE TIME MODE (3-
MINUTES) WAS EXPLORED. SCALE FREE OPERATION WAS ACHIEVED IN THIS MODE
UNDER THE FOLLOWING CONDITIONS* 8 PERCENT SOLIDS (NO FLY ASH) IN THE
RECIRCULATEO SLURRY* PH OF THE SCRUBBER LIQUOR INLET WAS 8.0* SUPERFICIAL
GAS VELOCITY OF 9.4 FT./SFC.* AND A TOTAL LIQUID GAS RATION (L/G) OF 71
GAL./MCF). SOME SCALE FORMATION OCCURRED WHEN THE SOLIDS CONTENT IN THE
RECIRCULATED SLURRY DROPPED BELOW THE
-------
SHAWNEE NOS. 10A AND 10B (CONTINUED)
FGO SYSTEM OPERATING HOURS
TEST RUN PERIOD 10A 10B COMMENTS
PPM* SUPERFICIAL GAS VELOCITY WAS 12.5 FT./SEC.* L/G WAS 50* THE SCRUBBING
SOLUTION INLET PH WAS 7.0* AND RESIDENCE TIME MAS t»MINUTES. THE S02
REMOVAL EFFICIENCY WAS APPROXIMATELY 90 PERCENT. WHEN THE L/G WAS REDUCED
TO 37, WHILE ALL OTHER CONDITIONS REMAINED CONSTANT, SEVERE GYPSUM SCALE
FORMATION RESULTED. INCREASING THE EFFECTIVE MAGNESIUM ION CONCENTRATION
TO 4000 PPM AND THE SCRUBBER LIQUOR INLET PH TO 8.0 DID NOT AMELIORATE THE
SCALE PROBLLEH. PRESENTLY, THE VENTURI/SPRAY TOWER SYSTEM IS OPERATING ON
FLY ASH-FREE FLUE GAS WITH A MAGNESIUM OXIDE INNOCULATEO LIME SCRUBBING
SLURRY.
SEP. 76 IN SEPTEMBER AND OCTOBER 1976, THE VENTURI/SPRAY SYSTEM WAS OPERATED WITH FLY
OCT. 76 ASH-FREE FLUE GAS USING LIME SLURRY WITH ADDED MAGNESIUM OXIDE. TYPICAL TEST
CONDITIONS WERE 9.H FT/SEC SPRAY TOWER GAS VELOCITY, 21 GAL/MCF VENTURI L/S, 50
GAL/MCF SPRAY TOWER L/G* 8 PERCENT SLURRY SOLIDS (FLY ASH-FREE), 3 MINUTES
RESIDENCE TIME, 7.0 SCRUBBER INLET PH, AND 2000 PPM EFFECTIVE MG ION CONCENTRA-
TION (I.E., EXCESS OVER EQUIVALENT CHLORIDE ION). RESULTS WERE NOT CONSISTENT
AT THE CONDITIONS. DURING ONE PERIOD, SCRUBBING INLET LIQUOR GYPSUM SATURA-
TION AVERAGED 85 PERCENT WITH 80 PERCENT S02 REMOVAL AND WITH SOME GYPSUM
SCALE FORMATION. IN A LATER PERIOD, AT SEEMINGLY IDENTICAL TEST CONDITIONS,
GYPSUM SATURATIONS DROPPED TO 10 PERCENT WITH 98 PERCENT 802 REMOVAL AND THE
SCRUBBER DESCALED. A SEVEN-WEEK PROGRAM OF INTENSIVE FLUE GAS CHARACTERIZATION
TESTING WAS STARTED IN MID-OCTOBER ON THE VENTURI/SPRAY TOWER SYSTEM. THESE
TESTS ARE BEING HADE TO MEASURE SIMULTANEOUS INLET AND OUTLET FLUE GAS PART.
MASS LOADING, PARTICULATE SIZE DISTRIBUTION. AND GASEOUS S03 CONCENTRATION.
THE TCA SYSTEM CONTINUED TO OPERATE DURING THIS PERIOD ON FLY ASH-LADEN FLUE GAS
USING LIME SLURRY WITH ADDED MAGNESIUM OXIDE. THE TEST RESULTS SO FAR INDICATED
THAT THE DEGREE OF SuLFATE (GYPSUM) SUB-SATURATION
192 PEOCO ENVIRONMENTAL
-------
SHAWNEE NOS. IDA AMD 10B (CONTINUED)
IS A SENSITIVE FUNCTION OF THE EFFLUENT RESIDENCE TIME AND THE APPEARS TO BE AN
OPTIMIM RESIDENCE TIME AT WHICH MINIMUM SULFATE (GYPSUM) SUBSATURATION OCCURS.
TYPICAL CONDITIONS* GAS VELOCITY 12.5 FT/SEC , L/6 OF 50,PH OF 7.0, 2000 PPM OF
MG ION, AND 6 PERCENT SOLIDS. AT THESE CONDITIONS GYPSUM SATURATIONS WERE 95, 50
AND 92 PERCENT, AT RESIDENCE TIMES OF 3tf< AND MINUTES, RESPECTIVELY. FURTHER
TEST WERE RUN AT 37 GAL/MCF L/G AND 6/0 SCRUBBER INLET PH WITH OTHER CONDITIONS
THE SAME. DURING THESE TESTS GYPSUM SATURATIONS WERE 95, 95* so* AND 90 PERCENT
AT 3,»
GAS FLOW RATE (20,00 TO 35,000 ACFM). SPRAY TOWER LIQUOR RATE (0 TO 1400
GPM) AND VENTURI PRESSURE DROP (3 TO 9 IN. H20). WITH H TO 6 GR/DSCF
PART1CULATE AT THE INLET, TYPICAL OUTLET LOADINGS WERE 0.02 TO 0.04
GR/DSCF. WHEN THE ESP WAS IN SERVICE, THE SCRUBBER OUTLET LOADING AVERAGED
LESS THAN 0.005 GR/DSCF. SIZE DISTRIBUTION ANALYSIS IS PROCEEDING.
ACID MIST VALUES WERE APPROXIMATELY 2 TO 25 PPM AT THE SCRUBBER INLET
WITH REMOVAL IN THE 50 TO 75 PERCENT RANGE. DURING THE REMAINDER OF
THE MONTH THE UNIT WAS DOWN FOR MODIFICATIONS FOR 2-STAGE OXIDATION
TESTING (SEC FIGURE 2 -A IN APPENDIX C>. FLY ASH-FREE AND LADEN FLUE
GAS TESTING WITH LIME AND AND LIMESTONE SLURRIES WERE CONDUCTED DURING
THE PERIOD ON THE TCA UNIT. MAGNESIUM OXIDE WAS NOT ADDED TO THE SLURRIES.
193 PEOCO ENVIRONMENTAL
-------
19H PCOCO ENVIRONMENTAL
-------
TABLE *
NUMBER AND TOTAL HW OF FGO SYSTEMS
195 PEDCO-ENVIRONMENTAL
-------
196 PEOCO ENVIRONMENTAL
-------
TABLE H
NUMBER AND TOTAL MW OF FG0 SYSTEMS
STATUS
OPERATIONAL
UNDER CONSTRUCTION
PLANNING
CONTRACT AWARDED
NO.OF
UNITS
30
31
20
LETTER OF INTENT 2
REQUESTING/EVALUATING BIDS H
CONSIDERING ONLY FGD SYSTEMS 37
TOTAL 12*
MM
6H59.
13309.
9981.
3t»5.
2327.
16726.
H9167.
197
PEDCO ENVIRONMENTAL
-------
19d PEDCO ENVIRONMENTAL
-------
TABLE 5
SUMMAKY OF FGD SYSTEMS BY COMPANY
199 PEDCO-ENVIRONMENTAL
-------
200 PEOCO ENVIRONMENTAU
-------
TABLE 5
SUMMARY OF FGD SYSTEMS BY COMPANY
UTILITY
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTEM
ARIZONA ELECTRIC POWER COOP
ARIZONA PUBLIC SEhVlCE
BASIN ELECTRIC PO»ER COOP
BIG RIVtKS ELECTRIC COOP CORP.
BRAZOS ELECTRIC POWER COOP
CENTRAL ILLlfcOIS LIGHT CO.
CEN1KAL ILLINOIS PUBLIC SERV
CINCINNATI GAS & ELECTRIC CO.
COLORADO UTE ELECTRICAL ASSN.
COLUMBUS & SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
DETROIT EDISON
DUOUESNE LIGHT
EASTERN KENTUCKY POWER COOP
GENERAL MOTORS
GULF POWER CO.
INDIANAPOLIS POWER & LIGHT CO.
KANSAS CITY POWER & LIGHT
KANSAS POWER £ LIGHT
KENTUCKY UTILITIES
KEY WEST UTILITY BOARD
LOUISVILLE GAS & ELECTRIC
MINNESOTA POWER AND LIGHT co.
KINNKOTA POWER COOPERATIVE
MONTANA POWER CO.
NEVADA POWER
NEW ENGLAND ELEC SYSTEM
NIAGARA MOHAWK POWER COOP.
NORTHERN INDIANA PUB SERVICE
NORTHERN INDIANA PUBLIC SERVIC
NORTHERN STATES POWER CO.
OTTER TAIL POWER COMPANY
PACIFIC POWER AND LIGHT CO.
PENNSYLVANIA POWER CO.
PHILADELPHIA ELECTRIC co.
POTOMAC ELECTRIC & POWER
PUBLIC SERVICE CO OF COLORADO
PUBLIC SERVICE CO OF NEW MEX.
PUBLIC SERVICE OF INDIANA
RICKENBACKER AFB
SALT KIVER PROJECT
SOUTH CAROLINA PUBLIC SERVICE
TAT AI nprPATTnfDAt
1 v 1 Al- Ur C**H 1 lUl>iA&»
WWIVM 1 F»wi* 1 A WI*
CONTRACT
AWARDED
NO.
2
2
2
5
5
1
1
3
1
1
2
4
2
1
2
1
1
1
2
3
4
1
1
8
1
1
4
10
1
1
2
1
4
1
1
3
if
2
1
-------
TABLE 5
SUMMARY OF FGD SYSTEMS BY COMPANY
UTILITY
SOUTHERN CALIFORNIA EDISON
SOUTHERN ILLINOIS POWER COOP
SOUTHERN INDIANA GAS&ELECTRIC
SOUTHERN MISSISSIPPI ELECTRIC
SPRINGFIELD CITY UTILITIES
TENNESSEE VALLEY AUTHORITY
TEXAS UTILITIES CO.
UNITED POWER ASSOCIATION
UTAH POWER & LIGHT CO.
WISCONSIN POWER & LIGHT CO.
TfiT Al ftPF*R AT TfllUAl
1 v I AL U"C.f»M 1 AUnlAi-
fewm^ • nww , * w*«
CONTRACT
AWARDED
NO.
2
1
1
2
1
3
5
2
2
1
MW
1410.
184.
2bO.
360.
200.
570.
3922.
1090.
615.
527.
NO.
0
0
0
0
0
2
0
0
0
0
MW
0.
0.
0.
0.
0.
20.
0.
0.
0.
0.
NO.
0
0
0
2
1
1
3
0
1
0
MW
0.
0.
0.
360.
200.
550.
2336.
0.
415.
0.
NO.
0
1
1
0
0
0
2
2
1
0
MW
0.
184.
250.
0.
0.
0.
1586.
1090.
400.
0.
LETTER OF REQUESTING/
INTENT
NO.
0
0
0
0
0
0
0
0
0
0
MW
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
EVAL.
NO.
0
0
0
0
0
0
0
0
0
1
BIDS
MW
0.
0.
0.
0.
0.
0.
0.
0.
0.
527.
CONSIDERING
FGD
NO.
2
0
0
0
0
0
0
0
0
0
SYSTEMS
HW
1410.
0.
0.
0.
0.
0.
0.
0.
0.
0.
TOTALS
124 49167. 30 6459. 31 13309. 20 9981,
365.
2327. 37 16726,
202
PEDCO ENVIRONMENTAL
-------
TABLE b
SUMMARY OF FGD SYSTEMS BY VENDOR
203 PEDCO-ENVIRONMENTAL
-------
204 PEDCO ENVIRONMENTAL
-------
TABLE 6
SUMMARY OF FGD SYSTEMS BY VENDOR
TOTAL
MANUFACTURER/PROCESS
AOL/COMBUSTION EQUIP ASSOCIATE
LIKE/ALKALINE FLYASH SCRUBBING
SODIUM CARBONATE SCRUBBING
TOTAL* ADL/COMBUSTiON EQUIP ASS
AMERICAN AIR FILTER
LIME SCRUBBING
TOTAL, AMERICAN AIR FILTER
BABCOCK & WILCOX
LIMESTONE SCRUBBING
TOTAL, BABCOCK & WILCOX
BABCOCK AND WILCOX
LIME SCRUBBING
TOTAL, BABCOCK AND WILCOX
BUELL/ENVIROTECH
DOUBLE ALKALI SCRUBBING
TOTAL, BUELL/ENVIROTECH
CHEMICO
LIME SCRUBBING
LIME/LIMESTONE SCRUBBING
LIMESTONE SCRUBBING
TOTAL, CHEMICO
CHIYOOA INTERNATIONAL
THOROUGHBRED 101
TOTAL, CHIYODA INTERNATIONAL
COMBUSTION ENGINEERING
LIME SCRUBBING
LIMESTONE INJECTION AWET SCRUB
LIMESTONE SCRUBBING
TOTAL, COMBUSTION ENGINEERING
DAVY POWERGAS/ALHEO CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
TOTAL, DAVY POWERGAS/ALLIED CHE
NO.
3
3
6
4
H
3
3
2
2
1
1
5
1
1
7
1
1
2
4
4
10
3
3
MW
1170.
375.
15H5,
917.
917.
1267.
1267.
1250.
1250.
575.
575.
3005.
10.
750.
3765.
23.
23.
248.
765.
2750.
3763.
830.
830.
OPERATIONAL CONSTRUCTION
NO.
2
3
5
2
2
2
2
0
0
0
0
3
1
0
4
1
1
1
4
1
6
0
0
MW
720.
375.
1095.
242.
242.
987.
987.
0.
0.
0.
0.
1755.
10.
0.
1765.
23.
23.
65.
765.
710.
1540.
0.
0.
NO.
1
0
1
2
2
1
1
2
2
1
1
2
0
1
3
0
0
. 1
0
3
4
3
3
MU
450.
0.
450.
675.
675.
280.
280.
1250.
1250.
575.
575.
1250.
0.
750.
2000.
0.
0.
183.
0.
2040.
2223.
830.
830.
205
PEOCO ENVIRONMENTAL
-------
TABLE 6
SUMMARY OF FGO SYSTEMS BY VENDOR
TOTAL
MANUFACTURER/PROCESS
KOCH/GENERAL MOTORS
DOUBLE ALKALI SCRUBBING
TOTAL « KOCH/GENERAL MOTORS
PEABOOY ENGINEERING
LIMESTONE SCRUBBING
TOTAL, PEABODY ENGINEERING
RESEARCH COTTRELL
LIME SCRUBBING
LIMESTONE SCRUBBING
TOTAL, RESEARCH COfTRELL
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
TOTAL, RILEY STOKER / ENVIRONEE
SO. CALIFORNIA EDISON
LIME SCRUBBING
TOTAL, SO. CALIFORNIA EDISON
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
TOTAL, TENNESSEE VALLEY AUTHOR I
UNITED EftGXNEERS / PECO
MAGNESIUM OXIDE SCRUBBING
TOTAL, UNITED ENGINEERS / PECO
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
LIME/LIMESTONE SCRUBBING
LIMESTONE SCRUBBING
TOTAL, UNIVERSAL OIL PRODUCTS
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
TOTAL, UOP / PUB SERVICE OF COL
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
TOTAL, ZURN AIR SYSTEMS
NO.
1
1
3
3
1
6
7
if
4
1
1
1
1
1
1
1
1
2
4
1
1
1
1
MW
32.
32.
613.
613.
20.
2361.
2371.
760.
760.
160.
160.
550.
550.
120.
120.
400.
10.
730.
1140.
50.
50.
37.
37.
OPERAT]
NO.
1
1
1
1
1
1
2
1
1
1
1
*
0
0
1
1
0
1
0
1
1
1
1
1
— STATU
:ONAL
Mb
32.
32,
163.
163.
20.
115.
135.
100.
100.
160.
160.
0.
0.
120.
120.
0.
10.
0.
10.
50.
50.
37.
37.
CONSTRUCTION
NO.
0
0
2
2
0
5
'5
3
3
0
0
1
1
0
0
1
0
2
3
0
0
0
0
MM
0.
0.
450.
450.
0.
2236.
2236.
660.
660.
0.
0.
550.
550.
0.
0,
400.
0.
730.
1130.
0.
0.
0.
0.
206
PEDCO ENVIRONMENTAL
-------
TABLE 6
SUMMARY OF FGU SYSTEMS BY VENDOR
STATUS
TOTAL OPERATIONAL CONSTRUCTION
MANUFACTURER/PROCESS NO. MW NO. Mta NO. MW
61 19760. 30 6459. 31 13309.
207 PEDCO ENVIRONMENTAL
-------
20d PEOCO ENVIRONMENTAL
-------
TABLE 7
SUMMARY OF I\IEW AND RETROFIT FGD SYSTEMS BY PROCESS
209 PEDCO-ENVIRONHENTAL
-------
210 PEDCO ENVIRONMENTAL
-------
TABLE 7
SUMMARY OF NEW AND KETKOFJT FGD SYSTEMS BY PROCESS
MW CAPACITY(NO. OF PLANTS)
PROCESS
LIME SCRUBBING
LIME/ALKALINE FLYAsH SCRUBBING
(PROCESS NOT SELECTED)
LIME/LIMESTONE SCRUBBING
(PROCESS NOT SELECTED)
LIMESTONE SCRUBBING
SUBTOTAL - LIME/LIMESTONE
AQUEOUS CARBONATE SCRUBBING
DOUBLE ALKALI SCRUBBING
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
REGENERABLE NOT SELECTED
SODIUM CARBONATE SCRUBBING
THOROUGHBRED 101
WELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/LIMESTONE X OF TOTAL MU
NLU OR
OPERATIONAL
CONSTRUCTION
RETROFIT
N
R
I N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
1 N
R
NO.
1
7
2
0
0
2
5
7
6.
16.
0
0
0
1
0
1
0
0
0
0
1
2
0
1
0
0
9.
21.
MU
635
1407
720
0
0
20
2067
860
3622.
2287.
0
0
0
32
0
120
0
0
0
0
125
250
0
23
0
0
3747.
2712.
97
64
NO. MM
7 3575
1 163
1 450
0 0
0 0
0 0
17 7146
1 550
2*. 11171.
2. 733.
0 0
0 0
1 575
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
1 375
2 455
27.12121.
4. 1166.
92
62
CONTRACT
AWARDED
NO.
6
0
2
0
0
0
6
1
16.
1.
0
0
1
1
0
0
0
0
0
0
1
0
0
0
0
0
18.
2.
MU
3150
0
1400
0
0
0
3970
425
6520.
425.
0
0
250
277
0
0
0
0
0
0
509
0
0
0
0
0
9279.
702.
92
61
LETTER OF REQUESTING/
INTENT
NO.
0
0
0
0
0
0
0
0
0.
0.
0
0
0
0
0
1
0
0
0
0
1
0
0
0
0
0
1.
1.
MU
0
0
0
0
0
0
0
0
0.
o.
0
0
0
0
0
240
0
0
0
0
125
0
0
0
0
0
125.
240.
0
0
EVAL. BIOS
NO.
0
0
0
0
1
0
0
0
1.
0.
0
0
0
0
0
0
3
0
0
0
0
0
0
0
0
0
4.
0.
MU
0
0
0
0
527
0
0
0
527.
0.
0
0
0
0
0
0
1600
0
0
0
0
0
0
0
0
0
2327.
0.
23
0
CONSIDERING
TUTAL NO,
OF PLANTS
FGD SYSTEM
NO.
0
2
0
0
2
2
3
0
5.
4.
0
1
0
0
0
2
16
6
2
1
0
0
0
0
0
0
23.
14.
MU
0
660
0
0
900
1410
1260
0
2160.
2070.
0
100
0
0
0
486
7920
2320
1000
650
0
0
0
0
0
0
11100.
5626.
20
37
NO.
14
10
5
0
3
4
33
9
55.
23.
0
1
2
2
0
4
19
6
2
1
3
2
0
1
1
2
82.
42.
MW
7560
2250
2570
0
1427
1430
14463
1835
26020.
5515.
0
100
825
309
0
846
9720
2320
1000
650
759
250
0
23
375
455
38699.
10466.
67
S3
211
PEDCO ENVIRONMENTAL
-------
212 PEDCO ENVIRONMENTAL
-------
TABLE 6
SUMMARY OF OPERATING FGD SYSTEMS BY PROCESS AND GENERATING UNITS
213 PEOCO-ENVIRONMENTAL
-------
21t PCOCO ENVIRONMENTAL
-------
TABLE a
SUMMARY OP OPERATING FGD SYSTEMS BY
PROCESS AND GENERATING UNITS AS OF 12/76
PROCESS/GENERATING UNITS
FGO/MU STARTUP EXPERIENCE(MO.)
DOUBLE ALKALI SCRUBBING
CHEVROLET PARMA 1 2 3 S 4
32.
3-74
33
33
LIME SCRUBBING
BHUCE MANSFIELD NO, 1
CANE HUN NO 4
ELRAMA POWER STATION
FOUR CORNERS NO. 5A
GREEN RIVER UNITS i AND 2
PADDYS RUN NO 6
PHILLIPS POWER STATION
RICKENBACKER
835
178
510
160
64
65
410
20
4-76
8-76
10-75
2-76
9-75
4-73
7-73
3-76
2242.
8
4
14
10
15
44
41
9
145
LIME/ALKALINE FLYASH SCRUBBING
COLSTRIP NO 1
COLSTRIP NO 2
360
360
720.
10-75
7-76
14
5
19
LIME/LIMESTONE SCRUBBING
SHAUNEE N0.10A
SHAWNEE N0.10B
10
1U
20.
4-72
4-72
56
56
112
LIMESTONE SCRUBBING
HAWTHORN NO 3
HAWTHORN NO 4
LAWRENCE NO 4
LAWRENCE NO 5
CHOLLA NO 1
DUCK CREEK NO.
LA CY6NE NO 1
1A
14 U
100
125
400
115
100
620
11-72
8-72
12-68
11-71
10-73
9-76
2-73
49
52
96
61
36
3
46
215
PEDCO ENVIRONMENTAL
-------
TABLE 6
SUMMARY OF OPERATING FGO SYSTEMS BY
PROCESS AND GENERATING UNITS AS OF 12/76
PROCESS/GENERATING UNITS FGD/MW STARTUP EXPERIENCED.)
SHERBURNE COUNTY STATION NO.l 710 3-76 9
ST. CLAIR NO 6 163 5-76 7
STOCK ISLAND PLANT 37 10-72 50
VALMONT NO. 5 50 10-7
-------
TABLE 9
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL F6D SYSTEMS
217 PEDCO-ENVIRONMENTAL
-------
218 PEDCO ENVIRONMENTAL.
-------
TABLE 9
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL F6D SYSTEMS AS OF 12/76
PROCESS/GENERATING UNIT
—SLUuGE— --SLUUGL-- —POND— —POND-
STABILIZED UNSTABILI2ED LINED UNLINED
DOUBLE ALKALI SCRUBBING
CHEVROLET PARMA 1 2 3 & 4
TOTAL
32
32.
0.
32
32.
LIME SCRUBBING
BRUCE MANSFIELD NO. 1
CANE RUN NO 4
ELRAMA POWER STATION
GREEN RIVER UNITS 1 AND 2
PADDYS RUN NO 6
PHILLIPS POWER STATION
RICKENBACKER
TOTAL
835
178
510
64
410
1997.
65
20
85.
20
20.
835
178
510
64
65
410
2062.
LIME/ALKALINE FLYA&H SCRUBBING
COLSTRIP NO 1
COLSTRIP NO 2
TOTAL
360
360
720,
0.
360
360
720.
LIMESTONE SCRUBBING
HAWTHORN NO 3
HAWTHORN NO 4
LAWRENCE NO 4
LAWRENCE NO 5
CHOLLA NO 1
DUCK CREEK NO. 1A
LA CYGNE NO 1
SHERBURNE COUNTY STATION NO.l
ST. CLAIR NO 6
STOCK ISLAND PLANT
VALMONT NO. 5
WILL COUNTY NO 1
• TOTAL
167
167.
140
100
125
400
115
100
820
710
163
37
50
2760.
100
710
163
50
167
1190.
140
100
125
400
115
620
37
1737.
219
PCOCO ENVIRONMENTAL
-------
TABLE 9
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGO SYSTEMS AS OF 12/76
PROCESS/GENERATING UNIT —SLUDGE— —SLUDGE— —POND— POND-
STABILIZED UNSTABILI2ED LINED UNLINED
SODIUM CARBONATE SCRUBBING
REID GARDNER NO 1
REID GARDNER NO 2
REID GARDNER NO 3
125
125
125
125
125
125
TOTAL 0. 375. 0. 375.
THOROUGHBRED 101
SCHOLZ NOS. IB * 28 23 23
TOTAL 0. 23. 23. 0.
220 PEOCO ENVIRONMENTAL
-------
TABLE 10
SUMMARY OF FGD SYSTEMS BY PROCESS ANJ REGULATORY CLASS
221 PEDCO-ENVIRONMENTAL
-------
222 PEOCO EHV1RONKEN-IM.
-------
TABLL 10
SUMMARY OF FGO SYSTEMS BY PROCESS AND REGULATORY CLASS
MU CAPACITY(NO. OF PLANTS)
PROCESS
LIME SCRUBBING
LIME/ALKALINE FLYASH SCRUBBING
(PROCESS NOT SELECTED)
LIME/LIMESTONE SCRUBBING
(PROCESS NOT SELECTED)
LIMESTONE SCRUBBING
SUBTOTAL - LIME/LIMESTONE
REGULATORY OPERATIONAL
CLASS
NO.
A 0
B 4
C 3
0 0
E 1
ENG A 1
B 0
C 1
D 0
E 0
A 0
B 0
C 2
D 0
E 0
A I
B 4
C 4
D 2
E 1
A 2.
B 8.
C 10.
D 2.
E 2.
CONSTRUCTION
CONTRACT
AWARDED
MU
0
1915
307
0
2U
360
0
360
0
0
0
0
20
0
0
100
1065
1167
525
50
460.
2980.
187*.
525.
70.
NO.
5
2
1
0
0
0
1
0
0
G
0
0
0
0
0
11
6
1
0
0
16.
9.
2.
0.
0.
MU
2340
1235
163
0
0
0
450
0
0
0
0
0
0
0
0
4456
2690
550
0
0
6796.
4375.
733.
0.
0.
NO.
4
2
0
0
0
2
0
0
0
0
0
0
0
0
0
3
4
1
0
1
9.
6.
1.
0.
1.
MU
1915
1235
0
0
0
1400
0
0
0
0
0
0
0
0
0
1770
1800
425
0
too
5065.
3035.
425.
0.
400.
LETTER OF REQUESTING/
INTENT
NO.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
C
0
0
0
0.
0.
0.
0.
0.
MU
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.
0.
0.
0.
0.
CVAL.
NO.
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
1.
0.
0.
0.
0.
BIDS
MU
0
0
0
0
0
0
0
0
0
0
527
0
0
0
0
0
0
0
0
0
527.
0.
0.
0.
0.
CONSIDERING
TOTAL NU.
OF PLANTS
FGD SYSTEM
NO.
0
0
2
0
0
0
0
0
0
0
0
2
0
0
2
2
1
0
0
0
2.
3.
2.
0.
z.
MM
0
0
660
0
0
0
0
0
0
0
0
900
0
0
1410
930
350
0
0
0
930.
1250.
660.
0.
1410.
NO.
9
a
6
0
1
3
1
1
0
0
1
2
2
0
2
17
15
6
2
2
30.
26.
15.
2.
5.
MU
4255
4385
1150
0
20
1760
450
360
0
0
527
900
20
0
1410
7256
5905
2162
525
45Q
13798.
11640.
3692.
525.
IfldO.
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
c. BOILER SUBJECT TO STATE STANDARD THAT is EQUAL TO OK LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
223
PEDCO ENVIRONMENTAL
-------
TABLE: 10
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
MU CAPACITY(NO. OF PLANTS)
PROCESS
AQUEOUS CARBONATE SCRUBBING
DOUBLE ALKALI SCRUBBING
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
REGENERABLE NOT SELECTED
REGULATORY OPERATIONAL
CLASS
A
B
C
0
E
A
B
C
0
E
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
NO.
0
0
0
0
0
0
1
0
0
0
0
1
0
0
0
0
0
0
0
0
o'
0
0
0
0
MW
0
0
0
0
0
0
32
0
0
0
0
120
0
0
0
0
0
0
0
0
0
0
0
0
0
CONSTRUCTION
NO.
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
MW
0
0
0
0
G
575
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
C
CONTRACT
AWARDED
NO.
0
0
0
0
0
1
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
MW
0
0
0
0
0
250
0
277
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
LETTER OF REQUESTING/
INTENT EVAL. BIDS
NO.
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
MW
0
0
0
0
0
0
0
0
0
0
0
2
-------
TABLE 10
SUMMARY OF FGD SYSTEMS BY PROCESS MO REGULATORY CLASS
M* CAPACITY(NO. OF PLANTS)
PROCESS
SODIUM CARBONATE SCRUBBING
THOROUGHBRED 101
UELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/STONE X OF TOTAL HW
REGULATORY OPERATIONAL
CLASS
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
A
B
C
0
E
NO.
0
3
0
0
0
0
0
1
0
0
0
0
0
0
0
2.
13.
11.
2.
2.
100
as
99
100
100
MW
0
375
0
0
0
0
0
23
0
0
0
0
0
0
0
460.
3507.
1697.
525.
70.
CONSTRUCTION
NO. MW
0
0
0
0
0
0
0
0
0
0
0
2
1
0
0
17
11
3
0
0
0
0
0
0
0
0
0
0
0
0
0
715
115
0
0
. 7371.
. 5090.
. a<*8.
o.
0.
92
86
86
0
0
CONTRACT
AWARDED
NO.
0
1
0
0
0
0
0
0
0
0
0
0
0
0
C
10.
7.
2.
0.
1.
MW
0
509
0
0
0
0
0
0
0
0
0
0
0
0
0
5335.
35
-------
226 PEDCO ENVIRONMENTAL
-------
TABLE 11
SUMMARY OF OPERATIONAL FGD SYSTEMS
227 PEDCO-ENVIRONMENTAL
-------
22a PEDCO ENVIRONMENTAL
-------
TABLE 11
SUMMARY OF OPERATIONAL FGD SYSTEMS AS OF 12/76
UTILITY COMPANY
POWER STATION
NEM OR SIZE OF FGO PROCESS/VENDOR
RETROFIT UNIT (HW)
FUEL CHARACTERISTICS
MO/YR
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 5A
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO. 1A
COMMONWEALTH EDISON
WILL COUNTY NO 1
DETROIT EDISON
ST. CLAIR NO 6
DUOUESNE LIGHT
PHILLIPS POWER STATION
OUUUESNL LIGHT
ELRAMA POWER STATION
GENERAL MOTORS
CHEVROLET PARMA 1 2 3 & t
GULF POWER CO.
SCHOLZ NOS. IB & 2B
KANSAS CITY POWER & LIGHT
HAWTHORN NO 3
KANSAS CITY POWER & LIGHT
HAWTHORN NO 4
KANSAS CITY POWER & LIGHT
LA CYGNL NO 1
KANSAS POWER & LIGHT
LAWRENCE NO 1
KANSAS POWER & LIGHT
LAWKENCE NO 5
KENTUCKY UTILITIES
GREEN RIVER UNITS 1 AND 2
R
R
N
R
R
R
R
R
R
R
K
N
R
N
R
160
115
100
167
163
mo
510
32
23
140
100
820
125
too
6H
SO. CALIFORNIA EDISON
LIME SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RILEY STOKER / ENVIRONEERING
LIMLSTONE SCRUBBING
BABCOCK & WILCOX
LIMESTONE SCRUBBING
PEABODY ENGINEERING
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
CHEMICO
LIME SCRUBBING
KOCH/GENERAL MOTORS
DOUBLE ALKALI SCRUBBING
CHIYODA INTERNATIONAL
THOROUGHBRED 101
COMBUSTION ENGINEERING
LIMESTONE INJECTION &WET SCRUB
COMBUSTION ENGINEERING
LIMESTONE INJECTION iWET SCRUB
BABCOCK & WILCOX
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE INJECTION SWET SCRUB
COMBUSTION ENGINEERING
LIMESTONE INJECTION &WET SCRUB
AMERICAN AIR FILTER
LIME SCRUBBING
COAL 0.7 PERCENT SULFUR 2/76
COAL 0.4t-l PERCENT SULFUR 10/73
COAL 2.5 - 3.0 PERCENT SULFUR 9/76
COAL <».0 PERCENT SULFUR 2/72
COAL 3.7 PERCENT SULFUR 5/76
COAL i.o- 2.8 PERCENT SULFUR 7/73
COAL i.o - 2.8 PERCENT SULFUR 10/75
COAL 2.5 PERCENT SULFUR 3/71
COAL 5.0 PERCENT SULFUR (MAX) 3/75
COAL 0.6- 3.0 PERCENT SULFUR 11/72
COAL 0.6- 3.0 PERCENT SULFUR 8/72
COAL 5.0 PERCENT SULFUR 2/73
COAL 0.5 PERCENT SULFUR 12/68
COAL 0.5 PERCENT SULFUR 11/71
COAL 3.8 PERCENT SULFUR 9/75
229
PEOCO ENVIRONMENTAL
-------
TABLE 11
SUMMARY OF OPERATIONAL FGO SYSTEMS AS OF ia/76
UTILITY COMPANY
POWER STATION
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
LOUISVILLE GAS & ELECTRIC
PADDYS RUN NO 6
LOUISVILLE GAS £ ELECTRIC
CANE RUN NO 4
MONTANA POWER CO.
COLSTRIP NO 1
MONTANA POUER CO.
COLSTRIP NO 2
NEVADA POWER
REID GARDNER NO 1
NEVADA POWER
REID GARDNER NO Z
NEVADA POWER
REID GARDNER NO 3
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.l
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. i
PHILADELPHIA ELECTRIC CO.
.EDDYSTONE NO 1A
PUBLIC SERVICE CO OF COLORADO
VALMONT NO. 5
RICKENBACKER AFB
RICKENBACKER
TENNESSEE VALLEY AUTHORITY
SHAUNEE NO.IOB
TENNESSEE VALLEY AUTHORITY
SHAWNEE NO.10A
NEW OR
RETROFIT
N
R
R
N
N
R
R
N
N
N
R
R
R
R
R
SIZE OF FGO
UNIT (MW)
37
65
178
360
360
125
125
125
710
835
120
50
20
10
10
PROCESS/VENDOR
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
ACL/COMBUSTION E«UIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
ADL/COMBUSTION EUUlP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIME SCRUBBING
CHEMICO
LIME/LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
FUEL CHARACTERISTICS MO/YR
OIL 2.4 PERCENT SULFUR 10/72
COAL 3.5-4.0 PERCENT SULFUR 4/73
COAL 3*5 - 4.0 PERCENT SULFUR 6/76
COAL 0.8 PERCENT SULFUR 10/75
COAL 0.8 PERCENT SULFUR 7/76
COAL 0.5- ItO PERCENT SULFUR 4/74
COAL o.s- i.o PERCENT SULFUR 4/74
COAL o.s- i.o PERCENT SULFUR 7/76
COAL 0.8 PERCENT SULFUR
COAL 4.7 PERCENT SULFUR
COAL 2.5 PERCENT SULFUR
COAL 0.72 PERCENT SULFUR
COAL 3.6 PERCENT SULFUR
COAL 2.9 PERCENT SULFUR
COAL 2.9 PERCENT SULFUR
3/76
4/76
9/75
10/74
3/76
4/72
4/72
230
PEDCO ENVIRONMENTAL
-------
TABLE \
-------
232 PCDCO ENVIRONMENTAL
-------
TABLE 12
SUMMARY OF FGO SYSTEMS UNDER CONSTRUCTION AS OF 12/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD PROCESS/VENDOR
RETROFIT UNIT
-------
TABLE 12
SUMMARY OF FGO SYSTEMS UNDER CONSTRUCTION AS OF 12/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE. OF F&O PROCESS/VENDOR
RETROFIT UNIT
-------
TABLE 12
SUMMARY OF FGD SYSTEMS UNDER CONSTRUCTION AS OF 12/76
UTILITY COMPANY
POWER STATION
NEW OR
RETROFIT
SIZE OF FGD
UNIT (MM)
PROCESS/VENDOR
FUEL CHARACTERISTICS
MO/YR
UTAH POWER & LIGHT CO.
HUNTIfcGTON NO.l
CHEMICO
LIME SCRUBBING
COAL 0.5 PERCENT SULFUR
6/77
235
PEOCO ENVIRONMENTAL
-------
>PEOCO ENVIRONMENTAL
-------
TABLE 13
SUMMARY OF PLANNED FGD SYSTEMS
237 PEDCO-ENVIRONMENTAL
-------
238 PEUCO ENVIRONMENTAL
-------
TABLE 13
SUMMARY OF PLANNED FGD SYSTEMS AS OF 12/76
UTILITY COMPANY
POWER STATION
CONTRACTS AWARDED
BASIN ELECTRIC POuER COOP
MISSOURI BASIN NO 2
COLUMBUS ft SOUTHERN OHIO ELEC.
COUESVILLE NO 6
PENNSYLVANIA POUER CO.
BRUCE MANSFIELD NO. 3
BASIN ELECTRIC POwER COOP
MISSOURI BASIN NO 1
PACIFIC POUER AND LIGHT CO*
JIM BKIOGER NO. 4
MONTANA POWER CO.
COLSTRIP NO.4
MONTANA POWER CO.
COLSTRIP NO.3
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 6
BRAZOS ELECTRIC POWER COOP
ATACOSA MCMULLCN NO. 1
COMMONWEALTH EDISON
PCWERTON NO. 51
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 4
TEXAS UTILITIES CO.
MARTIN LAKE NO. 4
UTAH POWER & LIGHT CO.
EMERY NO.l
SOUTHERN INDIANA GAS&ELECTRIC
A.B. BROWN NO.l
SOUTHERN ILLINOIS POWER COOP
SOUTHERN ILLINOIS POWER PT. 4
NEW OR
RETROFIT
N
N
N
N
N
N
N
R
N
R
N
N
N
N
N
SIZE OF FGD
UNIT (MW)
550
400
635
550
509
700
700
277
400
425
425
793
400
250
184
VENDOR/PROCESS
FUEL CHARACTERISTICS
MO/YR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
PULLMAN KELLOGG
LIME SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
SODIUM CARBONATE SCRUBBING
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
AUL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI SCRUBBING
BABCOCK & WILCOX
LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
FMC CORPORATION
DOUBLE ALKALI SCRUBBING
BABCOCK £ WILCOX
LIMESTONE SCRUBBING
COAL
COAL 4.5 - 4.9 PERCENT SULFUR
COAL 4.7 PERCENT SULFUR
LIGNITE 0.8 PERCENT SULFUR
COAL 0.56 PERCENT SULFUR
-------
TABLE; is
SUMMARY OF PLANNED FGD SYSTEMS AS OF ia/?t,
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD VENDOR/PKOCESS
RETROFIT UNIT
FUEL CHARACTERISTICS
MO/YR
UNITED POWER ASSOCIATION
COAL CREEK NO. 2
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
SALT RIVER PROJECT
CORONADO NO.2
SALT RIVER PROJECT
CORONADO NO.l
TEXAS UTILITIES Co.
MARTIN LAKE NO. 3
LETTER OF INTENT SIGNED
NEVADA POWER
REID GARDNER NO 4
PHILADELPHIA ELECTRIC CO.
EDOYSTONE NO IB
REQUESTING/EVALUATING BIOS
MINNESOTA POWER AND LIGHT co.
CLAY BOSWELL STATION NO.4
PU3LIC SERVICE OF INDIANA
GIBSON NO. 4
PUBLIC SERVICE OF INDIANA
GIBSON NO. 3
WISCONSIN POWER & LIGHT CO.
COLUMBIA NO. 2
CONSIDERING FGD SYSTEM
NEVADA POWER
WARNER VALLEY STATION NO. 1
NEVADA POWER
HARRY ALLEN STATION NO. 2
N
N
N
N
N
N
R
OS
N
N
N
N
N
N
545
545
350
350
793
125
240
500
650
fa50
527
250
500
COMBUSTION ENGINEERING
LIME SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
PULLMAN KELLOGG
LIMESTONE SCRUBBING
PULLMAN KELLOGG
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING-
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME/LIMESTONE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIGNITE
LIGNITE
COAL 1.
COAL 1.
COAL 1.
COAL
COAL 2.
COAL 0.
COAL 3.
COAL 3.
COAL 0.
COAL
COAL
- 0.63 PERCENT SULFUR
- 0.63 PERCENT SULFUR
0 PERCENT SULFUR (MAX)
0 PERCENT SULFUR (MAX)
0 PERCENT SULFUR
0-5- itO PERCENT SULFUR
5 PERCENT SULFUR
8 PERCENT SULFUR
3 PERCENT SULFUR
3 PERCENT SULFUR
8 PERCENT SULFUR
11/79
11/78
4/80
4/79
12/78
O/ 0
6/80
0/80
0/79
0/78
1/80
6/82
6/84
240
PEOCO ENVIRONMENTAL
-------
TABLE 13
SUMMARY OF PLANNED FGD SYSTEMS AS OF 12/76
UTILITY COMPANY
POWER STATION
NEW OR SI2E OF FGD VENDOR/PROCESS
RETROFIT UNIT (HW)
FUEL CHARACTERISTICS
MO/YR
NEVADA POWER
HARRY ALLEN STATION NO. 3
BASIN ELECTRIC POWER COOP
MISSOURI BASIN NO 3
BASIN ELECTRIC POwER COOP
ANTELOPE VALLEY NO. 1
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY NO. 2
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 1
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 2
PHILADELPHIA ELECTRIC CO.
CROMBY
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO.2
CINCINNATI GAS & ELECTRIC CO.
EAST BEND NO 2
COLORADO UTE ELECTRICAL ASSN.
CRAIG STATION NO.l
COLORADO UTE ELECTRICAL ASSN.
CRAIG STATION NO.2
COLUMBUS & SOUTHERN OHIO ELEC.
POSTON NO. f>
INDIANAPOLIS POWER £ LIGHT CO.
PETERSBURG NO f
COLUMBUS & SOUTHERN OHIO ELEC.
POSTON NO. 5
EASTERN KENTUCKY POWER COOP
SPURLOCK GENERATING PLANT NO.2
NEVADA POWER
HARRY ALLEN STATION NO. 1
N
N
N
N
R
R
R
N
N
N
N
N
N
N
N
N
500
550
450
450
330
330
150
400
(,00
450
450
375
530
375
500
500
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME SCRUBBING
NOT SELECTED
LIME SCRUBBING
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME/LIMESTONE SCRUBBING
NOT SELECTED
LIME/LIMESTONE SCRUBBING
MOT SELECTED
NOT SELECTED
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
COAL 6/85
COAL 6/83
LIGNITE 1.0 PERCENT SULFUR 0/81
LIGNITE 1.0 PERCENT SULFUR 0/84
COAL 3.5- t.o PERCENT SULFUR 1/82
COAL 3.5- 4*0 PERCENT SULFUR 1/81
COAL 2-4 PERCENT SULFUR 6/80
COAL 2.5-3.0 PERCENT SULFUR 1/82
COAL 1/81
COAL 0.45 PERCENT SULFUR 3/79
COAL 0.45 PERCENT SULFUR 3/79
COAL 2.5 PERCENT SULFUR 0/83
COAL 3.5 PERCENT SULFUR 4/62
COAL 2.5 PERCENT SULFUR 0/81
COAL 3/80
COAL 6/83
241
PEOCO ENVIRONMENTAL
-------
TABLE 13
SUMMARY OF PLANNED F6D SYSTEMS AS OF l2/7fa
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD VENDOR/PROCESS
RETROFIT UNIT (MM)
FUEL CHARACTERISTICS
MO/YR
NEVADA POWER
WARNER VALLEY STATION NO. 2
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. 2
OTTER TAIL POWER COMPANY
COYOTE STATION NO.l
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 4
NORTHERN STATES POWER co.
SHERBURNE COUNTY STATION NO.3
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.«*
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 58
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 7
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 8
NIAGARA MOHAWK POnER COOP.
CHARLES R. HUNTLEY NO. 6
NEW ENGLAND ELEC SYSTEM
BRAYTON POINT NO.3
NEVADA POWER
HARRY ALLEN STATION NO. if
SOUTHERN CALIFORNIA EDISON
MOHAVE NO IB
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2
SALT RIVER PROJECT
CORONADO NO.3
POTOMAC ELECTRIC & POWER
OICKERSON NO.l
N
R
N
R
N
N
R
R
R
R
R
N
R
R
N
R
250
336
400
755
660
860
595
190
too
100
650
500
620
790
350
190
NOT SELECTED
NOT SELECTED
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
ATOMICS INTERNATIONAL
AUUEOUS CARBONATE SCRUBBING
NOT SELECTED
REGEIMERABLE NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME/LIMESTONE SCRUBBING
NOT SELECTED
LIME/LIMESTONE SCRUBBING
NOT SELECTED
LIMESTONE SCRUBBING
CHEMICO
NOT SELECTED
COAL 6/83
COAL 2.if PERCENT SULFUR 6/80
LIGNITE 0.9 PERCENT,SULFUR 0/81
COAL 0.7 - 0.758 SULFUR (AVG) O/ 0
COAL 0.8 PERCENT SULFUR
COAL 0.6 PERCENT SULFUR
5/81
5/83
COAL 0.7 - 0.75S SULFUR (AVG) O/ 0
COAL 3 PERCENT SULFUR O/ 0
COAL 3 PERCENT SULFUR O/ 0
COAL 2.5-
-------
TABLE 13
SUMMARY OF PLANNED FGO SYSTEMS AS OF 12/76
UTILITY COMPANY NEW OR SIZE OF FGD VENDOR/PROCESS FUEL CHARACTERISTICS MO/YR
POWER STATION RETROFIT UNIT (MU)
POTOMAC ELECTRIC & POWER R 190 CHEMICO COAL 0/76
DICKERSON NO.2 NOT SELECTED
PUBLIC SERVICE CO OF NEW HEX. N 500 NOT SELECTED COAL 0*8 PERCENT SULFUR 5/81
SAN JUAN NO. t REGENERABLE NOT SELECTED
PUBLIC SERVICE CO OF NEW MEX. N 500 NOT SELECTED COAL 0*6 PERCENT SULFUR 5/81
SAN JUAN NO. 3 REGENERABLE NOT SELECTED
2
-------
2H<* PEOCO ENVIRONMENTAL
-------
TABLE 1H
SUMMARY LIST OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
PEDCO-ENVIRONMENTAL
-------
PEOCO ENVIRONMENTAL
-------
TABLE IH
SUMMARY LIST OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
F6D STATUS REPORT 12/76
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
1 GENERAL PUBLIC UTILITIES
2 GENERAL PUBLIC UTILITIES
3 GULF POWER CO.
n GULF POWER co.
5 GULF POWER co,
6 KENTUCKY UTILITIES
7 POTOMAC ELECTRIC & POWER
8 POTOMAC ELECTRIC & POWER
9 POWER AUTHORITY OF NEW YORK
10 SALT RIVER PROJECT
11 SALT RIVER PROJECT
12 SALT RIVER PROJECT
13 SPRINGFIELD WATER LIGHT POWER
l«f TEXAS POWER AND LIGHT CO.
15 TEXAS POWER AND LIGHT CO.
16 VIRGINIA ELECTRIC AND POWER co
COHO NO.l
SEWARU NO.7
CRIST NO. 4 AND NO. 5
CKIST NO. 6 AND NO. 7
LANSING SMITH NO, 1 AND NO.
GHENT NO. 2
CHALK POINT NO. H
DICKERSON NO H
ARTHUR KILL
NAVAJO NO 1
NAVAJO NO 2
NAVAJO NO 3
DALLMAN NO 3
TWIN OAKS NO. 1
TWIN OAKS NO. 2
HT, STORM
ERIE PENNSYLVANIA 5-87 7
SEWARO PENNSYLVANIA 5-8t 7
PtNSACOLA FLORIDA 0-78 7
PENSACOLA FLORIDA 0-80 7
PANAMA CITY FLORIDA 0-80 7
GHENT KENTUCKY 0-0 7
PRINCE GEORGE COUNTY MARYLAND 0-80 7
DICKERSON MARYLAND 5-82 7
STATEN ISLAND NEW YORK 9-82 7
PAGE ARIZONA 0-0 7
PAGE ARIZONA 0-0 7
PAGE ARIZONA 0-0 7
SPRINGFIELD ILLINOIS 6-79 7
ROBERTSON COUNTY TEXAS 8-80 7
ROBERTSON COUNTY TEXAS 9-61 7
MT, STORM WEST VIRGINIA 0-0 7
A
A
B
B
B
E
D
D
B
D
D
D
A
A
A
C
7. CONSIDERING FGD SYSTEM AS WELL AS ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
D. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
C. REGULATORY CLASS UNKNOWN
2*7
PEDCO ENVIRONMENTAL
-------
PEDCO ENVIRONMENTAL
-------
TABLE 15
STATUS OF FGD SYSTEMS IN THE EAKLY PLANNING STAGES
PEDCO-ENVIRONMENTAL
-------
250 PEOCO ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING
CURRENT MONTH
12/76
1.0. NUMBER 1
GENERAL PUBLIC UTILITIES
COHO NO.l
800 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 5/87
STARTUP DATE CHANGED TO 5/67 FOR BOTH BOILER AND FGD SYSTEM. LIME, LIME-
STONE SCRUBBING, AND COAL OESULFURIZATION ARE THE PRIMARY PROCESSES BEING
CONSIDERED. NO DECISION HAS BEEN MADE YET.
I.D. NUMBER 2
GENERAL PUBLIC UTILITIES
SEWARD NO.7
800 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 5/8H
STARTUP DATE CHANGED TO 5/8
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING 12/76
CURRENT MONTH
I.D. NUMBER 6
KENTUCKY UTILITIES
GHENT NO. 2
510 MW - NEW
COAL 3.0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP O/ 0
THIS NEW COAL-FIkED POWER BOILER WAS SUPPLIED BY COMBUSTION
ENGINEERING-AND IS SCHEDULED TO COMMENCE COMMERCIAL
OPERATION IN JANUARY 1977. THE UTILITY ALSO HAS AN EXISTING
510-MW COAL-FIRED UNIT INSTALLED AT THIS STATION AND IS
PRESENTLY EVALUATING PLANS TO INSTALL A SCRUBBER ON ONE
OF THESE TWO UNITS.
I.D. NUMBER 7
POTOMAC ELECTRIC & POWER
CHALK POINT NO. i»
630 MW - NEW
OIL
NOT SELECTED
NOT SELECTED
STARTUP 0/80
AWAITING PERFORMANCE RESULTS FROM MGO UNIT ON DICKERSON NO. 3 (MONTGOMERY
COUNTY). UNIT WILL HAVE PEABODY-LURGI 2-STAGE VENTURI SCRUBBERS FOR PAR-
TICULATE CONTROL. COMPANY MAY ELECT NOT TO INSTALL FGD SYSTEM IF USE OF
LOW SULFUR OIL IS CONTINUED.
I.D. NUMBER 8
POTOMAC ELECTRIC & POWER
DICKERSON NO
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF FGO SYSTEMS IN THE EARLY PLANNING STAGES DURING
CURKENT MONTH
12/76
I.D. NUMBER 11
SALT RIVLR PROJECT
NAVAJO NO 2
750 MW - RETROFIT
COAL 0.45 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP O/ 0
THE. UTILITY IS PRESENTLY INVESTIGATING THE USE OF LOW SULFUR COAL AND
DESULFURIZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THE SRP/EPA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPECIFIED.
1.0. NUMbER 12
SALT RIVER PROJECT
NAVAJO NO 3
750 MW - RETROFIT
COAL 0.<»5 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP O/ 0
THE UTILITY IS PRESENTLY INVESTIGATING THE USE OF LOW SULFUR COAL AND
DESULFUR1ZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THE SRP/EPA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPECIFIED.
I.D. NUMBER 13
SPRINGFIELD WATER LIGHT POWER
DALLMAN NO 3
190 MW - NEW
COAL 3.0- «».3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 6/79
FGD SYSTEM IS UNDER CONSIDERATION WITH BOTH REGENERABLE AND LlMESToNE
SCRUBBING BEING CONSIDERED. BECAUSE OF SPACE LIMITATIONS A REGENERABLE:
SYSTEM IS THE LIKELY CHOICE. THE COMPANY IS ALSO CONSIDERING COMPLIANCE
THROUGH BURNING OF LOW SULFUR WESTERN COAL.
I.D. NUMBER l
-------
TABLE 15
COMPANY STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING 13/76
POWER STATION CURRENT NONTH
• .____*_««.* — *_* — *»**•• —— — ^••••••w**_»~~~-.« —** — — •••*•» — **-_*<_• — •*.»**-.•..<•» — •**••••_«•_•*__._*•._•_*••_•••••*•_..•*.
1.0, NUMBER 16 THE UTILITY IS PRESENTLY CONSIDERENG BOTH DESULFURIZATION AND THE USE OF
VIRGINIA ELECTRIC AND POWER CO LOW SULFUR COAL. A DESULFURIZATION SYSTEM WOULD TREAT 69 PERCENT OF THE
hT. STORh FLOE GAS FROM THREE BOILERS. CONSTRUCTION AND STARTUP DATES ARE CON-
Il«f7 MW - RETROFIT SIDERED INDEFINITE AT THIS TIME.
COAL
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
2St PCDCO ENVIRONMENTAL
-------
APPENDIX A
FbD SYSTEM OPERATIONS THAT HAVE BEEN TERMINATED OR SHUT DOWN INDEFINITELY
A"] PEDCO-ENVIRONMENTAL
-------
A-2
-------
APPENDIX A
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULARS
S02
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
1
BOSTON EDISON
MYSTIC NO 6
EVLRETT MASSACHUSETTS
ISO MW
OIL 2.5 PERCENT SULFUR
CHEMICO
MAGNLSIUH OXIDE SCRUBBING
RETROFIT
H/72
TERMINATED
50 PERCENT
90 PERCENT
ACID PLANT REGENERATION
S32/KW CAPITAL + CALCINATION
AVERAGE FGD SYSTEM AVAILABILITY FACTORS - APRIL 72 TO MAY 73* 17X.
JUNE 73 TO DEC. 73, 48X. JAN. 74 TO JUNE 74. 60S. JUNE 74, 80X.
THE F6D SYSTEM HAS BEEN SHUT DOWN INDEFINITELY SINCE JUNE 74.
A-3
PEDCo ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE MYSTIC POWER STATION, UNIT NO. 6
THE MAGNESIUM OXIDE-BASED FPO SYSTEM INSTALLED AT THE MYSTIC POWER STATION OF THE BOSTON EDISON COMPANY CONSISTS OF A CHEMICO-DESIGNED SINGLE-
STAGE VENTURI SCRUBBER MODULE. THE MODULE IS CONSTRUCTED OF CARBON STEEL LINED KITH A SPRAY-APPLIED POLYESTER MATERIAL. TOTAL FLUE GAS CAPACITY OF
THE SYSTEM IS 440,000 ACFM AT 300°F. MAXIMUM DESIGN SULFUR DIOXIDE CONCENTRATION AND REMOVAL EFFICIENCY IS 1500 PPM AND 90 PERCENT RESPECTIVELY.
THIS EXPERIMENTAL MAGNESIUM OXIDE SCRUBBING UNIT IS RETROFITTED ON A 155-MW, OIL-FIRED STEAM-GENERATING BOILER MANUFACTURED BY COMBUSTION
ENGINEERING. THIS BOILER FIRES NO. 6 RESIDUAL FUEL OIL WITH THE FOLLOWING AVERAGE CHARACTERISTICS: HEAT CONTENT OF 149,000 BTU/GAL; ASH CONTENT OF
0.07 PERCENT; AND A SULFUR CONTENT OF 2.0 PERCENT. THE UNIT'S HEAT RATE IS APPROXIMATELY 9500 BTU/NET KWH.
SIMULTANEOUS REMOVAL OF SULFUR DIOXIDE AND PARTICULATES OCCURS IN THE VENTURI SCRUBBER MODULE. DESIGN REMOVAL EFFICIENCIES ARE 90 PERCENT AND
55 PERCENT RESPECTIVELY. SULFUR DIOXIDE REMOVAL FROM THE FLUE GAS OCCURS BY WET SCRUBBING WITH MAGNESIUM OXIDE SLURRY. THE SULFUR DIOXIDE IS
CAPTURED AND CONVERTED TO MAGNESIUM SULFITE IN THE VENTURI. THIS PRODUCT SLURRY IS THEN FILTERED AND DRIED. THE DRY MATERIAL IS CALCINED AT HIGH
TEMPERATURES TO DRIVE OFF THE SULFUR DIOXIDE AND REGENERATE MAGNESIUM OXIDE. THE SULFUR DIOXIDE STREAM IS PROCESSED IN A SULFURIC ACID PLANT TO MAKE
98 PERCENT GRADE OF SULFURIC ACID. A SCHEMATIC FLOW DIAGRAM OF THE SCRUBBING AND REGENERATION FACILITIES IS PRESENTED IN FIGURE 22.APPENDIX C.
THE UTILITY AND THE EPA PROVIDED THE MAJOR PORTION OF THE FUNDING FOR THIS REGENERABLE DEMONSTRATION PROJECT. EACH PARTY CONTRIBUTED APPROXIMATELY
$4.5 MM TO THE PROJECT. BOSTON EDISON'S INVESTMENT HAS BEEN SPENT PRIMARILY ON CONSTRUCTION AND OPERATION OF THE SCRUBBER AND RELATED EQUIPMENT
AT THE MYSTIC STATION. EPA'S INVESTMENT WAS PROVIDED PRIMARILY FOR THE REGENERATION FACILITIES AT ESSEX CHEMICAL'S SULFURIC ACID PLANT IN RUMFORD,
RHODE ISLAND. THE SYSTEM SUPPLIER ALSO UNDERWROTE PART OF THE COSTS FOR FUTURE PROCESS DEVELOPMENT.
PROBLEMS AND SOLUTIONS
FROM THE INITIAL START-UP IN APRIL 1972 UNTIL MAY 1973 THE SCRUBBER OPERATED INTERMITTENTLY BECAUSE OF MECHANICAL DIFFICULTIES. THE MAJOR PROBLEM,
ENTAILING DESIGN AND OPERATION OF THE MAGNESIUM SULFITE CRYSTAL DRYER, APPARENTLY HAS BEEN RESOLVED BY REDESIGN AND FUEL CHANGE. PROBLEMS WITH THE
STACK AND PUMP OCCURRED DURING USE OF REGENERATED MAGNESIUM OXIDE. OVERHEATING OF THE SLURRY DURING ACTIVATION OF THE STEAM FREEZE PROTECTION SYSTEM
CAUSED FORMATION OF SCALE IN THE MgO SLURRY PIPING. IN 1974, SYSTEM OPERATION WAS LIMITED BY BOILER AVAILABILITY. SINCE FEBRUARY 1974 AVAILABILITY
OF THE BOILER HAS BEEN INCREASED. THE SYSTEM HAS BEEN SHUT DOWN INDEFINITELY SINCE JUNE 1974, WHEN EPA FUNDS FOR THE CALCINING PORTION OF THIS OPERATION
WERE EXHAUSTED.
AVAILABILITY FACTORS AND COMMENTS CONCERNING THE OPERATION OF THIS SYSTEM SINCE STARTUP ARE PRESENTED IN THE FOLLOWING TABLE.
A-4
PEDCo ENVIRONMENTAL
-------
FGD SYSTEM AVAILABILITY
MYSTIC UNIT NO. 6
Boiler Scrubber
Operation Operation
Month (hr) (hr) Operabnity (X) Comments
Apr. 72 17 The module operated Intermittently because of mechanical difficulties. A major problem con-
to cerned the operation of the magnesium sulfite crystals dryer.
May 73
Jun. 73 592 402 68 The longest period of continuous operation, 7.5 days, occurred during June and July.
Jul. 73 575 351 61
Aug. 73 Boiler shutdown The boiler was down for the annual overhaul. System availability decreased during the last
Sep. 73 637 243 38 quarter of the year because of heavy erosion/corrosion In the liquor recirculation pumps and
Oct. 73 627 377 60 centrifuge.
Nov. 73 629 162 26
Dec. 73 658 86 13
Jan. 74 555 152 28 System availability was limited by boiler-related problems that caused frequent shutdowns in
Feb. 74 541 138 25 January and February.
Har. 74 408 353 87
Apr. 74 585 471 81 Two 7-day continuous operation periods occurred during the month.
May 74 488 280 57 The 57 percent operability index value for the month was due to a 2-weeks outage of the acid
Jun. 74 559 288 80 plant rather than to FGO system failure. Demonstration program was completed and FGD system
was shut down. EPA funding of MgS03 calcination has expired. There are no definite plans for
restarting of this unit. Major problem areas encountered during the operation of this proto-
type unit Included trihydrate instead of hexahydrate sulfite crystal formation, dust problems
in the dryer, lack of stack gas reheat causing condensation in the stack, louver damper
problems, erosion of pumps, piping, and centrifuge, and minor ancillary equipment failures.
A-5
PEDCo ENVIRONMENTAL
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APPENDIX A
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
DAIRYLAND POWER COOP
ALMA STATION
ALMA WISCONSIN
60 MW
FUEL CHARACTERISTICS COAL 3.0- 3.5 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
FOSTER WHEELER
LIME INJECTION
RETROFIT
6/71
TERMINATED
S02
25 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
THIS EXPERIMENTAL WET LIME FURNACE INJECTION SYSTEM HAS BEEN OPERATIONAL
SINCE 1971 FOR PERIODS UP TO 30 DAYS. IN AUGUST 1974 THE UNIT WAS TESTED
FOR TWO DAYS USING WESTERN LOW SULFUR COAL. THE TEST SHOWED ABOUT SOX
S02 REMOVAL EFFICIENCY. BUT PRECIPITATOR PERFORMANCE WAS ADVERSELY
AFFECTED. THE FGD PROJECT HAS BEEN SHUT DOWN INDEFINITELY SINCE
AUGUST 1974. AND THERE ARE NO PLANS FOR FUTURE OPERATION.
A-6
PEDCo ENVIRONMENTAL
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APPENDIX A
TERMINATED OPERATIONAL F6D SYSTEMS
luLMIFlCATlOH NO.
UTILITY l-HKE.
UMIT NAfiL
UfilT LOCATION
UMIT KwTliMG
FUEL CHARACTERISTICS
FGli VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PftRTICULATES
GULF POWER CO.
SCHOL2 NO. 1A
CHATTAHOOCHEE FLORIDA
20 Mta
COAL 3.0 PERCENT SULFUR
AOL/COnBUSTION EuUIP ASSOCIATE
DOUBLE ALKALI SCKUBBIUG
RETKOFIT
TERMINATED
99.7 PERCENT
S02
9b PERCENT
WATLK f.AKL UP
DISPOSAL
CLOSED LOOP
DESTABILIZED SLUUSE DISPOSED IN LINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFLK TO THE BACKGROUND INFORMATION SECTION IN APPENDIX A OF THIS REPORT.
THIS PHOTOTYPE SCRUBBING SYSTEM UAS INITIALLY PLACED Ih SERVICE
1973 AND WAS OPERATIONAL A TOTAL
-------
BACKGROUND INFORMATION
ON
SCHOLZ NO. 1A - DOUBLE ALKALI
THE SCHOLZ STEAM POWER PLANT OF GULF POWER COMPANY IS LOCATED IN CHATTAHOOCHEE, FLORIDA. UNIT NO. 1 IS A COAL-FIRED STEAK BOILER DESIGNED AND
INSTALLED BY BABCOCK AND WILCOX IN 195*. THIS UNIT IS NOMINALLY RATED AT 40 MW AND IS CAPABLE OF 47.5 MW MAXIMUM CAPACITY. THIS UNIT FIRES VARIOUS
TYPES OF COAL FOR TEST PURPOSES. THE AVERAGE CHARACTERISTICS OF THE COAL BURNED IN THIS UNIT DURING THE FGD DEMONSTRATION PROGRAM ARE: HEAT CONTENT
OF 12,400 BTU/LB; MAXIMUM SULFUR CONTENT OF 5 PERCENT; ASH CONTENT OF 14 PERCENT; AND A MAXIMUM CHLORIDE CONTENT OF 0.15 PERCENT.
A 20-MW PROTOTYPE DUAL ALKALI SYSTEM WAS JOINTLY DEVELOPED, DESIGNED, AND INSTALLED BY COMBUSTION EQUIPMENT ASSOCIATES AND ARTHUR D. LITTLE. THE
PROTOTYPE SYSTEM AT THE SCHOLZ STEAM PLANT IS INSTALLED ON THE NO. 1 BOILER. THE SYSTEM IS DESIGNED TO HANDLE APPROXIMATELY 50 PERCENT OF THE FLUE GAS
FROM THE BOILER. THE BOILER HAS BEEN RETROFITTED WITH A SECTIONALIZED, HIGH-EFFICIENCY ESP INSTALLED UPSTREAM OF THE FGD SYSTEM AND CAPABLE OF 99.7
PERCENT PARTICULATE REMOVAL. THE ESP CAN BE SELECTIVELY DE-ENERGIZED FOR STUDY OF PARTICULATE IMPACT ON THE FGD OPERATION.
THE PROTOTYPE UNIT INCORPORATES A HIGH DEGREE OF FLEXIBILITY FOR GENERATION OF DESIGN AND OPERATING INFORMATION FOR A WIDE VARIETY OF APPLICATIONS.
ALTHOUGH THE BASIC MODE OF SYSTEM OPERATION IS DUAL ALKALI WITH LIME REGENERATION, THE SYSTEM WAS DESIGNED TO ACCOMMODATE LIMESTONE REGENERATION
AND LIME/LIMESTONE REGENERATION. THE SYSTEM CONSISTS OF A VENTURI SCRUBBER AND AN ABSORPTION TOWER, WITH AN ADDITIONAL STORAGE SILO FOR LIMESTONE. A
MIX TANK, AND OTHER ASSORTED TANKS, PUMPS, CONTROLLERS, PIPING, AND A LINED DISPOSAL POND.
THE PROTOTYPE SYSTEM WAS COMPLETED AND PUT IN OPERATION BY CEA/ADL IN EARLY FEBRUARY 1975. IN MID-MAY AN EPA DUAL ALKALI TEST PROGRAM WAS
INITIATED BY SOUTHERN SERVICES, CEA, AND ADL. THE SYSTEM WAS OPERATIONAL THROUGH EARLY JANUARY 1976, WHEN THE BOILER WAS SHUT DOWN FOR A SCHEDULED
OVERHAUL. THE BOILER AND PROTOTYPE SYSTEM WERE PLACED BACK IN SERVICE IN EARLY MARCH 1976. THE SYSTEM HAS OPERATED CONTINOUSLY DURING THIS
PERIOD ON A HIGH SULFUR COAL (3.5 TO 4.5 PERCENT) APPLICATION, TREATING FLUE GAS WITH SULFUR DIOXIDE CONCENTRATIONS IN THE 2000 TO 2500 PPM RANGE. IN
ADDITION, SYSTEM WAS TESTED OUT ON FLUE GAS OF VARYING PARTICULATE LOADING TO DETERMINE THE IMPACT OF FLY ASH OF SYSTEM OPERATIONS. THE PROTOTYPE
PROGRAM WAS SUCCESSFULLY CONCLUDED ON JULY 3, 1976 AT 6 A.M. RESULTS OF THE PROGRAM ARE BEING PREPARED FOR PUBLICATION. THIS PROCESS IS NOW SCHEDULED
FOR FULL SCALE DEMONSTRATION APPLICATION AT LOUISVILLE GAS AND ELECTRIC'S CANE RUN NO. 6 UNIT.
THE PERFORMANCE OF THE SCHOLZ PROTOTYPE UNIT AND COMMENTS ARE LISTED BELOW IN THE PERFORMANCE TABLE. A PROCESS FLOW DIAGRAM OF THE SCHOLZ PROTOTYPE
FGD UNIT IS PROVIDED IN FIGURE 23 OF APPENDIX C.
A-8 PEDCo ENVIRONMENTAL
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SCHOLZ 1A - DOUBLE ALKALI
Unit Operating Hours
Period
Feb. 75
Har. 75
Apr. 75
May 75
Jun. 75
Jul. 75
Aug. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Total
hours
672
744
720
744
720
744
744
720
744
720
744
Boiler
459
507
604
598
720
683
744
577
559
620
732
F6D system
454
485
336
375
720
221
0
254
55S
560
732
FGD system
operabillty
99
96
56
63
100
32
0
44
100
90
100
Performance (1
utilization
68
65
47
50
100
30
0
35
75
78
98
Comnents
Unit was placed in operation February 8, 1975, and operated until July
18 when it was shut down for 2 months modifications, repairs, and
replacement of parts. The system was unavailable to the boiler for
a 491-hour period because of adjustments and modifications required for
the formal EPA test program in mid-May.
The system was shut down from mid-July to mid-September for mechanical
overhaul involving replacement parts for valves that had failed.
The system was put back in operation on September 16, 1975. From mid-
September to mid-October the air preheater was repaired and boiler
operation adjusted to reduce oxygen levels in the flue gas to the 5 to
6 percent range. The system operated approximately 800 hours during
this period.
The system ran continuously for the remainder of the test period through
January 2, 1976. S02 levels during this period ranged from 800 to
1700 ppm. The system operated in the concentrated mode throughout
the remainder of the test period. In the period from mid-September to
January 2, 1976, the system operated about 2100 hours, with an
operabillty factor of 97 percent.
A-9
PEDCo ENVIRONMENTAL
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SCHOLZ 1A - DOUBLE ALKALI (continued)
Period
Jan. 76
Feb. 76
Apr. 76
Nay 76
Jun. 76
Total
hours
744
696
Mar. 76 744
720
744
720
Unit Operating Hours
Boiler FGD system
742
642
735
445
616
651
656
641
FGD system Performance (X)
operabiHty utilization
60
96
89
60
86
88
93
89
Comments
The FGD system and boiler underwent a scheduled overhaul during the
report period. System restart is scheduled for mid-March 1976, to con-
tinue till June. During this operating period high-sulfur coal
(3.5-4.0 percent) will be burned to allow evaluation of system per-
formance on high-sulfur coal.
The system was put back In service on March 12, 1976. The total number
of operating hours for the month of March was 445 hours. This trans-
lates into a 94% operability factor since the March 12 restart.
Some minor mechanical problems in the form of agitator shaft and
control value failures were encountered during the report period.
Since the system restart on March 12, high sulfur coal has been
burned in the boiler (3.5 to 4.5 percent sulfur), resulting in the
SO- inlet concentration levels in the 2000 to 2500 ppm range.
During the last phase of operation, the system was treating flue gas
of varying particulate loads. The upstream ESP was selectively
de-energized, both partially and totally. No major upsets in the
process chemistry occurred. Boiler load variation ranged from 30 to
100 percent. The prototype program at the plant was successfully
conducted on July 2. ADL is currently completing data acquisition and
analysis.
A-10
PEDCo ENVIRONMENTAL
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SCHOLZ 1A - DOUBLE ALKALI (continued)
Unit Operating Hours
Total F6D system Performance (X)
Period hours Boiler F6D system operablHty utilization Comments
Jul. 76 744 54* 54 100* The prototype test program was successfully concluded on July 3, 1976.
*Note: The boiler hours, system operation hours, and the corresponding
performance value calculated Includes system operation up to
the scheduled shutdown, which occurred on July 3, 6:00 A.M.,
1976.
A - 1 1 PEDCo ENVIRONMENTAL
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APPENDIX A
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT MAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY!
PARTICULATES
S02
UATER MAKE UP
GULF POWER CO.
SCHOLZ NO. 2A
CHATTAHOOCHEE FLORIDA
20 HW
COAL 3.0 PERCENT SULFUR
FOSTER WHEELER
ACTIVATED CARBON
RETROFIT
3/76
TERMINATED
99.7 PERCENT
7
-------
BACKGROUND INFORMATION
ON
SCKOLZ NO. 2A - FWBF SYSTEM
IN JANUARY 1973, THE SOUTHERN SERVICES COMPANY OF GULF POWER AWARDED A CONTRACT TO THE FOSTER WHEELER CORPORATION TO BUILD A 20 MW PROTOTYPE DRY
ADSORPTION SYSTEM FOR FLUE GAS DESULFURIZATION. CONSTRUCTION ON THE FOSTER WHEELER PROCESS STARTED FEBRUARY 15, 1974, AT THE SCHOLZ STEAM POWER
PLANT IN CHATTACHOOCHEE, FLA. CONSTRUCTION WAS COMPLETED AND A TESTING PROGRAM WAS INITIATED IN MAY 1975.
THE SYSTEM AT THE SCHOLZ PLANT CONSISTS OF A 20-MW ADSORBER SECTION AND A 47.5-MW REGENERATION AND REDUCTION SECTION. THE 20 MW ADSORBER IS
DESIGNED TO ACCEPT HALF OF THE MAXIMUM FLUE GAS FLOW FROM UNIT NO. 2. THE COAL-FIRED BOILER IS RATED AT 40 MW (NOMINAL); IT FIRES COAL WITH AN AVERAGE
HEATING VALUE OF 12,400 BTU/LB. MAXIMUM ASH AND SULFUR CONTENTS ARE 14 AND 5 PERCENT, RESPECTIVELY.
THE PURPOSE OF THE ADSORPTION SECTION OF THE FWBF DRY REMOVAL SYSTEM IS TO REMOVE SULFUR DIOXIDE, NITROGEN OXIDES, AND PARTICULAR FROM THE FLUE
GAS WITH ACTIVATED CHAR, CONVERTING THE CAPTURED POLLUTANTS TO SULFURIC ACID. THE REGENERATION SECTION PROVIDES CONTINUOUS ON-SITE REGENERATION OF
THE CHAR, WHICH HAS BEEN LOADED WITH SULFUR DIOXIDE IN THE FORM OF SULFURIC ACID. THE CHAR IS REGENERATED AND A LOW-VOLUME, SULFUR DIOXIDE-RICH
OFF-GAS STREAM IS FED FORWARD TO THE RESOX REACTOR, WHICH REDUCES THE SULFUR DIOXIDE STREAM TO GASEOUS ELEMENTAL SULFUR THAT IS COLLECTED AND STORED IN
AN INSULATED TANK.
THE DEMONSTRATION UNIT HAS TWO ROWS OF MODULES, EACH ROW CONSISTING OF SIX MODULES. THE ADSORPTION SECTION IS A TWO-STAGE DESIGN CONSISTING
OF VERTICAL COLUMNS OF PARALLEL LOUVER BEDS WHICH SUPPORT AND CONTAIN THE ACTIVATED CHARCOAL. SULFUR DIOXIDE, OXYGEN, WATER VAPOR, AND NITROGEN OXIDES
ARE ADSORBED BY THE CHAR PELLETS FROM THE CROSS-FLOWING FLUE GAS AT 250 TO 300°F. THE SULFUR DIOXIDE THEN REACTS WITH OXYGEN AND WATER TO FORM SUL-
FURIC ACID WHICH IS FIRMLY RETAINED IN THE INTERIOR PORE SYSTEM OF THE CHAR PELLETS. THE CHAR IS THEN REGENERATED IN THE REGENERATOR VESSEL BY HEATING
TO 1200°F, DRIVING OFF THE ENTRAINED GASES, AND REDUCING SULFURIC ACID TO SULFUR DIOXIDE. THE SULFUR DIOXIDE-RICH GAS IS THEN PASSED THROUGH A VESSEL
CONTAINING CRUSHED COAL, RESULTING IN REDUCTION TO GASEOUS ELEMENTAL SULFUR AND CARBON DIOXIDE. THIS LATTER PROCESS IS CARRIED OUT AT 1200° TO 1500°F.
A SCHEMATIC OF THE PROCESS COMPONENTS FOR THE FW-BF DRY ADSORPTION IS PRESENTED IN FIGURE 24 OF APPENDIX C.
THE INITIAL SHAKEDOWN ON FLUE GAS BEGAN AUGUST 11, 1975, AND PROCEEDED CONTINUOUSLY FOR 10 DAYS. THE REGENERATION SECTION WAS OPERATIONAL ABOUT
60 PERCENT OF THE TIME. HOWEVER, THE REDUCTION SECTION HAS NOT YET BEEN INTEGRATED INTO SYSTEM OPERATION. SULFUR DIOXIDE REMOVAL WAS WELL ABOVE
EXPECTATIONS AND PRESSURE DROP ACROSS THE ADSORBER HAS WELL BELOW DESIGN LEVELS. THE SYSTEM WAS SHUT DOWN FOR CORRECTION OF SEVERAL OPERATING PROBLEMS,
PEDCo ENVIRONMENTAL
A-13
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SCHOLZ NO. 2A - FWBF SYSTEM (Continued)
EQUIPMENT MODIFICATIONS, AND EVALUATION OF THE INTIAL OPERATING DATA. OPERATION WAS RESUMED IN OCTOBER 1975, WHEN TWO CONSECUTIVE RUNS WERE CONDUCTED
WITH THE REDUCTION PORTION OF THE SYSTEM PROCESSING FRONT-END OFF-GAS AT FULL OPERATING TEMPERATURES. A PROGRAM OF MODIFICATION WAS COMPLETED ON THIS
SYSTEM IN EARLY JANUARY 1976. REPRODUCTION OF FLUE GAS INTO THE INTEGRATED SYSTEM COMMENCED IN FEBRUARY 1976. OPERATIONS THROUGH A FINAL 4-MONTH
TEST PROGRAM WERE PREMATURELY TERMINATED ON MAY 2, 1976.
A -1 4 pEDCo ENVIRONMENTAL
-------
FHBF SYSTEM OPERATING HISTORY
Period Comments
May 75 Completion of construction was followed by a 3-month commissioning period during which
Jun. 75 various pieces of equipment were operated individually and then in combinations to
Jul. 75 simulate subsystem operation. Subsystem operations were integrated into section
Aug. 75 operations and flue gas was passed through the adsorber and regenerator for a 10-day
period beginning August 11. RESOX construction was incomplete at this time.
Oct. 75 Two consecutive runs were conducted on the RESOX portion of the system on front-end
process off-gas at full operating temperatures. This operational period lasted 5
days.
Nov. 5 A program of modifications on the system began in late August 1975 and continued
Dec. 75 through January 1976, with the exception of the 5-day RESOX operation in October.
Jan. 75 Modifications were completed and pre-startup testing was conducted in late January
and early February. A 3-day continuous dry run was successfully completed.
Feb. 76 All materials-handling loops and RESOX loops were operated at full operating
temperatures and pressures. Reintroduction of flue gas into the system commenced,
and a 4-month formal test program conducted by Southern Services and Foster Wheeler
is now in progress.
Mar. 76 Three operational periods were logged by the prototype system during the report
Apr. 76 months. During these runs the adsorption and regeneration sections performed
adequately. The RESOX section operated intermittently because of plugging problems
1n the sulfur condenser. Also, the front end of the system was taken down at one
point due to frequent high temperature excursions. This problem was corrected by
modifying system operating procedures. Currently, work 1s proceeding on the
solution of the sulfur condenser problem.
A-1 5 PEDCo ENVIRONMENTAL
-------
FMBF SYSTEM OPERATING HISTORY (Continued)
Period Comments
May 76 The FW-BF unit completed an operational period in early May which had commenced on
April 26. The system was taken down at this point for the following reasons:
0 Depletion of char supply.
0 High char consumption rates due to mechanical attrition.
0 Correct/modify the char/sand screen separator.
At this point the decision was made to prematurely terminate the FW-BF demonstration
program rather than shut down, debug, and restart the system again. The system
supplier is pursuing additional funding for the continuation of the prototype
demonstration program.
A-16
PEDCo EKYIRONMEHTW.
-------
APPENDIX A
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
ILLINOIS POWER
WOOD RIVER NO 4
EAST ALTON ILLINOIS
110 MW
FUEL CHARACTERISTICS COAL 2.9- 3.2 PERCENT SULFUR
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F60 STATUS
EFFICIENCY!
PARTICULATES
MONSANTO ENVIRO CHEM SYSTEMS
CATALYTIC OXIDATION
RETROFIT
10/72
TERMINATED
99 PERCENT
S02
AS PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
SULFURIC ACID PRODUCT
$82.5/KH CAPITAL + $952,000 OPERATING
THE FGD SYSTEM HAS HAD CONSIDERABLE AMOUNT OF PROBLEMS SINCE STARTUP IN
1972. TOTAL OPERATION WAS
-------
BACKGROUND INFORMATION
ON
WOOD RIVER NO. 4
THE WOOD RIVER POWER STATION OF THE ILLINOIS POWER COMPANY IS LOCATED NEAR EAST ALTON, ILLINOIS, NORTH OF ST. LOUIS, MISSOURI. THE NO. 4 BOILER
IS A COMBUSTION ENGINEERING PULVERIZED-COAL-FIRED UNIT THAT HAS A GROSS RATED CAPACITY OF 109 MW AND A NET CAPACITY OF 103 MW. THIS UNIT FIRES A HIGH
SULFUR CENTRAL ILLINOIS COAL WITH TYPICAL CHARACTERISTICS OF 3.1 PERCENT SULFUR, 10 PERCENT ASH AND A HEAT CONTENT OF 10,800 BTU/LB. ANNUAL COAL
CONSUMPTION IS APPROXIMATELY 275,000 TONS/YEAR.
THE EMISSION CONTROL EQUIPMENT FOR THIS BOILER INCLUDES MECHANICAL COLLECTORS, A HIGH EFFICIENCY ESP, AND A MONSANTO CATALYTIC OXIDATION (CATOX)
FGD SYSTEM FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. DESIGN REMOVAL EFFICIENCIES OF THIS CONTROL SYSTEM ARE 99.9 PERCENT FOR PARTICULATES AND
85 PERCENT FOR SULFUR DIOXIDE. INLET SULFUR DIOXIDE CONCENTRATIONS TO THE CATOX SYSTEM ARE GENERALLY IN THE 2000 TO 2200 PPM RANGE.
FOLLOWING PASSAGE THROUGH THE PARTICULATE REMOVAL SYSTEM, THE FLUE GAS ENTERING THE SCRUBBING SYSTEM IS HEATED TO A TEMPERATURE OF 850°F AND
PASSES THROUGH A VANADIUM PENTOXIDE FIXED-BED CATALYTIC CONVERTER, WHERE THE SULFUR DIOXIDE IS OXIDIZED TO SULFUR TRIOXIDE. THE GAS THEN FLOWS THROUGH
AN ACID ABSORPTION TOWER, WHERE THE SULFUR TRIOXIDE IN THE GAS IS CONVERTED TO SULFURIC ACID. AN ACID MIST ELIMINATOR ENSURES REMOVAL OF ENTRAINED
ACID MIST FROM THE GAS STREAM. THE CLEANED GAS IS DISCHARGED TO THE STACK AND THE PRODUCT ACID IS COOLED AND STORED IN TANKS. A SIMPLIFIED PROCESS
FLOW DIAGRAM OF THE WOOD RIVER CATOX SYSTEM IS PRESENTED IN FIGURE 25 OF APPENDIX C.
THIS DEMONSTRATION SYSTEM, PARTIALLY FINANCED BY EPA, WAS STARTED UP IN SEPTEMBER 1972. WHILE THE MAIN PARTS OF THE UNIT HAVE PERFORMED ACCEPTABLY,
VARIOUS TROUBLES WITH ASSOCIATED EQUIPMENT HAVE CAUSED EXTENSIVE SHUTDOWNS AND DELAYS, TO THE EXTENT THAT APPROXIMATELY 27 DAYS OF FULL OPERATION HAS
BEEN OBTAINED IN ALMOST TWO YEARS. A 24-HOUR PERFORMANCE TEST RUN WAS COMPLETED IN JULY 1973. THE FOLLOWING GUARANTEES WERE ACHIEVED AND EXCEEDED:
90 PERCENT CONVERSION OF SULFUR DIOXIDE TO SULFUR TRIOXIDE (ABOUT 85 PERCENT NET REMOVAL); 99 PERCENT REMOVAL OF PARTICULATE ENTERING THE SYSTEM; LESS
THAN 1 MG/ACF OF ACID MIST IN GAS LEAVING SYSTEM; PRODUCTION OF 60° BAUME1 ACID.
PERFORMANCE SUMMARY
THE WOOD RIVER SYSTEM WAS STARTED UP IN SEPTEMBER 1972 BUT WAS SHUT DOWN ALMOST IMMEDIATELY (IN OCTOBER) TO CONVERT THE BURNERS TO OIL FIRING,
WHICH WAS NOT COMPLETED UNTIL JUNE 1973. A SUCCESSFUL PERFORMANCE TEST WAS THEN MADE, BUT BECAUSE OF THE CATALYST PLUGGING HAZARD THE SYSTEM WAS' SHUT
DOWN AGAIN TO INSTALL AN EXTERNAL BURNER SYSTEM, WHICH WAS NOT COMPLETED UNTIL APRIL 1974. VARIOUS OTHER PROBLEMS WITH STANDARD EQUIPMENT HAVE BEEN
ENCOUNTERED SINCE, WITH THE RESULT THAT ONLY 657 HOURS OF OPERATING TIME HAVE BEEN LOGGED IN ALMOST TWO YEARS.
A-18
PEDCo ENVIRONMENTAL
-------
MOOD RIVER NO. 4 (Continued)
SEVERAL OTHER MAJOR PROBLEM AREAS ENCOUNTERED DURING THE INTERMITTENT OPERATION OF THIS REGENERABLE SYSTEM INCLUDED: FROZEN DAMPERS ON REHEAT
BURNERS, CRACKS IN THE TEFLON LINER ON THE ACID PUMP'S DISCHARGE HEADER, CRACKS IN THE REHEAT DUCTING, FALL OF REFRACTORY BRICKS FROM THE REHEATER
BURNER DOME, AND NEED FOR REINFORCEMENT OF THE STRUCTURE SUPPORTING THE HIGH TEMPERATURE FLUE GAS DUCT TO THE CATALYTIC CONVERTER. MOST OF THESE
PROBLEMS HAVE BEEN CORRECTED. ILLINOIS POWER AND EPA ARE NOW DETERMINING HOW TO CORRECT LEAKING ACID COOLERS. PATCHING ATTEMPTS HAVE BEEN UNSUCCESSFUL.
REPAIR OR REPLACKENT OF THE COOLERS IS EXPECTED TO TAKE SEVERAL MONTHS. EVALUATION FOR THE CONTINUATION OF FUTURE OPERATION IS STILL UNDER CONSIDERA-
TION. A DECISION ON FUTURE OPERATIONS OF THIS SYSTEM WILL BE ANNOUNCED SHORTLY.
PEDCo ENVIRONMENTAL
A-19
-------
OPERATING LOG
CATALYTIC OXIDATION SYSTEM
WOOD RIVER NO. 4 - ILLINOIS POWER CO..
1972 TO 1973
System operating
System operating
Date
9-4-72
9-5-72
9-6-72
9-7-72
9-10-72
9-11-72
9-12-72
9-13-72
9-14-72
9-15-72
9-16-72
9-17-72
9-18-72
9-19-72
9-24-72
10-6-72
10-7-72
hours
12
24
24
2
6
2
16
24
24
24
24
24
24
3
17
12
24
Date
10-8-72
10-9-72
10-10-72
10-12-72
10-13-^72
10-14-72
10-30-72
10-31-72
7-21-73
7-22-73
7-23-73
7-24-73
7-25-73
7-26-73
7-17-73
7-28-73
7-29-73
hours
24
24
18
16
20
16
24
16
18
24
18
24
14
13
19
19
9
NOTE: The operation time log does not Include Intermittent system operation during
1974. System operations for 1974 amounted to 55 hours. Total operation
time for 2.5 years of operation was 657 hours.
A-20
PEDCo ENVIRONMENTAL
-------
APPENDIX A
TERMINATED OPERATIONAL F6D SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
POTOMAC ELECTRIC * POWER
DICKERSON NO 3
DlcKERSON MARYLAND
95 MW
FUEL CHARACTERISTICS COAL 2.0 PERCENT SULFUR
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
CHEMICO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/73
TERMINATED
99.3 PERCENT
S02
90 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
3.2 GPM/MW
ACID PLANT REGENERATION
UNIT COST
S70/KW CAPITAL
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN APPENDIX A OF THIS REPORT. THIS
FGO SYSTEM HAS BEEN OPERATIONAL SINCE SEPTEMBER 1973. THE UNIT HAS BEEN
TERMINATED AS AN S02 SCRUBBER. HOWEVER.IT WILL CONTINUE TO OPERATE AS A
PARTICULATE SCRUBBER.
PEDCo ENVIRONMENTAL
A-21
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BACKGROUND INFORMATION
ON
DICKERSON NO. 3
THE DICKERSON STATION OF POTOMAC ELECTRIC POWER CO. (PEPCO) IS LOCATED ON THE POTOMAC RIVER NEAR DICKERSON, MARYLAND, ABOUT 30 MILES NORTHWEST OF
WASHINGTON, D.C. THE STATION HAS THREE ELECTRIC GENERATORS, EACH RATED AT 190 MU. UNIT NO. 3 IS A DRY BOTTOM COAL-FIRED BOILER DESIGNED BY COMBUSTION
ENGINEERING AND INSTALLED IN 1962. THE COAL NOW BURNED HAS AN AVERAGE GROSS HEATING VALUE OF 11,700 BTU/LB AND AVERAGE ASH AND SULFUR CONTENTS OF
14 AND 2 PERCENT, RESPECTIVELY. THE BOILER IS FITTED WITH AN ELECTROSTATIC PRECIPITATOR DESIGNED AND INSTALLED BY RESEARCH-COTTRELL IN 1962. THE FGD
SYSTEM EMPLOYS THE CHEMICO-BASIC MAGNESIUM OXIDE SCRUBBING PROCESS. THE RETROFIT SYSTEM HANDLES APPROXIMATELY 50 PERCENT OF THE EXHAUST GAS FROM THE
NO. 3 UNIT.
THE FGD SYSTEM CONSISTS OF A SINGLE, TWO-STAGE SCRUBBER/ABSORBER, WHICH INCORPORATES AN ADJUSTABLE-THROAT VENTURI SCRUBBER FOR PARTICULATE
REMOVAL AND A SECOND STAGE ABSORBER WITH A FIXED VENTURI TO REMOVE 3ULFUR DIOXIDE. THE LIQUOR STREAMS FOR BOTH STAGES ARE SEPARATE AND OPERATE IN A
CLOSED-LOOP MODE. UNTIL MID-1975 THE MAGNESIUM SULFITE GENERATED WAS TRANSFERRED TO AN EPA FINANCED FACILITY AT THE ESSEX CHEMICAL COMPANY SULFURIC
ACID MANUFACTURING PLANT IN RUMFORD, RHODE ISLAND, WHERE MAGNESIUM OXIDE WAS REGENERATED AND SUFLUR DIOXIDE FROM THE REGENERATION PROCESS WAS CONVERTED
TO SULFURIC ACID. THE RUMFORD FACILITY HAS SINCE BEEN CLOSED DOWN. A GENERAL PROCESS FLOW DIAGRAM OF THE DICKERSON NO. 3 WET SCRUBBING SYSTEM AND
REGENERATION FACILITIES IS PRESENTED IN FIGURE 25 OF APPENDIX C.
CONSTRUCTION WAS COMPLETED IN AUGUST AND THE SYSTEM STARTED UP IN SEPTEMBER 1973. DURING INTERMITTENT OPERATIONS FOR SHAKEDOWN THROUGH JANUARY
1974, THE SYSTEM'S LONGEST CONTINUOUS RUN WAS 271 HOURS. THE SYSTEM WAS RESTARTED FROM JULY THROUGH DECEMBER 1974, AND AGAIN ON AUGUST 11, 1975, FOR
APPROXIMATELY 87 HOURS.
FGD UNIT OUTAGES WERE CAUSED PRIMARILY BY PIPE AND PUMP CORROSION AND MAJOR TURBINE OVERHAUL OF THE BOILER. PARTICULATE AND SULFUR DIOXIDE REMOVAL
EFFICIENCY GUARANTEES WERE CORROBORATED DURING OPERATIONAL PHASES.
THE REMAINING SUPPLY OF MAGNESIUM OXIDE, ABOUT 100 TONS (10 DAYS), HAS BEEN DEPLETED. AND THE DICKERSON UNIT HAS BEEN TERMINATED AS AN FGD SYSTEM.
A-22
PEDCo ENVIRONMENTAL
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DICKERSON NO. 3
FGD SYSTEM OPERATING HISTORY
Operating Period Comments
Sep. 73 Problems during this period ranged from corrosion leaks in expansion joints to problems in material
to handling equipment, feeding and slaking of MgO, plugging in the MgO mix tank and suction lines, to
Jan. 74 the MgO make-up pumps.
Jan. 74 Maintenance and modifications were performed on the system. The major system revision made during
to this period was the addition of a pre-mix tank in the MgO system.
Apr. 74
Apr. 74 Limited operation because the utility did not have access to the EPA calcining facility at the Essex
to Chemical Company sulfuric acid plant. By the end.of June 1974, all the MgO at Dickerson had been used
Jul. 74 and a silo plus three train cars were full of MgSOj.
Aug. 74 During this period the system generally operated at 75 percent of the design gas flow.
to
Dec. 74
Jan. 75 Problems developed in the bucket elevator transporting the MgSO- from the dryer to the storage silo.
Feb. 75 Unit No. 3 was taken out of service for an 8 to 12 week turbine overhaul. The scrubber was inspected,
to maintenance and modifications were made.
Jul. 75
A-23
PEDCo ENVIRONMENTAL
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DICKERSON NO. 3 (Continued)
F6D SYSTEM OPERATING HISTORY
Operating Period Comments
Aug. 75 The FGD system was restarted 1n August. Steam was lost to the MgO mix tank, resulting in a very moist
product from the centrifuge. Caking in the dryer occurred. At this point, the utility decided to test
only the first-stage of the scrubbing system, taking gas ahead of the precipitator. FGD operation at
Dickerson terminated at this point.
PEDCo ENVIRONMENTAL
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APPENDIX A
TERMINATED OPERATIONAL F60 SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F60 VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYt
PARTICIPATES
S02
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
SOUTHERN CALIFORNIA EDISON
MGHAVE NO 1A
LAboHLIN NEVADA
170 nw
COAL 0.5- 0.8 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
RETROFIT
11/7H
TERMINATED
93 PERCENT
95 PERCENT
0.92 GPM/MW
EXPERIMENTAL METHODS
NOT AVAILABLE
THIS EXPERIMENTAL MODULE STARTED UP OCT. 31, 197<* AND OPERATED WITH AN
AVAILABILITY OF 60.t* THROUGH FOUR MONTHS OF TESTING. TESTS HAVE BEEN
COMPLETED, AND THE FGD SYSTEM WAS SHUT DOWN INDEFINITELY ON JULY 2, 197S.
NEVADA ASSEMBLY BILL NO. 708 HAS PLACED A 2-YEAR MORATORIUM ON THE
ENFORCEMENT OF THE COMPLIANCE SCHEDULE FOR THIS STATION. FURTHER FGD
ACTIVITIES WILL BE DEPENDENT ON FUTURE LEGISLATION*
PEDCo ENVIRONMENTAL
A-25
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APPENDIX A
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO. 8
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
so2
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2A
LAUGHLIN NEVADA
160 MW
COAL 0.5- 0.8 PERCENT SULFUR
SCE/ STEARNS ROGER
LIME SCRUBBING
RETROFIT
11/73
TERMINATED
93 PERCENT
95 PERCENT
1.0 GPM/MW
STABILIZED SLUDGE DISPOSED IN UNLINED POND
NOT AVAILABLE
SINCE STARTUP OF FORMAL TEST PROGRAM ON JANUARY 16. 1974, AND UP TO DECEMBER 20, 1974,THIS EXPERIMENTAL
HORIZONTAL MODULE OPERATED 5280 HRS. WITH AN OVERALL AVAILABILITY OF 77.4 PERCENT, SOz REMOVAL
EFFICIENCY WAS 90 IN FLUE GAS TO SIMULATE CONDITIONS FROM COMBUSTION OF HIGH SULFUR COAL. THIS FGD
SYSTEM OPERATED FROM NOVEMBER 1973 UNTIL FEBRUARY 1975. FGD PLANS AT THIS STATION WILL BE BASED
ON INFORMATION THAT INCLUDES OPERATIONAL DATA THAT HAVE BEEN OBTAINED DURING THE FGD TEST PROGRAMS
AT THE MOHAVE STATION. THE PHOTOTYPE SYSTEM AT MOHAVE IS NOW BEING DISMANTLED AND IS BEING SHIPPED
TO THE FOUR CORNERS PLANT, OPERATED BY ARIZONA PUBLIC SERVICE, FOR INSTALLATION.
PEDCo ENVIRONMENTAL
A-26
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BACKGROUND INFORMATION
ON
THE MOHAVE TEST MODULES PROGRAM: NOS. 1A AND 2A
TWO PROTOTYPE SULFUR DIOXIDE ABSORBER MODULES WERE INSTALLED IN 1973 AT THE MOHAVE GENERATING STATION OF THE SOUTHERN CALIFORNIA EDISON
COMPANY. A VERTICAL MODULE, RATED AT 170 MW, WAS INSTALLED TO TREAT 450,000 SCFM PORTION OF THE FLUE GAS FROM UNIT NO. 1. A HORIZONTAL MODULE,
ALSO RATED AT 170 MW, WAS INSTALLED TO TREAT A SIMILAR FLUE GAS PORTION FROM UNIT NO. 2. UNITS 1 AND 2 ARE IDENTICAL BOILERS, EACH HAVING A
MAXIMUM NET CONTINUOUS GENERATING CAPACITY OF 790 MW AND EACH BURNING A WESTERN, LOW-SULFUR COAL WITH A HEATING VALUE OF 11,500 BTU/LB AND ASH
AND SULFUR CONTENTS OF 10 AND 0.4 PERCENT RESPECTIVELY.
VERTICAL MODULE
THE VERTICAL MODULE, A UNIVERSAL OIL PRODUCTS TURBULENT CONTACT ABSORBER (TCA), WAS TESTED IN TWO MODES: FIRST, AS A TCA UNIT, FROM NOVEMBER
2, 1974 TO APRIL 30, 1975, AND SECOND AS A POLYGRID PACKED ABSORBER (PPA), WHEN THEN THE "PING PONG BALLS" WERE REPLACED WITH A PLASTIC "EGGCRATE"
PACKING WITH TESTING CONTINUING TO JULY 2, 1975.
STARTUP OF THE VERTICAL MODULE WAS INITIATED ON SCHEDULE JANUARY 1, 1974. ON JANUARY 24, 1974, A FIRE BURNED MOST OF THE CHLOROBUTYL
LINING AND SYSTEM RESTART WAS DELAYED UNTIL OCTOBER 1, 1974. TESTING OF THIS MODULE FOLLOWED A MONTH LATER AND WAS COMPLETED AFTER 3,131 HOURS
OF OPERATION. THE MODULE IS PRESENTLY SHUT DOWN IN A COLD STAND-BY CONDITION AT THE MOHAVE GENERATING STATION.
HORIZONTAL MODULE
THE HORIZONTAL MODULE, A FOUR-STAGE HORIZONTAL CROSSFLOW SPRAY SCRUBBER, WAS OPERATED BY THE UTILITY IN A SHORT SERIES OF STARTUP TESTS THAT
ENDED ON JANUARY 16, 1974, WHEN A FORMAL TEST PROGRAM WAS INITIATED TO ASSESS THE PERFORMANCE AND RELIABILITY CHARACTERISTICS OF THE SCRUBBING
SYSTEM. THE TEST PROGRAM WAS TERMINATED ON FEBRUARY 9, 1975, FOLLOWING 5,927 HOURS OF OPERATION. THE MODULE WAS SUBSEQUENTLY DISMANTLED,
TRANSPORTED, AND REASSEMBLED AT THE FOUR CORNERS PLANT OF ARIZONA PUBLIC SERVICE WHERE ADDITIONAL TESTING IS NOW BEING CONDUCTED.
INFORMATION AND DATA CONCERNING THE PERFORMANCE OF THE MOHAVE TEST MODULES ARE GIVEN IN THE FOLLOWING PERFORMANCE TABLES. PROCESS FLOW DIAGRAMS
OF THE TEST MODULES ARE PROVIDED IN FIGURES 27 AND 28 OF APPENDIX C.
PEDCo ENVIRONMENTAL
A-27
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MOHAVE NO. 1A - VERTICAL TEST MODULE
OUTAGE TIME HISTORY: NOVEMBER 2, 1974 TO JULY 2, 1975
Reason Time (hr)
1. Repair grids and redistribute TCA balls 710
2. Clean scale from scrubber internals 344
3. Repair/replace plugged nozzles 153
4. Repair leaks in trap-out tray 120
5. Repair/realign PPA packing 85
6. Correct booster fan trip problems 72
7. Conduct inspections for extended operations 46
8. Remove hardhat from thickener 46
9. Total outage time 1585
Total outage time: 1585 hours
Total calendar time: 5813 hours
Total operational time: 4228 hours
Percent availability: 72.73
A-28
PEDCo ENVIRONMENTAL
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MOHAVE NO. 2A - HORIZONTAL TEST MODULE
OUTAGE TIME HISTORY: JANUARY 16, 1974 TO FEBRUARY 9, 1975
Reason Time (hr)
1. Modify and repair plastic demister blades 503
2. Correct booster fan balance problems 317
3. Pump repair 256
4. Spray nozzle replacement 238
5. Modify gas Inlet flow distribution 162
6. Repair hopper leaks 135
7. Remove hardhat from thickener 82
8. Modify slaking water for scale prevention 45
9. Conduct inspections for extended operations 19_
10. Total outage time 1757
Total outage time: 1757 hours
Total calendar time: 9328 hours
Total operating time: 7571 hours
Percent availability: 81.162
A-29
PEDCo ENVIRONMENTAL
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APPENDIX A
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO. 9
TENNESSEE VALLEY AUTHORITY
-^
SHAWNEE NO. IOC
PADUCAH KENTUCKY
10 MW
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS COAL 2.9 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
TENNESSEE VALLEY AUTHORITY
LIME/LIMESTONE SCRUBBING
RETROFIT
H/72
OPERATIONAL
EXPERIMENTALLY CONTROLLED
EXPERIMENTALLY CONTROLLED
EXPERIMENTALLY CONTROLLED
EXPERIMENTALLY CONTROLLED
UNIT COST
OPERATIONAL
EXPERIENCE
REFEK TO BACKGKOUND INFORMATION SECTION IN APPENDIX C. THIS
FGO SYSTEM HAS liEEN OPERATIONAL SINCE APRIL.1972. THIS MARBLE-BED AB-
SORBER, MANUFACTURED BY COMBUSTION ENGINEERING CO., WAS DISCONTINUED
EARLY IN THE TEST PROGRAM BECAUSE OF CONTINUED OPERATING PROBLEMS WITH
NOZZLE FAILURE AND SUBSEQUENT PLUGGING OF THE MARBLE BED. THIS SYSTEM
BECAME OPERATIONAL IN APRIL 1972 AND WAS PERMANENTLY TERMINATED IN
JULY 1973.
PEDCo ENVIRONMENTAL
A-30
-------
BACKGROUND INFORMATION
ON
SHAWNEE NOS. IDA, 10B, AND IOC
IN JUNE 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE WET LIME AND LIMESTONE SCRUBBING SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND PARTICULATES
FROM FLUE GAS. THE PROGRAM WAS CARRIED OUT IN A TEST FACILITY INCORPORATED INTO THE FLUE GAS DUCT WORK OF UNIT NO. 10, A COAL-IFRED BOILER AT THE
TVA SHAWNEE POWER STATION, PADUCAH, KENTUCKY. TVA IS THE CONSTUCTOR AND FACILITY OPERATOR AND THE BECHTEL CORP. IS THE MAJOR CONTRACTOR AND TEST
DIRECTOR.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE TREATING PART OF THE FLUE GAS FROM THE BOILER. EACH SCRUBBER
TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30,000 ACFM, OR THE EQUIVALENT OF APPROXIMATELY 10 MW OF POWER PLANT GENERATING CAPACITY.
THREE PARALLEL WET SCRUBBER SYSTEMS WERE SELECTED FOR THE TEST PROJECT: 1) A VENTURI WITH A SPRAY TOWER AFTER ABSORBER; 2) A TURBULENT CONTACT
ABSORBER (TCA) AND 3) A MARBLE-BED ABSORBER. THE VENTURI SYSTEM, MANUFACTURED BY CHEMICAL CONSTRUCTION CO., CONTAINS AN ADJUSTABLE THROAT THAT PERMITS
CONTROL AND VARIATION OF PRESSURE DROP UNDER A WIDE RANGE OF FLOW CONDITIONS. THE TCA UNIT, MANUFACTURED BY UNIVERSAL OIL PRODUCTS, EMPLOYS A
FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT ARE FREE TO MOVE BETWEEN RETURNING GRIDS. THE MARBLE-BED ABSORBER, SUPPLIED BY COMBUSTION ENGINEERING
CO., USES A PACKING OF 3/4-INCH GLASS MARBLE SPHERES AND A TURBULENT LAYER OF LIQUID AND GAS ABOVE THE MARBLE LAYER TO ENHANCE MASS TRANSFER.
THE TEST FACILITY WAS DESIGNED SO THAT MODIFICATIONS AND VARIATIONS OF SCRUBBER INTERNALS AND PIPING COULD BE READILY EMPLOYED FOR EACH SCRUBBER
SYSTEM. EACH SYSTEM CAN TREAT APPROXIMATELY 30,000 ACFM OF FLUE GAS AT 300°F CONTAINING 1800 TO 4000 PPM OF S02 AND 2 TO 5 GRAINS/SCF OF PARTICULATES.
TESTING OF THE TCA AND THE VENTURI SPRAY TOWER IS IN PROGRESS; OPERATION OF THE MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
PEDCo ENVIRONMENTAL
A-31
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A-32
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APPENDIX b
FGU ECONOMICS
B-l
PEDCO-ENVIRONMENTAL
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B-2
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APPENDIX B. FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Alabama Electric Coop.
Tombigbee Power Station
Nos. 2 & 3
450
Arizona Public Service
Choi la Electric Generating
Station
No. 1
115
Boston Edison Company
Mystic Power Station
No. 1
155
PROCESS
STATUS
START-UP DATE
Limestone
Construction
3/78 & 3/79
Limestone
Operational
10/73
Magnesium Oxide
Terminated
4/72
REPORTED CAPITAL
COSTS,
$ MILLION
40.464
6.555
9.510
$/KW
89.92
57.0
63.4
REPORTED OPERATING
COSTS,
$ ANNUAL
240,323
615,000
MILLS/KWH
0.77
2.20
3.0
COMMENTS
1. Capital cost figures include upstream particulate con-
trol equipment (ESP's).
2. 7Q% of the flue gas capacity is scrubbed.
3. Annual operating costs are calculated for 1978 with a
60% boiler capacity factor.
1. Capital cost figure includes the venturi scrubbers (2)
for particulate control. This figure represents
total expenditures made by the utility through 1973.
2. Capital cost figure does not include limestone prep-
aration and sludge handling facilities and interest
on capital during construction.
3. Additional costs incurred by the system supplier have
not been reported.
1. All cost figures are reported for the project com-
pletion date of 1974.
2. The total installed capital cost of the Rumford cal-
cination facility was approximately $4.5 MM.
3. Capital charges are not included because of non-
applicability to a 2-year demonstration program.
4. Operating costs for the acid plant regeneration
facility are not included.
5. The cost of make-up magnesium oxide ($150/T) are not
included.
6. 3.0 mills/kWh is an estimate for total operation and
maintenance costs, including calcination.
7. BECO and EPA each subsidized approximately 50% of the
costs of the demonstration program. Chemico also
underwrote some of the program costs.
Note: N/A indicates figures are not available.
B-3
PEDC6 ENVIRONMENTAL
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APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Big Rivers Electric Coop
Reid Steam Station
No. 2
280
Central Illinois Light Co.
Duck Creek Power Plant
No. 1
400
Central Illinois Public Serv.
Newton Station
No. 1
575
PROCESS
STATUS
START-UP DATE
Lime
Contract
Awarded
1979
Limestone
Operational,
Construction
9/76 & 8/78
Double Alkali
REPORTED CAPITAL
COSTS,
$ MILLION
16
36
48.875
$/KW
64
90
85
REPORTED OPERATING
COSTS,
$ ANNUAL
N/A
13.425 MM
MILLS/KWH
3.81
COMMENTS
1. The reported capital cost figure applies to the amount
of the contract awarded to AAF for a turnkey emission
control installation.
2. The figure includes an AAF-ELEX ESP, two spray towers,
reheater, ancillary equipment, ductwork, and molecular
pre-wired control rooms.
3. All figures are reported in 1976 dollars.
4. Escalation factors, costs, and indirect costs are not
included.
1. The capital cost figure is an estimate of expend-
itures, including $4.0 MM for the ESP, and the cost of
the limestone milling and waste disposal facilities.
2. One module has been completely installed and tempo-
rarily started-up in September 1976. The remaining
three modules are scheduled for operation in August
1978.
1. The capital cost figure is an estimate for total
projected expenditures. Since construction has re-
cently commenced, exact figures are not available.
Total expenditures may well run higher than the $85/kW
posted in the table.
2. Cost to own and operate figures are projections based
upon firing the design coal (10,900 Btu/lb, 4% S,
0.2% Cl at a load factor of 7055 with a system SO?
removal efficiency of 95%. Full load heat release is
5500 MM Btu/hr. Stack exit temperature is 154°F.
System lifetime is 30 years.
Note: N/A indicates figures are not available.
PEDCo ENVIRONMENTAL
B-4
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APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Columbus & So. Ohio Electric
Conesville Generating Station
Nos. 5 & 6
800
Colorado Ute Electric
Craig Station
Nos. 1 & 2
900
Commonwealth Edison
Powerton Station
No. 51
425
PROCESS
STATUS
START-UP DATE
Lime
Construction
12/76 & 1/78
Not selected
Considering
Spring, 1979
Limestone
Contract
Awarded
REPORTED CAPITAL
COSTS,
$ MILLION
38.661
105
50
$/KW
48.32
117
117.65
REPORTED OPERATING
COSTS,
$ ANNUAL
7.826 MM
15 MM
MILLS/KWH
2.83
8.70
COMMENTS
1. The capital cost figure includes direct costs only.
2. The electrostatic precipitators are also included
in the capital cost figure ($4.973 MM for 2 units).
3. Annual operating costs are estimated for both units at
a load factor of 39.5%.
4. The cost estimates are given in 1975 dollars.
1. The total capital cost figure is an estimate provided
by the utility that does not include limestone
preparation and sludge disposal facilities. This
figure is based upon a non-regenerable SO. scrubbing
system (lime/limestone).
2. Electrostatic precipitators are included in the
capital cost figure.
3. The annual operating cost figure is a utility es-
timate also based upon the installation of a non-
regenerable SO- scrubbing system.
1. The total installed capital cost expenditures apply
to the following timetable: all expenditures will be
made from May 1976 to December 1978; expenditures
of $16 MM will be made from October 1976 to October
1977.
2. The annual operating cost is an estimate which in-
cludes the following items:
2.7 mills/kWh for operation and maintenance.
6.0 mills/kWh for auxiliary power requirements.
Scrubber life span is estimated for an annual
usage rate of 148,000,000 kWh.
Note: N/A Indicates figures are not available.
PEDCo ENVIRONMENTAL
B-5
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APPENDIX B (Continued). FGO SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Commonwealth Edison
Will County Station
No. 1
167
Detroit Edison
St. Clair Plant
No. 6
163 MW
Duquesne Light
F.R. Phillips Station
Nos. 1 to 6
410 MW
Elrama Station
Nos. 1 to 4
510 MW
PROCESS
STATUS
START-UP DATE
Limestone
Operational
2/72
Limestone
Operational
5/76
Lime
Operational
7/73
Lime
Operational
10/75
REPORTED CAPITAL
COSTS,
$ MILLION
15.542
14.996
40
42
$/KW
113
92
103
93
REPORTED OPERATING
COSTS,
$ ANNUAL
3.985 KM
2.139 KM
32 MM
MILLS/KWH
13.06
2.3
6.0
COMMENTS
1. The capital cost figure includes the venturi scrubbers
for particulate control.
2. The annual operating cost figure is based on a
system lifetime of 14 years. Sludge treatment costs
include hauling to an off-site disposal area. The
figure provided is the cost to own and operate the
scrubbing system for 1975.
3. The $/kW figure is based upon the unit's maximum net
generating capacity with the FGD system, 137 MW.
4. Unit load capacity factor for 1975 was 49.4%.
1. The total capital cost figure includes expenditures
made through 1976.
2. Because of demonstration status, limestone preparation
facilities are not required and a disposal pond
capacity of 1 year is necessary.
3. Operating costs are estimates for operation during
1975 at a unit load factor of 65%.
1. Total capital cost figure for Phillips includes
expenditures of $32 million through 1975 and an addi-
tional $8 million required to bring the entire
plant into compliance. The figure for Elrama includes
expenditures of $34 million through 1975 and an
additional $12 million required to bring the entire
plant into compliance.
2. Total capital cost figures include all process equip-
ment, engineering costs, contractor's fees and interest
on capital during construction. Excluded are the
costs of additional sludge disposal facilities that
may be required. The $/kW values are based upon the
station's net generating capacities with the scrubbers
in service. The Phillips station net generating
capacity is 387 MW. Elrama's net generating capacity
is 494 MW.
3. Annual operating cost figures of 6 mills/kWh is based
upon the combined operating costs for the Phillips and
E1ra.ua stations when full S02 compliance is achieved.
This amounts to approximately $32 million.
Note: N/A indicates figures are not available.
B-6
PEDCo ENVIRONMENTAL
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APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MM
General Motors
Chevrolet Parma Plant
Nos. 1,2,3 & 4
Gulf Power
Scholz Steam Plant
Nos. 1 & 2
23
Gulf Power
Scholz Steam Plant
No. 2
20
Illinois Power
Wood River Power Station
No. 4
110
PROCESS
STATUS
START-UP DATE
Double Alkali
Operational
3/74
Dilute Acid,
Operational
2/75
Dry Adsorption
Terminated
2/76
Catalytic
Oxidation
Terminated
10/72
REPORTED CAPITAL
COSTS,
J MILLION
3.2
3.0
N/A
8.5
$/KW
100
130
N/A
82.5
REPORTED OPERATING
COSTS,
$ ANNUAL
643,500
N/A
N/A
952,000
MILLS/KWH
N/A
N/A
COMMENTS
1. Total capital cost figure includes all expenditures
made on the system through 1975.
2. Annual cost figure is based upon the consumption of
55,000 tons/year- of high sulfur (2.0 to 2.5%) eastern
Ohio coal in the boilers. This equals approximately
$11.70 per ton of coal consumed at the plant.
1. The total installed capital cost figure provided for
the CT-101 prototype unit includes the scrubbers and
ancillary equipment, engineering costs and contractors
fee. This figure is not representative of a full-
scale application.
1. Actual cost figures for this prototype unit are not
available. Foster Wheeler has published initial
capital cost figures which range from $25 to $35 per
kW for low sulfur removal efficiency and $70 to $75
per kW for high sulfur removal efficiency.
1. Reported capital cost figure represents the total
expenditures during the 2.5 year duration of the
program.
2. The $/kW figure is based upon the system's net
generating capacity of 103 MW.
3. ESP cost is included since upstream fly ash removal
is a necessary feature of this regenerable system.
4. The annual cost figure is an estimate representing
system running costs only. Excluded are capital
charges and a credit for product. This figure trans-
lates into a value of $3.46 per ton of coal consumed.
Note; N/A Indicates figures are not available.
PEDCo ENVIRONMENTAL
B-7
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APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Indianapolis Power & Light
Petersburg Generating Station
No. 3
530
Kansas City Power & Light
Hawthorn Power Station
Nos. 3 & 4
525
Kansas City Power & Light
La Cygne Power Station
No. 1
820
PROCESS
STATUS
START-UP DATE
Limestone
Construction
9/77
Limestone
Injection &
Wet Scrubbing
Operational
11/72
Limestone
Operational
2/73
REPORTED CAPITAL
COSTS,
$ MILLION
36.885
5.32
52.4
$/KW
69.9
19
63.9
REPORTED OPERATING
COSTS,
$ ANNUAL
1.79 MM
MILLS/KWH
2.2-2.5
0.94
COMMENTS
1. Capital cost figure includes the ESP's installed
upstream for primary particulate control.
2. Interest during construction is not included.
3. FGD design and costs are based upon 4.5% sulfur coal,
which is the maximum allowable for the system.
1. This figure is unrealistically low because these
installations are experimental in nature and were
heavily underwritten by the system supplier.
2. Sludge disposal facilities are not included in the
total cost figure.
3. The annual operating cost figure does not include
fixed costs.
1. The capital cost figure includes $45.4 million in
expenditures already made plus an additional $7
million required to reach optimum system performance
($5.2 million for the installation of an eighth
scrubber module).
2. The annual operating cost figures are estimates for
1976 operations based upon extrapolation of first
quarter figures provided by the utility. Included are
operating labor and materials, maintenance labor and
materials, and limestone.
Note: N/A Indicates figures are not available.
PEDCo ENVIRONMENTAL
B-8
-------
APPENDIX B (Continued). FGO SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, HW
Kansas Power & Light
Lawrence Energy Center
Nos. 4 & 5
525 HW
Kentucky Utilities
Green River Power Station
Nos. 1 & 2
64
Key West Utility
Stock Island Power Plant
37
PROCESS
STATUS
START-UP DATE
Limestone
Injection &
Wet Scrubbing
Operational
12/68 & 11/71
Lime
Operational
9/75
Limestone
Operational
10/72
REPORTED CAPITAL
COSTS,
$ MILLION
3.5
3.996
0.750
$/KW
7
62.44
20.7
REPORTED OPERATING
COSTS,
$ ANNUAL
N/A
MILLS/KWH
N/A
2.0
0.7
COMMENTS
1. The capital cost figure presented represents a sum
paid by the utility for both systems in 1968. Ex-
penses incurred in many subsequent modifications
over the years were largely underwritten by the
system supplier. Therefore, the figures listed are
unreal istically low and are not meaningful.
2. These units are now being replaced with venturi rod
scrubber and spray tower systems. The total installed
costs for these systems are not available.
1. The capital cost figure for this turnkey installa-
tion does not include the utility's expenditures
for engineering, operator training, and other indirect
cost factors.
1. This system was jointly funded by the EPA and the
utility. The system supplier has also underwritten
a considerable amount of the capital expenditures.
This figure, therefore, Is unreal Istically low.
2. The utility has had to pay for the cost of a new
primary crushing system.
3. The operating cost figure provided was an original
estimate and has not been corroborated or disputed
by actual experience. This estimate was based upon
the following factors:
Capitalization rate of 10%; no taxes, no insurance.
Maintenance cost of 5% of equipment cost.
Labor cost at $20,000 per year.
Limestone cost at $4.05 per ton.
Note: N/A Indicates figures are not available.
PEDCo ENVIRONMENTAL
B-9
-------
APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Louisville Gas & Electric
Cene Run Power Station
No. 4
178
Louisville Gas & Electric
Cane Run Power Station
No. 5
183
Louisville Gas & Electric
Cane Run Power Station
No. 6
277
Louisville Gas & Electric
Paddy Run Power Station
No. 6
65
Minnkota Power Coop.
M.R. Young Station
No. 2
450
PROCESS
STATUS
START-UP DATE
Lime
Operational
8/76
Lime
Operational
12/77
Double Alkali
Contract Awarded
2/79
Lime
Operational
4/73
Fly Ash/Lime
Construction
8/77
REPORTED CAPITAL
COSTS,
$ MILLION
10
12
16.3
3.7
44
$/KW
50
66
58.9
57
98
REPORTED OPERATING
COSTS,
$ ANNUAL
N/A
7.3 MM
905,000
MILLS/KWH
N/A
2.5
COMMENTS
1. The total installed capital cost is an estimated
figure that includes the costs for lime handling and
sludge disposal facilities.
1. The total installed capital cost is an estimated
figure that includes the costs for lime handling and
sludge disposal facilities.
1. The total installed capital cost figure is an estimate
provided by the utility.
2. The annual operating cost figure provided is an
estimate for one year's service following the first
three months of npertions. $4.5 million of this total
will be subsidized by the EPA for technology research,
development and report writing. This, subsidy will not
be utilized for any capital expenditures.
1. The capital cost figures are based on the boiler
rating minus system power consumption. The costs
include everything except the final waste disposal
site. This is a borrow pit supplied by the State
highway department at no cost to the utility.
2. The operating costs provided has been derived by
assuming a 60% unit 60 factor and a 15% fixed charge
factor.
3. Cost of the carbide lime absorbent is confidential.
4. Costs are atypical because the unit is used for
peak loads and the scrubber is a research and
development tool for future full scale installations
now operational, under construction or planned.
1. The total installed capital cost figure represents
an estimated value for the unit's entire emission
control system, including an upstream ESP for pri-
mary parti cul ate control ($12 million).
2. The capital cost figure does not include the ex-
tensive sludge handling and disposal strategy proposed
for this unit (vacuum filters and building, conveyor,
by-pass equipment, trucks and front-end loaders.
Note; N/A indicates figures are not available.
B-10
PEDCo ENVIRONMENTAL
-------
APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, HW
Montana Power Co.
Colstrip Plant
Nos. 1 & 2
716
Montana Power Co.
Colstrip Plant
Nos. 3 & 4
Nevada Power Co.
Reid Gardner Station
Nos. 1 & 2
250
Northern Indiana Public Serv.
D.H. Mitchell Station
No. 11
115
PROCESS
STATUS
START-UP DATE
Fly Ash/Lime
Operational
10/75 & 7/76
Fly Ash/Lime
Contract
Awarded
7/80 & 7/81
Sodium Carbonate
Operational
4/74
Well man-Lord
Construction
1977
REPORTED CAPITAL
COSTS,
$ MILLION
32.663
N/A
11
14.825
$/KW
45.32
N/A
44
129
REPORTED OPERATING
COSTS,
$ ANNUAL
1.185 MM
N/A
1.2 MM
6.006 MM
MILLS/KWH
0.26
N/A
N/A
8.1
COMMENTS
1. The total installed capital cost figure is an es-
timated value that includes the venturi scrubbers
installed for paniculate emissions control.
2. The annual operating cost figure is an estimated
value that excludes fixed charges and solid waste
disposal operations.
3. Capital charges were not available to be included
in the figures provided.
4. The cost figures are presented in 1975 and 1976
dollars.
1. Capital cost figures are currently not available for
publication. The contract recently awarded to the
system supplier is expected to exceed $50 MM for both
units.
1. The total installed capital cost figure is an estimate
that was originally provided by the utility for
expenditures completed by installation date (1974).
Included are both scrubbing systems along with all the
raw material handling and pond equipment cost.
2. The annual operating cost figure includes $600,000
annual i zed for each unit.
1. The capital figure includes interest during con-
struction and overhead charges.
2. Reported operating cost figure is a total annualized
cost value that includes:
Operation and maintenance costs.
Anti-oxidant agent costs.
Fixed charges are calculated a 10-15 year plant life-
time (26% of $14,825 MM). Assume an annual unit load
factor of 73.5%.
3. All figures are reported in 1976 dollars.
Note: N/A indicates figures are not available.
B-ll
PEDCo ENVIRONMENTAL
-------
APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Northern States Power
Sherburne County Generating
Plant
Nos. 1 & 2
1420
Pacific Power & Light
Idaho Power Company
Jim Bridger Plant
No. 3
PROCESS
CTA T( 1C
STATUS
START-UP DATE
Limestone
Operational,
Construction
5/76 & 5/77
Sodium
Contract
Awarded
9/79
REPORTED CAPITAL
COSTS,
$ MILLION
60
50-60 MM
$/KW
44
110-120
REPORTED OPERATING
COSTS,
j
$ ANNUAL
3.77 KM
MILLS/KWH
0.37
COMMENTS
1. The total installed capital cost figure includes
direct costs only, indirect costs are excluded.
2. The total cost figure applies to 1975 installation
and does not include escalation factors.
3. The annual operating cost figure includes both
direct and indirect costs for 1976 operations.
4. The $/kW figure is based upon the net generating
capacity of both units (680 Mw/unit, 1360 MW total).
5. The cost of one redundant scrubber train is included.
6. The annual operating cost figure is estimated for
1977 operations at a capacity load factor of 80%.
1. The total installed capital cost figures provided
are estimated values.
2. The system will be comprised of 3 parallel absorp-
tion towers each handling 30.3* of the flue gas
capacity.
3. The reagent, a nominal 30 wt. % Na2C03 purge solu-
tion, will be purchased from a local soda ash
manufacturer.
Note: N/A Indicates figures are not available.
B-12
PEDCo ENVIRONMENTAL
-------
APPENDIX B (Continued). F6D SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MM
Pennsylvania Power
Bruce Mansfield Plant
Nos. 1 & 2
1670
Philadelphia Electric
Eddystone Generating
Unit No. 1A
316
PROCESS
STATUS
START-UP DATE
Lime
Operational ,
Construction
4/76 & 4/77
Magnesium Oxide
Operational
9/75
REPORTED CAPITAL
COSTS,
$ MILLION
213.200
20.273
$/KW
127.66
64
REPORTED OPERATING
COSTS,
$ ANNUAL
10.344 MM
N/A
MILLS/KWH
2.7
N/A
COMMENTS
1. All cost figures presented are estimates provided
by the utility.
2. The total installed capital cost figure includes
all direct and indirect costs plus escalation
factors .
3. The cost of the venturi scrubbers required for par-
ticulate emission control are included.
4. The cost of one redundant scrubbing train is included.
5. The annual operating cost, calculated in mills/kWh,
is based upon a 90% unit capacity factor.
6. Indirect costs are not included in the annual opera-
ing cost total .
7. All cost figures are reported in 1975 and 1977 dollars.
1. The total installed capital cost figure is a 1972
estimated value, devoid of any escalation factors.
2. Total direct and indirect costs include the three
first stage particulate scrubbers and one second stage
S02 absorber. Also included are the S02 recovery
equipment at the plant, site improvements, and access
roads, engineering and contractor's fees and in-
terest on capital during construction.
3. The costs for the magnesium oxide regenerating
facilities are not Included in the total cost figure.
Note: N/A Indicates figures are not available.
PEDCo ENVIRONMENTAL
B-13
-------
APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Potomac Electric Power
Dickerson Station
No. 3
190
Public Service of New Mexico
San Juan Station
Nos. 1 & 2
715
PROCESS
STATUS
START-UP DATE
Magnesium Oxide
Terminated
9/73
Well man Lord
Construction
7/77
REPORTED CAPITAL
COSTS,
$ MILLION
6.5
89.510
$/KW
68
127.87
REPORTED OPERATING
COSTS,
$ ANNUAL
990,000
7.236 W
NILLS/KWH
N/A
5.0
COMMENTS
1. The total installed capital cost figure is an estimate
provided by the utility in 1973.
2. This figure does not include regeneration and acid
plant costs.
3. The operating cost figure is an estimate provided
for 1974 operations. This figure includes operation
and maintenance costs and acid plant freight and
operation charges. Not included in this figure are
fixed charges, utility charges, project management
and engineering costs.
1. The total installed capital cost figure is an es-
mated value that applies to 1977 installation. In-
cluded are all direct and indirect costs plus an
escalation factor.
2. The $/kW figure is based on a net generating capacity
of 700 MW.
3. The costs of the venturi scrubbers for particulate
removal are included in the total cost figure.
4. The cost of one redundant scrubber train is included.
5. The annual operating costs and the mills/kWh value
derived are estimated for 1978 operations and based
upon a capacity factor of 77%.
6. No credit is allowed for by-product recovery (this
includes both the elemental sulfur product and the
sodium sulfate purge product for use in pulp and paper
processes .
Note: N/A Indicates figures are not available.
PEDCo ENVIRONMENTAL
B-14
-------
APPENDIX B (Continued). F6D SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Rickenbacker AFB
Rickenbacker
Nos. 1 to 7
20
Salt River Project
Coronado Station
Nos. 1 & 2
700 HW
South Carolina Public Service
Wlnyah Generating Station
No. 2
280
Southern Mississippi Power
R.D. Morrow Generating Plant
Nos. 1 & 2
360
PROCESS
STATUS
START-UP DATE
Lime
Operational
3/76
Limestone
Contract
Awarded
4/79 & 4/80
Limestone
Construction
Limestone
Construction
11/77 & 6/78
REPORTED CAPITAL
COSTS,
$ MILLION
2.2
N/A
6.189
18.847
$/KW
110
N/A
24.35
52.35
REPORTED OPERATING
COSTS,
$ ANNUAL
N/A
N/A
MILLS/KWH
N/A
N/A
COMMENTS
1. The total installed capital cost figure includes
adjacent electrical costs, sludge disposal facility
costs, external flue work costs, and other non-
typical equipment costs.
2. Figures are reported in 1976 dollars.
1. The contracts for the ESP and scrubbing system
have just been recently awarded. Actual capital
cost figures have not yet been determined. The
combined cost of these two new power-generating
facilities, including emission control, is estimated
at 685 MM.
1. Fifty percent of the boiler's flue gas will be
scrubbed for S02 removal. SO? removal efficiency is
69%.
2. The total installed capital cost figure is an
estimated value.
3. Total direct and indirect costs for the ESP provided
for primary particulate control upstream of the
scrubbers are included.
4. Sludge handling and disposal facilities, utilities
and services costs, interest on capital during con-
struction, and contractor's fees are not included in
the total installed cost figure.
1. The total installed capital cost figure is an estimate
that applies to 1975 installation dates.
2. Included in the cost figure are the ESP's, scrubbers
and ancillary equipment, fans, construction field
expenses, and interest during construction.
3. Sludge handling and disposal facilities are not In-
cluded in the total cost figure.
Note: N/A Indicates figures are not available.
PEDCo ENVIRONMENTAL
B-15
-------
APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Tennessee Valley Authority
Widows Creek Steam Plant
No. 8
550
Utah Power & Light
Emery Plant
No. 1
400
Utah Power & Light
Hunt ing ton Plant
No. 1
415 MW
PROCESS
STATUS
START-UP DATE
Limestone
construction
3/77
Lime
Letter of Intent
6/78
Lime
Construction
6/77
REPORTED CAPITAL
COSTS,
$ MILLION
56.284
29.0
26
$/KW
102.33
72.5
62.65
REPORTED OPERATING
COSTS,
$ ANNUAL
5.226 K
MILLS/KWH
A 1.72
COMMENTS
1. The total installed capital cost figure is an estimate
that includes all expenditures made by February 1977.
2. Included in the total intalled figure are the costs
of the existing ESP and venturi scrubbers for control
of particulate emissions, plus all direct and in-
direct costs, and escalation.
3. Sludge handling and disposal facilities are not
included in the above estimate.
4. The annual operating cost figure is an estimate that
applies to operation in 1977.
5. The annual operating cost estimate includes par-
ticulate removal costs. Amortization of investment
is not included.
6. The mills/kWh figure derived from is the total annual
cost estimates (direct and indirect) at a unit
capacity facto.- of 63%.
1. The total installed capital cost is a preliminary es-
timate that includes the cost of the scrubbers and
ancillary equipment, lime and sludge handling and dis-
posal equipment.
2. No water is returned to the process from the settling
pond.
3. A part of the flue gas will be by-passed for reheat
requirements.
1. The total installed capital cost is a preliminary
estimate that incldues the cost of the scrubbers and
ancillary equipment, lime handling and sludge hand-
ling and disposal equipment.
Note: N/A indicates figures are not availabe.
B-16
PEDCo ENVIRONMENTAL
-------
APPENDIX B (Continued). FGD SYSTEMS ECONOMICS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Wisconsin Power & Light
Columbia Plant
No. 2
527
PROCESS
STATUS
START-UP DATE
Lime/Limestone
Requesting/
Evaluating
Bids
1/80
REPORTED CAPITAL
COSTS,
$ MILLION
30
$/KW
57
REPORTED OPERATING
COSTS,
$ ANNUAL
4.2 MM
MILLS/KWH
COMMENTS
1. The total installed capital cost figure is a pre-
liminary estimate that includes the scrubbers and
ancillary equipment, erection, disposal piping and
basin area.
2. Sludge handling and disposal equipment and the up-
stream ESP are not included in this figure.
3. The operating cost figures provided are estimated
values.
Note: N/A indicates figures are not available.
B-17
PEDCo ENVIRONMENTAL
-------
B-18
-------
APPENDIX C
FGD PROCLSS FLOW DIAGRAMS
C-1
PEOCO-ENVIRONMENTAL
-------
C-2
-------
LOUVER
FIVE
K39ULC (>)
1
Mi*
l-
EtC
r-..._
L 1
;a
nf,
>
«S
t n .11
<
|
e
1
JJ
TACK
0-s
ST
-L
^^
..-
\ N
S02 SCKiB3E>
DEXIST£il
[
Jy.1::^""!
I
I I
1 t
6.5
HOXLE (3)
Figure 1. Choi la No. 1 FGD System: General Flow Diagram.
C-3
-------
Figure 2. Four Corners Prototype Scrubber Module: Cross Section Diagram.
C-4
-------
MIST
ELIMINATOR
RILEY
VENTRI-SORBER
SCRUBBER
LIMESTONE
SLURRY
A
ELECTROSTATIC
PRECIPITATOR
SCRUBBER
I D BOOSTER FAN
PUMP
FLUE GAS
FROM
BOILER
RECYCLE
TO FGD
SETTLING POND
Figure 3. Simplified Process Diagram of the Duck Creek No. 1 FGD Module.
C-5
-------
TO sludge
treatment plant
Figure 4. Will County No. 1 FGD System: General Process Diagram.
C-6
-------
FLUE
GAS
SLURRY
BLEED
TO-*-
SETTLING
POND
REHEATER [~~\
MAKEUP
WATER
PEABODY/LURGI
RADIAL VENTURI
PEABODY
SPRAY TOWER
so "REMOVAL
MIST ELIMINATOR
z
PARTICULATE
REMOVAL
LIMESTONE
_L
SLURRY HOLD TANK
WASHWATER
RECYCLE
TANK
Figure 5. St. Clair No. 6 FGD System: General Process Diagram.
C-7
-------
1ST STAGE
ADJUSTABLE VENTURI
FOR FLY ASH/S02
2ND STAGE
S00 ABSORBER SCRUBBER
CaS03/S04
FLY ASH SLURRY
RECYCLE RETURN SYSTEM
TO
STABILIZATION
FACILITIES
Figure 6. F. R. Phillips FGD System: General Process Diagram.
C-8
-------
NaOH
FILTRATE
PUSC?
SLUDGE
BLEND TANK
CaSOi;
, CaC03
1 VACUUM'
FILTER
CHEMICAL
HJX
XO. I
FEEDER
SLAKER
LIME FEED
PUMP
CAUSTIC
STORAGE TAXS
SURGE
'<• TAR*
CARBON
DIOXIDE
STORAGE TANK
SCRUBBER
FEED PUMP
SODA ASH
FEED PUMP
Figure 7. General Motors Chevrolet Parma Plant: General Process Flow Diagram.
C-9
-------
LIMESTONE
SILO
WASTE
DISPOSAL
WASTE
DISPOSAL
MOTHER
LIQUOR
TANK
GYPSUM
Figuare 8. Chiyoda Thoroughbred 101 FGD Prototype: General Process Diagram.
C-10
-------
COAL
SUPPLY
STACK
•I.D. FAN.
LIMESTONE
SUPPLY
FEEDER
F.D. FAN
STACK-GAS-
SCRUBBER
PULVERIZER
RECYCLE
PUMP
CLARIFIER
MAKE U?
WATER
TO ASH DISPOSAL
POND
Figure 9. Hawthorn No. 3 FGD System: General Process Diagram.
C-ll
-------
COAL
SUPPLY
STACK
•I.D. FAN.
LIMESTONE
SUPPLY
FEEDER
STACK GAS
REHEATER
,AIR HEATER
DEMISTER
STACK GAS-
SCRUBBER
RECYCLE
PUMP
Figure 10. Hawthorn No. 4 FGD System: General Process Diagram.
C-12
CLARIFIER
MAKE UP
WATER
TO ASH DISPOSAL
POND
-------
Figure 11. La Cygne No. 1 FGO System: General Process Diagram.
C-13
-------
EXIST. STACK
n
UET
SCRUB
8ER STACK
T\_/T
BY-PASS
DAMPENS
r
_ SCRSJB3ER
A BOOSTER
V '
SPARE
SPARE
SPARE
Figure 12.
Green River F6D System: General Process Diagram.
C-14
-------
Figure 13. Stock Island Plant FGD System: Process Flow Diagram.
C-15
-------
x^7"'
«QOtT:-E
-------
JTEAH 760'F
«?« PS:A
«76.7 IS/KM
Figure 15. Reid Gardner FGD Systems, Units 1, 2, and 3:
General Process Diagram.
C-17
-------
FLUE GAS
TO
SCRUBBER
FIRST
STAGE
OOOi
OXIOIZER
REHEATER
HIST
ELIMINATOR
OVERFLOW POTS
& MARBLE BED
REACTION
TANK
FLUE GAS
TO STACK
RIVER
MAKE-UP
WATER
WEIR
THICKENER
UNDERFLOW
PUMP
SPRAY
PUMP ,
ASH POND
LIMESTONE —i
N—
THICKENER
RE
T
i
GIF
AN
f
*C
(
T€?
SLURRY
TA.NK
SLURRY
PUMP
ASH POND
RETURN PUMP
Figure 16. Sherburne No. 1 FGD System: Simplified Process Diagram.
C-18
-------
PIPELINES TO RESERVOIR
Figure 17. Bruce Mansfield No. 1 FGD System: Simplified Process Diagram.
C-19
-------
FRESH
WATER -
INLET
BACKWASH
SPRAYS
STACK GAS
FROM I.D.
FANS
PARTICULATE
SCRUBBER
HUMIDIFIED
GAS STREAM
Mg (OH)2 SLURRY
PARTICULATE
SCRUBBER
SURGE TANK
TO WASTE WATER
'TREATMENT SYSTEM
CLEAN GAS OUi^ET
MIST ELIMINATORS
MIST ENTRAPMENT SEPARATOR
S02 SCRUBBER
SURGE TANK
VENTURI ROD MODULES
SCRUBBING SLURRY INLET
TO Mg S03
RECOVERY
Figure 18. Eddystone No. 1 FGD System: General Process Diagram.
C-20
-------
FLUE GAS FRCM
7 COAL-FIRED
STORES BOILtSS
Figure 19. Rickenbacker FGD System: General Process Diagram.
C-21
-------
I AIR >---.
IFUEL OIL>—»»] RE HEATER]-- 1
\ v v/
SCRUBBER\i—lA
•-0--
[MAKEUP WATER]
I.D. FAN
SECOND
HOLD
TANK
SAMPLE POINTS
i
PROCESS
WATER
HOLD
TANK
STACK
^MAKEUP WATERl
DISCHARGE
OGAS COMPOSITION
® PARTICIPATE COMPOSITION & LOADING
0 SLURRY OR SOLIDS COMPOSITION
GAS STREAM
LIQUOR STREAM
SETTLING POND
Figure 20. Shawnee No. 10 Prototype Test Unit: General Process Diagram.
C-22
-------
AIR
I FUEL OIL >—>[ REHEATER-— ;
PROCESS
WATER I
HOLD TANK
SCRUBBER
EFFLUENT
HOLD
TANK
SAMPLE POINTS
OGAS COMPOSITION
®PARTICULATE COMPOSITION & LOADING
©SLURRY OR SOLIDS COMPOSITION
GAS STREAM
LIQUOR STREAM
SETTLING POND
Figure 21. Shawnee No. 10 Prototype Test Unit: General Process Diagram.
C-23
-------
FLUE GAS
MAKE-UP WATER
SPRAY TOWER
SPRAY TOWER EFFLUENT
HOLD TANK
VENT AIR
A
OXIDATION
TANK
CLARIFIED LIQUOR
WATER
D
=>
=»
* A
1
t
_«3
1
c
D
1 t^-
f v_
1
DESUPERSATURATION
TANK
BLEED TO
DEWATERING
^ SYSTEM
Figure 21A. Shawnee No. 10 Prototype Test Unit: Modified
Mentui/Spray Tovier System for 2-Stage Oxidation Testing.
-------
BOILER
FLUE
GAS
SULFUR1C ACID
CONTACT ACID
PLANT
98% GRADE
PUMP
Figure 22. Mystic No. 6 FGD System and Essex Chemical Plant
Regeneration Facility: Schematic Flow Diagram.
C-25
-------
SCRUBBED
GAS
VACUUM WATER RECOVERY H?0
Figure 23. CEA/ADL Dual Alkali Prototype: General Process Diagram.
C-26
-------
Off REGENERATION
ADSORPTION SECTION
1. INLET FLUE
GAS DUCTING, DILUTION AIR
DESIGN, AND ADSORPTION
SECTION OVERALL LAYOUT.
2. ADSORPTION DISCHARGE FANS.
3. ADSORBER DISCHARGE FEEDERS
CONVEYORS AND SITE GLASSES
WHICH SHOW CHAR MOVEMENT.
4. ADSORBER FEED CONVEYORS.
5. CHAR BUCKET ELEVATORS.
REGENERATION SECTION
6. AIR PREHEATER, SAND
FLUID BED HEATER, HOT
SAND BUCKET ELEVATOR.
7. START UP AIR HEATER.
8. SATURATED CHAR SURGE
TANK, SATURATED CHAR
FEEDER, REGENERATOR.
9. SAND HEATER BLOWER.
10. SAND MAKE UP HOPPER,
FEEDER.
11. HOT SAND CONVEYOR.
12. CHAR-SAND SEPARATOR
FEEDER.
13. REGENERATED CHAR
COOLER.
14. REGENERATED CHAR
BUCKET ELEVATOR, CHAR
MAKE UP HOPPER, FEEDER.
REDUCTION SECTION
15. COAL MAKE UP HOPPER,
FEEDER FEED BUCKET
ELEVATOR.
16. COAL FEED BIN.
17. COAL FEED BIN ACTIVATOR,
ROTARY COAL AIRLOCK,
RESOX START UP HEATER.
18. RESOX REACTOR.
19. SULFUR CONDENSER, TAIL
GAS BLOWER.
20. CONTROL AIR BLOWER.
21. ASH DISCHARGE FEEDER
22. ASH RECEIVER VESSEL,
WEIGH SCALE.
23. SULFUR STORAGE TANK,
SULFUR TRANSFER PUMP.
Figure 24. FW-BF Dry Adsorption Prototype:
C-27
General Equipment Schematic.
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CAT-OX MIST
ELIMINATOR
FLUE GAS
FROM EXISTING
ID FAN
*• STORAGE
Figure 25. Wood River No. 4 Catalytic Oxidation FGD System:
Simplified Process Diagram.
C-28
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' i FLUE GAS BY-PASS
v.i
VENTURI
dbi SCRUBBER/ABSORBER
1ST STAGE
ELECTRO-STATIC
PRECIPITATOR
TO 2ND
STAGE
MIST
ELIMINATOR
TO DRY ASH HANDLING SYSTEM
DUST COLLECTOR
RECYCLED
POND WATER
TANKCHU-
- —/ * TRANSFER
CRYSTAL
DRYER
ASH FOND
MgO FROM
ACID PLANT
MgS03 TO ACID PLANT
Figure 26. Dickerson No. 3 Regenerative FGD System:
General Process Diagram.
C-29
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ALKALI
STORAGE SILO
SLURRY 8
MIX TANK
FLUE GAS FROM
PRECIPITATORS
CONTROL
BUILDING
THICKENER
MOTOR CONTROL
THICKENER CENTER
OVERFLOW TANK
ABSORBE
HOLD TANK
POWER
', PLANT
STACK
ALKALI
MIX TANKS
TURBULENT
CONTACT
ABSORBER
Figure 27. Mohave No. 1 Vertical Test Module:
Simplified Process Diagram.
C-30
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FOUR SCRUBBER STAGES
J
I
HOT AIR
INJECTION
BOOSTER FAN
MIST ELIMINATOR
Figure 28. Mohave No. 2 Horizontal Test Module: Simplified Side View.
C-31
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C-32
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APPENDIX 0
DEFINITIONS
D-l
PEOCO-ENVIRONMENTAL
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D-2
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DEFINITIONS
Boiler Capacity Factor
Boiler Utilization Parameter
Efficiency,
Particulates
SO,
FGD Availability Factor
FGD Reliability Factor
FGD Operability Factor
FGD Utilization Factor
FGD Status
Category 1
Category 2
Category 3
(kWh generation in year)/(maximum continuous generating
capacity in kW x 8760 hr/yr).
Hours boiler operated/hours in period, expressed as a
percentage.
Operational - The actual percentage of particulates re-
moved by the FGD system and the particulate control de-
vices from the untreated flue gas. All others - The
design efficiency (percentage) of particulate removed by
the FGD system and the particulate control devices.
Operational - The actual percentage of S02 removed from
the flue gas. All others - The design efficiency.
Hours the FGD system was available for operation (whether
operated or not)/hours in period, expressed as a percentage.
Hours the FGD system operated/hours FGD system was called
upon to operate, expressed as a percentage.
Hours the FGD system was operated/boiler operating hours
in period, expressed as a percentage.
Hours FGD system operated/hours in period, expressed as
a percentage.
Operational - Unit has been or is in service removing SO-.
Under Construction - Ground has been broken for installa-
tion of FGD system, but FGD system has not become opera-
tional.
Planned, Contract Awarded - Contract has been signed for
purchase of FGD system but ground has not been broken
for installation.
D-3
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DEFINITIONS
Category 4
Category 5
Category 6
Category 7
FGD Vendor
Fuel Characteristics
Identification Number
New
Operational Experience
Process
Planned, Letter of Intent Signed - Letter of intent has
been signed, but legal contract for purchase has not been
awarded.
Planned, Requesting/Evaluating Bids - Bid requests have
been released but no letter of. intent or contract has
been issued.
Considering only FGD Systems - An FGD system is proposed
as a means to meet an SO- regulation.
Considering an FGD system as well as alternative methods
(Tables 14, 15).
Vendor with a signed contract, letter of intent or strong
commitment because of test unit or past purchases.
Type of fuel, average gross heating value in Btu/lb,
average percent ash and average percent sulfur content
for fuel as fired.
Number of unit in the alphabetical listing in Tables 1,
2, 3 or Tables 14, 15.
FGD unit and boiler were designed at the same time or
space for addition of an FGD unit was reserved when
boiler was constructed.
Operational - Brief summary of FGD system operation
since start-up and description of current month's per-
formance. All others - Comments regarding state of con-
struction, etc.
Company name if process is patented. Generic name if
several companies have similar processes.
D-4
-------
DEFINITIONS
Regulatory Class
Retrofit
Sludge Disposal
Start-up Date
Unit Cost
A. New boiler constructed subject to Federal New Source
Perforiuancc Standards.
B. Existing boiler subject to State Standard that is
more stringent than the Federal New Source Perform-
ance Standard (NSPS).
C. Existing boiler subject to Stats Standard that is
equal to or less stringent than NSPS.
D. Other.
E. Unknown.
FGD unit must be added to an existing bciler not
specifically designed to accommodate FGD unit.
Comments on disposal method for those units generating
sludge including: lined or unlined ponds, stabilized or
unstabilized sludge, and on- or off-site disposal.
Operational - Date when S02 removal began. All others -
Date when SO2 removal is scheduled to begin. Generally
this will be the start-up date of the boiler.
Capital Cost in $/kW including: S02 absorption and regen-
eration system, S02 recovery system, solids disposal,
site improvements, land, roads, tracks, substation, engi-
neering costs, contractors fee and interest on capital
during construction.
Annualized Cost in mills/kWh including fixed and variable
costs. Fixed costs include: interest on capital, deprecia-
tion, insurance, taxes, and labor costs including overhead.
Variable costs include: raw materials, utilities, and
maintenance.
D-5
-------
DEFINITIONS
Unit Location
Unit Name
Unit Rating
Utility Name
Water Make-Up
City and State listed in mailing address.
Unit identification as it appears in Electrical World -
Direction of Electrical Utilities, McGraw-Hill - Current
Edition - or as indicated by utility representative for
installations in planning stages.
Operational - Maximum continuous gross generation capacity
in MW; Preoperational - maximum continuous design genera-
tion capacity in MW.
Name of corporation as it appears in Electrical World -
E/irectory of Electrical Utilities, McGraw-Hill - Current
Edition - as space permits.
Gallons per
capacity.
minute of make-up water required per MW of
D-6
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