SUMMARY REPORT - FLUE GAS DESULFURIZATION SYSTEMS - MAY - JUNE 1977
PAGE
TABLL
1 SUMMARY LIST OF FGD SYSTEMS
2 STATUS OF FGD SYSTEMS
3 SUMMARY LIST OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
H STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
5 PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
6 NUMBER AND TOTAL MW OF FGD SYSTEMS
7 SUMMARY OF FGD SYSTEMS BY COMPANY
8 SUMMARY CF FGD SYSTEMS BY VENDOR
9 SUMMARY OF NEW AND RETROFIT FGD SYSTEMS BY PROCESS
10 SUMMARY OF OPERATING FGD SYSTEMS BY PROCESS AND GENERATING UNITS
11 SUMMARY CF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS
12 SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
13 SUMMARY OF OPERATIONAL FGD SYSTEMS
1** SUMMARY OF FGD SYSTEMS UNDER CONSTRUCTION
15 SUMMARY OF PLANNED FGD SYSTEMS
16 FGD SYSTEM OPERATIONS THAT HAVE BEEN TERMINATED OR SHUT DOWN INDEFINITELY
17 TOTAL OF FGD MEGAWATT CAPACITY BY YEAR 311
FGD SYSTEMS ECONOMICS APPENDIX A
FGD PROCESS FLOW DIAGRAMS APPENDIX B
DEFINITIONS APPENDIX C
3
9
35
39
<*5
201
205
209
213
217
221
225
231
235
239
PREPARED BY
PEDCO ENVIRONMENTAL INC.
11**99 CHESTER ROAD
CINCINNATI. OHIO <*52«*6
PREPARED FOR
DIVISION OF STATIONARY SOURCE ENFORCEMENT
AND
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
U.S. ENVIRONMENTAL PROTECTION AGENCY
RESEARCH TRIANGLE PARKt
NORTH CAROLNA 27711
CONTRACT NO. 66 •
TASK NO. 3
-------
July 12, 1977
PEDCo ENVIRONMENTAL
11.499 CHESTER ROAD
CINCINNATI. OHIO 4524.6
(513) 782--47OO
Enclosed is a copy of the April-May 1977 report titled, 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
27
29
20
5
5
33
119
MW
7,319
12,648
9,797
1,892
3,565
14,856
50,077
Table II gives the categorized breakdown for FGD units,
comparing the May report totals with those of the March
report.
Table III summarizes the individual units that changed
status during the report period.
BRANCH OFFICES
CHESTER TOWERS
Crown Center
Kansas City. Mo.
Professional Village
Chapel Hill. M.C.
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Table II
NUMBER AND TOTAL MW OF FGD SYSTEMS
MAY REPORT VERSUS MARCH REPORT PERIOD
Status
Operational
Under construction
Planning
Total
April-May
1977
No. of
units
27
29
63
119
MW
7,819
12,648
30,110
50,077
January-February-March
1977
No. of
units
24
33
62
119
MW
5,997
13,918
29,775
49,690
The performance of the operating systems is summarized in
Table IV. Other activity highlights during the months of
April and May are outlined below:
Arizona Public Service reported the following items in
connection with the utility's FGD installations:
0 Cholla No. 1 remained in service throughout the
report period. The average system reliability
index values for the months of April and May were
100 percent and 87 percent, respectively. The
unit was brought down during the month of May for
a scheduled mid-year cleanout and minor repair
work.
0 Construction of Cholla No. 2 is still in progress
and on schedule. Start-up is scheduled for June
1978.
0 Cholla No. 4, a 350-MW, coal-fired, power-generating
unit, is currently under construction. APS is now
in the preliminary design stage for the inclusion
of an FGD system on this unit. The SO2 emission
regulations, scrubbing process, and system supplier
have not been determined.
Central Illinois Light Company reported that the experimental
operations of the scrubber module at Duck Creek have been
terminated. The 100-MW equivalent ventri-sorber module,
supplied by Riley Stoker/Environeering, was taken out of the
gas stream April 1, 1977, after approximately 9 months of
experimental operations. This module is the first of four
modules designed to treat the flue gas resulting from the
combustion of high-sulfur Illinois coal in a 400-MW steam
boiler. All four modules will be brought on line in August
-------
1978 for full-scale integrated operations. During the
interim, Duck Creek No. 1 will remain in commercial service,
firing low sulfur (0.6 percent) Colorado coal. Particulate
matter removal is being achieved by two parallel electrostatic
precipitators installed upstream of the scrubber plant.
Central Illinois Public Service Company reported that con-
struction of the double alkali scrubbing facility at the
Newton Station is approximately 15 percent complete. This
sodium-calcium double alkali scrubbing system is supplied by
Buell-Envirotech and designed to treat flue gas resulting
from the combustion of high sulfur (4 percent), high chloride
(0.2 percent) coal in a 575-MW boiler. The start-up date
for the No. 1 unit has been delayed to November 1979. The
utility cites problems with financing, cash flow, and an
unprecedented scrubber plant design as the major causes for
the start-up delay.
Cincinnati Gas and Electric reported that bids are still
being evaluated for a scrubber plant planned for the 600-MW
rated No. 2 unit at the East Bend Station. A process,
system supplier, and a coal type and source have not been
determined. The No. 2 unit start-up date is January 1981.
Colorado-Ute Electric Assn. reported that a contract in ex-
cess of $60 million has been awarded to Peabody Engineered
Systems for two limestone slurry spray tower scrubbing sys-
tems for installation on two 450-MW coal-fired power-generating
units at the Craig station. The start-up date for the
operation of both scrubber plants is March 1979.
Columbus and Southern Ohio Electric (C&SOE) reported that
the B-side TCA module on Convesville No. 5 was in service
during the report period, operating 261 hours in April and
355 hours in May. Problems encountered in FGD operations
were as follows: an abundance of scrap rocks and metal in
the lime supply, rubber lining peeling in the absorber
(C&SOE has determined the peeling problem to be an application
problem), and continuing stack liner failure. Preliminary
tests indicate SO2 removal of greater than 90 percent. The
replacement A-side TCA module will be available for commercial
service in January 1978.
Commonwealth Edison reported that experimental scrubber
operations at the Will County Station continued during the
months of April and May. During the period, a number of
scrubber characterization and component evaluation studies
were conducted. Specifically, a high sulfur coal sludge
study, conducted by the utility and UOP, and a magnesium
oxide innoculation and forced oxidation study, also conducted
by the utility, were completed during the period. In addition,
an SO2 analyzer was also evaluated for performance and
reliability characteristics.
-------
Duquesne Light reported the following items in connection
with the utility's FGD installations:
0 The Elrama Station continued operations with flue
gas from two boilers being discharged into the
five module-single-stage scrubber plant. Con-
struction of the two additional 120-foot diameter
thickeners continued during the period. In addi-
tion, the utility also reported that the rubber-
lined recycle pump evaluation study has been ter-
minated because of severe corrosion and gouging.
Full compliance plant operations are scheduled to
commence sometime during the early part of 1978.
0 The scrubber plant at the F.R. Phillips Station
was in service and available 75 percent during the
report period. The interim IOCS sludge stabliza-
tion facility remained in service during the
period. Construction of the permanent IOCS stabi-
lization complex is continuing and will be ready
for full-compliance plant operations scheduled for
December 1978. The Carborundum impeller and wear
ring recycle pump evaluation study also continued
during the period, bringing total operating time
to in excess of 5000 hours of problem-free operations
The Kansas City Power and Light Co. reported the following
items concerning the utility's FGD installations.
0 The Hawthorn No. 3 and No. 4 scrubbing systems
were in service during the report period, operating
408 hours and 311 hours, respectively, in April
and 302 hours and 180 hours, respectively, in May.
The system operability values for the No. 3 unit
were 57 and 58 percent for the months of April and
May, respectively. Unit No. 4 FGD system operability
values for the same period were 43 and 54 percent,
respectively. Low systems' demand during the
month of May was caused by a natural gas supply
availability. The operability index values shown
above are calculated only for coal-fired operations.
0 The total system availability index value for the
La Cygne No. 1 scrubber plant was approximately 93
percent for the month of April. Turbine problems
forced the unit out of service for the month of
May. The eighth scrubber module was in service
for a short period during the month of April. The
unit is expected to be back in service during the
latter part of June with all eight modules in the
flue gas stream.
-------
Kansas Power and Light reported that Lawrence No. 4 fired
natural gas during the report period, thus requiring no
scrubber plant operations. The original limestone injection
and tail-end scrubbing system installed on Lawrence No. 5 in
1971 has been and still is in service, removing fly ash and
sulfur dioxide from coal-fired flue gas. Adjacent to the
original scrubber installation, a new rod section and spray
tower absorber system is being constructed. This wet lime-
stone scrubbing system consists of two large rod section and
spray tower absorber modules, each module capable of handling
50 percent of the flue gas from the boiler. The original
system will remain in service until the new system is com-
pleted and cut into the gas path in March 1978.
Kentucky Utilities reported that the Green River FGD system
was in service during the April-May period, treating flue
gas from two of the three boilers ducted into the FGD sys-
tem. Scrubber service times for the months of April and May
were 164 and 513 hours, respectively. The system's avail-
ability, operability, reliability, and utilization index
values for the month of April were 40, 98, 98, and 23 per-
cent, respectively. The May values were 99, 98, 98, and 69
percent, respectively.
Louisville Gas and Electric reported the following items
concerning the utility's FGD installations:
0 The 178-MW Cane Run No. 4 scrubber plant ran for
the first 18 days of April with a reliability in-
dex value of 94 percent. At that time, the unit
was shutdown for extensive modifications scheduled
to last through July 12. Modifications include
increasing the liquid-to-gas ratio by the addition
of a new spray header, replacing the centrifugal
demister with a Chevron demister, the installation
of direct-fired oil reheat designed for AT = 50°F,
replacing the Carboline liner from the demister to
the stack with Plasite 4005, and the installation
of a Precrete stack liner.
0 The 65-MW Paddy's Run No. 6 lime-based scrubbing
plant operated through mid-April demonstrating an
operability index value of 95 percent. During the
remainder of the report period, the scrubber was
shutdown because the scrubber operations crew was
temporarily assigned to boiler operations. The
re-start of scrubber operations was scheduled for
late-June. Preliminary results of the high-calcium,
virgin lime scrubber/sludge characterization study
indicate that SO2 removals greater than 99.5
percent can be obtained with the addition of
magnesium hydroxide to the scrubbing slurry.
-------
Minnesota Power and Light Company announced that it has
signed a letter-of-intent with Peabody Engineering for a
lime/alkaline fly ash FGD system at the 500-MW Clay Boswell
No. 4 plant. The spray tower absorbers will be designed to
remove 89 percent of the inlet SO2- The Combustion-Engineering
boiler will fire low-sulfur Colstrip coal with a sulfur con-
tent of 0.8 percent.
Minnkota Power reported that construction of the Milton R.
Young No. 2 scrubber plant is approximately 90 percent
complete and that start-up is still planned for August 1977.
This system is designed to treat flue gas from the 450-MW
steam boiler, using the fly ash collected in the electrostatic
precipitators as the principal source of SO2 absorbent.
Commercial lime will supplement the natural alkali ash
supply when necessary.
Nevada Power provided the following general information for
the Reid Gardner FGD systems:
0 The Reid Gardner No. 1 scrubber plant remained out
of service throughout the entire report period be-
cause of on-going repairs to the scrubber liner.
Damage was caused by an air preheater malfunction.
0 The Reid Gardner No. 2 scrubber plant was operating
during the entire report period except for a two-
week outage for boiler maintenance.
0 The Reid Gardner No. 3 scrubber system operated
with no problems during April, but was down from
May 1 to May 21 for the replacement of the FRP
liner in the separator.
Northern Indiana Public Service Company announced that ini-
tial scrubber operations have commenced at the D.H. Mitchell
No. 11 unit. The Wellman-Lord SC>2 recovery system first
operated June 13 and the Allied SC>2 reduction unit first
operated June 15, thereby achieving integrated mode opera-
tions. Unit No. 11 will operate at a reduced rating of 70
to 75 MW until June 27 at which time it will go down for
final repairs to the preheater. Subsequent to these repairs,
the utility plans to begin a 16-day acceptance test in early
July.
Northern States Power reported the following items concerning
the utility's FGD activities:
0 Sherburne No. 1 was in service during the report
period until May 14 at which time it was taken
off-line for major turbine overhaul. The C-E
marble bed absorber system demonstrated an avail-
ability index of 95 percent during April and 92
percent for the first 13 days in May. The unit
was scheduled for re-start on June 19.
-------
0 Sherburne No. 2 scrubber operations began April 1.
The emissions control system is currently undergoing
performance testing. During April, the No. 2
scrubber system demonstrated a 92 percent availability
and for May, the availability index was 91 percent.
The first two months of operations have been
relatively problem-free.
Pennsylvania Power reported that it is in the process of
rewriting the Bruce Mansfield No. 1 file for the FGD summary
report and that this updated information will be available
for the next report period.
Philadelphia Electric Company reported that Mag-Ox FGD
operations were re-started at Eddystone Unit No. 1A in May
on a noncontinuous basis. During May, the system operated
206 hours, representing a utilization index value of 28
percent. Currently, only one of the two available ventri-
rod beds is being used for SO2 removal. No removal efficiencies
had been measured as of the end of the report period. The
first MgSC«3 regeneration operations were schedule for late
June at the Essex Chemical plant.
Springfield City Utilities reported the start-up of scrubbing
operations at the Southwest Station for Unit No. 1, a new
20Q-MW coal-fired power-gtnerating unit. System start-up
occurred at 2:00 a.m. on April 6. Subsequent operations
through the report period were intermittent as attempts were
made to rectify varous start-up related problems. Boiler
related problems, specifically in the air heater, have
caused very high excess air requirements and contributed to
the delay of full-scale, continuous scrubber operations.
The South Carolina Public Service Authority reported a tem-
porary delay in the start-up of power generating and S02 re-
moval operations at the 280-MW Winyah Unit No. 2. All
equipment is on-site, installed, and ready for start-up with
the exception of three relays. Delivery is expected at any
time and subsequent to installation all systems will commence
operations.
The Bechtel Corporation reported that experimental work
continued at the Shawnee TVA/EPA Alkali Scrubbing Test
Facility through March, but a scheduled 2-month boiler
maintenance outage curtailed testing through April and May.
During March, forced oxidation tests in the lime scrubbing
mode (venturi/spray tower prototype) greatly enhanced solids
settling rates and filter cake solids content. In addition,
limestone type and grind tests (TCA prototype) indicated
improved SO2 removal with the use of finer ground limestone.
-------
Tennessee Valley Authority announced the start-up of scrubber
operations at its 550-MW Widow's Creek Unit No. 8, in Bridgeport,
Alabama. Start-up and shakedown procedures began on April
30. Commercial operation for the four-train limestone SO2
removal system is anticipated by the end of summer.
Utah Power and Light Company reported the following items
regarding its FGD installations:
0 Construction has begun at the 400-MW Emery No. 1
installation in Emery County, Utah. SO2 removal
will be effected by a Chemico pebble lime wet
scrubbing system.
0 At the 415-MW Huntington No. 1 unit, the start-up
of scrubbing operations has been delayed from June
1977 until December 1977.
Wisconsin Power and Light has signed a letter-of-intent with
Chemico to design and supply an SO2 control system for the
527-MW Columbia No. 2 unit. The control system will utilize
a lime/alkaline fly ash absorbent in spray tower absorber
modules. Current plans include SO2 removal from 60 percent
of the flue gas as opposed to the original 50 percent. Re-
heat will be provided by the 40 percent of the flue gas
which is bypassed around the scrubber plant.
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Table III. SUMMARY OF CHANGES: FGD SUMMARY REPORT,
APRIL - MAY 1977
FGD status report
3/31/77
Alabama Electric Power Co -Op
Tomb ig bee No. 3
Arizona Public Service
Choi la No. 4
Arizona Public Service
Four Corners No. S
Central Illinois Light Co.
Duck Creek No. 1A
Central Illinois Light Co,
Duck Creek No. 1
Colorado- UTE
Craig Mo. 1
Craig No. 2
Gulf Power Co.
Scholz No. IB and 2B
Kansas Power and Light Co.
Lawrence No. 5
Minnesota Power and Light Co.
Clay Boswell No. 4
Northern Indiana Public Service
Co.
Mitchell No. 11
Northern States power Co.
Sherburne No. 2
Springfield City Utilities
Southwest No. 1
Tennessee Valley Authority
Widow's Creek No. 8
Utah Power and Light Co.
Emergy No. 1
Wisconsin Power and Light Co.
Columbia No. 2
5/31/77
Operational
No.
24
-1
-1
+1
+ 1
+1
•fl
+1
27
MW
5,997
100
23
400
115
680
200
550
7,819
Under
construction
No.
33
-1
-1
-1
-1
-1
•H
29
MW
13,918
225
100
115
680
200
550
400
12,648
Contract
awarded
No.
18
+ 1
+ 1
+1
-1
20
MW
9,072
225
450
450
400
9,797
Letter of
intent
No.
3
4-1
+ 1
5
MW
865
500
527
1,892
Requesting/
evaluation
bids
No.
9
-1
-1
-1
-1
5
MW
5,492
450
450
500
527
3,565
Considering
PGD
No.
32
+ 1
31
MW
14,346
350
160
14,856
Total
No.
119
tl
-1
-1
+1
119
MW
49,690
350
160
100
23
50,077
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Table IV. PERFORMANCE OF OPERATIONAL UNITS DURING APRIL - MAY PERIOD
Plant
Cholla 1
Coneeville 5
Will County 1
Elrasia
Phillips
Hawthorn 3
Hawthorn 4
La Cygne
Lawrence 4
Lawrence 5
Green River
1, 2, ind )
Cane Run
Paddys Run
Colstrip 1
Colstrip 2
Reid Gardner 1
Reid Gardner 2
Reid Gardner }
D.H. Mitchell 11
Sherburne 1
Sherburne 2
Bruce
Mantfield 1
Eddystone 1A
Southwest 1
Shavnee 10A
shavrnee 1 08
Widow's Creek 8
Total (27)
FGD system
denqn
capacity
115
400
167
510
410
140
100
820
US
400
64
lit
6S
360
360
125
12S
125
115
710
680
8J5
120
200
10
10
550
7B19
FGD unit
on-1 me
during
per iod*
115
200
167
200
410
HO
100
820
400
43
178
65
125
129
70
710
680
120
200
275
614}
NO
infornat ion
for this
period
360
)«0
835
1555
Shut down
throughout
period
200
310
125
21
12S
45
10
10
275
1121
FGD lystem
avail-
ability («)••
April
42
66
75
93
40
98
95
92
May
58
94
75
99
12
91
FGD systen
op«ra-
bility (»)••
Apr 1 1
99
40
49
57
43
98
95
H»y
87
48
27
58
54
98
FGD system
reliability
[«)"
April
100
41
98
May
87
51
98
FGD syaten
utilization
(%!*•
April
37
41
23
May
50
25
69
* Thi. category include* the flue ?as capacity beinf handled by the FCD iyeten at least part of the Um>
the report period,
" The percent figures listed sre average values for sll the system scrubbing trains during the period in
during
-------
TABLE 1
SUMMARY LIST OF FGD SYSTEMS
oo
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CO
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PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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TABLE 1
SUMMARY LIST OF FGD SYSTEMS
FGO STATUS REPORT 06/77
I.D. 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
»' ALLEGHENY POWER SYSTEM
5 ARIZONA ELECTRIC POWER COOP
6 ARIZONA ELECTRIC POWER COOP
7 ARIZONA PUBLIC SERVICE
8 ARIZONA PUBLIC SERVICE
9 ARIZONA PUBLIC SERVICE
10 ARIZONA PUBLIC SERVICE
11 ARIZONA PUBLIC SERVICE
12 BASIN ELECTRIC POWER COOP
13 BASIN ELECTRIC POWER COOP
1H BASIN ELECTRIC POWER COOP
15 BASIN ELECTRIC POWER COOP
16 BASIN ELECTRIC POWER COOP
17 B^S RIVERS ELECTRIC COOP CORP.
18 BUZOS ELECTRIC POWER COOP
19 CENTRAL ILLINOIS LIGHT CO.
20 CENTRAL ILLINOIS LIGHT CO.
21 CENTRAL ILLINOIS PUBLIC SERV
22 CINCINNATI GAS X ELECTRIC CO.
23 COLORADO UTE ELECTRIC ASSN.
2H COLORADO UTE ELECTRIC ASSN.
25 COLUMBUS X SOUTHERN OHIO ELEC.
26 COLUMBUS s SOUTHERN OHIO ELEC.
27 COLUMBUS A SOUTHERN OHIO ELEC.
28 COLUMBUS X SOUTHERN OHIO ELEC.
29 COMMONWEALTH EDISON
30 COMMONWEALTH EDISON
31 DUOUESNE LIGHT
32 OUOUESNE LIGHT
33 EASTERN KENTUCKY POWER COOP
3«» INDIANAPOLIS POWER X LIGHT CO.
35 INDIANAPOLIS POWER X LIGHT CO.
TOMBIGBEE NO. 2
TOMBIGBEE NO. 3
PLEASANTS NO. 1
PLEASANTS NO. 2
APACHE NO 2
APACHE NO 3
CHOLLA NO 1
CHOLLA NO 2
CHOLLA NO. H
FOUR CORNERS NO. H
FOUR CORNERS NO. SB
ANTELOPE VALLEY NO. 1
ANTELOPE VALLEY NO. 2
LARAMIE RIVER NO. 1
LARAMIE RIVER NO. 2
LARAMIE KIVER NO. 3
REID NO. 2
ATACOSA MCMULLEN NO. 1
DUCK CREEK NO. 1
DUCK CREEK NO.2
NEWTON NO.l
EAST BEND NO 2
CRAIG NO. 1
CRAIG NO. 2
CONESVILLE NO 5
CONESVILLE NO 6
POSTON NO. 5
POSTON NO. 6
POWERTON NO. 51
WILL COUNTY NO 1
ELRAMA POWER STATION
PHILLIPS POWER STATION
SPURLOCK GENERATING PLANT
PETERSBURG NO 3
PETERSBURG NO t
JACKSON ALABAMA
JACKSON ALABAMA
BELLMONT W VIRGINIA
BELLMONT W VIRGINIA
COCHISE ARIZONA
COCHISE ARIZONA
JOSEPH CITY ARIZONA
JOSEPH CITY ARIZONA
JOSEPH CITY ARIZONA
FARMINGTON NEW MEXICO
FARMINGTON NEW MEXICO
BEULAH NORTH DAKOTA
BEULAH NORTH DAKOTA
WHEATLAND WYOMING
WHEATLANO WYOMING
WHEATLAND WYOMING
SEBREE KENTUCKY
SAN MIGUEL TEXAS
CANTON ILLINOIS
CANTON ILLINOIS
NEWTON ILLINOIS
RABBIT HASH KENTUCKY
CRAIG COLORADO
CRAIG COLORADO
CONESVILLE OHIO
CONESVILLE OHIO
ATHENS OHIO
ATHENS OHIO
PEKIN ILLINOIS
ROMEOVILLE ILLINOIS
ELRAMA PENNSYLVANIA
SOUTH HEIGHT PENNSYLVANIA
NO.2 MAYSVILLE KENTUCKY
PETERSBURG INDIANA
PETERSBURG INDIANA
1. OPERATIONAL UNITS
2* UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
<*. PLANNED - LETTER OF INTENT SIGNED
5* PLANNED " REQUESTING/EVALUATING BIOS
6. CONSIDERING ONLY FGD 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 STANUAKQ THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
6.78
6-79
3-79
3-80
6-78
*-79
10-73
6-78
6-80
0- 0
0- 0
0-81
0-83
*-80
10-80
6-83
12-79
12-79
8-78
1-82
11-79
1-81
3-79
3-79
2-77
1-78
0-81
0-83
12-79
2-72
10-75
7-73
3-80
9-77
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TABLE 1
SUMMARY LIST OF FGD SYSTEMS
FGD STATUS REPORT 06/77
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
36 KANSAS CITY POWER
37 KANSAS CITY POWER
LIGHT
* LIGHT
38 KANSAS CITY POWER * LIGHT
39 KANSAS POWER & LIGHT
40 KANSAS POWER ft LIGHT
41 KANSAS POWER ft LIGHT
42 KANSAS POWER ft LIGHT
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TABLE 1
SUMMARY LIST OF FGO SYSTEMS
FGO STATUS REPORT 06/77
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
RE6
CLASS
71 NORTHERN INDIANA PUB SERVICE
72 NORTHERN INDIANA PUB SERVICE
73 NORTHERN STATES POWER CO.
7* NORTHERN STATES POWER CO.
75 NORTHERN STATES POWER CO.
76 NORTHERN STATES POWER CO.
77 OTTER TAIL POWER COMPANY
76 PACIFIC POWER AND LIGHT CO.
79 PENNSYLVANIA POWER CO*
80 PENNSYLVANIA POWER CO.
81 PENNSYLVANIA POWER CO.
82 PHILADELPHIA ELECTRIC CO.
83 PHILADELPHIA ELECTRIC CO.
81 PHILADELPHIA ELECTRIC CO.
85 PHILADELPHIA ELECTRIC CO.
86 POTOMAC ELECTRIC ft POWER
87 POTOMAC ELECTRIC ft POWER
88 PUBLIC SERVICE CO OF NEW MEX.
89 PUBLIC SERVICE CO OF NEW MEX.
90 PUBLIC SERVICE CO OF NEW MEX.
91 PUBLIC SERVICE CO OF NEW MEX.
92 PUBLIC SERVICE OF INDIANA
93 PUBLIC SERVICE OF INDIANA
91 SALT RIVEK PROJECT
95 SALT RIVER PROJECT
96 SALT RIVER PROJECT
97 SOUTH CAROLINA PUBLIC SERVICE
98 SOUTHERN ILLINOIS POWER CO OP
99 SOUTHERN INDIANA GASXELECTRIC
100 SOUTHERN MISSISSIPPI ELECTRIC
101 SOUTHERN MISSISSIPPI ELECTRIC
102 SPRINGFIELD CITY UTILITIES
103 TENNESSEE VALLEY AUTHORITY
101 TENNESSEE VALLEY AUTHORITY
105 TENNESSEE VALLEY AUTHORITY
1. OPERATIONAL UNITS 1.
2. UNITS UNDER CONSTRUCTION 5.
3. PLANNED - CONTRACT AWARDED 6.
BAILLY NO. 8
D.H. MITCHELL NO.11
SHERBURNE COUNTY STATION NO.l
SHERBURNE COUNTY STATION NO.2
SHERBURNE COUNTY STATION NO.3
SHERBURNE COUNTY STATION N0.i»
COYOTE NO. 1
JIM BRIDGER NO. 1
BRUCE MANSFIELD NO. 1
BRUCE MANSFIELD NO. 2
BRUCE MANSFIELD_NO. 3
CROHBY
EODYSTONE NO. lA
EDOYSTONE NO. IB
EDDYSTONE NO. 2
DICKERSON NO.l
DICKERSON NO.2
SAN JUAN NO. 1
SAN JUAN NO. 2
SAN JUAN NO. 3
SAN JUAN NO. 1
GIBSON NO. 3
GIBSON NO. 1
CORONADO NO.l
CORONADO NO.2
CORONAOO NO.3
WINYAH NO. 2
MARION NO. 1
A.B. BROWN NO.l
R.O. MORROW NO.l
R.D. MORROW NO.2
SOUTHWEST NO. 1
SHAWNEE N0.10A
SHAWNEE N0.10B
WIDOWS CREEK NO. 8
CHESTERTON INDIANA
GARY INDIANA
bECKER MINNESOTA
BECKER MINNESOTA
BECKER MINNESOTA
BECKER MINNESOTA
BEULAH NORTH DAKOTA
ROCK SPRINGS WYOMING
SHIPPIN6PORT PENNSYLVANIA
SHIPPINGPORT PENNSYLVANIA
SHIPPINGPORT PENNSYLVANIA
PHOENIXVILLE PENNSYLVANIA
EDDYSTONE PENNSYLVANIA
EODYSTONE PENNSYLVANIA
EDDYSTONE PENNSYLVANIA
OICKERSON MARYLAND
DICKERSON MARYLAND
WATERFLOW NEW MEXICO
WATERFLOW NEW MEXICO
WATERFLOW NEW MEXICO
WATERFLOW NEW MEXICO
GIBSON COUNTY INDIANA
GIBSON COUNTY INDIANA
ST. JOHNS ARIZONA
ST. JOHNS ARIZONA
ST. JOHNS ARIZONA
GEORGETOWN SOUTH CAROLINA
MARION ILLINOIS
WEST FRANKLIN INDIANA
HATTIESBURG MISSISSIPPI
HATTIESBURG MISSISSIPPI
SPRINGFIELD MISSOURI
PAOUCAH KENTUCKY
PADUCAH KENTUCKY
BRIDGEPORT ALABAMA
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIOS
CONSIDERING ONLY FGD 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
0- 0
6-77
3-76
1-77
5-81
5-83
5-81
9-79
1-76
10-77
1-80
6-60
9-75
6-80
6-60
0-78
0-76
11-77
11-77
1-79
5-61
0-76
0-79
1-79
1-60
0-87
7-77
6-76
1-79
11-77
8-78
1-77
1-72
1-72
5-77
6
1
1
1
5
5
6
3
1
2
3
6
1
1
6
6
6
2
2
1
6
5
5
3
3
6
2
2
3
2
2
1
1
1
1
C
C
B
B
A
A
B
B
B
B
B
8
B
B
B
C
C
B
B
B
B
A
A
B
B
B
A
C
C
C
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 4S246
-------
TABLE 1
SUMMARY LIST OF FGD SYSTEMS
FGO STATUS REPORT 06/77
X.O. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
106 TEXAS POWER « LIGHT CO.
107 TEXAS POWER AND LIGHT CO.
106 TEXAS POWER AND LIGHT CO.
109 TEXAS UTILITIES
110 TEXAS UTILITIES CO.
Ill TEXAS UTILITIES CO.
112 TEXAS UTILITIES CO.
113 TEXAS UTILITIES CO.
11* TEXAS UTILITIES CO.
115 UNITED POWER ASSOCIATION
116 UNITED POWER ASSOCIATION
117 UTAH POWER * LIGHT CO.
116 UTAH POWER ft LIGHT CO.
119 WISCONSIN POWER I LIGHT CO.
SANOOw NO.*
TWIN OAKS NO. 1
TWIN OAKS NO. 2
FOREST GROVE NO. 1
MARTIN LAKE NO. 1
MARTIN LAKE NO. 2
MARTIN LAKE NO. 3
MARTIN LAKE NO. H
MONTICELLO NO.3
COAL CREEK NO. 1
COAL CREEK NO. 2
EMERY NO.l
HUNTINGTON NO.l
COLUMBIA NO. 2
ROCKDALE TEXAS
ROBERTSON COUNTY TEXAS
ROBERTSON COUNTY TEXAS
ATHENS TEXAS
TATUM TEXAS
TATUM TEXAS
TATUM TEXAS
TATUM TEXAS
MT. PLEASANT TEXAS
UNDERWOOD NORTH DAKOTA
UNDERWOOD NORTH DAKOTA
EMLRY COUNTY UTAH
PRICE UTAH
PORTAGE WISCONSIN
7-80
8-83
9-6*
0-81
10-77
2-78
12-78
11-62
2-78
11-76
11-79
6-76
12-77
1-60
5
6
6
6
2
2
3
3
2
3
3
2
2
It OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
*. PLANNED - LETTER OF INTENT SIGNED
5. PLANNED - REQUESTING/EVALUATING BIDS
6. CONSIDERING ONLY FGD 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
Ot OTHER
E. REGULATORY CLASS UNKNOWN
8
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 2
STATUS OF FGD SYSTEMS
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
COMPANY
TABLE 2
STATUS OF FSD SYSTEMS DURING 06/77
POWER STATION
CURRENT MONTH
1.0. NUMBER 1
ALABAMA ELECTRIC COOP
TOHBIGBEE NO. 2
225 MW - NEW
COAL 0.6- 1.5 PERCENT SULFUR
PEABOOY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/78
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 FGO SYSTEM CONTAINS TWO SCRUBBING TRAINS,
TREATING APPROXIMATELY ?0 PERCENT OF THE FLUE GAS FOR REMOVAL OF SULFUR
DIOXIDE. STACK GAS REHEAT WILL NOT BE REQUIRED. DURING THE REPORT PERIOD.
THE UTILITY REPORTED THAT THE TWO SCRUBBER lOWERS, BREECHING, AND ANCIL-
LARY EOUIPMENT ARE NOW BEING ERECTED AT THE PLANT SITE.
I.D. NUMBER 2
ALABAMA ELECTRIC COOP
TOMBIGBEE NO. 3
225 MW - NEW
COAL 0.6- 1.5 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/79
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 FGO 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. UNIT NO. 3 TURBINE AND
BOILER ARE CURRENTLY UNDER CONSTRUCTION. NO WORK ON THE SCRUBBER PLANT
HAS COMMENCED AS OF THIS REPORT PERIOD.
1.0. NUMBER 3
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 1
625 MW - NEW
COAL H.5 PERCENT SULFUR (MAX)
BABCOCK AND WILCOX
LIME SCRUBBING
STARTUP 3/79
THE UTILITY REPORTS THAT FOUNDATION WORK IS NEARLY COMPLETE. EQUIPMENT IS
BEING DELIVERED TO THE PLANT SITE. THE COMMENCEMENT OF FULL-SCALE CON.
STRUCTION IS IMMINENT. A HIGH-EFFICIENCY ESP AND FOUR SPRAY TOWERS WILL
BE INSTALLED WITH DESIGN EFFICIENCIES OF 99.5 AND 90 PERCENT RESPEC-
TIVELY. PILOT STUDIES INDICATE THAT MG ION CONCENTRATION SUPERSEDES ALL
OTHER EFFICIENCY EFFECTS, AND THE UTILITY MAY SUPPLEMENT DRAVO THIOSORBIC
WITH DOLOMITE IF NECESSARY. THE UTILITY ALSO REPORTS THAT PLASlTE W005 IS
BEING CONSIDERED FOR USE AS STACK LINING DUE TO VINYL CONTENT.
1.0. NUMBER <»
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 2
625 MW - NEW
COAL H.5 PERCENT SULFUR (MAX)
BABCOCK AND WILCOX
LIME SCRUBBING
STARTUP 3/80
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 ORAVO CO. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS AND CONSTRUCTORS. CURRENTLY* FOUNDA-
TION WORK ON THE SCRUBBER PLANT IS NOW IN PROGRESS.
I.D. NUMBER 5
ARIZONA ELECTRIC POWER COOP
APACHE NO 2
*0ff '"MW - NEW
COAL 0.5- 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/78
SIMULTANEOUS CONSTRUCTION ON BOTH UNITS NO. 2 AND 3 FGD SYSTEMS IS CON-
TINUING. THE STRUCTURAL STEELWORK FOR THE HOT-SIDE UOP ESP»S IS IN. EREC-
TION OF THE SCRUBBER-ABSORBER TOWERS IS NEARLY COMPLETE. BOILER CONSTRUC-
TION HAS NOT BEGUN. THERE ARE CURRENTLY 2 PONoS WITH A TOTAL OF 20-YRS
CAPACITY FOR THE DISPOSAL OF THE UNFIXATED SLUDGE. 2 ADDITIONAL PONDS ARE
PLANNED PROVIDING AN ADDITIONAL 20 YRS OF DISPOSAL CAPABILITY. THERE WILL
BE NO REHEAT AND A ZEOLITE LINER IS PLANNED FOR THE WET STACK* WHICH WILL
CONSIST OF A COMMON OUTER SHELL AND A SEPARATE FLUE FOR EACH UNIT.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
COMPANY
TABLE 2
STATUS OF FGU SYSTEMS DURING
06/77
POWER STATION
CURRENT MONTH
1.0. NUMBER 6
ARIZONA ELECTRIC POWER COOP
APACHE NO 3
200 MW - NEW
COAL 0.5- 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 4/79
SIMULTANEOUS CONSTRUCTION ON BOTH UNITS NO. 2 AND 3 FGD SYSTEMS IS CON-
TINUING. THE STRUCTURAL STEELWORK FOR TH£ HOT-SIDE UOP tSP'S IS IN. EREC-
TION OF THE SCRUBBER-ABSORBER TOWERS IS NEARLY COMPLETE. BOILER CONSTRUC-
TION HAS NOT BEGUN. THERE ARE CURRENTLY 2 PONDS WITH A TOTAL OF 20-YRS
CAPACITY FOR THE DISPOSAL OF THE UNFIXATEO SLUDGE. 2 ADDITIONAL PONDS ARE
PLANNED PROVIDING AN ADDITIONAL 20 YRS OF DISPOSAL CAPABILITY. THERE WILL
BE NO REHEAT AND A ZEOLITE LINER IS PLANNED FOR THE WET STACK. WHICH WILL
CONSIST OF A COMMON OUTER SHELL AND A SEPARATE FLUE FOR EACH UNIT.
I.D. NUMBER 7
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
115 MW - RETROFIT
COAL 0.44-1 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 10/73
THE BOILER OPERATED 91.6R OF THE TIME IN THE PERIOD INCLUDING MARCH.
APRIL. « MAY. AVERAGE OPERABILITIES OF THE A-SIOE AND B-SIUE SCRUBBERS
WEKE 69.4 AND 96.6 PERCENT« RESPECTIVELY. AVERAGE RELIABILITIES OF THE
TWO SCRUBBERS FOR THE SAME PERIOD WERE 66.4 AND 93.5 PERCENT, RESPEC-
TIVELY. OUTAGES WERE REQUIRED FOR MID-YEAR CLEANING AND SOME MINOR REPAIR
WORK. RESEARCH-COTTRELL PERSONNEL ARE CURRENTLY CONDUCTING TESTS AT THIS
PLANT TO OBSERVE THE EFFECTS OF FORCED SULFITE-TO-SULFATE OXIDATION
ON THE SCRUBBER PROCESS.
I.D. NUMBER 8
ARIZONA PUBLIC SERVICE
CHOLLA NO 2
250 MW - NEW
COAL 0.44-1 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/78
THE CONTRACT FOR THIS WET LIMESTONE SCRUBBING SYSTEM HAS BEEN AWARDED
BY THE UTILITY TO RESEARCH-COTTRELL. THIS SYSTEM IS A LARGER-SCALE
APPLICATION OF THE CHOLLA NO.l DESIGN. ALL DESIGN AND ENGINEERING WORK
HAS BEEN COMPLETED. THE TURBINE, BOILER AND SCRUBBER ARE UNDER
CONSTRUCTION. THE UNIT COMMERICAL START-UP DATE IS SCHEDULED FOR JUNE
I97a. THE SCRUBBER PLANT CONSISTS OF FOUR PARALLEL FLOOOED-DISC
SCRUBBER AND PACKED TOWER ABSORBER TRAINS. THREE ARE REQUIRED FOR
FULL LOAD CAPACITY.
I.D. NUMBER 9
ARIZONA PUBLIC SERVICE
CHOLLA NO. *
350 MW - RETROFIT
COAL 0.44-1 PERCENT SULFUR
NOT DETERMINED
LIMESTONE SCRUBBING
STARTUP 6/80
UNIT NO. 4 IS CURRENTLY UNDER CONSTRUCTION. APS IS IN THE PRELIMINARY
DESIGN STAGE FOR INCLUSION OF A WET SCRUBBER PLANT FOR SOg CONTROL.
THL STATE REGULATORY AGENCY HAS NOT YET DECIDED THE EMISSIONS REGULATIONS
WHICH WILL APPLY TO THE PLANT. THE C-E BOILER WILL FIRE THE SAME COAL
AS CHOLLA NO. 1, WITH SULFUR CONTENT OF 0.44-1.0 PERCENT. THE A-C FIRM
IS EBASCO. COMMERCIAL START-UP IS SLATED FOR 06/80.
I.D. NUMBER 10
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 4
755 MW - RETROFIT
COAL 0.7 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THE UTILITY IS CURRENTLY EVALUATING THE DATA AND INFORMATION
ACCUMULATED DURING THE HORIZONTAL PROTOTYPE SCRUBBING PROGRAM
IN ORDER TO ASCERTAIN VARIOUS POSSIBLE STRATEGIES TO CONTROL
THE EMISSIONS FROM THIS COAL-FIRED 755-MW UNIT. A DECISION
HAS NOT YET BEEN FINALIZED.
12
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
06/77
CURRENT MONTH
I.D. NUMBER 11
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. SB
755 MW - RETROFIT
COAL 0.7 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THE UTILITY IS CURRENTLY EVALUATING THE DATA AND INFORMATION
ACCUMULATED DURING THE HORIZONTAL PROTOTYPE SCRUBBING PROGRAM
IN ORDER TO ASCERTAIN VARIOUS POSSIBLE STRATEGICS TO CONTROL
THE EMISSIONS FROM THIS COAL-FIflED 755-MW UNIT. A DECISION
HAS NOT YET BEEN FINALIZED.
FOR THIS UNIT HAS NOT YET BEEN FINALIZED.
I.D. NUMBER 12
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY NO. 1
ISO Mw • NEW
LIGNITE 1.0 PERCENT SULFUR
NOT SELECTED
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 0/81
THE UTILITY IS CURRENTLY PLANNING TO INSTALL A WET SCRUBBING SYSTEM TO
CONTROL S02 EMISSIONS FROM THIS LIGNITE-FIRED BOILER. THE ABSORBENT
WILL BE EITHER LIME ANo/OR ALKALINE FLYASH. THIS NEW FACILITY IS
LOCATED IN THE MERCER COUNTY AREA NEAR BEULAH, NORTH DAKOTA AND IS
KNOWN AS THE ANTELOPE VALLEY STATION. BOTH UNITS 1 AND 2 WILL BE REQUIRED
TO COMPLY WITH AIR EMISSION STANDARDS VIA BEST AVAILABLE TECHNOLOGY.
START-UP IS SCHEDULED FOR 1961.
1.0. NUMBER 13
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY NO. 2
HSO MW - NEW
LIGNITE 1.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/63
THE UTILITY IS CURRENTLY INVESTIGATING VARIOUS FGD PROCESSES FOR THIS
SECOND LIGNITE-FIRED UNIT SCHEDULED AT THIS NEW STATION LOCATED IN MERCER
COUNTYiNEAR BEULAH,NOHTH DAKOTA. THIS NEW FACILITY WILL BE KNOWN AS
THE ANTELOPE VALLEY STATION AND WILL BE REOUIR£D TO COMPLY WITH AIR
EMISSION STANDARDS VIA THE BEST AVAILABLE TECHNOLOGY. START-UP IS NOW
SCHEDULED FOR 1983.
I.D. NUMBER m
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 1
S50 MW - NEW
COAL 0.6 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP "»/80
RESEARCH-COTTRELL IS CURRENTLY FABRICATING THE DUAL-LOOP LIMESTONE WET
SCRUBBERS. NO ON.SITE CONSTRUCTION HAS YET BEGUN. NO SLUDGE DISPOSAL CON.
TRACT HAS AS YET BEEN AWARDED. BUT THE DISPOSAL STRATEGY WILL BE ONE
WHICH OEWATERS THE SLUDGE TO 63 PERCENT SOLIDS PRIOR TO DISPOSAL.
THE LARAMIE RlyER STATION WILL UTILIZE A SUB-BITUMINOUS COAL WITH A
HEATING VALUE OF 6100 BTU/LB AND SULFUR AND ASH CONTENTS OF 0.6 PERCENT
AND 7.0 PERCENTt RESPECTIVELY. THE CAPITAL COST FOR THL FGD SYSTEM IS
ESTIMATED AT 60 MILLION DOLLARS.
I.D. NUMBER 15
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 2
550 MW - NEW
COAL 0.6 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 10/60
RESEARCH-COTTRELL IS CURRENTLY FABRICATING THE DUAL-LOOP LIMESTONE WET
SCKUBBERS. NO ON-SlTE CONSTRUCTION HAS YET BEGUN. NO SLUDGE DISPOSAL CON'
TRACT HAS AS YET BEEN AWARDED, BUT THE DISPOSAL STRATEGY WILL BE ONE
WHICH DEWATERS THE SLUDGE TO 63 PERCENT SOLIDS PRIOR TO DISPOSAL.
THE LARAMIE RIVER STATION WILL UTILIZE A SUB-BITUMINOUS COAL WITH A
HEATING VALUE OF 6100 BTU/LB AND SULFUR AND ASH CONTENTS OF 0.6 PERCENT
AND 7.0 PERCENT, RESPECTIVELY. THE CAPITAL COST FOR THE FGD SYSTEM Is
ESTIMATED AT 60 MILLION DOLLARS.
13
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F6D SYSTEMS DURING 06/77
CURRENT MONTH
1.0. NUMBER 16
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 3
950 MU • NEW
COAL 0.6 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 6/63
THE. UTILITY IS STILL CONSIDERING VARIOUS F6D PROCESSES. LARANlE RIVER
STATION WILL FIRE SUB-BITUMINOUS COAL WITH THE FOLLOWING CHARACTERIS-
TICS* 6100 BTU/LBi 0.6 PERCENT SULFUR AND 7.0 PERCENT ASH.
1.0. NUMBER 17
BI6 RIVERS ELECTRIC COOP CORP.
REID NO. 2
250 MW » NEW
COAL 3.5-<».0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 12/79
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT IS BEING SUPP-
LIED BY AMERICAN AIR FILTER. THE SYSTEM WILL CONSIST OF A COLO.SIDE ESP
AND TWO SPRAY TOWERS CONTROLLING PARTICIPATE AND SOg TO 99.6 PERCENT AND
90 PERCENT. RESPECTIVLEV, THE saw BOILER WILL FIRE HIGH SULFUR ta.s TO
H.5 PERCENT! WESTERN KENTUCKY COAL. FGD SYSTEM FOUNDATIONS HAVE BEEN
LAID, BUT NO ON.SITE ASSEMBLY HAS COMMENCED. A SLUDGE FIXATION STRATEGY
is PLANNED, BUT NO CONTRACT HAS BEEN AWARDED. THE FGD SYSTEM WILL BE
FOLLOWED BY STEAM-TUBE REHEAT BUNDLE.
I.D. NUMBER 16
BRAZOS ELECTRIC POWER COOP
ATACOSA MCMULLEN NO. 1
HOO MW - NEW
LIGNITE 1.67 PERCENT SULFUR
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
STARTUP 12/79
THE EMISSION CONTROL EQUIPMENT FOR THE COAL-FIRED RADIANT BOILER WILL
CONSIST OF AN E.S.P. UPSTREAM OF FOUR LIMESTONE SCRUBBING MODULES.
THE SCRUBBER FLUE GAS CAPACITY IS NOMINALLY DESIGNED AT 1.579 MILLION
ACFM (302 F). DESIGN S02 REMOVAL EFFICIENCY IS 66 PERCENT FOR t«»00 PPM
S02 INLET. THE BOILER WILL BE FIRED WITH 436 TON/HR OF LIGNITE, THE
SCRUBBING WASTES WILL BE DISPOSED OF IN AN OFF.SITE MINEFILL. FGD SYSTEM
CONSTRUCTION IS CURRENTLY SCHEDULED TO BEGIN IN EARLY 1976. BOILER
START-UP is SCHEDULED FOR 01/79 WITH FGD START-UP SET FOR 12/79.
I.D. NUMBER 19
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO. 1
«»00 MW - NEW
COAL 2.5 - 3.0 PERCENT SULFUR
RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
STARTUP 8/78
A CONTRACT HAS BEEN AWARDED BY THE UTILITY TO THE RILEY STOKER CORP. FOR
THE DESIGN* FABRICATION AND INSTALLATION OF FOUR VENTRI-SORBER MODULES
TO TREAT THE FLUE GAS FROM THIS COAL-FIRED STEAM BOILER. THE FIRST
LIMESTONE SLURRY SCRUBBER MODULE WAS PLACED IN SERVICE ON SEPTEMBER 9.
1976, AND OPERATED INTERMITTENTLY UNTIL APRIL 1, 1977. A HIGH EFFICIENCY
ESP IS INSTALLED UPSTREAM OF FOUR VENTRI-SORBER SCRUBBER MODULES FOR
PARTICULATE CONTROL. DESIGN PARTICIPATE AND SULFUR DIOXIDE REMOVAL
EFFICIENCIES ARE 99.8 AND 75 PERCENT,RESPECTIVELY.
I.D. NUMBER 20
CENTRAL ILLINOIS LIGHT CO.
DUCK CRELK NO.2
HOO MW - NEW
COAL 2.5-3.0 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 1/62
THE PROPOSED LIMESTONE SCRUBBING SYSTEM FOR THIS NEW COAL-FIRED
UNIT is SCHEDULED TO COMMENCE OPERATIONS IN JANUARY 1952. THE
UTILITY HAS NOT YET SELECTED A SYSTEM SUPPLIER, A DECISION CONCERNING
THE STATUS OF THE BOILER AND CONTROL STRATEGY WILL BE ANNOUNCED
DURING THE LATTER PART OF 1977,
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO -45246
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
06/77
CURRENT MONTH
1.0* NUMBER 21
CENTRAL ILLINOIS PUBLIC SERV
NEWTON NO.l
579 MM - NEW
COAL 2.6-3*2 PERCENT SULFUR
BUELL/ENVIROTECH
DOUBLE ALKALI SCRUBBING
STARTUP 11/79
A CONTRACT HAS BEEN AWARDED BY CIPSCO TO BUELL/ENVIROTECH FOR THE
INSTALLATION OF AN EMISSION CONTHOL SYSTEM ON UNIT N0.lt A COAL-FIRED
575-MW POWER BOILER LOCATED IN NEwTON.ILLINOIS. THE KEY COMPONENTS OF THE
EMISSION CONTROL SYSTEM INCLUDE* A HIGH-EFFICIENCY ESP, FOUR PRECOOLERS,
FOUR POLVSPHERE ABSORBERS, THREE THICKENERS. TWO EXPERIMENTAL REHEAT S
SYSTEMS. AND THREE HORIZONTAL EXTRACTION FILTERS FOR SLUDGE DEMATERING. E
AT PRESENT, 15 PERCENT OF THE CONSTRUCTION WORK AT THE PLANT HAS BEEN
COMPLETED. THE FgO SYSTEM WILL HAVE CEILCOTE-LINEO ABSORBER MODULES.
I.0. NUMBER 22
CINCINNATI GAS ft ELECTRIC CO.
EAST BEND NO 2
600 MW . NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 1/81
BIO REQUEST AND EVALUATION IS SCHEDULED TO COMMENCE SHORTLY.
CONSTRUCTION AND OPERATING PERMITS ARE BElNtt PROCURED. A COAL
SOURCE AND SUPPLY HAS NOT BEEN FINALIZED. COMMERCIAL
START-UP DATE HAS BEEN DELAYED ONE YEAR TO JANUARY 1981.
THE A-E DESIGN FIRM IS SARGENT AND LUNDY.
I.D. NUMBER 23
COLORADO UT£ ELECTRIC ASSN.
CRAIG NO. 1
•ISO MW - NEW
COAL O.H5 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/79
PEABODY ENGINEERED SYSTEMS HAS BEEN AWARDED A CONTRACT IN EXCESS OF
S60 MILLION TO DESIGN AND SUPPLY A LIMESTONE SLURRY SPRAY TOWER
SCRUBBING SYSTEM FOR SULFUR DIOXIDE REMOVAL FROM LOW-SULFUR COAL-FIRED
BOILER FLUE GAS. PARTICULATE CONTROL WILL BE PROVIDED BY HOT-SIDE
ESP'S UPSTREAM OF THE SCRUBBER PLANT.
REQUIRED PARTICULATE AND SULFUR DIOXIDE REMOVAL EFFICIENCIES ARE 99.8
AND 85 PERCENT, RESPECTIVELY. FGD START-UP IS SCHEDULED FOR SPRING 1979.
I.D. NUMBER 21
COLORADO UTE ELECTRIC ASSN.
CRAIG NO. 2
ISO MW - NEW
COAL 0.<»5 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/79
PEABODY ENGINEERED SYSTEMS HAS BEEN AWARDED A CONTRACT IN EXCESS OF
$60 MILLION TO DESIGN AND SUPPLY A LIMESTONE SLURRY SPRAY TOWER
SCRUBBING SYSTEM FOR SULFUR DIOXIDE REMOVAL FROM LOW-SULFUR COAL-FIRED
BOILER FLUE GAS. PARTICULATE CONTROL WILL BE PROVIDED BY HOT-SIDE
ESP'S UPSTREAM.OF THE SCRUBBER PLANT.
REQUIRED PARTICULATE AND SULFUR DIOXIDE REMOVAL EFFICIENCIES ARE 99.8
AND 85 PERCENT. RESPECTIVELY. FGD START-UP IS SCHEDULED FOR SPRING 1979.
I.D. NUMBER 25
COLUMBUS ft SOUTHERN OHIO ELEC.
CONESVILLE NO 5
HOO MW - NEW
COAL ».5 - *.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
STARTUP 2/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE BOILER AND ESP WERE COMPLETED AND PLACED IN SERVICE IN SEPT. 1976.
THE B-SIDE MODULE BECAME AVAILABLE FOR SERVICE IN JANUARY 1977.
COMMERCIAL OPERATIONS WERE ACHIEVED ON FEBRUARY 13. 1977. THE EMISSION
CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A COLD.SIDE ESP FOLLOWED BY
TWO TCA LIME SCRUBBING MODULES SUPPLIED BY UOP. DRAVO IS SUPPLYING THE
THIOSORBIC LIME SCRUBBING REAGENT. IUCS IS SUPPLYING THEIR POZ-0-TEC
SLUDGE STABILIZATION FACILITY. B-SIDE STARTUP IS SCHEDULED FOR JAN. 1978.
15
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
COMPANY
POWER STATION
1.0. NUMBER 26
COLUMBUS ft SOUTHERN OHIO ELCCt
CONESVILLE NO 6
HOO AW - NEW
COAL *.S - «».9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
STARTUP 1/78
TABLE 2
STATUS OF F60 SYSTEMS DURING 06/77
CURRENT MONTH
THE~UTIL1TY~SIGNEO~UONG-TERM CONTRACTS WITH ORAVO FOR THE PURCHASE OF
THIOSORBIC LIME AND WITH IUCS FOR THE PURCHASE OF SLUDGE FIXATIVES. CON-
STRUCTION OF THIS UNIT COMMENCED IN 1977 AND IS SCHEDULED TO BE
COMPLETED BY JANUARY 1976. SIMILAR TO CONESVILLE NO.5, THIS MINE MOUTH
PLANT WILL BURN COAL WITH 17 PERCENT ASH CONTENT AND <».9 TO i».9 PERCENT
SULFUR CONTENT. AN ELECTROSTATIC PRLClPITATOR MILL BE INSTALLED UPSTREAM
THE FGD SYSTEM. THE FGD SYSTEM WILL INCLUDE TWO TCA MODULES FOR THE RE-
MOVAL OF S02. THE A-E DESIGN FIRM IS BLACK AND VEATCH.
I.D. NUMBER 27
COLUMBUS 1 SOUTHERN OHIO ELEC.
POSTON NO. 5
975 MW • NEW
COAL 2.9 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
THIS UNIT WILL BURN HIGH SULFUR OHIO COAL I APPROXIMATELY 2.5 PERCENT
SULFUR CONTENT). THE DESIGN OF THE EMISSION CONTROL STRATEGY HAS
NOT YET BEEN FINALIZED.
I.D. NUMBER 28
COLUMBUS * SOUTHERN OHIO ELEC.
POSTON NO. 6
975 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
FOK THIS UNIT HAS NOT YET BEEN FINALIZED.
1.0. NUMBER 29
COMMONWEALTH EDISON
POWERTON NO. 51
t25 MM - RETROFIT
COAL 3.6 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 12/79
UOP WAS AWARDED THE CONTRACT FOR THE INSTALLATION OF A WET LIMESTONE
SCRUBBING SYSTEM THAT HILL BE BACKFITTED ONTO BOILER NO.51. ONE OF TWO
IDENTICAL BOILERS SUPPLYING STEAM TO AN 850-MW TURBINE-GENERATOR* THE
FGO SYSTEM IS DESIGNED 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 MEET S02 EMISSION STANDARDS OF 1.8 Lfl.
S02/MM BTU. CURRENTLY. EXCAVATION. BACKFILL. AND STRUCTURAL STEEL
ERECTION IS IN PROGRESS.
I.D* NUMBER 30
COMMONWEALTH EDISON
WILL COUNTY NO 1
167 MW - RETROFIT
COAL «.o PERCENT SULFUR
BABCOCK I WILCOX
LIMESTONE SCRUBBING
STARTUP 2/72
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 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*
OPLRABILITY* RELIABILITY* AND UTILIZATION INDEX VALUES FOR THE REPORT
PERIOD ARE PROVIDED IN TABLE 5. A SLUDGE STUDY. CONDUCTED BY UOP* AND A
MAGNESIUM INNOCULATION AND FORCED OXIDATION STUDY, CONDUCTED BY THE
UTILITY* WERE COMPLETED DURING THE REPORT PERIOD.
16
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING
06/77
POWER STATION
CURRENT MONTH
1.0. NUMBER 31
OUQUESNC LIGHT
CLRAMA POWER STATION
310 MW . RETROFIT
COAL 1.0 - 2.B PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 10/75
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
OPERATIONS ARE CONTINUING WITH TWO BOILERS COUPLED INTO THL FIVE-MODULE
SCRUBBING SYSTEM. RUBBER-LINED RECYCLE PUMPS HAVE BEEN REMOVED FROM TEST-
ING AS THEY WERE UNDERGOING SEVERE ABRASION AND GOUGING. ANOTHER SET OF
RUBBER-LINED PUMPS MAY BE TESTED. SCRUBBING WASTES ARE CHEMICALLY FIXATED
BY THE IUCS METHOD AND LANDFILLED. UUOUE.SNE LIGHT IS CONTINUING EFFORTS
TO OBTAIN ALTERNATE LANDFILL AREAS AS I HE CURRENT ONES ARE BEING FILLED
FAIRLY RAPIDLY.
1.0. NUMBER 32
OUOUESNE 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 5 OF THIS REPORT.
THIS SCRUBBING SYSTEM HAS BEEN IN SERVICE SINCE JULY 1973. FOUR BOILERS
CUKRENTLY ARC COUPLED INTO THE SCRUBBING SYSTEM. THE OTHER TWO BOILERS
ARE DOWN FOR MAINTENANCE. THE SCRUBBER SYSTEM WAS SHUT DOWN FOR ABOUT •*
DAYS IN MAY DUE TO LEAKING IN THE WET GAS HEADER THAT CONNECTS THE STACK.
OVERALL SCRUBBER AVAILABILITY HAS BEEN ABOUT 75 PERCENT OUKING THE RE-
PORTING PERIOD. DEWATEREO SLUDGE FROM THE IUCS INTERIM PROCESSING PLANT
IS BEING HAULED TO AN OFF-SITE LANDFILL. THE SLUDGE CONTAINS NO FIXATIVE.
I.D. NUMBER 33
EASTERN KENTUCKY POWER COOP
SPURLOCK GENERATING PLANT NO,2
SOO MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 3/80
THE SPURLOCK GENERATING PLANT IS LOCATED APPROXIMATELY 3 MILES WEST OF
MAYSVILLE,KENTUCKY, TWO NEW UNITS ARE SCHEDULED FOR THIS STATION. UNIT
NO.l WILL BEGIN OPERATION IN EARLY JULY* IT DOES NOT HAVE TO MEET NSPS.
THE CONTRACTED COAL FOR UNIT NO.l WILL MEET S02 COMPLIANCE. UNIT NO.2
BE CONTROLLED BY A 99.5 PERCENT EFFICIENT ESP. OESULFURIZATlON MAY BE
RE8UIRED IF THE UTILITY CANNOT SECURE A LTERM ONG-CONTRACT FOR THE
PURCHASE OF LOW-SULFUR COAL. THE UTILITYSIS NECURING THE SERVICES OF AN
A-E FIRM IN THE EVENT AN FGD SYSTEM IS REED.R
I.D. NUMBER 3
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS DURING 06/77
CURRENT MONTH
1.0. NUMBER 36
KANSAS CITY POWER ft LIGHT
HAWTHORN NO. 3
mo nw • RETROFIT
COAL 0.5-3.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 11/72
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT.
THE SCRUBBER PLANT HAS BEEN CONVERTED FROM A LIMESTONE FURNACE INJECTION
AND TAIL-END SCRUBBING STRATEGY TO A TAIL-END WET LIME SCRUBBING STRATEGY
LIME-BASED OPERATIONS COMMENCED ON FEBRUARY 7, 1977. COMPLIANCE TESTING
FOR KANSAS CITY PARTICIPATE STANDARDS INDICATED THE NO.3 UNIT W«S WELL
WITHIN THE 0.17 POUND REGULATION. THE 2-MODULE SCRUBBER PLANT WAS IN
SERVICE 006 HOURS IN APRIL (57 PERCENT OPERABILITY) AND 302 HOURS IN MAY
(58 PERCENT OPERABILITY).
I.D. NUMBER 37
KANSAS CITY POWER t LIGHT
HAWTHORN NO, n
100 MW - RETROFIT
COAL 0.5-3.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 6/72
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT.
THE. SCRUBBER PLANT HAS BEEN CONVtRTEO FROM A LIMESTONE FURNACE INJECTION
AND TAIL-END SCRUBBING DESIGN TO A TAIL-END WET LIME SCRUBBING SYSTEM.
OPERATIONS IN THE LIME SCRUBBING MODE COMMENCED ON JANUARY It 1977.
COMPLIANCE TESTING FOR KANSAS CITY PARTICU|.ATE REGULATIONS INDICATED THE
UNIT IS MEETING THE 0.17 POUND REGULATION. THL 2-MOOULE SCRUBBER PLANT
WAS IN SERVICE 311 HOURS IN APRIL («»3 PERCENT OPERABILITY) AND 160 HOURS
IN MAY (5H PERCENT OPERABILITY).
I.D. NUMBER 36
KANSAS CITY POWER * LIGHT
LA CYGNE NO 1
620 MW - NEW
COAL S.O PERCENT SULFUR
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
STARTUP 2/73
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT.
THE. EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED POWER-GENERATING UNIT
CONSISTS OF EIGHT SCRUBBER MODULES FOR FLY ASH AND S02 REMOVAL. EACH
MODULE INCLUDES A VENTURI SCRUBBED IN SERIES WITH A 2-STAGE IMPINGEMENT
PLATE ABSORBER. THE SCRUBBER PLANT IS AN INTEGRAL PART OF THE POWER-
GENERATING COMPLEX, ALLOWING NO FLUE GAS BYPASS. INITIAL OPERATIONS
COMMENCED IN FEB. 1973. COMMERCIAL SERVICE WAS ATTAINED BY JUNE 1973.
TOTAL SYSTEM AVAILABILITY FOR THE MONTH OF APRIL WAS 93 PERCENT.
1.0. NUMBER 39
KANSAS POWER ft LIGHT
JEFFERY NO. 1
660 MW - NEW
COAL 0.30 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/76
THE UTILITY HAS PURCHASED AN AIR QUALITY CONTROL SYSTEM FROM COMBUSTION
ENGINEERING FOR PARTICIPATE AND S02 REMOVAL. THE SYSTEM WILL CONSIST OF
A COLO-SIDE ESP, I.D. FANS, BY-PASS CAPABILITY, 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/LBt O.jl SULFUR AND 6* ASH.
1.0. NUMBER <»0
KANSAS POWER ft LIGHT
JEFFERY NO. 2
680 MW . NEW
COAL 0.30 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/79
THE UTILITY HAS PURCHASED AN AIR QUALITY CONTROL SYSTEM FROM COMBUSTION
ENGINEERING FOR PARTICIPATE AND S02 REMOVAL. THE SYSTEM WILL CONSIST OF
A COLO-SIDE ESP, I.D. FANS, BYPASS CAPABILITY, AND SPRAY TOwERS. AN
OVE.RFIRE 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 250 TONS/HR OF WYOMING
COAL HAVING A HEAT CONTENT OF 8000 BTU/LB, 0.3X SULFUR AND 6X ASH.
16
PEDCo ENVIRONMENTAL
CINCINNATI, OHIO 45248
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
06/77
CURRENT MONTH
I.D. NUMBER 41
KANSAS POWER * LIGHT
LAWRENCE NO 4
125 MW - RETROFIT
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 12/68
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE NEW LIMESTUNE FcD SYSTEM COMMENCED OPERATIONS IN EAHLY JANUARY 1977.
THERE HAVE BEEN NO FORCED SCRUBBER OUTAGES SINCE START-UP.
CONTINUOUS S02 MONITORS ARE RECORDING S02 REMOVAL EFFICIENCIES
BETTER THAN 85 PERCENT. PARTICULATE REMOVAL IS REPORTED TO
BE EXCELLENT. YIELDING NO VISIBLE PLUME, MINOR PROBLEMS HAVE
REVOLVED AROUND MAINTAINING SOLIDS LEVELS. SEVERAL DIFFERENT
TYPES OF SLURRY PUMPS ARE BEING COMPARED UNDER OPERATING CONDITIONS,
I.D. NUMBER 42
KANSAS POWER I LIGHT
LAWRENCE NO 5
400 MW . NEW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/76
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THt ORIGINAL LIMESTONE INJECTION AND TAIL-END SCRUBBING SYSTEM IS STILL
IN SERVICE WHILE A NEW ROD-SCRUBBER AND SPRAY TOwER ABSORBER SYSTEM IS
BEING ERECTED ALONGSIDE THE EXISTING SYSTEM. THE NEW SCRUBBER PLANT
INCLUDES 2 MODULES EACH CAPABLE OF HANDLING APPROXIMATELY 50X OF THE TO-
TAL BOILER FLUE GAS FLOW. THE SYSTEM DESIGNER AND SUPPLIER IS COMBUSTION
ENGINEERING. THE UNIT FIRES APPROXIMATELY 140 TONS/HOUR OF LOW SULFUR
WYOMING COAL HAVING HEAT AND SULFUR CONTENTS OF 10,000 BTU/LB AND 0.5X.
I.D. NUMBER 43
KENTUCKY UTILITIES
GREEN RIVER NOS. 1 2 AND
64 MW - RETROFIT
COAL 3.6 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 9/75
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
STACK REPAIRS WERE COMPLETED DURING THE REPORT PERIOD* AND BOILER
SCRUBBER OPERATIONS RESUMED IN APRIL, THE STACK is NOW LINED WITH
PRECRETE G-8, A REFRACTORY LINING APPLIED BY AAF. DURING APRIL, OPERA-
BILITY AND RELIABILITY INDEX VALUES WERE 98*. AND THE AVAILABILITY INDEX
WAS 40X. DURING MAY, OPERABILITY AND RELIABILITY INDEX VALUES WERE 98»,
AND THE AVAILABILITY INDEX VALUE WAS 99*.
I.D. NUMBER 44
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 4
176 MW - RETROFIT
COAL 3.5 - 4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 6/76
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
SCRUBBER OPERATIONS WERE TERMINATED APRIL IB FOR THE IMPLEMATION OF
SEVERAL MODIFICATIONS TO THE FGD SYSTEM, A CHEVRON-TYPE MIST ELIMINATOR
WILL BE INSTALLED, A NEW SPRAY HEADER WILL INCREASE L/G, REHEAT WILL
BE ADDED AND THE CARBOLINE DUCT LINING WILL BE REPLACED WITH
PLASTITE 4005 (BY GENERAL COATINGS). THE MODIFICATIONS ARE EXPECTED TO
BE COMPLETE BY JULY 5.
I.D. NUMBER 45
LOUISVILLE GAS * ELECTRIC
CANE RUN NO 5
183 MW . RETROFIT
COAL 3.5 - 4.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 12/77
THE UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGO EQUIPMENT ON THIS UNIT BY DECEMBER Iil977.
THE CONTRACT FOR THIS LIME SCRUBBING SYSTEM HAS BEEN AWARDED TO
COMBUSTION ENGINEERING. THE SYSTLM IS NOW UNDER CONSTRUCTION. WORK IS
IN PROGRESS ON THE FOUNDATION AND ERECTION OF STRUCTURAL STEEL. CON-
STRUCTION OF THE FGD SYSTEM WAS DELAYED BECAUSE OF RE8UIREO FGD MODIFI-
CATIONS ON BOILER 4. BOILER 5 FGD WORK wILL BE DELAYED ABOUT 45 DAYS.
19
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
COMPANY
POWER STATION
TABLE: 2
STATUS OF FGD SYSTEMS DURING
0&/77
CURRENT MONTH
I.D. NUMBER <*6
LOUISVILLE GAS X ELECTRIC
CANE RUN NO 6
277 NW - RETROFIT
COAL 3.3 - 4.0 PERCENT SULFUR
ADL/COMiMJSTlON EQUIP ASSOCIATE
DOUBLE A'.KALI SCRUBBTNC
STARTUP 2/79
THE CONTRACT FOR THIS FULL-SCALE DEMONSTRATION SCRUBBING SYSTEM HAS BEEN
AWARDED TO A,0.LITTLE/COMBUSTI ON EQUIPMENT ASSOC. FOR THE INSTALLATION
OF A DOUBLE ALKALI SCRUBBER, THE FEDERAL EPA WILL SUBSIDIZE A MAXIMUM
SU.5 MM FOR OPERATION. RESEARCH AND DEVELOPMENT, A'.'D "F.POHT WRITING FOR
,\ ONE-YEA1' PERIOD FOLLOWING THE FIRST THR[.[. MONTHS <,F- OPtRfl T I Orj (NOjf.a THl S
SUBSIDY KILL. NUT BF. APPLIED F:OR ANT rr^lTAI. EXPENUI fUSES ) , ENGINEERING
DESIGN WORK IS NOW UNOLRHAy, START-UP IS SCHEDULED "OH FEBRUARY 1.JL979.
I.D. NUMBER i»7
LOUISVILLE GAS I. ELECTRIC
MILL C"EEK NO 1
330 H*l - RETROFIT
COAL 3.5- <*.0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 1/82
A COMPLIANCE SCHEDULE: HAS BEEN SUBMITTED TO THE; JEPI--IRSOM COUNTY AIH POL-
LUTION CONTROL DISTRICT WITH 1/B2 ESTABLISHED AS I'ME STARTUP 0,',TC. ; OR AN
FGU SYSTEM,
I.D. NUMBER H8
LOUISVILLE GAS 4 ELECTRIC
MILL CREEK NO S
330 HW - RETROFIT
COAL 3.5- "».0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 1/B1
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
F6D SYSTEM.
I.D. NUMBER 1*9
LOUISVILLE GAS * ELECTRIC
MILL C"EEK NO 3
<»25 MW - NEW
COAL 3.5- t.O PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 12/77
out TO THE FACT THAT POWER DEMAND HAS NOT COME UP AS RAPIDLY
AS HAD BEEN EXPECTED, START-UP HAS BEEN MOVLO BACK TO
DECEMBER 31,1977. CONSTRUCTION ON THIS NEW FACILITY'S
FGO SYSTEM IS APPROXIMATELY 60 PERCENT COMPLETE.
THIS AAF SYSTEM WILL OPERATE ON A CLOSED WATER LOOP
AND WILL PRODUCE A STABALIZEO SLUDGE.
1.0. NUMBER 50
LOUISVILLE GAS 4 ELECTRIC
MILL CREEK NO 14
i»25 MW - NEW
COAL 3.5- 4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 6/60
DUE TO THE FACT THAI POWER DEMAND HAS NOT COME UP AS
RAPIDLY AS HAD BEEN EXPECTED, START-UP HAS CIEEN MOVED
BACK TO JUNE 1980. THIS <*2-b-MW NEW FACILITY WILL
BE REQUIRED TO COMPLY WITH NSPS, FOUNDATION WORK
is CURRENTLY BEING EFFECTED. THIS AAF SYSTEM WILL
OPERATE ON A CLOSED WATER LOOP AND PRODUCE
STABALIZED SLUDGE.
20
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO -452.46
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING
06/77
POWER STATION
CURRENT MONTH
I.D. NUMBER 51
LOUISVILLE GAS * ELECTRIC
PADDYS RUN NO 6
65 MW - RETROFIT
COAL 3.5 - H.O PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP H/73
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS SCRUBBING SYSTEM MAS 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 HIGH-CALCIUM VIRGIN LIME STUDY
BEGAN IN MID-MARCH AND THE FGD SYSTEM DEMONSTRATED 9a» AVAILABILITY UNTIL
MID-APRIL. AT THAT TIME SCRUBBING OPERATIONS WERE TEMPORARILY SHUT-
DOWN BECAUSE THE SCRUBBER CREW WAS REQUIRED AT THE POWER-GENERATING OPER--
ATIONS. RESTART IS SCHEDULED FOR MID-JUNE.
I.D. NUMBER 52
MINNESOTA POWER AND LIGHT CO.
CLAY BOSWELL NO. <*
500 MW - NEW
COAL 0.6 PERCENT SULFUR
PEABODY ENGINEERING
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 0/60
MINNESOTA P 1 L HAS ANNOUNCED THAT IT HAS SIGNED A LETTER-OF-INTENT WITH
PEABODY ENGINEERING FOR A LIME/ALKALINE FLYASH S02 CONTROL SYSTEM.
THE MOST LIKELY CONFIGURATION WILL BE VENTURI SCRUBBERS FOLLOWED BY SPRAY
TOWERS. EMISSIONS FROM THIS NEWi COMBUSTION-ENGINEERING BOILER WILL BE
CONTROLLED TO COMPLY KITH NSPS, THE UNIT WILL FIRE SUB-BITUMINOUS
COLSTRIP COAL WITH A HEATING VALUE OF 8300 BTU/LB, SULFUR CONTENT OF
0.8*, AND ASH CONTENT OF 9.OX. THE START-UP OF COMMERCIAL OPERATIONS
is SCHEDULED FOR THE SPRING OF i960.
I.D. NUMBER 53
MINNKOTA POWER COOPERATIVE
MILTON R. YOUNG NO. 2
450 MW - NEW
LIGNITE • 6.500 BTU, 0.7* S
AOL/COMBUSTION EOUIP. ASSOC.
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 8/77
THE CONTRACT FOR THIS LIME/ALKALINE FLYASH SCRUBBING SYSTEM HAS BEEN
AWARDED TO AOL/COMBUSTION EQUIPMENT ASSOCIATES.
DURING THIS REPORTING PERIOD, THE UTILITY ANNOUNCED THAT CONSTRUCTION
IS APPROXIMATELY 90* COMPLETE, AND THAT THE AUGUST 1977 START-UP DATE
IS STILL GOOD. THE EMISSION CONTROL SYSTEM WILL CONSIST OF A COLO-SIDE
ESP FOLLOWED BY TWO SPRAY TOWERS. MIST ELIMINATION WILL BE EFFECTED BY
A SIEVE TRAY FOLLOWED BY A CHEVRON M-E. 15X OF THE FLUE GAS WILL BYPASS
THE SCRUBBER AND BE USED AS REHEAT.
I.D. NUMBER 54
MONTANA POWER CO.
COLSTRIP NO 1
360 MW - NEW
COAL 0.8 PERCENT SULFUR
AOL/COMBUSTION EOUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 10/75
THE COLSTRIP PLANT IS A MINE MOUTH INSTALLATION. THE FGD SYSTEM STARTED
UP IN LATE 1975 AND PROCEEDED THROUGH A SHAKEDOWN AND DEBUGGING OPER-
ATION PHASE. THE UNIT HAS BEEN OPERATING AT FULL COMERCIAL CAPACITY.
THE SCRUBBING SYSTEM DESIGN INCORPORATES VENTURI WET SCRUBBERS FOR
PART1CULATE AND SULFUR DIOXIDE REMOVAL. FLUE GAS CANNOT BE BY-PASSED
AROUND THE SCRUBBING SYSTEM. INFORMATION AND OPERATING DATA WERE NOT
MADE AVAILABLE BY THE UTILITY DURING THE REPORT PERIOD.
I.D. NUMBER 55
MONTANA POWER CO.
COtSTRlP NO 2
360 MW - NEW
COAL 0.8 PERCENT SULFUR
AOL/COMBUSTION EOUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/76
THE COLSTRIP PLANT IS A MINE MOUTH FACILITY. INITIAL OPERATION OF THE
SCRUBBING SYSTEM COMMENCED IN JULY 1976. THIS UNIT is IDENTICAL TO
THE. NO.l SYSTEM DESIGN IN THAT THREE SCRUBBLR MODULES ARE INSTALLED FOR
PARTICULATE AND SULFUR DIOXIDE REMOVAL. FLUE GAS CANNOT BE BY-PASSED
AROUND THE SCRUBBING SYSTEM. INFORMATION AND OPERATING DATA WERE NOT
MADE AVAILABLE BY THE UTILITY DURING THE REPORT PERIOD.
21
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
06/77
CURRENT MONTH
1.0. NUMBER 56
MONTANA POWER CO.
COLSTRIP NO, 3
700 MW - NEW
COAL 0.7 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/80
A CONTRACT FOR THE INSTALLATION OF TWO ADDITIONAL LIME/ALKALINE FLYASH
SCRUBBING SYSTEMS HAS BEEN AWARDED TO A.D. LITTLE/COMBUSTION EQUIPMENT
ASSOCIATES. THESE SYSTEMS WILL BE INSTALLED ON UNITS NOS. 3 ANQ «4 OF
THL COLSTRIP POWLK STATION, COLSTRIP UNITS 1 ANO 2 ARE fOTH E3UIPPEO
WITH OPERATIONAL LI ME/ALKALINE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL
OF PARTICULATES AND SULFUR DIOXIDE. ENGINEERING WORK FOR THE f«EW SYSTEMS
IS NOW UNDERWAY. THIS CONTRACT Is EXPECTED TO EXCEED J50 MM.
I.D. NUMBER 57
MONTANA POWER CO,
COLSTRIP NO. 4
700 MW - NEW
COAL 0.7 PERCENT SULFUR
ADL/COMRUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/fll
A CONTRACT FOR THE INSTALLATION OF TWO ADDITIONAL LIME/ALKALINE FLYASH
SCRUBBING SYSTEMS HAS BEEN AWARDED TO A.D. LITTLE/COMBUSTION EQUIPMENT
ASSOCIATES. THESE SYSTEMS WILL BE INSTALLED ON UNITS NOS, 3 AND •* OF
THE COLSTRIP POWER STATION. COLSTRIP UNITS 1 ANO Z ARE BOTH EQUIPPED
WITH OPERATIONAL LIME/ALKALINE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL
OF PARTICULATES ANO SULFUR UIOXIUE. ENGINEERING WORK FOR THE NEW SYSTEMS
IS NOW UNDERWAY. THIS CONTRACT IS EXPECTED TO EXCEED $50 MM.
I.D. NUMBER 58
NEVADA POWER
HARRY ALLEN STATION NO,
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP fc/83
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM,
TIONS HAVE NOT YET BEEN PREPARED.
SPECIFICA-
I.D. NUMBER 59
NEVADA POWER
HARRY ALLEN STATION NO,
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/8i»
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
I.D. NUMBER 60
NEVADA POWER
HARRY ALLLN STATION NO. 3
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/85
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM,
TIONS HAVE NOT YET BEEN PREPARED'
SPECIFICA-
22
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
06/77
CURRENT MONTH
I.D. NUMBER 61
NEVAOA POWER
HARHY ALLEN STATION NO.
500 MU • NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/66
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM.
TIONS HAVE NOT YET BEf.U PREPARED.
SPECIFICA-
I.D. NUMBER 62
NEVADA POWER
REID GARDNER NO 1
125 Mh - RETROFIT
COAL 0.5 - 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP <»/7<»
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS SODIUM CARBONATE-BASED JTRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A TWIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A
SEPARATOR IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER.
THE MODULE WAS FIRST PLACED IN SERVICE ON BOILER FLUE GAS IN APRIL 197<».
DURING THE REPORT PERIOD THE SCRUBBER WAS UNAVAILABLE FOR SERVICE BECAUSE
OF REPAIRS TO DAMAGED LINER MATERIAL. THE SYSTEM is SCHEDULED TO BE BACK
IN OPERATION BY MID-JUNE.
I.D. NUMBER 63
NEVADA POWER
REID GARDNER NO 2
125 MW . RETROFIT
COAL 0.5 - 1.0 PERCENT SULFUR
AOL/COMBUSTION E8UIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP i»/7«»
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MOUULE CONTAINING A TWIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED 8Y A
SEPARATOR IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER.
THE MODULE WAS FIRST PLACED IN SERVICE ON BOILER FLUE GAS IN APRIL 197<*.
DURING THE REPORT PERIOD THE SYSTEM WAS IN SERVICE WITH THE EXCEPTION OF
A 2-wEEK BOILER OUTAGE FOR MAINTAlNENCE AND REPAIRS.
I.D, NUMBER 64
NEVADA POWER
REID GARDNER NO 3
125 MM - NEW
COAL 0.5 - 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP 7/76
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS UNIT is A NEW COAL-FIRED BOILER THAT is EQUIPPED WITH SODIUM
CARBONATE-BASEDITRONA>SCRUB8ING SYSTEM WHICH INCORPORATES A TWIN
VAKIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A SEPANATOK IN SERIES WITH
A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER, THE MODULE WAS FIRST
PLACED IN SERVICE ON BOILER FLUE GAS IN JULY 1976. DURING THE PERIOD
THE SYSTEM WAS OPERATIONAL IN APRIL AND DO«N IN MAY FOR A S-WEEK OUTAGE
FOR AN FRP LINER REPLACEMENT IN THE SEPARATOR.
I.D. NUMBER 65
NEVADA POWER
REID GARDNER NO n
125 MM - NEW
COAL 0-5- 1.0 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 THE. CONSTRUCTION OF *N FGD SYSTEM ON REID GARDNER NO.
H, HOWEVER, CONSTRUCTION OF THE BOILER HAS BEEN INDEFINITELY POSTPONED.
23
PEDCo ENVIRONMENTAL
CINCINNATI OHIO
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
06/77
CURRENT MONTH
1.0. NUMBER 66
NEVADA POWER
WARNER VALLEY STATION NO.
250 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/82
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM.
I.D. NUMBER 67
NEVADA POWER
WARNER VALLEY STATION NO. 2
250 MW • NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/63
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM.
I.D. NUMBER 66
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 RE.GENERABLE
FLUE GAS DESULFURIZftTlON SYSTEMS WHICH OFFER A BREAKTHROUGH IN
OPERATING COSTS ANO 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.
1,0. NUMBER 69
NIAGARA MOHAWK POWER COOP.
CHARLES R. HUNTLEY NO.6
100 MW - RETROFIT
COAL 3,5-4,5 PERCENT SULFUR
ATOMICS INTERNATIONAL
AQUEOUS CARBONATE SCRUBBING
STARTUP 6/78
DURING THE REPORT PERIOD, CONTRACTS WERE SIGNED AWARDING A CONTRACT
TO ATOMICS INTERNATIONAL FOK THE DESIGN AND INSTALLATION OF AN AQUEOUS
CARBONATE FGD SYSTEM. THIS DEMONSTRATION SYSTEM WILL PRODUCE END-PRODUCT
SULFUR. FUNDS ARE BEING PROVIDED BY THE US EPA AND THE EMPIRE STATE
ELECTRIC ENERGY RESEARCH CORP. THE DESIGN SOj REMOVAL EFFICIENCY WILL
BE 90 PERCENT.
I.D. NUMBER 70
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 7
190 MW - RETROFIT
COAL 3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
CONSIDERING A LIME OR LIMESTONE SCRUBBING UNIT. ALSO WAITING FOH PER-
FOKMANCE OF WELLMAN LORD/ALLIED CHEMICAL UNIT IN SERVICE AT THEIR
D.H. MITCHEL NO.H UNIT. LOW SULFUR COAL MAY BE EMPLOYED TO COMPLY WITH
S02 EMISSION REGULATIONS.
APPLICABLE INDIANA S02 REGULATIONS ARE STILL NOT FIRMLy ESTABLISHED.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING
06/77
POWER STATION
CURRENT MONTH
I.D. NUMQCR 71
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 8
i»00 M* - 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 bURNEU TO COMPLY WITH
S02 EMISSION REGULATIONS.
1.0. NUMBER 72
NORTHERN INDIANA PUB SERVICE
D.H. 1ITCHELL NO.11
115 MW - RETROFIT
COAL 3.2-3.5 PERCENT SULFUR
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 6/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS FGO SYSTEM IS AN INTEGRATION OF THE WELLMAN-LORU S02 RECOVERY PROCES
OFFERED BY UAVY POWERGAS AND THE S02 TO SULFUR REDUCTION PROCESS DE-
VELOPED BY ALLIED CHEMICAL, DAVY POHERGAS IS THE DESIGN AND CONSTRUCTION
FIRM AND ALLIED CHEMICAL IS SYSTEM OPERATOR AND PRODUCT MARKETER.
DURING THE REPORT PERIOD THE DEMONSTRATION SCRUBBER PLANT WAS STARTED UP
ANU OPERATED AT APPROXIMATELY 60 PERCENT FLUE GAS CAPACITY BECAUSE OF
AIR PREHEATER PROBLEMS IN THE BOILER.
I.D. NUMBER 73
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.l
710 MW - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/76
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
FULL COMMERCIAL OPERATION OF THE SYSTEM BEGAN ON MAY 1, l976t THE SCRUB-
BING SYSTEM FO* THIS UNIT CONSISTS OF 12 MODULES. EACH SCRUBBING MODULE
INCORPORATES A VENTuRI-ROO SECTION AND A MARBLE BED ABSORBER FOR PAR-
TICULATE AND SULFUR DIOXIDE REMOVAL. AVAILABILITY INDEX VALUES FOR
THE MONTHS OF APRIL AND MAY WERE 95 AND 92 PERCENT, RESPECTIVELY. THE
UNIT WAS TAKEN OUT OF SERVICE IN MID-MAY FOH A SCHEDULED TURBINE/BOILER
OVERHAUL. RESUMPTION OF OPERATIONS IS SCHEDULED FOR MID-JUNE.
I.D. NUMBER 7U
NORTHERN STATES POWER CO,
SHERBURNE COUNTY STATION NO.2
680 MW - NEW
COAL 0.6 PERCENT SuLFuR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP t»/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THL SHERBURNE NO.2 AIR QUALITY CONTROL SYSTEM IS IDENTICAL IN DESIGN TO
THE SYSTEM IN OPERATION ON THE NO.l UNIT AT THIS STATION. TWELVE 2-STAGE
PAKT1CULATE SCRUBBER (VENTURI-ROD SCRUBBER) AND SULFUR DIOXIDE ABSORBER
(MARBLE-BED ABSORBER) MODULES ARE PROVIDED FOR FLY ASH AND S02 CONTROL.
ELEVEN MODULES ARE REQUIRED FOR HULL GENERATING CAPACITY OPERATIONS.
TOTAL SYSTEM AVAILABILITY INDEX VALUES REPORTED FOR THE MONTHS OF APRIL
AND MAY WERE 92 AND 91 PERCENT, RESPECTIVELY.
I.D. NUMBER 75
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 1981 AND MAY 1983. EACH UNIT IS NOMINALLY RATED AT
660 MW. THE UTILITY IS CURRENTLY REUUESTING/EVAtUATING BIDS FOR THE
FGD SYSTEM. THE BOILER CONTRACT HAS BEEN AWARDED TO BABCOCK AND
WILCOX AND THE TURBINE WILL BE SUPPLIED BY GENERAL ELECTRIC.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING 06/77
POWER STATION
CUKRENT MONTH
1.0, NUMBER 76
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO,
660 MW • NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
NOT 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
STATICS IN BECKER, MINNESOTA, COMMERCIAL OPERATION UATES ARE NOW
SCHEDULED FOR MAY 1981 AND MAY 1983. EACH UNIT IS NOMINALLY RATED AT
860 MW, THE UTILlTy IS CURRENTLY REQUESTING/EVALUATING BIOS FOR THE
FGU SYSTEM. THE BOILER CONTRACT HAS BEEN AWARDED TO BABCOCK AND
WILCOX AND THE TURBINE WILL BE SUPPLIED BY GENERAL ELECTRIC.
I.D. NUMBER 77
OTTER TAIL POWER COMPANY
COYOTE NO. 1
1400 MM - NEW
LIGNITE 0.9 PERCENT SULFUR
NOT SELECTED
HOT SELECTED
STARTUP 5/81
THIS NEW COAL-FIRED STATION IS JOINTLY OWNED BY FIVE UTILITIES, OTTER
TAIL POWER is THE MAJOR OWNER AND CONSTRUCTOR. MONTANA-UAKOTA UTILITIES
is THE FACILITY OPERATOR. THIS PLANNED 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 WLT REMOVAL PROCESSES AND DKY NAHCOLITE INJECTION COLLECTED
ON FABRIC FILTERS. THIS <»OO-MW UNIT WILL BE A B*W CYCLONE-FIRED BOILER.
I.D. NUMBER 78
PACIFIC POWER AND LIGHT CO.
JIM BRIOGER NO. i»
509 MW - NEW
COAL 0.56 PERCENT SULFUR(AVG.)
UNIVERSAL OIL PRODUCTS
SODIUM CARBONATE SCRUBBING
STARTUP 9/79
THE UTILITY IS CONTINUING PILOT PLANT WORK DESIGNED TO FINALIZE FGD
SYSTEM OPERATING PARAMETERS. CURRENT TESTING IS CENTLHEO AROUND DETER-
MINATION OF SPRAY NOZZLE CONFIGURATION. FOLLOWING THL SPRAY NOZZLE
EVALUATION, THE TESTING WILL PROCEED INTO A PERIOD OF DETERMINING EFFECTS
OF L/G, PH, AND GAS FLOW RATE, SUBSEQUENT TESTS WILL BE AIMED AT MINIMI-
ZING MIST ENTRAINMLNT. CURRENT PLANS INCLUDt THE USE OF COOLING TOWER
SLOWDOWN AS THE SOURCE OF MAKEUP WATER. THE WLT/DRY STACK wILL HAVE A
CEILCOTE LINING.
1.0. NUMBER 79
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 1
835 MW - NEW
COAL H.l PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 1/76
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS EMISSION CONTROL SYSTEM IS CAPABLE OF REMOVING FLYASH AND S02 FROM
3.35 MM ACFM OF FLUE GAS VIA WET LI«E SCRUBBING. THL INITIAL SHAKLOOWN
ANU 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 TKAINS HAVE BEEN SUCCESSFULLY PUT INTO OPERATION.
THt AVAILABILITY INDEX VALUE FOR THE ENTIRE SCRUBBING SYSTEM HAS
BEEN IN THE MID-90 PERCENT RANGE SINCE COMMERCIAL START-UP.
I.D. NUMBER 80
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 2
835 Mw - NEW
COAL H.7 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STAKTUP 10/77
THE FGD SYSTEM FOR THIS INSTALLATION WILL BE A CHEMICO WET LIME SCRUBBING
SYSTEM CAPABLE OF REMOVING PARTICULATE MATTER AND 502 FROM THE FLUE GAS.
THIS SYSTEM IS CURRENTLY UNfjER CONSTRUCTION. INITIAL FGD SYSTEM START-
UP IS NOW SCHEDULED FOR EARLY JULY, FOLLOWING A 3-MONTH SHAKEDOWN
PERIOD, THE UTILITY is SCHLOULING COMMERCIAL OPERATION FOR OCTOBER
1977.
26
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
06/77
CURRENT MONTH
I.D. NUMBER 81
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 3
835 MW - NEW
COAL «».7 PERCENT SULFUR
PULLMAN KELLOSG
LIME SCRUBBING
STARTUP <+/80
THE PULLMAN KELLOGG DIVISION OF PULLMAN INCORPORATED HAS BEEN
AWARDED A CONTRACT IN EXCESS $50 MILLION BY THE CAPCO CONSOHTIUM
FOR THE INSTALLATION OF SULFUR DIOXIDE SCRUBBER ON THIS 835 MW COAL-
FIREO POWER-GENERATING UNIT. THE EMISSION CONTROL SYSTEM FOR THIS
UNIT WILL CONSIST OF ESP'S UPSTREAM OF WEIR HORIZONTAL CROSSFLOW WET
SCRUBBING MODULES. CONSTRUCTION OF THE BOILER is CURRENTLY IN PROGRESS.
DUL TO REVISED CAPCO LOAD FORECASTS, UNIT START-UP HAS BEEN MOVED
BACK TO 0"*/60.
I.D. NUMBER 82
PHILADELPHIA ELECTRIC CO.
CROMBY
150 MW - RETROFIT
COAL 2-H PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 6/80
THE. UTILITY PLANS TO RETROFIT ONE OF THE TWO BOILERS AT CROMBY WITH AN
FGU SYSTEM. HOWEVER. A FINAL DECISION HAS NOT BEEN MAUL. 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. TENTATIVE FGD SYSTEM
START-UP IS SCHEDULED FOR JUNE 1980.
I.D. NUMBER 83
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 5 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF THREE PARALLEL
SCRUbBING TRAINS FOR THE CONTROL OF PARTICULATE AND SULFUR UIOXIOE.
THL C-SIUE SCRUBBING TRAIN INCLUDES AN S02 ABSORBER MODULE IN SERIES
WITH A PARTICULATE SCRUBBER. APPROXIMATELY ONE-THIRD OF THE BOILER FLUE
GAS is SCRUBBED WITH MAGNESIUM OXIDE SLURRY FOR 502 REMOVAL. THE SPENT
SLURRY IS REGENERATED AT THE ESSEX SULFURIC ACID PLANT IN NEWARK. N.J.
THE REGENERATED MAGOX IS RETURNED TO THE PLANT FOR S02 SCRUBBING SERVICE.
I.D. NUMBER 8V
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. IB
2<»o MW - RETROFIT
COAL 2.5 PERCENT SuLFuR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 6/80
THE INSTALLATION OF S02 SCRUBBERS ON THE BALANCE OF THE FLUE GAS FROM
THIS UNIT WILL FOLLOW PENDING THE OUTCOME 0^ THE PERFORMANCE OF THE
SCRUBBING UNIT WHICH HAS BLEN INSTALLED AND INTERMITTENTLY OPERATIONAL
ON THE EDDYSTONE NO.l UNIT. CURRENTLY. 3 WET PARTICULAR SCRUBBERS ARE
SERVICE ON THIS UNIT,
I.D. NUMBER 85
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. 2
336 MW - RETROFIT
COAL 2.«» PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 6/80
THE UTILITY IS AWAITING PERFORMANCE RESULTS FROM THE EXISTING MAGOX
SCRUBBER INSTALLED ON UNIT NO.I AT THIS STATION BEFORE PROCEEDING
WITH THE DESIGN OF AN FGo SYSTEM FOR THIS COAL-FIRE.U 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. TENTATIVE FGD SYSTEM
START-UP is SCHEDULED FOR JUNE i960.
27
PEDCo ENVIRONMENTAL
CINONNAT,. OHIO .45246
-------
COMPANY
TABLE: 2
STATUS OF FGD SYSTEMS DURING
06/77
POWER STATION
CUKRENT MONTH
1.0. NUMBER 86
POTOMAC ELECTRIC S POWER
DICKERSON 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 SCKUBBER
CONSISTS OF A SINGLE MODULE DOUBLE VENTURI THROAT UKIT. THE FlKST
VENTURI STAGE IS DESIGNED FOR REMOVAL OF PAHT1CULATE HATTEH ONuT. THE
SECOND VENTuRI STAGE WILL BE INSTALLED FOR FgTuRE CONSIDERATIONS IF
THE UTILITY ELECTS TO SCRUB SULFUR DIOXIDE. THE DESIGN ALLOWS CON-
SIDERATION FOR EITHER A REGENERATIVE OR NON-HEGENERAT1VE ^GQ SYSTEM,
FINAL DECISIONS ARE NOT EXPECTED UNTIL EARLT 1979.
1.0. NUMBER 87
POTOMAC ELECTRIC 4 POWER
OICKERSON 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. TH
SECOND VENTURI STAGE WILL 6E INSTALLED FOR FUTURE CONSIDERATIONS IF
THE UTILITY ELECTS TO SCRUB SULFUR DIOXIDE. THE DESIGN ALLOWS CON-
SIDERATION FOR EITHER A REGENERATIVE OR NON-REGENEKATIVE FGD SYSTEM,
FINAL DECISIONS ARE NOT EXPECTED UNTIL EARLY 1979.
I.O. NUMBER 88
PUBLIC SEHVICE CO OF NEW HEX.
SAN JUAN NO. 1
375 Mw - NEW
COAL 0.8 PERCENT SULFUR
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 11/77
THE CONSTRUCTION OF THIS SYSTEM IS NOW UNDERWAY. CONSTRUCTION IS
CUKRENTLY APPROXIMATELY 30 PERCENT COMPLETE. START-UP IS NOW SCHEDULED
FOK NOV. 1977. THIS FGD SYSTEM IS AN INTERbRATlON OF THE WLLLMAN LORD
S02 RECOVERY PROCESS OF DAVY POWERGAS AND ALLIED CHEMICAL'S S02 RE-
DUCTION TO SULFUR PROCESS. A HOT SIDE ELECTROSTATIC PRECIPlTAToR WILL
PRECEDE THE SCRUBBING UNIT. FOUR ABSORBER TOWERS WILL BE INSTALLED
FOR LACH UNIT. THREE WILL CARRT THL FULL LOAD. MOLTEN SULFUK WILL BE
STORED ON THE PLANT SITE.
I.D. NUMBER 89
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 2
3"»0 Mw - RETROFIT
COAL 0,8 PERCENT SULFUR
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 11/77
THE CONSTRUCTION OF THIS SYSTEM IS NOW UNDERWAY. CONSTRUCTION IS
CUKRENTLY APPROXIMATELY 30 PERCENT COMPLETE. START-UP IS NOW SCHEDULED
FOrt NOV. 1977. THIS FGD SYSTEM IS AN INTERGKAUON OF THE w^LL^AN LO«D
502 RECOVERY PROCESS OF OAvY POWERGAS AND ALLIED CHEMICAL'S S02 RE-
DUCTION TO SULFUR PROCESS. A HOT SIDE ELECTROSTATIC PRECIPITATQR WILL
PRt-CEDE THE SCRUBBING UNIT. FOUR ABSORBER TOWERS WILL BE INSTALLED
FOR LACH UNIT. THREE WILL CARRY THE FULL LOAD. MOLTE.N SULFUR WILL BE
STORED ON THE PLANT SITE.
I.O. NUMBER 90
PUBLIC SEHVICE CO OF NEW MEX.
SAN JUAN NO. 3
500 MW - NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
REGENERABLE NOT SE.LECTEO
STARTUP 1/79
THE UTILITY HAS SIGNED A LETTEH-OF-INTENT WITH DAVY POWERGAS FOR
ONL SCRUBBER MODULE WHICH WILL BE DESIGNED TO BRING THE UNIT INTO
COMPLIANCE WITH NSPS BY JAN. 1979. THE FGO SYSTEM FOR THE REMAINDER
OF THE FLUE GAS FROM THIS 500-MW UNIT HAS NOT BEEN SELECTED. PRIMARY
PARTICIPATE CONTROL WILL BL EFFECTED BY AN UPSTREAM LSP.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING Ob/77
POWER STATION
CUKHENT MONTH
I.D. NUMBER 91
PUBLIC SLHVICE CO OF NEW MEX,
SAN JUAN NO. 4
500 MW - NEW
COAL O.B PERCENT SULFUR
NOT SELECTED
REGENERABLE NOT SELECTED
STARTUP 5/81
THE UTILITY MAS PLACED A HOLD ON FURTHER ENGINEERING DESIGN WORK AT THE
PRESENT TIME. THE PROJECTED START-UP DATE FOR UNIT 4 IS
MAY 1981. THE WELLMAN LORD AND OTHE« SULFUR DIOXIDE HLCOVEHY PROCESSES
ARL NOW UNDER CONSIDERATION BY THE UTILITY. AN ESP WILL BE PROVIDED
UPSTREAM OF THE FGU SYSTEM FOR PRIMARY ^ARTICULATE CUNTHOL.
1,0. NUMBER 92
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 FOK ROTH UNITS 3 AND 4 AT THIS STATION.
NO DECISION HAS YET BEEN MADE.
I.D. NUMBER 93
PUBLIC SERVICE OF INDIANA
GIBSON NO. 4
650 MW • NEW
COAL 3.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/79
THE UTILITY HAS COMPLETED THE EVALUATION OF BIO SPECIFICATIONS
SUBMITTED FOR FGD SYSTEMS FOR BOTH UNITS 3 AND if AT THIS STATION.
NO DECISION HAS YET BELN MAUE.
I.D. NUMBER 94
SALT RIVER PROJECT
CORONADO NO.l
350 MU - NEW
COAL 1.0 PERCENT SULFUR (MAX)
PULLMAN KELLOGG
LIMESTONE SCRUBBING
STARTUP 4/79
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. A MAXIMUM OF 60* OF THE
FLUE GAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
PULLMAN/KELLOGG WILL DESIGN AND FABRICATE TWO WEIR HORIZONTAL
CROSSFLOW SCRUBBER MODULES. WHICH WILL UTILIZE LIMESTONE SLURRY FOR
S02 CONTROL. THE SYSTEM WILL UTILIZE RUBBER-LINED SLURRY RECYCLE PUMPS.
EACH RATED AT 9300 GPM, RIGIFLAKE-LINED SCRUBBER MODULES, VERTICAL HEIL
DEMISTERSt AND A MINIMUM OF 20 PLRCENT REHEAT. A SLUDGf DISPOSAL STRATEGY
HAS NOT BEEN FINALIZED? BUT SLUDGE WILL BE EITHER PONDCU OH FIXATED.
I.D. NUMBER 95
SALT RIVEN PROJECT
CORONADO NO.2
350 MW - NEW
COAL i.o PERCENT SULFUR
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 06/77
CURRENT MONTH
1,0. NUMBER 96
SALT RIVER PROJECT
CORONAOO NO.3
350 MW . NEW
COAL 1.0 PERCENT SULFUR (MAX)
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 0/87
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. 80 PERCENT OF THE
GAS HILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION RESULATIONS.
THE UTILITY IS CURRENTLY CONSIDERING THE INSTALLATION OF T*0 HORIZONTAL
CROSSFLOW SCRUBBING MODULES EMPLOYING A LIMESTONE SCRUBBING SOLUTION
TO REMOVE, soj FROM THE FLUE GAS, SCHEDULED COMMERCIAL OPERATION
DATE IS 1987. PLANS FOR AN EMISSION CONTROL SYSTEM HAVE <<(OT
BEEN FINALIZED.
I.D. NUMBER 97
SOUTH CAROLINA PUBLIC SERVICE
WINYAH NO. 2
280 MW . NEW
COAL 1.0 PERCENT SULFUR
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
STARTUP 7/77
BOILER START-UP HAS BEEN DELAYED* DUE TO THE DELAY IN THE DELIVERY
OF THREE RELAYS. ALL OTHER EQUIPMENT IS ON-SITE, INSTALLED AND PREPARED
FOR START-UP. THE BjW LIMESTONE FGD SYSTEM WILL SCRUB 50 PERCENT OF THE
FLUE GAS, REMOVING 69 PERCENT OF THE SCRUBBER INLET SO?. RUBBER LIVING
WILL BE A FEATURE OF THE SLURRY PREP TANK, RETENTION TANK. AND THE SLURRY
RECYCLE PUMPS. THE STACK FEATURES AN FRP LINING, THE UNSTABILIZED SLUDGE
WILL BE DISPOSED IN AN UNLINED 20-YEAR CAPACITY POND.
I.D. NUMBER 98
SOUTHERN ILLINOIS POWER CO OP
MARION NO. i»
18H MU - NEW
COAL <*.5-5.0 PERCENT SULFUR
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
STARTUP 6/78
CONSTRUCTION HAS BEGUN ON THIS 18H-MU UNIT AND FGD SYSTEM, WITH FOUNDA-
TION WORK COMPLETED AND PRECIPITATOR INSTALLATION UNDERWAY, TOTAL CAPI-
TAL COST FOR THE SCRUBBING SYSTEM IS REPORTED AS $10,000,000, OR «5t»/KW.
THIS FIGURE INCLUDES THE TWO SPHAY TOWERS, AND ALL ANCILLARY EUUIPMENT.
THIS FIGURE DOES NOT INCLUDE THE E.S.P. OR CONSTRUCTION COSTS. SIPc IS
NOT PLANNING TO UTILIZE FLUE GAS REHEAT AND IS CURRENTLY PLANNING ON
INCORPORATING A CEILCOTE LINING IN THE STACK, NINETY PERCENT OF THE NEC-
ESSARY EQUIPMENT IS ON-SITE AS OF THIS REPORT PERIOD.
I.D. NUMBER 99
SOUTHERN INDIANA GAS4ELECTRIC
A.B. BROWN NO.i
250 MW . NEW
COAL 3.75 PERCENT SULFUR
FMC CORPORATION
DOUBLE ALKALI SCRUBBING
STARTUP 4/79
THIS NEW COAL-FIRED POWER-GENERATING UNIT IS PART OF A NEW GENERATING
STATION LOCATED IN WEST FRANKLIN,INDIANA, THE SYSTEM WILL PRODUCE FIL-
TER CAKES AS A WASTE PRODUCT WHICH WILL BE DISPOSED OF IN AN ONSITE
LANDFILL. A BUELL-ENVIHOTECH ESP WILL CONTROL PARTICULATE
EMISSIONS. THE UTILITY HAS AWARDED A CONTRACT TO FMC FOR THE
INSTALLATION OF A DOUBLE ALKALI SCRUBBING SYSTEM UTILIZING SODA ASH
ANU LIME. FGD SYSTEM CONSTRUCTION IS SCHEDULED TO BEGIN IN THE FALL
OF 1977, START-UP IS SCHEDULED FOR 0<«/79.
I.D. NUMBER 100
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW NO.I
100 MU - NEW
COAL i.o PERCENT SULFUR
RILEY STOKER / ENVIRONEERING
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 SCRUBHING SYSTEM. PARTICULATES WILL BE CONTROLLED 3Y A
HIGH-EFFICIENCY ESP UPSTREAM OF THE SCRUBBING SYSTEM. DESIGN SULFUR
DIOXIDE AND PARTICULATE REMOVAL EFFICIENCIES ARE as AND 99.6 PERCENT,
RESPECTIVELY. SCRUBBER SLUUGE WILL HE STABILIZED WITH FLYASH AND DISPOSED
ON THE PLANT SITE. CONSTRUCTION OF THE SCRUBBING SYSTEM is NOW IN
PROGRESS. ERECTION OF THE ABSORBER TOWERS HAS BEEN COMPLETED.
30
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
COMPANY
TABLE 2
STATUS OF FGC SYSTEMS DURING
06/77
POWER STATION
CURRENT MONTH
1.0. NUMBER 101
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW NO.2
160 MW - NEW
COAL 1.0 PERCENT SULFUR
RILEY STOKER / ENV1RONLERING
LIMESTONE SCRUBBING
STARTUP 6/78
THIS NEW COAL-FIRED UNIT WILL FIRE 1.0 PERCENT SULFUR COAL. A CONTRACT
HAi> BEEN AWARDED TO RILEY STOKER/ENVIRONEERING FOR THE INSTALLATION OF
A WET LIMESTONE SCRUBBING SYSTEM. PARTICULARS 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 SITE. ERECTION OF THE ABSORBER TOWERS IS NOW IN PROGRESS.
I.D. NUMBER 102
SPRINGFIELD CITY UTILITIES
SOUTHWEST NO. 1
200 MW - NEW
COAL 3.5 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP <»/77
THE SCRUBBER BECAME OPERATIONAL ON A TRIAL BASIS IN EARLY APRIL. COMMER-
CIAL OPERATION IS SLATED BY 6/15, THE SYSTEM IS EXPERIENCING DEMlSTER
SCALING AND SOME CONTROL PROBLEMS. ALSO CORROSION OF THE PRESATURATOR
HAS TAKEN PLAcE AND RE-LINING APPEARS NECESSARY. NO DEFINITE EFFICIENCY
TESTS HAVE BEEN MADE AS YET DUE TO THE EFFECTS OF THESE PROBLEMS. THE
TOP PORTION OF THE STACK AND BKEECHING ARE CEILCOTE LINED.
I.D. NUMBER 103
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10A
10 MW - RETROFIT
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
STARTUP <»/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT. THIS
TUKBULENT 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, ANU REPORT WRITER.
I.D. NUMBER 104
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10B
10 MW . RETROFIT
COAL 2.9 PERCENT SULFUR
CHEMICO
LIME/LIMESTONE SCRUBBING
STARTUP i»/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT. THIS
VENTURI/SPRAY TOWER LIML/LIME.STONE. 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 CONTRACTORiTEST DIRECTOR. AND REPORT WHITER.
I.D. NUMBER 105
TENNESSEE VALLEY AUTHORITY
WIDOWS cREEK NO. e
550 MW - RETROFIT
COAL 3.7 PERCENT SULFUR
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
STARTUP 5/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS 550-MW COAL-FIRED POWER-GENERATING
UNIT CONSISTS OF EXISTING ELECTROSTATIC PRE.CIPITATORS FOLLOWED B* FOUR
PARALLEL SCRUBBING TRAINS, EACH CAPABLE OF HANDLING 25 PERCENT OF THE
BOILER FLUE GAS FROM UNIT NO. 8. INITIAL OPERATION OF THE SCRUBBER PLANT
OCCURRED ON MAY 16. FLUE GAS WAS PASSED THROUGH TWO (TRAINS A AND B) OF
THE 14 TRAINS, FLUSHING AND CLEANOUT OF THE REMAINING 2 TRAINS IS STILL IN
PROGRESS. BOILER CAPACITY WAS APPROXIMATELY 50 PERCENT OF FULL LOAD,
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 45246
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING
Ob/77
POWER STATION
CURRENT MONTH
106
1 LIGHT CO.
l.Dt NUMBER
TEXAS POWER
SANOOW NO.V
5<*5 MW - NEW
LIGNITE
LIMESTONE SCRUBBING
STARTUP 7/80
COMBUSTION-ENGINEERING HAS BEEN CHOSEN AS THE BOILER VENDOR FOR THIS 5<*5-
Mw UNIT, B01LLH CONSTRUCTION IS SCHEDULED TO BEGIN IN JULY 1977. THE
UTILITY IS CURRENTLY REQUESTING/EVALUATING BIOS FOR A LIMESTONE THROWAWAY
FGU SYSTEM, PAKTICULATE KLMOVAL IS TO TAKE PLACE ON THE COLO-SIUE OF THE
AIR HEATER. REHEA' PLANS CURRENTLY FAVOK BYPASS OF SOI».E PORTION OF THE
FLUE-GAS. FGD SYSTEM CONSTRUCTION is SCHEDULED FOR JULY 1973.
I.D. NUMBER 107
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 1
750 MW - NE.W
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 6/63
THIS UNIT WILL BE JOINTLY -OWNED BY TPftL AND ALCOA. A FIRM DECISION HAS
NOT BEEN MADE WHETHER TO INSTALL FGD FACILITIES. THIS is PRIMARILY
DUE TO THE FACT THAT SUCH A DECISION IS NOT YET REQUIRED IN THE
UTILITIES PLANNING TIMETABLE.
I.D. NUMBER 106
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 2
750 MW • NEW
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 9/8H
THIS UNIT WILL BE JOINTLY OwNED BY TPSL AND ALCOA. A FIRM DECISION HAS
NOT BEEN MADE WHETHER TO INSTALL FGD FACILITIES. THIS is PRIMARILY
DUE TO THE FACT THAT SUCH A DECISION is NOT YET REQUIRED IN THE
UTILITIES PLANNING TIMETABLE.
I.D. NUMBER 109
TEXAS UTILITIES
FOREST GROVE NO.
750 MW - NEW
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 0/Bl
TEXAS UTILITIES REPORTED THAT A NEW 750-MW LIGNITE-FIRED UNIT IS IN
THE EARLY PLANNING STAliE FOR THE FOREST GROVE STATION IN ATHENS* TEXAS.
START-UP is SCHEDULED FOR LATE 1951. THE BOILER WILL BE SUPPLIED
BY THE BABCOCK * WlLCOX COMPANY.
I.D. NUMBER 110
TEXAS UTILITIES CO.
MARTIN LAKE NO. i
793 MW - NEW
COAL 1.0 PERCENT SuLFuR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 10/77
THE CONTRACT FOR THIS FGO SYSTEM WAS AWARDED TO RESEARCH.COTTRELL, THIS
NEW FACILITY IS NOW UNDER CONSTRUCTION, THE FGU SYSTEM STARTUP DATE IS
NOW SCHEDULED FOR OCTOBER 1977. PARTICULATE REMOVAL WILL BE EFFECTED
BY A RESEARCH-COTTRELL COLD-SIDE E5>n. SULFUR DIOXIDE EMISSIONS WILL
BE CONTROLLED TO COMPLY WITH NSPS,
32
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
Ob/77
CURRENT MONTH
I.D. NUMBER 111
TEXAS UTILITIES CO.
MARTIN LAKE NO. 2
793 MW - NEW
COAL i.o PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 2/78
THE CONTRACT FOR THIS f-l»D SYSTEM WAS AWARDED TO RESEARCH-COTTRELL. THIS
NEW FACILITY IS NOW UNDER CONSTRUCTION. THE FGO SYSTt* STARTUP DATE IS
NOW SCHEDULED FOR THE FIRST QUARTER OF 1978.
I.D. NUMBER 112
TEXAS UTILITIES CO.
MARTIN LAKE NO. 3
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 12/78
THL CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO RESEARCH-COTTRELL.
THE BOILER IS NOW BEING ERLCTE.D. START-UP IS SCHEDULED FOH DECEMBER
1978.
I.D. NUMBER 113
TEXAS UTILITIES co.
MARTIN LAKE NO. H
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 11/82
THE CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO RESEARCH-COTTRELL.
THE BOILER IS NOW BEING ERECTED. START-UP IS SCHEDULED FOR THE FOURTH
QUARTER OF 1962.
I.D. NUMBER 114
TEXAS UTILITIES CO.
MONTICELLO NO.3
750 MW - NEW
LIGNITE 1.0 PERCENT SULFUR
CHEMICO
LIMESTONE SCRUBBING
STARTUP 2/78
THIS NEW STEAM BOILER WILL FIRE LOW SULFUR (0.6 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 SPRAY TOwERS. THE ESP IS A COLD-SIDE UNIT SUPPLIED By POL-
LUTION CONTROL-WALTHER. DESIGN PARTICULATE AND SULFUR DIOXIDE REMOVAL
EFUCIENCY WILL ENABLE THIS UNIT TO MEET NSPS. START-UP IS SCHEDULED
FOK THE FIRST QUARTER OF 1978.
I.D. NUMBER 115
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
5<*5 MM . NEW
LIGNITE - 0.63 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 11/78
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
H SPRAY TOWER ABSORBER MODULES FOR REMOVING S02 FROM THE FLUE GAS.
ELECTROSTATIC PRECIPITATORS WILL BE INSTALLED UPSTREAM OF EACH SCRUBBING
SYSTEM. THE UTILITY IS PLANNING TO COMMENCE FGD CONSTRUCTION BY JULY 1.
1977.
33
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING 06/77
POWER STATION
CURRENT MONTH
I.D, NUMBER 116
UNITED POWER ASSOCIATION
COAL CREEK MO. 2
51*5 MW . NEW
LIGNITE - 0.63 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME 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
t SPRAY TOWER ABSORBER MODULES FOR 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 EACH UNIT. FGD CONSTRUCTION IS SCHEDULED TO COMMENCE 0«»/78
I.D. NUMBER 117
UTAH POWER 8 LIGHT CO.
EMERY NO.I
400 MW - NEW
COAL 0.5 PERCENT SuLFUR
CHEMICO
LIME SCRUBBING
STARTUP 6/78
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 ao PEKCENT FOR LOW SULFUR UTAH COAL. PRIMARY
PARTICuLATE CONTROL wILL BE PROVIDED BY AN ESP yPSTREAM OF THE SCRuBBERS
THE SCRUBBER SLUDGE WILL BE STABILIZED WITH FLYASH AND DISPOSED ON THE '
PLANT SITE. THE A-E DESIGN FIRM >-OR THIS PROJECT is STEARNS-KOGER.
CONSTRUCTION IS UNDERWAY ON THE FGD SYSTEM FOR THIS UNIT.
1.0. NUMBER 118
UTAH POWER > LIGHT CO.
HUNTINGTON NO.l
415 MW - NEW
COAL 0.5 PERCENT SuLFuR
CHEMICO
LIME SCRUBBING
STARTUP 12/77
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. LATE DELIVERY OF EQUIPMENT HAS SLOWED CONSTRUCTION
ANU START-UP IS NOW SET FOK LATE DECEMBER 1977.
I.D. NUMBER 119
WISCONSIN POWER i LIGHT CO.
COLUMBIA NO. 2
527 MW . NEW
COAL o.a PERCENT SULFUR
CHEMICO
LIME/ALKALINE FLYASH
STARTUP 1/80
A LETTER OF INTENT HAS BEEN ISSUED TO CHEMICO FOR A LIME/FLYflSH FGD SYS-
TEM. IT WILL CONSIST OF TWO SPRAY MODULES WITH A HOT-SIDE ESP FOR PAR-
TICULATE REMOVAL. A CLOSED L'OOP WATER SYSTEM IS ANTICIPATED WITH FLYASH
STABILIZATION OF THE SLUDGE. A SLUDGE DISPOSAL POND IS TO BE LOCATED ON.
SITE. THE SCRUBBERS ARE BEING DESIGNED TO TREAT 60 PERCENT OF THE FLUE
GAi RESULTING FROM THE COMBUSTION OF LOW SULFUR COLSTKIP COAL. THr RE-
MAINING HO PERCENT WILL BE BYPASSED FOR REHEAT.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 3
SUMMARY LIST OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
35
-------
3b
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 3
SUMMARY LIST OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
FGD STATUS REPORT 06/77
I.D. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
1 GENERAL PUBLIC UTILITIES
2 GENERAL PUBLIC UTILITIES
3 GULF POWEK COt
14 GULF POWER CO.
5 GULF POWER CO.
6 KENTUCKY UTILITIES
7 POTOMAC ELECTRIC « POWER
6 POTOMAC ELECTRIC S POWER
9 POWER AUTHORITY OF NEW YORK
10 SALT RIVER PROJECT
11 SALT RIVER PROJECT
12 SALT RIVER PROJECT
13 SPRINGFIELD WATER L1GHTJPOWER
m VIRGINIA ELECTRIC AND POWER CO
COHO NO.l
SEWARD NO.7
CKIST NO. t AND NO.
CKIST NO. 6 AND NO.
LANSING SMITH NO. 1
GHENT NO. 2
CHALK POINT NO. 4
D1CKERSON NO. 4
AKTHUR KILL
NAVAJO NO 1
NAVAJO NO 2
NAVAJO NO 3
DALLMAN NO. 3
MT. STORM
ERIE PENNSYLVANIA 5-87 7
SEWARD PENNSYLVANIA 5-81 7
5 PENSACOLA FLORIDA 0-78 7
7 PENSACOLA FLORIDA 0-80 7
AND NO. 2 PANAMA CITY FLORIDA 0-80 7
GHENT KENTUCKY o- o 7
PRINCE GEORGE COUNTY MARYLAND 0-80 7
DICKERSON MARYLAND 5-ez 7
STATEN ISLAND NEW YORK 9-82 7
PAGE ARIZONA 0-07
PAGE ARIZONA 0-0 7
PAGE ARIZONA 0-0 7
SPKINGFIELD ILLINOIS 6-78 7
MT. STORM WEST VIRGINIA 0-0 7
A
A
B
B
B
E
D
0
B
0
U
0
A
C
7. CONSIDERING FGO SYSTEM AS WELL AS ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEDEKAL 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
0. OTHER
E. REGULATORY CLASS UNKNOWN
37
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
38
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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TABLE «t
STATUS OF FGO SYSTEMS IN THE EARLY PLANNING STAGES
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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PEDCo ENVIRONMENTAL
CINCINNATI. OHIO -452-46
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COMPANY
POWER STATION
TABLE f
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING Ob/77
CURRENT MONTH
1.0. NUMBER 1
GENERAL PUBLIC UTILITIES
COHO NO.l
600 MM - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 5/87
STARTUP DATE CHANGED TO 5/87 FOR BOTH BOILER AND FGO SYSTEM. LIME, LIME-
STONE SCRUBBING, AND COAL ULSULFUKIZATION A«E THE PRIMARY PROCESSES BEING
CONSIDERED. NO DECISION HAS BEEN MADE YET.
1.0. NUMBER 2
GENERAL PUBLIC UTILITIES
SEWARD NO.7
BOO Mb - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 5/8«*
STARTUP DATE CHANGED TO b/8<4 FOR BOTH BOILER AND FGD SYSTEM.
LIMESTONE SCRUBBING, AND COAL DESULFURIZATION ARE THE PRIMARY PROCESSES
BEING CONSIDERED. NO DECISION HAS BEEN MADE YET.
I.D. NUMBER 9
GULF POWER CO.
CRIST NO. H AND NO* 5
150 MW - RETROFIT
NOT SELECTED
NOT SELECTED
STARTUP 0/76
EACH UNIT IS 75 MW.
1978.
IF SCRUBBERS ARE SELECTED THEY HILL BE REQUIRED IN
I.D. NUMBER H
GULF POWER CO.
CRIST NO. 6 AND NO. 7
820 MW - RETROFIT
NOT SELECTED
NOT SELECTED
STARTUP 0/80
UNIT 6 IS 320 MW. UNIT 7 IS 500 MW.
I.D. NUMBER 5
GULF POWER CO.
LANSING SMITH NO. 1 AND NO.
305 MW - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP 0/80
UNIT NO. 1 IS 125 MW. UNIT NO. 2 IS 180 MW. IF SCRUBBERS ARE SELECTED.
THEY WILL BE REOUIKLD IN 1979 AND I960 ON THE RESPECTIVE UNITS.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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COMPANY
POWER STATION
TABLE <»
STATUS OF FSO SYSTEMS IN THE EARLY PLANNING STAGES DURING
CURRENT MONTH
06/77
1.0. 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-FIRED POWER BOILER WAS SUPPLIED BY COMBUSTION
ENGINEERING AND IS SCHEDULED TO COMMENCE COMMERCIAL
OPERATIONIN J1977. 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 UMTS.
I.D. NUMBER 7
POTOMAC ELECTRIC £ POWER
CHALK POINT NO. <*
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 PEABOOY-LURGI 2-STAGE VENTURI SCRUBBERS FOR PA«-
TICULATE CONTROL. COMPANY MAY ELECT NOT TO INSTALL FGD SYSTEM IF USE OF
LOW SULFUR OIL IS CONTINUED.
I.D. NUMBER 6
POTOMAC ELECTRIC & POWER
DICKERSON NO. t
800 MW • NEW
COAL 2.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 5/82
THERE ARE NO FIRM PLANS FOR INSTALLATION OF FGD SYSTEM.
BOILER IS PLANNED FOR 1982.
STARTUP DATE OF
1.0. NUMBER 9
POWER AUTHORITY OF NEW YORK
ARTHUR KILL
700 MW - NEW
COAL - 3* SULFUR - REFUSE
NOT SELECTED
NOT SELECTED
STARTUP 9/82
THE UTILITY IS CONSIDERING BOTH REGENERABLE AND LIMESTONE SCRUBBING
PROCESSES. FGO TECHNOLOGY IS BEING CONSIDERED FOR A FOSSIL FUEL BURNING
UNIT WHICH WILL EMPLOY COAL AS THE PRIMARY FUEL AND OIL AS BACKUP. REFUSE
WILL BE PROVIDED FOR SUPPLEMENTAL FUEL SUPPLIES. THE PREFERRED PLANT SITE
IS THE ARTHUR KILL FACILITY LOCATED ON STATEN ISLAND. THE PROJECT DESIGN
ENGINEERING FIRM IS SARGENT AND LUNDY.
I.D. NUMBER 10
SALT RIVEK PROJECT
NjrtfftdO- no i
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
DESULFURIZATION PROCESSES. A DEFINITIVE DECISION WILL-BE MADE PENDING
COMPLETION OF THE SRP/t-PA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPECIFIED. THE CONTRACT FOR THL ESP HAS BEEN AWARDED TO JOY/WESTERN
PRECIPITATION DIVISION.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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COMPANY
TABLE <»
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING
06/77
POWER STATION
CURRENT MONTH
I.D. NUMBER 11
SALT RIVEH PROJECT
NAVAJO NO 2
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
DEiULFURIZATION PROCESSES. A DEFINITIVE DECISION WILL BE lAOE PENDING
COMPLETION OF THE SRP/E.PA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPLCIFItl). THt CONTRACT FOR THE ESP HAS BLEN AWARDED TO JOY/WESTERN
PRECIPITATION DIVISION.
I.D. NUMBER 12
SALT RIVER PROJECT
NAVAJO NO $
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
OESULFUR1ZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THL SHP/EPA STiJDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPLCIFIED. THE CONTRACT FOR THE ESP HAS BEEN AWARDED TO JOY/WESTERN
PRECIPITATION DIVISION.
1.0. NUMBER 13
SPRINGFIELD WATER LIGHTSPOWER
DALLMAN NO. 3
190 Mw - NEW
COAL 3.0-i».3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 6/78
F6U SYSTEM IS UNQEK CONSIDERATION WITH BOTH REGENERABLE AND LIMESTONE
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. BOILER START-UP HAS BEEN
MOVED UP TO 06/78.
I.D. NUMBER m
VIRGINIA ELECTRIC AND POWER CO
MT. STORM
11H7 MW - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THE UTILITY IS PRESENTLY CONSIDERING BOTH DESULFURIZATION AND THE USE OF
LOW SULFUR COAL. A DESULFURIZATION SYSTEM WOULD TREAT 69 PERCENT OF THE
FLUE GAS FROM THREE BOILERS. CONSTRUCTION AND STARTUP DATES ARE CON-
SIoERED INDEFINITE AT THIS TIME.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 452.46
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<*"*
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
1*6
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
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
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
JOSEPH CITY ARIZONA
115 MW
COAL O.HH-1 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RETROFIT
10/73
OPERATIONAL
99.7 PERCENT
S02
58.5 PERCENT
WATER MAKE UP
OPEN LOOP 1.01 GPH/nu
SLUUGE DISPOSAL
UNSTABILIZED SLUDGE DISPOSED IN UNLINED
UNIT COST
S57/KU CAPITAL * 2.2 MILLS/KWH ANNUALIZED
OPERATIONAL
EXPERIENCE
THE BOILER OPERATED 91.81 OF THE TIME IN THE PERIOD INCLUDING MARCH,
APRIL, & MAY. AVERA6L OPERABILITIES OF THE A-SIDE AND B-SIDE SCRUBBERS
HERE 89.H AND 96.6 PERCENT, RESPECTIVELY. AVERAGE RELIABILITIES OF THE
TWO SCRUBBERS FOR THE SAME PERIOD WERE 66.<» AND 93.5 PERCENT, RESPEC-
TIVELY. OUTAGES HERE REQUIRED FOR MID-YEAR CLEANING AND SOME: MINOR REPAIR
WORK, RESEARCH-COTTRELL PERSONNEL ARE CURRENTLY CONDUCTING TESTS AT THIS
PLANT TO OBSERVE THE EFFECTS OF FOKCED SULFITE-TO-SULFATE OXIDATION
ON THE SCRUBBEH PROCESS.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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BACKGROUND INFORMATION
ON
CHOLLA NO.l
THE CHOLLA POWER STATIONt 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 DURINB THE COURSE OF 1975 ARE* HEAT CONTENT OF 10,150 BTU/LB* ASH CONTENT OF 13.U5 PERCENT*
SULFUR CONTENT OF 0.52 PERCENT* CHLORIDE OF 0.0<* PERCENT (MAX.)* AND MOISTURE CONTENT OF 1«*.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 DIOXIDE 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 2<»0,000 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 (FDS) FOLLOWED BY A PACKED
TOWER (MUNTERS 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
i».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 THKEE TUBE BUNDLES PER UNIT.
LIMESTONE FOR THE FGD 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 OXIOE CONTENT, 52 PERCENT* MINIMUM CALCIUM CARBONATE CONTENT,
95 PERCENT* MAXIMUM MAGNESIUM OXIOE CONTENT, 2 PERCENT* MAXIMUM MAGNESIUM CARBONATE CONTENT. 0.5 PERCENT* MAXIMUM SILICA CONTENT.
1 PERCENT.
THE PLANT HAS NO SLUDGE TREATMENT OK 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 APPENDIX B.
"48
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO .45346
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CHOLLA NO. 1 (CONTINUED)
PROBLEMS AND SOLUTIONS
DECEMBER. 1973 TO APRIL 2, 197"» - BECAUSE OF A DIFFERENCE IN THE SIZE OF THE MAIN DUCT AND REHEATER TRANSITION DUCT, THE GAS
FLOW PRODUCED HARMONIC VIBRATION*, IN THE REHEATEK. 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 WAS INSULATED. THE ACID CONDENSATION OCCURRED ONLY IN THE B-MOOULE WHICH CONTAINS NO INTERNAL PACKING AND THEREFORE HAS
A LOWER DEGREE OF SULFUR DIOXIDE REMOVAL (25 PERCENT).
ANOTHER PROBLLM RESULTED BECAUSE OF SOLIDS BUILDUP IN THE FDS 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, THE PACKING GLAND
POSITION WAS REVERSED (INSTALLED UPSIDE UOWN>. 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 WALLS OF THE FLOODED-DISC 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 ELIMINATOK* EROSION IN THE PUMPS* CORROSION IN THE BOILER EXHAUST ELBOW OF THE DUCTWORK LEADING FROM THE SCRUBBERS TO THE
STACK. ADDITIONAL INFORMATION AND DATA ON THE PERFORMANCE OF THE CHOLLA FGD SYSTEM ARE PROVIDED IN THE TABLE THAT FOLLOWS.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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FGD SYSTEM RELIABILITY
CHOLLA UNIT NO. 1
RELIABILITY (X)
MONTH
JAN. 7<»
FEB. 74
MAR. 74
APR. 74
MAY 74
JUN. 74
JUL. 74
AUG. 74
SEP. 74
OCT. 74
NOV. 74
DEC. 74
JAN. 75
FEB. 75
MAR. 75
APR. 75
MAY 75
JUN. 75
MODULE A
97
100
100
66
98
100
97
97
95
83
100
100
98
96
68
48
100
MODULE
90
94
66
57
99
100
92
97
99
68
98
100
99
99
65
40
100
COMMENTS
ANNUAL BOILER AND FGD SYSTEM OVERHAUL.
MODULES HERE BOTH OFF-LINE FOR MOST OF MONTH FOR SCHEDULED REPAIRS AND CLEANING.
SUBSTANTIAL PLUGGING IN THE TOWER PACKING (A-SIDE) AND MIST ELIMINATORS WAS OBSERVED.
NO OTHER MAJOR PROBLEMS WERE ENCOUNTERED DURING THE PERIOD.
JUL. 75 97 96 MODULES WERE SHUT DOWN TO CLEAN FLOW RESTRICTIONS IN FLOOOED-DISC REC1RCULATION
LINES,
AUG. 75 95 100 MODULE A WAS DOWN FOR INSPECTION ONE TIME.
50
PEDCo ENVIRONMENTAL
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FGO SYSTEM RELIABILITY
CHOLLA UNIT NO. 1 (CONTINUED)
RELIABILITY (X)
MONTH MODULE A MODULE B COMMENTS
SEP. 75 98 97 MINOR OUTAGE DUE TO FLOOOED-OISC LINES.
OCT. 75 6<» 55 OUTAGES RESULTED FROM SCHEDULED E8UIPMENT OVERHAULS AND RECOATING OF VESSELS.
NOV. 75 100 80 NO MAJOR OUTAGES OR PROBLEMS OCCURRED DURING THE REPORT PERIOD. MINOR PROBLEMS
DEC. 75 100 100 ENCOUNTERED INCLUDED RECYCLE PUMP REBUILDING AND MALFUNCTIONING OF THE B-SIDE
REHEATER COIL.
JAN. 76 99 99 MODULE A OPERATED 715 HOURS DURING THE REPORT MONTH, AND MODULE B OPERATED 65t HOURS.
MODULE A EXPERIENCED SOME MINOR VALVE AND LINE PLUGGING. MODULE B OPERATING HOURS
WERE LOWER BECAUSE OF REDUCED SYSTEM REQUIREMENTS.
FEB. 76
MAR. 76
APR. 76 99 98 THE UNIT IS CURRENTLY EXPERIENCING COATING FAILURES IN THE ELBOW OF THE SCRUBBER
EXHAUST DUCT. ALSO, THE UTILITY PERFORMED SOME MINOR REPAIRS TO THE HOUSING OF THE
B-SIDE REHEATER.
MAY 76 76 100 DURING THE MONTH THE A-SIDE EXPERIENCED SOME CORROSION AND PLUGGING PROBLEMS IN THE
REHEATER TUBES. IN ADDITION TO PLUGGED FDS LINES, PACKING AND OEMISTERS, THE UTILITY
ALSO REPORTED NORMAL HEAVY PUMP MAINTENANCE.
JUN. 76 64 39 LOW RELIABILITY FACTORS FOR THE MONTH OF JUNE RESULTED FROM A SCHEDULED MID-YEAR
SCRUBBER SHUTDOWN FOR MAINTENANCE, INSPECTION AND REPAIRS. SOME SCALING AND CORRO-
SION PROBLEMS WERE UNCOVERED IN THE SYSTEM'S RECYCLE TANKS.
bl
PEDCo ENVIRONMENTAL
CINCINNATI OHIO 45246
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FGD SYSTEM RELIABILITY
CHOLLA UNIT NO. 1 (CONTINUED)
RELIABILITY <*)
MONTH MODULE A MODULE B COMMENTS
JUL. 76 100 96 DURING THE JULY-AUGUST PERIOD THE UTILITY REPORTED THAT REPAIRS TO THE COATING IN THE
AUG. 76 100 100 ELBOW OF THE SCRUBBER EXHAUST DUCT WERE COMPLETED. A MALFUNCTIONING SOLENOID VALVE
IN THE DEMISTER WASH SYSTEM OF THE B-SIDE TRAIN, PREVENTING ADEQUATE WASHING OF
THE DEMISTERt RESULTED IN A MINOR SCRUBBER OUTAGE.
SEP. 76 100 100 THE BOILER REMAINED IN SERVICE THE ENTIRE MONTH. A-SIDE SERVICE TIME WAS 720 HOURS.
B-SIDE SERVICE TIME WAS 676 HOURS. NO OTHER SIGNIFICANT PROBLEMS WERE REPORTED.
OCT. 76 56 56 THE BOILER WAS IN SERVICE <»17 HQUKS DURING THE MONTH. A-SIDE AND B-SIDE OPERATIONAL
HOURS WERE <»15 AND 277 RESPECTIVELY.
NOV. 76 96 96 DURING THE MONTH THE BOILER.A-SIDE.AND B-SIDE TRAINS WERE IN SERVICE 720. 662 AND 556
HOURS, RESPECTIVELY. TWO MINOR FORCED SCRUBBER OUTAGES OCCURRED DURING THE PERIOD
DUE TO A REHEATER STEAM LEAK AND INLET GAS DAMPER ADJUSTMENTS TO BOTH THE A-SIDE
AND B-SIDE SCRUBBING TRAINS.
DEC. 76 98 100 BOILER, A-SIDE. AND B-SIDE OPERATION HOURS FOR THE MONTH WERE 7<*», 7<»2 AND H9B HOURS,
RESPECTIVELY. ONE OUTAGE WAS REPORTED BECAUSE OF AN ADDITIONAL ADJUSTMENT TO THE
A-SIDE GAS INLET DAMPER.
NOTE* THE PERFORMANCE INDEX VALVES CONTAINED IN THE TEXT OF THIS TABLE ARE BASED UPON
THE MODULES' ACTUAL SERVICE FOR A GIVEN PERIOD VERSUS THE NUMBER OF HOURS THE
MODULES ARE CALLED UPON TO OPERATE FOR THE SAME PERIOD. THE SCRUBBERS OPERATE ON A
DEMAND-ONLY BASIS. FLUE GAS IS BY-PASSED AROUND THE MODULES WHEN THEY A"E NOT
REQUIRED FOR SERVICE (SEE DEFINITION OF RELIABILITY INDEX IN DEFINITIONS APPENDIX).
52
PEDCo ENVIRONMENTAL
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FGD SYSTEM RELIABILITY
CHOLLA UNIT NO. 1 (CONTINUED)
RELIABILITY <*»
MONTH MODULE. A MODULE B COMMENTS
JAN. 77 72 93 SERVICE HOURS FOR JANUARY* BOILER = 7
-------
TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
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
25
COLUMBUS I SOUTHERN OHIO ELEC.
CONESV1LLE NO 5
CONESVILLE OHIO
400 MW
COAL «*.5 - 4.9 PERCENT SuLFuR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
NEW
2/77
OPERATIONAL
99.6 PERCENT
S02
89.5 PERCENT
WATER MAKE UP
SLUUGE DISPOSAL
STABILIZEU SLUDGE DISPOSED IN UNLINED PONQ
UNIT COST
*15.27 MILLION CAPITAL * 5.6! MILLS/KWH OPERATING
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE BOILER AND ESP WERE COMPLETED AND PLACED IN SERVICE IN SEPT. 1976.
THE B-SIDE MODULE BECAME AVAILABLE FOR SERVICE IN JANUARY 1977.
COMMERCIAL OPEKATIONS WERE ACHIEVED ON FEBRUARY 13. 1977. THE EMISSION
CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A COLU-SIDE ESP FOLLOWED BY
TWO TCA LIME SCRUBBING MODULES SUPPLIED BY UOP. DRAVO IS SUPPLYING THE
TH10SOHBIC LlML SCKUBBlNG REAGENT. IUCS IS SUPPLYING THEIR POZ-0-T£C
SLUDGE STABILIZATION FACILITY. B-SIDE STARTUP IS SCHEDULED FOR JAN. 1978.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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BACKGROUND INFORMATION
ON
CONESVILLE NO. 5
THE CONESVILLE POWER STATlOf. IS LOCATED ON THE MUSKINGUM RjVEK, APPROXIMATELY 7«»0 FEET ABOVE SEALEVELt NEAR COSHOCTON, IN
NORTHEAST OHIO. THE PLANT HAS A CURRENT CAPACITY OF 16
-------
CONESVILLE NO. 5 (CONTINUED)
OP 90 TO 95 PERCENT. THE LINE SLAKER DISCHARGED THE 20 PERCENT SOLIDS SLURRY INTO AN AGITATED LIME SLURRY SUMP WHERE IT IS RE-
TAINED FOR A 5-MINUTE PERIOD PRIOR TO TRANSFER TO THE LIME SLURRY STORAGE TANK, WHICH HANDLES THE SURGE REQUIREMENTS OF THE AB-
SORPTION SYSTEM. THE TRANSFER OF SLURRY FROM THE STORAGE TANK TO THE TCA RECYCLE TANKS IS ACCOMPLISHED 8Y VARIABLE SPEED PUMPS
WHICH RESPOND TO CHANGING S02 AND LOAD CONDITIONS VIA A PH MONITOR. THE SCRUBBING LIQUOR CONTAINS ABOUT 7 TO 12 PERCENT SOLIDS.
THE ABSORBENT LIOUOR IS RECIRCULATED BY t PUMPS (1 STANDBY) EACH RATED AT 12.000 GPM. SCRUBBER OUTLET PH IS 5.8, AND PH IN THE
RECYCLE TANK IS APPROXIMATELY 6.6.
A BLEED STREAM OF SPENT REACTION PRODUCTS IS CONTINUOUSLY WITHDRAWN FROM THE TANK PUMPED TO THE THICKENER SYSTEM. THE
THICKENER IS 100 FT IN DIAMETER AND 1<* FT DEEP IN THE CENTER. HERE THE REACTION PRODUCT SLURRY IS CONCENTRATED TO AN UNDERFLOW
COMPOSITION OF APPROXIMATELY <»0 PERCENT SOLIDS. THIS UNDERFLOW IS CYCLED TO THE IUCS FIXATION FACILITIES WHERE IT IS FURTHER
THICKENED, VACUUM FILTERED AND MIXED WITH A BLEND OF DRY FLY ASH AND LIME TO FORM A 73 PERCENT SOLIDS SUBSTANCE (IUCS P02-0-TEC).
THE PRODUCT IS BEING CYCLED TO A 3500 ACRE-FOOT DIKED POND, SCHEDULED TO BE ADEQUATE FOR 5 YEARS OF OPERATIONS.
THE WASTE WATER POND, WHICH WILL RECEIVE THE ASH WATER. COOLING WATER BLOWNDOWN AND WATER FROM THE SLUDGE TREATMENT PLANT
IS EXPECTED TO OVERFLOW INTO THE MUSKlNGUM RlVER DURING LOW LOAD PERIODS AND CANNOT, THEREFORE DURING THESE PERIODS, THE SYSTEM
WILL NOT BE CLOSED LOOP. HOWEVER, AT HIGH LOAD PERIODS, THE INCREASED DEMAND FOR POND WATER IS EXPECTED TO RENDER THE SYSTEM
CLOSED LOOP.
REFER TO APPENDIX B FOR A GENERAL PROCESS FLOW DIAGRAM.
56
PEDCo ENVIRONMENTAL
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MONTH/YR
DEC. 76
MODULE
AVAILABILITY
(PEHCLNT)
A B
MODULE
OPERABILITY
(PERCcM)
A B
JAN. 77
FEB. 77
OPERATING HISTORY
CONESVILLE NO. 5
COMMENTS
soz REMOVAL OPERATIONS WERE SCHEDULED TO COMMENCE IN DECEMBER.
HOWEVER A MAJOR FIRE IN MODULE N0.5A DELAYED START-UP.
THE FIRE CAUSED $2.1 MILLION DAMAGE TO THE MODULE. THE UTILITY'S
INSURANCE COVERED THE DAMAGE AND A NEW SCRUBBER MODULE WILL BE
PURCHASED FROM AND INSTALLED BY U.O.P. THE 5A MODULE IS SCHEDULED
TO COMMENCE OPERATIONS IN JULY 1977.
THE UTILITY IS CURRENTLY OPERATING AIR AND WATER TESTS ON MODULE SB
AND SCRUBBING OPERATIONS WITH SB ARE NOW SCHEDULED FOR JANUARY.
INITIAL START-UP FOR DEBUGGING AND COMMISSIONING PURPOSES OCCURRED
IN EARLY JANUARY. EARLY OPERATIONS WERE MARKED BY COLO WEATHER-RELATED
PROBLEMS SUCH AS FROZEN LINES AND GEARSt CRACKED FLANGES. A FROZEN
LIME BELT CONVEYER. AND A FROZEN PIPELINE FROM THE THICKENER TO THE
IUCS FACILITY. COMMEKClAL AVAILABILITY FOR SERVICE OCCURRED ON JAN-
UARY 27. NO JANUARY OPERATING HOURS ARE AVAILABLE.
COMMERCIAL START-UP OF MODULE SB ACHIEVED ON FEBRUARY 13. 1977.
AFTER START-UP, THE SCRUBBER LOGGED 286 HOURS OF OPERATION. THE
LONGEST PERIOD OF CONTINUOUS OPERATION WAS 132 HOURS. THE BOILER LOG-
GED 668 HOURS DURING FEBRUARY. PROBLEMS INCLUDED PRESSURE SURGES
IN THE PRESATURATOR PIPING LINE. UNSATISFACTORY OPERATION OF THE
CONTINUOUS S02 ANALYZERS. POOR VELOCITY DISTRIBUTION THROUGH THE TCA
BEDS. AND CARRYOVER OF SCRUBBING LIQUID INTO THE MIST ELIMINATOR SECTION.
THE ESP IS REPORTED TO BE OPERATING SATISFACTORILY. COMPLIANCE TESTING
FOR THIS UNIT IS SCHEDULED FOR MAY 1977.
PEDCo ENVIRONMENTAL
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CONESVILLE NO. 5 (CONTINUED)
OPERATION TIME (HR)
PERIOD BOILER fl-SIDE B-SIDE
APR. 77 685 261
AVAILABILITY = <»2 PERCENT
OPERABILITY = 38 PERCENT
RELIABILITY = i»0 PERCENT
UTILIZATION r 37 PERCENT
HAY 77 712 355
AVAILABILITY = 58 PERCENT
OPERABILITY = 50 PERCENT
RELIABILITY = 51 PERCENT
UTILIZATION = 50 PERCENT
COMMENTS
THE UTILITY REPORTED A NUMBER OF PROBLEM AREAS REGARDING SCRUBBER OPERATIONS
DURING THE REPORT PERIOD. SPECIFICALLY. SOME CORROSION HAS BEEN REPORTED IN THE
PRESATURATOR AREA <3l6 SS CONSTRUCTION!, THE RUBBER LINER IN THE RECYCLE TANK IS
PEELING OFF (PROBABLY AN APPLICATION PROBLEM), SOME PLUGGING IN THE TUBE
THICKENERS HAS OCCURRED, AND THE QUALITY OF THE LIME SUPPLY HAS BEEN A REAL
PROBLEM AREA (ROCKS UP TO FIVE INCHES IN DIAMETER HAVE BEEN DETECTED!. THE
LATTER ITEM HAS PROMPTED DRftVO TO INSTALL MECHANICAL SEPARATORS AND METAL
DETECTORS AT THE LIME SHIPMENT FACILITY. A STACK OUTLET TEMPERATURE OF 200F IS
BEING MAINTAINED IN ORDER TO MINIMIZE ACID RAINOUT AND STACK CORROSION PROBLEMS.
56
PEDCo ENVIRONMENTAL
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFIClENCYt
PARTICULARS
SO
COMMONWEALTH EDISON
HILL COUNTY NO 1
ROMEOVILLE ILLINOIS
167 HW
COAL "».0 PERCENT SULFUR
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
RETROFIT
2/72
OPERATIONAL
98 PERCENT
S02
62 PERCENT
WATER MAKE UP
OPEN LOOP 1.66 GPM/MW
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
STABILIZED SLUDGE DISPOSED IN HAULAWAY TO LANDFILL
S113/KW CAPITAL * 13 MILLS PER KUH OPERATING
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 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 PARTItULATES ANU SULFUR DIOXIDE. MODULE AVAILABILITY,
OPERABILITY, RELIABILITY. AND UTILIZATION INDEX VALUES FOR THE REPORT
PERIOD ARE PROVIDED IN TABLE 5. A SLUDGE. STUDY, CONDUCTED BY UOP, AND A
MAGNESIUM INNOCULATION AND FORCED OXIDATION STUDY, CONDUCTED BY THE
UTILITY, WERE COMPLETED DURING THE REPORT PERIOD.
PEDCo ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
WILL COUNTY NO. 1
IN 1970. 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 A'MD BlO 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 98 PERCENT QF 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
-------
WILL COUNTY (CONTINUED)
SLUDGE FROM THE SYSTEM IS SENT TO A CLARIFIER. THE OVERFLOW IS HETURNED TO THE PROCESS AND THE UNDERFLOW IS STABILIZED BY MIXING
IT WITH LIME AND FLY ASH. APPROXIMATELY 200 POUNDS OF LIME AND tOO POUNDS OF FLY ASH ARE USED PER TON OF DRY SOLIDS OF SLUDGE.
THE SLUDGE IS STABILIZED IN AND TRANSPORTED BY CONCRETE MIXING TRUCKS FOR ULTIMATE DISPOSAL IN AN OFF-SITE DISPOSAL
AREA.
PROBLEMS AND SOLUTIONS
1972 - DEHISTER PLUGGING WAS A CONSTANT PROBLEM, MAINLY BECAUSE OF HEAVY LIMESTONE ACCUMULATION ON THE BOTTOM OF THE DEMISTER
AND ALSO BECAUSE OF LOW WASH-WATER PRESSURE CAUSED BY LEAKS IN THE POND RETURN 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' 1972* 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 PARTIALLT, 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 DEMISTER ON MODULE B BROKE LOOSE FROM ITS MOUNTINGS AND THE RESULTANT
CARRYOVER OF WASHWATER PLUGGED THE REHEATER. THIS REHEATER ALSO LEAKED BECAUSE OF CHLORIDE PITTING CORROSION. MODULE A WAS DOWN
FROM APRIL 21* TO MAY 2H« 1973, AND MODULE B REMAINED OUT OF SERVICE FROM MAY 1973 TO MAY 20, 1975. THERE WAS NO SCRUBBER OPERA
TION FROM AUGUST 27 TO SEPTEMBER 26. 1973.
IN EFFORTS TO SOLVE THE DEMISTER AND REHEATER PROBLEMS,A CONSTANT UNOERSPRAY AND INTERMITTENT OVERSPRAY WERE USED TO WASH ALL
THE DEMISTER COMPARTMENTS OF MODULE A. EXTRA NOZZLES WERE ADDED AND A CLEAN WATER SUPPLY WAS MAINTAINED. THE REHEATER UNIT UAS
ALSO RETUBED.
197i» - ONLY MODULE A OPERATED DURING 197<». THE MAIN PROBLEMS WERE FREEZING OF THE VENTURI THROAT DRIVE MECHANISM, TANK SCREEN
BLINDING, DUCT CORROSION, AND VIBRATIONS, LOSS OF BUILDING HEAT CAUSED EXTENSIVE DAMAGE AND KEPT THE SYSTEM DOWN FOR THE ENTIRE
61
ENVIRONMENTAL.
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HILL COUNTY (CONTINUED)
MONTH OF JANUARY 197<».
1975 - ENTERING 1975 MODULE A WAS OPERATIONAL AND MODULE B WAS STILL UNDERGOING MODIFICATION. IN THE FIRST QUARTER OF 1975
THERE WERE 6 A-MODULE OUTAGESt ONE OF WHICH WAS A FORCED OUTAGE. DUE TO THE SPLITTING OF A SLURRY VENTURI SUPPLY HOSE. MODULE 6
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
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PERIOD OPERABILITY («)
MONTH/YEAR MODULE A MODULE B
MAR. 72
APR. 72
MAT 72
JUN. 72
JUL. 72
AUG. 72
SEP. 72
OCT. 72
35
70
32
31
79
21
30
FGD SYSTEM OPERABILITY
WILL COUNTY UNIT NO. 1
COMMENTS
MODULE A DOWN FOR REPAIR AND MODIFICATION OF OEMISTER WASH PIPING ASSEMBLY.
MODULE B WAS REMOVED FROM SERVICE EVERY 2 OR 3 DAYS TO HAND-WASH THE DEMISTER. OTHEK
PROBLEMS WERE VIBRATION OF REHEATER TUBE BUNDLL, RAPID EROSION OF SCRUBBER SPRAY
NOZZLES. PLUGGING OF VENTURI NOZZLES.
MODULE A OUT OF SERVICE FUR 6 DAYS BECAUSE OF NEAR-RUPTURE OF A VENTURI PIPE
EXPANSION JOINT & HEAVY BUILDUP OF SOLIDS ON DEMISTER. MODULE B OUT OF SERVICE MOST
OF THE TIME FOR SIMILAR REPAIR OF VENTURI PIPE EXPANSION JOINT, AND FOR MODIFICATION
OF REHEATER UNIT AND DEMISTER WASH SYSTEM.
A TWO.WEEK OUTAGE OF MODULE B WAS INCURRED TO REBRACE THE REHEATER UNIT. INSTALL
UNDERSPRAY NOZZLES ON DEMISTER. AND 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 A POND RETURN BYPASS VALVE CAUSED DEMISTER PLUGGING. ALSO
DURING THIS PERIOD. THE RUBBER LINING IN MODULE A .
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 DEMISTER. THE UNIT WAS SHUT DOWN FOR TWO DAYS FOR TURBINE-GENERATOR REPAIR.
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
REHEATER BAFFLE PLATES TO DAMPEN VIBRATIONS AND INSTALLATION OF AN EXPERIMENTAL
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PERIOD
MONTH/YEAR
NOV. 72
DEC. 72
JAN. 73
FEB. 73
MAR. 73
APR. 73
OPERABILITY (*)
MODULE A MODULE B
OCT. 73
NOV. 73
DEC. 73
0
22
0
22
65
32
51
0
30
11
13
MAY
JUN.
JUL.
AUG.
SEP.
73
73
73
73
73
0
16
51
19
0
0
0
0
0
0
WILL COUNTY UNIT NO. 1 (CONTINUED)
COMMENTS
DEMISTER WASH SYSTEM.
BOILER PROBLEMS CAUSING UNSTABLE OPERATION KEPT BOTH MODULES DOWN DURING THIS MONTH.
MODULES OPERATED INTERMITTENTLY BECAUSE OF ELECTROSTATIC PRECIPITATOR TESTING AND
MISCELLANEOUS INSTRUMENT PROBLEMS.
BOTH MODULES WERE DOWN FOR REPAIRS AND MODIFICATIONS.
MODULES WERE OUT OF SERVICE BECAUSE OF CRACKS IN THE INLET DUCTWORK OF THE BOOSTER
FAN. IMPROPER INSTALLATION OF THE Qt-MISTER IN THE B-SIDE CAUSED REHEATER PLUGGING.
MODULE A WAS OUT OF SERVICE FOR 5 DAYS BECAUSE OF DEMISTER PLUGGING. BOILER WAS DOWN
FOR n DAYS OF INSPECTION. MODULE B WAS DOWN BECAUSE OF LEAKS FROM REHEATER TUBES.
PERSISTING PROBLEMS WITH DEMISTER AND DEPOSITS OF CALCIUM SULFATE SCALE ON REHEATER
TUBES OF MODULE A WERE ENCOUNTERED DURING THE MONTH.
BOTH MODULES WERE OUT OF SERVICE DURING THIS MONTH.
MODULE B WAS KEPT DOWN TO ALLOW CONCENTRATION ON THE PROBLEMS WITH MODULE A. BOILER-
RELATED PROBLEMS WERE RESPONSIBLE FOR MOST OF THE OUTAGES OF MODULE A.
MODULE A PROBLEMS* REHEATER TUBES LEAKS AND HIGH FAN VIBRATIONS.
MORE REHEATER TUBE LEAKS ON MODULE A ATTRIBUTED TO CHLORIDE CORROSION ATTACK.
MODULES WERE DOWN. DURING THIS MONTH, CHICAGO FLY ASH CO. FINISHED CLEANING AND
TREATING THE NORTHEAST HALF OF THE SLUDGE POND.
MODULE A TRIPPED SEVERAL TIMES BECAUSE OF BAD LIMIT SWITCHES IN THE BYPASS AND BLOCK
DAMPERS. UNIT WAS ALSO TAKEN DOwN TO BALANCE THE BOOSTER I.D. FAN.
ROUTINE INSPECTION OF MODULE A REVEALED SOME PLUGGING, MODULE WAS KEPT DOWN FOR
CLEANING AND SOME MODIFICATION. POOR GAS DISTRIBUTION IN MODULE SUSPECTED TO CONTRI-
BUTE TO DEMISTER PROBLEMS.
MODULES WERE DOWN. THE MONTH WAS DEVOTED TO MODIFICATION AND MAINTENANCEi MOSTLY OF
£.<*
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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HILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD
MONTH/YEAR
JAN. 74
FEB. 7*
MAR. 7*
APR. 74
MAY 74
JUN. 74
JUL. 74
AUG. 74
SEP. 74
OCT. 74
OPERABILITY (k)
MODULE A MODULE B
21
72
93
55
96
91
85
94
COMMENTS
OEMISTERt VENTURI THROATSt PUMPS. AND ISOLATION VALVES.
MODULES WERE DOWN OWING TO FREEZING IN THE 10-lNCH-OlAMETEH, 4400-FT. LINE BETWEEN
MODULES AND POND. SOME DAMAGE TO SUMP PUMPS. FREEZING ALSO DAMAGED SOME INSTRUMENTS
THE FROZEN PIPELINE WAS THAWED. REANCHORED. AND RETURNED TO SERVICE. THE INSTRUMENTS
DAMAGED BY FREEZING WERE REPAIRED. MODULE A KEPT DOWN UNTIL ARRIVAL OF SECOND-STAGE
OEMISTER.
MODULE A WAS READY FOR SERVICE MARCH 20 BUT WAS NOT RETURNED TO SERVICE TILL MARCH 27
BECAUSE BOILER WAS DOWN.
MODULE A CONTINUED TO OPERATE UNTIL APRIL 19CEXCEPT FOR TWO SHORT INSPECTION OUTAGES)
FOR 23 CONSECUTIVE DAYS. OPERATION WAS ON LOw-SULFUR COAL. SUMP SCREEN FROM MODULE B
WAS SUBSTITUTED FOR DAMAGED SCREEN IN MODULE A.
MODULE A OPERATED FOK ENTIRE MONTH EXCEPT FOR SHORT OUTAGES FOR INSPECTION. MUCH OF
THIS OPERATION WAS ON HIGH-SULFUR COAL.
MODULE A OPERATED FOR ABOUT 300 HOURS. THE SYSTEM WAS OFF FOR 2 WEEKS FOR REPAIR OF
VENTURI THROAT DRIVE
MODULE A OPERATED FOR THE ENTIRE MONTH EXCEPT FOR ONE INSPECTION OUTAGE AND TWO
BOILER SHUTDOWNS. MODULE B REMAINS DOWN UNTIL SATISFACTORY OPERATION OF MODULE A IS
ACHIEVED.
MODULE A WAS DOWN SIX TIMES THIS MONTH* THREE TIMES BECAUSE OF NO BOILER DEMAND,
TWICE FOR REPAIR OF LEAKS IN STEAM PIPING, AND ONCE FQR BALANCING OF A FAN.
MODULE A WAS OFF THREE TIMES* ONCE FOR CLEANING OF DEPOSITS FROM THE VENTURI THROAT,
ONCE FOR REPAIR OF A DESUPERHEATER LEAK. AND ONCE BECAUSE BOILER WAS DOWN.
MODULE A WAS DOWN FOUR TIMES* ONCE BECAUSE OF BOILER OUTAGES, ONCE FOR INSPECTION,
AND TWICE FOR REPAIR OF HEHEATER LEAKS.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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PERIOD
MONTH/YEAR
NOV. 7"»
DEC.
JAN. 75
FEB. 75
OPERABILITY <*)
MODULE A MODULE B
97 0
99
99
WILL COUNTY UNIT NO. 1 (CONTINUED)
COMMENTS
MODULE A WAS OUT OP SERVICE. THREE TIMES* TWICL BECAUSE OF NO DEMAND AND ONCE FOR
INSPECTION.
MODULE A WAS DOWN TWICE* ONCE FOR INSPECTION AND ONCE FOR REPAIR OF VALVE IN SPENT.
LIOUOR LINE TO POND.
MODULE A WAS DOWN TWICE* ONCE FOR INSPECTION AND ONCE FOR NO DEMAND. MODIFICATION
OF MODULE B IS CONTINUING.
MODULE A WAS OUT OF SERVICE TWICE* ONCE FOR INSPECTION AND ONCE FOR NO DEMAND. ONE
SMALL REHEATER LEAK IN A STAINLESS STEEL BUNDLE WAS BLANKED-OFF ON-LINE. DURING THE
INSPECTION, DEMISTER UNDERWASH NOZZLES WERE CLEANED AND A SMALL SECTION OF DEMISTER
WAS REPLACED. INSPECTION SHOWED THAT CONDITIONS INSIDE THE SCRUBBER WERE ABOUT THE
SAME AS BEFORE. COAL BURNED THIS MONTH AVERAGED LESS THAN i« SULFUR. MODIFICATION OF
MODULE B IS CONTINUING. CHICAGO FLT ASH IS TREATING MATERIAL FROM THE SCRUBBER WITH
PORTLAND CEMENT AND FLY ASH AND DUMPING THE TREATED MATERIAL INTO THE NORTH HALF OF
THE HOLDING BASIN.
PEDCo ENVIRONMENTAL
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WILL COUNTr UNIT MO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
MAR. 75 A
SYSTEM PERFORMANCE FACTORS (ft)
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
99
93
APR. 75
37
35
MAY 75
A
B
84
37
84
37
84
37
84
37
COMMENTS
MODULE A WAS DOWN FOUR TIMES* TWICE FOR NO DEMAND,
ONCE FOR A VENTURI HOSE LEAK, ONCE FOR AN ACCIDEN-
TAL 50-MINUTE TRIP. THE SYSTEM OPERATED ON LOW
MODULE B SULFUR COAL DURING THE MONTH. MODIFICATI
ARE CONTINUING.
SLUDGE PONU WAS OVERBURDENED BY NEAR-CONTINUOUS
OPERATION OF MODULE A. THE FGD SYSTEM WAS SHUT
DOWN TO ALLOW EVAPORATION OF WATER FROM THE POND.
DURING SHUT DOWN, THE FOLLOWING MODIFICATIONS WERE
HADE* PUMP GLAND WATER FLOWS WERE REDUCED FROM 10
TO b GPM*FILTER BACKWASH WAS ROUTED OUT OF SYSTEM*
CONTINUOUS DEMISTER UNDERSPRAY WAS CHANGED TO
INTERMITTENT. RECLAIM COAL WAS BURNED IN THE
BOILER DURING THE MONTH.
MODULE A REMAINED OUT OF SERVICE UNTIL MAY 5, WHEN
IT WAS DETERMINED THAT THERE WAS ENOUGH FREEBOARU
IN THE POND To START OPERATING. THERE WERE TWO
MORE OUTAGES* ONE FOR 45 HINUTES, THE RESULT OF A
DAMPER TRIP* THE OTHER FOR CLEANING OF UNOERSPRAY
NOZZLES. MODULE B WAS PLACED IN SERVICE AT TEN
A.M., MAY 20, FOR THE FIRST TIME SINCE NOON ON
APRIL 13, 1973. AFTER BRIEF STARTUP, WHICH WAS
ROUTINE, OPERATION WAS DELAYED UNTIL THE 20TH
BECAUSE OF TWO BROKEN OIL PUMPS ON THE RECIRCU-
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS («)
AVAILABILITY OPERMSILITY RELIABILITY UTILIZATION
JUN. 75
64
85
61
85
60
8"*
75
JUL. 75
79
79
77
7
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WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/TEAR
SYSTEM PERFORMANCE FACTORS m
AVAILABILITY OPEHA8ILITY RELIABILITY UTILIZATION
AUG. 75
9«t
100
92
76
SEP. 75
63
63
63
OUT. 75
32
100
26
COMMENTS
SULFUR COAL WAS BURNED DUKING THE FIRST (3) WEEKS
AND HIGH SULFUR ILLINOIS COAL WAS BURNED DURING
THE LAST WEEK OF THE MONTH.
MUQULE 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 PHO.
DUCTION AND FORCING A 6-DAY, 10 HR/DAY, SLUDGE
DISPOSAL OPERATION. SLUDGE STABILIZATION IS
CONTINUING.
MODULE A REMAINED OUT OF SERVICE ALL MONTH BECAUSE
OF DELAY ON THE NEW REHEATER ORDER. MODULE B WAS
DOWN 8 TIMES BECAUSE OF MASSIVE ABSORBER SCALE,
DEMISTER AND I.D. BOOSTER FAN CLEANING, BALANCING
I.D. BOOSTER FAN, AND PLUGGING OF ABSORBER PUMP
SCREEN. TOTAL OUTAGE TIME WAS 236 HOURS, to
MINUTES FOR CLEANOUT 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
69
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WILL COUNTY UNIT NO. i (CONTINUED)
PERIOD MODULE
MONTH/YEAR
NOV. 75
SYSTEM PERFORMANCE FACTORS (%)
AVAILABILITY OPEKABILITY 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
SO
9
20
21
8
19
a
COMMENTS
OUT OF SERVICE PENDING DELIVERY OF THE NEW RE-
HEATEK
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. DURING MARCH
HIGH SULFUR ILLINOIS COAL WAS FIRED IN THE BOILER.
70
PEDCo ENVIRONMENTAL
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WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS (SI
AVAILABILITY OPEHAblLITY RELIABILITY UTILIZATION
APR. 76
A
B
A S B*
23
51
20
20
20
19
19
MAY 76
87
65
65
76
COMMENTS
DURING THE MONTH OF APRIL THE A-SIDE INCURRED PUMP
LINER FAILURES WHEN AN ISOLATION VALVE BROKE AND
FELL INTO THE VENTuRl RECYCLE PUMP. B-SIDE OUTAGES
DURING APRIL RESULTED FROM REHEATER TUBE BUNDLE
LLAKS* PLUGGED ABSORBER TANK SCREEN* AND VENTURI
PUMP LINER FAILURE. HIGH SULFUR COAL u.s 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 MAS 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 HAULED TO AN OFF-SITE
DISPOSAL AREA.
71
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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WILL COUNTY UNIT NO. 1 (CONTINUED*
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS m
AVAILABILITY OPEKABILITY RELIABILITY UTILIZATION
JUN. 76
A
B
A S B*
50
63
85
37
81
JUL. 76
A
B
20
86
0
90
0
8<*
AUG. 76
A
B
A S B*
96
65
57
61
17
96
36
70
31
0
72
38
11
COMMENTS
SIDE-A HAS RETURNED TO SERVICE JUNE 9 FOLLOWING
THE INSTALLATION OF A NEu VENTuRI PUMP LINER.
FOUR FORCED SCRUBBER OUTAGES WERE REPORTED-
TWO BECAUSE OF NO DEMAND, ONE FOR A BYPASS-
DAMPtR FAILURE AND ONE FOR I.D. BOOSTER FAN
FOULING. THE B-SIDE ENCOUNTERED SEVERAL FORCED
SCRUBBER OUTAGES. 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-SIDE REMAINED OUT OF SERVICE THE ENTIRE
MONTH BECAUSE OF REPAIRS TO A DAMAGED ABSORBER
PUMP AND POND THICKENER SLUDGE OVERLOADING. THE
8-SIDE ENCOUNTERED FOUR FORCED SCRUBBER OUTAGES*
TWICE FOR NO DEMANDi ONCE TO BALANCE THE I.D.
BOOSTER FANS, AND ONcE To WASH THE I.D. BOOSTER
FANS.
THE A-SIDE REMAINED OUT OF SERVICE 50 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-SlDE ENCOUNTERED
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO .452^6
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WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPEHABILITY RELIABILITY UTILIZATION
SEP. 76
A
B
A X B*
42
79
29
76
5
26
74
60
COMMENTS
THREE NO-UEMAND OUTAGES, 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.* 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.t 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-SIDE. 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.
73
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
OCT. 76
NOV. 76
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
A
A
A
B
* 8*
A
B
a B*
30
76
0
20
72
29
56
0
26
70
a
26
70
0
20
66
28
55
0
20
55
7
•NOTE- ASB DESIGNATION AND THE CORRESPONDING PERFORMANCE.
VALUES REFER TO THE SIMULTANEOUS OPERATION OF
BOTH SCRUBBING TRAINS DURING THE REPORT PERIOD
IN QUESTION.
COMMENTS
PROBLEMS RELATED To THE A-SIOE SCRUBBER WERE DUE
PRIMARILY TO REPAIRS NECESSARY TO THE 1A1 RECYCLE
PUMP, AND DELAYS IN REPLACEMENT PARTS SHIPMENTS.
THE A-SIDE MODULE HAS IN SERVICE WHEN THE B-SIDE
WAS DOWN, HOWEVER SCRUBBING LIQUOR FLOW WAS
REDUCED BECAUSE ONLY ONE RECYCLE PUMP WAS IN USE.
AT THE END OF NOVEMBER. THE REMAINING A-SIDE PUMP
WAS TAKEN OUT OF SERVICE FOR OVERHAUL AND REPAIRS.
FOLLOWING THIS THE A-SIDE WILL RESUME OPERATIONS
ON ONE PUMP.
ON THE B-SIDE. 3 FORCED SCRUBBER OUTAGES OCCURRED
DURING OCTOBER. ONE WAS BECAUSE OF REPAIRS OF A
REHEATER HEADER LEAK AND THE TIE-IN OF A VACUUM
FILTER AT THE THICKENER. THE OTHER TWO RESULTED
FROM A VENTURI NOZZLE CLEAN-OUT AND A VENTURI LOW-
FLOW TRIP. DURING NOVEMBER. "* SCRUBBER TRIPS
OCCURED BECAUSE OF A MILLING SYSTEM FAILURE, VEN-
TURI HEADER LEAK REPAIR AND VENTURI NOZZLE CLEAN-
ING, REPLACEMENT OF SPENT SLURRY VALVE, AND CHEM-
ICAL SYSTEM UPSET. TWO OUTAGES WERE ALSO LOGGED
BECAUSE OF NO DEMAND.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
DEC. 76
A
B
53
<*e
52
45
51
JAN. 77
A
B
98
99
1
96
1
96
1
COMMENTS
THE A-SIOE WAS PLACED IN SERVICE DURING THE LATTER
PART OF THE MONTH AND OPERATED CONTINUOUSLY WITH
THE EXCEPTION OF ONE MINOR OUTAGE FOR
SLURRY VALVE REPAIRS. A SPENT SLURRY VALVE
FAILURE FORCED THE B-SIDE OUT OF SERVICE THE
REMAINDER OF THE MONTH. SIMULTANEOUS MODULE OPER-
ATION TIME WAS 0 HOURS. THE SCRUBBER MODULES ARE
SEEING SERVICE ON A ROTATIONAL BASIS* I.E.* ONE
MODULE UP, ONE MODULE DOwN. SLUDGE STABILIZA-
TION PRACTICES AND OPERATION ON LOW SULFUR COAL
CONTINUED DURING THE MONTH.
ROTATIONAL MODULE OPERATIONS CONTINUED. A-SiDE
FORCED OUTAGES* SPENT SLURRY VALVE FAILURE AND
PLUGGED DEMISTER UNOERSPRAYS. THE DECEMBER SPENT
SLURRY VALVE FAILURE KEPT THE B-SIDE OUT OF SER-
VICE UNTIL JAN. 27. ACTUAL B-SIDE SERVICE TIME
WAS ONE DAY. SLUDGE STABILIZATION AND DISPOSAL
PRACTICES CONTINUED. LOW SULFUR WESTERN COAL WAS
BURNED IN THE BOILER.
75
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 45246
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WILL COUNTY UNIT NO. 1 (CONTINUED)
PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPEKABILITY RELIABILITY UTILIZATION
FEB. 77
39
72
A J B
12
COMMENTS
DURING THE ENTIRE MONTH OF FEB. 1977i LOW-SULFUR
COAL WAS BURNED IN THE BOILER. THERE WAS VERY
LITTLE DIGGING IN THE RECIRCULATION PONDS. CHICAGO
FLYASH SPENT MOST OF THEIR TIME ON CLEANING AND
MAINTENANCE.
MODULE A WAS OFF THE FIRST PART OF THE MONTH FOR
CLEANING OF UNOERSPRAYS. OVERSPRATS AND ABSORBER
SPRAY NOZZELS. PLUGGING WAS CAUSED BY A FAILED
CLASSIFIER LINER, WHICH ALLOWED OVERSIZED PARTICLES
TO ENTER THE SYSTEM. THE CLASSIFIER LINER WAS RE-
PLACED.
MODULE B WAS FORCED OUT OF THE GAS PATH THREE TIMES
THIS MONTH. THE REASONS WERE* HIGH VIBRATION OF
I.D. BOOSTER FAN, REPACKING OF IBl AND 1B2 ABSORBER
PUMPS. AND BEARING FAILURES IN A AND B SLURRY TRAN-
SFER PUMPS.
IN MARCH AN ERT soa ANALYZER WAS INSTALLED ON THE
DISCHARGE SIUE OF B MODULE I.D. BOOSTER FAN. THIS
IS AN *IN SITU* NON-DISPERSIVE ANALYZER THAT CON-
TINUALLY MEASURES AND READS OUT CONCENTRATIONS OF
S02, C02t CO AND NO. HIGH-SULFUR COAL WAS BURNED
FOR SEVEN DAYS DURING MARCH TO PROVIDE HIGH SULFUR
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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WILL COUNTY UNIT NO. 1 (CONTINUED)
SYSTEM PERFORMANCE FACTORS (X)
MONTH/YEAR COMMENTS
SLUDGE FOR THE U.O.P. SLUDGE TEST (A U.O.P. TEST
CREW WAS EXPERIMENTING WITH POWERTON FLYASH AND
HIGH-SULFUR SLUDGE). CHICAGO FLYASH SPENT ABOUT
75% OF THEIR TIME DIGGING IN THE RECIRCULATION
POND. THE REST WAS SPENT ON THE THICKENER AND
VACUUM FILTER OPERATIONS. THE SCRUBBER WASTE
MATERIAL WAS TREATED WITH LIME AND FLYASH AND HAUL-
ED TO AN OFF-SITE DISPOSAL AREA.
MAR. 77 A 97 66 64 MODULE FORCED OUT OF THE GAS PATH ONCE THIS MONTH
TO ALLOW FOR REPAIR TO A VENTURl FLOW DIFFERENTIAL
LINE.
B ai 75 73 MODULE FORCED OUT OF THE GAS PATH FOUR TIMES. THE
REASONS WERE* RUPTURED DIAPHRAM ON REHEATER STEAM
VALVE. ABSORBER SUCTION LEAK, SpENT SLURRY VALVE
GASKET LEAK AND PLUGGED FEED SLURRY RECIRCULATION
LINE.
A ft B 52 51
77
X PEDCo ENVIRONMENTAL
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PERIOD MODULE
MONTH/YEAR
SYSTEM PERFORMANCE FACTORS (*J
AVAILABILITY OPERABILITY RELIABILITY
WILL COUNTY UNIT NO. 1 (CONTINUED!
UILIZATION
APR. 77
A
B
A S B*
86
68
30
23
HAY 77
A
B
A * B*
69
98
Z
51
0
61
21
20
2
«*7
0
78
COMMENTS
2 OUTAGES WERE REPORTED FOR THE A-SIOE DURING
APRIL, ONE FOR A BOILER TUBE LEAK REPAIR. AND ONE
TO REPAIR A VENTURI THROAT LEAK. B-SIOE OUTAGES
OCCURRED TWICE FOR ABSORBER SUCTION HEADER REPAIR,
AND ONCE TO WASH THE I.D. BOOSTER FAN. BOTH MOD-
ULES WERE FORCED OUT OF SERVICE APRIL 23 WHEN THE
SLURRY STORAGE TANK MIXER STRIPPED A PINION GEAR.
PREPARATIONS ARE BEING MADE FOR MGD ADDITION AND
FORCED OXIDATION TEST. THE ERT S02 ANALYZER PER-
FORMANCE HAS BEEN INCONSISTENT PRIMARILY DUE TO A
FAULTY CIRCUIT. HIGH-SULFUR COAL WAS BURNED FOR
SEVEN DAYS AND SLUDGE STABILIZATION PRACTICES IN-
VOLVING LIME AND FLYASH TREATMENT WERE CONTINUED
DURING THE MONTH.
A-SIDE OUTAGE OCCUREO ONCE DURING MAY DUE TO INLET
VALVE FAILURE ON THE 1A2 ABSORBER PUMP. THE
B-SIDE MODULE WAS TAKEN OFF FOR INSPECTION AND
CLEANING OF THE REHEA*ER TUBES. TRANSFORMER FAIL-
URE ON THE POND RETURN PUMPS KEPT BOTH SIDES OUT
OF SERVICE FOR THE FIRST 15 DAYS OF THE MONTH.
THE ERT S02 ANALYZER HAS BEEN REMOVED FROM SERVICE
DUE TO POOR PERFORMANCE. HIGH-SULFUR COAL WAS
BURNED FOR ELEVEN DAYS FOR THE MGO TEST, WHICH
WENT WELL. RESULTS SHO* ABOUT 10 PERCENT GREATER
S02 REMOVAL EFFICIENCY WITH THE MG ION ADDITION,
PEDCo ENVIRONMENTAL
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BUT NO IMPROVEMENT FOR THICKENER OR SLUDGE PRO-
DUCTION PHOBLtMS. THE LIMESTONE CONSUMPTION RATE
WAS ABOUT THE SAME. SLUDGE STABILIZATION AND DIS-
POSAL PRACTICES CONTINUED. THERE WAS NO SIMUL-
TANEOUS OPLRATON OF A AND B SCRUBBER MODULES.
79
/^~^\
PEDCo ENVIRONMENTAL
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TABLE: 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
31
QUQUESNE LIGHT
ELRAMA POWLR 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
EFFICIENCYt
PARTICULATES
CHEMICO
LIME SCRUBBING
RETROFIT
10/75
OPERATIONAL
99 PERCENT
S02
63 PERCENT DESIGN - 2% S COAL
WATER MAKE UP
OPEN LOOP
SLUDGE DISPOSAL
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
$93/KW CAPITAL * 6 MILLS/KWH OPERATING COSTS (BOTH STATIONS)
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
OPERATIONS ARE CONTINUING WITH TWO BOILERS COUPLED INTO THE FIVE-MODULE
SCRUBBING SYSTEM. RUBBER-LINED RECYCLE PUMPS HAVE BEEN REMOVED FROM TEST.
ING AS THEY WERE UNDERGOING SEVERE ABRASION AND GOUGING. ANOTHER SET OF
RUBBER-LINED PUMPS MAY BE TESTEOt SCRUBBING WASTES ARE CHEMICALLY FIXATED
BY THE iucs METHOD ANU LANOFILLED. DUQUESNL LIGHT is CONTINUING EFFORTS
TO OBTAIN ALTERNATE LANDFILL AREAS AS THE CURRENT ONES ARE BEING FILLED
FAIRLY RAPIDLY.
ao
PEDCo ENVIRONMENTAL
CINCIIMNATI. OHIO 45246
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BACKGROUND INFORMATION
ON
ELRAMA POWER STATION
DUQUESNE LIGHT COMPANY. AN IrtVESTOR-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 THE ABSORBING REAGENT.
THE SCRUBBER FACILITY AT THE «»9«»-MW ELRAMA STATION IS ALMOST IDENTICAL TO THE SYSTEM AT THE PHILLIPS STATION. GIBBS X HILL
IS THE A-E FIRM AND CHEHICO SCRUBBERS HAVE BEEN INSTALLED WITHIN THE SAME DESIGNATED BATTERY LIMITS AS AT PHILLIPS. MECHANICAL
AND ELECTRICAL DUST-REMOVAL EQUIPMENT REMOVES MOST PARTICULATES FROM THE BOILER EMISSIONS, AND THE GAS To AND FROM THE SCRUBBERS
IS HEADEREO IN THE SAME WAY. UNLIKE THE PHILLIPS SYSTEM, HOWEVER, THERE ARE FOUR BOILERS, EACH WITH ITS OWN TURBINE GENERATOR.
FIVE SINGLE-STAGE SCRUBBERS WERE INSTALLED, WITH THE INTENTION THAT KNOWLEDGE GAINED FROM THE TEST PROGRftM AT PHILLIPS WOULD BE
APPLIED TO ELRAMA To ENABLE COMPLIANCE WITH EMISSION REGULATIONS.
THE FIRST ELRANA SCRUBBER WAS PLACED IN SERVICE ON OCTOBER 26, 1975. IT HAD BEEN SCHEDULED FOR AN EARLIER STARTUP DATE, BUT
BECAUSE OF THE SEVERITY AND NUMBER OF PROBLEMS ENCOUNTERED AT PHILLIPS, STARTUP WAS DELAYED UNTIL MANY OF THE PROBLEMS AT PHILLIPS
WERE RESOLVED AND THE MODIFICATIONS COULD BE INCORPORATED AT BOTH STATIONS.
BOILER NO. 2 WAS INITIALLY CONNECTED TO THE FGD SYSTEM ON OCTOBER 26, 1975. THIS BOILER HAS AN EQUIVALENT CAPACITY OF
APPROXIMATELY 100 MW, AND THE EMISSIONS ARE.HANDLED BY ONE SCRUBBER. TO ENSURE RELIABILITY IN THE CASE OF A SCRUBBER MALFUNCTION,
TWO SCRUBBERS ARE OPERATED AT PARTIAL LOAD TO PROTECT THE BOILER AND TURBINE GENERATOR AGAINST A TRIP-OFF.
THE BOILER OPERATED CONTINUOUSLY ON THE SCRUBBER SYSTEM THROUGH JANUARY 1976. TWO MINOR OUTAGES OCCURRED DURING THIS PERIOD,
ONE CAUSED BY INOPERATIVE THROAT DAMPERS AND THE OTHER INVOLVING FAILURE OF A LIME FEEDER BELT. ON FEB. «»,1976, A SECOND BOILER
WAS COUPLED INTO THE SCRUBBER COMPLEX. PRESENTLY, 2 UNITS ARE THE MAXIMUM THAT CAN BE TIED INTO THE SCRUBBER PLANT. TO DATE,
THE UTILITY HAS ENCOUNTERED THE USUAL MINOR STARTUP PROBLEMS AND SOME MAJOR PROBLEMS AS WELL. THE MAJOR PROBLEMS HAVE BEEN
FROZEN PIPES AND THICKENERS, THE LATTER INVOLVING HARDWARE AND DESIGN ASSOCIATED WITH RECIRCULATION OF THE SLUDGE WITHIN THE
THICKENERS TO ATTAIN 30 TO 40 PERCENT SOLIDS CONCENTRATION.
THE SLUDGE BEING GENERATED AT THIS STATION is TREATED BY THE lues METHOD, WHICH EMPLOYS A VACUUM FILTER THAT INCREASES THE
SOLIDS IN THE UNDERFLOW TO 50 TO 60 PERCENT, SO THAT LESSER AMOUNTS OF OR* FLY ASH ARE REQUIRED FOR MIXING WITH THE SLUDGE.
61
PEDCo ENVIRONMENTAL-
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PERIOD
OCT. 75
TO
JAN. 76
FEB. 76
MAR. 76
APR. 76
HAY 76
JUN. 76
JUL. 76
AUG. 76
SEP. 76
OPERATING HOURS
BOILER SCRUBBER VESSELS
1169 1508 976
638
ELRAMA POWER STATION
COMMENTS
ONE BOILER WAS CONNECTED TO THE SCRUBBER SYSTEM ON OCTOBER 26t 1975.
A SECOND BOILER WAS CONNECTED ON FEBRUARY <*, 1976. FOUR OF THE
SCRUBBER VESSELS HAVE BEEN IN SERVICE IN VARIOUS COMBINATIONS. THE
SERVICE HOURS TO JANUARY 31t 197i» ARL 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 REOUIREP 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 SYSTEM is STILL OPERATING AT THIS STATION.
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 E8UIPMENT 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
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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CLRAHA POWEfl STATION (CONTINUED)
PERIOD
OCT. 76
OPERATING HOURS
BOILER
SCRUBBER VESSELS
NOV. 76
DEC. 76
COMMENTS
TUO BOILERS COUPLED INTO THE 5-MODULE SCRUBBING SYSTEM. THE 5TH
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 S02 REMOVAL EFFICIENCIES. S02
REMOVAL EFFICIENCY WAS 50 PERCENT. PARTICULATE EMISSIONS WERE BEING
REDUCED WELL BELOW THE 0.1 LB/MM BTU STANDARD (ACTUAL RESULTS* 0.0<4
LB/MM BTU). THESE RESULTS WERE BASED ON 2 BOILERS COUPLED INTO THE 5
SCRUBBING MODULES WHILE BURNING MEDIUM-SULFUR (1.0 TO 2.8 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 ARC FULL LOAD CAPACITY IN THE DAYTIME AND 50 TO 60 PERCENT
LOAD REDUCTION AT NIGHT.
THE SCRUBBER REMAINED IN SERVICE THROUGHOUT THE REPORT 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 SERVICE TIME.
PEDCo ENVIRONMENTAL
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ELRAMA POWER STATION (CONTINUED)
OPERATING HOURS
PERIOD BOILER SCRUBBER VESSELS COMMENTS
JAN. 77 THE SCRUBBER PLANT CONTINUED OPERATIONS DURING THE REPORT PERIOD WITH
FEB. 77 TWO BOILERS COUPLED INTO THE SYSTEM. TESTING ON THIOSORBlC LIME WAS
«AR. 77 CONDUCTED DURING THE PERIOD. INSTALLATION OF THE ADDITIONAL THICKENERt
LIME FEEDERS AND SILOS IS STILL IN PROGRESS. FULL COMPLIANCE OPERATION
FOR THIS STATION IS SCHEDULED FOR EARLY 1976. THE FULL COMPLIANCE
STRATEGY WILL CONSIST OF THE FOLLOWING* 83* S02 REMOVAL FOR 2* SULFUR
COAL UTILIZING THIOSORBlC LIME <6-12*MG), FIXATING THE SCRUBBER
SLUDGE WITH THE IUCS POZ-0-TEC STABILIZATION METHOD AND HAULING
THIS MATERIAL TO AN OFF-SITE DISPOSAL/LANDFILL AREA. CURRENT S02 AND
PARTICULATE REMOVAL EFFICIENCIES ARE 50 AND 99+«, RESPECTIVELY. THE
INTERIM IUCS UNIT NOW IN SERVICE CONSISTS OF THE OLD MOHAVE PROTOTYPE
PLUS A VACUUM FILTER. THE STABILIZED MATERIAL HAS BEEN UTILIZED IN
A PARKING LOT CONSTRUCTION PROJECT. IUCS HAS BEEN AWARDED A 10-YEAR
CONTRACT FOR THE CONTINUED USE OF THIS SYSTEM FOR FUTURE PLANT
OPERATIONS.
APR. 77 CONSTRUCTION OF TWO 120-FOOT DIAMETER THICKENERS IS CONTINUING. DUE
MAY 77 TO THE GOUGING OF THE RUBBER-LINED RECYCLE PUMPS DURING THEIR TESTING,
THEY HAVE BEEN REMOVED. THE UTILITY IS CONSIDERING TRYING ANOTHER SET
OF RUBBER-LINED PUMPS, OUQUESNE LIGHT ALSO IS CONTINUING EFFORTS TO
OBTAIN ALTERNATE LANDFILL AREAS FOR SLUDGE DISPOSAL.
PEDCo ENVIRONMENTAL
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 06/77
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
32
DUOUESNE LIGHT
PHILLIPS POWER STATION
SOUTH HEIGHT PENNSYLVANIA
410 nw
COAL 1.0- 2.8 PERCENT SULFUR
CHEM1CO
LI«E SCRUBBING
RETROFIT
7/73
OPERATIONAL
99 PERCENT
S02
83 PERCENT DESIGN - 2* S COAL
WATER HAKE UP
OPEN LOOP
SLUDGE DISPOSAL
UNIT COST
STABILIZED SLUDGE DISPOSED IN UW.INED POND
S103/KW CAPITAL * 6 MILLS/KWH OPERATING COSTStBOTH STATIONS)
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS HEPORT.
THIS SCRUBBING SYSTEM HAS BEEN IN SERVICE SINCE JULY 1973. FOUR BOILERS
CURRENTLY ARE COUPLED INTO THE SCRUBBING SYSTEM. THE OTHER TWO BOILERS
ARE DOWN FOR MAINTENANCE. THE SCRUBBER SYSTEM MAS SHUT UQWN FOR ABOUT H
DAYS IN MAY DUt TO LEAKING IN THE WET GAS HEADER THAT CONNECTS THE STACK.
OVERALL SCRUBBER AVAILABILITY HAS BEEN ABOUT 75 PERCENT DURING THE RE-
PORTING PERIOD. DEWATERED SLUDGE FROM THE IUCS INTERIM PROCESSING PLANT
IS BEING HAULED TO AN OFF.SITE LANDFILL. THE SLUDGE CONTAINS NO FIXATIVE.
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BACKGROUND INFORMATION
ON
PHILLIPS POWER STATION
THE PHILLIPS POWER STATION IS LOCATED ON THE OHIO RIVE" ABOUT 20 MILES NORTHWEST OF PITTSBURGH. THE POWER STATION CONSISTS
OF SIX COAL-FIRED BOILERS HAVING A NET GENERATING CAPABILITY OF 387 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 FGO 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-FIRED BOILERS. THREE OF THE TRAINS A«E SINGLE-STAGE VENTUHI SCRUBBERS ORIGINALLY INTENDED FOR PANICULATE REMOVAL.
THE FOURTH TKAIN 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 APPENDIX B.
EACH TRAIN IS EQUIPPED WITH A NEW UET-TYPE ID FAN. A NEW COMMON DUCT DIRECTS GAS STREAMS FROM Al* 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 ACID-RESISTANT BRICK LINER.
SLAKED QUICKLIME IS ADDED TO THE LOWER CONE OF EACH OF THE SCRUBBER VESSELS TO NEUTRALIZE THE REClRcULATlNG 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 H PERCENT IS SENT TO ONE OR BOTH OF THE THICKENERS FOR REMOVAL OF SOLIDS. THE OVERFLOW IS
RETURNED TO THE SYSTEM AND THE UNDERFLOW is DISCHARGED TO THE iucs SLUDGE FIXATION SYSTEM. THIS INTERIM SLUDGE FIXATION SYSTEM
COMMENCED OPERATIONS IN DECEMBER 1976. THE FACILITY INCLUDES DEWATERING EQUIPMENT AND FLY ASH ADDITION EQUIPMENT (COLLECTED
FROM THE ESP). THE FIXATED MATERIAL IS THEN HAULED AWAY TO AN OFF-SITE LANDFILL AREA.
FLUE GASES FROM THE BOILERS ARE ACCELERATED TO A HIGH VELOCITY IN THE SCRUBBER. AT THE THROAT. THE GASES COLLIDE WITH THE
SCRUBBING LIQUID, ATOMIZING IT INTO SMALL DROPLETS. THE FLY ASH AND THE SULFUR DIOXIDE IN THE GAS ARE PICKED UP BY THE SLURRY
DROPLETS AND EXIT AT THE BASE OF THE TOWER. THE GAS THEN REVERSES DIRECTION AND FLOWS UP THROUGH THE MIST ELIMINATOR. WHERE FINE
86
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PHILLIPS POWER STATION (CONTINUED)
DROPLETS ARC REMOVLD BEFORE THE GAS 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 i97«». 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 «LL BOILERS WERE CONNECTED TO THE SCRUB-
BERS. THERE WAS AT LEAST ONE SPARE 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
-------
PHILLIPS POWER STATION
OPERATING HOURS
BOILER
MONTH 1 2 3 •» 5
JUL. 75 63 6<»<» 7()3 3<»9 605
AUG. 75 35«» 701
SEP. 75 «»63
OCT. 75 5H7
287 669 503
575 620 601*
NOV. 75 16
DEC. 75 172
720 668
660 709
70
0
JAN. 76 222
722 639
SCRUBBER-ABSORBER
101 201 301 401
HOO 160 531 723
"»57 517
-------
PHILLIPS POWER STATION (CONTINUED)
MONTH
BOILtR
2 3
OPERATING HOURS
SCRUBBER-ABSORBER
101 201 301 fOl
FEB. 76 «*<»3
MAR. 76
APR.76
568 672
633
571
657 662
695 353
166
659
H06
H61
HAY 76
JUN. 76
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.
PLANT OPERATION IS PROCEEDING WITH A TOTAL OF t
BOILERS COUPLED INTO THE SCRUBBING SYSTEM
(EQUALING 336 MW, WHICH IS 67 PERCENT OF THE TOTAL
PLANT CAPACITY). THE FGD SYSTEM OPERATED ON HIGH
CALCIUM LIME DURING THE REPORT PERIOD. THE
GENERAL OPERATION MODE AT THIS FACILITY HAS ONE OF
THE FOUR SCRUBBING TRAINS OUT CONTINUALLY FOR
REPAIRS. CLEANING. AND PREVENTATIVE MAINTENANCE.
THE UTILITY IS STILL EXPERIENCING PROBLEMS WITH
SOLIDS DEPOSITION IN THE VENTURI THROAT OF THE
SCRUBBING MODULE. CAUSING MOVEMENT INHIBITION AND
GREATER PRESSURE DROPS.THE FGD SYSTEM AVAILABILITY
FOR THE FIRST QUARTER OF 1976 WAS 72 PERCENT. THE
SLUDGE STABILIZATION PRACTICES ARE STILL
CONTINUNING AT THIS FACILITY.
REDUCED LOAD OPERATIONS WERE REPORTED BY THE
UTILITY FOR THE MAY-JUNE PERIOD BECAUSE OF A
89
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PHILLIPS POWER STATION (CONTINUED)
MONTH
BOILER
a 3
OPERATING HOURS
SCRUBBER*ABSORBER
101 201 301 401
JUL. 76
AUG. 76
90
COMMENTS
SCHEDULED TURBINE OVERHAUL TO UNIT NO. 6. THE
SCRUBBING SYSTEM WAS SHUT DOWN ON JUNE 27 FOR A
SCHEDULED FOUK *EE« REPAIR PERIOD. THE MAJORITY
OF THE WORK WILL BE CONCENTRATED ON THE STACK,
ASSOCIATED DUCTWORK. AND BOILER DAMPERS. ALSO,
THE UTILITY IS PROCEEDING WITH THE INSTALLATION OF
3 ADDITIONAL LIME STORAGE SILOS AND * THIRD
THICKENER.
THE H-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 I.D. 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
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PHILLIPS POW£K
.-,-. riON (CONTINUED!
MONTH
SEP. 76
OCT. 76
BOILER
2 3
OPERATING HOURS
SCRUBBER-ABSORBER
101
201
TOTAL SCRUBBER HOURS* 23*27*
TOTAL BOILER HOURS* 83.6S2
TOTAL SCRUBBER OUTAGE TIME* 5.500
TOTAL SCRUBBER AVAILABILITY HOURS. 23.274
AVERAGE MM LOAD/ SCRUBBER OPERATION HOUR* 2"»3
TOTAL OPERABILITY INDEX* 26 PERCENT
91
"»01 COMMENTS
LONG-TERM SLUDGE TREATMENT SYSTEM.
BOILCH NOS. 2-6 UEKE COUPLED INTO THE SCRUBBING
SYSTEM. BOILER NO. 1 IS DOWN FOR OVERHAUL AND
REPAIRS. THE iocs 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 50 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 PEKIOD 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
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PHILLIPS POWER STATION (CONTINUED)
MONTH
NOV. 76
DEC. 76
OPERATING HOURS
BOILER
12 3456
SCRUBBER-ABSORBER
101 201 301 KOI
JAN. 77
FEB. 77
MAR. 77
COMMENTS
SCRUBBER AVAILABILITY INDEX INCLUDES THE TIME WHEN
ONE OR MORE MODULES WE«E AVAILABLE FOR SERVICE.
THE UTILITY REPORTS THAT BOILERS 2-6 REMAINED
COUPLED INTO THE SCRUBBING SYSTEM DURING THE REPORT
PERIOD. THE INTERIM IUCS 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 THL VARIOUS UNITS WITH NO FAILURES OR
APPRECIABLE WEAR OBSERVED. THE ADDITIONAL DEUATERING
AND REAGENT PREPARATION EQUIPMENT IS NOW BEING IN-
STALLED. THE CONTRACT HAS BEEN AWARDED TO DRAVO TO
PROVIDE THIOSORBIC LIME FOR THIS SCRUBBING SYSTEM.
ALL BOILERS HAVE BEEN HEAOEREO INTO THE SCRUBBER PLANT.
A NUMBER OF THE UNITS HE«E DOWN FOR OVERHAUL AND REPAIR
THE INTERIM IUCS POZ-0-TEC UNIT REMAINED IN SERVICE,
FILTERING OUT WATER ONLY. THE RECYCLE PUMP EVALUATION
IS CONTINUING. AFTER i»000 MRS. OF OPERATION, THE
CARBORUNDUM IMPELLERS AND WEAR RINGS STILL LOOK GOOD.
S02 AND PARTICULATE REMOVAL EFFICIENCIES ARE 50 * 99+*
RESPECTIVELY. INSTALLATION OF THE ADDITIONAL SILOS,
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PHILLIPS POWER STATION (CONTINUED)
MONTH
OPERATING HOURS
BOILER SCRUBBER-ABSORBER
2 3 •» 5 6 101 201 301
APR. 77
HAY 77
«»01 COMMENTS
THICKENERS. AND LIME FEEDERS IS STILL IN PROGRESS. FULL
COMPLIANCE PLANT OPERATIONS ARE SCHEDULED FOR DEC. 1977
FULL COMPLIANCE OPERATIONS WILL INCLUDE 83* S02 REMOVAL
FOR 2* SULFUR COAL UTILIZING THIOSORBIC LIME (6-12*MG>
A FIXATING THE SCRUBBER HASTES WITH THE IUCS P02-0-TEC
METHOD. THE FIXATED MATTER WILL BE HAULED AWAY TO AN
OFF.SITE DISPOSAL AND LANDFILL. IUCS HAS BEEN AWARDED
A 10-YEAR CONTRACT FOR THE USE OF THIS METHOD.
THE CARBORUNDUM IMPELLORS AND WEAR RINGS CONTINUE TO
LOOK GOOD AFTER MORE THAN 5000 HOURS OF OPERATION.
THIOSOKBIC LIME TESTS BEGAN IN LATE MAY BUT LASTED ONLY
ABOUT ONE WEEK. THE SCRUBBER SYSTEM WAS SHUT DOWN FOR
3 TO if DAYS IN MAY DUE TO LEAKING IN THE WET DUCT
HEADER THAT LEADS TO THE STACK. WHILE FIXING THE LEAK,
INSPECTION OF OTHER COMPONENTS REVEALED THAT THE BOILER
EXIT DAMPERS WERE ERODING. ONE 201 EXTERNAL MIST ELIMI-
NATOR ALSO WAS SEVERLY ERODED AND PLUGGED. ONCE THE
LEAK TO THE HEADER WAS REPAIRED, FLUE GAS FROM FOUR
BOILERS BEGAN TO BE SCRUBBED. TWO OF THE SIX BOILERS
ARE DOWN FOR MAINTENANCE. THE DAMPERS AND MIST ELIMINA-
TOR REPAIRS WILL BE CORRECTED AT A SCHEDULED OUTAGE
TIME. OVERALL SCRUBBER AVAILABILITY IS ABOUT 75 PER-
CENT. THE INTERIM SLUDGE DISPOSAL SYSTEM STILL IS
OPERATIONAL. THE PERMANENT SLUDGE DISPOSAL FACILITY IS
ON SCHEDULE FOR THE DECEMBER 1977 COMPLETION DATE.
PEDCo ENVIRONMENTAL
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYt
PARTICIPATES
36
KANSAS CITY POWER 4 LIGHT
HAWTHORN NO. 3
KANSAS CITY MISSOURI
140 MW
COAL 0.5-3.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
RETROFIT
11/72
OPERATIONAL
99 PERCENT
S02
70 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
OPEN LOOP 7.0 GPM/MW
UNSTABILIZEQ SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
S19/KW CAPITAL * 2.5 MILLS/KWH OPERATING
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE SCRUBBER PLANT HAS BEEN CONVERTED FROM A LIMESTONE FURNACE INJECTION
AND TAIL.END SCRUBBING STRATEGY TO A TAIL-END WET LIME SCRUBBING STHATEGr
LIME-BASED OPERATIONS COMMENCED ON FEBRUARY 7t 1977. COMPLIANCE TESTING
FOR KANSAS CITY PARTICULATE STANDARDS INDICATED THE NO.3 UNIT WAS WELL
WITHIN THE 0.17 POUND REGULATION. THE 2-MODULE SCRUBBER PLANT WAS IN
SERVICE «»08 HOURS IN APK1L (57 PERCENT OPERABILITY) AND 302 HOURS IN MAY
(58 PERCENT OPERABILITY),
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BACKGROUND INFORMATION
ON
HAWTHORN NOS. 3 AND t
THE HAWTHORN POWER STATION IS OWNED AND OPERATED BY THE KANSAS CITY POWER AND LIGHT COMPANY AND SITUATED IN A HEAVILY
INDUSTRIALIZED AREA ON THE NORTH BANK OF THE MISSOURI RIVER IN EAST KANSAS CITY. MISSOURI. THE PLANT CONTAINS FIVE COAL-FIRED
BOILERS. UNITS 1 AND 2 ARE CONSIDERED PEAK BOILERS. EACH RATED AT BO MW. UNITS 3 AND <» ARE CYCLIC-LOAD BOILERS. EACH RATED AT
100 MW. UNIT 5 IS A BASE-LOAD BOILER RATED AT 500 MW. UNITS 1 TO H WERE PURCHASED AND PLACED IN SERVICE BETWEEN 1950 AND 1955.
UNIT NO. 5 WAS PLACED IN SERVICE IN EARLT 1970. ALL THE HAWTHORN BOILERS ARE DRY-BOTTOM PULVERIZED-COAL-FIRED UNITS DESIGNED AND
MANUFACTURED BY COMBUSTION ENGINEERING. TWO GRADES OF COAL ARE BURNED AT THE STATION. A LOW SULFUR COAL FROM THE WYOMING AREA
THAT TYPICALLY CONTAINS O.SX SULFUR AND 11 PERCENT ASH WITH A HEATING VALUE OF 9600 BTU/LB AND A HIGH SULFUR COAL FROM OKLAHOMA
THAT TYPICALLY CONTAINS s.sx SULFUR AND i* PERCENT ASH WITH A HEATING VALUE OF 11,300 BTU/LB. OF THE FIVE COAL-FIRED BOILERS
INSTALLED AT THE STATION, TWO UNITS 3 AND H HAVE BEEN RETROFITTED WITH PARTICULATE AND SULFUR DIOXIDE SCRUBBER PLANTS.
THE ORIGINAL SCRUBBER PLANTS INSTALLED ON UNITS 3 AND «» CONSISTED OF LIMESTONE INJECTION AND TAIL-END WET SCRUBBER MODULES
SUPPLIED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE NOVEMBER 1972 AND AUGUST 1972, RESPECTIVELY. A GENERAL PROCESS
DESCRIPTION OF THE PROCESS FOLLOWS* DRY LIMESTONE WAS INJECTED DIRECTLY INTO THE FURNACE BOX AND CALCINED TO LIME. THE FURNACE-
CALCINED LIMESTONE AND BOILER FLUE GAS WERE THEN DISCHARGED TO A TAIL-END WET SCRUBBING SYSTEM CONSISTING OF TWO MARBLE-BED
ABSORBERS WHERE PARTICULATES AND SULFUR DIOXIDE WERE REMOVED FROM THE GAS STREAM. THE SPENT LIME AND OTHER SCRUBBING WASTES WERE
THEN DISCHARGED INTO A COMMON CLARIFIER TANK AND THE UNDERFLOW WAS PUMPED, UNTREATED AND UNSTABILIZED, TO AN UNLINED
DISPOSAL POND USED FOR THE DISPOSAL OF FLY ASH FROM THE OTHER BOILERS. THE SCRUBBER PLANT INSTALLED ON EACH BOILER CONTAINED
TWO IDENTICAL MARBLE-BED ABSORBERS, EACH CAPABLE OF TREATING 500.000 ACFM OF FLUE GAS AT 300 F. A CHEVRON-TYPE MIST
ELIMINATOR AND A FINNED-TUBE STEAM REHEATER WERE ALSO INCORPORATED IN EACH MODULE IN ADDITION TO A MIST ELIMINATOR WASH
SYSTEM CONSISTING OF EIGHT AUTOMATICALLY-OPERATED WATER LANCES. BY-PASSING OF THE MODULES WAS POSSIBLE THROUGH A SERIES OF
DAMPERS AND DUCTWORK AROUND EACH MODULE.
THE ORIGINAL SCRUBBER DESIGN OF THE SYSTEM INSTALLED ON THE NO. it BOILER HAD TO BE MODIFIED SHORTLY AFTER START-UP BECAUSE
OF BOILER TUBE PLUGGING ATTRIBUTED TO THE LIMESTONE INJECTION. THE MODE OF OPERATION OF THIS SYSTEM WAS MODIFIED TO LIMESTONE
INJECTION INTO THE FLUE GAS DUCT NEAR THL INLET TO THE MARBLE-BED ABSORBER. THE SIMPLIFIED PROCESS FLOW DIAGRAMS OF THESE
ORIGINAL SCRUBBER PLANTS ARE PRESENTED IN APPENDIX B
95
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HAWTHORN UNIT NO. 3
OPERATING HOURS FGO OPERA8ILITY (X)
MONTH BOILER MODULE 3A MODULE 3B MODULE A MODULE. B COMMENTS
JUL. 75 584 0 0 PROBLEMS WITH MODULE 3A INCLUDED A LEAK IN CITY
WATER LINE, A PLUGGED DUCT TO THE I.D. FAN.
A MALFUNCTIONING OUTLET OA"PER FROM THE
SCRUBBER.
2<»7 «»2 MARBLES WERE LOST FROM THE BED AND A SPRAY HEADER
WAS BROKEN.
AUG. 75 0 0 00 0 LUST 1.0. FAN FOR HALF OF THE BOILER. CARRYOVER
OF JULY PROBLEMS
SEP. 75 358 247 81 69 23 OUTAGE DUE TO CLEANING AND MECHANICAL REPAIRS.
POTS, COVERS, AND MARBLES IN THE MARBLE BED
OF MODULE 3B WERE REPLACED.
OCT. 75 180 117 ItS 65 81 MODULE 3A OUTAGE WAS DUE LARGELY TO REPLACEMENT
OK A RECYCLE PUMP MOTOR. A SCHEDULED BOILER
OVERHAUL REDUCED BOILER OPERATION HOURS.
NOV. 75 0 0 00 0 BOILER AND SCRUBBERS WERE SHUT DOWN FOR A
SCHEDULED TRUBINE OVERHAUL.
DEC. 75 0 0 00 0 THE SYSTEM IS SCHEDULED TO 60 BACK ON-LINE IN
JANUARY 1976.
JAN. 76 0 0 00 0 SYSTEM WAS DOWN ALL MONTH BECAUSE OF FROZEN
EOUIPMENT AND LINES AND A MANPOWER SHORTAGE DUE
TO A BOILER AND TURBINE OVERHAUL ON ANOTHER UNIT
AT THIS STATION.
FEB. 76 503 140 7 37 1 SCRUBBER OUTAGES RESULTED FROM PLUGGING IN THE
SCRUBBER BED, CAUSED BY CONVERSION FROM AN UNDER-
BED TO OVEH-BED SPRAY SYSTEM.
96
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HAWTHORN NO. 3 (CONTINUED»
OPERATING HOURS FGD OPERABILITY (X)
MONTH BOILER MODULE 3A MODULE 3B MODULE A MODULE B COMMENTS
MAR. 76 0 0 00 0 RECONVERSION OF MODULE 3B'S SPRAY SYSTEM ARRANGE-
MLNT 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 00 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. 76 505 198 220 39 «»«f THE UTILITY IS IN THE PROCESS OF MODIFYING THE
DEMISTER WASH SYSTEM BOTH UNITS NOS. 3 AND 4.
THE WATER LANCESt FORMERLY CONSTRUCTED OF FRPt
ARE BEING CHANGED TO CARBON STEEL COMPONENTS IN
OKQER TO RECTIFY LOSS OF SPRAT NOZZLES AND
SUBSEQUENT SHATTERING OF THE LANCES,
JUL. 76 THE UTILITY IS NOW IN THE PROCESS OF CONVERTING
AUG. 76 THIS SYSTEM FROM LIMESTONE INJECTION AND TAIL END
SCRUBBING TO A LIME SLURRY BASED SCRUBBING SYSTEM.
SEP. 76 THE SYSTEM WAS VIRTUALLY OUT OF SERVICE THE
OCT. 76 ENTIRE REPORT PERIOD. MANPOWER COMMITMENTS WERE
SERIOUSLY HAMPERED BY A MAJOR EXPLOSION WHICH
OCCURRED IN THE COAL MILL PULVERIZING AREA OF
HAWTHORN NO. 5.
NOV. 76 0 0 00 0 THE UNIT UIU NOT OPERATE DURING THE PERIOD BECAUSE
DEC. 76 0 0 0 0 0 OF THE ONGOING MAJOR MODIFICATIONS BEING IMPLE-
MENTED TO THE SCRUBBING SYSTEM. THE SYSTEM SHOULD
BE READY FOR OPERATION FEB.l. THE UNIT MUST UNOEH-
97
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OPERATING HOURS
MONTH BOILER
HAWTHORN NO. 3 (CONTINUED)
FGD OPERABILITY (*)
MODULE 3A
MODULE 4 A
JAN. T7
FEB. 77
MAR. 77
0
383
482
0
337
476
0
264
411
0
86
99
0
69
85
APR. 77
HAY. 77
foe
302
408
302
57
56
57
58
GO A SERIES OF TESTS TO INSURE COMPLIANCE WITH
CITY AND FEDERAL REGULATIONS.
THE NO.3 UNIT WAS DOWN THE ENTIRE MONTH OF JANUARY
FOR COMPLETION OF MODIFICATIONS AND REPAIRS TO THE
SCRUBBERS AND BOILER. THE UNIT BECAME AVAILABLE
FOR SERVICE AND TESTING ON FEB. 7. THE UNIT'S MEA-
SURED PARTICULATE EMISSIONS AT THE SCRUBBER OUTLET
WAS 0.12 LB/MM BTU CWELL BELOW THE 0.17 LB REGS).
A BLEND OF APPROXIMATELY 2.0 PERCENT SULFUR IS
BEING FIRED IN THE BOILER. THE CONVERSION FROM
LIMESTONE TO LIME HAS BEEN GOOD. SOME INITIAL
PROBLEMS WITH PROCESS CHEMISTRY CONTROL HAVE BEEN
CORRECTED. IN ADDITION. SOME MINOR MECHANICAL
PROBLEMS IN THE FORM OF PUMP MALFUNCTIONS AND LOSS
OF SLAKING WATER PRESSURE HAVE BEEN ENCOUNTERED.
SYSTEM OPERATIONS ARE STILL CONTINUING AT OX
SOLIDS AND 100* SLOWDOWN. FRESH WATER MAKE-UP
REQUIREMENT IS APPROXIMATELY 7.0 GPM/MW.
THE SYSTEM IS NOW OPERATING WELL AT ABOUT 15-25
PERCENT SLOWDOWN. THE PH CONTROL SYSTEM OPERA-
TIONS HAVE BEEN EXCELLENT. DURING MAY THE BOILER
BURNED GAS FOR 216 HOURS. THE OPERABILITY VALUES
00 NOT INCLUDE THESE HOURS. S02 REMOVAL EFFICIEN-
CY IS ESTIMATED AT 50-60 PERCENT FOR BOTH A AND B
98
PEDCo ENVIRONMENTAL
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HAWTHORN wo. 3 (CONTINUED)
OPERATING HOURS FGD OPERABILITY (X)
MONTH BOILER MODULE 3A MODULE 3B MODULE A MODULE B COMMENTS
SCRUBBING MODULES. ALTHOUGH ACTUAL TESTS HAVE NOT
BEEN RUN FOR ABOUT ONE-ANO-A-HALF YEARS. CURRENT-
LY. BOTH MODULES ARE OPERATING SIMULTANEOUSLY.
99
PEDCO ENVIRONMENTAL
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEf.
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCYt
PARTICULATES
37
KANSAS CITY POWER « LIGHT
HAWTHORN NO. *
KANSAS CITY MISSOURI
100 MW
COAL 0.5-3.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
RETROFIT
6/72
OPERATIONAL
99 PERCENT
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
70 PERCENT
OPEN LOOP 7.0 GPM/MW
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
*19/KW CAPITAL * 2.5 MILLS/KWH OPERATING
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE SCRUBBER PLANT HAS BEEN CONVERTED FROM A LIMESTONE FURNACE INJECTION
AND TAIL-END SCRUBBING DESIGN TO A TAIL-END WET LIME SCRUBBING SYSTEM.
OPERATIONS IN THE LIME SCRUBBING MODE COMMENCED ON JANUARY 1, 1977.
COMPLIANCE TESTING FOR KANSAS CITY PARTICULATL REGULATIONS INDICATED THE
UNIT IS MEETING THE 0.17 POUND REGULATION. THE 2-MODULE SCRUBBER PLANT
WAS IN SERVICE 211 HOURS IN APRIL J^a PERCENT OPERABILITY> AND iso HOURS
IN HAY (5«» PERCENT OPERABILlTY).
100
PEDCo ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
HAWTHORN NOS. 3 AND "»
THE HAWTHORN POWER STATION is OWNED AND OPERATED BY THE KANSAS CITY POWEK AND LIGHT COMPANY AND SITUATED IN A HEAVILY
INDUSTRIALIZED AREA ON THE NORTH BANK OF THE MISSOURI RIVER IN EAST KANSAS CITYt MISSOURI. THE PLANT CONTAINS FIVE COAL-FIRED
BOILERS. UNITS 1 AND 2 ARE CONSIDERED PEAK BOILERS, EACH RATED AT 80 MW. UNITS 3 AND
-------
HAWTHOHN NO. "*
OPERATING HOURS FGO OPERftBILITY (X)
MONTH BOILER MODULE <*A MODULE <»B MODULE A MODULE B COMMENTS
JUL. 75 516 <*1 128 8 25 MARBLE BED PLUGGING AND STRAINER PROBLEMS ON BOTH
MODULES.
AUG. 75 168 212 LOST HALF OF BOILER DUE TO NO. HB 1,0. 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 ZERO
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 <*B SIDE.
NLW PROCESS DESIGN - MARBLES REMOVED FROM SCRUB-
BER BED OF MODULE A AND REPLACED WITH A STAIN-
LESS STEEL PERFORATED BED. THE MARBLES WERE
REMOVED BECAUSE OF CONTINUING OPERATIONAL DIF-
FICULTIES. VERY GOOD,PERFORMANCE RESULTED IN
INCREASED AVAILABILITY AND CONTINUATION OF
HIGH PARTICULATE REMOVAL EFFICIENCY (97 PERCENT).
OCT. 75 721 1(29 656 60 91 MINOR BOILER RESTRICTION ON THE MODULE «A SIDE
BETWEEN THE ECONOMIZER AND THE INLET DRAFT DUCT-
CHEMISTRY PROCESS MODIFICATION OF RUNNING AT 100
PERCENT SLOWDOWN AND ZERO PERCENT SOLIDS IS STILL
IN PROGRESS. S02 REMOVAL EFFICIENCY IN THE 50 TO
60 PERCENT RANGE. KcP*L IS CONCENTRATING HEAVILY
ON PARTICULATE EMISSION CONTROL.
102
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HAWTHORN NO. U »CONTINUED!
OPERATING HOURS F60 OPERABILITY (XI
MONTH BOILER MODULE 4A MODULE HB MODULE A MODULE B COMMENTS
NOV. 75 720 0 713 0 99 MODULE «»A WAS SHUT DOWN CURING THE REPORT PERIOD
BECAUSE OF LOSS OF DRAFT THROUGH THE DUCTWORK
FROM THE ECONOMIZER TO THE AIR PREHEATER. THE
REHEATER PLUGGED FREgUENTLY UNTIL THE SYSTEM WAS
SHUT DOWN.
DEC. 75 6UO 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 »50 0 78 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
BtD PLUGGING AND LOSS OF A RECYCLE PUMP OCCURRED
ON MODULE HB.
MAR. 76 706 0 21 0 3.4 DURING THE REPORT PERIOD THE UNIT'S BYPASS SEALS
APR. 76 550 231 220 «*2 40 WERE REPLACED WITH SLIDE-GATE DAMPERS.
MAY 76 965 99 99 27 27 THE UTILITY REPORTS THE B-SIDE REHEATER IS STILL
JUN. 76 <*60 294 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 CURRENTLYt 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
103
PEDCo ENVIRONMENTAL
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HAWTHORN NO. 4 (CONTINUED)
MONTH BOILER MODULE 4A MODULE <»B MODULE A MODULE B COMMENTS
SLURRY-BASED SYSTEM.
SEP. 76 THE SYSTEM WAS OUT OF SERVICE VIRTUALLY THE
OCT. 76 ENTIRE REPORT PERIOD. OPERATIONS AND MANPOWER
COMMITMENTS WERE SERIOUSLY HAMPERED BY A MAJOR
EXPLOSION WHICH OCCURRED IN THE COAL MILL PUL-
VERIZING AREA OF HAWTHORN NO. 5.
NOV. 76 486 442 0 91 0 THE UTILITY IS IN THE PROCESS OF CONVERTING THE
DEC. 76 0 0 0 00 SYSTEM TO A WET-LIME SCRUBBING SYSTEM. START-UP
IN THE LIME SCRUBBING MODE WILL COMMENCE
THE FIRST PART OF JANUARY.
JAN. 77 572 486 424 85 74 THE UNIT BECAME AVAILABLE FOR SERVICE IN THE LIME
FEB. 77 591 468 292 80 50 SCRUBBING MODE ON JAN.l. 1977. TESTING FOR COMPLI-
MAR. 77 539 440 525 97 82 ANCE WITH PARTICULATE CODES OCCURRED DURING THE
MONTH. THE 0.17 LB/MM BTU EMISSION REGULATION IS
BEING MET BY THE NO.4 UNIT. A BLEND OF APPROXI-
MATELY 2.OX SULFUR COAL IS BEING BURNED IN THE
TO REMEDY THIS. SOME REHEAT PROBLEMS AND PLUGGING
IN THE SUCTION OF THE RECYCLE TANK BY A RAINCOAT
WERE ALSO REPORTED. SYSTEM OPERATIONS ARE STILL
CONTINUING AT 0% SOLIDS AND 1001 SLOWDOWN. THE
FRESH WATER MAKE-UP REQUIREMENT IS 7.0 GPM/Mw.
104
S/^^\
PEDCo ENVIRONMENTAL
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HAWTHORN NO. 4 (CONTINUED)
OPERATING HOURS FGD OPERABILITY (XI
MONTH BOILER MODULE
-------
TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCYi
PARTICULATES
38
KANSAS CITY POWER & LIGHT
LA CYGNE NO 1
LA CYGNE KANSAS
820 MU
COAL 5.0 PERCENT SULFUR
BABCOCK * WILCOX
LIMESTONE SCRUBBING
NEW
2/73
OPERATIONAL
98 PERCENT
S02
76 PERCENT
WATER HAKE UP
OPEN LOOP l.i» GPM/MW
SLUDGE DISPOSAL
UNSTAfilLIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
S52/KH CAPITAL * 0.9H MILLS/KWH OPERATING
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED POWER-GENERATING UNIT
CONSISTS OF EIGHT SCRUBBER MODULES FOR FLY ASH AND S02 REMOVAL. EACH
MODULE INCLUDES A VENTURI SCRUBBER IN SERIES WITH A 2-STAGE IMPINGEMENT
PLATE ABSORBER. THE SCRUBBER PLANT IS AN INTEGRAL PART OF THE POWER-
GENERATING COMPLEX, ALLOWING NO FLUE GAS BYPASS. INITIAL OPERATIONS
COMMENCED IN FEB. 1973. COMMERCIAL SERVICE WAS ATTAINED BY JUNE 1973,
TOTAL SYSTEM AVAILABILITY FOR THE MONTH OF APRIL WAS 93 PERCENT.
106
PEDCo ENVIRONMENTAL
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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 1, 1973, AS A JOINT
PROJECT OF KANSAS 6AS AND ELECTRIC 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 820-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 26 MU.
THE BOILER AT LA CYGNE, DESIGNED BY BABCOCK AND WILCOXt IS A DRY-BOTTOM, PULVERIZED-COAL-FIRED CYCLONE UNIT. THE COAL
BURNED IS LOW-GRADE. SUBBlTUNlNOUS, WITH AN AS-FIRED HEATING VALUE OF 9000 TO 9700 BTU/LB 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 APPENDIX B.
PROBLEMS AND SOLUTIONS
THE FGO 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 FIRED. 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.
THE CORROSION ASSOCIATED WITH CONDENSATION OF ACID VAPORS FROM THE GAS ON THE REHEATER TUBE BUNDLES WAS CONTROLLED BY
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 RCDUCLD THE MAXIMUM GENERATING CAPACITY OF THE BOILER BY LIMITING.THE AIR AVAILABLE FOR COAL
COMBUSTION.
107
PEDCo ENVIRONMENTAL.
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LA CYGNE NO. 1 (CONTINUED)
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 PREVENTIVE 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 SUMMER OF 1977. THE ADDITIONAL MODULE IS ESTIMATED TO COST APPROXIMATELY S5.2 MILLION AND WILL
ENABLE THE PLANT TO INCREASE ITS MAXIMUM CONTlNOUS GENERATING CAPACITY FROM THE CURRENT 700-MW 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.Dt 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.
ADDITIONAL DATA AND INFORMATION ON THt SUBSEUUENT SCRUBBER PLANT OPERATIONS ARE PROVIDED ON A CHRONOLOGICAL BASIS IN THE
TABLE THAT FOLLOWS.
108
PEDCo ENVIRONMENTAL
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OPERATING HISTORY
LA CYGNE UNIT NO. 1
PERCENT AVAILABLITT-BY MODULE
MONTH
JAN.
FEB.
MAR.
APR.
HAY
JUN.
JUL.
AU6.
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
MAR.
APR.
MAY
JUN.
JUL.
AUG.
BOILER HOURS
74
74
7*
74
7«»
7«»
74
74
74
74
74
74
75
75
75 694
75
75 683
75 667
75 590
75 630
A
49
66
67
69
92
75
90
69
90
90
82
95
88
78
75
B
32
68
70
83
84
80
90
88
71
71
96
85
85
90
88
C
44
59
75
78
83
80
73
73
60
60
90
94
84
90
87
D E
87
76
BOILER
88
85
90
81
81
76
61
61
BOILER
BOILER
BOILER
76
5 DAYS
90
85
84
78
23
52
F G
37
100
81
65
AVERAGE
50
69
SHUTDOWN
74
78
82
85
81
83
84
84
100
84
83
79
78
89
85
85
88
80
87
77
99
86
84
84
80
80
86
80
85
81
76
76
SHUTDOWN
SHUTDOWN
SHUTDOWN
93
OF
90
84
85
92
92
OPERATION
89
86
87
85
96
83
89
85
83
90
89
86
86
84
109
COMMENTS
NOTE* THE 1974 FIGURES ARE BASED UPON
ACTUAL SYSTEM OPERATION HOURS AS A FUNCTION
OF ACTUAL BOILER HOURS. DURING REDUCED
LOAD CONDITIONS SOME OF THE MODULES WERE NOT
REQUIRED AND THEREFORE SHUT DOWN. ALTHOUGH
THEY WERE AVAILABLE. AVAILABILITY WAS
THEREFORE HIGHER THAN SOME OF THE POSTED
FIGURES INDICATE. 1975 FIGURES ARE BASED
UPON SYSTEM AVAILABLE HOURS AS A FUNCTION OF
HOURS IN THE PERIOD.
MODULES A ANU 0 ARE USED FOR RESEARCH TESTS.
ONE MODULE IS SHUT DOWN EACH EVENING FOR
CLEANING.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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F6D SYSTEM AVAILABILITY (CONTINUED)
LA CYGNE UNIT NO. 1
PERCENT AVAILABLITY-BY MODULE
MONTH
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
MAR.
APR.
75
75
75
75
76
76
76
76
BOILER HOURS
610
231
346
597
618
594
643
A
78
66
93
91
86
9*
92
B
84
77
90
67
85
90
90
C
84
46
60
81
91
86
88
0
85
74
93
85
72
91
93
BOILER
E
79
72
96
87
84
92
94
F G
78 74
73 65
89 94
89 84
52 84
93 95
91 91
AVERAGE
80
68
91
86
83
92
91
OVERHAUL
COMMENTS
SYSTEM SHUTDOWN OCT. 16, 1975 OWING TO
PROBLEMS WITH GENERATOR AND I.D. AIR FAN.
SYSTEM REMAINED INOPERATIVE THROUGHOUT THE
HONTH.
AVAILABILITY FIGURES FOR OCTOBER AND
NOVEMBER DO NOT INCLUDE THE OUTAGE TIME FROM
OCTOBER 16 TO NOVEMBER 13. BOILER OUTAGES
OF 80« 50. AND 11 HOURS, TOTALING 141 HOURS,
OCCURRED DURING DECEMBER.
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 89 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.
110
PEDCo ENVIRONMENTAL
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FGD SYSTEM AVAILABILITY (CONTINUED*
LA CYGNE UNIT NO. 1
PERCENT AVA1LABLITY-BY MODULE
MONTH BOILER HOURS A 8 C D E F 6 AVERAGE COMMENTS
JUN. 76 93 9"» 9
-------
FGD SYSTEM AVAILABILITY ICONTINUED)
LA CYGNE UNIT NO. 1
PERCENT AVAILABILITY - BY MODULE
MONTH BOILER HOURS A B C 0 E F G AVERAGE COMMENTS
NOV. 76 627 95 93 94 95 94 93 94 9<» DURING THE MONTH OF DECEMBER THE UTILITY
DEC. 76 706 87 89 81 94 94 95 91 90 CONDUCTED SOME MINOR REPAIR AND MODIFICATION
UORK ON THE AOCS. SPECIFICALLY A-MOOULE
EXPERIENCED SOME VENTURI RECYCLE PUMP
PROBLEMS AND THE C-MOOULE»S REHEAT STEAM
TUBE BUNDLES *ERE INCREASED IN NUMBER FROM
FOUR TO LIGHT.
JAN. 77 714 94 90 95 95 95 92 90 93 KCPiL REPORTS THAT THE 8TH MODULE HAS BEEN
FEB. 77 634 93 93 93 94 93 94 88 93 IMSTftLLED AND WILL 9E PLACED IN SERVICE SOME-
MAR. 77 94 92 86 94 91 94 90 92 TIME DURING THE MONTH OF APRIL. THE SYSTEM
MOOIFICflTIONS PROSRAM IS STILL IN PROGRESS.
TWO CRUCIAL MODIFICATION AREAS ARE REHEAT AND
MIST ELIMINATION. ADDITIONAL BANKS OF STEAM
TUBE BUNDLES HAVE BEEN INSTALLED IN SOME
MODULES. THE MIST ELIMINATORS IN TWO MODULES
HAVE BEEN MODIFIED TO THE POINT WHERE THEY
HAVE BEEN OPERATING CONTINUOUSLY CLEAN. THE
nacs's WATER LOOP is NOW 95* CLOSED. ALSO,
A NEW SETTLING POND IS BEING INSTALLED AT THE
PLANT. THE PLANT IS STILL GENERATING 700-720
MW DURING THE DAY AND 500-570 MW AT NIGHT.
50 F OF REHEAT HAS BEEN DETERMINED AS THE
NECESSARY AMOUNT FOR THE LA CYGNE NO.l UNIT.
112
PEDCo ENVIRONMENTAL-
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MONTH
APR. 77
HAY 77
BOILER HOURS
F6D SYSTEM AVAILABILITY (CONTINUED)
LA CTGNE UNIT NO. 1
PERCENT AVAILABILITY BY MODULE
B C D E F G
COMMENTS
DURING APRIL, THE AVERAGE AVAILABILITY IN-
DEX FOR THE SEVEN MODULES WAS 92.5
PERCENT. THE EIGHTH MODULE IS READY FOR
OPERATION AND IN FACT HAS BEEN RUN FOR TWO
DAYS. HOWEVER, THE BOILER AND SCRUBBER
SYSTEM ULRE SHUT DOWN IN MAY DUE TO TURBINE
PROBLEMS. THE BOILER AND EIGHT MODULES ARE
EXPECTED TO START UP ABOUT JUNE 27. WHEN IT
IS EXPECTED THAT 6gO MH WILL GO ON LINE.
THE MIST ELIMINATOR WASHING CONFIGURATION IS
BEING CHANGED TO WORK COUNTERCURRENT To THE
GAS FLOW. ADDITIONAL TUBE BUNDLES ARE BEING
ADDED TO INCREASE THE REHEAT AREA. THESE
CHANGES SHOULD BE TAKEN CARE OF BY THE END
OF JUNE. THE NEW SETTLING POND IS STILL
BEING DNAUM UP. EXCAVATION HAS NOT BEGUN.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 0^/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAHE
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
«H
KANSAS POWER & LIGHT
LAWRENCE NO 4
LAURENCE KANSAS
125 MH
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
RETROFIT
12/66
OPERATIONAL
99 PERCENT
S02
75 PERCENT
WATER HAKE UP
SLUDGE DISPOSAL
UNSTABILIZED SLUuGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGHOUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE NEW LIMESTONE FGD SYSTEM COMMENCED OPERATIONS IN EARLY JANUARY 1977-
THERE HAVE BEEN NO FORCED SCRUBBER OUTAGES SINCE START-UP.
CONTINUOUS S02 MONITORS ARE RECORDING S02 REMOVAL EFFICIENCIES
BETTER THAN 85 PERCENT, PAHTICULATE REMOVAL IS REPORTED TO
BE EXCELLENT. YIELDING NO VISIBLE PLUME. MINOR PROBLEMS HAVE
REVOLVED AROUNU MAINTAINING SOLIDS LEVELS. SEVERAL DIFFERENT
TYPES OF SLURRY PUKPS ARE BEING COMPARED UNDER OPERATING CONDITIONS.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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BACKGROUND INFORMATION
ON
LAWRENCE: NO.
-------
A HISTORY OF PROBLEMS WITH THE LIMESTONE INJECTION SYSTEM AT LAWRENCE NO. U
PROBLEMS WITH THE FGO SYSTEM ON BOILER NO. «» INCLUDED BUILDUP AND PLUGGING OF THE INLET DUCT WHERE HOT GASES ENTER THE
SCRUBBERS, EROSION OF SCRUBBERS HALLS, CORROSION OF SCRUBBERS INTERNALS, BUILDUP ON 10 FAN ROTORS, AND PLUGGING OF DRAIN LINES,
MARBLE BEDS. AND OEMISTERS. LOW S02 REMOVAL WAS CAUSED BY OVERBURNING OF THE LIMESTONE AND DROPOUT OF THE LIME WITH THE ftSH IN
THE BOTTOM OF THE SCRUBBER.
THE SCRUBBERS WERE MODIFIED IN 1969 BY RAISING THE. OEMlSTER AND ADDING SOOT BLOWERS IN THE INLET OUcT 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 COftTING OF THE INTERIOR OF THE SCRUBBERS, REPLACEMENT OF ALL INTERNAL
STEEL PIPES WITH PLASTIC AND FIBERGLASS, AND REPLACEMENT OF STAINLESS STEEL OEMISTERS WITH FIBERGLASS, SINCE OEMlSTER PLUGGING
WAS NOT COMPLETELY ELIMINATED, THE UNIT WAS WASHED MANUALLY EVERY NIGHT TO MAINTAIN THE REQUIRED OUTPUT.
THE MODIFICATIONS IN THE SUMMER OF 1972 ON THE TWO FSD MODULES INCLUDED ENLARGEMENT OF THE CRYSTALLIZATION TANK, AND
INSTALLATION OF NEW PLASTIC SPRAY NOZZLES, NEW SLURRY PUMPS AND 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 OLGREE OF S02 REMOVAL IS REQUIRED FOR COMPLIANCE. THE SCRUBBtR 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 4-HOUR SHIFTS PER
SCRUBBER PER WEEK.
IN 197«f THIS UNIT WAS AVAILABLE FOR OPERATION 3t3 DAYS. FIFTY PERCENT OF THE FUEL CONSUMED WAS COAL, 2 PERCENT FUEL OIL,
AND "»e PERCENT NATURAL GAS. DURING Ig75 THIS UNIT WAS AVAILABLE FOR OPERATING 333 DAYS. SIXTY-FOUR PERCENT OF THE FUEL CONSUMED
WAS COAL, 3 PERCENT FUEL OIL, AND 33 PERCENT NATURAL GAS.
BY LATE 1976, THE ORIGINAL EMISSION CONTROL SYSTEM WAS REPLACED WITH A ROD AND SPRAY TOWER SCRUBBER FOR PARTICULATE AND
S02 REMOVAL. INFORMATION ON THE ORIGINAL AND REPLACEMENT SYSTEM IS GIVEN IN THE FOLLOWING TABLE.
116
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OPERATING HISTORY - NOW DEFUNCT LIMESTONE INJECTION SYSTEM - LAWRENCE NO. H
MONTH
JUL. T5
AUG. 75
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN. 76
FEB. 76
MAR. 76
APR. 76
HAT 76
JUN. 76
JUL. 76
AUG. 76
OPERATING HOURS
BOILER MODULE A MODULE b
AVAILABILITY
MODULE A MODULE B
NOT LOGGED
NOT LOGGED
NOT LOGGED
NOT LOGGED
117
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
EVERY NIGHT. THEREFOREt ONE Op 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.
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 COAL. 12 PERCENT NATURAL GAS, AND 8 PERCENT
FUEL OIL. THE UTILITY IS REPLACING THIS SCRUBBER SYSTEM
WITH A VENTRI-ROO 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.
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MONTH
SEP. 76
OCT. 76
NOV. 76
DEC. 76
OPERATING HISTORY
BOILER
OPERATING HOURS
MODULE A MODULE B
NOW DEFUNCT LIMESTONE INJECTION SYSTEM - LAWRENCE NO. H (CONTINUED)
COMMENTS
AVAILABILITY
MODULE. A MODULE B
TURBINE OVERHAUL AND REPAIR
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
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 taILL CONTINUE TO FIRE LOW SULFUR
WYOMING COAL (0.5* SULFUR* 10,000 BTU/LB),
lie
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OPERATING HISTORY - WET LIMESTONE SCRUBBING Sr.^TEM - LAWRENCE NO. i»
JAN. 77 THE NEW LIMESTONE FGD SYSTEM BECAME COMMERCIALLY OPERABLE IN EARLY JANUARY 1977. THERE HAVE BEEN NO FORCED OUTAGES
FEB. 77 AND NO DOWNTIME SINCE START-UP. THE UTILITY REPORTS THAT BOTH pARTICULATE AND S02 REMOVALS ARE QUITE SATISFACTORY.
MAR. 77 MINOR PROBLEMS HAVE Br.EN RELATED TO MAINTAINING DESIRED SOLIDS LEVEL IN THE MAKE-UP TANK. MODIFICATION PLANS
INCLUDE CESSATION OF SLURRY DILUTION, WHICH CURRENTLY PRECEDES THE INTRODUCTION OF THE FRESH LIMESTONE SLURKY
INTO THE RECIRCULATION LOOP. THE UTILITY PLANS TO PUMP THE 35-PERCENT SOLIDS SLURRY DIRECTLY FROM THE SLURRY TANK
INTO THE RECIRC LOOP. CURRENTLY SEVERAL DIFFERENT MAKES OF SLURRy PUMPS ARE BEING USED. ALL ARE FUNCTIONING WELL
so FAR* THE PUMPS HAVE NOT BEEN IN SERVICE LONG ENOUGH FOR COMPARISONS TO BE DRAWN.
APR. 77 THE SCRUBBER WAS NOT REQUIRED FOR SERVICE DURING THE REPORT PERIOD BECAUSE NATURAL GAS WAS FIRED IN THE BOILER. KP&L
MAY 77 ANTICIPATES THAT THE NATURAL GAS AVAILABILITY SHOULD LAST THROUGHOUT THE MAJORITY OF THE SUMMER, REQUIRING NO SCRUBBER
PLANT OPERATIONS DURING THE PERIOD.
119
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 06/77
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
KANSAS POWER & LIGHT
LAWRENCE NO 5
LAURENCE KANSAS
*00 MW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
NEW
6/76
OPERATIONAL
99 PERCENT
S02
65 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNSTABILIZEO SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE ORIGINAL LIMESTONE INJECTION AND TAIL-END SCRUBBING SYSTEM IS STILL
IN SERVICE WHILE A NLW ROD-SCRURBER AND SPRAY TOWER ABSORBER SYSTEM IS
BEING ERECTED ALONGSIDE THE EXISTING SYSTEM. THE NEW SCRUBBER PLANT
INCLUDES 2 MODULES EACH CAPABLE OF HANDLING APPROXIMATELY 50* OF THE TO-
TAL BOILER FLUE GAS FLOW. THE SYSTEM DESIGNER AND SUPPLIER IS COMBUSTION
ENGINEERING. THE UNIT FIRES APPROXIMATELY 1«»0 TONS/HOUR OF LOW SULFUR
WYOMING COAL HAVING HEAT AND SULFUR CONTENTS OF 10,000 BTU/LB AND 0.5%.
120
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BACKGROUND INFORMATION
ON
LAURENCE NO. 5
UNIT NO. 5 AT LAWRENCE POWFR STATION IS A CYCLIC-LOAD STEAM BOILER EQUIPPED TO BURN COAL. NATURAL GAS SUPPLEMENTED WITH OIL,
OR COMBINATIONS OF THESE FUELS. THE BOILER, PLACED IN SERVICE IN 1971, HAS A RATED CAPACITY OF «*00 MW WHEN BURNING COAL AND
NATURAL GAS.
THE COAL NOW BURNED 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*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 i PERCENT MAGNESIUM CARBONATE).
SPENT SLURRY FROM THE UNIT ALONG WITH THE SLURRY FROM UNIT NO. i» IS SENT TO THREE INTERCONNECTED UNLINED SLUDGE DISPOSAL
PONDS OF 16, 26* AND H ACRES. COOLING TOWER SLOWDOWN SUPPLIES MAKE-UP WATER TO THE POND SYSTEM. CLARIFIED POND WATER IS RECYCLED.
THE SLUDGE IS NOT TREATED FURTHER AND IS REPORTED TO SET AND SOLIDIFY IN THE PONDS.
PROBLEMS AND SOLUTIONS
PROBLEMS WITH THE FGD SYSTEM ON BOILER NO. 5 WERE SIMILAR PROBLEMS TO THOSE OF THE SYSTEM ON BOILER NO. <»* LOCALIZED COR-
ROSION IN SOME EQUIPMENT, UNSATISFACTORY DAMPER OPERATION, DEMISTER FOULING, EXPANSION JOINT FAILURE, AND RAPID WEAR OF SLURRY-
RECIRCULATING PUMPS. IN ADDITION TO THESE PROBLEMS, BOILER NO. 5 is PLAGUED WITH POOR FLUE GAS DISTRIBUTION TO THE EIGHT FGD
MODULES WHICH, UNLIKE THE MODULES ON BOILER NO. H ARE ALL INTERCONNECTED TO A COMMON STACK.
FGD SYSTEM AVAILABILITY WAS ADEQUATE FOR THE OPERATION OF THIS STATION. BECAUSE THE STATION LOAD WAS REDUCED TO FIFTY
PERCENT. AS MANY AS FOUR MODULES WERE SHUT DOWN FOR CLEANING AND REPAIR EACH EVENING.
OPERATION OF THE SCRUBBER SYSTEM ON WYOMING COAL HAS PROVED TO BE MORE EFFICIENT AND ECONOMICAL BECAUSE OF THE LESSER DEGREE
OF soa REMOVAL REQUIRED.
IN 1971 THE UNIT WAS AVAILABLE FOR OPERATION 338 DAYS* 66 PERCENT OF THE FUEL CONSUMED WAS NATURAL GAS, 27 PERCENT COAL, AND
6 PERCENT FUEL OIL. DURING 1975 THE UNIT WAS AVAILABLE FOR OPERATION 352 DAYS, FUEL CONSUMPTION WAS i»5 PERCENT NATURAL GAS, H2
PERCENT COAL, AND 13 PERCENT FUEL OIL.
121
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LAWRENCE UNIT NO. 5 (CONTINUED)
KPSL« IN ORDER TO MAINTAIN SCRUBBING OPERATIONS FOR THIS UNIT* IS NOW FOLLOWING A COURSE SIMILAR TO THE ONE EMPLOYED FOR THE
NO. 1 UNIT AT THIS STATION. SPECIFICALLYt A TWO-TRAIN VENTURI-ROD SCRUBBER AND SPRAY TOWER ABSORBER ASSEMBLY IS BEING INSTALLED
ALONGSIDE THE EXISTING MARBLE-BED SYSTEM. THE MARBLE-BED UNITS WILL REMAIN IN SERVICE UNTIL THE NEW SPRAY TOWER SYSTEM HAS BEEN
COMPLETED AND DUCTED INTO THE BOILER FLuE GAS STREAM. THIS WILL OCCUR SOMETIME DURING THE COURSE OF 1978. ADDITIONAL DATA AND
INFORMATION IS PROVIDED IN THE TABLE THAT FOLLOWS. A FLOW DIAGRAM OF THE INJECTION SYSTEM IS PROVIDED IN APPENDIX B.
122
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MONTHS
JUL. 75
AUG. 75
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN. 76
FEB. 76
MAR. 76
APR. 76
HAY 76
JUN. 76
JUL. 76
AUG. 76
SEP. 76
OCT. 76
OPERATING HOURS
BOILER FGD MODULES
NOT LOGGED
NOT LOGGED
NOT LOGGED
NOT LOGGED
NOT LOGGED
LAWRENCE NO. 5
COMMENTS
WYOMING COftL IS BEING BURNED IN THIS UNIT. FGD 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 HERE 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 FGO 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 H, THIS UNIT MAY BE CONVERTED To A VENTRI-RQD AND SPRAY TOHER
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.
123
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LAWRENCE N0.5CCONTINUED)
MONTHS
NOV. 76
DEC. 76
OPERATING HOURS
BOILER FGD MODULES
JAN. 77
FEB. 77
MAR. 77
APR. 77
HAY 77
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 FGD
SYSTEM WILL OPERATE ON A FULLY AUTOMATED BASIS. KPSL REPORTS THAT C-E HAS
ENCOUNTERED SOME PROBLEMS WORKING OUT AND FINE-TUNING SQME QF THE LOGIC CIRCUITS.
THE BOILER FIRES NO.2 FUEL OIL IN ADDITION TO LOW SULFUR WYOMING COAL WHILE THE NEW
SCRUBBING FACILITIES ARE BEING INSTALLED. THE ORIGINAL INJECTION AND TAIL-ENO SCRUB-
BING SYSTEM IS STILL AVAILABLE FOR SERVICE AND OPERATED WHEN THE UNIT FIRES COAL,
THE SYSTEM WILL TREAT FLUE GAS RESULTING FROM THE BURNING OF LOW SULFUR
(0.5 PERCENT) WYOMING COAL.
KPSL REPORTED THAT CONSTRUCTION OF THE NEW SCRUBBING SYSTEM is STILL IN PROGRESS.
ALL FOUNDATION WORK HAS BEEN COMPLETED. ERECTION OF THE STRUCTURAL STEEL AND BREECH-
ING IS CONTINUING. THE ORIGINAL SCRUBBING SYSTEM IS STILL AVAILABLE FOR SERVICE.
THE INJECTION AND TAIL-END SCRUBBER PLANT WAS IN SERVICE AND OPERATED WHEN THE
BOILER FIRED COAL. ERECTION OF THE NEW SCRUBBER PLANT is CONTINUING. THE MODULES
ARE NOW BEING ERECTED AT THE PLANT SITE, PARALLEL TO THE EXISTING MARBLE-BED
SYSTEM.
124
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TABLE s
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAHE
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL,CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
502
KENTUCKY UTILITIES
GREEN RIVER NOS. 1 2 AND 3
CENTRAL CITY KENTUCKY
6<» MU
COAL 3.8 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
RETROFIT
9/75
OPERATIONAL
99.7 PERCENT
60 PERCENT GUARANTEE
HATER MAKE UP
SLUUGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
OPEN LOOP 1.20 GPM/MW
STABILIZED SLUDGE DISPOSED IN UNLINED POND
S6«/KW CAPITAL * 2.0 MILLS/KWH OPERATING
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
STACK REPAIRS WEKE COMPLETED DURING THE REPORT PERIOD, AND BOILER AND
SCRUBBER OPERATIONS RESUMED IN APRIL. THE STACK IS NOW LINED WITH
PRECRETE G-ft, A REFRACTORY LINING APPLIED BY AAF. DURING APRIL. OPERA-
BILITY AND RELIABILITY INDEX VALUES WERE 98*« AND THE AVAILABILITY INDEX
WAS 40X. DURING MAY, OPERABILITY AND RELIABILITY INDEX VALUES WEK£ 98X,
AND THE AVAILABILITY INDEX VALUE WAS 99*.
125
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BACKGROUND INFORMATION
ON
GREEN KIVER POWER STATION
THE GREEN RIVER POWER STATION IS WHOLLY OWNED AND OPERATED BT THE KENTUCKY UTILITIES COMPANY AND SITUATED ON THE GREEN RIVER,
NEAR CENTRAL CITY IN MUHLENBERG COUNTY. KENTUCKY. THE STATION CONSISTS OF TWO TURBINE. GENERATORS AMD FOUR COAL-FIRED BOILERS.
AS THE RESULT OF A CONTRACT AWARDED BY KENTUCKY UTILITIES (KUI TO AMERICAN AIR FILTErt ( AAF), A TAIL-END WET LI*E SCRUBBING
SYSTEM WAS DESIGNED AND INSTALLED ON BOILERS 1, 2, AND 3 AT THE GREEN RIVER POWER STATION.
THE FLUE GAS UESULFURIZATION (FGD) AND PARTICULATE. 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 ft CENTRIFUGAL
DEMISTER BEFORE DISCHARGE TO A LOCAL STACK. THE SLUHRY RECYCLE/DISCHARGE SYSTEM CONSISTS OF ONE COMMON ACID RESISTANT TANK WITH
TWO PARTITIONS MAKING A TOTAL OF THREE COMPARTMENTS. COMPLETION OF CHEMICAL REACTIONS, RLCIRCULATION OF SOLUTION AND WASTES
DISCHARGE ARE CONTROLLED AND MONITORED HLRE, 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., 3.8 TO 4.0 PERCENT SULFUR, 13 TO m PERCENT ASH).
THE FGD SYSTEM CAN BE BYPASSED 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 A^D 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 PHA*E OF OPERATION JAS TO DETECT ANr 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 TUHBINE 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-WATEK-LOOP MODE. GUARANTEED SULFUR DIOXIDE REMOVAL EFFICIENCY
IS 80 PERCENT FOR 3.8 PERCENT SULFUR COAL HAVING A HEATING VALUE EQUAL TO OR GREATER THAN 11,000 UTU/LB.
12fa
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GKEEN RIVEN POWER STATION (CONTINUED)
ADDITIONAL INFORMATION ON THE OPERATION OF THIS SYSTEM is PRESENTED IN THE PERFORMANCE TABLE THAT FOLLOWS. A GENERAL PROCESS
FLOW DIAGRAM IS PRESENTED IN APPENDIX B.
127
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GKEEN RIVER NOS. It 2, AND 3
TOTAL
PERIOD PERIOD ( HR )
DEC. 75
AVAILABILITY = 74*
RELIABILITY = 7fl*
OPERABILITY = 65*
UTILIZATION = 35*
JAN. 76 7"*«»
AVAILABILITY = i»2*
RELIABILITY = !«**
OPERABILITY = 11*
UTILIZATION = 9*
FEB. 76 696
AVAILABILITY = 70*
RELIABILITY = <«2*
OPERABILITY = 12%
UTILIZATION = 30*
MAR. 76
AVAILABILITY = 97*
RELIABILITY = 95S
OPERABILITY = 85*
UTILIZATION = 52*
BOILER
OPERATION
-------
GREEM RIVER NOS. It 2» AND 3 (CONTINUED)
TOTAL
PERIOD PERIOD HR
APR. 76 720
AVAILABILITY = 905
RELIABILITY = 1005
OPERABILITY = 100ft
UTILIZATION = 77*
MAY 76 7uu
AVAILABILITY = 815
RELIABILITY = 1005
OPERABILITY = 100*
UTILIZATION = 61*
JUN. 76 720
AVAILABILITY = 100k
RELIABILITY s 99*
OPERABILITY = 99*
UTILIZATION = 82%
JUL. 76 7«m
AVAILABILITY = 905
RELIABILITY = 99*
OPERABILITY = 98*
UTILIZATION = 72*
AUG. 76 7U<»
AVAILABILITY = 97*
BOILER
OPERATION HH
552
MODULE
AVAILABILITY (HH)
6U6
MODULE CALLED
10 OPERATE (HK)
552
HR. K-OOULE
OPEf^ATLD
552
COMMENTS
THL UTILITY MADE A PRIOR COMMITMENT
T^ HUN AT 100 PERCENT OPERAHILITY
THE MONTH OF APRIL.
«»56
6Q6
U56
597
720
596
589
58U
666
581
722
722
THE MAJORITY OF THE TOTAL FORCED
SCRUBBER OUTAGE TI^E OCCURRED
129
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GREEN
NOS. 1. 2. AND 3 (CONTINUED)
TOTAL
PERIOD PERIOD (HR)
RELUBILITY = 97*
OPERAPILITY = 97K
UTILIZATION = 97*
SEP. 76 720
AVAILABILITY = 86*
RELIABILITY = 100*
OPERABILITY = 100*
UTILIZATION = 79*
OCT. 76
AVAILABILITY
RELIABILITY =
OPERABILITY =
UTILIZATION =
NOV. 76
AVAILABILITY
OPERABILITY :
RELIABILITY =
UTILIZATION =
DEC. 76
AVAILABILITY
OPERABILITY =
RELIABILITY =
UTILIZATION =
= 100%
100*
100*
720
= 100*
100*
98*
98*
= 73*
97*
67*
70S
BOILER
OPERATION (HR)
MODULE
AVAILABILITY (HR)
MODULE CALLED HR. MODULE
TO OPERATE (HR) OPERATED
571
617
571
571
699
699
699
70H
720
70U
70t
536
539
591
517
COMMENTS
BECAUSE OF VIBRATION IN THE SCRUB-
BER BOOSTER i.o. FAN, NECESSITATING
SYSTEM SHUTDOWN ANQ REPAIR.
HALF-LOAD OPERATIONS WERE CONDUCTED
THROUGHOUT THE PERIOD BECAUSE OF
BEARING PROBLEMS TO ONE OF THE TWO
TURBINE GENERATING UNITS. MINOR
FAN PROBLEMS OCCURRED,
REQUIRING NO FORCED OUTAGE TIME.
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.
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TOTAL
PERIOD PERIOD (HR)
JAN. 77 7"»"4
AVAILABILITY = 9<*X
OPERABILITY = 9«*
RELIABILITY = 9<*X
UTILIZATION = 9<*X
FEB. 77 672
AVAILABILITY = 36*
RELIABILITY = 91%
OPERABILITY = 91«
UTILIZATION = 36X
MAR. 77 0
ALL INDEX VALUES = OX
BOILER
OPERATION
-------
TOTAL
PERIOD PERIOD (HR)
MAY 77 7<*<»
AVAILABILITY = 99*
RELIABILITY = 98*
OPERABILITY s 98*
UTILIZATION = 69X
BOILER
OPERATION (HK)
527
GREEN RIVER NOS. It 2. AND 3 (CONTINUED)
MODULE MODULE CALLED HR. MODULE
AVAILABILITY < HR ) TO OPERATE (HR) OPERATED
736 527 513
COMMENTS
THE STACK WAS REPAIRED FIRST BY
WELDING A BACKUP METAL PLATE TO THE
PORTIONS OF THE STACK WHE^E PITTING
OCCURRED. THEN Twf; ENTIRE STACK
WAS LINED WITH ^EFHACTOKY COATING
CALLED PPECRETE G-S BY AAF. STACK
REPAlKS WEKE COMPLETED MARCH 7.
132
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
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
LOUISVILLE GAS X ELECTRIC
CANE RUN NO t
LOUISVILLE KENTUCKY
178 MW
COAL 3.5 - H.O PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
RETROFIT
8/76
OPERATIONAL
99 PERCENT GUARANTEE
S02
90 PERCENT GUARANTEE
WATER MAKE UP
SLUDGE DISPOSAL
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
S50/KW (INCLUDING LIME AND SLUDGE DISPOSAL FACILITIES)
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
SCRUBBER OPERATIONS WERE TERMINATED APRIL 18 FOR THE IMPLEMATiON OF
SEVERAL MODIFICATIONS TO THE FGD SYSTEM. A CHEVRON-TyPE MIST ELIMINATOR
WILL BE INSTALLED* A NEW SPRAY HEADER WILL INCREASE L/Gi REHEAT WILL
BE ADDED AND THE CARBOLINE DUCT LINING WILL BE REPLACED WITH
PLASTITE i»005 »BY GENERAL COATINGS). THE MODIFICATIONS ARE EXPECTED To
BE COMPLETE BY JULY 5.
133
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BACKGROUND INFORMATION
ON
CANE RUN NO.
-------
PERIOD HOURS BOILER (HR) SCRUBBERS IHR)
AUG. 76 7«C* 740 666
FGD SYSTEM PERFORMANCE
CANE RUN UNIT NO.
-------
PERIOD HOURS BOILER (HR) SCRUBBERS (HR)
NOV. 76 730
DEC. 76 7Ut
JAN. 77 7U<» 0 0
FGD SYSTEM PERFORMANCE
CAME RUN UNIT NO. <»
PERFORMANCE FACTORS <*)
OPERABILITY UTILIZATION
95
90
FEB. 77 672
MAR. 77 7«»H
132 356
•AFTER (AFTER
RESTART! RESTART)
83*
(AFTER
RESTART)
83%
(AFTER
RESTART)
APR. 77
MAY 77
COMMENTS
OF THE SYSTEM, AS A FUNCTION OF SERVICE TIME VERSUS
OUTAGE TIME. HAS BEEN VERY GOOD.
THE SYSTEM INCURRED NO MAJOR PROBLEMS OR UPSETS
DURING THE REPORT PERIOD. CARBIDE LIME SLURRY IS
EMPLOYED »S THE SULFUR DIOXIDE ABSORBENT.
DURING JAN.l - JAN.11, THE SCRUBBER WAS UTILIZED 95
PERCENT OF THE TIME. THEN THE GREEN RIVER BECAME IM-
PASSABLE DUE TO ICE FORMATION AND THIS CAUSED THE
CESSATION OF BARGE DELIVERIES OF LIME.
DURING FEBRUARY, THE SCRUBBER WAS ONLY OPERATED FOR
TWO <»-HOUR PERIODS TO PREVENT TOTAL FREEZE-UP.
IN MARCH, THE SCRUBBER CAME BACK ON-LINE AT 10 AM.
ON MARCH IHTH, AND HAS RUN CONTINUOUSLY THROUGH
THE END OF THE PERIOD. FROM THE IfTH THROUGH THE END
OF THE MONTH, THERE WAS ONE PERIOD OF SCRUBBER BY-PASS,
WHEN DC SUPPLY TO THE BY-PASS HAD To BE REPAIRED-
THE SCRUBBER SYSTEM RAN FOR THE FIRST 18 DAYS IN APRIL,
WITH A RELIABILITY OF 95*. FROM THAT TIME (APRIL le>
THROUGH AN EXPECTED DATE OF JULY 12, THE SCRUBBER
SYSTEM WILL BE DOWN FOR THE FOLLOWING MODIFICATIONS*
1. TO REMOVE DEMISTER AND REPLACE WITH CHEVRON UNITS.
136
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PERIOD HOURS BOILER I MR I SZRUBBER INK)
FGD SYSTEM PERFORMANCE
CANE RUN UNIT NO. <*
PERFORMANCE FACTORS(X)
OPERABILITY UTILIZATION
COMMENTS
2. TO INCREASE L/G BY ADDING A NEW SPRAY HEADER.
3. TO ADD DIRECT. OIL-FIRED REHEAT, AND
4. TO REPLACE THE LINING IN THE SYSTEM FROM
THE DEMISTEH THROUGH THE STACK WITH PLASTITE «*oos
TO BE INSTALLED BY GENERAL COATINGS. (THE ORIGINAL
LINING WAS BUBBLING. BUT HAD NOT YET FAILED* FAIL-
URE SEEMED IMMINENT WITHIN 1-5 MONTHS.)
137
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 06/77
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
51
LOUISVILLE GAS * ELECTRIC
PADDYS RUN NO fa
LOUISVILLE KENTUCKY
65 MW
COAL 3.5 -
-------
BACKGROUND INFORMATION
ON
PADDY'S RUN NO. 6
PADDY'S RUN POWER STATION J3 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 ACFn OF 350 F FLUE GAS. EACH MODULE IS MADE UP OF TWO STAGES
OF 3-INCH MARBLE BEOS, FOLLOWED BY A TWO-STAGE CHEVRON-TYPE DEMISTER. 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. A PROCESS FLOW DIAGRAM IS PROVIDED IN APPENDIX B.
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 PERCENT CALCIUM HYDROXIDE, 2.0 TO 2.5 PERCENT SILICA, 3.0 TO 8.0
PERCENT CALCIUM CARBONATE, AND 0.1 PERCENT MAGNESIUM OXIDE.
THE UNIT OPERATES IN 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 CLARIFIER TANK. THE CALCIUM SULFITE CRYSTALS PRECIPITATE WITH THE AID OF A FLOCCULANT, WHICH is ADDED AT
THE RATE OF » TO 7 PPM. THE OVERFLOW is RETURNED TO THE REACTION TANK. THE UNDERFLOW. CONTAINING 22 TO 2* PERCENT SOLIDS, is
STABILIZED BY MIXING IT WITH LIME. APPROXIMATELY 60 TO 100 POUNDS OF LIME ARE USED PER TON OF DRV SOLIDS OF SLUDGE. THE FIXED
SLUDGE IS TRANSPORTED BY TRUCKS TO A 10-ACRE OFF-SITE LANDFILL AREA.
139
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MONTH
APR. 73
MAY 73
JUN. 73
JUL. 73
AUG. 73
SEP. 73
OCT. 73
NOV. 73
DEC. 73
JAN. 74
THROUGH
JUL. 74
OPERABILITY Ik)
MODULE A MODULE B
18 56
11
21
53
85
49
35
44
0
21
64
72
94
100
78
0
FGD SYSTEM OPERABILITY
PADDY'S RUN 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 WAS INTERMITTENT FROM JUNE 19 TO JULY n BECAUSE OF MECHANICAL PROBLEMS WITH THE
SLURRY PUMPS.
DURING A SCHEDULED OUTAGE FROM JULY 12 THROUGH AUGUST 1« SEVERAL REPAIRS WERE MADE TO THE LIME
SLURRY MAKEUP SYSTEM. A DISINTEGRATOR UNIT WAS INSTALLED TO REDUCE PLUGGING OF STRAINERS AND
SLURRY CONTROL VALVES.
THE OPERATION WAS CONTINUOUS FROM AUGUST Z To AUGUST 18 EXCEPT FOR A BRIEF SHUTDOWN DUE TO A
BOILER-RELATED PROBLEM. FROM AUGUST 19 TO SEPTEMBER 5. 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 FGD SYSTEM REMAINED IN SERVICE TO DEC. 20 AFTER WHICH THE BOILER AND THE SCRUBBER MODULES
WERE SHUT DOWN BECAUSE OF NO DEMAND*(THIS IS A PEAKING-LOAD BOILER).
BOILER SHUT DOWN BECAUSE OF NO DEMAND.*
140
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MONTH
AUG. 7H
SEP. 7«»
OCT. 7*
NOV. 7<»
THROUGH
AUG. 75
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN. 76
FEB. 76
OPERABILITY <*)
MODULE A MODULE B
50
0
100
NO DEMAND
77
0
100
100
100
100
90
100
100
100
90
100 100
NO DEMAND
FGD SrSTEM OPERABILITY
PADDY'S RUN NO. 6
COMMENTS (CONTINUED)
UNIT HAS BEEN ON AND OFF FREQUENTLY DUE TO FLUCTUATION IN POWER DEMAND.
BOILER DOWN BECAUSE OF NO DEMAND.
BOILER TURNED ON SPECIFICALLY TO PERFORM LIMESTONE TESTS ON FGD SYSTEM.
BOILER AND FGO 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 LGSE'S PEAK LOAD DETERMINATION). S02 REMOVAL WAS REPORTED To BE OVER 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.
S02 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.
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MONTH
MAR. 76
APR. 76
MAY 76
JUN. 76
JUL. 76
AUG. 76
SEP. 76
OCT. 76
NOV. 76
DEC. 76
OPERABILITY (X)
MODULE A MODULE B
NO DEMAND
NO DEMAND
100 100
100 100
100
100
100
100
NO DEMAND
99
99
99
99
FGO SYSTEM OPERABILITY
PADDY'S RUN NO. 6
COMMENTS (CONTINUED)
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 WERE
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-DAY 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
CALCIUM) LIME.
THE UNIT 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 S02 ABSORBENT. THE
HIGH CALCIUM (VIRGIN) LIME RUN, SCHEDULED AS PART OF THE SCRUBBER/SLUDGE STUDY, WILL COMMENCE
ON MARCH 1. 1977.
112
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FGD SYSTEM OPERABILITY
PADDY'S RUN NO. b
OPERABILITY (X)
MONTH MODULE A MODULE E COMMENTS (CONTINUED)
JAN. 77 BECAUSE OF SEVERE WEATHER CONDITIONS. THERE WERE NO BOILER OPERATIONS AND NO SCRUBBER
FEB. 77 OPERATIONS UNTIL MARCH 15, 1977.
MAR. 77 99 99 BOILER AND SCRUBBER RESTART OCCURRED ON MARCH 15 AND OPERATION WAS CONTINUOUS THROUGH THE
(AFTER RESTART)
END OF MARCH. THERE WERE NO PROBLEMS AND ONLY ONE HOUR OF SCRUBBER DOWNTIME.
APR. 77 A HIGH-CALCIUM LIME RUN. WITH MAGNESIUM HYDROXIDE ADDITION* WAS STARTED IN MARCH AND RAN
MAY 77 THROU6H MID-APRIL. THE SCRUBBER AVAILABILITY WAS ABOUT 9S-98X (ONTIME VERSUS OFFTIMEU S02
REMOVALS OF GREATER THAN 99 PERCENT WERE CONSISTENTLY OBTAINED DURING THESE TESTS.
FROM MID-APRIL UNTIL THE PRESENT, THE SCRUBBERS HAVE BEEN BYPASSED, NOT BECAUSE OF NON-
AVAILABILITY, BUT BECAUSE THE BOILER LOAD HAS CAUSED THE SCRUBBER CREW TO BE TRANSFERRED TO
BOILER OPERATIONS. NON-AVAILABILITY WAS THUS CAUSED BY A LACK OF MANPOWER TO RUN THE SYSTEMS.
SCRUBBER OPERATIONS ARE EXPECTED TO RESTART IN MID-JUNE, ONCE AGAIN UTILIZING A HIGH-CALCIUM
LIME ADDITIVE.
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TABLE: s
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS oe/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICULATES
5«f
MONTANA POWER CO.
COLSTRIP NO 1
COLSTRIP MONTANA
360 MW
COAL 0.8 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
NEW
10/75
OPERATIONAL
99 PERCENT
S02
60 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
CLOSED LOOP
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
S50/KW CAPITAL
THE COLSTRIP PLANT IS A MINE MOUTH INSTALLATION. THE FGD SYSTEM STARTED
UP IN LATE 1975 AND PROCEEDED THROUGH A SHAKEDOWN AND DEBUGGING OPEK-
ATION PHASE. THE UNIT HAS BEEN OPERATING AT FULL COMERCIAL CAPACITY.
THE SCRUBBING SYSTEM DESIGN INCORPORATES VENTURI WET SCRUBBERS FOR
PARTICULATE AND SULFUR DIOXIDE REMOVAL. FLUE GAS CANNOT BE BY-PASSED
AROUND THE SCRUBBING SYSTEM. INFORMATION AND OPERATING DATA WERE NOT
MADE AVAILABLE BY THE UTILITY DURING THE REPORT PERIOD.
PEDCo ENVIRONMENTAL
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TABLE 5
PERFORMANCE DESCRIPTION FOH OPERATIONAL FGD SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY*
PARTICULATES
55
MONTANA POWER CO.
COLSTRIP NO 2
COLSTRIP MONTANA
360 MW
COAL 0.0 PLRCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
NEW
7/76
OPERATIONAL
99 PERCENT
S02
60 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
CLOSED LOOP
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
S50/KW CAPITAL
THE COLSTRIP PLANT IS A MINE MOUTH FACILITY. INITIAL OPERATION OF THE
SCRUBBING SYSTLM COMMENCED IN JULY 1976. THIS UNIT IS IDENTICAL TO
THE NO.l SYSTEfl DESIGN IN THAT THREE SCRUBBER MODULES ARE INSTALLED FOR
PARTICULATE AND SULFUR DIOXIDE REMOVAL. FLUE GAS CANNOT BE BY.PASSED
AROUND THE SCRUBBING SYSTEM. INFORMATION AND OPERATING DATA WERE NOT
MADE AVAILABLE BY THE UTILITY DURING THE REPORT PERIOD.
145
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BACKGROUND INFORMATION
ON
COLSTR1P UNITS 1 AND 2
THE COLSTRIP POWER STATION OF THE MONTANA POWER COMPANY IS LOCATED NEAR COLSTRIP, MONTANA, APPROXIMATELY 100 MILES EAST OF
BILLINGS, MONTANA. THE STATION CONTAINS TWO NEW 360-MW COAL-FIRED POWER-GENERATING UNITS. AT THE PRESENT TIME, THE UTILITY IS
PLANNING THE ADDITION OF TWO MORE 700-MW COAL-FIRED POWER-GENERATING UNITS AT THE STATION. THIS MINE MOUTH PLANT FIRES LOW-SULFUR,
LOW HEAT CONTENT COLSTRIP COALi PRODUCING A FLUE GAS CONTAINING UP TO 6 GR/SCFD PARTICULATE AND UP To 1000 PPM SuLFuR DIOXIDE.
THE GENERAL CHARACTERISTICS OF THIS COAL ARE* HEATING VALUE (AS FIRED). 8555 BTU/LB.* SULFUR CONTENT, 0.77 PERCENT* ASH CONTENT,
8.59 PERCENT* MOISTURE CONTENT, 23.87 PERCENT.
IN ORDER TO MEET AIR POLLUTION EMISSION STANDARDS OF 400 PPM FOR SULFUR DIOXIDE (1.0 LB/MM BTU) AND 0.03 GR/SCFO FOR PARTIC-
ULATES. THE BOILERS ARE EQUIPPED WITH SCRUBBER PLANTS FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. THE SYSTEMS INSTALLED
ON UNITS 1 AND 2 WERE DESIGNED AND SUPPLIED BY COMBUSTION EOUIPMENT ASSOCIATES CCEA) AND AUTHUR 0. LITTLE (ADL). THE PROCESS
INSTALLED UTILIZES THE HIGH ALKALINITY OF THE FLY ASH (APPROXIMATELY 20 PERCENT CALCIUM OXIDE) FOR THE REMOVAL OF SULFUR DIOXIDE
AND SUPPLEMENTAL LIME SLURRY FOR PH AND SCALE CONTROL. DESIGN PARTICULATE AND SULFUK DIOXIDE REMOVAL EFFICIENCIES ARE 99.5 AND
60 PERCENTt RESPECTIVELY.
EACH BOILER IS EQUIPPED WITH THREE SCRUBBER MODULES, EACH MODULE CAPABLE OF HANDLING 40 PERCENT OF THE BOILER FLUE GAS
CAPACITY (1.430,000 ACFM AT 291F). EACH SCRUBBER MODULE INCORPORATES A VARIABLE-THROAT VENTURI (DESIGN SUPERFICIAL GAS VELOCITY*
200 FT/SEC), A SPRAY ABSORPTION SECTION (DESIGN SUPERFICIAL GAS VELOCITY* 11.5 FT/SEC), AN INTERNAL RECYCLE TANK, A WASH TRAY,
AND A CHEVRON-TYPE MIST ELIMINATOR. THE VENTURI AND SPRAY SECTIONS OPERATE ON A RECIRCULATING SLURRY LOOP CONTAINING 12 PERCENT
SOLIDS (CONSISTING PRIMARILY OF CALCIUM SALTS AND FLY ASH). TOTAL MODULE PRESSURE DROP IS APPROXIMATELY 23.5 INCHES H20. TOTAL
MODULE LIQUID-TO-GAS RATIO is APPROXIMATELY 33 GAL/IOOO ACF. A WASH TRAY is SITUATED BENEATH THE MIST ELIMINATOR IN ORDER TO
DILUTE ANY ENTRAINMENT REACHING THE COMPONENT, THUS REDUCING THE POTENTIAL FOR PLUGGING AND SCALING. THE TRAY OPERATES OFF A
SEPARATE RECYCLE TANK AND RECIRCULATION LOOP. REHEAT IS SUPPLIED BY IN-THE-FLUE-GAS-STREAM STEAM TUBE BUNDLES (MINIMUM DELTA T*
50 F>> THE REHEATERS ARE ALSO EQUIPPED WITH SOOT BLOWERS FOR CLEANING. THE SCRUBBER BOOSTER FANS (INDUCED DRAFT, 43.5 INCHES
H20) ARC LOCATED DOWNSTREAM OF THE SCRUBBERS AND OPERATE ON DRY, REHEATED FLUE GAS. THE FANS WERE LOCATED DOWNSTREAM IN THIS
SCRUBBER DESIGN BECAUSE OF THE HIGH PARTICULATE LOADING OF TH£ INLET FLUE GAS. THE SCRUBBING WASTES (UNREACTEO FLY ASH, 9 PARTS
CALCIUM SULFATE/1 PART CALCIUM SULFITE) ARE DISCHARGED TO AN INITAL HOLDING BASIN (520 ACRE-FEET) ADJACENT TO THE SCRUBBER PLANT
146
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COLSTRIP (CONTINUED!
AND THEN PUPPED (50.8 DRY TPH/2 UNITS) THREE MILES TO A PERMANENT SLUDGE DISPOSAL POND (2218 ACRE-FEETt CLAY-LINED WHERE NECESS-
ARY). CLEAR LIQUOR IS RETURNED FROM PONDS FOR ADDITIONAL SCRUBBING SERVICE. FRESH MAKE-UP WATER TO THE SYSTEM IS LIMITED TO
APPROXIMATELY THE AMOUNT OF WATER LOST IN THE SCRUBBER PLANT VIA EVAPORATION AND SLUDGE.
PERFORMANCE HISTORY*
UNIT NO.l BECAME AVAILABLE FOR SERVICE DURING THE LATTER PA>*T OF 1975. UNIT NO.2 WAS PLACED IN SERVICE DURING THE SUMMER OF 1976.
INFORMATION AND DATA CONCERNING PERFORMANCE OF THE SCRUBBER PLANTS HAVE NOT BEEN MADE AVAILABLE BY THE UTILITY. CEA/ADL HAS
REPORTED SUCCESSFUL AND RELIABLE OPERATIONS FOR BOTH SCRUBBER PLANTS SINCE START-UP.
PEDCo ENVIRONMENTAL
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 06/77
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
62
NEVADA POWER
REIO GARDNER NO i
MOAPA NEVADA
125 MW
COAL 0.5 - 1.0 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
RETROFIT
OPERATIONAL
99 PERCENT
S02
85 PERCENT
WATER MAKE UP
OPEN LOOP 1.52 GPM/Mk,
SLUDGE DISPOSAL
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
Si»if/KW (1974 DOLLARS) * $600«OSfcOO. 000 ANNUALIZED
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A TWIN VARlABLE-THKOAT VENTURI SCRUBBER FOLLOWED BY A
SEPARATOR IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER.
THE MODULE WAS FIRST PLACED IN SERVICE ON BOILER FLUE GAS IN APHIL 1971*.
DURING THE REPORT PERIOD THE SCRUBBER WAS UNAVAILABLE FOR SERVICE BECAUSE
OF REPAIRS TO DAMAGED LINER MATERIAL. THE SYSTEM IS SCHEDULED TO BE BACK
IN OPERATION BY MID-JUNE.
PEDCo ENVIRONMENTAL
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TABLE 5
PERFORMANCE: DESCRIPTION FOR OPERATIONAL FGD SYSTEMS oe/77
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
63
NEVADA POWER
REID GARDNER NO 2
MOAPA NEVADA
125 MM
COAL 0.5 - 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
RETROFIT
OPERATIONAL
99 PERCENT
S02
65 PERCENT
WATER MAKE UP
OPEN LOOP 1.52 GPM/MH
SLUDGE DISPOSAL
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
Sl»i»/KW(197t DOLLARS)* S600.00000 ANNUALIZEO
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A TWIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED By A
SEPARATOR IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER.
THE MODULE WAS FIRST PLACED IN SERVICE ON BOILER FLUE GAS IN APKIL 197H.
DURING THE REPORT PERIOD THE SYSTEM WAS IN SERVICE WITH THE EXCEPTION OF
A 2-taEEK BOILEK OUTAGE FOR flAlNTAlNENCE AND REPAIRS.
1<*9
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS Ofc/77
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
NEVADA POWER
REID GARDNER NO 3
MOAPA NEVADA
125 MW
COAL 0.5 - 1.0 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
NEW
7/76
OPERATIONAL
99 PERCENT
S02
65 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
OPEN LOOP 1.52 GPM/HW
UNSTABILIZED SLUuGE DISPOSED IN UNLlNED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS UNIT IS A NEW COAL-FIRED BOILER THAT IS EQUIPPED WITH SODIUM
CARBONATE-BASEU(TRONA»SCRUBBING SYSTEM WHICH INCORPORATES A TWIN
VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A SEPARATOR IN SERIES WITH
A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER. THE MODULE WAS FIRST
PLACED IN SERVICE ON BOILER FLUE GAS IN JULY 1976. DURING THE PERIOD
THE SYSTEM WAS OPERATIONAL IN APRIL AND DOWN IN MAY FOR A 3-WEEK OUTAGE
FOR AN FRP LINER REPLACEMENT IN THE SEPARATOR.
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BACKGROUND INFORMATION
ON
HEIU OARDNER UNITS 1, 2t AND 3
THE REID GARDNER POWER STATION IS LOCATED NEAR MOAPA. NEVADA, ABOUT 50 MILES NORTH OF LAS VEGAS. THE STATION HAS THREE
ELECTRIC POWER GENERATING UNITS. CREID GARDNER i, 2. AND 3) EACH RATED AT 125 nw. UNITS i AND 2 ARE RETROFITTED WITH sooiun
CARBONATE-BASED FGO SYSTEMS. UNIT NO. s is A NEW INSTALLATION. ALSO EQUIPPED WITH A SODIUM CARBONATE-BASED FGD SYSTEM. THE COAL
BURNED AT THE PLANT HAS AN AVERAGE GROSS HEATING VALUE Qf 12.450 BTU/LB. AND ASH AND SULFUR CONTENTS OF 8 AND 0.5 PERCENT RESPEC-
TIVELY*
THE FGD SYSTEMS INSTALLED ON REID GARDNER UNITS i, 2, AND s 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"». THE SYSTEM FOR UNIT 3 WAS
PLACED IN OPERATION ON JULY 12, 1976. THE SCRUBBING SYSTEM DESIGN WAS BASED ON INFORMATION AND DATA OBTAINED FROM AN 8000-ACFM
PILOT PLANT PROGRAM CONDUCTED AT THIS STATION IN 1971 AND 1972.
THE FGD SYSTEM CONSISTS OF A SINGLE MODULE, DESIGNED TO HANDLE «*73.000 ACFM OF GAS AT 350 F. THE MODULE IS MADE UP OF A TWIN
VARIABLE-THROAT VENTURI SCRUBBER, FOLLOWED BY A SINGLE-STAGE WASH TRAY. BYPASSING OF THE MODULE IS POSSIBLE THROUGH A GUILLOTINE-
TYPE BY-PASS. A COMMON FACILITY FOR TRONA (SODIUM CARBONATE ORE) STORAGE AND SAND REMOVAL SERVES ALL THE FGD MODULES AT THE REID
GARDNER PLANT. SULFUR DIOXIDE REMOVAL EFFICIENCY IS REPORTED TO BE 85 PERCENT. PRIMARY PARTICULATE REMOVAL IS ACCOMPLISHED BY 75
PERCENT EFFICIENT MECHANICAL 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
TWIN-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 THE REMAINING LIQUID DROPLETS CARRIED OVER WITH THE GAS ARE
TRAPPED AND REMOVED.
EFFLUENT FROM THE F6D SYSTEM IS FROM TWO SOURCES* THE SLIP STREAM OF SPENT LIQUOR DISCHARGED FROM THE RECIRCULATION TANK,
AND THE ALKALINE CLARIFIER UNDERFLOW, WHICH SERVES TO NEUTRALIZE THE PH OF THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE
SLUDGE SETTLING PONDS. THE SPENT LIQUOR Is PUMPED INTO ONE OF TWO SETTLING PONDS. THE OVERFLOW FROM THIS POND Is PUMPED TO A
LARGER «>5-ACRE POND, WHERE THE BRINE IS EVAPORATED. THE FGD SYSTEM OPERATES ON AN OPEN WATER LOOP WITH NO LIQUOR RECYCLED TO THE
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REID GARDNER UNITS 1, 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 APPENDIX B
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REID GARDNER 1
PERIOD
MAR. 75
APR. 75
MAY 75
JUN. 75
BOILER
TOTAL OPERATION
(HR.I (HR.)
HR.
CALLED
AVAILABILITY UPON TO
(HR.) OPERATE
OPERATION
«HR. >
JUL. 75
AU6. 75
SEP. 75 720 716
OPERABILITY * 78*
UTILIZATION = 78*
OCT. 75 7«H» 303
OPERABILITY = 60*
UTILIZATION = 1<*X
NOV. 75 720 65«»
OPERABILITY = 60*
UTILIZATION = 55*
DEC. 75
559
106
39H
COMMENTS
DURING FEBRUARY THE FGD SYSTEM OPERATED WITH 95 PERCENT AVAILA-
BILITY ON TRONA SUPPLEMENTED WITH SODA ASH. AVAILABILITY IN
JANUARY WAS ONLY ABOUT 65 PERCENT BECAUSE OF FROZEN SODIUM
CARBONATE FEED LINES. PROBLEMS IN FEBRUARY INCLUDED A 2-DAY
LACK OF CHEMICALS. NO SIGNIFICANT PROBLEMS OCCURRED IN MARCH.
THE UNIT RAN APRIL 1 THROUGH APKIL 12 WITH 100 PERCENT AVAILA-
BILITY. THE BOILER WAS THEN SHUT DOWN FOR ROUTINE MAINTENANCE.
THE SYSTEM WAS PLACED BACK ON LINE MAY 12. SECOND PERFORMANCE
TEST WAS PASSED. PROBLEMS INCLUDED ABRASION OF RUBBER-LINED
PIPES AND ROUTINE MECHANICAL AND INSTRUMENTAL PROBLEMS. HIGH ASH
CONTENT. UP TO 20 PERCENT, HAD NO EFFECT ON EMISSIONS.
OPERABILITY FOR THE MONTH OF JULY WAS 85 PERCENT.
OF FOUR FORCED OUTAGES. THREE WERE CAUSED BY SCRUBBER MALFUNC-
TIONS.
LOW OPERATING TIME WAS DUE TO SCHEDULED BOILER MAINTENANCE. ONE
OUTAGE WAS DUE TO THE MALFUNCTION OF A SODA ASH BLOWER.
THE UTILITY REPORTS SYSTEM PERFORMANCE IN TERMS OF THE OPERA-
BILITY INDEX. UNIT NO. 1 OPERABILITY WAS LOW FOR THE MONTH OF
NOVEMBER BECAUSE OF DELAYS IN DELIVERY OF REPAIR MATERIALS.
THREE FORCED OUTAGES DURING THE MONTH WERE DUE TO REHEATER STEAM
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REID GARDNER 1 (CONTINUED)
PERIOD
BOILER
TOTAL OPERATION
(HR.I (HP.)
JAN. 76 7«t«» 6<»7
AVAILABILITY = SIX
OPERABILITY = 291
RELIABILITY = 57*
UTILIZATION = 25*
FEB. 76 696 66
-------
REID GARDNER 1 (CONTINUED)
BOILER
TOTAL OPERATION
(HR.» 8
COMMENTS
THE NO. 1 UNIT UAS SHUT DOWN THE ENTIRE MONTH FOR A SCHEDULED
TURBINE OVERHAUL AND BURNER LINE CONDUIT REPLACEMENT.
THE NO. 1 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 BY 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 TIME 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.
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REID GARDNER 1 (CONTINUED)
BOILER
TOTAL OPERATION
PERIOD HR. HR.
NOV. 76 720 631
AVAILABILITY = 87*
RELIABILITY = 6tX
OPERABILITT = 81*
UTILIZATION = 71X
DEC. 76 7«»<» 677
AVAILABILITY = 93X
RELIABILITY s 92X
OPERABILITY = 681
UTILIZATION = 80X
JAN. 77 7«»«» 6
-------
REID GARDNER 2
PERIOD
FEB. 75
MAR. 75
APR. 75
HAY 75
JUN. 75
BOILER
TOTAL OPERATION
(HR.) (HR.I
HR.
CALLED
AVAILABILITY UPON TO
(HH.) OPERATE
OPERATION
(HH. )
JUL. 75
AUG. 75
SEP. 75 720 6«5
OPERABILITY = 77*
UTILIZATION = 69*
OCT. 75 7i»U 531
OPERABILITY = 87*
UTILIZATION = 62*
NOV. 75 720 603
OPERABILITY = 99*
UTILIZATION = 83*
DEC. 75
JAN. 76 74i» 691
AVAILABILITY = 72*
RELIABILITY r 66*
596
535
691
458
COMMENTS
DURING FEBRUARY THE FGD SYSTEM OPERATED WITH 90 PERCENT OPERA-
BILITY ON TRONA SUPPLEMENTED WITH SODA ASH. PROBLEMS INCLUDED
A PLUGGED RECYCLE LINE STRAINER. SEAL WATER FILTERS. AND BOILER
CONTROLS. UNIT HAS RESTARTED AFTER SHUTDOWN FOR 5-YEAR TURBINE
OVERHAUL. SECOND PERFORMANCE TEST WAS PASSED. PROBLEMS
INCLUDED ABRASION OF RUBBER-LINED PIPES AND ROUTINE MECHANICAL
AND INSTRUMENTAL PROBLEMS. HIGH ASH CONTENT. UP TO 20*. HAD NO
EFFECT ON EMISSIONS.
THE FGD SYSTEM OPERABILITY FOR THE MONTH OF JULY WAS 85 PERCENT.
THREE FORCED SCRUBBER OUTAGES OCCURRED BECAUSE OF STRAINER
PLUGGING, BROKEN BUCKET ELEVATOR, WORN RECIRCULATION PIPING, AND
RUBBER LINER LEAKAGE.
THREE FORCED SCRUBBER OUTAGES WERE REPORTED FOR THE MONTH OF
OCTOBER BECAUSE OF PUMP REPAIR, INSTRUMENT PLUGGING. AND REPAIR
OF SYSTEM PIPING LEAKAGE.
THE UTILITY PREFERS TO REPORT SYSTEM PERFORMANCE IN TERMS OF THE
OPERABILITY INDEX BECAUSE OF EASE OF CALCULATION, REQUIRES NO
JUDGMENTt AND REFLECTS THE ACTUAL PERFORMANCE OF THE FGD SYSTEMS
ACCURATELY IF THE REASONS FOR DOWNTIME ARE KNOWN.
BOILER WAS OUT OF SERVICE A TOTAL OF 3 DAYS DURING THE MONTN.
SCRUBBER OUTAGES WERE CAUSED BY FROZEN CARBONATE LINES, PLUGGED
PRESSURE-SENSING LINES. DUCT PRESSURE TRIPS. AND OVERHAUL OF A
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REID GARDNER 2 (CONTINUED!
BOILER
TOTAL OPERATION
PERIOD (HR.) CHR.)
OPERABILITY = 66*
UTILIZATION = 62«
FEB. 76 696 675
AVAILABILITY = 8"**
RELIABILITY s 86*
OPERABILITY = 86*
UTILIZATION = 631
MAR. 76 7H«f 660
AVAILABILITY = 67*
RELIABILITY = 62*
OPERABILITY = 60*
UTILIZATION = 53»
APR. 76 720 629
AVAILABILITY = 86*
RELIABILITY = 631
OPERABILITY = 77*
UTILIZATION = 68*
HAY 76
JUN. 76 720 662
AVAILABILITY = 99*
RELIABILITY = 98*
OPERABILITY = 83*
UTILIZATION = 79*
AVAILABILITY
(HR.)
582
HR.
CALLED
UPON TO
OPERATE
675
OPERATION
(HR. I
578
«»95
633
395
622
H86
579
568
COMMENTS
TRAY RECYCLE PUMP.
THE UTILITY REPORTED FOUR SCRUBBER INACTIVE PERIODS DURING THE
MONTH, THREE OF WHICH WERE SCRUBBER-RELATED OUTAGES. THE FORCED
SCRUBBER OUTAGES OCCURRED BECAUSE OF PLUGGING IN A VENTURI PUMP.
DEPLETION OF CHEMICAL, CHEMICAL LINE PLUGGING, AND SEAL WATER
PROBLEMS.
TWO FORCED SCRUBBER OUTAGES WERE REPORTED FOR THE MONTH BECAUSE
OF AN ELECTRICAL FAILURE AND PLUGGING IN THE TRAY SYSTEM
RESULTING IN A SUBSEQUENT OVERHAUL OF THE TRAY RECYCLE PUMPS.
FOUR FORCED SCRUBBER OUTAGES HERE REPORTED BY THE UTILITY FOR
APRIL. PROBLEMS ENCOUNTERED WERE* PLUGGED SENSING LINES, A
REHEATER LEAK, VENTURI SPOOL RECYCLE REPLACEMENT. AND TANK
PATCHING.
PROBLEMS ENCOUNTERED DURING THE MONTH INCLUDED PLUGGED VENTURI
LINES AND A PLUGGED SENSING LINE. TOTAL SCRUBBER OPERATION TIME
TO DATE IS 9,«66 HOURS.
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REID GARDNER Z (CONTINUED)
BOILER
TOTAL OPERATION
PERIOD (HR.) (HR.)
JUL. 76 744 518
AVAILABILITY = 91*
RELIABILITY = 96*
OPERABILITY £ SIX
UTILIZATION s 57*
AUG. 76 744 709
AVAILABILITY = 95*
RELIABILITY s 94X
OPERABILITY r 75X
UTILIZATION * 71*
SEP. 76 720 681
AVAILABILITY = 94*
RELIABILITY = 94*
OPERABILITY s 96X
UTILIZATION s 91X
OCT. 76 744 694
AVAILABILITY = 93*
RELIABILITY = 95X
OPERABILITY s 95X
UTILIZATION = 88X
HR.
CALLED
AVAILABILITY UPON TO
(HR.) OPERATE
676
43
OPERATION
(HR.)
421
710
564
530
677
697
653
706
692
656
COMMENTS
TWO FORCED SCRUBBER OUTAGES WERE REPORTED DURING THE MONTH. A
PROBLEM WITH A HIGH SOLIUS CONCENTRATION IN THE VENTURI SCRUBBING
CYCLE AND THE REPLACEMENT OF A RUBBER-LINED PIPE IN THE VENTURI
SCRUBBER RESULTED IN AN OUTAGE TIME OF APPROXIMATELY 19. HOURS.
FORCED SCRUBBER OUTAGE TIME TOTALLED 34.5 HOURS. TWO TRIpS
OCCURRED DURING THE MONTH BECAUSE OF LEAKAGE IN THE VENTURI
RECYCLE LINE AND PLUGGING IN THE THICKENER TANK. THE REMAINING
SCRUBBER OUTAGE TIME DURING THE MONTH RESULTED FROM DEPLETION
OF CHEMICAL ABSORBENT (TRONA) AND BOILER TRIPS.
TWO FORCED SCRUBBER OUTAGES, TOTALING 43.5 HOURS OF OUTAGE TIME,
WERE REPORTED BY THE UTILITY DURING THE MONTH. MINOR TRIPS WERE
CAUSED BY PLUGGING IN THE I.D. FAN REFERENCE LINES AND A FALSE
HIGH TEMPERATURE READING IN THE VENTURI CAUSED BY WATER IN THE
INSTRUMENT.
TOTAL FORCED OUTAGE TIME FOR THE MONTH AMOUNTED TO APPROXIMATELY
36 HOURS. SCRUBBER TRIPS WERE CAUSED BY VENTURI GAS DAMPER
PROBLEHS. PLUGGING IN THE SCRUBBER EFFLUENT LINE, AND REPLACEMENT
OF THE CARBONATE FEED LINE. SCRUBBER OUTAGE TIME DUE TO BOILER
TRIPS AMOUNTED TO APPROXIMATELY 65 HOURS.
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REID GARDNER 2 (CONTINUED)
BOILER
TOTAL OPERATION
HR. HR.
NOV. 76 720 621
AVAILABILITY = 52X
RELIABILITY = 51*
OPERABILITY = 5B«
UTILIZATION s 50X
DEC. 76 7<»i» 275
ALL INDEX VALUES = OX
JAN. 77 7"»«» 0
ALL INDEX VALUES = OX
FEB. 77 672 516
AVAILABILITY = 93X
RELIABILITY s 88X
OPERABILITY = 75X
UTILIZATION = 56X
MAR. 77 7«m 659
AVAILABILITY = 92X
RELIABILITY = 97X
OPERABILITY = 66X
UTILIZATION = 76X
APR. 77
MAY 77
HR.
CALLED
AVAILABILITY UPON TO OPLRATION
HR. OPERATE HR.
371*
709
363
623
H31
387
688
585
567
DURING A BOILER OUTAGE TO REPAIR A CONDENSER TUBE LEftK AND
BOTTOM ASH NoZZLEt THE SCRUBBER'S GUILLOTINE DAMPERS WERE BADLY
DAMAGED, AND THE SCRUBBER REMAINED OUT OF SERVICE DURING THE
MONTH OF DECEMBER.
THE BOILER WAS OFF-LINE DURING
JANUARY FOR MAINTENANCE.
TWO. MINOR SCRUBBER OUTAGES RESULTED FROM A
VENTURI PIPING LEAK AND WASH TRAY RECYCLE
TANK CLEANING. AT THE ENU OF THE MONTH,
THERE WERE SOME ELECTRICAL PROBLEMS.
MINOR SCRUBBER OUTAGES WERE A RESULT OF
ELECTRICAL PROBLEMS, A PLUGGED SPRAY TRAY,
DUCT PRESSURE SWINGING, AND AN I.D. FAN SWING.
THE SYSTEM WAS IN SERVICE DURING THE REPORT PERIOD WITH THE EX-
CEPTION OF A 2-WEEK BOILER MAINTAINENCE PERIOD. OPERATING DATA
AND INFORMATION WAS NOT PROVIDED BY NPCO FOR THE APRIL - MAY
PERIOD, BUT WILL BE AVAILABLE FOR THE NEXT REPORT.
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REID GARDNER 3
BOILER
TOTAL OPERATION
PERIOD
-------
REID GARDNER 3 (CONTINUED)
BOILER
TOTAL OPERATION
PERIOD HR. HR.
NOV. 76 720 26"»
AVAILABILITY = 28*
RELIABILITY = 29*
OPERABILITY = 60*
UTILIZATION c 29*
DEC. 76 7HH 7H4
AVAILABILITY = 99*
RELIABILITY = 991
OPERABLIITY = 97»
UTILIZATION = 97X
JAN. 77 7H<» 690
AVAILABILITY = 96X
RELIABILITY = 98*
OPERABILITY = 96%
UTILIZATION = 91*
FEB. 77 672 575
AVAILABILITY = 81*
RELIABILITY = 72*
OPERABILITY = 74*
UTILIZATION = 63*
HR.
CALLED
AVAILABILITY UPON TO
HR. OPERATE.
205
727
OPERATION
HR.
212
737
728
721
731
689
676
59H
422
COMMENTS
THE SCRUBBER SYSTEM HAS 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
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.
TWO MINOR FORCED OUTAGES WERE THE RESULTS OF A
PLUGGED TRAY AND A REHEATER STEAM LEAK.
A TOTAL OF 117 HRS. OF DOWNTIME WAS THE RESULT
OF THREE FORCED SCRUBBER OUTAGES CAUSED BY
PROBLEMS WITH THE UPPER TRAY. A FOURTH OUTAGE
RESULTED FROM DOWNTIME FOR CLEANING OUT THE
SODIUM CARBONATE LINE.
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REID GARDNER 3 (CONTINUED)
BOILER
TOTAL OPERATION
HR .
MAR. 77 7«H»
AVAILABILITY =
RELIABILITY = 52*
OPERABILITY = 51*
UTILIZATION = <*«**
APR. 77
AVAILABILITY =
RELIABILITY =
OPERABILITY r
UTILIZATION =
MAY 77
AVAILABILITY =
RELIABILITY s
OPERABILITY =
UTILIZATION s
HR .
639
HR.
CALLED
AVAILABILITY UPON TO
HR. OPERATE
321
627
OPERATION
HR.
32
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL f&0 SYSTEMS 06/77
IDENTIFICATION NO.
UTILITT NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYt
PARTICULATES
72
NORTHERN INDIANA PUB SERVICE
O.H. MITCHELL NO.11
GARY INDIANA
115 MW
COAL 3.2-3.5 PERCENT SULFUR
DAVY POWERGAS/ALLIEO CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
RETROFIT
6/77
OPERATIONAL
99.5 PERCENT
S02
WATER MAKE UP
90 PERCENT GUARANTEE
CLOSED LOOP
SLUDGE DISPOSAL
UNIT COST
S129/KW (NETI CAPITAL * 8.1 MILLS/KWH OPERATING <1976)
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THIS FGO SYSTEM IS AN INTEGRATION OF THE WELLHAN-LORD S02 RECOVERY PROCES
OFFERED BY DAVY POWERGAS AND THE SOg TO SULFUR REDUCTION PROCESS DE-
VELOPED BY ALLIED CHEMICAL. DAVY POWERGAS IS THE DESIGN AND CONSTRUCTION
FIRM AND ALLIED CHEMICAL IS SYSTEM OPERATOR AND PRODUCT MARKETER.
DURING THE REPORT PERIOD THE DEMONSTRATIUN SCRUBBER PLANT WAS STARTED UP
AND OPERATED AT APPROXIMATELY 60 PERCENT FLUE GAS CAPACITY BECAUSE OF
AIR PREHEATER PROBLEMS IN THfc. BOILER.
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BACKGROUND INFORMATION
ON
D.H. MITCHELL NO. 11
IN JUNE OF 1972 THE NORTHERN INDIANA PUBLIC SERVICE CO. (NIPSCO) AND THE U.S. ENVIRONMENTAL PROTECTION AGENCY ENTERED INTO
A COST-SHARED CONTRACT FOR THE CONSTRUCTION AND OPERATION OF A WtLLMAN-LORD/ALLIED CHEMICAL FLUE GAS DESuLFURIZATION DEMONSTRATION
PLANT. THE SYSTEM WAS INSTALLED ON GENERATING UNIT NO. 11 AT NIPSCO'S D.H. MITCHELL POWER STATION IN GARYt INDlANAi ON THE
SOUTHERN TIP OF LAKE MICHIGAN. UNIT NO. 11 IS RATED AT 115 MW AND FIRES MIDWEST COAL WITH A HEAT VALUE OF 11,000 BTU/L8. AND
SULFUR AND ASH CONTENTS OF 3.5 AND 10.Ot RESPECTIVELY.
THIS UNIT WILL BE THE FIRST RE6ENERABLE FGD SYSTEM TO CONTROL THE TOTAL FLUE GAS EMISSION FROM A FULL SCALE COAL-FIRED
GENERATING UNIT. IT WILL ALSO BE THE FIRST SYSTEM TO RECOVER ELEMENTAL SULFUR OF A MARKETABLE QUALITY FROM THE FLUE GAS OF AN
ELECTRIC UTILITY.
THE FGD SYSTEM CONSISTS OF THREE MAJOR PROCESS UNITS* A WELLMAN-LORU S02 RECOVERY UNIT, A DAVY POWERGAS PURGE TREATMENT
UNIT, AND AN ALLIED CHEMICAL S02 REDUCTION UNIT.
THE S02 RECOVERY SYSTEM INCLUDES A FLUE 6AS BOOSTER BLOWER, A PRESCRUBBER (ORIFICE CONTACTOR), A THREE-STAGE TRAY TOWER
ABSORBER, AND AN EVAPORATOR/CRYSTALLI2ER. THE PRESCRUBBER IS A VAKIABLE-THROAT VENTURI USED TO SATURATE THE FLUE GAS AND REMOVE
ANY FLYASH NOT COLLECTED IN THE ESP UNIT. THE SCRUBBING SOLUTION IS PURGED CONTINUOUSLY TO A SLUDGE POND, THE ABSORBER IS A
THREE-STAGE MULTIVENTURI FLEXITRAY (MVFT».ABSORPTION TOWER FOLLOWED BY A HIST ELIMINATOR AND A STACK GAS REHEATER. THE SPENT
SCRUBBING (SODIUM SULFITE-BISULFITE) SOLUTION IS REGENERATED IN AN EVAPORATOR/CRYSTALLIZER, WHERE IT IS
HEATED UNTIL THE BISULFITE DECOMPOSES, EMITTING S02 GAS AND PRECIPITATING SODIUM SULFITE CRYSTALS. THESE ARE REMOVED AND REOIS-
SOLVED IN THE CONDENSATE FROM THE EVAPORATOR FOR RECYCLE TO THE ABSORBER.
A SHALL SIOESTREAM IS REMOVED FROM THE SCRUBBING LI8UOR LEAVING THE ABSORBER AND SENT TO THE PURGE TREATMENT UNIT TO REMOVE
SODIUM SULFATE. THIS SYSTEM CONSISTS OF FOUR CHILLED-WALL CRYSTALLIZERS WHERE SODIUM SULFATE CRYSTALS FORM, FOLLOWED BY A CENTRI-
FUGE AND CRYSTAL DRYER.
THE SULFUR DIOXIDE FROM THE EVAPORATOR/CRYSTALLIZER IS COMPRESSED AND SENT TO THE ALLIED CHEMICAL S02 REDUCTION PLANT, WHERE
IT IS REACTED WITH NATURAL GAS. THE RESULTING ELEMENTAL SULFUR IS CONDENSED AND STORED IN MOLTEN FORM, WHILE THE OFF-GASES ARE
BURNED IN A TAIL GAS INCINERATOR AND RETURNED TO THE ABSORBER INLET. THE ALLIED PLANT IS DESIGNED TO GENERATE 25 TON/DAY OF
SULFUR.
165
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D.H. MITCHELL NO. 11 «CONTINUED>
THE PRIMARY ENGINEERING AND CONSTRUCTION FIRM IS DAVY POUERGAS. ALLIED CHEMICAL WILL OPERATE THE UNIT AND MARKET THE
ELEMENTAL SULFUR AND SODIUM SALT BY-PRODUCTS ON A CONTINUED BASIS. PERFORMANCE TESTING IS BEING CONDUCTED JOINTLY BY THESE TWO
FIRMS, WITH TRW, INC. MONITORING UNDER CONTRACT TO THE EPA.
AFTER A DELAY OF SEVERAL MONTHS DUE TO BOILER UNAVAILABILITY, THE D.H. MITCHELL UNIT NO. 11 FGD SYSTEM BEGAN OPERATION
ON JUNE 13« 1977, WITH O^NLY THE ABSORBER IN OPERATION. ON JUNE 15, THE FIRST INTEGRATED OPERATION OF THE SYSTEM OCCURRLO. A
16-DAY ACCEPTANCE TEST IS EXPECTED TO GET UNDERWAY IN EARLY JULY, FOLLOWED BY A 1-YEAR PERIOD OF MONITORING LONG-TERM EFFICIENCY
AND AVAILABILITY. THE SCRUBBER SYSTEM HAS BEEN DESIGNED TO REMOVE A MINIMUM OF 90 PERCENT OF THE S02 IN THE FLUE GAS OR MAINTAIN
A MAXIMUM OF 200 PP« so2 IN THE FLUE GASf WHICHEVER is THE LESSER, soz REGULATIONS REQUIRE THE MITCHELL STATION TO COMPLY WITH
THE EMISSION LIMITATION OF 1.2 POUNDS S02 PER MILLION BTU.
REFER TO APPENDIX B FOR A PROCESS FLOW DIAGRAM.
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TABLE: s
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCYt
PARTICULATES
73
NORTHfRN STATES POWER CO.
SHERBURNE COUNlY STATION NU.l
BECKER- MINNESOTA
710 MH
COAL 0.6 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
NEW
3/76
OPERATIONAL
99 PERCENT GUARANTEE
S02
50 PERCENT GUARANTEE
HATER MAKE UP
OPEN LOOP 1.13 GPM/MU
SLUDGE DISPOSAL
UNSTABILI2EO SLUDGE DISPOSED IN LINED POND
UNIT COST
S60 MILLION CAPITAL FOR UNITS 1 AND 2
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT.
FULL COMMERCIAL OPERATION OF THE SYSTEM BEGAN ON MAY It 1976. THE SCRUB-
BING 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. AVAILABILITY INDEX VALUES FOR
THE MONTHS OF APRIL AND MAY WERE 95 AND 92 PtRCENT. RESPECTIVELY. THE
UNIT WAS TAKEN OUT OF SERVICE IN MID-MAY FOR A SCHEDULED TUKBINE/BOlLEK
OVERHAUL. RESUMPTION OF OPERATIONS is SCHEDULED FOH MID-JUNE.
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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 BECKERf MINNESOTA. THIS NEW POWER GENERATING PLANT CURRENTLY HAS TWO COAL-FIRED UNITS IN SERVICE AND TWO IN THE EARLY
PLANNING STAGES. UNIT NO. 1 IS RATED AT 710 «« AND FIRES MONTANA COLSTRIP COAL WITH A HEATING VALUE OF $300 BTU/LB, AND SULFUR,
ASH. AND MOISTURE CONTENTS OF 0.8. 9.0 AND 85.0 PERCENT. RESPECTIVELY. IN ORDER TO MEET MINNESOTA POLLUTION CONTROL AGENCY PAR-
TICULATE AND S02 EMISSION STANDARDS OF 0.96 LBS. S02 AND 0.087 LBS. PARTICULATE PER MILLION BTU HEAT INPUT TO THE BOILER, THE UNIT
WAS FITTED WITH A LIMESTONE-BASED WET SCRUBBING SYSTEM FOR SIMULTANEOUS PARTICULATE AND S02 REMOVAL.
THE NORTHERN STATES POWER CO., SHERBURNE NO. 1 SCRUBBER 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 O.OH GR/DSCF, WHICHEVER OUTLET VALUE IS GREATER. THE SULFUR DIOXIDE DESIGN REMOVAL
EFFICIENCY IS BASED UPON THE REMOVAL OF 50 PERCENT OF THE SU(_FUR 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 ACFW 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 I&O-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 OF HO F 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 A SETTLING POND WHICH IS 45-FEET DEEP AND 62 ACRES IN AREA, WITH AN 16-INCH CLAY LINING.
168
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SHERBURNE COUNTY (CONTINUED)
THE WATER IS RFCYCLED FROM THE POND BACK TO THE PROCESS. A GENERAL FLOW DIAGRAM OF THE SHERBURNE SCRUBBER ARRANGEMENT IS PROVIDED
IN APPENDIX B
INITIAL OPERATION OF THE SYSTEM COMMENCED MARCH 16, 1976. FULL COMMERCIAL OPERATION COMMENCED MAY 1, 197fe. PROBLEMS ENCOUN-
TERED DURING INITIAL STARTUP OPERATIONS HAVE INCLUDED THE USUAL MECHANICAL PROBLEMS ASSOCIATED WITH A NEW SYSTEM AND SOME PLUGGING
IN THE SCRUBBER INTERVALS. SPECIFICALLY* PROBLEMS HAVE BEEN ENCOUNTERED IN THE SPRAY SYSTEM, REOUIRING THE DESIGN OF THE NOZZLES
TO BE CHANGED FROM PLASTIC AND RUBBER COMpUNENTS 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.
169
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SHERBURNE NO. i
BOILER OPERATION TIME AND MODULE OPERABILITY
BOILER
PERIOD HR. 101 102 103 10«» 105 106 107 108 109 110 111 112
MAR. 76
APR. 76
HAT 76 657 62 83 81 59 72 90 57 b9 60
TOTAL SYSTEM AVAILABILITY = 86X
MEGAWATT-HOURS GENERATED = 318,050
JUN. 76 686 69 78 73 62 61 63 78 73
TOTAL SYSTEM AVAILABILITY = 8HX
MEGAWATT-HOURS GENERATED = 372,450
JUL. 76 512 60 62 71 81 60
TOTAL SYSTEM AVAILABILITY = 8"»X
MEGAWATT-HOURS GENERATED = 269,700
705 «»6 93 51 8<+ 63 76 71 84 61
TOTAL SYSTEM AVAILABILITY = 9«X
MEGAWATT-HOURS GENERATED = 421,110
75 72
68 70
170
83
68 81 75 79 63 91
76 87
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
67 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
75 ARE PROCEEDING ON THE SPRAY SYSTEM, SPRAY NOZZLES,
AND STRAINER SYSTEM.
69 DEVELOPMENTAL WORK IS CONTINUING ON THIS SCRUBBING
SYSTEM. SINCE JULY i, THE NO. i UNIT HAS BEEN
GENERATING 95 TO 98 PERCENT THE NUMBER OF MW-HOURS
91 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
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NO. 1 (CONTINUED)
BOILER
PERIOD HR.
BOILER OPERATION TIME AND MODULE OPERAfalLITY
101 102 103 10<» 105 106 107 108 109 110 111 112
SEP. 76 566 87 90 93 76 76 79 85 79 85 80 92 96
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED = 3H9.«»70
OCT. 76 606 97 8*» 96 96 95 30 74 76 91 81 100
TOTAL SYSTEM AVAILABILITY s 93 PERCENT
MEGAWATT.HOURS GENERATED = 385,610
87
COMMENTS
SCRUBBER OPERATIONS. THE PREVENTIVE MAINTENANCE
AND CLEANING PROCEDURES NOW EMPLOYED FOR THE
SCRUBBING SYSTEM CALLS FOR 3 TO H 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 BYPASSED 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 SOD I 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.
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SHERBURNE NO.l (CONTINUEDI
BOILER OPERATION TIME AND MODULE AVAILABILITY
BOILER
PERIOD HR. 101 102 103 lot 105 106 107 108 109 110 111 112
80 93 89 69 78 73
97
91 95
NOV. 76 720 83 80 87 79 92
TOTAL SYSTEM AVAILABILITY = 93 PERCENT
MEGAWATT-HOURS GENERATED = 470,820
DEC. 76 722 88 84 87 80 71
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT.HOURS GENERATED = 480,920
JAN. 77 607 9«» 75 99 76 96 77 70 92 81
TOTAL SYSTEM AVAILABILITY = 901
MEGAWATT-HOURS GENERATED = 386*060
FEB. 77 609 89 99 6* 96 64 99 81 62
TOTAL SYSTEM AVAILABILITY = 9lK
MEGAWATT-HOURS GENERATED = 395*210
MAR. 77 743 47 92 95 93 93 95 88 93
TOTAL SYSTEM AVAILABILITY = 95*
MEGAWATT-HOURS GENERATED = 510.650
APR. 77 718 84 65 92 95 96 62 73
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED = 460.100
MAY 77 312 96 48 92 87 95 96 81 98
88 73
93
75
75 95
98 93 98 61
95 83 78 72
91 58 93 90 88
96 78 35 87
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 STUDY*
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.)
LOW OPERABILITIES ARE DUE PRIMARILY TO THE COMPLE-
TION OF STRAINER MODIFICATIONS. THESE MODIFICA-
TIONS WERE EFFECTED ONE MODULE AT A TIME.
MODULE 101 WAS THE LAST TO UNDERGO MODIFICATION
AND WORK WAS COMPLETED IN THE THIRD WEEK OF MARCH.
AT THE PRESENT TIME. ALL MODULES ARE FITTED WITH
IN-TANK STRAINERS. THE 10 MODULE VS. 11 MODULE
EVALUATION WILL BE RESUMED IN THE NEAR FUTURE.
DURING THE REPORT PERIOD, THE UNIT WAS IN SERVICE
ONLY 13 DAYS DURING THE MONTH OF MAY BECAUSE OF A
SCHEDULED TURBINE OVERHAUL EXTENDING FROM MAY 14
TO MID-JUNLtJUNE 18 PROJECTED).
172
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 06/77
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
7«f
NOR HERN STATES POWER CO.
SHERBUKNE COUNTY STATION NO.2
BECKER MINNESOTA
680 MW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
NEW
i»/77
OPERATIONAL
99 PERCENT GUARANTEE
S02
50 PERCENT GUARANTEE
WATER MAKE UP
OPEN LOOP 1.13 GPM/MW
SLUDGE DISPOSAL
UNSTABILIZED SLUDGE DISPOSED IN LINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
$60 MILLION CAPITAL FOR UNITS 1 AND 2
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE SHERBURNE NO,2 AIR QUALITY CONTROL SYSTEM IS IDENTICAL IN DESIGN TO
THE SYSTEM IN OPERATION ON THE NO.I UNIT AT THIS STATION. TWELVE 2.STAGE
PARTICULATE SCRUBBER (VENTURI-ROD SCRUBBER) AND SULFUR DIOXIDE ABSORBER
(MARBLE-BED ABSORBER) MODULES ARE PROVIDED FOR FLY ASH AND S02 CONTROL.
ELEVEN MODULES ARE REQUIRED FOR FULL GENERATING CAPACITY OPERATIONS.
TOTAL SYSTEM AVAILABILITY INDEX VALUES REPORTED FOR THE MONTHS OF APRIL
AND MAY WERE 92 AND 91 PERCENT, RESPECTIVELY.
173
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BACKGROUND INFORMATION
ON
SHERBURNE COUNTY GENERATING PLANT
THE SHERBURNE COUNTY GENERATING PLANT (SHERCO) OF THE NORTHERN STATES POWER COMPANY (NSP> IS LOCATED ON THE MISSISSIPPI
RIVER IN SHERBURNE COUNTY, BECKER. MINNESOTA, APPROXIMATELY *5 MILES NORTHWEST OF MINNEAPOLIS. THIS NEW POWER-GENERATING PLANT
CURRENTLY HAS TWO COAL-FIRED UNITS IN SERVICE AND TWO IN THE EARLY DESIGN STAGES, UNIT NO.2 IS RATED AT 710 Mw AND FIRES LOW
SULFUR COLSTRlp MONTANA" COAL THAT HAS A HEATING VALUE OF 6300 BTU/LB, SULFUR CONTENT OF 0.8 PERCENT, ASH CONTENT OF 9.0 PERCENTi
AND A MOISTURE CONTENT OF 25.0 PERCENT. IN ORDER TO MEET MINNESOTA POLLUTION CONTROL AGENCY EMISSION CODES OF 0.96 LB SULFUR
DIOXIDE AND 0.087 LB PARTIcULATES PER MILLION BTU HEAT-INPUT TO THE BOILER, THE UNIT WAS FITTED WITH A NQN-REGENERABLE LI1ESTONE-
BASED WET SCRUBBING SYSTEM.
THE DESIGN OF THE SCRUBBER PLANT FOR SHERCO NO.2 IS IDENTICAL TO THAT EMPLOYED FOR THE NO.l UNIT NOW IN SERVICE AT THIS STA-
TION (SEE THE PRECEDING FILE IN THIS REPORT FOR ADDITIONAL INFORMATION). THE SCRUBBER DESIGN IS BASED UPON PILOT PLANT AND PROTO-
TYPE PLANT RESEARCH PROGRAMS CONDUCTED AT COMBUSTION-ENGINEERING'S (C-EJ KREISINGER LABORATORY AND NSP»S BLACK DOG STATION. THE
BLACK DOG PROTOTYPE UNIT WAS OPERATED FOR FOURTEEN MONTHS FROM MARCH 1973 TO MAY 197<». NSP, C-E, AND BLACK ft VEATCH WERE RESPON-
SIBLE FOR THE OPERATION OF THE 13000 ACFH PROTOTYPE SCRUBBER. THE RESULTS OF THIS PROGRAM INDICATED THAT C-E FIXED-ROD SCRUBBER
AND SINGLE-STAGE MARBLE-BED ABSORBER MODULES WOULD PROVIDE SUFFICIENT POLLUTANT REMOVAL CAPABILITY WITH MINIMAL SCALING AND PLUG-
GING PROBLEMS. THE SCRUBBING SYSTEM HAS BEEN GUARANTEED TO REMOVE 99 PERCENT OF THE INLET PARTICULATE MATTER ENTERING THE SCRUB-
BER PLANT OR MAINTAIN AN EMISSION OUTLET OF 0.0* GR/SCF, WHICHEVER VALVE IS GREATER* AND REMOVE 50 PERCENT OF THE SULFUR IN THE
FUEL (MAXIMUM FUEL SULFUR CONTENT OF 1.2 PERCENT) OR MAINTAIN AN EMMISSION OUTLET OF 200 PPM S02« WHICHEVER VALUE IS GREATER.
THE SCRUBBER PLANT DESIGN FOR SHERCO NO.2 CONSISTS OF 12 C-E VENTRI-ROD SCRUBBER AND MARBLE BED ABSORBER MODULES, 11 OF
WHICH ARE REQUIRED FOR UNIT FULL-LOAD CAPACITY. EACH MODULE HAS A MAXIMUM FLUE GAS CAPACITY OF 220,000 ACFM AT 135 F. INCLUDED
IN EACH MODULE IS A VEfjTURI SECTION WITH TWO PARALLEL ROWS OF HORIZONTALLY ORIENTED RODS (PRIMARY CONTACTOR), A SINGLE STAGE
MARBLE-BED (3.5 TO I*.0-INCH DEEP BED OF 13/16-INCH DIAMETER GLASS SPHERES), LADDER VANES FOR GAS-FLOW DISTRIBUTION, TWO-STAGE
CHEVRON-TYPE DEMISTER, FINNED-TUBE HOT WATER HLAT EXCHANGER, AND AN INTERNAL REACTION TANK. THE REACTION TANK IS LOCATED AT THE
BOTTOM OF EACH MODULE AND FACILITATES THE COMPLETION OF THE CHEMICAL ABSORPTION OF SOg TO CALCIUM SULFITE. IN ADDITION,
THE SULFITE SPECIES FORMED IS FORCIBLY OXIDIZED TO SULFATE IN THE REACTION TANK VIA AIR BUBBLING AND AGITATION. THE SULFATE
SPECIES FORMED IS PRECIPITATED OUT BY THE ADDITION OF A GYPSUM SEED TO THE REACTION TANK LIQUOR, DEWATERED IN A 160-FOOT DIAMETER
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SHERBURNE COUNTY (CONTINUED)
CLARIFIERt AND DISPOSED OF WITH THE COLLECTED PARTICULATE MATTER IN AN ON-SITE Ifl-INCH CLAY-LINED SLUDGE POND (2790 ACRE-FEET
CAPACITY). WATER is RECYCLED BACK TO THE SCRUBBER PLANT FROM THE DISPOSAL POND FOR FURTHER SERVICE.
THE ABSORPTION OF SULFUR DIOXIDE FROM THE FLUE GAS STREAM RESULTS FROM THE PRESENCE OF TWO ALKALINE MATERIALS. THE CALCIUM
OXIDE IN THE COAL FLY ASH (APPROXIMATELY 17 PERCENT BY WEIGHT) AND THE CALCIUM CARBONATE IN THE TAIL-END LIMESTONE ADDITIVE.
ADDITIONAL INFORMATION ON THE OPERATION OF THIS UNIT IS PROVIDED IN THE PERFORMANCE HISTORY TABLE THAT FOLLOWS. A SIMPLIFIED
PROCESS FLOW DIAGRAM OF THE SHLRCO SCRUBBER SYSTEM IS PROVIDED IN FIGURE 16« APPENDIX B.
175
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SHERBURNE NO. 2
BOILER TIME AND MODULE OPERABILITY (*)
BOILER
PERIOD HR. 201 202 203 20"» 205 206 207 208 209 210 211 212
APR. 77 697 0 95 93 67 83 8<» 9«» 7<* 91 87 85 86
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENLRATEb =
-------
TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
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
79
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 1
SHIPPINGPORT PENNSYLVANIA
635 MW
COAL H.7 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
NEW
OPERATIONAL
99.6 PERCENT
S02
92 PERCENT GUARANTEE
WATER MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
S133/KW CAPITAL * 2.7 MILLS/KWH ANNUALI2EO
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 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 SCRUBBING. 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 OATEt 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.
177
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BACKGROUND INFORMATION
ON
BRUCE MANSFIELD UNIT NO. 1
THE BRUCE MANSFIELD PLANT IS A 2700-Mw, 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 AMD AS AGENT FOR
THE OTHER PARTICIPATING COMPANIES* THE CLEVELAND ELECTRIC ILLUMINATING CO., DUOUESNE 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/LB COAL HAVING AVERAGL ASH AND SULFUR CONTENTS OF 12.5 AND
-------
BRUCE MANSFIELD NO. 1
MONTH
DEC. 75
JANt 76
FEB. 76
MAR. 76
APR. 76
BOILER
OPERATING HOURS
FGU MODULES
506
0 210 96
-------
BRUCE MANSFIE.LD NO, 1 (CONTINUED)
MONTH
BOILER
OPERATING HOURS
FGD MODULES
C
COMMENTS
A B C D E
AUG. 76 705.3 672 620 653 535 500
TOTAL SYSTEM AVAILABILITY = 95*
TOTAL SYSTEM OPERABILITY z 100*
TOTAL SYSTEM RELIABILITY a 100*
TOTAL SYSTEM UTILIZATION = 95*
SEP. 76 720 708 617 693 695 596
TOTAL SYSTEM AVAILABILITY = 100*
TOTAL SYSTEM OPERABILITY = 100*
TOTAL SYSTEM RELIABILITY = 100*
TOTAL SYSTEM UTILIZATION = 100*
OCT. 76 739 710 5«»9 631 619 b91
TOTAL SYSTEM AVAILABILITY = 99*
TOTAL SYSTEM OPERABILITY = 100*
TOTAL SYSTEM RELIABILITY s 100*
TOTAL SYSTEM UTILIZATION r 99*
NOV.76 277 270 278 282 113 159
TOTAL SYSTEM AVAILABILITY s 100*
TOTAL SYSTEM OPERABILITY s 100 *
TOTAL SYSTEM RELIABILITY = 100 *
TOTAL SYSTEM UTILIZATION = 38*
DEC. 76 722 58* 726 6B<« <*33 622
TOTAL SYSTEM AVAILABILITY = 100 *
TOTAL SYSTEM OPERABILITY = 100 *
TOTAL SYSTEM RELIABILITY = 100 *
TOTAL SYSTEM UTILIZATION =975
F
668
691
2«»6
626
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BKl/Cf MANSFIELD NO. 1 (CONTINUED)
MONTH
BOILER
OPERATING HOURS
FGO MODULES
C D
A B
JAN. 77 THE UTILITY WAS UNABLE TO PROVIDE
FEB. 77 UPDATE INFORMATION
MAR. 77 FOR THIS REPORT PERIOD.
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 195,700
APR. 77 PENN POWER REPORTED THAT IT IS
MAY 77 IN THE PROCESS OF REWRITING THE
BRUCE MANSFIELD NO. 1 FILE FOR
THE FGD SUMMARY REPORT AND THAT
IT WILL BE AVAILABLE FOR THE
NEXT REPORT PERIOD.
COMMENTS
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FcD SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFIClENCYi
PARTICIPATES
63
PHILADELPHIA ELECTRIC CO.
EODYSTONE NO. IA
EDDYSTONE PENNSYLVANIA
120 MW
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/75
OPERATIONAL
99.9 PERCENT
S02
90 PERCENT
WATER MAKE UP
CLOSED LOOP 1.1 GPM/MW
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
S17 MILLION CAPITAL
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF THREE PARALLEL
SCRUBBING TRAINS FOR THE CONTROL OF PARTICULATE AND SULFUH DIOxIDE.
THE C-SIDE SCRUBBING TRAIN INCLUDES AN S02 ABSORBER MODULE IN SERIES
WITH A PARTICULATE SCRUBBER. APPROXIMATELY ONE-THIRD OF THE BOILER FLUE
GAS is SCRUBBED WITH MAGNESIUM OXIDE SLURRY FOR 502 REMOVAL. THE SPENT
SLURRY is REGENERATED AT THE ESSEX SULFURIC ACID PLANT IN NEWARK. N.J.
THE REGENERATED MAGOx IS RETURNED TO THE PLANT FOR S02 SCRUBBING SERVICE.
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BACKGROUND INFORMATION
ON
EUDYSTONL NO. 1
THt EDDYSTONE STATION OF THE PHILADELPHIA ELECTRIC CO. (PECO) IS LOCATED ON THE DELAWARE RIVER IN EDDYSTONE, 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 UNITS. UNITS 3 AND SYSTEM ON BOILER NO. i AT THE EDDYSTONE STATION OF PHILADELPHIA
ELECTRIC COMPANY (PECO) WAS DESIGNED AND INSTALLED BY UNITED ENGINEERS AND CONSTRUCTORS, INC., IN COOPERATION WITH PHILADELPHIA
ELECTRIC. THE SYSTEM CONSISTS OF THREE FIRST-STAGE SCRUBBER MODULES IN PARALLEL FOR PARTICULATE CONTROL (TWO ENVIRONEERING VENTRI
ROD UNITS AND ONE PEABODY-LURGI VENTURI UNIT) AND A SECOND-STAGE ENVIRONEERING ABSORBER MODULE WITH TWO VENTRI.ROD BEOS FOR SULFUR
DIOXIDE REMOVAL.
THE THREE FIRST-STAGE SCRUBBERS TOGETHER ARE SIZED TO HANDLE ALL THE EXHAUST GAS FROM UNIT 1 WHICH HAS A NET ELECTRIC GENER-
ATING CAPACITY OF 316 MW. THE SECOND-STAGE ABSORBER Is SIZED TO HANDLE ONE-THIRD OF THE GAS FLOW, EQUIVALENT TO APPROXIMATELY 105
MU (NET). THE SYSTEM IS DESIGNED TO REMOVE 90 PERCENT OF THE SULFUR DIOXIDE FROM BOILER STACK GAS. A GENERAL PROCESS FLOW DIAGRAM
OF THE WET SCRUBBING SYSTEM IS PRESENTED IN APPENDIX B.
SCRUBBER OPERATING HISTORY
THERE WAS A BRIEF OPERATING PERIOD ON THE PARTICULATE SCRUBBERS FROM MID-NOVEMBER, 1974, TO MARCH, 1975, THAT UNCOVERED A
NUMBER OF PROBLEM AREAS. DUE TO A NUMBER OF EXTENUATING CIRCUMSTANCES, PARTICULATE SCRUBBING WAS NOT RESTARTED UNTIL JULY 23,
1975. WITH ONE PARTICULATE SCRUBBING TRAIN FOLLOWED BY THE OTHER TWO TRAINS, ON AUGUST 15 AND OCTOBER 2, RESPECTIVELY. THE SULFUR
DIOXIDE ABSORBER WAS STARTED FOR THE FIRST TIME ON OCTOBER 2« 1975, AND THE MAGNESIUM OXIDE REGENERATION FACILITY FIRST PROCESSED
MAGNESIUM SULFITE FROM THE EDOYSTONE SCRUBBER ON OCTOBER 26, 1975.
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EDOYSTONE NO. KCONTINUED)
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 EDOYSTONE SCRUBBER.
THE SULFUR DIOXIDE SCRUBBING SYSTEM WAS TEMPORARILY SHUT DO*N DECEMBER 31, 1975. BECAUSE THE ACID PLANT REGENERATION FACILITY
AT THE OLlN CHEMICAL SULFURIC ACID PLANT IN PAULSBORO, NEW JERSEY PERMANENTLY CEASED OPERATIONS. THE ACID PLANT REGENERATION
FACILITY WAS RELOCATED TO THE ESSEX CHEMICAL PLANT IN NEWARK* NEW JERSLY.
THE PARTICULATE AND SULFUR DIOXIDE REMOVAL SYSTEM INSTALLED ON THE EDDYSTONE 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 EDOYSTONE NO. 2 AND ONE Of THE TWO EXISTING UNITS AT THE CROMBY STATION.
ADDITIONAL INFORMATION AND DATA CONCERNING THE OPERATION OF THE PARTICULATE AND SULFUR DIOXIDE SCRUBBERS INSTALLED AT THIS
PLANT ARE PROVIDED IN THE PERFORMANCE TABLE. FOLLOWING.
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FGO SYSTEM PERFORMANCE
EDDYSTONE NO. 1
COMMENTS
NOV. 7» THE SCRUBBING SYSTEM AT THIS PLANT CONSISTS OF THREE PARALLEL SCRUBBING TRAINS INCORPORATING 3 WET PARTICIPATE SCRUBBERS
DEC. 7» AND ONE S02 ABSORBER MODULE. THERE WAS A BRIEF OPERATING PERIOD ON THE PARTICULATE SCRUBBERS FROM MID-NOVEMBER 197"* TO
JAN. 75 MARCH 1975. PROBLEMS ENCOUNTEKED CENTERED AROUND THE SCRUBBER BOOSTER FANS AND THE FLUE GAS AND LIQUID CONDITIONS.
FEB. 75 THE B-SIOE BOOSTER FAN DEVELOPED HIGH SHAFT VIBRATION WHEN STARTED FOR THE FIRST TIME. THIS PROBLEM WAS DESIGN-RELATED.
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 COLD START PROCEDURE. AT APPROXIMATELY
THIS TIME. A CHECKOUT OF S02 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 23i 1975. THE TWO REMAINING TRAINS. B-SIDE AND A-SIDE. WERE PUT INTO
AUG. 75 OPERATION ON AUGUST 15 AND OCTOBER 2. RESPECTIVELY. THE S02 ABSORBER MODULE IN THE C-SIOE SCRUBBING TRAIN WAS INITIALLY
SEP. 75 PLACED IN SERVICE OCTOBER 2i 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. THE 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 2"* 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 S02 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 REOUIRED FOR RELOCATION ONCE A
185
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FGD SYSTEM PERFORMANCE (CONTINUED)
EDDYSTONt NO. 1
COMMENTS
MAY 76 CHOICE IS HADE. 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 PARTICULATE 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 ABOVEJ.
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 ScRUBBEKS IS IN THE FLUE GAS STREAM. TO DATE, ALL THREE OF THE WET PARTICULATE SCRUBBERS HAVE NOT
SEEN ANY APPRECIABLE SIMULTANEOUS SERVICE TIME.
NOV. 76 MGO SCRUBBING OPERATIONS ARE NOW SCHEDULED TO RESTART IN MAY 1977. REGENERATION FACILITY RELOCATION IS BEING COM-
DEC. 76 PLETEO, 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.
JAN. 77 THE MAGNESIUM OXIDE SCRUBBING SYSTEM AT EDDYSTONE NO. 1A IS STILL SCHEDULED FOR RESTART IN MAY 1977. THE START-UP
FEB. 77 OF THE NEW MAGNESIUM SULFITE REGENERATION FACILITY AT THE ESSEX CHEMICAL PLANT AT NEWARK, N.J. IS ALSO SCHEDULED
MAR. 77 FOR MAY 1977. THE THREE PARALLEL VENTURI SCRUBBERS CONTROLLING PARTICULATE EMISSIONS ON EDDYSTONE NO. 1 WENT BACK
INTO SERVICE IN MARCH 1977.
APR. 77 RESUMPTION OF MAGNESIUM OXIDE SCRUBBING OPERATIONS OCCURRED DURING THE REPORT PERIOD. THE UTILITY REPORTED THAT
MAY 77 S02 SCRUBBING OPERATIONS WERE NOT CONTINUOUS THROUGHOUT THE PERIOD. THE ABSORBER WAS IN SERVICE APPROXIMATELY 206 HOURS
DURING MAY. REGENERATION OPERATIONS AT THE ESSEX FACILITY WERE NOT CONDUCTED DURING THE PERIOD. PECO INTENDS
TO INITIATE S02 RECOVERY AND MAGOX REGENERATION OPERATIONS DURING THE MONTH OF JuNE. THE S02 MODULE CONTAINS TwO
ABSORBER SECTIONS IN SERIESCEACH SECTION CONSISTING OF AN ADJUSTABLE ROD DECK WITH UNDERSPRA^S). ONLY ONE OF ABSORBER
SECTIONS IS BEING USED FOR S02 REMOVAL. S02 REMOVAL EFFICIENCY HAS NOT BEEN MEASURED, MAGNESIUM OxIOE LOSSES IN THE
SYSTEM IABSORTION AND REGENERATION) ARE ESTIMATED AT 10 PERCENT.
166
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
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
102
SPRINGFIELD CITY UTILITIES
SOUTHWEST NO. 1
SPRINGFIELD MISSOURI
200 nw
COAL 3.5 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
NEW
H/77
OPERATIONAL
99.7 PERCENT
S02
60 PERCENT
WATER HAKE UP
SLUDGE DISPOSAL
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
S20 MM CAPITAL FOR AQCS
THE SCRUBBER BLCA«E OPERATIONAL ON A TRIAL BASIS IN EARLY APRIL. COMMER-
CIAL OPERATION IS SLATED BY 6/15. THE SYSTEM IS EXPERIENCING DEMISTER
SCALING AND SOME CONTROL PROBLEMS. ALSO CORROSION OF THE PRESATUKATOR
HAS TAKEN PLACE AND RE-LINING APPEARS NECESSARY. NO DEFINITE EFFICIENCY
TESTS HAVE BEEN MADE AS YET DUE TO THE EFFECTS OF THESE PROBLEMS. THE
TOP PORTION OF THE STACK AND BREECHING ARE CEILCOTE LINED.
187
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
103
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10A
PADUCAH KENTUCKY
10 MW
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
RETROFIT
«»/72
OPERATIONAL
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT. THIS
TURBULENT CONTACT ABSORBER(TCA) LIME/LIMESTONE SCRUBBING SYSTEM HAS BECN
OPERATIONAL SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDtD 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.
106
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TABLE; s
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F60 STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
TENNESSEE VALLLY AUTHORITY
SHAWNEL N0.10B
PADUCAH KENTUCKY
10 nw
COAL 2.9 PERCENT SULFUR
CHEMICO
LIME/LIMESTONE SCRUBBING
RETROFIT
«»/72
OPERATIONAL
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT. THIS
VENTURI/SPRAY 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.
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BACKGROUND INFORMATION
ON
SHAWNEE NOS. IDA AND 10B
IN JUNE 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE LIME AND LIMESTONE SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND
PARTICULATE FROM COAL-FIRED BOILER FLUE GASES. THE PROGRAM MAS CARRIED OUT IN A TEST FACILITY INCORPORATED INTO THE FLUE GAS
DUCTWORK OF UNIT NO. 10. A COAL-FIRED BOILER AT THE TVA SHAWNEE POWER STATION, PADUCAH, KENTUCKY. TVA IS THE CONSTRUCTOR AND
FACILITY OPERATOR AND BECHTEL 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* 11 A VENTURI WITH A SPRAV TOWER AFTER ABSORBER, 2) A
TURBULENT CONTACT ABSORBER (TCA), AND 3) A MARBLE-BED ABSORBER. THE VENTURI SYSTtM, 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 FLU1DIZEO BED OF LOW DENSITY PLASTIC SPHERES THAT ARE FREE TO HOVE
BETWEEN RETAINING 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.
IN JUNE I97ti 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
J3) 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 APPENDIX B. OPERATION OF THE
MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
EACH OF THE SCRUBBING SySTEMS CONTAINS ITS 0«N SLURRY HANDLING FACILITIES AND CAN TREAT APPROXIMATELY 30,000 ACFM OF GAS AT
300 F CONTAINING 1800 TO <*000 PPM OF SULFUR DIOXIDE AND 2 TO H GRAINS/SCF OF PARTICULATE. BOILER NO. 1 NORMALLY BURNS A HIGH-
SULFUR BITUMINOUS COAL.
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SHAWNEE HOS. 10A AND 10B (CONTINUE!))
FROM JUNE 197«» TO JANUARY 1976, MIST ELIMINATION AND LIMESTONE UTILIZATION TESTS HERE CONDUCTED AT THE SHAWNEE FACILITY.
DURING THIS TEST PERIOD THE VENTURI/SPRA* TOMER 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 i»0
TO 50 PERCENT-BY-WEIGHT FLY ASH BECAUSE OF RELATIVELY HIGH GAS INLET PARTICULATE LOADING. THIS TESTING PROGRAn 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.
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SHAWNEE NOS. IDA AND 10B
SEP. 75 THIS EXPERIMENTAL EPA-FUNDED OPERATION IS PROCEEDING WITH THE TEST PROGRAM, TWO ABSORBER MODULES ARE CURRENTLY OPERAT-
OCT. 75 IONAL (10 MW EACH}» THE MARBLE-BED ABSORBER IS STILL INOPEKATIVE (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 SPRAY TOWER AND THE TCA CAN BE KEPT
DEC. 75 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 RE-
DUCED SCRUBBER INLET SLURRY PH (ABOUT 5.21 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 ELIMINATOR 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*
FEB. 76 EVALUATE SCRUBBER OPERABILITy DURING VARIABLE LOAD OPERATION.
CONTINUE LONG-TERM RELIABILITY TESTING.
INVESTIGATE METHODS FOR IMPROVING WASTE SOLIDS SEPERATION.
CONTINUE SLUDGE OXIDATION AND SLUDGE FIXATION STUDY PROGRAMS.
EVALUATE SYSTEM PERFORMANCE AT REDUCED FLY ASH LOADINGS.
DETERMINE THE PRACTICAL UPPER LIMITS OF SOg REMOVAL EFFICIENCY.
EVALUATE ADDITION OF MAGNESIUM ION TO THE SCRUBBING SLURHY.
CHARACTERIZE ALL STACK GAS EMISSION COMPONENTS.
EVALUATE MATERIALS OF CONSTRUCTION OF ALL SCRUBBER AND PLANT-RELATED COMPONENTS.
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 OF THE LIME/LIMESTONE SCRUBBING
APR. 76 SYSTEMS WITH AND WITHOUT MAGNESIUM ADDITION HAS BEEN COMPLETED. CURRENTLY TESTING IS PROCEEDING ON THE EVALUATION
OF SYSTEM PERFORMANCE AS A FUNCTION OF LOW RESIDENCE TIMES (1.5 TO 5.0 MINUTESj IN THE RECYCLE TANKS. IN ADDITION,
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NOS. IDA AND 108 (CONTINUED)
A FLY ASH-FREE DUCT IS BEING INSTALLED AT THE TEST FACILITY. THUS ENABLING EVALUATION OF SYSTEM PERFORMANCE IN
THE ABSENCE OF FLY ASH,
HAY 76 THE TEST DIRECTOR, BECHTEL, PROVIDED THE FOLLOWING INPUT CONCERNING THE OPERATION OF THE EXPERIMENTAL SCRUBBING
JUN. 76 SYSTEMS DURING THE REPORT PERIOD*
THE EFFECT OF MGO AUDITION WAS EXPLORED IN BOTH SCRUBBER SYSTEMS. RESULTS INDICATE MAGNESIUM ION IN THE
SCRUBBER SLURRY LIQUOR ENHANCES SOg 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 93 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 IN-
CREASING 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.
BOTH SCRUBBING SYSTEMS OPERATED IN THE SUBSATURATED SULFATE MODE WHEN MAGNESIUM OXIoE 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 UITH LIME SLURRY SCRUBBING SOLUTIONS,
THE TCA SYSTEM ON FLUE GAS CONTAINING FLY ASH AND THE VENTURI/SPRAY TOWER SYSTEM ON FLY ASH-FR£E FLUE GAS.
JUL. 76 EXPERIMENTAL OPERATION OF THE EPA/TVA ALKALI SCRUBBING TEST FACILITY CONTINUED DURING THE REPORT PERIOD. BECHTEL.
AUG. 76 THE TEST DIRECTOR, PROVIDED THE FOLLOWING INPUT CONCERNING THE OPERATION OF THE PROTOTYPE TEST UNITS.
VENTURI/SPRAY TOWER SYSTEM* THIS SYSTEM RAN ON FLY ASH.FREE FLUE GAS USING A LIME SLURRY SCRUBBING SOLUTION.
NO SIGNIFICANT DIFFERENCES IN 502 REMOVAL. GYPSUM SATURATION AND SULFITE OXIDATION WERE DETECTED (VERSUS FLY
ASH-LADEN FLUE GAS}. ONE DIFFERENCE NOTED WAS THE FILTER CAKE SOLIDS CONTENT WHICH WAS APPROXIMATELY 10 PER-
CENT LOWER FOR THE FLY ASH-FREE SLUDGE O»0 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
193
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SHAWNEE NOS. IDA AND 10B (CONTINUED)
OPERATION WAS ACHIEVED IN THIS MODE. UNDER THE FOLLOWING CONDITIONS* 8 PERCENT SOLIDS (NO FLY ASH) IN THE RE-
CIRCULATED SLURRY* PH OF THE SCRUBBER LIQUID INLET WAS 6.0* SUPERFICIAL GAS VELOCITY OF 9.<» FT./SEC.* AND A
TOTAL LIOUIO-TO-GAS RATIO (L/G) OF 7! GAL./MCF. SOME SCALE FORMATION OCCURRED WHEN THE SOLIDS CONTENT IN THE
RECIRCULATED SLURRY DROPPED BELOW THE
-------
NOS. 104 /. 138 (CONTINUED)
AND THERE APPEARS TO BE AN OPTIMIM RESIDENCE: TIME AT WHICH MINIMUM SULFATE (GTPSUM) SUBSATURATiON OCCURS. TYPICAL
CONDITIONS* GAS VELOCITY 12.5 FT/SEC, L/G 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 3. 4, AND 12 MINUTES, RESPECTIVE-
LY. FURTHER TESTS WERE RUN AT 37 GAL/hCF L/G, AND 8.0 SCRUBBER INLET PH WITH OTHER CONDITIONS THE SAME. DURING
THESE TESTS GTPSUM SATURATIONS WERE 95t 95. 50. AND 90 PERCENT AT 3, <»» 5.It AND 16 MINUTES RESIDENCE TIMES.
RESPECTIVELY.
NOV. 76 FROM MID-OCTOBER THROUGH EARLY DECEMBER AN INTENSIVE FLUE GAS CHARACTERIZATION TESTING PROGRAM WAS CONDUCTED ON
DEC. 76 THE VENTURI/SPRAY TOWER SYSTEM WITH LIME SLURRY.
OVER THE RANGE TESTED, OUTLET PARTICULATE MASS LOADING WAS FOUND TO BE INDEPENDENT OF SLURRY COMPOSITION (8 TO 15
PERCENT SUSPENDED SOLIDS, 3,000 TO 16,000 PPM DISSOLVED SOLIDS), GAS FLOW RATE (20,000 To 35,000 ACFM), SPRAY
TOWER LIQUID RATE (0 TO 1,400 6PM), AND VENTURI PRESSURE DROP (3 TO 9 INCHES H20). WITH H TO 6 GR/OSCF PARTICU-
LATE IN THE INLET, TYPICAL OUTLET LOADINGS WERE 0.02 TO O.Oi* GR/OSCF. WHEN OPERATING WITH FLUE GAS FROM THE
ELECTROSTATIC PRECIPITATOR (0.1 TO O.t GR/DSCF TO THE SCRUBBER), THE SCRUBBER OUTLET LOADING AVERAGED 0.005
GR/OSCF. THUS, ENTRAINED SLURRY FROM THE MIST ELIMINATOR MUST HAVE BEEN LESS THAN 0.005 GR/DSCF. SIZE DISTRIBU-
TION DATA ARE STILL BEING ANALYZED. SULFURIC ACID MIST VALUES WERE APPROXIMATELY 2 TO 25 PP« AT THE SCRUBBER IN-
LET AND REMOVALS HAVE BEEN ABOUT 50 TO 75 PERCENT.
FOR THE REMAINDER OF DECEMBER THE VENTURl/SPRAY TOWER SYSTEM WAS DOWN FOR MODIFICATIONS FOR TWO-STAGE OXIDATION
TESTING. SEE APPENDIX B FOR A PROCESS FLOW DIAGRAM.
DURING NOVEMBER THE TCA WAS OPERATED WITH FLY-ASH CONTAINING FLUE GAS USING LIME SLURRY WITHOUT ADDED MAGNESIUM
OXIDE. OPERATING CONDITIONS WERE 12.5 FT/SEC GAS VELOCITY, 50 GAL/MCF L/G, 6.0 SCRUBBER INLET PH, AND 8 TO 15
PERCENT SLURRY SOLIDS. AT THESE CONDITIONS THE S02 REMOVAL WAS ABOUT 80 PERCENT.
FLY-ASH FREE LIMESTONE TESTS WITHOUT MAGNESIUM OXIDE ADDITION BEGAN ON THE TCA SYSTEM IN LATE NOVEMBER. TYPI-
CAL OPERATING CONDITIONS WERE 12.5 FT/SEC GAS VELOCITY. 50 GAL/MCF L/G, AND 1.1 TO 1.2 STOICHIOMETRIC RATIO. AT
THE SAME STOICHIOMETRY, THE PH OF THE FLY-ASH FREE SLURRY WAS 0.2 TO 0.3 UNITS HIGHER THAN OBSERVED IN PREVIOUS
RUNS WITH FLY ASH.
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SHAWNEE NOS. IDA AND 108 (CONTINUED)
JAN. 77 THE VENTURI/SPRAY TOWER SYSTEM HAS BEEN OPERATED IN A TWO-SERIES-SCRUBBER MODE WITH FORCED OXIDATION SINCE EARLY
FEB. 77 JANUARY 1977 AFTER SYSTEM MODIFICATIONS TO ALLOW OPERATION OF THE VENTURI AND SPRAY TOWER WITH INDEPENDENT SLURRY
RECIRCULATION LOOPS. SULFITE OXIDATION WAS CARRIED OUT IN AN e FT. DIAMETER VENTURI CPRE-SCRUBBER) EFFLUENT HOLD
TANK WHICH HAD A 130 - 1/8 INCH HOLE AIR SPARGER IMMERSED IN 18 FT. OF SLURRY. THE SPRAY TOWER (AFTER SCRUBBER)
FUNCTIONED AS A PRIMARY S02 ABSORBER.
TYPICAL OPERATING CONDITIONS. USING LIMESTONE SLURRY, WERE 6.7 FT/SEC SPRAY TOWER GAS VELOCITY, 20-30 6AL/MCF
VENTURI L/G, 70 GAL/MCF SPRAY TOWER L/G. 15 PERCENT SOLIDS (WITH FLY ASH) IN VENTURI RECIRCULATED SLURRY. 4.5-5.0
VENTURI INLET (OXIDATION TANK) PH, AND 11.3 MINUTES OXIDATION TANK RESIDENCE TIME (BASED ON 600 GPM SLURRY FLOW TO
VENTURI).
DURING THESE TESTS, AVERAGE OVERALL SULFITE OXIDATION RANGED FROM 93 TO 99 PERCENT AT AIR STOICHIOMETRIC RATIO OF
1.0 TO i».7 LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED. CORRESPONDING AVERAGE OXIDATION IN THE SPRAY TOWER RANGED FROM
10 TO 16 PERCENT. AVERAGE OVERALL LIMESTONE UTILIZATION RANGED FROM 83 TO 96 PERCENT. NO SCALING JAS EXPERIENCED
IN EITHER SCRUBBER. AVERAGE FILTER CAKE SOLIDS WERE 79 TO 86 PERCENT BY WEIGHT COMPARED WITH 55-65 PERCENT WITH-
OUT FORCED OXIDATION. SLURRY SOLIDS SETTLING RATE RANGED 0.5 TO l.H CM/MIN. 5 TO 10 TIMES FASTER THAN THAT FOR
UNOXIDIZED SLURRY. FINAL SETTLED DENSITY RANGED 65-80 PERCENT SOLIDS COMPARED WITH if5-60 PERCENT FOR SLURRY WITH-
OUT FORCED OXIDATION.
FLY ASH-FREE LIMESTONE TESTING ON THE TCA SYSTEM WAS COMPLETED IN EARLY FEBRUARY. THE PH OF THE FLY ASH-FREE
SLURRY WAS 0,2 TO 0.3 UNITS HIGHER THAN OBSERVED IN PREVIOUS RUNS WITH FLY ASH. IN ADDITION, THE FLY ASH-FREE
SLURRY APPEARED TO HAVE INFERIOR SOLIDS OEWATERING CHARACTERISTICS. FOR EXAMPLE, THE CENTRIFUGE CAKE SOLIDS
AVERAGED ABOUT 50 PERCENT COMPARED WjTH ABOUT 60 PERCENT FOR SLUDGE CONTAINING FLY ASH.
INTENSIVE FLUE GAS CHARACTERIZATION TESTING WITH LIMESTONE SLURRY ON THE TCA SYSTEM BEGAN IN EARLY FEBRUARY AND
ENDED IN EARLY MARCH 1977. PRELIMINARY ANALYSIS OF THE DATA SHOWED AN OUTLET MASS LOADING OF o.oi-o.OB GRAIN/DSCF
FOR FLUE GAS CONTAINING FLY ASH AND 0.02-0.03 GRAlNS/DSCF FOR FLUE GAS WITHDRAWN DOWNSTREAM OF THE ESP. IT WAS
ESTIMATED THAT THESE OUTLET MASS LOADINGS CONTAINED ABOUT 0.03 GRAIN/DSCF FLY ASH, 0.02 GRAIN/DSCF RE-ENTRAINED
SLURRY SOLIDS, AND 0.015 ENTRAINED DISSOLVED SOLIDS (WHEN A CONTINUOUS MIST ELIMINATOR UNDER WASH WAS USED). THESE
VALUES VARY DEPENDING ON THE MIST ELIMINATOR WASH SCHEME AND GAS FLOW RATE.
196
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SHAWNEE NOS. 10A AND 10B (CONTINUED)
MAR. 77 DURING MARCH, THE VENTURI/SPRAY TOWER t»AS TESTED WITH LIME SLURRY AND FLY ASH LADEN FLUE GAS IN A TWO-STAGE SCRUB-
BER NODE WITH FORCED OXIDATION. OPERATION WITH LIME WAS SIMILAR TO THE PREVIOUSLY REPORTED LIMESTONE OPERATION
WITH GREATER THIN 95 PERCENT OXIDATION AT AN AIR STOICHIOMETRIC RATIO OF 1.5 LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED
WITH A SIMPLE AIR SPARGER IN A VENTURI HOLD TANK. SLURRY SOLIDS SETTLING RATE VARIED FROM 0.6 TO 1.3 CM/MIN (A 5
TO 10 FOLD ENHANCEMENT OVER UNOXIDIZED SLURRY) AND FILTER CAKE SOLIDS RANGED FROM 7t TO 86 PERCENT (COMPARED WITH
<*5 TO 60 PERCENT WITH UNOXIDIZED SLURRY).
TWO MAJOR DIFFERENCES BETWEEN LIME AND LIMESTONE WERE OBSERVED IN A TWO-STAGE FORCED OXIDATION. TO MAINTAIN PH
CONTROL, IT WAS NECESSARY TO FEED LIME TO BOTH STAGES. WITH LIMESTONE, FEED ONLY TO THE SECOND STAGE WAS ADEQUATE.
TO MAINTAIN 80 PERCENT S02 REMOVALt IT WAS NECESSARY TO OPERATE WITH HIGHER SLURRY SOLIDS CONCENTRATION IN THE
SPRAY TOWER LOOP WITH LIMESTONE (15 PERCENT) THAN WITH LIME (6 PERCENT), RESULTING IN A TIGHTER WATER BALANCE WITH
LIMESTONE AND INADEQUATE WATER TO FLUSH THE MIST ELIMINATOR.
PRELIMINARY LIMESTONE TYPE AND GRIND TESTS MADE ON THE TCA SYSTEM DURING MARCH INDICATED THAT S02 REMOVAL IS
IMPROVED BY THE USE OF FINER GROUND LIMESTONE. S02 REMOVAL WITH EQUIVALENT GROUND FREDONlA WHITE AND LONGVlEW,
ALABAMA LIMESTONES WAS THE SANE.
BLEEDSTREAM FORCED OXIDATION TESTS ARE BEING CONDUCTED WITH A PENBERTHY ELL-3 EJECTOR IN A CLOSED LOOP AROUND A
BLEED STREAM HOLD TANK. INITIAL TESTS WERE UNSUCCESSFUL DUE TO HIGH PH OF 7 TO 8 IN THE HOLD TANK. BY LOWERING
THE HOLD TANK PH TO 5 TO 6, SULFITE,OXIDATION UP TO 96 PERCENT WAS ACHIEVED.
APR. 77 UNIT 10 BOILER WAS SHUT DOWN FOR A SCHEDULED TWO-MONTH MAINTAINANCE OUTAGE. BECAUSE OF THE BOILER OUTAGE, THE
MAY. 77 SHAWNEE SCRUBBERS WILL NOT OPERATE DURING APRIL AND MAY.
197
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TABLE 5
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCYt
PARTICULATES
105
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK NO. 6
BRIDGEPORT ALABAMA
550 MW
COAL 3.7 PERCENT SULFUR
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
RETROFIT
5/77
OPERATIONAL
99.5 PERCENT
S02
80 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNSTABILIZEO SLUQGE DISPOSED IN UNLINED POND
UNIT COST
S102/KW CAPITAL*!.72 MILLS/ KWH OPERATING
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS 550-HW COAL-FIRED POWER-GENERATING
UNIT CONSISTS OF EXISTING ELECTROSTATIC PREClPITATOHS FOLLOWED BY FOUR
PARALLEL SCRUBBING TRAINS, EACH CAPABLE. OF HANDLING 25 PERCENT OF THE
BOILER FLUE GAS FROM UNIT NO. 8. INITIAL OPERATION OF THE SCRUBBER PLANT
OCCURRED ON MAY 16. FLUE GAS WAS PASSED THROUGH TWO (TRAINS A AND B) OF
THE *> TRAINS. FLUSHING AND CLEANOUT OF THE REMAINING 2 TRAINS IS STILL IN
PROGRESS. BOILLR CAPACITY WAS APPROXIMATELY 50 PERCENT OF FULL LOAD.
196
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BACKGROUND INFORMATION
ON
WIDOWS CREEK NO. 8
IN MID-1970. TENNESSEE VALLEY AUTHORITY DECIDED TO INSTALL A FULL-SCALE DEMONSTRATION LIMESTONE SCRUBBING S02 REMOVAL SYSTEM
ON GENERATING UNIT NO. 8 AT THE WIDOWS C«EEK PLANT. THE PRIMARY OBJECTIVE WAS TO WORK OUT DESIGN AND OPERATING PROBLEMS IN S02
REMOVAL OPERATIONS AS A PREPARATION FOR THE POSSIBILITY OF FUTURE TVA FGD OPERATIONS.
THE WIDOWS CREEK POWER STATION IS LOCATED IN NORTHEAST ALABAMA, NEAR CHATTANOOGA, TENNESSEE. UNIT NO. 8 IS A COAL-FIRED
BOILER WITH A MAXIMUM GENERATING CAPACITY OF 550 MW, AND A MAXIMUM STACK GAS RATE OF 1,600,000 CFM AT 280 DEGREES F. THE BOILER
AND ESP UNITS WERE COMMISSIONED BY TVA IN 1963.
THE UET LIMESTONE FGD SYSTEM AT WIDOWS CREEK WAS PLACED IN SERVICE ON MAY Ifc, 1977. THE SYSTEM CONSISTS OF FOUR IDENTICAL
SCRUBBING MODULES (IDENTIFIED AS A, B, C» AND 0) EACH HANDLING 25 PERCENT OF THE FLUE GAS FROM UNIT NO. 8. LIMESTONE STORAGE AND
MILLING FACILITIES AND A SLUDGE DISPOSAL POND ARE ALSO LOCATED ON SITE.
FLUE GAS ENTERING THE SCRUBBING MODULE FROM THE EXISTING ELECTROSTATIC PRECIPITATORS PASSES THROUGH A HOO.OOO ACFM CAPACITY
F.D. FAN AND INTO THE VENTURI. THE VENTUKI SCRUBBER IS A RECTANGULAR THROAT DESIGN USED TO SATURATE, AND REMOVE FLYASH
FROM THE GAS. DUE TO THE INEFFICIENCY OF THE OLD ESP UNITS, LARGE VENTuRI SCRUBBERS WERE REQUIRED IN ALL MODULES TO REMOVE PARTI-
CULATES. S02 REMOVAL EFFICIENCY IN THE VENTURI IS ABOUT 10 PERCENT. THE ABSORBER IS A GRID TYPE ABSORPTION TOWER WHICH WAS
SUPPLIED BY POLYGON. THE GRID TOWER WILL BE USED INITIALLY AS A SPRAY TOWER AND WILL OPERATE AT A LlOUlD-TO-GAS RATIO OF 50.
THE S02 REMOVAL EFFICIENCY FOR THE ABSORBER IS ABOUT 70*, GIVING A COMBINED SCRUBBER DESIGN EFFICIENCY OF ABOUT 80 PERCENT FOR
THE ABSORBER AND VENTURI TOGETHER. THE ENTRAPMENT SEPARATOR IS A CHEVRON VANE TYPE (4 PASS) LOCATED VERTICALLY IN A HORIZONTAL
SHELL. THE REHEAT SYSTEM CONSISTS OF A STEAM/HOT AIR INJECTION SYSTEM RAISING THE FLUE GAS TO AN OUTLET TEMPERATURE OF 175F.
LIMESTONE HANDLING AND MILLING EQUIPMENT INCLUDES A SHAKER FOR TRUCK AND RAIL UNLOADING, A LIVE STORAGE SILO, A WET BALL
MILL, AND A CYCLONE CLASSIFIER. THE GRINDING SySTEM IS DESIGNED TO PRODUCE A GROUND PARTICLE SIZE OF 90 PERCENT MINUS 200 MESH.
AT THE DESIGN RATE OF 50 TONS PER HOUR DRY LIMESTONE. THE UNLOADING AND STORAGE FACILITIES UP TO AND INCLUDING THE LIVE STORAGE
SILO ARE DESIGNED TO ACCOMODATE A FUTURE LIMESTONE SCRUBBING FACILITY ON WIDOWS CREEK UNIT NO. 7.
WASTE BY-PRODUCT SOLIDS FROM THE SCRUBBING FACILITY WILL BE DISPOSED OF IN A DIKED POND 100 ACRES IN AREA BY 30 FEET IN
HEIGHT. AN ADDITIONAL 10 FEET IN HEIGHT MAY BE ADDED TO YIELD A TOTAL SLUDGE STORAGE CAPACITY OF 5.8 MM. CUBIC YARDS, OR 10 YEARS
OF SCRUBBER EFFLUENT STORAGE. THE SLUDGE, CONSISTING OF FLYASH, REACTION PRODUCTS (HYDRATES OF CALCIUM SULFITE AND SULFATE) AND
199
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WIDOWS CREEK NO. 8 (CONTINUED)
UNREACTED LIMESTONE IS PUMPED TO THE PONU AS A 15-16 PERCENT SOLIDS SOLUTION.
THE WIDOWS CREEK NO. a SCRUBBING UNIT IS DESIGNED TO BE AS FLEXIBLE AS POSSIBLE. A LARGE RESERVOIR OF QUENCH WATER IS LOCATED
ABOVE THE ABSORBER TO GRAVITY FEED WATER TO THE TOWER IN CASE OF POWER FAlLUREt THEREBY SAVING THE ABSORBER AND RUBBER LINING.
THE ABSORBER CAN BE OPERATED AS A MULTI-GRID, TURBULENT CONTACT, OR SPRAY TOWER ABSORBER. PROVISIONS HAVE BEEN HADE IN THE
ABSORBER DESIGN SO THAT IT CAN READILY BE CONVERTED TO A MOBILE BED TYPE ABSORBER SHOULD IT PROVE DESIRABLE IN THE FUTURE TO
OBTAIN IMPROVED S02 REMOVAL. REFER TO APPENDIX B FOR A PROCESS FLOW DIAGRAM.
200
/X~^\
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TABLE 6
NUMBER AND TOTAL MW OF FGD SYSTEMS
201
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202
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TABLE fa
NUMBER AND TOTAL WW OF FGD SYSTEMS
STATUS
OPERATIONAL
UNDER CONSTRUCTION
PLANNING
CONTRACT AWARDED
NO.OF
UNITS
27
29
20
LETTER OF INTENT 5
REQUESTING/EVALUATING BIDS 5
CONSIDERING ONLY FGD SYSTEMS 33
TOTAL 119
MW
7819.
9797.
1892.
3565.
1*656.
50577.
203
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20<*
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TABLE 7
SUMMARY OF F6D SYSTEMS BY COMPANY
205
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206
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TABLE 7
SUMMARY OF FGO SYSTCMS BY COMPANY
UTILITY
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTEM
ARIZONA ELECTRIC POWER COOP
ARIZONA PUBLIC SERVICE
BASIN ELECTRIC POWER COOP
BIG RIVERS ELECTRIC COOP CORP.
BRAZOS ELECTRIC POWER COOP
CENTRAL ILLINOIS LIGHT CO.
CENTRAL ILLINOIS PUBLIC SERV
CINCINNATI GAS > ELECTRIC CO.
COLORADO UTE ELECTRIC ASSN.
COLUMBUS ft SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
DUOUESNE LIGHT
EASTERN KENTUCKY POWER COOP
INDIANAPOLIS POWER ft LIGHT CO.
KANSAS CITY POWER ft LIGHT
KANSAS POWER ft LIGHT
KENTUCKY UTILITIES
LOUISVILLE GAS I ELECTRIC
MINNESOTA POWER AND LIGHT CO.
MINNKOTA POWER COOPERATIVE
MONTANA POWER CO.
NEVADA POWER
NEW ENGLAND ELEC SYSTEM
NIAGARA MOHAWK POWER COOP.
NORTHERN INDIANA PUB SERVICE
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 NEW MEx.
PUBLIC SERVICE OF INDIANA
SALT RIVER PROJECT
SOUTH CAROLINA PUBLIC SERVICE
SOUTHERN ILLINOIS POWER CO OP
SOUTHERN INDIANA GASSELECTRIC
SOUTHERN MISSISSIPPI ELECTRIC
SPRINGFIELD CITY UTILITIES
TENNESSEE. VALLEY AUTHORITY
TEXAS POWER & LIGHT CO.
TEXAS POWER AND LIGHT CO.
TftT Al
TUT AL
flDCO AT TAMAI
V/rl_KA| lUrVAC
CONTRACT LETTER OF REOUESTING/
AWARDED INTENT
NO.
2
2
2
5
5
1
1
2
1
1
2
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TABLE 7
SUMMARY OF FGO SYSTEMS BY COMPANY
UTILITY
TEXAS UTILITIES
TEXAS UTILITIES CO.
UNITED POWER ASSOCIATION
UTAH POWER « LIGHT CO.
WISCONSIN POWER * LIGHT CO.
T fl T A 1
1 U 1 AL
OOPDATTOMAI
UrEKA j lUNAU
CONTRACT
AWAKUED
NO.
1
5
2
2
1
MU
750.
3922.
1090.
615.
527.
NO.
0
0
0
0
0
MU
0.
0.
0.
0.
0.
NO.
0
3
0
2
0
MW
0.
2336.
0.
615.
0.
NO.
0
2
2
0
0
MU
0.
1566.
1090.
0.
0.
LETTER OF REQUESTING/
INTENT
NO.
0
0
0
0
1
MW
0.
0.
o.
0.
527.
EVAL.
NO.
0
0
0
0
0
BIDS
MW
0.
0.
0.
0.
0.
CONSIDERING
FGO SYSTEMS
NO.
1
0
0
0
0
MW
750.
0.
0.
0.
o.
TOTALS
119 50577. 27 7819. 29 126H8. 20 9797.
1692.
3565. 33 14656.
206
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TABLE S
SUMMARY OF FGD SYSTEMS BY VENDOR
209
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210
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TABLE 8
SUMMARY OF FGD SYSTEMS BY VENDOR
TOTAL OPERATIONAL CONSTRUCTION
MANUFACTURER/PROCESS
AOL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
SODIUM CARBONATE SCRUBBING
TOTAL, ADL/COMBUSTION EQUIP ASS
AOL/COMBUSTION EQUIP. ASSOC.
LIME/ALKALINE FLYASH SCRUBBING
TOTAL, ADL/COMBUSTION EQUIP. AS
AMERICAN AIR FILTER
LIME SCRUBBING
TOTAL, AMERICAN AIR FILTER
BABCOCK X WILCOX
LIMESTONE SCRUBBING
TOTAL, BABCOCK ft UILCOX
BABCOCK AND WILCOX
LIME SCRUBBING
TOTAL, BABCOCK AND UILCOX
BUELL/ENVIROTECH
DOUBLE ALKALI SCRUBBING
TOTAL, BUELL/ENVIROTECH
CHEMICO
LIME SCRUBBING
LIME/LIMESTONE SCRUBBING
LIMESTONE SCRUBBING
TOTAL, CHEMICO
COMBUSTION ENGINEERING
LIME SCRUBBING
LIMESTONE SCRUBBING
TOTAL, COMBUSTION ENGINEERING
DAVY POWERGAS/ALLIEO CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
TOTAL. DAVY POWERGAS/ALLIED CHE
PEABODY ENGINEERING
LIMESTONE SCRUBBING
TOTAL, PEABODY ENGINEERING
NO.
2
3
5
1
1
4
4
4
4
2
2
1
1
6
1
1
8
4
6
10
3
3
1
1
MW
720.
375.
1095.
450.
450.
917.
917.
1451.
1451.
1250.
1250.
575.
575.
3405.
10.
750.
4165.
468.
3275.
3763.
830.
830.
225.
225.
NO.
2
3
5
0
0
2
2
2
2
0
0
0
0
3
1
0
4
3
4
7
1
1
0
0
MM
720.
375.
1095.
0.
0.
242.
242.
987.
987.
0.
0.
0.
0.
1755.
10.
0.
1765.
305.
1915.
2220.
115.
115.
0.
0.
NO.
0
0
0
1
1
2
2
2
2
2
2
1
1
3
0
1
4
1
2
3
2
2
1
1
MU
0.
0.
0.
450.
450.
675.
675.
464.
464.
1250.
1250.
575.
575.
1650.
0.
750.
2400.
183.
1360.
1543.
715.
715.
225,
225.
211
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO -45246
-------
TABLE S
SUMMARY OF FGO SYSTEMS BY VENDOR
MANUFACTURER/PROCESS
TOTAL
NO. MW
STATUS
OPERATIONAL CONSTRUCTION
NO.
NO.
RESEARCH COTTRELL
LIMESTONE SCRUBBING
TOTAL. RESEARCH COTTRELL
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
TOTAL. RILEY STOKER / ENVIRONEE
RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
TOTAL. RILEY STOKER/ENVIRONEERI
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
TOTAL. TENNESSEE VALLEY AUTHORI
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
TOTAL. UNITED ENGINEERS / PECO
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
LIME/LIMESTONE SCRUBBING
LIMESTONE SCRUBBING
TOTAL. UNIVERSAL OIL PRODUCTS
6
6
2
2
1
1
1
1
1
1
2
1
3
6
2351.
2351.
360.
3bO.
400.
«00.
550.
550.
120.
120.
800.
10.
1155.
1965.
1
1
0
0
0
0
1
1
1
1
1
1
1
3
115.
115.
0.
0.
0.
0.
550.
550.
120.
120.
400.
10.
200.
610.
5
5
2
2
1
1
0
0
0
0
1
0
2
3
2236.
2236.
360.
360.
400.
400.
0.
0.
0.
0.
400.
0.
955.
1355.
56 20467.
27 7fll9.
29 1264B.
212
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 9
SUMMARY OF NEW AND RETROFIT FGD SYSTEMS BY PROCESS
213
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 9
SUMMARY OF NEW AND RETROFIT FGO SYSTEMS BY PROCESS
MW CAPACITYCNO. OF PLANTS)
PROCESS
LIME SCRUBBING
LIME/ALKALINE FLYASH
(PROCESS NOT SELECTED)
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
WELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/LIMESTONE * OF TOTAL MW
NEW OR OPERATIONAL
RETROFIT
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
N
R
U N
R
NO.
2
7
0
0
2
0
0
2
5
4
9.
13.
0
0
0
0
0
1
0
0
0
0
1
2
0
1
10.
17.
MW
1235
1467
0
0
720
0
0
20
2610
957
4765.
2444.
0
0
0
0
0
120
0
0
0
0
125
250
0
115
4890.
2929.
97
63
CONSTRUCTION
NO. MW
8
1
0
0
1
0
0
0
15
1
24
2
0
0
1
0
0
0
0
0
0
0
0
0
1
1
26
3
3975
103
0
0
450
0
0
0
6325
425
.10750.
. 608.
0
0
575
0
0
0
0
0
0
0
0
0
375
340
.11700.
. 948.
92
64
CONTRACT
AWARDED
NO.
4
0
0
0
2
0
0
0
10
0
16.
0.
0
1
1
1
0
0
0
0
0
0
1
0
0
0
18.
2.
MW
235o
0
0
0
1400
0
0
0
4911
0
8661.
0.
0
100
230
277
0
0
0
0
0
0
509
0
0
0
9420.
377.
92
0
LETTER OF RE8UESTING/
INTENT EVAL. BIOS
NO.
0
0
1
0
1
0
0
0
0
0
2.
0.
0
0
0
0
0
1
0
0
1
0
1
0
0
0
4.
1.
MW
0
0
527
0
500
0
0
0
0
0
1027.
0.
0
0
0
0
0
240
0
0
500
0
125
0
0
0
1652.
240.
62
0
NO.
0
0
0
0
0
0
0
0
1
0
1.
o.
0
0
0
0
0
0
4
0
0
0
0
0
0
0
5.
0.
MW
0
0
0
0
0
0
0
0
545
0
545.
0.
0
0
0
0
0
0
3020
0
0
0
0
0
0
0
3565.
0.
15
0
CONSIDERING
FGO SYSTEM
NO.
0
2
0
0
1
0
0
0
3
1
4.
3.
0
0
0
0
0
2
16
6
1
1
0
0
0
0
21.
12.
MW
0
66Q
0
0
450
0
0
0
1280
350
1730.
1010.
0
0
0
0
0
486
8000
2480
500
650
0
0
0
0
10230.
4626.
17
22
TOTAL NO.
OF PLANTS
NO.
14
10
1
0
7
0
0
2
34
6
56.
18.
0
1
2
1
0
4
20
6
2
1
3
2
1
2
84.
35.
MW
7560
2310
527
0
3520
0
0
20
15871
1732
27478.
4062.
0
100
825
277
0
846
11020
2480
1000
650
759
250
375
455
41457.
9120.
66
45
215
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
216
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
TABLE 10
SUMMARY OF OPERATING FGD SYSTEMS BY PROCESS AND GENERATING UNITS
217
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
216
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
TABLE 10
SUMMARY OF OPERATING FGD SYSTEMS BY
PROCESS AND GENERATING UNITS AS Of 06/77
PROCESS/GENERATING UNITS
FGD/MW STARTUP EXPERIENCE(MO.)
LIME SCRUBBING
BRUCE MANSFIELD NO. 1
CANE RUN NO 4
CONESVILLE NO 5
ELRAMA POWER STATION
GREEN RIVER NOS. 1 2 AND 3
HAWTHORN NO. 3
HAWTHORN NO. 4
PADDYS RUN NO 6
PHILLIPS POWER STATION
LIME/ALKALINE FLYASH
COLSTRIP NO 1
COLSTRIP NO 2
835
178
400
510
64
140
100
6S
410
2702.
SCRUBBING
360
360
4-76
8-76
2-77
10-75
9-75
11-72
8-72
4-73
7-73
10-75
7-76
14
10
i*
20
21
55
58
50
47
279
20
11
720.
31
LIME/LIMESTONE SCRUBBING
SHAUNEE N0.10A
SHAwNEE N0.10B
10
10
20.
1-72
4-72
62
62
124
LIMESTONE SCRUBBING
CHOLLA NO 1
LA CY6NE NO 1
LAURENCE NO 4
LAURENCE NO 5
SHERBURNE COUNTY STATION NO.I
SHERBURNE COUNTY STATION NO.2
SOUTHWEST NO. 1
WIDOWS CREEK NO. 8
WILL COUNTY NO 1
115
82U
400
710
680
20U
b50
167
10-73
2-73
12-68
6-76
3-76
4-77
4-77
5-77
2-72
3767.
44
52
102
-12
15
2
2
1
64
270
219
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 10
SUMMARY OF OPERATING FGO SYSTEMS BY
PROCESS AND GENERATING UNITS AS OF 06/77
PROCESS/GENERATING UNITS FGO/MU STARTUP EXPERIENCE(MO.)
MAGNESIUM OXIDE SCRUBBING
EDDYSTONE NO. 1A 120 9-75 21
120. 21
SODIUM CARBONATE SCRUBBING
REID GARDNER NO 1 125 H-7H 36
REID GARDNER NO 2 125 H-7H 36
REID GARDNER NO 3 125 7-76 11
375. 87
UELLHAN LORD/ALLIED CHEMICAL
D.H. MITCHELL NO.11 115 6-77 0
D.H. MITCHELL NO.11 3HO 11-77 -5
155. -5
220
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 11
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS
221
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
222
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 452.46
-------
TABLE 11
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGO SYSTEMS AS OF 06/77
PROCESS/GENERATING UNIT
—SLUDGE— --SLUDGE-- ---POND POND--
STABILI2EO UNSTABILIZED LINED UNLINED
LIME SCRUBBING
BRUCE MANSFIELD NO. 1
CANE RUN NO 4
CONESVILLE NO 5
ELRAMA POWER STATION
GREEN RIVER NOS. 1 2 AND 3
HAWTHORN NO. 3
HAWTHORN NO. 4
PADDYS RUN NO 6
PHILLIPS POWER STATION
TOTAL
635
178
too
510
64
410
2397.
140
100
65
305.
635
178
400
510
64
140
100
65
410
2702.
LIME/ALKALINE FLYASH SCRUBBING
COLSTRIP NO 1
COLSTRIP NO 2
TOTAL
0.
360
360
720.
360
360
720,
LIMESTONE SCRUBBING
CHOLLA NO 1
LA CTGNE NO 1
LAWRENCE NO 4
LAWRENCE NO 5
SHERBURNE COUNTY STATION NO.l
SHERBURNE COUNTY STATION NO.2
SOUTHWEST NO. 1
WIDOWS CREEK NO. 8
WILL COUNTY NO 1
TOTAL
200
167
367.
115
620
125
400
710
680
550
3400.
710
660
167
1557.
115
620
125
400
200
550
2210.
SODIUM CARBONATE SCRUBBING
REID GARDNER NO 1
REID GARDNER NO 2
REID GARDNER NO 3
TOTAL
0.
125
125
125
375.
0.
223
125
125
125
375.
PEDCo ENVIRONMENTAL-
CINCINNATI. OHIO 452.46
-------
TABLE: 11
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS AS OF 06/77
PROCESS/GENERATING UNIT
--SLUDGE--
STABILIZED
--SLUDGE--
UNSTABILIZED
POND-
LINED
POND--
UNLINED
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 12
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
225
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 12
SUMMARY OF FGO SYSTEMS BY PROCESS AND REGULATORY CLASS
MU CAPACITYINO. OF PLANTS)
PROCESS
LIME SCRUBBING
LIME/ALKALINE FLYASH
(PROCESS NOT SELECTED)
CLASS
A
B
C
D
E
A
B
C
0
E
LIME/ALKALINE FLYASH SCRUBBING
(PROCESS NOT SELECTED)
LIME/LIMESTONE SCRUBBING
I PROCESS NOT SELECTED)
LIMESTONE SCRUBBING
SUBTOTAL - LIME/LIMESTONE
A
B
C
D
E
A
B
C
D
E
A
B
C
0
E
A
B
C
D
"E
OPERATIONAL
CONSTRUCTION
CONTRACT
AWARDED
NO.
0
6
3
0
0
0
0
0
0
0
0
2
0
0
0
0
0
2
0
0
1
3
3
2
0
1.
11.
8.
2.
0.
nw
0
2395
307
0
0
0
0
0
0
0
0
720
0
0
0
0
0
20
0
0
200
1505
1537
525
0
200.
4620.
1864.
525.
0.
NO.
6
2
1
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
10
5
1
0
0
16.
a.
2.
0.
0.
nw
27*0
1235
163
0
0
0
0
0
0
0
0
450
0
0
0
0
0
0
0
0
1*315
2010
425
0
0
7055.
3695.
606.
0.
0.
NO.
3
1
0
0
0
0
0
0
0
0
0
2
0
0
0
0
0
0
0
0
3
6
0
0
1
6.
9.
0.
0.
1.
nw
1515
835
0
0
0
0
0
0
0
0
0
moo
0
0
0
0
0
0
0
0
1811
2700
0
0
400
3326.
«t935.
0.
0.
400.
LETTER OF REQUESTING/
INTENT
NO.
0
0
0
0
0
1
0
0
0
u
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2.
0.
0.
o.
0.
nw
0
0
0
0
0
527
0
0
0
0
500
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1027.
0.
0.
0.
o.
EVAL.
NO.
0
0
0
0
0
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.
BIDS
MW
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
5*5
0
0
0
0
5i*5.
0.
0.
0.
0.
CONSIDERING
TUTAU NU.
OF PLANTS
FGD SYSTEM
NO.
0
0
2
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
2
1
0
0
1
2.
2.
2.
0.
1.
nw
0
0
660
0
0
0
0
0
0
0
0
450
0
0
0
0
0
0
0
0
930
350
0
0
350
930.
800.
660.
0.
350.
NO.
9
9
6
0
0
1
0
0
0
0
1
6
0
0
0
0
0
2
0
0
17
15
-------
TABLE 12
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
MW CAPACITYJNO. OF PLANTS*
REGULATORY OPERATIONAL CONSTRUCTION
PROCESS
AQUEOUS CARBONATE SCRUBBING
DOUBLE ALKALI SCRUBBING
MAGNESIUM OXIOE SCRUBBING
NOT SELECTED
REGENERAeLE NOT SELECTED
CLA^SS
A
B
C
D
e
A
B
C
D
E
A
B
C
D
E
A
B
C
0
E
A
B
C
D
E
NO.
0
0
0
0
0
0
0
0
u
0
0
1
0
0
u
0
0
0
u
0
0
0
0
0
0
MW
0
0
0
0
0
0
0
0
0
0
0
120
0
0
0
0
0
0
0
0
0
0
0
0
0
NO.
0
0
0
0
0
MW
0
0
0
0
0
I 575
0 0
0 0
0 0
0 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
CONTRACT
AWARDED
NO.
0
0
1
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
100
0
0
250
0
277
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
LETTER OF REOUESTING/
INTENT
NO.
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
1
0
0
0
MW
0
0
0
0
0
0
0
0
0
0
0
2tO
0
0
0
0
0
0
0
0
0
500
0
0
0
EVAL
NO.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
n
0
0
0
0
0
0
0
0
0
. BIDS
MW
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3020
0
0
0
0
0
0
0
0
0
CONSIDERING
TU1AL NU.
OF PLANTS
FGD SYSTEM
NO.
0
0
0
0
0
0
0
0
0
0
0
2
0
0
0
4
13
<4
0
1
0
1
1
0
0
MW
0
0
0
0
0
0
0
0
0
0
0
486
0
0
0
2600
6160
970
0
750
0
500
65Q
0
0
NO.
0
0
1
0
0
2
0
1
0
0
0
4
0
0
0
8
13
H
0
1
0
2
1
0
0
MW
0
0
100
0
0
825
0
277
0
0
0
8<»6
0
0
0
5620
6160
970
0
750
0
1000
65o
0
0
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TQ STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT To STATE STANDARD THAT IS EQUAL TO OR LLSS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
226
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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TABLE. 12
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
Mw CAPACITY(NO. OF PLANTS)
PROCESS
SODIUM CARBONATE SCRUBBING
WELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/STONE X OF TOTAL MW
CLASS
A
B
C
D
E
A
B
C
0
E
A
B
C
D
E
A
B
C
0
E
f OPERATIONAL
CONSTRUCTION
CONTRACT
AWARDED
NO. MW
0
3
0
0
U
0
0
1
0
0
1
15
9
2
0
0
375
0
0
0
0
0
115
0
0
200.
. 5115.
. 1979.
525.
0.
100
90
9t
100
0
NO. MW
0
0
0
0
0
0
2
0
0
0
17
10
2
0
0
0
0
0
0
0
0
715
0
0
0
. 7630.
. HtlO.
. 606.
0.
0.
92
81
100
0
0
NO.
0
1
0
0
0
0
0
0
0
0
7.
10.
2.
0.
1.
MW
0
509
0
0
0
0
0
0
0
0
3576.
5 •»•»<».
377.
0.
too.
93
91
0
0
100
LETTER OF REQUESTING/
INTENT
NO.
0
1
0
0
0
0
0
0
0
0
2.
3.
0.
o.
o.
MW
0
125
0
0
0
0
0
0
0
0
1027.
865.
0.
0.
0.
100
0
0
0
0
EVAL.
NO.
0
0
0
0
0
0
0
0
0
0
5.
0.
0.
0.
0.
BIOS
MW
0
0
0
0
0
0
0
0
0
0
3565.
0.
0.
0.
0.
15
0
0
0
0
CONSIDERING
TOTAL NO.
OF PLANTS
FGD SYSTEM
NO.
0
0
0
0
0
0
0
0
0
0
6.
16.
7.
0.
2.
MW
0
0
0
0
0
0
0
0
0
0
3530.
79«*6.
2260.
0.
1100.
26
10
29
0
32
NO.
0
5
0
0
0
0
2
1
0
0
36.
56.
20.
2.
3.
MW
0
1009
0
0
0
0
715
115
0
0
19526,
23780.
52<»<».
525.
1500.
67
59
60
100
50
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 EiUAL TO OR LLSS STRINGENT THAN NSPS
D. OTHER
E, REGULATORY CLASS UNKNOWN
229
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
230
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 13
SUMMARY OF OPERATIONAL FGD SYSTEMS
231
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
232
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
TABLE 13
SUMMARY OF OPERATIONAL FGD SYSTEMS AS OF 06/77
UTILITY COMPANY
POWER STATION
NEW OR SIZE. OF FGD PROCESS/VENDOR
RETROFIT UNIT (nui
FUEL CHARACTERISTICS
MO/YR
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
COLUMBUS ft SOUTHERN OHIO ELEC.
CONESVILLE NO 5
COMMONWEALTH EDISON
WILL COUNTY NO I
OUQUESNE LIGHT
ELRAMA POWER STATION
DUQUESNE LIGHT
PHILLIPS POWER STATION
KANSAS CITY POWER ft LIGHT
HAWTHORN NO. 4
KANSAS CITY POWER X LIGHT
LA CYGNE NO 1
KANSAS CITY POWER ft LIGHT
HAWTHORN NO. 3
KANSAS POWER ft LIGHT
LAWRENCE NO 0
KANSAS POWER ft LIGHT
LAWRENCE NO 3
KENTUCKY UTILITIES
GREEN RIVER NOS. 1 2 AND 3
LOUISVILLE GAS ft ELECTRIC
CANE RUN NO 4
LOUISVILLE GAS ft ELECTRIC
PADDYS RUN NO 6
MONTANA POWER CO.
COLSTRIP NO 1
MONTANA POWER CO.
COLSTRIP NO 2
R
N
R
R
R
R
N
R
R
N
R
R
R
N
N
115
400
167
510
410
100
820
110
125
400
64
176
65
360
360
RESEARCH COTTRELL
LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
CHEMICO
LIME SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
COAL 0.44-1 PERCENT SULFUR 10/73
COAL 4.5 - 4.9 PERCENT SULFUR 2/77
COAL 4.0 PERCENT SULFUR 2/72
COAL i.o - 2.8 PERCENT SULFUR 10/75
COAL i.o- 2.8 PERCENT SULFUR 7/73
COAL 0.5-3.5 PERCENT SULFUR 8/72
COAL 5.0 PERCENT SULFUR 2/73
COAL 0.5-3*5 PERCENT SULFUR 11/72
COAL 0.5 PERCENT SULFUR 12/68
COAL 0.5 PERCENT SULFUR 6/78
COAL 3.8 PERCENT SULFUR 9/75
COAL 3.5 - 4.0 PERCENT SULFUR 8/76
COAL 3.5 - 4.0 PERCENT SULFUR 4/73
COAL 0.8 PERCENT SULFUR 10/75
COAL 0.8 PERCENT SULFUR 7/76
233
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 13
SUMMARY OF OPERATIONAL F6D SYSTEMS AS OF 06/77
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD PROCESS/VENDOR
RETROFIT UNIT
FUEL CHARACTERISTICS
MO/YR
NEVADA POWER
REID GARDNER NO 2
NEVADA POWER
REID GARDNER NO 1
NEVADA POWER
REID GARDNER NO 3
NORTHERN INDIANA PUB SERVICE
O.H. MITCHELL NO.11
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.l
NORTHERN STATES POWER co.
SHERBURNE COUNTT STATION NO.2
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 1
PHILADELPHIA ELECTRIC CO.
EDOYSTONE NO. 1A
SPRINGFIELD CITY UTILITIES
SOUTHWEST NO. 1
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10A
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10B
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK NO. 6
R
R
N
R
N
N
N
R
N
R
R
R
125
125
125
115
710
680
835
120
200
10
10
550
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
CHEMICO
LIME/LIMESTONE SCRUBBING
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
COAL 0.5 - 1.0 PERCENT SULFUR "»/7<»
COAL 0.5 • 1.0 PERCENT SULFUR H/7H
COAL 0.5 - 1.0 PERCENT SULFUR 7/76
COAL 3.2-3.5 PERCENT SULFUR 6/77
COAL 0.8 PERCENT SULFUR 3/76
COAL 0.8 PERCENT SULFUR H/77
COAL 4.7 PERCENT SULFUR
-------
TABLE m
SUMMARY OF F6D SYSTEMS UNDER CONSTRUCTION
235
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 49246
-------
236
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE 1*
SUMMARY OF FGD SYSTEMS UNDEK CONSTRUCTION AS OF 06/77
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGO PROCESS/VENDOR
RETROFIT UNIT IMWI
FUEL CHARACTERISTICS
HO/YR
ALABAMA ELECTRIC COOP
TOMBIGBEE NO. 2
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 2
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 1
ARIZONA ELECTRIC POWER COOP
APACHE NO 2
ARIZONA ELECTRIC POWER COOP
APACHE NO 5
ARIZONA PUBLIC SERVICE
CHOLLA NO 2
BIG RIVERS ELECTRIC COOP CORP.
REID NO. 2
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO. 1
CENTRAL ILLINOIS PUBLIC SERV
NEWTON NO.l
COLUMBUS ft SOUTHERN OHIO ELEC.
CONESVILLE NO 6
COMMONWEALTH EDISON
POWERTON NO. 51
INDIANAPOLIS POWER ft LIGHT CO.
PETERSBURG NO 3
KANSAS POWER S LIGHT
JEFFERY NO. 1
KANSAS POWER * LIGHT
JEFFERY NO. 2
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 5
N
N
N
N
N
N
N
N
N
N
R
N
N
N
R
225
625
625
200
200
250
250
000
575
*00
025
530
680
680
183
PEABODY ENGINEERING
LIMESTONE SCRUBBING
BABCOCK AND WILCOX
LIME SCRUBBING
BABCOCK AND WILCOX
LIME SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
BUELL/ENVIROTECH
DOUBLE ALKALI SCRUBBING
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
COAL 0.6- 1.5 PERCENT SULFUR 6/78
COAL 4.5 PERCENT SULFUR (MAXI 3/80
COAL 1.5 PERCENT SULFUR (MAX) 3/79
COAL 0.5- 0.8 PERCENT SULFUR 6/78
COAL o.s- 0.8 PERCENT SULFUR 1/79
COAL 0.10-1 PERCENT SULFUR
6/78
COAL 3.S-H.O PERCENT SULFUR 12/79
COAL 2.5 - 3.0 PERCENT SULFUR 8/78
COAL 2.8-3.2 PERCENT SULFUR 11/79
COAL i».5 - *.9 PERCENT SULFUR 1/78
COAL 3.6 PERCENT SULFUR
12/79
COAL 3.0-3.5 PERCENT SULFUR 9/77
COAL 0.30 PERCENT SULFUR
COAL 0.30 PERCENT SULFUR
6/78
6/79
COAL 3.5 - H.O PERCENT SULFUR 12/77
237
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE l«t
SUMMARY OF FGO SYSTEMS UNDER CONSTRUCTION AS OF 06/77
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGO PROCESS/VENDOR
RETROFIT UNIT
FUEL CHARACTERISTICS
MO/YR
LOUISVILLE GAS t ELECTRIC
HILL CREEK NO 3
MINNKOTA POWER COOPERATIVE
HILTON R. YOUNG NO. 2
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 2
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. i
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 2
SOUTH CAROLINA PUBLIC SERVICE
WINYAH NO. 2
SOUTHERN ILLINOIS POWER CO OP
MARION NO. H
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW NO.l
SOUTHERN MISSISSIPPI ELECTRIC
R.O. MORROW NO.2
TEXAS UTILITIES CO.
MONTICELLO NO.3
TEXAS UTILITIES CO.
MARTIN LAKE NO. i
TEXAS UTILITIES co.
MARTIN LAKE NO. 2
UTAH POWER I LIGHT CO.
HUNTING!ON NO.l
UTAH POWER X LIGHT CO.
EMERY NO.l
N
N
R
N
N
N
N
N
N
N
635
375
3«»0
260
16*
160
160
750
793
793
«»25 AMERICAN AIR FILTER
LIME SCRUBBING
450 AOL/COMBUSTION EQUIP. ASSOC.
LIME/ALKALINE FLYASH SCRUBBING
CHEMICO
LIME SCRUBBING
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
CHEMICO
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
«00 CHEMICO
LIME SCRUBBING
COAL 3.5- <».o PERCENT SULFUR 12/77
LIGNITE - 6.500 BTU, 0.7* S 6/77
COAL H,7 PERCENT SULFUR 10/77
COAL 0.6 PERCENT SULFUR 11/77
COAL 0.8 PERCENT SULFUR 11/77
COAL 1.0 PERCENT SULFUR 7/77
COAL 4.5-5.0 PERCENT SULFUR 6/76
COAL 1.0 PERCENT SULFUR 11/77
COAL 1.0 PERCENT SULFUR 8/78
LIGNITE i.o PERCENT SULFUR 2/78
COAL 1.0 PERCENT SULFUR 10/77
COAL 1.0 PERCENT SULFUR 2/78
COAL 0.5 PERCENT SULFUR 12/77
COAL 0.5 PERCENT SULFUR 6/76
238
PEDCo ENVIRONMENTAL
CINCINNATI, OHIO -45246
-------
TABLE 15
SUMMARY OF PLANNED FGD SYSTEMS
239
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
2 "40
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
TABLE 15
SUMMARY or PLANNED FGD SYSTEMS AS OF 06/77
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD VENDOR/PROCESS
RETROFIT UNIT CMWI
FUEL CHARACTERISTICS
MO/YR
CONTRACTS AWARDED
COLORADO UTE ELECTRIC ASSN.
CRAIG NO. 2
COLORADO UTE ELECTRIC ASSN.
CRAIG NO. 1
BRAZOS ELECTRIC POWER COOP
ATACOSA MCMULLEN NO. i
LOUISVILLE GAS ft ELECTRIC
CANE RUN NO 6
PACIFIC POWER AND LIGHT CO.
JIM BRIDGER NO. 4
MONTANA POWER CO.
COLSTRIP NO. 3
MONTANA POWER CO.
COLSTRIP NO. 4
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 2
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 3
LOUISVILLE GAS * ELECTRIC
MILL CREEK NO 4
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 1
NIAGARA MOHAWK POWER COOP.
CHARLES R. HUNTLEY NO.6
ALABAMA ELECTRIC COOP
TOMBI6BEE NO. 3
TEXAS UTILITIES CO.
MARTIN LAKE NO. 3
UNITED POWER ASSOCIATION
COAL CREEK NO. 2
N
N
N
R
N
N
N
N
N
N
N
R
N
N
N
450
450
400
277
509
700
700
550
ess
425
550
100
225
793
545
PEABODY ENGINEERING
LIMESTONE SCRUBBING
PEABODY ENGINEERING
LIMESTONE SCRUBBING
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI SCRUBBING
UNIVERSAL OIL PRODUCTS
SODIUM CARBONATL SCRUBBING
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
PULLMAN KELLOGG
LIME SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
ATOMICS INTERNATIONAL
AQUEOUS CARBONATE SCRUBBING
PEABODY ENGINEERING
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
COAL 0.45 PERCENT SULFUR 3/79
COAL 0.45 PERCENT SULFUR 3/79
LIGNITE 1.67 PERCENT SULFUR 12/79
COAL 3.5 - 4.0 PERCENT SULFUR 2/79
COAL 0.56 PERCENT SULFUR(AVG.) 9/79
COAL 0.7 PERCENT SULFUR 7/eo
COAL 0.7 PERCENT SULFUR 7/61
COAL 0.8 PERCENT SULFUR 10/60
COAL 4.7 PERCENT SULFUR 4/60
COAL s.s- t.o PERCENT SULFUR e/so
COAL 0.8 PERCENT SULFUR 4/80
COAL 2.5-4*5 PERCENT SULFUR 6/78
COAL o.a- i.s PERCENT SULFUR 6/79
COAL 1.0 PERCENT SULFUR 12/78
LIGNITE - 0.63 PERCENT SULFUR 11/79
241
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE. 15
SUMMARY OF PLANNED F6D SYSTEMS AS OF Ofc/77
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGO VENDOR/PROCESS
RETROFIT UNIT inwi
FUEL CHARACTERISTICS
MO/YR
SALT RIVER PROJECT
CORONADO NO.l
SOUTHERN INDIANA GAS4ELECTRIC
A.B. BROWN NO.l
SALT RIVER PROJECT
CORONADO NO.2
TEXAS UTILITIES CO.
MARTIN LAKE NO. 4
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
LETTER OF INTENT SI6NED
NEVADA POWER
REID GARDNER NO 1
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. IB
MINNESOTA POWER AND LIGHT CO.
CLAY BOSUELL NO. H
WISCONSIN POWER & LIGHT co.
COLUMBIA NO. 2
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 3
REQUESTING/EVALUATING BIDS
N
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.3
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.l*
TEXAS POWER ft LIGHT CO.
SANDOW N0.it
PUBLIC SERVICE OF INDIANA
GIBSON NO. H
N
350
250
350
793
5*5
125
210
500
527
500
860
660
5<»5
650
PULLMAN KELLOGG
LIMESTONE SCRUBBING
FMC CORPORATION
DOUBLE ALKALI SCRUBBING
PULLMAN KELLOGG
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
AOL/COMBUST ION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
PEABODY ENGINEERING
LIME/ALKALINE FLYASH SCRUBBING
CHEMICO
LIME/ALKALINE FLYASH
NOT SELECTED
REGENLRABLE NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
NOT SELECTED
COAL 1.
COAL 3.
COAL 1.
COAL 1.
LIGNITE
COAL
COAL 2.
COAL 0.
COAL 0.
COAL 0.
COAL 0.
COAL 0.
LIGNITE
COAL 3.
0 PERCENT SULFUR (MAX)
75 PERCENT SULFUR
0 PERCENT SULFUR (MAX)
0 PERCENT SULFUR
- 0.63 PERCENT SULFUR
0-5- i.o PERCENT SULFUR
5 PERCENT SULFUR
6 PERCENT SULFUR
6 PERCENT SULFUR
6 PERCENT SULFUR
8 PERCENT SULFUR
8 PERCENT SULFUR
3 PERCENT SULFUR
H/79
»/79
H/80
11/82
11/78
O/ 0
6/80
0/80
1/80
1/79
5/81
5/83
7/80
0/79
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 4524S
-------
TABLE 15
SUMMARY OF PLANNED FGO SYSTEMS AS OF 06/77
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF F6D VENDOR/PROCESS
RETROFIT UNIT
FUEL CHARACTERISTICS
MO/YR
PUBLIC SERVICE OF INDIANA
GIBSON NO. 3
CONSIDERING FGD SYSTEM
LOUISVILLE GAS I ELECTRIC
MILL CREEK NO 1
NEVADA POWER
WARNER VALLEY STATION NO. 2
NEVADA POWER
WARNER VALLEY STATION NO. 1
COLUMBUS ft SOUTHERN OHIO ELEC.
POSTON NO. 5
NEVADA POWER
HARRY ALLEN STATION NO. 1
NEVADA POWER
HARRY ALLEN STATION NO. 2
NEVADA POWER
HARRY ALLEN STATION NO. 3
COLUMBUS I SOUTHERN OHIO ELEC.
POSTON NO. 6
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 3
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY NO. 1
LOUISVILLE GAS 8 ELECTRIC
MILL CREEK NO 2
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO. 2
CINCINNATI GAS 8 ELECTRIC CO.
EAST BEND NO 2
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY NO. 2
N
R
N
N
N
N
N
N
N
N
N
R
N
N
N
650
330
250
250
375
500
500
500
375
550
H50
330
too
600
450
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME 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
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME/ALKALINE FLYASH SCRUBBING
NOT SELECTED
LIME SCRUBBING
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
COAL 3.3 PERCENT SULFUR 0/78
COAL 3.5- H.O PERCENT SULFUR 1/62
COAL 6/83
COAL 6/02
COAL 2.5 PERCENT SULFUR 0/61
COAL 6/83
COAL 6/8*
COAL 6/85
COAL 2.5 PERCENT SULFUR 0/83
COAL 0.8 PERCENT SULFUR 6/83
LIGNITE i.o PERCENT SULFUR o/ai
COAL 3.5- ».o PERCENT SULFUR i/8i
COAL 2.5-3.0 PERCENT SULFUR 1/82
COAL 1/81
LIGNITE i.o PERCENT SULFUR o/83
243
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TABLE: is
SUMMARY OF PLANNED FGO SYSTEMS AS OF 06/77
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGO VENDOR/PROCESS
RETROFIT UNIT
-------
TABLE 15
SUMMARY OF PLANNED FGD SYSTEMS AS OF 06/77
UTILITY COMPANY
POWER STATION
TEXAS UTILITIES
FOREST 6ROVE NO. 1
PUBLIC SERVICE CO OF NEW HEX.
SAN JUAN NO. 4
SALT RIVER PROJECT
CORONADO NO.3
NEW OR
RETROFIT
SIZE OF FGD
UNIT inwi
750
500
350
VENDOR/PROCESS
NOT SELECTED
NOT SELECTED
NOT SELECTED
REGENERABLE NOT SELECTED
NOT SELECTED
LIMESTONE SCRUBBING
FUEL CHARACTERISTICS MO/YR
LIGNITE 0/81
COAL 0.6 PERCENT SULFUR 5/61
COAL 1.0 PERCENT SULFUR (MAX) 0/67
2*5
PEDCo ENVIRONMENTAL
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PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
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TABLE 16
FGD SYSTEM OPERATIONS THAT HAVE BEEN TERMINATED OR SHUT DOWN INDEFINITELY
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45346
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2<»8
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
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TABLE 16
TERMINATED FGU SYSTEMS 06/77
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 HAKE UP
SLUDGE DISPOSAL
UNIT COST
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 5A
FARHINGTON NEW MEXICO
160 HW
COAL 0.7 PERCENT SULFUR
SO. CALIFORNIA EDISON
LIME SCRUBBING
RETROFIT
2/76
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 16 OF THE REPORT.
THIS MODULE WAS ORIGINALLY INSTALLED AT THE MOHAVE GENERATING STATION
AND OPERATED DURING THE TEST MODULES EVALUATION PROGRAM. THE UNIT
WAS THEN SHUTDOWN* MOVED FROM THE MOHAVE TEST SITE. AND REASSEMBLED
AT THE FOUK CORNERS STATION OF APS. THE MODULE WAS IN SERVICE DURING
SEGMENTS FROM FEB. 1976 TO DEC. 6« 1976. TREATING APPROXIMATELY 20 PER-
CENT OF THE FLUE GAS FLOW FROM THE 755-MW RATED UNIT. THE PROGRAM HAS
BEEN TERMINATED AND THE MODULE DISASSEMBLED.
249
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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-MU. ONLY UNIT NO. 5 IS RETROFITTED WITH AN FGD SYSTEM.
UNIT NO. 5 IS A COAL-FIRED BOILER CAPABLE OF GENERATING 5.1H6.000 LBS. OF STEAM. WHICH IS EQUIVALENT TO 600-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. 5 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 MOHAyE NO.
2A IN TABLE 16 OF THIS REPORT I.
DURING THE MOHAVE TEST PROGRAM THE HORIZONTAL MODULE WAS OPERATIONAL FROM NOVEMBER It 1973. TO JANUARY 16.197H, 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 - H8 FEET* WIDTH - 26 FEET*
HEIGHT - 15 FEET. THE MODULE ITSELF IS A HOLLOW CHAMBER CONSISTING OF FOUR STAGES OF CROSSFLOW SPRAY NOZZLES. EACH STAGE CONTAIN
A ROW OF 36 EXTERNALLY-MOUNTED NOZZLES. THE SLURRY IS CYCLED THROUGH THE SCRUBBER IN A COUNTERCURRENT 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 LIQUID RECIRCULATION RATE CAN BE ADJUSTED OyER A WIDE RANGE. THE MODULE IS DESIGNED TO
TREAT A MAXIMUM FLUE GAS CAPACITY OF <»50«000 SCFM. THE DESIGN GAS VELOCITY THROUGH THE MODULE IS 21.6 FT./SEC. THE CLEANED GASES
THEN PASS THROUGH A DEHISTER AND ARE REHEATED BEFORE BEING DISCHARGED TO THE STACK. THE SPENT SLURRY IS DISCHARGED FROM THE
250
PEDCo ENVIRONMENTAL
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FOUR CORNERS NO. 5A (CONTINUEEDI
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 APPENDIX B.
251
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FOUR CORNERS NO. 5A
OPtRATlNG HOURS
PERIOD BOILER F&O SYSTEM
MONTH/YEAR
FEB. 76
MAR. 76
APR. 76
HAT 76
JUN. 75
JUL. 76
AUG. 76
SEP. 76
OCT. 76
NOV. 76
DEC. 76
COMMENTS
INSTALLATION OF THE MODULE AT THE FOUR CORNERS GENERATING STATION WAS
COMPLETED AND THE MODULE WAS PLACED IN-SERVICE FEBRUARY 17i 1976i
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.
252
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TABLE 16
TERMINATED FGU SYSTEMS
06/77
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
S02
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
BOSTON EDISON
MYSTIC NO b
EVERETT MASSACHUSETTS
iso nu
OIL 2.5 PERCENT SULFUR
CHEMICO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
«/72
50 PERCENT
90 PERCENT
SJ2/KW CAPITAL * CALCINATION
AVERAGE FGD SYSTEM AVAILABILITY FACTORS - APRIL 72 TO MAY 73. 17*.
JUNE 73 TO DEC* 73. 481. JAN. 7>» TO JUNE 7t. 60*. JUNE 74* BOX.
THE FGO SYSTEM HAS BEEN SHUT DOWN INDEFINITELY SINCE JUNE 74.
253
PEDCp ENVIRONMENTAL
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THE MAGNESIUM OXIDE-BASED FGD SYSTEM INSTALLED AT THE MYSTIC POWER STATION OF THE BOSTON EDISON COMPANY CONSISTS OF A CHEH-
KO-DESIGNED SINGLE-STAGE VENTURI SCRUBBER MODULE. THE MODULE IS CONSTRUCTED OF CARBON STEEL LINED WITH A SPRAY-APPLIED POLYEST-
ER MATERIAL. TOTAL FLUE GAS CAPACITY OF THE SYSTEM IS
-------
MONTH/YR
APR.
TO
HAY
JUN.
JUL.
AUG.
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
MAR*
APR.
MAY
JUN.
72
73
73
73
73
73
73
73
73
7*
7«»
7«»
74
7«»
7«f
BOILER
OPERATION
(HR»
592
575
BOILER
637
627
629
658
555
5*1
*oa
585
488
559
SCRUBBER
OPERATION
(HR)
102
351
SHUTDOWN
243
377
162
86
152
138
353
471
280
288
OPERABILITY IK)
17
68
61
38
60
26
13
28
25
87
81
57
80
srsrcn AVAILABILITY
MYSTIC UNIT NO. b
COMMENTS
THE MODULE OPERATED INTERMITTENTLY BECAUSE OF MECHANICAL DIFFICULTIES. A MAJOR
PROBLEM CONCERNED THE OPERATION OF THE MAGNESIUM SULFITE CRYSTALS DRYER.
THE LONGEST PERIOD OF CONTINUOUS OPERATION. 7.5 DAYS. OCCURRED DURING JUNE AND
JULY.
THE BOILER WAS DOWN FOR THE ANNUAL OVERHAUL. SYSTEM AVAILABILITY DECREASED
DURING THE LAST QUARTER OF THE YEAR BECAUSE OF HEAVY EROSION/CORROSION IN THE
LIQUOR RECIRCULATION PUMPS AND CENTRIFUGE.
SYSTEM AVAILABILITY WAS LIMITED BY BOILER-RELATED PROBLEMS THAT CAUSED FREQUENT
SHUTDOWNS IN JANUARY AND FEBRUARY.
TWO 7-DAY CONTINUOUS OPERATION PERIODS OCCURRED DURING THE MONTH.
THE 57 PERCENT OPERABILITY INDEX VALUE FOR THE MONTH WAS DUE TO A 2-WEEKS OUT-
AGE OF THE ACID PLANT RATHER THAN TO FGD SYSTEM FAILURE. DEMONSTRATION PRO-
GRAM WAS COMPLETED AND FGD SYSTEM WAS SHUT DOWN. EPA FUNDING OF MGS03 CALCIN-
ATION HAS EXPIRED. THERE ARE NO DEFINITE PLANS FOR RESTARTING OF THIS UNIT.
MAJOR PROBLEM AREAS ENCOUNTERED DURING THE OPERATION OF THIS PROTOTYPE UNIT
INCLUDED TRIHYDRATE INSTEAD OF HEXAHYDRATE SULFITE CRYSTAL FORMATION, OUST
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.
255
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TABLE 16
TERMINATED FGD SYSTEMS
06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F60 VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
S02
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
CENTRAL ILLINOIS LIGHT CO,
DUCK CHEEK NO. 1A
CANTON ILLINOIS
100 MW
COAL 2.5 - 3.0 PERCENT SULFUR
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
NEW
9/76
99.8 PERCENT
75 PERCENT
CLOSED LOOP
UNSTABILIZED SLUuGE DISPOSED IN LINED POND
$80/KW CAPITAL (ESTIMATED)
THE INSTALLATION OF ONE OF A TOTAL OF FOUR SCRUBBER MODULES WAS
COMPLETED IN JULY 1976 AND START-UP OPERATIONS COMMENCED. SHAKEDOWN
AND DEBUGGING OPERATIONS PROCEEDED ON AN INTERMITTENT BASIS
BECAUSE OF NUMEROUS CHEMICAL AND MECHANICAL-RELATED PROBLEMS.
THE SINGLE COMPLETED SCRUBBER MODULE HflS BEEN SHUTDOWN UNTIL THE OTHER
THREE MODULES. REPRESENTING 300 MW OF SCRUBBING CAPACITY. ARE READY IN
AUGUST 1978. UNTIL THAT TIME THE «»00-MW UNIT WILL BE UTILIZING COLORADO
LOW-SULFUR COAL FOR POWER GENERATION OPERATIONS.
256
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BACKGROUND INFORMATION
ON
DUCK CREEK PLANT NO 1A
THE DUCK CREEK PLANT OF THE CENTRAL ILLINOIS LIGHT COMPANY (CILCO) IS A NEW COAL-FIRED POWER-GENERATING STATION LOCATED IN
AN UNRECLAIMED STRIP-MINING AREA NEAR CANTON, ILLINOIS. AT THE PRESENT TIME, ONE HOO-MW COAL-FIRED UNIT IS IN SERVICE AND THREE
MORE IDENTICAL UNITS ARE BEING PLANNED. BRINGING THE TOTAL PLANNED PLANT CAPACITY TO 2000 HW.
THE NO. 1 POWER-GENERATING UNIT INCLUDES A 3-MILLION LBS./HR. STEAM-GENERATING BOILER (2600 PSlGt 1005F/1005F, SINGLE REHEAT,
PULVERIZED-COAu-FIREO. BALANCED DRAFT) SUPPLIED BT THE RlLEY STOKER CORPORATION TO PROVIDE STEAM TO «»00-MW TURBINE. THE BOILER
IS DESIGNED TO FIRE HIGH-SULFUR ILLINOIS COAL, AVAILABLE FROM NEARBY MINES, HAVING THE FOLLOWING AVERAGE CHARACTERISTICS* HEAT
CONTENTt 10«500 BTU/LB* SULFUR CONTENT 2>*t TO <>.0 PERCENT* ASH CONTENT, 6.0 TO 16.0 PERCENT. CONSTRUCTION OF THE NO. 1 UNIT BEGAN
IN THE EARLY PART OF 1972. COMMERCIAL SERVICE COMMENCED IN JUNE 1976.
THE DESIGN OF THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF TWO H9.6 PERCENT-EFFICIENT ELECTROSTATIC PRE-
CIPITATORS SUPPLIED BT POLLUTION CONTROL-WALTHER (PCW) FOR THE CONTROL OF PARTICULATES AND FOUR WET-LIMESTONE SCRUBBER MODULES
SUPPLIED BY RILET STOKER/ENVIRONEERING FOR THE REMOVAL OF 75 PERCENT OF THE SULFUR DIOXIDE. THE EMISSION CONTROL SYSTEM IS DE-
SIGNED TO FUNCTION IN THE FOLLOWING MANNER* THE BOILER FLUE GAS, AFTER PASSING THROUGH TWO AIR PREHEATER UNITS, ENTERS THE PCW
ESP'S WHERE PRIMARY PARTICULATE REMOVAL OCCURS. THE PARTICULATE-CLEANED GAS IS THEN DISCHARGED TO A MANIFOLD SUPPLYING FOUR CEN-
TRIFUGAL INDUCED DRAFT FANS (RADICAL TIP, INLET-DAMPER CONTROL, 900 RPM, <>000 HP EACH). THE FLUE GAS IS BOOSTED THROUGH A COMMON
HEADER INTO THE 4-HODULE SCRUBBER PLANT. EACH VENTURI-ABSORBER MODULE IS EQUIPPED WITH INLET/OUTLET DAMPERS SO THAT GAS CAN BE
ROUTED AROUND ONE OR ALL THE MODULES THROUGH BY-PASS BREECHING TO THE MAIN STACK. SULFUR DIOXIDE IS REMOVED FROM THE FLUE GAS IN
COUNTERCURRENT FASHION VIA LIMESTONE SLURRY SPRAYED ON THE ROD SECTIONS IN THE ABSORBER MODULES. THE LIMESTONE REAGENT IS STORED
ON THE PLANT SITE AND PREPARED IN SLURRY FORM VIA GRINDING IN A HO TPH WET BALL MILL. THE PRODUCT OF THE MILL SYSTEM, A 35 TO
-------
DUCK CREEK PLANT NO 1A (CONTINUED)
TO THE PLANT FOR REUSE IN THE ASH AND S02-REMOVAL SYSTEMS.
CURRENT STATUS* CONSTRUCTION OF THE NO.1 UNIT COMMENCED IN THE EARLY PART OF 1972 AND WAS VIRTUALLY COMPLETED BY THE SPRINB OF
1976. COMMERCIAL OPERATION COMMENCED IN JUNE 1976 WITH THE ESP MODULES IN THE 6AS PATH. THE FIRST MODULE OF THE FOUR-MODULE
SCRUBBER PLANT WAS INSTALLED BY JUNE 1976 AND START-UP FOR SHAKEDOWN AND DEBUGGING PURPOSES OCCURRED IN JULY. ONE MODULE IS
CAPABLE OF TREATING THE EQUIVALENT OF APPROXIMATELY 100-MW OF BOILER FLUE GAS. THE REMAINING THREE MODULES OF THE SCRUBBER
PLANT ARE NOW BEING INSTALLED. INITIAL OPERATION OF THE SCRUBBING SYSTEM WITH ALL FOUR MODULES IN THE GAS PATH IS SCHEDULED FOR
AUGUST 1. 1978. A SIMPLIFIED PROCESS FLOW DIAGRAM OF THE. DUCK CREEK NO. 1 EMISSION CONTROL SYSTEM IS PROVIDED IN
APPENDIX B. ADDITIONAL INFORMATION ADDRESSING THE INITIAL OPERATION OF THE NO.i MODULE IS PROVIDED IN THE PERFORMANCE TABLE THAT
FOLLOWS.
258
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PERIOD
JULY 76
MODULE
OPERATION, HRS.
8 MRS.
AUG. 76
18 HRS.
SEP. 76
360 HRS.
OCT. 76
385 HRS.
NOV. 76
20 HRS.
DUCK CHEEK NO.14* PERFORMANCE HISTORY
COMMENTS
INITIAL OPERATION OF THE FIRST SCRUBBER MODULE FOR SHAKEDOWN
AND DEBUGGING PURPOSE OCCURED DURING THE MONTH. LIMITED SERVICE
TIME RESULTED FROM PROBLEMS WITH BAD WELDS. FAULTY PIPE MANGES.
AND ABSORBER LEAKS.
LIMITED OPERATIONS CONTINUED THROUGHOUT AUGUST BECAUSE OF THE
START-UP AND CONSTRUCTION PROBLEMS MENTIONED ABOVE. THE MODULE WAS
TAKEN OUT OF THE GAS PATH AT THIS POINT TO CONCENTRATE ON RESOLVING
THESE PROBLEM AREAS.
MODULE RESTART OCCURRED ON SEPT. 9, OPERATION CONTINUED THROUGHOUT
THE REMAINDER OF THE MONTH ON AN INTERMITTANT BASIS. MAJOR PROBLEMS
INCLUDED PIPE BREAKING. PUMP LINER FAILURES, PLUGGING AND SEALING
OF MIST ELIMINATORS, AND SOME BOILER-RELATED PROBLEMS. THE MODULE
REMAINED IN SERVICE FOR APPROXIMATELY is DAYS OF NON-CONTINUOUS
OPERATION. THE PCW ESP MODULES HAVE REMAINED IN SERVICE WITHOUT THE
OCCURRANCE OF ANY MAJOR PROBLEMS.
TOTAL OPERATION TIME DURING THE MONTH WAS APPROXIMATELY 16 DAYS
(NON-CONTINUOUS). MAJOR PROBLEM AREA WAS THE CONTINUATION OF MASSIVE
SCALE DEVELOPMENT ON THE MIST ELIMINATORS, RESULTING IN PLUGGING OF
THE PIPING AND NOZZLES TO THE COMPONENTS SPRAY SYSTEM.
SPORADIC OPERATION RESULTED FROM CONTINUED SCALING PROBLEMS IN THE
MIST ELIMINATOR SECTION. RILEY AND CILCO INITIATED MODIFICATIONS TO
THE DESIGN OF THE MODULE. SPECIFICALLY, A ROD DECK WAS CHANGED IN
THE ABSORBER, PRESSURE DROP ACROSS THE ABSORBER WAS INCREASED,
PIPING AND PUMP LINER MATERIALS WERE MODIFIED/REPLACED, AND A FRESH
WATER WASH SYSTEM WAS INSTALLED FOR THE MIST ELIMINATOR.
259
PEDCo ENVIRONMENTAL.
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MODULE
PERIOD OPERATION, MRS.
DEC. 76
JAN. 77
FEB. 77
MAR. 77 350 MRS.
DUCK CREEK NO. 1A* PERFORMANCE HISTORY (CONTINUED)
COMMENTS
THE MODULE REMAINED OUT OF SERVICE THE ENTIRE MONTH. DURING THIS
TIME, THE BOILER FIRED LOW SULFUR (0.6K) KENTUCKY COAL.
TH£ NO. 1 UNIT UAS DOWN THROUGHOUT THE ENTIRE PERIOD FOR TURBINE/
BOILER OVERHAUL. DURING THE UNIT OUTAGE, A NUMBER OF MODIFICATIONS
WERE MADE TO THE SCRUBBER.
THE NO. 1 UNIT WAS RETURNED TO SERVICE IN MID-MARCH. THE SCRUBBER WAS
PLACED IN SERVICE TO TEST THE MODIFICATIONS MADE DURING THE PRECEDING
OUTAGE. THESE MODIFICATIONS INCLUDED*
* THE. MIST ELIMINATOR SPKAY WASH SYSTEM PIPING WAS CHANGED FROM PVC TO
FRP MATERIALS. ALSO, AN ADDITIONAL SPRAY HEADLR WAS ADDED.
* THt SLURRY CIRCULATION SYSTEM WAS RLVAMPEU.
* NEOPRENE PUMP LINERS HAVE REPLACED THE ORIGINAL RUBBER LINERS. FLUSH/
DRAIN SYSTEMS HAVE BEEN INCLUDED TO MINIMIZE SOLIDS BUILD UP,
* PIPING VALVES *OVEO CLOSER TO THE KECYCLE TANK.
« SLURRY STORAGE TANKS EQUIPPED WITH FLUSH/DRAIN SYSTEMS.
* ADDITIONAL MIXERS ADDED FOR GREATER AGITATION TO PROMOTE PROCESS
CHEMISTRY.
DURING THE LAST PART OF MARCH THE MODULE REMAINED IN SERVICE ON A CON-
TINUAL BASIS WITH THE EXCEPTION OF A FEW MINOR BOILER OUTAGES. CILCO
INTENDS TO CONTINUE EXPERIMENTAL OPERATIONS THROUGHOUT THE APRIL-MAY
PERIOD, TESTING THE MECHANICAL MODIFICATIONS AND THE AUTOMATIC CONTROL
LOOPS (SYSTEM CHEMISTRY WILL BE CONTROLLED BY INLET/OUTLET 803 LOADING.
SOLUTION PH, SOLUTION SOLIDS. OPERATION UP TO THIS POINT HAS PROCEEDED
IN A MANUAL CONTROL MODE). CONTINUED OPERATION BEYOND THIS TIME FRAME
WILL DEPEND UPON THE SUCCESS OF EXPERIMENTAL OPERATIONS. CILCO HAS THE
2foU
PEDCo ENVIRONMENTAL
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PERIOD
APR. 77
MAY 77
MODULE
OPERATION. MRS.
UUCK CRECK NO. 1A* PERFORMANCE HJSTORf {CONTINUED!
COMMENTS
OPTION OF FIRING LOW SULFUR COAL UNTIL THE ENTIRE H-MOOULE SCRUBBER PLANT
IS READY FOR SERVICE IN AUGUST 197S.
THE UNIT CONTINUED TO FIRE LOW-SULFUR COLORADO COAL DURING THE REPORT PERIOD. THE RESTART OF
SCRUBBER OPERATIONS CONTINUES TO BE SCHEDULED FOR AUGUST 1976
261
PEDCo ENVIRONMENTAL.
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TABLE 16
TERMINATED FGO SYSTEMS
06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
DAIRYLAND POHE« 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
S02
25 PERCENT
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
THIS EXPERIMENTAL WET LIME FuRNACE SYSTEM BEGAN OPERATIONS IN '71 AND WAS
OPERATIONAL FOK PERIODS UP TO 30 DAYS. IN AUGUST 1971* THE UNIT WAS TESTED
FOR TWO DAYS USING WESTERN LOW-SULFUR COAL. THE TEST SHOWED ABOUT SOX
S02 KEHOVAL EFFICIENCY. BUT PRECIPITATOK PERFORMANCE WAS ADVERSELY
AFFECTED. THE FGD PROJECT HAS BEEN SHUT DOWN INDEFINITELY SINCE
AUGUST 197*. AND THERE AKE NO PLANS FOR FUTURE OPERATION.
262
PEDCo ENVIRONMENTAL
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TABLE 16
TERMINATED FGD SYSTEMS
06/77
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
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
DETROIT EDISON
ST. CLAIR NO 6
BELLE RIVER MICHIGAN
163 MW
COAL 0.3 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
RETROFIT
5/76
99.7 PERCENT
90 PERCENT
OPEN LOOP 1.07 GPM/MW
UNSTAalLIZED SLUU6E DISPOSED IN LINED POND
S92/KU CAPITAL * 2.4 MILLS/KWH OPERATING
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 16 OF THIS REPORT.
FOLLOWING THE COMPLETION OF A TWO MONTH INTERNAL S02 SCRUBBING DEMONSTRA-
TION PROGRAM THE SCRUBBER PLANT WAS BYPASSED. MODIFICATIONS ARE BEING
IMPLEMENTED TO OPERATE IN THE PARTICIPATE MODE ONLY. VENTURI SCRUBBERS
FOR PARTICIPATE REMOVAL WILL BE PUT IN OPERATION IN SEVERAL MONTHS. SPRAY
TOWERS WILL NOT BE USED AS ORIGINALLY PLANNEU. THE BOILER IS NOW FIRING
LOW-SULFUR (0.3 PERCENT) WESTERN (DECKER) COAL. COMPLIANCE WITH S02
REGULATIONS IS BEING ACHIEVED WITHOUT THE NECESSITY OF SCRUBBING.
263
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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 45 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. & IS A COAL-FIRED TWO-STAGE SUPERHEATER UNIT* CONTAINING TWO SEPARATE BOILER BOXES KNOWN
AS THE SOUTH BOILER AND THE NORTH BOILER. THE TOTAL NET 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
DIETZ MINE LOCATED IN SOUTHERN MONTANA. THE AVERAGE CHARACTERISTICS OF THIS COAL ARE* HEAT CONTENT 9900 TO 9600 BTU/LB*SULFUR CON-
TENT OF 0.3 TO O.t PERCENT* ASH CONTENT OF «».0 PEKCENT* AND A TOTAL MOISTURE CONTENT OF 22.0 TO 2*».0 PERCENT.
THE EMISSION CONTROL SYSTEM INSTALLED ON THE NORTH BOILER CONSISTS OF MECHANICAL COLLECTORS AND AN ELECTROSTATIC PRECIPITATOR
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FGD SYSTEM PERFORMANCE
ST. CLAIR NO. 6
PERIOD COMMENTS
NOV. 71 INSTALLATION OF THE FGD SYSTEM WAS ESSENTIALLY COMPLETED BY THIS TIME. A FAULTY INSTRUMENT PANEL WHICH WAS
DEC* 7«» INCORRECTLY WIRED HAS BEEN RETURNED TO THE MANUFACTURER FOR REPAIR. TO DATE, THE UTILITY HAS WATER TESTED ALL
JAN. 75 THE AUXILIARY EQUIPMENT. THE I.D. FAN HAS BEEN TESTED AND AIR BALANCE HAS BEEN CHECKED.
FEB. 75
MAR. 75 A COLD FLUE 6AS RUN WAS SUCCESSFULLY CONDUCTED MARCH 22 TO 25. DURING THIS PERIOD* THE RUBBER-LINED PUMPS
APR. 75 WERE REPAIRED AND THE LIMESTONE PREPARATION SYSTEM WAS CALIBRATED.
MAY 75
JUN. 75 THE FIRST HOT FLUE 6AS RUN WAS CONDUCTED ON JUNE 22, 1975. THE RUN LASTED FOR A PERIOD OF 22 HOURS. DURING
JUL. 75 THIS RUN, THE SCRUBBER WAS PURPOSELY TRIPPED OFF AT LOADS OF tO AND 80 PERCENT. THIS WAS PERFORMED TO OBSERVE
IF ANY DETRIMENTAL EFFECTS TO THE STEAM GENERATION OPERATIONS RESULTED. NONE WERE DETECTED. THE SYSTEM WAS
TAKEN OUT OF SERVICE FOLLOWING THIS GAS RUN TO CORRECT THE FOLLOWING MAJOR OPERATION AREAS*
GAS CIRCUIT* LURGI THROAT POSITIONAL FAILURE* DETERIORATION OF THE DAMPER SEALS* SEVERE DUCT VIBRATIONS*
S02 ANALYZERS INOPERATIVE.
LIQUID CIRCUIT* FAILURE OF PH CONTROL SYSTEM* TARGET FLOW METER TARGETS HAVE BEEN BROKEN OFF* PUMP SEAL
WATER LOU FLOW ALARM TRIPS.
AUG. 75 A SECOND HOT FLUE GAS RUN WAS INITIATED ON AUGUST 6 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 m HOURS DURATIONWAS COMPLETED OCTOBER 9. THE MAIN OBJECTIVE OF THIS RUN WAS TO
EVALUATE VARIOUS COMPONENTS OF THE FRESH WATER SPRAY SYSTEM AND EFFECTS ON SYSTEM OPERATION. THE TEST RUN WAS
PREMATURELY TERMINATED BECAUSE OF A BOILER FEED PUMP MALFUNCTION, RESULTING IN A REDUCED BOILER LOAD
CAUSING SUBSEQUENT WEEPING OF THE WASH TRAY.
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FGD SYSTLH PERFORMANCE tCONTINUEDl
STi CLAIK NO. 6
PERIOD COMMENTS
NOV. 75
DEC. 75 « FOURTH FLUE GAS RUN OF 23 OATS DURATION WAS TERMINATED DUE TO EXCESSIVE VIBRATION IN THE I.D. BOOSTER FAN.
ONE OTHER SCRUBBER-RELATED OUTAGE OCCURRED WHEN THE PACKING OF ONE OF THE SCRUBBER RECIRCULATION PUMPS NEEDED
MAINTENANCE. S02 REMOVAL DURING THIS PERIOD MAS 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
NAY 76 RUN WAS CONDUCTED ON A *HANDS OFF* BASIS USING PLANT PERSONNEL EXCLUSIVELY. THE SYSTEM HAS IN SERVICE 100
PERCENT OF THE TIME THE BOILER WAS OPERATIONAL. THE FINAL ACCEPTANCE TEST CONSISTED OF SIX H-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.if 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 m. 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 ASSEMBLY, CAUSING VIBRATION AND
BALANCE PROBLEMS. IT WAS DECIDED TO SANDBLAST THE FAN TO REMOVE SOLIDS BUILDUP ON THE FAN ASSEMBLY.
THE. UTILITY PLANS TO MODIFY THE COMPONENT'S WASH SYSTEM FOR GREATER FLOW CAPABILITY AFTER COMPLETION
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FGO SYSTEM PERFORMANCE (CONTINUED)
ST. CLA1R NO. 6
OF THE S02 SCRUBBING PROGRAM. DECO ALSO PLANS TO CONTINUE PARTICIPATE SCRUBBING FOLLOWING THE
TERMINATION OF THE S02 PROGRAM BY UNCOUPLING THE SPRAT TOWERS AND MAINTAINING THE PEABODY-LURGI
VENTURI SCRUBBERS IN THE FLUE GAS STREAM. SGML 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 ANU CONTINUED THROUGHOUT THE MONTH. THE SYSTEM*S AVAILABILITY
INDEX FOR THE MONTH WAS BO PERCENT. THE MAJORITY OF THE OUTAGE TIME WAS CONSUMED PROCURING SAND BLASTING
SERVICES. THE OPERATION ITSELF REQUIRED ONLY 8 HOURS.
DEC. 76 THE S02 DEMONSTRATION PROGRAM CONTINUED THROUGHOUT DECEMBER. THE SYSTEMS*S AVAILABILITY INDEX FOR THE PERIOD
WAS si 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.
JAN. 77 THE S02 DEMONSTRATION PROGRAM WAS OFFICIALLY TERMINATED ON DEC. 31, 1976. THE SCRUBBER PLANT WAS SHUT DOWN AT
FEB. 77 THIS POINT AND FLUE GAS WAS BY-PASSED AROUND THE SYSTEM. THE BOILER REMAINS IN SERVICE, FIRING LOW SULFUR
MAR. 77 (0.3X) WESTERN COAL. CURRENT PLANS CALL FOR THE SCRUBBER PLANT TO REMAIN OUT OF SERVICE UNTIL HID-JUNE FOR
DESIGN AND OPERATIONS MODIFICATIONS. RESUMPTION OF SCRUBBER OPERATIONS WILL OCCUR IN THE PRIMARY PARTICULATE-
REMOVAL MODE. THE PEABODY-LUKGI VENTUKI SCRUBBERS AND SPRAY TOWER ABSORBERS WILL REMAIN IN THE GAS STREAM.
SOLUTION WILL BE CIRCULATED THROUGH THE VENTURI«s, WASH TRAYS, AND MIST ELIMINATORS. NO SOLUTION WILL BE
CIRCULATED THROUGH THE SPRAY ZONE OF THE ABSORBER TOWERS. LIMESTONE REAGENT WILL BE ADDED TO THE SCRUBBING
SOLUTION IN ORDER TO PREVENT LOW PH SWINGS AND SUBSEQUENT MATERIALS DAMAGE TO THE SCRUBBER'S INTERNALS.
S02 REMOVAL SHOULD RESIDE IN THE 3J> TO SOX RANGE IN THIS MODE OF OPERATION BECAUSE OF THE SOLUTION'S
ALKALINITY DUE TO THE FLY ASH AND LIMESTONE. ALSO. DECO PLANS TO MAINTAIN A HIGHER L/G RATIO IN THE SCRUBBER
MODULES. THIS MODE Oh OPERATION IS PKOJLCTED TO CONTINUE FOR A ONE TO THREE-YEAR PERIOD FOLLOWING THE MID-JUNE
RESTART.
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TERMINATED
TABLE 16
SYSTEMS
Ofa/77
IDENTIFICATION NO.
UTILITY NAME
UNIT N*"E
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYt
PARTICULATES
GULF POWER CO.
SCHOLZ NO. 1A
CHATTAHOOCHEE FLORIDA
20 nw
COAL 3.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI SCRUBBING
RETROFIT
2/75
99.7 PERCENT
SOZ
WATER HAKE UP
SLUDGE DISPOSAL
95 PERCENT
CLOSED LOOP
UNSTABILIZED SLUpGE OlSPOSLD IN LINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE it OF THIS REPORT.
THIS PROTOTYPE SCRUBBING SYSTEM WAS INITIALLY PLACED IN SERVICE FEBRUARY
1975 AND WAS OPERATIONAL A TOTAL OF H7HH HOURS THROUGHOUT THE YEAR. THE
SYSTEM REMAINED IN SERVICE DURING THE FOLLOWING 6 MONTHS IN 1976.
SUCCESSFUL COMPLETION OF THIS PROGRAM OCCURRED ON JULY 2. 1976. PRESENT
PLANS CALL FOR A FULL SCALE EPA-SPONSORED DEMONSTRATION PROGRAM WITH
THE INSTALLATION SITE BEING LOUISVILLE GAS & ELECTRIC'S CANE RUN STATION
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THE SCHOLZ STEAM POWER PLANT OF 6ULF POWER COMPANY IS LOCATED IN CHATTAHOOCHEEt FLORIDA. UNIT NO. 1 IS A COAL-FIRED STEAM
BOILER DESIGNED AND INSTALLED BY BABCOCK AND WILCOX IN 1953. THIS UNIT IS NOMINALLY RATED AT 40 MW AND IS CAPABLE OF H7.5 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 It 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 SECTlONALIZED, HIGH-EFF-
ICIENCY 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 DE-
SIGNED 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 CE.A/ADL IN EARLY FEBRUARY 1975. IN MID-MAY AN EpA DUAL ALKALI
TEST PROGRAM WAS INITIATED BY SOUTHERN SERVICES, CEA» AND AOL. 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 CONTINUOSLY DURING THIS PERIOD ON A HIGH SULFUR COAL (3.5 TO i»,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 FUN 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 APPENDIX B.
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SCHOL2 1A - DOUBLE ALKALI
UNIT OPERATING HOURS
TOTAL FGD SYSTEM PERFORMANCE <*)
PERIOD HOURS BOILER FGD SYSTEM OPERABILITY UTILIZATION COMMENTS
FEB. 75 672 "»59 »»5«» 99 68 UNIT WAS PLACED IN OPERATION FEB. 6, 1975 AND OPERATED UNTIL
HAR. 75 THH 507 «»85 96 665 JULY 18 WHEN IT WAS SHUT DOWN FOR 2 MONTHS MODIFICATIONSi RE-
APR. 75 720 60<» 336 56 H7 PAIRS* AND REPLACEMENT OF PARTS. THE SYSTEM WAS UNAVAILABLE
HAY 75 7*H 598 375 63 50 TO THE BOILER FOR A <»91-HR PERIOD BECAUSE OF ADJUSTMENTS AND
JUN. 75 720 720 720 100 100 MODIFICATIONS REQUIRED FOR THE FORMAL EPA TEST PROGRAM IN
JUL. 75 7<»«» 683 221 32 30 MID-MAY.
AUG. 75 7«»«» 7«M» 0 0 0 THE SYSTEM WAS SHUT DOWN FORM MID-JULY TO MID-SEPTEMBER FOR
MECHANICAL OVERHAUL INVOLVING REPLACEMENT PARTS FOR VALVES
THAT HAD FAILED.
SEP. 75 720 577 25* «Mt 35 THE SYSTEM WAS PUT BACK IN OPERATION ON SEP 16. 1975. FROM
OCT. 75 7«»«* 559 559 100 75 MIO-SEP. TO MID OCT. THE AIR PREHEATER WAS REPAIRED AND BOIL-
£K OPERATION ADJUSTED To REDUCE OXYGEN LEVELS IN THE FLUE GAS
TO THE 5 TO 6 PERCENT RANGE, THE SYSTEM OPERATED APPROXI*
MATELY 000 MRS. DURING THIS PERIOD.
NOV. 75 720 620 560 90 78 THE SYSTEM RAN CONTINUOUSLY FOR THE REMAINDER OF THE TEST
DEC. 75 7H«» 732 732 100 98 PERIOD THROUGH JANUARY 2i 19769 S02 LEVELS DURING THIS PER-
IOD RANGED FROM 800 TO 1700 PPM. THE SYSTEM OPERATED IN THE
CONCENTRATED MODE THROUGHOUT THE REMAINDER OF THE TEST PER-
IOD. IN THE PERIOD FROM MID-SPE. TO JAN. 2, i976t THE SYSTEM
OPERATED ABOUT 2100 HRS.i WITH AN OPERABILITY FACTOR OF 97
PERCENT.
JAN. 76 7«M» THE FGD SYSTEM AND BOILER UNDERWENT A SCHEDULED OVERHAUL OUR.
FEB. 76 696 ING THE REPORT PERIOD. SYSTEM RESTART IS SCHEDULED FOR MID-
MARCH 1976. TO CONTINUE UNTIL JUNE. DURING THIS OPERATING
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SCHOLZ 1A - DOUBLE ALKALI (CONTINUED)
UNIT OPERATING HOURS
TOTAL FGD SYSTEM PERFORMANCE (X)
PERIOD HOURS BOILER FGD SYSTEM OPERABILITY UTILIZATION COMMENTS
PERIOD HIGH-SULFUR COAL 13.5-4.0 xj WILL BE BURNED TO ALLOW
EVALUATION OF SYSTEM PERFORMANCE ON HIGH-SULFUR COAL.
MAR. 76 744 7*2 445 60 60 THE SYSTEM WAS PUT BACK IN SERVICE ON MAR. 12, 1976. THE TO-
TAL NUMBER OF OPERATING HRS. FOR THE MONTH OF MAR. MAS 445
HRS. THIS TRANSLATES INTO A 94X OPERABILITY FACTOR SINCE THE
MAR. 12 RESTART.
APR. 76 720 642 616 96 86 SOME MINOR MECHANICAL PROBLEMS IN THE FORM OF AGITATOR SHAFT
MAY 76 744 735 651 89 68 AND CONTROL VALVE FAILURES WERE ENCOUNTERED DURING THE REPORT
PERIOD. SINCE THE SYSTEM RESTART ON MAR. 12, HIGH-SULFUR
COAL HAS BEEN BURNED IN THE BOILER (3.5 TO 4.5 X SULFUR), RE-
SULTING IN THE S02 INLET CONCENTRATION LEVELS IN THE 2000 TO
2&00 PPM RANGE.
JUN. 76 720 656 641 93 89 DURING THE LAST PHASE OF OPERATION, THE SYSTEM WAS TREATING
FLUE GAS OF VAkYING PARTICIPATE LOADS. THE UPSTREAM ESP WAS
WAS SELECTIVELY DE-LNERGIZEO, BOTH PARTIALLY AND TOTALLY. NO
MAJOR USETS IN THE PROCESS CHEMISTRY OCCURRED. BOILER LOAD
VARIATION RANGED FROM 30 TO 100*. THE PROTOTYPE PROGRAM AT
THE PLANT WAS SUCCESSFULLY CONDUCTED ON JULY 2. AOL is CURR-
ENTLY COMPLETING DATA ACQUISITION AND ANALYSIS.
JUL. 76 744 54* 54 100* THE PROTOTYPE TEST PROGRAM WAS SUCCESSFULLY CONCLUDED ON JULY
3* 1976.
•NOTE* THE BOILER HRS., SYSTEM OP HRS., AND THE CORRESPONDING
PERFORMANCE VALUE CALCULATED INCLUDES SYSTEM OP UP TO
THE SCHEDULED SHUTDOWN, ON JULY 3, 6*00 A.M., 1976.
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TABLE it.
TERMINATED F60 SYSTEMS
Ob/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
GULF POWER CO.
SCHOLZ NO. 2 A
CHATTAHOOCHEE FLORIDA
20 MW
COAL 3.0 PERCENT SULFUR
FOSTER WHEELER
ACTIVATED CARBON
RETROFIT
2/76
99.7 PERCENT
7H.5 PERCENT (DESIGN)
N/A DRY ADSORPTION SYSTEM
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 16 OF THIS
REPORT. THIS IS A PROTOTYPE DRY ADSORPTION REGENERABLE SYSTEM
DESIGNED BY FOSTER WHEELER AND BER&BAU FORSCHUNG. OPERATION OF
THE PROTOTYPE UNIT DURING THE SCHOLZ DEMONSTRATION PROGRAM PROCEEDED
ON AN INTERMITTENT BASIS. OPERATIONAL SEGMENTS OCCURED IN AUGUST 1975,
OCTOBER 1975. AND MARCH, APRIL AND MAY 1976. SYSTEI OPERATIONS HERL
PREMATURELY TERMINATED AT THIS POINT AND THE PHOTOTYPE UNIT WAS SHUT
DOWN. THE SYSTEM IS CURRENTLY INACTIVE.
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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 FOH FLUE GAS DESULFURIZATIUN. CONSTRUCTION ON THE FOSTER WHEELER PROCESS STARTED FEBRUARY
15t 1971*. 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-Mb, ADSOKBER SECTION AND A «»7.5-MW REGENERATION AND REDUCTION SECTION. THE 20
HW 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
I NOMINALI» IT FIRES COAL WITH AN AVERAGE HEATING VALUE 0* 12.HOO bTU/Lb. MAXIMUM ASh AND SULFUR CONTENTS ARE 1» AND 3 PERCENT,
RESPECTIVELY.
THE PURPOSE OF THE ADSORPTION SECTION OF THE FWBF uRY REMOVAL SYSTEM IS TO REMOVE SULFUH UlUXIDEi NITROGEN OXIDES. AND
PARTICULATE FROM THE FLUE GAS WITH ACTIVATED CHAR, CONVERTING THE CAPTURED POLLUTANTS TO SULFURIC ACID. THE REGENERATION SECTION
PROVIDES CONTINUOUS ON-SITE REGENEhATION OF THE CHAR. WHICH HAS BLEN LOADED WITH SULFUR DIOXIUE IN THE FORM OF SULFURIC ACID. THE
CHAR IS REGENERATED AMD A LOw-VOLUME, SULFUR DIOXIDE-HICH OFF-GAS STREAM IS FEU FORWARD TO THL RESOX REACTOR, WHICH REDUCES THE
SULFUR DIOXIDE STREAM TO GASEOUS ELEMENTAL SULFUR THAT IS COLLECTEU AND STORED IN AN INSULATED TftNK.
THE DEMONSTRATION UNIT HAS TWO ROkS OF MODULES, EACH R0« CONSISTING UF SIX MODULES. THE ADSORPTION SECTION IS A TWO-STAGE
DESIGN CONSISTING OF VERTICAL COLJFNS OF PAHALLEL LOUVEK BLDS WH1LH SUPPOKT ANU CONTAIN THt ftCTIVATEO CHARCOAL. SULFUR DIOXIDE,
OXYGEN, WATER VAPOR, AND NITROGEN OXIDES ARE ADSORBEL BY THE CHAK PELLETS FROM THE CROSS.FLOWING FLUE GAS AT 250 TO 300 F. THE
SULFUR DIOXIDE THEN REACTS WITH OXYGEN A"0 WATER TO FOKM SULFURIC 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 ftMD CARBON DIOXIDE. THIS LATTER PROCESS IS CARRIED OUT AT J200 TO
isoo F. A SCHEMATIC OF THE PROCESS COMPONENTS FOR THE FW-BF DKY ADSORPTION is PRESENTED IN APPENDIX B.
THE INITIAL SHAKEDObN ON FLUE GAS BEGAN AUG. 11, 1975, ANU PROCEEDED CONTINUOUSLY FOR 10 OAyS. THE REGENERATION SECTION WAS
OPERATIONAL ABOUT 60 PERCENT OF THE TIME. HOWEVER, THE REDUCTION SECTION HAS NOT YET BEEN INTEGRATED INTO SYSTEM OPERATION. SUL-
FUR DIOXIDE REMOVAL WAS WELL ABOVE EXPECTATIONS AND PRESSURE DROP ACROSS THE ADSORBER WAS WELL BELOW DESIGN LEVELS. THE SYSTEM
WAS SHUT DOWN FOR CORRECTION OF SEVERAL OPERATING PROBLEMS, EQUIPMENT MODIFICATIONS. AND EVALUATION OF THE INITIAL OPERATING
DATA. OPERATION WAS RESUMED IN OCTOBER 1975. WHEK Tk'O CONSECUTIVE RUMS WERE CONDUCTED WITH THE REDUCTION PORTION OF THE SYSTEM
PROCESSING FRONT-END OFF-GAS AT FULL OPEKATING TEWPEKATUKES. A PROGRAM OF MODIFICATION WAS COMPLETED ON THIS SYSTEM IN EARLY
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SCHULZ NO. 2A - FWBF SYSTEM (CONTINUED!
JANUARY 1976. REINTROOUCTION OF FLUE GAS INTO THE INTEGRATED SYSTEM COMMENCED IN FEBRUARY 1976. OPERATIONS THROUGH A FINAL
H-HONTH TEST PROGRAM WERE PREMATURELY TERMINATED ON MAY 2. 1976.
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FHBF SYSTEM OPERATING HISTORY
PERIOD COMMENTS
HAT 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 HERE INTEGRATED INTO SECTION
AUG. 75 OPERATIONS AND FLUE GAS WAS PASSED THROUGH THE ADSORBER AND REGENERATOR FOR A 10-UAY
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. 75 A PROGRAM OF MODIFICATIONS ON THE SYSTEM BEGAN IN LATE AUGUST 1975 AND CONTINUED
DEC. 75 THROUGH JAN. 1976. WITH THE EXCEPTION OF THE 5-DAY RESOX OPERATION IN OCTOBER.
JAN. 76 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 HESOX LOOPS WERE OPERATED AT FULL OPERATING
TEMPERATURES AND PRESSURES. REENTRODUCTION OF FLUE GAS INTO THE SYSTEM COMMENCED,
AND A 4-HONTH FORMAL TEST PROGRAM CONDUCTED BY SOUTHERN SERVICES AND FOSTER WHEELER
IS NOW IN PROGRESS.
MAR. 76 THREE OPERATIONAL PERIOuS WERE LOGGED BY THE PROTOTYPE SYSTEM DURING THE REPORT
PAR. 76 MONTHS. DURING THESE RUNS THE ADSORPTION AND REGENERATION SECTIONS PERFORMED
ADEQUATELY. THE RESOX SECTION OPERATED INTERMITTENTLY BECAUSE OF PLUGGING PROBLEMS
IN 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 IS PROCEEDING ON THE
SOLUTION OF THE SULFUR CONDENSER PROBLEM.
MAY 76 THF 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*
275 f^
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FhHF STSTtM OPERATING HISTORY ICONTINUEUI
COMMENTS
* DEPLETION OF CHAK SUPPLY.
* HIGH CHAR CONSUMPTION RATES DUE TO MECHANICAL ATTRITION.
* CORRECT/MODIFY THE CHAR/SAND SCREEN SEPARATOR.
AT THIS POINT THL DECISION WAS MAUL TO PREMATURELY TERMINATE THE FW-BF DEMONSTRATION
PROGRAM RATHER THAN SHUT OOWNt DEBUG. AND RESTART THL SYSTEM AGAIN. THt SYSTEM
SUPPLIER IS PURSUING ADDITIONAL FUNDING FOR THE CONTINUATION OF THE PROTOTYPE
DEMONSTRATION PROGRAM.
PEDCo ENVIRONMENTAL
276 V^^^Vy CINCINNATI. OHIO
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TABLE 16
TERM IN ATE. 0 FGO SYSTEMS
06/77
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
GULF f-OWER CO.
SCHOLZ NOS. IB X 2B
CHATTAHOOCHEC FLORIDA
23 MW
COAL 5.0 PERCENT SULFUR (MAX)
CHIYODA INTERNATIONAL
THOROUGHBRED 101
RETROFIT
3/7b
99.7 PERCENT
S02
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
90 PERCENT
OPEN LOOP
UNSTABILIZEQ SLUDGE DISPOSED IN DRY GYPSUM POND
S3 MILLION CAPITAL COST
REFER TO THE BACKGROUND INFORMATION IN TABL E I&OF THIS REPORT. CHIYOOA
AND GULF POWER ANNOUNCED ON MAHC THE COMPLETION OF Thl& DEMONSTRATION
PROGRAM. DURING JANUARYt FEBRUARYt AND MARCH OPERATIONS, THERE WERE ONLY
20 MINUTES OF FORCED SCRUBBER OUTAGE. UTILIZATION WAS ESSENTIALLY 100
PERCENT UNTIL PROGRAM TERMINATION. PROCESS UTILIZATION WAS GREATER THAN
99 PERCENT FROM OCT. 17 THROUGH PROGRAM COMPLETION. SOUTHERN SERVICES
IS CURRENTLY PKEPAKlNG A COMPREHENSIVE REPOKT ON THE CT-101 FGD SYSTEM
DEMONSTRATION PROGRAM AT GULF POWER.
277
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BACKGROUND INFORMATION
ON
SCHOLZ UNITS 1 AND 2 - CHIYODA
THE SCHOLZ POWER PLANT IS LOCATED IN CHATTAHOOCHEE. FLORIDA. ABOUT 50 MILES WEST OF TALLAHASSEE. THE FSO 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 FKOM CLAUS UNITS.
THE SYSTEM AT SCHOLZ CAN HANDLE ONE-HALF THE LOAD (S3.000 SCFHI FROM EITHER OF THE <*0-MW NOMINALLY RATED BOILERS. WHICH WERE
DESIGNED AND INSTALLED BY BABCQCK AND WILCQX IN 1953. DLSIGN ABSuRBER INLET SULFUR DlQXIUE CONCENTRATION IS 2250 PPM. VARIOUS
TEST COALS WITH SULFUR CONTENTS RANGING UP TO 5 PERCENT ARE SCHEDULED FOR BURNING.
THE PARTIcULATE LOADS FROM NEWLY INSTALLED ELECTROSTATIC PREcIPITATORS ON THE TWO UNITS RANGE FROM 0.02 TO 0.1 GR/ScF. FLUE
GAS FROM THE PRECIHITATORS IS SlUENCHLD WITH COOLING WATER TO REMOVE ADDITIONAL FLY ASH AND TO COOL THE GAS BEFORE IT ENTERS THE
SULFUR DIOXIDE ABSORBER.
SULFUR DIOXIDE IS ABSORBED IN WATER AND CATALYTICALLY OXIDIZED WITH AIR TO FORM SULFURIC ACID. THE DILUTE ACID IS RECIRCU-
LATED THROUGH THE ABSORBER. A PORTION OF THE ACID is NEUTRALIZED WITH LIMESTONE TO PRODUCE GYPSUM AS A BY-PRODUCT.
BREAK.IN TESTING COMMENCED IN FEBRUARY 1975. THE FIRST FEW MONTHS OF THE SHAKEDOWN PERIOD WERE CHARACTERIZED BY MANY MINOR
PROBLEMS, RESULTING IN A LOW OPERABILITY INDEX VALUE <3o* FOR FEU-MAY). MANY OF THESE PROHLEMS W^RE RESOLVED BY JUNE. (MANIFESTED
BY A HIGHER OPERABILITY INDEX <8<»X> VALUE FOR THE JUNE-JULY PERIOD). A 6-WEEK SCRUBBER OUTAGE PERIOD COMMENCED IN AUGUST FROM
UNBALANCING OF THE GYPSUM CENTRIFUGES. AFTER REPAIR OF THE CENTRIFUGES AND INSTALLATION ON SEPTEMBER 15, THE OPERABILITY INDEX
THROUGH DECEMBER 1975, AVERAGED ABOVE 97 PERCENT.
CHIYODA. GULF POWER, AND SOUTHERN COMPANY SERVICES SUCCESSFULLY CONCLUDED CT-101 OPERATIONS ON MARCH 22. 1977, AFTER MORE
THAN TWO YEARS OF INTENSIVE TESTING, EVALUATION, AND DEMONSTRATION. INFORMATION AND UATA CONCERNING THE OPERATION OF THE
Ct-101 PROTOTYPE UNIT A«E PRESENTED IN THE PERFORMANCE TABLE THAT FOLLOWS. A PROCESS FLOW DIAGRAM IS IN FIGURE 6, APPENDIX C.
270
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SCHOL2 IB AND 28 - CHIYOOA
MONTH
FEB. 75
APR. 75
HAY 75
TOTAL
HOURS
672
720
744
JUN. 75 720
JUL. 75 744
AU6. 75 744
SEP. 75 720
OCT. 75 744
NOV. 75 720
UNIT OPERATING HOURS
BOILER FGD SYSTEM
672
FGO SYSTEM PERFORMANCE (X)
OPERABILITY UTILIZATION
720
744
200
100
20
13
26
13
685
744
720
665
624
0
337
100
8*
95
84
46
744
720
744
720
100
100
000
100
279
COMMENTS
THIS IS A PILOT PLANT SIZE DEMONSTRATION UNIT.
PRELIMINARY ENGINEERING AND DESIGN WORK BEGAN IN
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. AFTLR 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 S02 REMOVAL EFFICIENCY DURING THIS
PERIOD. GULF POWER IS ATTEMPTING TO UPGRADE THIS
VALUE TO A HIGHER EFFICIENCY LEVEL.
WASTE WATER DISCHARGE FRQM THIS UNIT STILL A
PROBLEM AREA.
OUTAGE TIME. WAS LESS THAN ONE HOUR DURING NOVEMBER
PEDCo ENVIRONMENTAL
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SCHOLZ IB AND 2B - CHIYOOA (CONTINUED)
UNIT OPERATING HOURS
TOTAL FGD SYSTLH PERFORMANCE (X)
HOURS BOILER FGD SYSTEM OPERABILITY UTILIZATION
MONTH
NOV. 75 (CONTINUED)
DEC. 75
JAN. 76
FEB. 76
696
680
690
726
H50
77
98
66
11
98
60
11
WAR. 76
APR. 76
720
7f«t
720
7V1
101
100
100
RAY 76
JUN. 76
260
COMMENTS
OPERATION DUE TO A BROKEN FLUE GAS BLOWER INLET
VANE AND REPAIR OF A PINHOLE IN THE PRESCRUBBER
FRP LINING.
SCRUBBEK OUTAbES DURING DECEMBER RESULTED FROM
CONTINUING REPAIRS TO A PINHOLE IN THE PRESCRUBBER
FRP LINING.
OUTAbE TIME IN JANUARY-FEBRUARY WAS PRIMARILY FOR
REPAIR AND MODIFICATION OF THE SUCTION AND DIS-
CHARGE PIPING ON THE ABSORBENT CIRCULATION PUMPS.
THESE FRP LINES BROKE IN JANUARY AT SOME WEAK
FIELD JOINTS. S02 REMOVAL EFFICIENCY HAS BEEN AS
HIGH AS 95*.
PLANT WAS STOPPED APRIL 5 FOR A SCHEDULED SHUTDOWN
TO ALLOW INSTALLATION AND MODIFICATIONS FOR
REDUCING THE QUANTITY OF LIQUID WASTE FROM THE
SYSTEM. START-UP AND TESTING OF THIS MODIFICATION
WAS PLANNED FOR THE FIRST WEEK IN MAY. A FIRE AT
THE PLANT. HOWEVERt NECESSITATED A DELAY IN
SYSTEM RESTART FOR AN ADDITIONAL 3 TO * WEEKS.
THE SYSTEM WAS SHUT DOWN APRIL 2* BECAUSE OF
EXTENSIVE FIRE DAMAGE IN THE OXIDIZING TOWER.
THE FIRE. CAUSED BY A WELDING ACCIDENT.
DAMAGED FRP AND POLYPROPYLENE COMPONENTS IN
THE OXIDIZING TOWER. REPAIRS CONTINUED AS
THE SYSTEM REMAINED OUT OF SERVICE DURING
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SCHOLZ IB AND 28 - CHIYOOA (CONTINUED)
MONTH
JUL. 76
AUG. 76
TOTAL
HOURS
UNIT OPERATING HOURS
BOILER FGD SYSTEM
FGO SYSTEM PERFORMANCE (X)
OPERABILITY UTILIZATION
1(92
66
COMMENTS
THE REPORT PERIOD. SYSTEM RESTART IS
SCHEDULED FOR THE END OF JULY.
T«E PROTOTYPE UNIT REMAINED OUT OF SERVICE
MAYt 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. 241.67 HOURS OF THE 251.75 HOURS
OF AUGUST OUTAGE TIME WAS CONSUMED FOR THESE
ADDITIONAL REPAIRS. THE WATER SAVINGS PRO-
GRAM IS NOW BEING CONDUCTED ON THIS SYSTEM.
BASICALLYt THIS TEST PROGRAM CALLS FOR A
REDUCTION IN WASTEWATER SLOWDOWN AND FRESH
WATER MAKEUP REQUIREMENTS BY RECYCLING THE
MOTHER LIOUOR BLEED BACK TO THE PROCESS FOR
ADDITIONAL SERVICE.
261
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SCHOLZ IB AND «>b - CHIYODA
-------
MONTH
TOTAL
HOURS
SCHOLZ 18 AND 2B - CHIVO0A (CONTINUED)
UNIT OPERATING HOURS
FGD SYSTEM PERFORMANCE i»
BOILER F60 SYSTEM AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
JAN. 77
FEB. 77
MAR. 77
672
7'K
672
672
100
100
100
100
100
100
100
100
100
100
THE PROGRAM WAS TERMINATED TO ALLOW CIC TO DEVELOP AND DEMONSTRATE A NEW F6D DESIGN.
NO DEMONSTRATION COMMITMENTS HAVE YET BEEN MADE.
COMMENTS
PROBLEMS INCLUDED A MALFUNCTION OF
A LEVEL INDICATOR, A BROKEN
GUIDE VANE* AND AN OPERATOR ERROR
RESULTING IN A LEAK OF SLURRY INTO
THE WATER HEADER. ON NOV.lt SOU-
THERN SERVICES FINISHED ITS ScHOLZ
EVALUATION OF THE CT-101. A PER-
FORMANCE REPORT IS DUE SPRING 1977.
GULF POWER WILL CONTINUE OPERATION
OF THE CHIYOOA UNIT FOR AN UNSPE-
CIFIED PERIOD IN 1977.
CIC, GPC, 1 SCS SUCCESSFULLY CON-
CLUDED THE CT-101 TESTING AND DE-
MONSTRATION PROGRAM ON MARCH 22.
DURING THE REPORT PERIOD, THE TOTAL
SCRUBBER OUTAGE TIME WAS 0.33 HR.
THE SYSTEM HAS BEEN IN SERVICE ON A
VIRTUALLY CONTINUOUS BASIS SINCE
OCT. 17« TOTALLING OVER 3 MONTHS OF
100* RELIABLE OPERATION.
283
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TABLE 16
TERMINATED FGO SYSTEMS
Ob/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT KATINS
FUEL CHAKACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCYt
PARTICIPATES
ILLINOIS POWER
WOOD RIVER NO t
EAST ALTON ILLINOIS
110 MW
COAL 2.9-3.2 PERCENT SULFUR
MONSANTO ENVIRO CHEN SYSTEMS
CATALYTIC OXIDATION
RETROFIT
10/72
99 PERCENT
S02
WATER HAKE UP
SLUUGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
85 PERCENT
•82.5/KW CAPITAL * S952tOOO OPERATING
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 16. SYSTEM START-UP
OCCURRED IN OCTOBER 1972. INITIAL AND SUBSEQUENT OPERATIONS WERE
ACCOMPANIED BY A NUMBER OF SEVERE MECHANICAL-RELATED PROBLEMS RESULTING
IN LIMITED OPERATIONS ANU EVENTUAL TERMINATION OF THE PROGRAM. TOTAL
OPERATION TIME WAS <»«»H HOURS IN 1972* 156 HOURS IN 1973 AND 55 HOURS IN
264
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THt WOOD RIVER POWER STATION OF THE ILLINOIS POWER COMPANY IS LOCATED NEAR EAST ALTON, ILLINOIS, NORTH OF ST. LOUIS. HISS-
OURI. THE NO. H BOILER IS A COMBUSTION ENGINEERING PULVERIZED-COAL-FIRLD 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 CONTEN*. 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 CATALY-
TIC 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 65 PERCENT FOR SULFUR DIOXIDE. INLET SULFUR DIOXIDE CONCENTRATIONS TO THE CATOX SYS.
TEM 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 TEMPERA-
TURE 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 TRIOXIOE IN THE GAS IS CONVERTED TO SUL-
FUR 1C 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 UF THE WOOD RIVER CATOX SYS-
TEM IS PRESENTED IN APPENDIX B.
THIS DEMONSTRATION SYSTEM, PARTIALLY FINANCED BY EPA, WAS STARTED UP IN SEPTEMBER 1972. WHILE THE MAIN PARTS OF THE UNIT
PERFORMED ACCEPTABLY, VARIOUS TROUBLES WITH ASSOCIATED EQUIPMENT 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 DEGREES BAUME ACID.
PERFORMANCE SUMMARY
THE WOOD RIVER SYSTEM WAS STARTED-UP IN SEPTEMBER 1972 BUT WAS SHUT DOWN ALMOST IMMEDIATELY (IN OCTOBER) TO CONVERT THE BURN-
ERS 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
197*. 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.
SEVERAL OTHER MAJOR PROBLEM AREAS ENCOUNTERED DURING THE INTERMITTENT OPERATION OF THIS REGENERABLE SYSTEM INCLUDED* FROZEN
265 " ' xx PEDCo ENVIRONMENTAL
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WOOD RIVEK NO. <» (CONTINUED)
DAMPERS ON REHEAT BURNERS. CRACKS IN THE TEFLON LINER ON THE ACID PUMP'S DISCHARGE HEADER. CRACKS IN THE REHEAT DUCTIN6. FALL OF
REFRACTORY BRICKS FRO« THE REHEATER BUHNER DOME, AND NEED FOR REINFORCEMENT OF THE STRUCTURE SUPPORTING THE HIGH TEMPERATURE FLUE
GAS DUCT TO THE CATALYTIC CONVERTER.
286
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DATE
10-8-72
10-9-72
10-10-72
10-13-72
10.11-72
10-30-72
10-31-72
7-21-73
7-22-73
7-23-73
7-21-73
7-25-73
7-26-73
7-17-73
7-28-73
7-29-73
HOURS
21
21
18
20
16
21
16
18
21
18
21
11
13
19
19
9
of*f.n*rxj*iG LOS
C/lTALfTJC OXIDATION SfSTE«
WOOD RIVER NO. <» - ILLINOIS POWER CO.,
1972 TO 1973
DATE
9-1-72
9-3-72
9-6-72
9-7-72
9-11-72
9-12-72
9-15-72
9-11-72
9-15-72
9-16-72
9-17-72
9-18-72
9-19-72
9-2H-72
10-6-72
10-7-72
HOURS
12
2*
21
2
2
16
21
21
2*
21
21
21
3
17
12
21
MOTE* THE OPERATION T1«C LOS DOES NOT INCLUDE INT
EHWITTNET SYSTEM OPERATION DURING 1971. SYSTEM
OPERATIONS FOR 1971 AMOUNTED TO 55 HRS. TO
TAL OPERATION TIME FOR 2.5 TRS. OF OPERATION WAS
657 HRS.
287
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TABLE 16
TERMINATED FGU SYSTEMS 06/77
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
10
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
KEY MEST FLORIUA
37 MW
OIL 2.4 PERCENT SULFUR
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
NEW
10/72
90 PERCENT
S02
WATER MAKE UP
SLUDGE DISPOSAL
PERCENT-ESTIMATED
OPEN LOOP 2.7 GPM/MW
UNSTABILIZEQ SLUjGE DISPOSED IN UNLINED POND
UNIT COST
* 21.6/KW CAPITAL COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION IN TABLE 16 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE OCTOBER 1972. THE FGD SYSTEM HAS
BEEN OUT OF SERVICE SINCE JANUARY 26,1975. 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 DID NOT OPERATE BECAUSE OF
REPAIRS TO BOILER TUBES THAT FAILED. RESTART IS SCHEDULED SHORTLY.
268
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BACKGROUND INFORMATION
ON
STOCK ISLAND PLANT
THE UTILITY BOARD OF THE CITY OF KEY WEST OWNS AND OPERATES A NEW 37-HW OIL-FIRED POWER BOILER. INSTALLED AT THEIR STOCK
ISLAND PLANT WHICH IS LOCATED DIKECTLY ADJACENT TO THE ISLAND CITY OF KLY WEST. THE BOILEK IS AN ERIE CITY BALANCED-DRAFT OIL-
FIRED UNIT THAT IS NOMINALLY RATED AT 37 «W AND CAN ACHIEVE HZ MW AT FULL PERFORMANCE. THE UNIT FIRLS NO. 6 RESIDUAL FUEL OIL
FROM VENEZUELA WITH SULFUR AND ASH CONTENTS OF 2.75 AND 0.05 PERCENT. RESPECTIVELY. THE UNIT'S GROSS HEAT RATE IS 11,300
BTU/KWH. INITIAL OPERATION OF THE UNIT COMMENCED IN NOVEMBER 1972.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A MULTIPLE TUBE MECHANICAL DUST 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 6AS 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 SEAWATCR.
ZURN DUSTRAXTORS ARE EMPLOYED FOR THE REMOVAL OF SULFUR DIOXIDE AND RESIDUAL PARTICIPATE FROM THE BOILER FLUE GAS. THE TWO
SCRUBBER MODULES ARE DESIGNED TO HANDLE A COMBINED TOTAL OF 126,9bO 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 SCRUBBERS 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 m INCHES WATER GAUGE IS THE
NORMAL 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 SLUUGE 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* TO e2 PERCENT AND 69 TO 73 PERCENT.
RESPECTIVELY. ACTUAL INLET AND OUTLET SULFUR DIOXIDE LOADINGS ARE 1300 TO 1500 PPM AND 300 TO 500 PPM. INLET AND OUTLET PARTI-
CULATE LOADINGS ARE 0.20 GR/SCF AND 0.05 GR/SCF.
289 '( ' ^ PEDCo ENVIRONMENTAL
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STOCK ISLAND (CONTINUED)
SYSTEM PERFORMANCE
START-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 I APPROXIMATELY 20 PERCENT).
INDUCED DRAFT FAN REPAIRS.
REPLACEMENT OF INTERNAL STAINLESS STEEL PARTS WITH MONEL COMPONENTS.
BOILER FOUNDATION AND BOILER TUBE PKOBLEMS.
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.
290
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STOCK ISLAND fCONTINUED)
OPERATING HOURS FGD SYSTEM
MONTH BOILER FGD SYSTEM AVAILABILITY COMMENTS
FGD SYSTEM WAS SHUT DOWN ON JANUARY 26, 1975, BECAUSE OF DAMAGED
DUCTWORK BAFFLES. SPRAY TREES AND OTHER STAINLESS STEEL PARTS HAVE
BEEN REPLACED WITH MONEL.
JUL. 75 FGO SYSTEM IS STILL OUT OF SERVICE BUT IS SCHEDULED FOR RESTART IN
EARLY OCTOBER.
AU6. 75 BOILEH HAS BEEN DOWN SINCE AUGUST 30 FOR REPAIRS OF THE INDUCED-DRAFT
FAN.
SEP. 75 FGD SYSTEM IS STILL OUT OF SERVICE. DATE OF SYSTEM RESTART IS
INDEFINTE.
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 HALL
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 FGO SYSTEM RESTART HAS BEEN DELAYED BECAUSE OF BOlLER.REi.ATED
APR. 76 PROBLEMS. DATE OF SYSTEM RESTART IS STILL INDEFINITE.
MAY 76 THE UTILITY REPORTED THAT REPAIRS AND MODIFICATIONS ARE NEARING
COMPLETION.
JUN. 76 SYSTLM RESTART IS EXPECTED SHORTLY.
291
PEDCo ENVIRONMENTAL
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STOCK ISLAND (CONTINUED)
OPERATING HOURS FGD SYSTEM
MONTH BOILER FGD SYSTEM AVAILABILITY COMMENTS
JUL. 76 ALL MODIFICATIONS TO THE SCRUBBING SYSTEM WHICH CAN BE MADE AT THE
AUG. 76 PRLSENT TIME HAVE BEEN COMPLETED. THE SCRUBBING SYSTEM HAS BEEN
SEALE.D 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. TENTATIVE RESTART DATE IS FEB. If 1977.
JAN. 77 DURING THIS REPORT PERIOD. STOCK ISLAND IS BEING
FEB. 77 REMOVED FROM THE OPERATIONAL SYSTEMS TABLE.
MAR. 77 IT HAS NOT YET BEEN DECIDED WHETHER THERE WILL
BE FUTURE FGD OPERATIONS AT THE UTILITY.
PEDCo ENVIRONMENTAl
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STOCK ISLAND PLANT
PERFORMANCE HISTORY
PERIOD TOTAL PERIOD (MRS)
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
HAR.
APR.
HAY
JUN.
JUL.
AUG.
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
MAR.
APR.
HAY
JUN.
JUL.
AUG.
72
72
72
72
73
73
73
73
73
73
73
73
73
73
73
73
7*
7*
7%
7«»
7*
7*
7«»
7*
696
7
-------
STOCK ISLAND PLANT
PERFORMANCE HISTORY
AUG.
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
MAR.
APR.
MAT.
JUN.
JUL.
AUG.
7*
7*
74
7*
74
75
75
75
75
75
75
75
75
840
672
672
840
672
672
840
672
672
840
672
672
840
641
36
672
840
672
672
642
672
672
840
672
672
160
SCRUBBER (HKS)
216
0
252
362
108
110
0
0
0
0
0
0
0
OPERABII
34
0
38
43
16
16
0
0
0
0
0
0
0
TOTAL
26880
20895
1579
PEDCo ENVIRONMENTAL
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TABLE K,
TERMINATED FGU SYSTEMS
06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICULATES
S02
11
POTOMAC ELECTRIC & POWER
OICKERSON NO. 3
OICKERSON MARYLAND
95 MM
COAL 2.0 PERCENT SULFUR
CHEHICO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/73
99.3 PERCENT
90 PERCENT
WATER HAKE UP
3.2 GPM/MW
SLUDGE DISPOSAL
UNIT COST
S70/KU CAPITAL
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE i& 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.
295
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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 DICKERSONt MARYLAND. ABOUT
SO MILES NORTHWEST OF WASHINGTON, O.C. THE STATION HAS 3 ELECTRIC GENERATORS, EACH RATED AT 190 MW. 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 l
-------
OICKCRSOH IVO. 3
FGD SYSTCH OPERATING HlSTOHV
OPERATING PERIOD COMMENTS
SEP. 73 PROBLEMS DURING THIS PERIOD RANGED FROM CORROSION LEAKS IN EXPANSION JOINTS TO PROBLEMS IN MATERIAL
10 HANDLING EQUIPMENT FEEDING AND SLAKING OF MGOt PLUGGING IN THE MGO MIX TANK AND SUCTION LINES TO THE
JAN. 71 MGO MAKE-UP PUMPS.
J*N» ™ MAINTENANCE AND MODIFICATIONS MERE PERFORMED ON THE SYTSTEM. THE MAJOR SYSTEM REVISION HADE DURING
TO THIS PERIOD MAS THE ADDITION OF A PRE-MIX TANK IN THE MGO SYSTEM.
APR. 70
APR. 7* 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 197<». ALL THE MGO AT DlCKERSON HAD BEEN USED
JUL. 74 AND A SILO PLUS THREE CARS HERE FULL OF MGS03.
AU6. 71 DURING THIS PERIOD THE SYSTEM GENERALLY OPERATED AT 75 PERCENT OF THE DESIGN GAS FLOM.
TO
DEC. 7*
JAN. 75 PROBLEMS DEVELOPED IN THE BUCKET ELEVATOR TRANSPORTING THE M6S03 FROM THE DRYER TO THE STORAGE SILO.
FEG. 75 UNIT NO. 3 HAS TAKEN OUT OF SERVICE FOR AN 6 TO 12 WEEK TURBINE OVERHAUL. THE SCRUBBER UAS INSPECTEDt
TO MAINTENANCE AND MODIFICATIONS MERE MADEt
JUL. 75
AUG. 75 THE F6D SYSTEM WAS RESTARTED IN AUGUST. STEAM MAS LOST TO THE MGO MIX TANK, RESULTING IN A VERY MOIST
PRODUCT FROM THE CENTRIFUGE. CAKING IN THE DRYER OCCURED. AT THIS POINT, THE UTILITY DECIDED TO TEST
ONLY THE FIRST-STAGE OF THE SCRUBBING SYSTEM, TAKING GAS AHEAD OF THE PgECIPITATOR. FGD OPERATION AT
DlCKERSON TERMINATED AT THIS POINT.
297
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TABLE; i
TERMINATED F6U SYSTEMS
06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F60 VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICULATES
12
PUBLIC SERVICE CO OF COLORADO
VALMONT NO. 5
VALMONT COLORADO
so nw
COAL 0.72 PERCENT SULFUR
UOP/PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
RETROFIT
10/7*
95 PERCENT
S02
05 PERCENT
WATER HAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
UNSTABILIZED SLUoGE DISPOSED IN LINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION IN TABLE 16 OF THIS REPORT. THIS FGD
SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 1V7"». THE FGD SYSTEM
TERMINATED AT THIS STATION IS AN EXPERIMENTAL UNIT, ORIGINALLY DESIGNED
BY UNIVERSAL OIL PRODUCTS FOR PARTICIPATE REMOVAL ONLY. ONE OF THE TWO
PARALLEL SCRUBBING MODULES MAS CONVERTED TO LIMESTONE SCRUBBING FOR
EXPERIMENTAL PURPOSES ONLY.
298
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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. 5 IS A COAL-FIRED UNIT 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 BTU/LB WITH ASH CONTENT IN THE 6 TO
7 PERCENT RANGE AND SULFUR CONTENT LESS THAN 1 PERCENT.
THE F6D SYSTEM BEING TESTED AT THIS STATION IS AN EXPERIMENTAL UNIT ORIGINALLY DESIGNED BY UNIVERSAL OIL PRODUCTS FOR PANIC-
ULATE REMOVAL ONLY. THIS TCA UNIT CONSISTS OF TWO PARALLEL MODULES WITH A COMBINED CAPABILITY OF TREATING APPROXIMATELY 90
PERCENT OF THE TOTAL FLUE GAS LOAD OR THE EQUIVALENT OF APPROXIMATELY 100 «W GENERATING CAPACITY (50 HW PER MODULE}. THIS SYSTEM
WAS COMPLETED AND OPERATIONAL IN 1971 AND RAN UNTIL OCTOBER 197*». PARTICULATE REMOVAL EFFICIENCY WAS MEASURED AT 95 PERCENT,
SULFUR DIOXIDE REMOVAL EFFICIENCY WAS «5 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 CONTKOL 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 NOT MATERIALIZE. SCALE BUILDUP CONTINUED AND AVAILABILITY DECREASED. TESTS DURING THE PH CONTROL PROGRAM SHOWED
PARTICULATE REMOVAL EFFICIENCY AT 95 PERCENT. SULFUR DIOXIDE REMOVAL EFFICIENCY INCREASED TO 85 PERCENT, AND AVAILABILITY DROPPED
TO 70 PERCENT. THE UNSTABILIZED SLUDGE GENERATED DURING THIS OPERATION MAS PUMPED TO A LINED POND. THE OPERATIONAL DATA GENER-
ATED FROM THE LIMESTONE MODIFICATION PROGRAM ARE PRELIMINARY. BASED UPON A 4.5 MONTH TESTING PROGRAM.
299
" ^ PEDCo ENVIRONMENTAL
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VALMONT NO. 5
OPERATING HOURS F6D SYSTEM
RONTH BOILER FGD SYSTEM OPERABlLlTY (X) COMMENTS
SEP. 75 THIS FACILITY HAS BEEN INACTIVE SINCE SEPTEMBER 1. 1975. BECAUSE OF A
OCT. 75 TURBINE GENERATOR FAILURE. THt UNIT IS SCHEDULED TO GO ON LINE AGAIN
NOV. 75 IN DECEMBER 1975. THIS UNIT IS STILL INACTIVE BECAUSE OF A BOILER
DEC. 75 OVERHAUL. THE SCNUBBER/ABSORBEK TRAIN IS AVAILABLE AND WILL BE COUPLED
INTO THE SYSTEM WHEN THE BOILER GOES BACK ON-LINE.
JAN. 76 THE BOILER OVERHAUL HAS BEEN COMPLETED. THE UNIT IS AVAILABLE IN THE
FEB. 76 PARTICULATE REMOVAL MODE ONLY. THE UTILITY IS SUSPENDING RESUMPTION
OF THE LIMESTONE MODIFICATION OPERATION FOR AN INDEFINITE PERIOD.
MAR. 76 THE EXPERIMENTAL LIMESTONE SCRUBBING PROGRAM HAS INACTIVE DURING THE
APR. 76 REPORT PERIOD. RESUMPTION OF THE PROGRAM IS CONSIDERED INDEFINITE AT
MAY 76 THE PRESENT TIME.THE EXPERIMENTAL LIMESTONE SCRUBBING PROGRAM REMAINED
JUN* 76 INACTIVE DURING THE REPORT PEKIOD. PRESENT PLANS CALL FOR THE RESUMP-
JUL. 76 TION OF THIS PROGRAM SOMETIME IN THE FALL OF 1976. THE TCA UNIT IS
AUG. 76 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.
SEP. 76 NO CHANGE IN STATUS. THE RESUMPTION OF THE EXPERIMENTAL LIMESTONE
OCT. 76 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 30H SS PARTS WITH 316 SS.
NOV. 76 THE UTILITY HAD NO CHANGE IN STATUS TO ANNOUNCE FOR THE
DEC. 76 CURRENT REPORT PERIOD.
300
PEDCo ENVIRONMENTAL
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VALMONT NO.5 (CONTINUED)
OPERATING HOURS FGD SYSTEM
MONTH BOILER FGD SYSTEM OPEHABILITY (X) COMMENTS
PARTICULATL-REMOVAL OPERATIONS ARE STILL IN PROGRESS. THE CONTINUATION
OF ANY FUTURE FGD OPERATIONS IS CONTINGENT UPON REGULATORY DECISIONS.
301
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TABLE; i&
TERMINATED FGU SYSTEMS 06/7T
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
13
SOUTHERN CALIFORNIA EDISON
MOHAVE NO 1A
LAuGHLIN NEVADA
170 HW
FUEL CHARACTERISTICS COAL 0.5 - 0.6 PERCENT SULFUR
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICIPATES
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
RETROFIT
11/7H
93 PERCENT
S02
WATER HAKE UP
95 PERCENT
0.92 GPM/MW
SLUUGE DISPOSAL
UNIT COST
NOT AVAILABLE
OPERATIONAL
EXPERIENCE
THIS EXPERIMENTAL MODULE STARTED UP OCT. 31. 197* AND OPERATED WITH AN
AVAILABILITY OF fc0.i»* THROUGH FOUR MONTHS OF TESTING. TEST HAVE BEEN
COMPLETEo« AND THE F&O SYSTEM WAS SHUT DOWN INDEFINITELY ON JULY 2, 1975.
NEVADA ASSEMBLY BILL NO. ?oe HAS PLACED A TWO YEAH MORATORIUM ON THE
ENFORCEMENT OF THE COMPLIANCE SCHtDULE FOR THIS STATION. FURTHER FGO
ACTIVITIES WILL BE DEPENDENT ON FUTURE LEGISLATION.
302
PEDCo ENVIRONMENTAL
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TABLE 16
TERMINATED FGU SYSTEMS
Ob/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY.
PARTICIPATES
It
SOUTHERN CALIFORNIA EDISON
HOHAVE NO. 2A
LAUGHLIN NEVADA
160 MM
COAL 0.5-0.6 PERCENT SULFUR
SCE/STEARNS KOGER
LIME SCRUBBING
RETROFIT
11/73
93 PERCENT
S02
WATER PAKE UP
SLUDGE DISPOSAL
95 PERCENT
1.0 6PH/HU
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
NOT AVAILABLE
SINCE STARTUP OF FORMAL TEST PROGRAM ON JANUARY 16. 197H« AND UP TO DEC-
EMBER 20.197U. THIS EXPERIMENTAL HORIZONTAL MODULE OPERATED 5260 HRS.
WITH AN OVERALL AVAILABILITY OF 77.«» PERCENT, S02 REMOVAL WAS 90 PERCENT
IN FLUE GAS TO SIMULATE CONDITIONS FROM COMBUSTION OF HIGH-SuLFUK COAL.
THIS FGD SYSTEM OPERATED FROM NOVEMBER 1973 UNTIL FEBRUARY 1975. THE
UTILITY HAS NO CURRENT PLANS FOR FGD AT ANY OF ITS PLANTS.
303
PEDCo ENVIRONMENTAL
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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 MQHAVE GENERATING STATION OF THE SOUTHERN CAL-
IFORNIA 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 NW AND EACH BURNING A WESTERN, LOW.
SULFUR COAL WITH A HEATING VALUE OF 11.900 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
-------
MOHAVE NO. 1A - VEKTICAL TEST MODULE
OUTAGE TIME HISTORY* NOVEMBER 2. 197«t TO JULY 2. 1975
REASON TIME (HR1
1. REPAIR 6RIDS AND REDISTRIBUTE TCA BALLS 710
2. CLEAN SCALE FROM SCRUBBER INTERNALS 3«»«»
3. REPAIR/REPLACE PLUGGED NOZZLES 153
«. REPAIR LEAKS IN TRAP-OUT TRAY 120
5. REPAIR/REALIGN PPA PACKING 65
6. CORRECT BOOSTER FAN TRIP PROBLEMS 72
7. CONDUCT INSPECTIONS FOR EXTENDED OPERATIONS
-------
MOHAVE NO. 2A - HORIZONTAL TEST MODULE
OUTAGt TIME HISTORY* JANUARY l6t 197* TO FEBRUARY 9. 1975
KEASON TINE (HR)
i. MODIFY AND REPAIR PLASTIC OEMISTER BLADES 503
2. CORRECT BOOSTER FAN BALANCE PROBLEMS 317
3. PUMP REPAIR 256
4. SPRAY NOZZLE REPLACEMENT 236
5. MODIFY 6AS INLET FLOW DISTRIBUTION 162
6. REPAIR HOPPER LEAKS 135
7. REMOVE HARDHAT FROM THICKENER 82
8. MODIFY SLAKING MATER FOR SCALE PREVENTION 45
9. CONDUCT INSPECTIONS FOR EXTENDED OPERATIONS 19
10. TOTAL OUTAGE TIME 1757
TOTAL OUTAGE TIME* 1757 HOURS
TOTAL CALENDER TIME* 9328 HOURS
TOTAL OPERATING TIME* 7571 HOURS
PERCENT AVAILABILITY* 81.16*
306
PEDCo ENVIRONMENTAL
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TABLE 16
TERMINATED FGU SYSTEMS
06/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY.
P ARTICULATES
15
TENNESSEE VALLtY AUTHORITY
SHAWNEE NO. IOC
PADUCAH KENTUCKY
10 MW
COAL 2.9 PERCENT SULFUR
TENNESSEE VALLEY AUTHORITY
LIRE/LinESTONE SCRUBBING
RETROFIT
EXPERIMENTALLY CONTROLLED
S02
EXPERIMENTALLY CONTROLLED
WATER HAKE UP
EXPERIMENTALLY CONTROLLED
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 16. THIS
FGD SYSTEM HAS BEEN 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 HAS PERMANENTLY TERMINATED IN
JULY 1973.
307
PEDCo ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
SHAWNEE NOS. 10A, 108, AND IOC
IN JUNE 1968i 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-FIRED BOILER AT THE TVA SHAWNEE POWER STATION. PAOUCAH, KENTUCKY. TVA IS THE CONSTRUCTOR AND FACILITY
OPERATOR AND THE BETCHEL CORP. IS THE MAJOR CONTRACTOR AND TEST DIRECTOR.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE TREATING PART OF TH£ 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* u A VENTURI WITH A SPRAY TOWER AFTER ABSORBER* 21 A
TURBULENT CONTACT ABSORBER (TCA) AND 3) A MARBLE-BED ABSORBER. THE VENTURI SYSTEM, MANUFACTURED BY CHEMICAL CONSTRUCTION CO.,
CONTAINS A" 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 A"D VARIATIONS OF SCRUBBER INTERVALS AND PIPING COULD BE READILY EMPLOY-
ED FOR EACH SCRUBBER SYSTEM. EACH SYSTEM CAN TREAT APPROXIMATELY 30,000 ACFM OF FLUE GAS AT 300 F CONTAINING 1600 TO *000 PPM OF
SOg 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.
308
PEDCo ENVIRONMENTAL
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TABLE 16
TERMINATED FGU SYSTEMS
Ob/77
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OH RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
S02
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
16
UNION ELECTRIC CU.
MEREMAC NO. 2
ST. LOUIS COUNTY MISSOURI
1HO MW
COAL 3.«» PERCENT SULFUR
COMBUSTION ENGINEERING
LlMESTONt INJECTION/WET SCRUB
RETROFIT
3/68
99 PERCENT
63 PERCENT
CLOSED LOOP
UNSTABILIZEO SLUuGE DISPOSED IN UNLINED POND
THE FIRST COMMERCIAL SCRUBBER APPLICATION ON A UTILITY COAL-FIRED BOILER
OCCURRED AT THIS STATION IN EARLY 19(iS. THE SCRUBBING STRATEGY INCLUDED
LIMESTONE INJECTION INTO THE FURNACE WITH AN EXISTING C"AL PULVERIZER AND
TAIL-END SCRUBBING WITH THE CALCINED REAGENT IN TWO MARBLE-BED ABSORBERS.
THIS FULL-bCALE EXPERIMENTAL SCRUBdING PROGRAM WAS EVENTUALLY TERMINATED
AND THE INSTALLATION WAS ABANDONED. PROBLEMS ENCOUNTERED INCLUDED BOILER
TUBE FOULING BECAUSE OF CLOSE TUBE SPACING. WIDESPREAD SCALING. SEVEHL
CORROSION, INEFFICIENT MIST ELIMINATOR AND PROBLEMS WITH WASTE DISPOSAL
309
PEDCo ENVIRONMENTAL.
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310
PEDCo ENVIRONMENTAL
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TABLE 17
TOTAL OF FGD MEGAWATT CAPACITY BY YEAR
311
PEDCo ENVIRONMENTAL
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312
PEDCo ENVIRONMENTAL
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-------
TABLE 17
TOTAL OF F6D MEGAWATT CAPACITY BY YEAR
YEAK
1960
1972
1973
1971
1975
1976
1977
1978
1979
1900
1901
1902
1903
190*
1905
1906
1907
UNDEFINED
MtGAUATTS
125
«»27
1*10
250
1051
2200
6751
7330
7361
7103
4965
2303
3735
1250
500
500
350
2075
313
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 45246
-------
APPENDIX A
FGD SYSTEMS ECONOMICS
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 452<4e
-------
A-2
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
APPENDIX A. FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPMT
PLANT
UNITS
TOTAL CAPACITY, l*»
Arizona Public Service
Cholla Electric Generating
Station
No. 1
115
Columbus I So. Ohio Electric
Conesvllle Generating Station
No. 5
400
Cuumjnmialth Edison
Hill County Station
No. 1
167
PROCESS
STATUS
START-UP DATE
Lines tone
Operational
10/73
Line
Operational
1/77
Lines tone
Operational
2/72
REPORTED CAPITAL
COSTS,
J MILLION
6.5S5
15.27
15.542
*/KM
57.0
37.90
113
REPORTED OPERATING
COSTS.
J ANNUAL
7.765
3.985 MM
MILLS/KWH
2.20
5.61
13.06
COMMENTS
1. Capital cost figure Includes the venturl scrubbers (2)
for participate control. This figure represents
total expenditures made by the utility through 1973.
2. Capital cost figure does not Include limestone prep-
aration, sludge handling facilities and interest on
capital during construction.
3. Additional costs incurred by the system supplier have
not been reported.
4. The operating cost figure Includes operating and main-
tenance expenditures only.
1. The capital cost figure Includes direct costs only.
2. The capital cost figure Includes two scrubber nodules,
all ancillary equipment, sludge disposal system, site
preparation, and construction costs. Indirect* are
not Included.
3. Annual operating costs are estimated at a load factor
of 39.5t.
4. Annual costs Include capitalization, raw materials,
waste disposal, maintenance, labor, and utilities.
5. All cost estimates are given In 1976 dollars.
1. The capital cost figure includes the venturi scrubbers
for particulate control.
2. The t/kU figure Is based upon the unit's maximum net
generating capacity with the FGD system, 137 MU.
3. The annual operating cost figure Is based on a
system lifetime of 14 years. Sludge treatment costs
include handling to an off-site disposal area. Jhe
figure provided Is the cost to own and operate the
scrubbing system for 1975.
4. Unit load capacity factor for 1975 Mas 49.41.
Note: N/A Indicates figures are not available.
A-3
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
Piwrr
IMtTC
UnlTS
TOTAL CAPACITY. MU
Duquesne Light
F.R. Phillips Station
NOS. 1 to 6
410
Elrama Station
Nos. 1 to 4
510
Kansas City Power 1 Light
La Cygne Power Station
No. 1
820
Kansas Power & Light
Lawrence Energy Center
Nos. 4 ! 5
525
PROCESS
STATUS
START-UP DATE
Line
Operational
7/73
line
Operational
10/75
Limestone
Operational
2/73
Limestone
Injection &
Met Scrubbing
Terminated,
Operational
12/68 & 11/71
REPORTED CAPITAL
COSTS.
1 MILLION
40
42
53.2
3.5
S/KH
103
93
63.9
7
REPORTED OPERATING
COSTS.
J ANNUAL
32 MM
1.79 m
N/A
MILLS/KWH
6.0
0.94
N/A
COMMENTS
1. Total capital cost figure for Phillips Includes
expenditures of $32 million through 197S 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 addi-
tional $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 nay 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 494 MM.
3. Annual operating cost figures of 6 mllls/kWh Is based
upon the combined operating costs for the Phillips and
Elrama stations when full SO? compliance 1s achieved.
This amounts to approximately $32 million annually.
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.
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 have been and are now being replaced with
venturi rod scrubber and spray tower systems utilizing
a limestone-based scrubbing slurry.
Lawrence No. 4 rod scrubber and spray tower limestone
scrubbing system was placed in service Jan. 1977. The
original Injection unit has been dismantled.
4. Lawrence No. 5 rod scrubber and spray tower scrubbing
-*ys4«m Is now being erected. The original Injection
/VGruT^svstiH In service. Start up of the new system
/£Smi PEOC^o. JEJSIViRQrslMENTAL
Note: N/A indicates figures are not available.
CINCINNATI. OHIO
i-4
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Kentucky Utilities
Green River Power Station
No*. 1, 2 » 3
64
Louisville Gas S Electric
One Run Power Station
No. 4
178
Louisville Gas S Electric
Paddy Run Power Station
No. 6
65
Montana Power Co.
Colstrip Plant
Nos. 1 » 2
PROCESS
STATUS
START-UP DATE
Lime
Operational
9/75
Lime
Operational
8/76
Lime
Operational
4/73
Fly Ash/Lime
Operational
10/75 a 7/76
REPORTED CAPITAL
COSTS,
$ MILLION
3.996
10
3.7
3?. 663
t/KH
63.44
50
57
45. 3Z
REPORTED OPERATING
COSTS,
$ ANNUAL
N/A
905,000
1.185 MM
MILLS/KWH
2.0
N/A
2.5
0.26
COMMENTS
1. The capital cost figure for this turnkey Installa-
tion does not include the utility's expenditures
for engineering, operator training, and other in-
direct cost factors.
2. The operating cost figure includes operating and
maintenance expenditures only.
1. The total Installed capital cost Is an estimated
figure that includes the costs for lime handling and
sludge disposal facilities.
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 601 unit load factor and a 151 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 by the
utility.
1. The total installed capital cost figure is an es-
timated value that includes the venturi scrubbers
installed for particulate 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.
Note: N/A Indicates figures are not available.
A-5
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MH
Nevada Power Co.
Reid Gardner Station
Nos. ] 4 2
250
Northern Indiana Public Serv.
O.H. Mitchell Station
No. 11
115
Northern States Power
Sherbume County Generating
Plant
Nos. 1 » 2
1420
Pennsylvania Power
Bruce Hansfleld Plant
Nos. 1 * 2
1670
PROCESS
STATUS
- START-UP DATE
Sodium Carbonate
Operational
4/74
Hel Iran-Lord
Operational
6/77
Limestone
Operational
5/76 ft 5/77
Lime
Operational,
Construction
4/76 8 10/77
REPORTED CAPITAL
COSTS.
S MILLION
11
14.825
60
213.200
S/KU
44
129
44
127.66
REPORTED OPERATING
COSTS.
$ ANNUAL
1.2 MM
6.006 MM
3.77 MM
10.644 MM
MILLS/KHH
N/A
8.1
2.7
COMMENTS
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
annualized for each unit.
1. The capital figure includes Interest during con-
struction and overhead charges.
2. Reported operating cost figure 1s a total annual i zed
cost value that includes:
0 Operation and maintenance costs.
• Anti-oxidant agent costs.
Fixed charges are calculated for a 10-15 year plant
lifetime (26X of $14,825 MH). Assume an annual unit
load factor of 73.5'-.
1. The total Installed capital cost figure includes
direct costs only, indirect costs are excluded.
2. The total cost figure applies to 1976/1977 Installa-
tion and does not include escalation factors.
3. The annual operating cost figure is an estimate that
applies to 1977 operations at an 80% unit load factor.
Included In this figure are direct and indirect costs.
4. The S/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
for each system.
1. All cost figures presented are estimates provided
by the utility.
2. The total Installed capital cost figures includes
all direct and Indirect costs plus escalation factors.
3. The cost of the ventuH 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//Tndir>cX costs are not included in the annual opera-
A&£4Wt*BE:DCo ENVIRONf*
Note: N/A indicates figures are not available.
CINCINNATI. OHIO 45346
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY. HH
Pennsylvania Power
(Continued)
Philadelphia Electric
Eddys ton Generating
Unit No. 1A
316
Tennessee Valley Authority
Widows Creek Steam Plant
No. 8
550
PROCESS
STATUS
START-UP DATE
Magnesium Oxide
Operational
9/75
Limestone
Construction
5/77
REPORTED CAPITAL
COSTS,
S MILLION
20.0
56.284
S/KU
63
102.33
REPORTED OPERATING
COSTS.
J ANNUAL
N/A
5.226 MM
MILLS/KWH
N/A
1.72
CriMMfNTS
7. Operating cost fiq'jre includes maintenance costs.
8. All cost figures arr 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 paniculate scrubbers and one second
stage SO? absorber. Also included are the SO? re-
covery equipment at the plant, site improvements and
access roads, engineering and contractor's fees and
interest on capital during construction.
3. The costs for the magnesium oxide regenerating
facilities are not included in the total cost figure.
1. The total Installed capital cost figure is an estimate
that includes all e»penditures made by February 1977.
2. Included in the total installed 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 partic-
ulate removal costs. Amortization of investment is
not included.
6. The mills/kith figure derived from the operating ex-
penditures is the total annual cost esti»>ates (direct
and indirect) *t a unit capacity fac'pr nf 63*.
Note: N/A Indicates figures are not available.
A-7
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 45246
-------
A-8
PEDCo ENVIRONMENTAL
CINCINNATI, OHIO
-------
APPENDIX A. FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY. MW
Alabama Electric Coop.
Tombigbee Power Station
Nos. 2 S 3
450
Basin Electric Power Coop
Laramie River Station
Nos. 1 and 2
1100
Big Rivers Electric Coop
Reid Stean Station
No. 2
250
Boston Edison Company
Mystic Power Station
!«o. 1
155
PROCESS
STATUS
START-UP DATE
Limestone
Construction
3/78 ft 3/79
Limestone
Contract awarded
4/80 t 10/80
Line
Contract
Awarded
1979
Magnesium Oxide
Terminated
4/72
REPORTED CAPITAL
COSTS,
$ MILLION
40.464
75
16
9.510
t/KU
89.92
68.2
64
63.4
REPORTED OPERATING
COSTS,
$ ANNUAL
240,323
615,000
NILLS/KWH
0.77
3.0
COMMENTS
1. Capital cost figures include upstream participate con-
trol equipment (ESP's).
2. 701 of the flue gas capacity 1s scrubbed.
3. Annual operating costs are calculated for 1978 with a
60" boiler capacity factor.
4. Included in the operating costs are all direct costs
minus malntainence and solid waste disposal costs.
5. Indirect costs are note Included in the operating cost
figure provided.
1. The reported capital cost figure provided in the table
applies to the total installed cost for both double-
loop wet limestone scrubbing systems.
2. The total revenues of the contract awarded to
Research-Cottrel 1 is expected to exceed S35.
3. Breakdown of the capital cost is not available.
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 nodular
pre-wired control rooms.
3. All figures are reported In 1976 dollars.
4. Escalation factors, costs, and indirect costs are not
included.
1. All cost figures are reported for the project com-
pletion date of 1974.
2. The total installed capital cost of the Runford cal-
cination facility was approximately S4.5 m.
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. Ths^ESJ^of "Bke-up "wqnesium oxide (J150/T) is not
/TiS\ papror-r^ FTMWIRON
No»«: N/A indicates figures are not available.
A-9
CINCINNATI. OHIO 45246
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, HW
Boston Edison Company
(Continued)
Central Illinois Light Co.
Duck Creek Power Plant
Ho. 1
400
Central Illinois Public Serv.
Newton Station
No. 1
575
Colorado Ute Electric
Craig Station
Nos. 1 & 2
900
PROCESS
^STATUS
START-UP DATE
Limestone
Operational,
Construction
8/78
Double Alkali
Limestone
Contract
Awarded
Spring, 1979
REPORTED CAPITAL
COSTS,
t MILLION
36
108.5
105
$/KH
90
189
117
REPORTED OPERATING
COSTS.
$ ANNUAL
N/A
15 m
MILLS/KHH
2.7
COMMENTS
6. 3.0 mills/kWh is an estimate for total operation and
maintenance costs, including calcination.
7. BECO and EPA each subsidized approximately SOT of the
costs of the demonstration program. Chemico also
underwrote some of the program costs.
1. The capital cost figure is an estimate of e«pendi-
tures, including $4.0 MH for the ESP, and the cost of
the limestone milling and waste disposal facilities.
2. One module has been completely installed and tempo-
rarily operated from September 1976 to April 1977.
Full system operation is scheduled to commence in
August 1978.
1. The capital cost figure is an estimate covering all
the scrubber unit operation areas.
2. Capital figure is quite high because Of the deliber-
ate overdesign and redundancy incorporated into the
system for achievement of reliable operations.
3. The $/kH figure is calculated on the unit's net
generating capacity of 575 MM. 3T of the unit's net
generating capacity is required to Dower the scrubber
plant.
1. The total capital cost figure is an estimate provided
by the utility that does not include reagent prepara-
tion and sludqe disposal facilities. This figure is
based upon a non-reqenerable SO? scrubbing system
(lime/limestone).
2. The total revenues of the contract awarded to Peabody
Engineered Systems for two limestone slurry spray
tower scrubbing systems is expected to exceed $60 MM.
3. Electrostatic precipitators are included in the
capital cost fiqure.
4. The annual operating cost figure is a preliminary
utility estimate also based upon the installation of
a nonreqenprable 50j scrubbing system.
5. The mills/kWh fiqure is based upon a 70" load factor
Note: N/A indicates figures are not available.
A-10
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MM
Commonwealth Edison
Powerton Station
No. 51
425
Gulf Power
Scholz Steam Plant
Nos. 1 » 2
23
Gulf Power
Scholz Steam Plant
No. 2
20
Illinois Power
Hood River Power Station
No. 4
110
PROCESS
STATUS
START-UP DATE
Limestone
Construction
12/79
Dilute Acid.
Terminated
2/75
Dry Adsorption
Terminated
2/76
Catalytic
Oxidation
Terminated
10/72
REPORTED CAPITAL
COSTS,
1 MILLION
50
3.0
N/A
8.5
$/KW
117.65
130
N/A
82.5
REPORTED OPERATING
COSTS,
$ ANNUAL
N/A
N/A
952.000
MILLS/KWH
8.70
N/A
N/A
COMMENTS
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:
0 2.7 mllls/kUh for operation and maintenance.
° 6.0 mills/kWh for auxiliary power requirements.
0 Scrubber life span is estimated for an annual
usage rate of 148,000.000 kWh. This is equivalent
to approximately $900.000 annual for auxiliary
power consumption.
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 JAW figure is based upon the system's net
generating capacity of 103 NW.
3. ESP cost is included since upstream fly ash removal
is a necessary feature of this regenerate system.
4. The annual cost figure is an estimate representing
system running cosU only. Excluded art capital
charges and a credit for product. This figure trans-
lates into a value of $3.«6 per ton of coal consumed.
Note: N/A Indicates figures are not available.
A-ll
PEDCo ENVIRONMENTAL-
CINCINNATI. OHIO 45246
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MM
Indianapolis Power & Light
Petersburg Generating Station
No. 3
530
Kansas City Power ft Light
Hawthorn Power Station
Nos. 3*4
525
Key West Utility
Stock Island Power Plant
37
" PROCESS
STATUS
START-UP DATE
Lines tone
Construction
9/77
Limestone
Injection ft
Net Scrubbing
Terminated
11/72
Limestone
Terminated
10/72
REPORTED CAPITAL
COSTS.
$ MILLION
36.885
5.32
0.750
S/KM
69.9
19
20.7
REPORTED OPERATING
COSTS,
$ ANNUAL
HHLS/KWH
2.2-2.5
0.7
COMMENTS
1. Capital cost figure Includes the ESP's Installed
upstream of the scrubber plant for primary particu-
late control ($4.083 MM); scrubbers, pumps, fans.
reheat and all auxiliary equipment ($25.9 MM); sludge
stabilization, fixation, and disposal ($3.5 to $4.0
MM); and total Indirect costs ($1.616 MM).
2. Interest during construction 1s not Included.
3. FGO design and costs are based upon 4.51 sulfur coal.
which 1s the maximum allowable sulfur content for the
scrubber plant.
1. This figure Is unreallstlcally low because these
installations were experimental In nature and were
heavily underwritten by the system supplier.
2. This system has been terminated as limestone-based
system and converted to a wet lime scrubbing system.
The costs of additional slakers, feeders, and other
necessary equipment are not Included.
3. Sludge disposal facilities are not Included In the
total cost figure.
4. The annual operating cost figure does not Include
fixed costs.
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 unreallstlcally 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:
t
° Capitalization rate of 101; no taxes, no Insurance.
° Maintenance cost of 5T 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.
A-12
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY. MM
Louisville Gas t Electric
Cane Run Power Station
No. 5
183
Louisville Gas ft Electric
Cane Run Power Station
No. 6
277
Minnkota Power Coop.
M.R. Young Station
No. 2
450
Montana Power Co.
Colstrip Plant
Nos. 3*4
Pacific Power t Light
Idaho Power Company
Jin Bridger Plant
No. 3
PROCESS
STATUS
START-UP DATE
Lime
Construction
12/77
Double Alkali
Contract Awarded
2/79
Fly Ash/Line
Construction
8/77
Fly Ash/Lime
Contract
Awarded
7/80 * 7/81
Sodium Carbonate
Contract
Awarded
9/79
REPORTED CAPITAL
COSTS,
$ MILLION
12
16.3
44
N/A
50-60 HH
J/KW
66
58.9
98
N/A
110-120
REPORTED OPERATING
COSTS.
$ ANNUAL
7.3 MM
N/A
MILLS/KWH
N/A
COMMENTS
1. The total installed capital cost is an estimated
figure that includes the costs for Hme 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 opertions. $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 total installed capital cost figure represents
an estimated value for the unit's entire emission
control system. Including an upstream ESP for pri-
mary participate 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.
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 figures are estimated
values provided by the utility.
2. The system will be comprised of 3 parallel absorp-
tion towers each handling 33.3* of the flue gas
capacity.
3. The reagent, a nominal 30 wt. t Na;C03 purge solu-
tion, will be purchased from a local soda ash
manufacturer.
Note: N/A indicates figures are not available.
A-13
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 45246
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MM
PotoMc Electric Power
Dlckerson Station
No. 3
190
Public Service of New Mexico
San Juan Station
No*. 1 i 2
715
S«1t River Project
Coronado Station
Nos. 1 t 2
700
South Carolina Public Service
Mlnyah Generating Station
No. 2
280
PROCESS
- STATUS
START-UP DATE
Magnesium Oxide
Terminated
9/73
Hellmn Lord
Construction
11/77
Limestone
Contract
Awarded
4/79 & 4/80
Limestone
Construction
6/77
REPORTED CAPITAL
COSTS,
t MILLION
6.5
89.510
N/A
6.189
S/KW
68
127.87
N/A
24.35
REPORTED OPERATING
COSTS,
t ANNUAL
990,000
7.236 K>
N/A
MILLS/KHH
N/A
5.0
N/A
COMMENTS
1. The total Installed capital cost figure 1s an estimate
provided by the utility in 1973.
2. This figure does not Include regeneration and add
plant costs.
3. The operating cost figure 1s 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 esti-
mated value that applies to 1977 installation. In-
cluded are all direct and Indirect costs plus an
escalation factor.
2. The J/kW figure Is based on a net generating capacity
of 700 MW.
3. The costs of the venturl scrubbers for participate
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 mllls/kUh 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.
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 SO? removal. SO? removal efficiency is
69*.
2. The total Installed capital cost figure is an esti-
mated value.
Note: N/A indicates figures are not available.
A-14
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY. MU
South Carolina Public Service
(Continued)
So. Indiana Gas * Electric
A. 8. Brown Station
No. 1
250
Southern Mississippi Power
R.O. Morrow Generating Plant
Nos. 1 S 2
360
Wisconsin Power ( Light
Columbia Plant
No. 2
527
PROCESS
STATUS
START-UP DATE
Double Alkali
Contract Awarded
4/79
Lilies tone
Construction
11/77 & 6/78
lime/Limestone
Requesting/
Evaluating
Bids
1/80
REPORTED CAPITAL
COSTS,
$ MILLION
8.0
18.847
30
S/KH
52.35
57
REPORTED OPERATING
COSTS,
$ ANNUAL
4.2 MM
MILLS/KWH
COMMENTS
3. Total direct and indirect costs for the ESP provided
for primary participate control upstream of the
scrubbers are included (11. 686 MM).
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. FHC was awarded a contract in excess of 18 million
for the design and installation of a double alkali
scrubbing system.
2. Total expenditures for this new plant are estimated
at 1134 MM.
3. Excluded are all other direct and indirect capital
cost factors.
4. The Initial capital Investment and annual! zed costs
are estimated to be 20. to 30 percent and 10 to 15
percent less, respectively, than competing lime and
limestone systems.
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. ($5.4 MM
equipment costs for two units), scrubbers and ancil-
lary equipment, fans, construction field expenses,
and Interest during construction.
3. Sludge handling and disposal facilities are not in-
cluded in the total cost figure.
1. The total installed capital cost figure Is a pre-
liminary estimate that includes the scrubbers and
ancillary equipment, erection, disposal piping and
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.
A-15
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
A-16
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO -45246
-------
APPENDIX B
FGD PROCESS FLOW DIAGRAMS
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 45246
-------
B-2
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
I IOUVH
Choila No. 1 FGD System: General Flow Diagram.
B-3
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 45246
-------
HIST
ELIMINATOR
RILEY
VENTRI-SORBER
SCRUBBER
LIMESTONE
SLURRY
t 1
RECYCL
E TANK
PW
ELECTROSTATIC
PRECIPITATOR
VVV
SCRUBBER
I 0 BOOSTER FAN
SETTLING POND
FLUE GAS
FROM
BOILER
RECYCLE
TO FGD
Simplified Process Diagram of the D
B-4
eek No. 1 FGD Module.
PEDCo ENVIRONMENTAL
CI MCI MM ATI. OHIO -45246
-------
CLEAN GAS
SERVICE
WATER
FLUE GAS
TO BY PASS
TT DUCT
LIME
Y
WEIGHT FEEDER
w
)ER
j '
?L^ ?
LIME SLAKING
AND DILUTION
I STEAM I
NOT NE"CE"sS~AR"Y~I?~SufF7ciENT
REHEAT GAS IS AVAILABLE
L-W
MAKE UP
SLURRY TANK
WASTE
DISPOSAL
SYSTEM
Conesville No. 5 F6D System: Process Flow Diagram.
B-5
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 452.46
-------
Will County No. 1 FGD System: Gen
B-6
ISHfiR ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
1ST STAGE
ADJUSTABLE VENTURI
FOR FLY ASH/SO,
S02 ABSORBER SCRUBBER
RECYCLE RETURN SYSTEHr
RETURN TO POND
CaS03/S04
FLY ASH SLURRY
TO
STABILIZATIQN
FACILITIES
F. R. Phillips FGD System: General Diagram.
B-7
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
LIMESTONE
SILO
CRYSTALLIZER
THICKENER
WASTE
DISPOSAL
WASTE
DISPOSAL
Chiyoda Throughbred 101 FGD Prototype: G
Process Diagram.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
COAL
SUPPLY
STACK
•I.D. FAN.
-STACK GAS
REHEATER
PULVERIZER
RECYCLE
PUMP
CLARIFIER
HAKE UP
WATER
TO ASH DISPOSAL
POND
Terminated Hawthorn No. 3 F6D System: General Process Diagram.
B-9
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
COAL
SUPPLY
STACK
.D. FAN.
LIMESTONE
SUPPLY
FEEDER
STACK GAS
REHEATER
STACK GAS "
SCRUBBER
RECYCLE
PUMP
Terminated Hawthorn No. 4 FGD System: G
E-AO
CLARIFIER
MAKE UP
WATER
TO ASH DISPOSAL
POND
CINCINNATI. OHIO 45246
-------
STACK
I.D. FAN
COAL
SUPPLY
STACK GAS
REHEATER
AIR HEATER
DEMISTER
STACK GAS
SCRUBBER
PULVERIZER
RECYCLE
PUMP
Simplified Process Flow Diagram of the Lime Scrubbing
B-ll
LIME
PREPARATION
TANK
CLARIFIER
MAKE UP
WATER
TO ASH DISPOSAL
POND
for Hawthorn Units 3 and 4.
PEDCo ENVrRONMENTAL
CINCINNATI. OHIO 45246
-------
^V(c
La Cygne No. 1 FGD System: Ge^
ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
STACK
COAL SUPPLY-
I.D. FAN
PULVERIZER
STACK GAS
IR HEATER
DEMISTER
MARBLE BED
TACK GAS REHEATER
F.D. FAN
RECYCLE
WATER
STACK
GAS
SCRUBBER
Simplified Process Flow Diagram of the Terminated
Original FGD System Installed at Lawrence.
B-13
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
FLUE GAS
ROD SCRUBBER
00
7
SPRAY TOWER
A
A
A
A
+• EFFLUENT LINE
€
Lawrence No. 4 Operational FGD System: S
B-U
fied Flow Diagram.
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
wit n
WlltR 11
WCH.
ctCt«S.
n«'
J r
B(R STACK
irxyir
»T-P»SS
OAWESS
f
^ SCP-JBBCR
1 «ftKir»
FM
SPARC
Green River FGD System: General Process Diagram.
PEDCo ENVIRONMENTAL
B-15
CINCINNATI. OHIO 45246
-------
QUENCHER
ELECTROSTATIC
PRECIPITATOR
BOILER
FLUE
GAS
OEMISTER
CONTACTOR
SCRUBBFR
- MODULE
REACTION
TANK
DAMPERS -
y
Ql
1
;
QUENCHER
-DEHISTER
CONTACTOR
SCRUBBER
MODULE
ABSOPBER
RECYCLE
FAN
FLOCCULANT
ADDITION
Simplified Process Flow Diagram of the Cane Run No. 4 FGD System.
B-16
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO -45246
-------
SO 5PM FRESH WATER (AVE )
2SOGPM FBESH WATER (MAX.
pH 6 OR HIGHER
i.oo
• «.mr CMI/SCIU8MI
«»«• f««««CS Ot»«fSt«T JO'I ««TIO
IIOOO CFH
dAlfl WATCH
«.U>KT
CL*»lfltl Dl«ClU*
Paddys Run No. 6 F6D System: P
B-17
b ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
MAKE-UP
LIME
SLURRY
POND LIQUOR
RETURN f
TO
DISPOSAL
PONDS
VENTURI/SPRAY
SCRUBBER AND TANK
TRAY RECIRCULATION
TANK
Montana Power and Light Coldstrip F6D Systems
General Process Diagram
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
$*f
17.000 Mffl
473.000 ACm
3SST
S3«m
HU1KUM
JTEW 763V
«W.7 18/Wll
ITPASS
DMPW
1
V
ISOUTICK U9 >r 1
_ OWKR 1 M8.000 XCFM f 119-F 364.480 Ml
'
isounoa
owws __
1300 NT
toasTE*
rati
Hlt-s'.iC*
CVSI
CO' L' CT!»S
,r"i rnrMiALLn.
LJ UJ nxruRjs
T 7
j
S
^
£€*!
SUVt
«fef >
«T£t ntON
KUS
Reid Gardner FGD Systems, Units 1, 2, and 3:
General Process Diagram.
B-19
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
DISCHARGE
TO STACK
CONDENSER
TRAY TOWER
ABSORBER
Na2C03
MAKE-UP
PRESCRUBBER
(VARIABLE-THROAT
VENTURI)
FLUE GAS FROM
UNIT #11
FLY ASH PURGE TO POND
furhjftjft^
fimtfL-
y } ^ ^ } ^ ^^
J
* ^
w
^
J-
t
1 '
^
1
/">
J
TREATED
PURGE STREAM
STORAGE
BIN
Y
DRIED
SULFATE
PRODUCT
CENTRIFUGE
SODIUM SULFATE
CAKE
PURGE
STREAM
TO S02
REDUCTION
PLANT
CRYSTALLIZER
-STEAM
EVAPORATOR/
CRYSTALLIZER
COMPRESSOR
NIPSCO D. H. Mitchell No. 11 Wellman Lord/
General Process Diagram
B-20
ENVIRONMENTAL
CINCINNATI, OHIO 45246
-------
FLUE GAS
TO
SCRUBBER
REHEATER
MIST
ELIMINATOR
OVERFLOW POTS
& MARBLE BED
RIVER
MAKE-UP
WATER
WEIR
THICKENER
UNDERFLOW
PUMP
ASH POND
LIMESTONE —i
1 1 1
THICKENER
RE
CIS
C
TANK
*x
SLURRY
TANK
SLURRY
PUMP
ASH POND
RETURN PUMP
Sherburne No. 1 FGD System: Simplified Process Diagram.
B-21
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
Wl'LK
riPELINES TO P.EOERVOIR
Bruce Mansfield No. 1 FGD System: Simplified Process Diagram.
B-22
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
FRESH
WATER «•
INLET
BACKWASH
SPRAYS
STACK GAS
FROM 1.0.
FANS
PARTICIPATE
SCRUBBER
HUMIDIFIED
GAS STREAM
Mg (OH), SLURRY
PARTICULATE
SCRUBBER
SURGE TANK
TO WASTE WATER
TREATMENT SYSTEM
tf-MJf.
4f
CLEAN GAS UUILLl
MIST ELIMINATORS
MIST ENTRAPMENT SEPARATOR
S02 SCRUBBER
SURGE TANK
O-'--'1
Eddystone No. 1 FGD System: Gene
B-23
VENTURI ROD MODULES
SCRUBBING SLURRY INLET
TO Mg S03
RECOVERY
PEDCo ENVIRONMENTAL
S DlagrXtlMCINNATI. OHIO 45246
-------
I AIR
I FUEL OIL>—^REHEATER]—,
SCRUBBER
I FLUE GAS
I LIMESTONE
A A A
T
FIRST
HOLD
TANK
CMAKEUP WATER]
I.D. FAN
SECOND
HOLD
TANK
SAMPLE POINTS
OGAS COMPOSITION
®PARTICIPATE COMPOSITION & LOADING
©SLURRY OR SOLIDS COMPOSITION
i
GAS STREAM
LIQUOR STREAM
PROCESS
WATER
HOLD
TANK
STACK
-QlAKEUP WATER|
DISCHARGE
SETTLING POND
Shawnee No. 10 Prototype Test Unit:
B-24
pREQCSagrCJVJVIRONMENTAL
CINCINNATI, OHIO 45246
-------
i AIR >— ^
I FUEL OIL >~»| REHEATER"]—-;
IFLUE GAS>-Q-®-
VENTURI
SCRUBBER
j LIME >-
®~-fea.D. FAN
SCRUBBER
EFFLUENT
HOLD
TANK
SAMPLE POINTS
OGAS COMPOSITION
®PARTICULATE COMPOSITION & LOADING
©SLURRY OR SOLIDS COMPOSITION
SETTLING POND
GAS STREAM
LIQUOR STREAM
Shawnee No. 10 Prototype Test Unit: General Process Diagram.
PEDCo ENVIRONMENTAL
B-25
CINCINNATI. OHIO 45246
-------
FLUE GAS
MAKE-UP WATER
VENT AIR
A
OXIDATION
TANK
CLARIFIED LIQUOR
WATER
SPRAY TOWER EFFLUENT
HOLD TANK
C5
C3
*• »
T
^
!
c
->
— i /W
1 L
i
DESUPERSATURATION
TANK
Shawnee No. 10 Prototype Test
Venturi/Spray Tower System for 2-Stage Oxid
BLEED TO
DEWATERING
_ SYSTEM
PEDCo ENVIRONMENTAL
.. CINCINNATI. OHIO 45246
sting.
-------
REHEATER
ENTRAPMENT SEPARATOR
FLUE GAS DUCT
FROM POWER HOUSE
EXISITNG ESP'S
VENTURI CIRCULATION TANKS
ABSORBER CIRCULATION TANKS
ABSORBER CIRCULATION PUMPS
TVA Widows Creek No. 8 FGD Sys
Schematic Diagram
B-27
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 4S248
-------
Four Corners Prototype Scrubber Module: Cross Section Diagram.
B-28
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
BOILER
FLUE-r
GAS
98% GRADE
SULFURIC ACID
CONTACT ACID
PLANT
PUMP
Mystic No. 6 FGD System and Essex Chemical Plant
Regeneration Facility: Schematic Flow Diagram.
B-29
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
REHEATER F 1
n r
SLURRY
BLEED
TO-<-
SETTLING
POND
PEABODY/LURGI
RADIAL VENTURI
•7
PEABODY
SPRAYJTOWER
sb2 "REMOVAL
PARTICULATE
REMOVAL
LIMESTONE
SLURRY HOLD TANK
WASHWATER
RECYCLE
TANK
St. Clair No. 6 FGD System: General Process Diagram.
B-30
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
SCRUBBED
GAS
SOLIDS
VACUUM WATER RECOVERY H?0
U, --L-
CEA/ADL Dual Alkali Prototype: General Process Diagram.
B-31
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
2) ADSORPTION
REGENERATION
FW-BF Dry Adsorption Prototype: Gene
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.
PEDCp. ENVIRONMENTAL
-------
CAT-OX MIST
ELIMINATOR
FLUE GAS
FROM EXISTING
ID FAN
*• STORAGE
Wood River No. 4 Catalytic Oxidation FGD System:
Simplified Process Diagram.
B-33
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
STACK
•I.D. FAN
COAL SUPPLY-
FEEDER
PULVERIZER
STACK GAS
IR HEATER
DEMISTER
TACK GAS REHEATER
7 RECYCLE
WATER
STACK'
GAS
SCRUBBER
Terminated Operational FGD System at Lawrence No. 5.
B-34
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
Stock Island Plant FGD System: Process Flow Diagram.
PEDCo ENVIRONMENTAL
B-35
CINCINNATI. OHIO 45246
-------
VENTURI
SCRUBBER/ABSORBER
TO DRY ASH HANDLING SYSTEM
/ ' TRANSFE
ASH POND
MgO FROM
ACID PLANT
MgSO TO ACID PLANT
Dickerson No. 3 Regenerative FGD System:
General Process Diagram.
B-36
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
ALKALI
STORAGE SILO
SLURRY 8
MIX TANK
FLUE GAS FROM
PRECIPITATORS
CONTROL
BUILDING
MOTOR CONTROL
THICKENER CENTER
OVERFLOW TANK
ABSORBE
HOLD TANK
POWER
iPLANT
STACK
ALKALI
MIX TANKS
TURBULENT
CONTACT
ABSORBER
Mohave No. 1 Vertical Test Module:
Simplified Process Diagram.
B-37
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
FOUR SCRUBBER STAGES
HOT AIR
INJECTION
BOOSTER FAN
MIST ELIMINATOR
Mohave No. 2 Horizontal Test Module: Simplified Side View.
B-38
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
TO STACK
FLUE GAS
FROM VR
BOILER
HEAT
EXTRACTOR
ASH
•MftdtehMMhHJbu^A
«» I ^^ | w^
REHEATER
OEMISTER
RECYCLE
MARBLE BED
SPRAY
•LADDER
VANES
WATER
LADDITIVE
SOLIDS
TO -
DISPOSAL
—LIQUID
CLARIFIER
•VACUUM FILTER
Simplified Process Flow Diagram of
Injection and Time-End Scrubbing S
B-39
ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO
-------
APPENDIX C
DEFINITIONS
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO
-------
C-2
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 45246
-------
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 SO2 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.
^X PEDCo ENVIRONMENTAL
-_, V^^^/ CINCINNATI. OHIO 45246
-------
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.
C-4
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO 4524-6
-------
DEFINITIONS
Regulatory Class
Retrofit
Sludge Disposal
Start-up Date
Unit Cost
A. New boiler constructed subject to Federal New Source
Performance 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 State 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 SO2 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.
C-5
PEDCo ENVIRONMENTAL.
CINCINNATI. OHIO 45246
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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 -
Directory of Electrical Utilities, McGraw-Hill - Current
Edition - as space permits.
Gallons per minute of make-up water required per MW of
capacity.
C-6
PEDCo ENVIRONMENTAL
CINCINNATI. OHIO -45246
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