EPA-650/2-75-047
June 1975
Environmental Protection Technology Series
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EPA-650/2-75-047
EPA ALKALI
SCRUBBING TEST FACILITY
SUMMARY OF TESTING
THROUGH OCTOBER 1974
by
Dr. Michael Epstein, Project Manager
Bechtel Corporation
50 Beak Street
San Francisco, California 94119
Contract No. P1I 22-68-67
ROAP No. 21ACY-032
Program Element No. 1AB013
EPA Project Officer. John E. Williams
Control Systems Laboratory
National Environmental Research Center
Research Triangle Park , N. C. 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF RESEARCH AND DEVELOPMENT
WASHINGTON, D. C. 20460
June 1975
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EPA REVIEW NOTICE
This report has been reviewed by the National Environmental Research
Center - Research Triangle Park, Office of Research and Development.
EPA. and approved for publication. Approval does not signify that the
contents necessarily reflect the views and policies of the Environmental
Protection Agency, nor does mention of trade names or commercial
products constitute endorsement or recommendation for use.
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development. U.S. Environ-
mental Protection Agency, have been grouped into series. These broad
categories were established to facilitate further development and applica-
tion of.environmental technology. Elimination of traditional grouping was
consciously planned to foster technology transfer and maximum interface
in related fields. These series are:
1. ENVIRONMENTAL HEALTH EFFECTS RESEARCH
2. ENVIRONMENTAL PROTECTION TECHNOLOGY
3. ECOLOGICAL RESEARCH
4. ENVIRONMENTAL MONITORING
5. SOCIOECONOMIC ENVIRONMENTAL STUDIES
6. SCIENTIFIC AND TECHNICAL ASSESSMENT REPORTS
9. MISCELLANEOUS
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to
develop and demonstrate instrumentation, equipment and methodology
to repair or prevent environmental degradation from point and non-
point sources of pollution. This work provides the new or improved
technology required for the control and treatment of pollution sources
to meet environmental quality standards.
I'his document is available to the public for sale through the National
Technical Information Service, Springfield, Virginia 22161.
Publication No. EPA-650/2-75-047
11
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ABSTRACT
The report presents the test results from March 1972 to October 1974
on a prototype lime/limestone scrubbing test facility for removing SO-
and particulates from flue gases. The facility consists of three parallel
scrubbers -- a venturi/spray tower, a Turbulent Contact Absorber (TCA),
and a Marble-Bed Absorber -- each treating 10 Mw equivalent (30, 000
acfm) of flue gas from a coal-fired boiler at TVA's Shawnee Station.
Limestone factorial tests to determine effects of independent variables
on SO2 and particulate removal, and limestone reliability verification
tests to define regions for scale-free operation have been conducted
on all three scrubbers. Lime and limestone reliability tests have been
conducted on the venturi/spray tower and TCA systems, respectively,
to demonstrate long-term reliability of the mist elimination systems.
Mathematical models have been developed for predicting system per-
formance. Test results have shown that scrubber internals can be
kept relatively free of scale if the sulfate (gypsum) saturation of the
'scrubber liquor is kept below about 135 percent. The TCA mist elim-
ination system consists of a Koch Flexitray in series with a chevron
mist eliminator, both with underside wash. This system has been
maintained essentially clean for over 1000 hours in a test at 8. 6 ft/sec
superficial velocity and 15 percent slurry solids concentration. The
spray tower has a chevron mist eliminator with provision for under-
side and topside wash. At 6. 7 ft/sec superficial velocity and 8 per-
cent slurry solids concentration, neither intermittent nor continuous
bottomside wash prevented solids buildup. A recent test has shown
that a combination of intermittent topside and bottomside wash can
keep the mist eliminator free of solids at the above conditions, but
entrainment from the topside wash remains to be evaluated.
111
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A CKNO WLEDGEMENT
The following Bechtel personnel were the principal contributors to the
preparation of this report:
Dr. M. Epstein, Project Manager
A.H. Abdul-Sattar R.G. Rhudy
D.A. Burbank C.H, Rowland
Dr. H. N. Head L. Sybert
Dr. J. A. Hoiberg Dr. S. C. Wang
C. C. Leivo
The authors wish to acknowledge the various personnel from the
Environmental Protection Agency and the Tennessee Valley Authority
who also contributed to the preparation of this report.
The authors also wish to acknowledge the contributions of the Bechtel
and TVA on-site personnel at the Shawnee Test Facility.
iv
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CONTENTS
Section Page
1 SUMMARY 1-1
1. 1 Venturi/Spray Tower 1-4
1.2 TCA Scrubber 1-6
1.3 Marble-Bed Scrubber 1-7
1.4 Mist Elimination 1-8
1.5 Scaling and Sulfate Saturation 1-9
1. 6 Equipment 1-10
1.7 Particulate Removal 1-15
2 INTRODUCTION 2-1
3 TEST FACILITY 3-1
3. 1 Scrubber Selection 3-1
3.2 System Description 3-6
3. 3 EPA Pilot Plant Support 3-11
4 TEST PROGRAM 4-1
4. 1 Test Periods and Test Program Schedule 4-1
4.2 Test Designs 4-6
4. 3 Analytical Program 4-7
4.4 Data Acquisition and Processing 4-9
4.5 Materials Evaluation Program 4-10
5 AIR/WATER AND SODIUM CARBONATE TEST 5-1
RESULTS
5. 1 Pressure Drop Data from Air/Water and
Sodium Carbonate Tests 5-1
5.2 Sulfur Dioxide Removal Data from Sodium
Carbonate Tests 5-9
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Section
6 LIMESTONE FACTORIAL TEST RESULTS 6-1
6.1 SO£ Removal Results 6-3
6.2 Analytical Results 6-12
7 LIMESTONE RELIABILITY VERIFICATION TEST
RESULTS 7-1
7. 1 Reliability Verification Performance Data 7-1
7.2 Analytical Data 7-18
7.3 Scaling Potential as a Function of Liquor
Sulfate Saturation 7-20
7.4 Limestone Utilization 7-24
7.5 Material Balances 7-25
8 LIMESTONE RELIABILITY TEST RESULTS 8-1
8. 1 Performance Data and Test Evaluation 8-1
8.2 Material Balances 8-20
8. 3 Conclusions 8-22
9 LIME RELIABILITY TEST RESULTS 9-1
9. 1 Performance Data and Test Evaluation 9-1
9.2 Material Balances 9-17
9.3 Conclusions 9-19
10 OPERATING EXPERIENCE DURING LIME/
LIMESTONE TESTING 10-1
10.1 Closed Liquor Loop Operation 10-1
10.2 Mist Eliminator Operability 10-2
10.3 Scrubber Internals 10-6
10.4 Hot-Gas/Liquid Interface 10-9
10.5 Reheaters 10-11
VI
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10.6 Fans 10-12
10.7 Pumps 10-13
10.8 Waste Solids Handling 10-14
10.9 Linings 10-16
10.10 Instrument Operating Experience 10-17
10.11 Materials Evaluation 10-21
11 PARTICULATE REMOVAL TEST RESULTS 11-1
11.1 Overall Particulate Removal Efficiencies 11-1
i
11.2 Particulate Removal as a Function of
Particle Size 11-10
12 ANALYSIS OF PRESSURE DROP DATA 12-1
12.1 Venturi Scrubber 12-1
12.2 TCA Scrubber 12-4
12.3 Marble-Bed Scrubber 12-8
13 ANALYSIS OF SODIUM CARBONATF SCRUBBING
DATA 13-1
13.1 Gas-Side Resistance Data 13-1
13.2 Gas/Liquid-Side Resistance Data 13-8
14 ANALYSIS OF LIMESTONE FACTORIAL DATA 14-1
14.1 Theoretical Model 14-1
14.2 Fitted Equations 14-5
15 REFERENCES 15-1
vn
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Appendices Page
A Converting Units of Measure A-l
B Scrubber Operating Periods B-l
C Properties of Raw Materials Used during
the Test Program C-l
D Tabular Listing of Air/Water and Sodium
Carbonate Test Data D-l
E Tabular Listing of Limestone Factorial Test
Data E-l
F Selected Graphical Operating Data from
Limestone Reliability Verification Tests F-l
G Bechtel Modified Radian Equilibrium
Computer Program G-l
H Graphical Operating Data from Limestone
Reliability Tests H-l
I Graphical Operating Data from Lime
Reliability Tests 1-1
J First TVA Interim Report of Corrosion
Studies J-l
K Second TVA Interim Report of Corrosion
Studies K-l
L Definition of Statistical Terms L-1
Vlll
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ILLUSTRATIONS
Figure Page
3-1 Schematic of Venturi Scrubber and Spray Tower 3-3
3-Z Schematic of Three-Bed TCA Scrubber 3-4
3-3 Schematic of Marble-Bed Scrubber 3-5
3-4 Test Facility Mist Eliminator Configurations 3-7
3-5 Typical Process Flow Diagram for Venturi/
Spray Tower System 3-8
3-6 Typical Process Flow Diagram for TCA System 3-9
3-7 Typical Process Flow Diagram for Marble-Bed
System 3-10
3-8 Scrubber Area 3-12
3-9 Operations Building and Thickener Area 3-13
3-10 Control Room 3-14
4-1 Shawnee Test Schedule 4-2
5-1 Effect of Liquid-to-Gas Ratio and Throat Gas Ve-
locity on Pressure Drop for the Chemico Venturi 5-2
5-2 Effect of Plug Opening and Throat Gas Velocity on
Pressure Drop for the Chemico Venturi 5-3
5-3 Effect of Liquid-to-Gas Ratio and Gas Velocity on
Pressure Drop per Bed for the TCA 5-4
5-4 Effect of Internals and Gas Velocity on Pressure
Drop per Bed for the TCA 5-5
5-5 Effect of Liquid-to-Gas Ratio and Gas Velocity on
Pressure Drop Across the Marble-Bed 5-6
IX
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Figure Page
5-6 Effect of Bed Height and Gas Velocity on Pressure
Drop across the Marble-Bed 5-7
5-7 Effect of Pressure Drop on SO, Removal in the
Chemico Venturi (Gas-Side Resistance Tests) 5-10
5-8 Effect of Liquid-to-Gas Ratio and Pressure Drop
on SO2 Removal in the Chemico Venturi (Gas/
Liquid-Side Resistance Tests) 5-11
5-9 Effect of Sodium Concentration and Pressure Drop
on SO, Removal in the Chemico Venturi (Gas/
i-Side Resistance Tests) 5-12
on SU-
Liquicf-
5-10 Effect of Inlet SO2 Concentration and Pressure
Drop on SO- Removal in the Chemico Venturi
(Gas/Liquid-Side Resistance Tests) 5-13
5-11 Effect of Gas Velocity and Liquid-to-Gas Ratio
on SO- Removal for the TCA Operated as a
Spray Tower (Gas-Side Resistance Tests) 5-14
5-12 Effect of Bed Height and Liquid-to-Gas Ratio on
SO- Removal in the Marble-Bed Scrubber (Gas-
Side Resistance Tests) 5-15
5-13 Effect of Gas Velocity and Liquid-to-Gas Ratio on
SO2 Removal in the Marble-Bed Scrubber (Gas-
Side Resistance Tests) 5-16
6-1 Effect of Gas and Liquor Flow Rates on SO_
Removal in the Chemico Venturi with Nine
Inches of Pressure Drop 6-4
6-2 Effect of Gas and Liquor Flow Rates on SO^
Removal in the Spray Tower 6-5
6-3 Effect of Liquid-to-Gas Ratio and Gas Velocity
on SO, Removal in the Spray Tower i>-7
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Figure Page
6-4 Effect of Scrubber Inlet Liquor pH and Liquid -
to-Gas Ratio on SO2 Removal in the Spray
Tower at 8. 0 ft/sec Gas Velocity 6-8
6-5 Effect of Spheres versus no Spheres and Gas Flow
Rate on SO? Removal in the Six-Grid, Three-Bed
TCA 6-9
6-6 Effect of Gas and Liquor Flow Rates on SO2
Removal in the Four-Grid, Three-Bed TCA 6-10
6-7 Effect of Liquid-to-Gas Ratio and Gas Velocity
on SO2 Removal in the Four-Grid, Three-Bed
TCA 6-11
6-8 Effect of Gas and Liquor Flow Rates on SO2
Removal in the Marble-Bed Scrubber with Five
Inches of Marbles 6-13
6-9 Effect of Liquid-to-Gas Ratio and Gas Velocity
on SO, Removal inthe Marble-Bed Scrubber
with Five Inches of Marbles 6-14
7-1 Calculated Degree of Sulfate Saturation versus
pH for Limestone Reliability Verification Tests 7-22
7-2 Calculated Degree of Sulfate Saturation for TCA
Limestone Reliability Verification Tests 7-23
11-1 Particle Size Distributions at TCA Inlet and
Outlet 11-12
11-2 TCA Particulate Removal Efficiency as a
Function of Particle Size 11-13
12-1 Comparison of Experimental Data and Predicted
Values of Pressure Drop in the Chemico Venturi
from Equation 12-1 12-3
XI
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Figure Page
12-2 Comparison of Experimental Data and Predicted
Values of Pressure Drop in the Chemico Venturi
from Equation 12-4 12-5
12-3 Comparison of Experimental Data and Predicted
Values of Pressure Drop in the TCA from
Equation 12-5 12-7
12-4 Comparison of Experimental Data and Predicted
Values of Pressure Drop in the Marble-Bed
Scrubber from Equation 12-6 12-9
12-5 Comparison of Experimental Data and Predicted
Values of Pressure Drop in the Marble-Bed
Scrubber from Equation 12-7 12-11
13-1 Comparison of Experimental Data and Predicted
Values of SO2 Removal in Chemico Venturi from
Equation 13-2 (Gas-Side Resistance Tests) 13-5
13-2 Comparison of Experimental Data and Predicted
Values of SO^ Removal in Chemico Venturi from
Equation 13-3 (Gas-Side Resistance Tests) 13-6
13-3 Comparison of Experimental Data and Predicted
Values of SC>2 Removal in Chemico Venturi from
Equation 13-8 (Gas/Liquid-Side Resistance Tests) 13-10
14-1 Comparison of Experimental Data and Predicted
Values of SO2 Removal in the Spray Tower from
Equation 14-8 (Limestone Factorial Tests) 14-6
14-2 Comparison of Experimental Data and Predicted
Values of SCu Removal in the TCA from Equation
14-9 (Limestone Factorial Tests) 14-8
14-3 Comparison of Experimental Data and Predicted
Values of SC^ Removal inthe Marble-Bed Scrubber
from Equation 14-9 (Limestone Factorial Tests) 14-10
Xll
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TABLES
Table Page
4-1 Field Methods for Batch Chemical Analysis of
Slurry and Alkali Samples 4-8
7-1 Summary of Limestone Reliability Verification
Tests: Venturi/Spray Tower System 7-4
7-2 Summary of Limestone Reliability Verification
Tests: TCA System 7-6
7-3 Summary of Limestone Reliability Verification
Tests: Marble-Bed System 7-8
7-4 Limestone Reliability Verification Test Run
Evaluations: Venturi/Spray Tower System 7-10
7-5 Limestone Reliability Verification Test Run
Evaluations: TCA System 7-1Z
7-6 Limestone Reliability Verification Test Run
Evaluations: Marble-Bed System 7-14
7-7 Average Scrubber Inlet Liquor Compositions
for Limestone Reliability Verification Runs 7-19
7-8 Summary of Material Balances for Sulfur and
Calcium from Limestone Reliability Verification
Tests 7-26
8-1 Summary of Limestone Reliability Tests on TCA
System 8-2
8-2 Average Scrubber Inlet Liquor Compositions and
Calculated Sulfate Saturations for TCA Lime-
stone Reliability Runs 8-5
8-3 Summary of Material Balances for Sulfur and
Calcium from Limestone Reliability Tests 8-21
Xlll
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Table Page
9-1 Summary of Lime Reliability Tests on Venturi/
Spray Tower System 9-2
9-2 Average Scrubber Inlet Liquor Compositions and
Calculated Sulfate Saturations for Venturi/Spray
Tower Lime Reliability Tests 9-5
9-3 Summary of Material Balances for Sulfur and
Calcium from Lime Reliability Tests 9-18
10-1 Corrosion Test Results 10-23
11-1 Overall Particulate Removal in Venturi and Spray
Tower During Limestone Factorial Tests 11-2
11-2 Overall Particulate Removal in TCA Scrubber
with Five Grids and No Spheres during Lime-
stone Factorial Tests 11-3
11-3 Overall Particulate Removal in Marble-Bed
Scrubber during Limestone Factorial Tests 11-4
11-4 Overall Particulate Removal in TCA Scrubber
during Limestone Reliability Verification Tests 11-5
11-5 Overall Particulate Removal in Venturi/Spray
Tower during Lime Reliability Tests 11-6
11-6 Overall Particulate Removal in TCA Scrubber
during Limestone Reliability Tests 11-7
xiv
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Section 1
SUMMARY
This report describes a program by the Environmental Protection
Agency (EPA) through its Office of Research and Development and
Control Systems Laboratory to test prototype lime and limestone wet-
scrubbing systems for removing sulfur dioxide and particulate matter
from coal-fired boiler flue gases. The program is being conducted
in a test facility integrated into the flue gas ductwork of a coal-fired
boiler at the Tennessee Valley Authority (TVA) Shawnee Power Station,
Paducah, Kentucky. Bechtel Corporation of San Francisco is the major
contractor and test director, and TVA is the constructor and facility
operator. This report presents the results of the testing program from
its inception in March 1972 through October 1974. It includes mathe-
matical models developed for predicting performance. An advanced
testing program is continuing.
The test facility consists of three parallel scrubber systems:
• A venturi followed by a spray tower
• A Turbulent Contact Absorber (TCA)
• A Marble-Bed Absorber
1-1
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Each system is capable of treating approximately 10 Mw equivalent
*r
(30, 000 acfm @ 300°F) of flue gas containing 1800 to 4000 ppm sulfur
dioxide and 2 to 5 grains/scf of participates.
The major goals of the test program have been:
• To characterize the effect of important process variables
on sulfur dioxide and particulate removal.
• To develop mathematical models to allow scale-up to full-
size scrubber facilities.
• To demonstrate long-term reliability.
The test program was divided into four test blocks:
(1) Air/water tests
(2) Sodium carbonate tests
(3) Limestone wet-scrubbing tests
(4) Lime wet-scrubbing tests
The air/water tests, which used air to simulate flue gas and water
to simulate alkali slurry, were designed to determine the effects of
the major independent variables on pressure drop for the three scrub-
bers in clean systems. Models for predicting pressure drop were
fitted to the data.
Although it is the policy of the EPA to use the Metric System for
quantitative descriptions, the British System is used in this report.
Readers who are more accustomed to metric units are referred to
the conversion table in Appendix A.
1-2
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The sodium carbonate tests used water solutions of soda-ash to absorb
SO- from flue gas and from a synthetic flue gas composed of air and
SO_. These tests were designed to determine the effects of independent
variables on SO7 removal for the three scrubbers under conditions
L*
where the gas-side mass transfer resistance is rate controlling and
under conditions where both liquid and gas-side resistances are im-
portant. Models for predicting SC^ removal were fitted to the soda-
ash data.
The limestone wet-scrubbing tests were divided into three categories:
• Factorial tests
• Reliability verification tests
• Reliability tests
The limestone factorial tests were designed to determine the effects
of the major independent variables on SO? and particulate removal
for the three scrubbers. Models for predicting SO- removal were
fitted to the data. The data showed that the percent of SO2 removal
was a function of liquor rate, scrubber internals (e.g., number of beds
in the TCA), scrubber liquor pH, SO_ inlet gas concentration, and scrub-
ber liquor temperature. It showed that SO7 removal was a function of
£
gas rate in the spray tower and Marble-Bed scrubber, but varied only
slightly with gas rate, if at all, in the venturi and TCA scrubbers.
The limestone reliability verification tests were designed to define
regions for scale-free operation of the three scrubber systems. The
scaling potential of scrubber internals was correlated to the degree
of calcium sulfate (gypsum) saturation of the scrubber slurries.
1-3
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The limestone reliability tests were designed to demonstrate long-term
(2 to 5 month) operability. These tests were run on the TCA system only.
The lime wet-scrubbing tests were originally scheduled to be divided
into the same three categories as the limestone wet-scrubbing tests.
It was decided, however, to begin the lime testing with long-term
reliability tests and to defer the factorial and reliability verification
testing to a later data. Lime reliability tests were run on the venturi/
spray tower system only.
Included in the overall test program were a particulate removal test
program and an equipment evaluation program.
1. 1 VENTURI/SPRAY TOWER
The adjustable throat venturi scrubber (manufactured by Chemical
Construction Co. ) was followed by a four-header spray tower for
additional gas absorption capability. A chevron mist eliminator was
used in the spray tower for demisting.
Typical scrubbing conditions during limestone factorial tests were:
Venturi scrubber alone - 40 percent SO? removal at 25 gal/mcf
liquid-to-gas ratio, 30,000 acfm (330°F) gas rate, and 6 to 12
inches r^O pressure drop.
Spray tower alone - 70 percent SO2 removal at 50 gal/mcf liquid-
to-gas ratio, 8 ft/sec gas velocity (30,000 acfm at 330°F), and
4 inches H_O pressure drop.
Lt
1-4
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Major problems alleviated during the venturi/spray tower lime relia-
bility testing were:
• Scaling of scrubber internals
• Spray nozzle plugging
A continuing problem has been the scaling and plugging of the chevron
mist eliminator.
The longest lime reliability test (Run 601-1A) on the venturi/spray tower
system lasted 2150 hours (3 months). The test conditions were:
*
Spray tower gas velocity 6. 7 ft/sec
Venturi liquid-to-gas ratio 30 gal/mcf
Spray tower liquid-to-gas ratio 60 gal/mcf
Percent solids recirculated 8 percent
Effluent residence time 12 minutes
Scrubber inlet slurry pH (controlled) 8
In this test, SO- removal was 75 to 95 percent, lime utilization was
L*
approximately 90 percent, and the total pressure drop was about 12. 5
inches H~O, including 9 inches H_O across the venturi. The run was
£* £
terminated because of fan vibration and solids falling on the mist
eliminator from the inlet ductwork which plugged up the mist eliminator.
*
In this report, all gas velocities and liquid-to-gas ratios are at scrub-
ber operating conditions, i. e., saturated gas at scrubber temperature.
With flue gas operation, the scrubber temperature is approximately
125°F. The gas velocities are all superficial velocities.
1-5
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1.2 TCA SCRUBBER
The TCA scrubber (manufactured by Universal Oil Products) uses a
mobile bed of low density plastic spheres that are retained between
fixed grids. The TCA mist elimination system consisted of a wash
tray in series with a chevron mist eliminator.
Typical scrubbing conditions during limestone factorial tests for a
three-bed TCA were 90 percent SO, removal at 60 gal/mcf liquid-to-
gas ratio, 10. 5 ft/sec gas velocity, and 7 inches H_O pressure drop.
Major problems alleviated during the TCA limestone testing were:
• Scaling of scrubber internals
• Scaling and plugging of mist elimination system (at 8. 6 ft/sec
gas velocity)
• Solids deposition at hot-gas/liquid interface
• Deterioration of wire mesh grids caused by vibrational wear
at the points of contact
A continuing problem has been the operational life of the plastic spheres.
The most successful TCA limestone reliability test (Run 535-2A), still
in progress at the end of October 1974, has accumulated nearly 1000
operating hours without significant accumulation of scale and solids
on the scrubber internals and the mist elimination system. The test
conditions for this run were:
1-6
-------
Gas velocity 8.6 ft/sec
Liquid-to-gas ratio 73 gal/mcf
Percent solids recirculated 15 percent
Effluent residence time 15 minutes
Percent SO, removal (controlled) 85 percent
Ct
The scrubber inlet slurry pH was 5. 7 to 6. 0, the limestone utilization
was approximately 65 percent, and the total pressure drop was about
6. 5 inches H,O. It is anticipated that a 3 month reliability run will
Li
be completed at these run conditions without scaling or plugging.
1. 3 MARBLE-BED SCRUBBER
The Marble-Bed scrubber (supplied by Combustion Engineering Co. )
uses a packed bed of 3/4-inch glass spheres (marbles). A turbulent
layer of liquid and gas above the marble bed enhances mass transfer
and particulate removal.
Typical scrubbing conditions during limestone factorial tests were
70 percent SO, removal at 33 gal/mcf liquid-to-gas ratio, 8. 2 ft/sec
Li
gas velocity, and 11 inches H_O pressure drop.
Major problems with the operation of the Marble-Bed scrubber
were associated with the erosion of spray nozzles and the resultant
plugging of the marble bed. Testing with the Marble-Bed scrubber
was discontinued in July 1973.
1-7
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1.4 MIST ELIMINATION
The most significant reliability problem encountered during the lime/
limestone wet-scrubbing tests has been the tendency for mist elimina-
tors to scale and/or plug. Hard scale formation is thought to be caused
by the absorption of SO2 into the process liquor adhering to the mist
eliminator, oxidation in the liquor, and subsequent precipitation of
calcium sulfate. Plugging results from slurry solids adhering to
the mist eliminator surfaces. Additionally, these soft solids may act
as sites for scale formation.
1.4.1 Wash Tray and Chevron Mist Eliminator in Series
The TCA mist elimination system consisted of a Koch Flexitray in
series with a six-pass, closed-vane, stainless steel, chevron type
mist eliminator during both the limestone reliability verification and
reliability testing.
As of October 1974, a TCA run (Run 535-2A), operating at a super-
ficial gas velocity of 8. 6 ft/sec, has been in operation for almost 1000
hours without any significant scaling or plugging of the Koch tray or
mist eliminator surfaces. For Run 535-2A, the underside of the Koch
tray has been intermittently steam sparged (125 psig) for one minute
every hour. The underside of the mist eliminator has been washed
continuously with 15 gpm (0. 3 gpm/ft^) diluted clarified liquor, while
the Koch tray has been irrigated with a combination of 8 gpm of clarified
liquor plus the 15 gpm mist eliminator wash.
1-8
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1.4.2 Chevron Mist Eliminator
A three-pass, open-vane, stainless steel, chevron type mist eliminator
was used in the venturi/spray tower system during most of the testing
to date.
In the venturi/spray tower system, operating at a superficial gas ve-
locity of 6. 6 ft/sec, there has been a continuing problem of scale for-
mation on the top mist eliminator vanes. A variety of washing config-
urations have been tried in order to alleviate this problem.
Underside washing only, either continuously with low pressure water
or intermittently with high pressure water, was unsuccessful in elim-
inating scale formation on the top vanes. A combination of intermittent
high pressure topside and bottomside washing appears to have been
successful in eliminating the scale accumulation on the upper mist elim-
inator vanes. However, operating experience in this configuration is
limited, and entrainment of the topside wash water may be a problem.
1. 5 SCALING AND SULFATE SATURATION
The limestone reliability test results with the TCA system have shown
that scrubber internals can be kept relatively free of scale by main-
taining sulfate (gypsum) saturation of the slurry liquor below about
135 percent at the scrubber inlet. This can be accomplished by proper
selection of percent solids recirculated, effluent residence time, and
liquid-to-gas ratio.
1-9
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The data have shown that an effluent residence time of 10 minutes or
more will maintain sulfate saturation below 135 percent in a limestone
system at 15 weight percent solids recirculated and at a liquid-to-gas
ratio of 64 to 80 gal/mcf. Under these test conditions, the bar-grids
on the TCA were covered with less than 15 mils of sulfate scale after
1190 hours of operation during limestone reliability Run 526-2A.
Results from the lime reliability tests on the venturi/spray tower
system have shown that the sulfate saturation of the scrubber inlet
slurry liquor can be similarly correlated with percent solids recirculated,
effluent residence time, and liquid-to-gas ratio. In addition, the lime
testing has shown that the sulfate saturation is a strong function of
flue gas inlet SO2 concentration (SO2 absorption rate). Also, the lime
testing has shown that lime addition to the scrubber downcomer can
substantially reduce the sulfate saturation, allowing for operation at
reduced percent solids recirculated and/or residence time.
1.6 EQUIPMENT
1. 6. 1 TCA Internals
Until recently, sphere life has limited the long-term operability of the
TCA scrubber. High-density polyethylene (HDPE) spheres eroded through
and filled with slurry after about 2000 hours of operation. Thermo-
plastic rubber (TPR) spheres have been more successful, showing a
weight loss of only 6 percent after 2500 hourvs. The TPR spheres tend
to dimple, however, and can slip through the supporting bar-grids.
This problem may be alleviated by respacing the bar-grids or using
heavier spheres.
1-10
-------
There has been no evidence of significant erosion of the bar-grids in
the TCA after more than 5000 hours of operation. The original wire
mesh grids deteriorated considerably during approximately 3000 hours
of operation.
1.6.2 Spray Tower Nozzles
Initially, nozzle reliability in the spray tower was poor because of
frequent plugging with foreign materials. Plugging was greatly reduced
by installing dual strainers in the circulating slurry lines and by cover-
ing the hold tanks.
The original spiral tip Bete nozzles employed in the spray tower
experienced severe erosion of the stainless steel tips after about
5400 hours in service. The original nozzles were replaced with
stellite-tipped Bete nozzles, which have shown no measurable signs
of erosion after approximately 5000 hours in service.
1.6.3 Hot-Gas/Liquid Interface
During limestone reliability verification testing, there was a continual
problem of soft solids buildup at the hot-gas/liquid interface in the
TCA and Marble-Bed scrubber inlet ducts, where the hot flue gas
was cooled by slurry sprays to protect the rubber linings of the vessels.
The problem was solved by careful selection of proper size, location,
and orientation of the slurry spray nozzles and by modification of the
soot blower head to blow accumulated solids into the scrubber.
1-11
-------
1.6.4 Reheaters
Fuel-oil-fired reheaters (from Hauck Manufacturing Co. ) with external
air supply and direct combustion in the flue gas stream were originally
installed. They were difficult to ignite, had frequent flame-outs, and
generated considerable soot. A fuel-oil-fired external combustion chamber
(manufactured by Bloom Engineering Co.) was installed on the venturi/
spray tower system in March 1974. This unit has performed satis-
factorily with high reliability for over 4000 operating hours. An identical
unit will be provided for the TCA.
1. 6. 5 Fans
Erosion, corrosion, pitting, scaling, etc. have been negligible on all
three fans. Operation has been with 125°F flue gas reheat to give a
fan inlet temperature of 250 F.
1. 6. 6 Pumps
The major pumps used in alkali slurry service at the Shawnee test
facility are rubber lined variable-speed centrifugal pumps manufactured
by Allen-Sherman-Hoff. In general, the rubber linings have shown
excellent erosion-corrosion resistance and have remained in good
condition. The original pumps had water-sealed packing, but were
converted to air-purged packing during the boiler outage in February
1973 to help tighten the scrubber water balance.
1-12
-------
1. 6. 7 Linings
The neoprene rubber linings in the spray tower, TCA, Marble-Bed,
process water hold tanks, pumps, circulating slurry piping, and agitator
blades have been found, generally, to be in excellent condition. Essen-
tially no erosion or deterioration has been noted, except slight wear
on some of the rubber-coated agitator blades. Hairline cracks have
been noted in the glassflake lining on the effluent hold tanks and clari-
fiers. However, the cracks did not appear to penetrate the entire
thickness of the lining.
1.6.8 Waste Solids Handling Equipment
Separate clarifiers to concentrate slurry discharge are provided for
each scrubber system. A rotary drum vacuum filter and a horizontal
solid bowl centrifuge are common to the three systems.
The venturi/spray tower and Marble-Bed systems have 20-foot diameter
clarifiers while the TCA clarifier is 30 feet in diameter. The TCA
clarifier has operated satisfactorily, with underflow solids concen-
trations approaching 40 wt %. The smaller clarifiers are undersized,
averaging about 25 wt % underflow solids concentration. To maintain
a tight water balance for closed liquor loop operation, the smaller units
must be used in series with the filter or centrifuge.
The rotary drum vacuum filter manufactured by Ametek has produced
a filter cake containing 50 to 55 and 45 to 50 wt % solids from limestone
and lime slurries, respectively. Filter operation has been significantly
hampered by the short life of the filter cloth which has been generally
below 260 hours.
1-13
-------
The continuous solid-bowl centrifuge manufactured by Bird Machine
Co. , operating either directly on scrubber slurry bleed or in series
with a clarifier, has produced cake solids of 55 to 65 wt % in limestone
service with centrate solids averaging 0. 5 to 1. 0 wt %. A major repair
of the unit was necessary after about 1400 hours of operation due to
severe erosion.
1.6.9 Instruments
The Du Pont Model 400 UV sulfur dioxide analyzers have operated
essentially trouble-free following modification of the sampling systems
to reduce leaking and plugging.
Two types of pH meters have been used in slurry service: (1) Uniloc
in-line flow-through meters and (2) Uniloc submersible electrode meters.
Performance of the in-line flow-through meters has been unsatisfactory
because of erosion and failure of the glass cells and plugging of sample
lines. The submersible electrode meters have been free of such pro-
blems during approximately 9000 hours of operation.
Three types of density meters have been used in slurry service: (1) Ohmart
radiation meters, (2) differential pressure (bubbling tube) meters, and
(3) Dynatrol vibrating U-tube meters. The radiation meter has a continual
calibration shift which is accelerated by scale formation. The gas line
on the differential pressure meter plugs frequently but the meter is
accurate when clean. Performance of the vibrating U-tube meters
has been excellent with few in-service problems.
1-14
-------
Slurry flow rates have been measured by Foxboro magnetic flow meters
and by both orifice and Annubar differential pressure meters. Perform-
ance of the magnetic flowmeters and orifice flowmeters has generally
been adequate. Annubar meters have plugged frequently and required
excessive maintenance.
Operating experience with control valves in slurry service has generally
been unsatisfactory. Severe erosion and frequent plugging has been
experienced with stainless steel plug valves, stainless steel globe
valves, and rubber pinch valves. Trouble-free flow control has been
achieved only with variable-speed pumps.
1. 7 PARTICULATE REMOVAL
EPA has conducted overall particulate removal tests on all three
scrubber systems and particulate distribution tests on the TCA system.
TVA personnel have made additional particulate removal measurements
at various times on the venturi/spray tower and TCA systems.
In general, measured particulate removal efficiencies on the three scrub-
ber systems have been higher than efficiencies predicted from impac-
tion theory. The enhanced efficiencies are probably the result of con-
densation of water vapor from the flue gas on the solid particles during
the scrubbing operation.
Particulate loadings in the flue gas entering the scrubbers averaged
about 2 to 5 grains/scf. Mass mean diameter of the particles in the
inlet flue gas averaged about 20 to 30 microns.
1-15
-------
For the Chemco venturi alone, measured particulate removal effi-
ciency averaged 99.6 percent at 9 inches I^O and 12 to 25 gal/mcf.
For the spray tower alone, measured removal efficiency averaged
98.4 percent at 4 ft/sec gas velocity (0. 5 inch H2O) and 37 gal/mcf.
For the venturi and spray tower operating simultaneously, measured
removal efficiency averaged 99. 1 percent with the venturi at 9 inches
ELO and 30 gal/mcf and the spray tower at 6. 6 ft/sec gas velocity
(2 to 3 inches H^O) and 61 gal/mcf.
For the TCA with 3 beds and 5 inches of spheres per bed, measured
removal efficiency ranged from 99. 2 percent at 8. 6 ft/sec gas velocity
(5. 6 inches H2O) and 36 gal/mcf to 99. 8 percent at 10. 7 ft/sec gas
velocity (9.8 inches H^C) and 72 gal/mcf. Mass mean diameter
of the particles in the outlet gas averaged 0. 5 to 0. 75 microns.
For the TCA with 5 grids and no spheres, measured removal efficiency
averaged 99. 3 percent at 8. 3 ft/sec gas velocity (4 to 7 inches H_O)
and 46 gal/mcf.
For the Marble-Bed, measured removal efficiency averaged 99. 1
percent at 5. 5 ft/sec gas velocity (12 inches H^O) and 51 gal/mcf.
1-16
-------
Section Z
INTRODUCTION
In June 1968, the Environmental Protection Agency (EPA), through its
Office of Research and Development (OR&D) and Control Systems Lab-
oratory, initiated a three phase program to test a prototype lime and
limestone wet-scrubbing system for removing sulfur dioxide and par-
ticulates from flue gases. The system is integrated into the flue gas
ductwork of a coal-fired boiler at the Tennessee Valley Authority (TVA)
Shawnee Power Station, Paducah, Kentucky. Bechtel Corporation of
San Francisco is the major contractor and test director, and TVA is
the constructor and facility operator.
The major goals of the test program were: (1) to characterize as com-
pletely as possible the effect of important process variables on sulfur
dioxide and particulate removal, (2) to develop mathematical models to
allow economic scale-up of attractive operating configurations to full-
size scrubber facilities, and (3) to perform long-term reliability testing.
Phase I of the test program consisted of preliminary engineering,
equipment evaluation, and site selection. Phase II involved the detailed
design and construction of the facility, and the development of the test
plan and mathematical models for predicting system performance.
Phase III, the testing portion of the program, began in March 1972.
2-1
-------
The following sequential test blocks were defined for the program:
(1) Air/water tests
(2) Sodium carbonate tests
(3) Limestone wet-scrubbing tests
(4) Lime wet-scrubbing tests
The limestone and lime wet-scrubbing test blocks were divided into
three general categories: (1) short-term (less than 1 day) factorial
tests, (2) longer term (about 3 weeks) reliability verification tests,
and (3) long-term (2 to 5 months) reliability tests. The object of the
factorial tests was to determine the effect of independent variables
(e.g. , gas rate) on SO2 removal for the scrubber systems. The pri-
mary objective of the reliability verification tests was to define regions
for reliable (e.g. , scale-free) operation of the scrubber systems.
The object of the reliability tests was to determine the long-term
operating reliability for the scrubber systems and to develop definitive
process economics data and scale-up factors. The test program has
been described in detail in References 1 and 2.
This report presents the results of testing at the Shawnee facility from
March 1972 to October 1974 (Phase III) and the mathematical models
developed for predicting system performance (Phase II).
In June 1974, the EPA initiated a two-year Advanced Test Program
at the Shawnee facility. The advanced program will involve, primarily,
limestone testing on the TCA system and lime testing on the venturi/
spray tower system. The major goals of the advanced program are:
2-2
-------
To continue long-term testing with emphasis on the demon-
stration of reliable mist eliminator operation.
To investigate advanced process and equipment design varia-
tions (e.g., operation with process slurry unsaturated with
respect to gypsum) for the improvement of system reliability
and process economics.
To perform long-term (2 to 5 months) reliability testing on
advanced process and equipment design variations.
To determine the practical upper limits of sulfur dioxide
removal efficiency.
To evaluate system performance and reliability without fly
ash in the flue gas.
To evaluate process variations for substantial increase in
limestone utilization with corresponding minimization of
sludge production.
To evaluate the effectiveness of three commercially offered
sludge fixation processes and of untreated sludge disposal.
To develop a computer program, in conjunction with TVA,
for the design and cost comparison of full-scale limestone
and lime systems.
The Advanced Test Program is described in detail in Reference 3.
The Advanced Test Program Manual, although not prepared for wide-
spread distribution, is available upon request from Bechtel Corporation.
The first interim report for the Advanced Test Program will be issued
by the EPA in late 1975.
2-3
-------
Section 3
TEST FACILITY
The test facility consists of three parallel scrubber systems, each
with its own slurry handling system. Scrubbers are of prototype size,
each capable of treating approximately 30, 000 acfm of flue gas from
the TVA Shawnee coal-fired boiler No. 10. This gas rate is the equi-
valent of approximately 10 Mw of power plant generation capacity.
The equipment selected was sized for minimum cost consistent with
the ability to extrapolate results to commercial scale.
Boiler No. 10 burns a high-sulfur bituminous coal which produces
SO2 concentrations of 1800 to 4000 ppm and inlet particulate loadings
of 2 to 5 grains/scf in the flue gas.
3. 1 SCRUBBER SELECTION
The major criterion for scrubber selection was the potentiality for
removing both sulfur dioxide and particulates at high efficiencies
(sulfur dioxide removal greater than 80 percent and particulate removal
greater than 99 percent). Other criteria considered in the selection
of the scrubbers were:
• Ability to handle slurries without plugging or excessive scaling
• Reasonable cost and maintenance
3-1
-------
• Ease of control
• Reasonable pressure drop
Based on the information available in the literature, the following
scrubbers were selected:
(!) Venturi followed by a spray tower
(2) Turbulent Contract Absorber (TCA)
(3) Marble-Bed Absorber
The venturi scrubber (manufactured by Chemical Construction Co. )
contains an adjustable throat that permits control of pressure drop
over a wide range of flow conditions. Although a venturi is an
effective particulate removal device, it has limited capability for gas
absorption in lime/limestone wet scrubbing systems because of low
slurry residence time. For this reason the spray tower was included
for additional absorption capability.
The TCA scrubber (manufactured by Universal Oil Products and de-
scribed in Reference 4) utilizes a fluidized bed of 1 1/2-inch-diameter,
5-gram hollow spheres which are free to move between retaining grids.
The Marble-Bed scrubber (supplied by Combustion Engineering Co.
and described in Reference 5) utilizes a packing of 3/4-inch glass
spheres (marbles). A "turbulent layer11 of liquid and gas above the
glass spheres enhances mass transfer and particulate removal.
Figures 3-1, 3-2, and 3-3 (drawn roughly to scale) show the three
scrubber systems along with the mist elimination systems selected for
3-2
-------
GAS OUT
CHEVRON MIST
ELIMINATOR
SPRAY TOWER
INLET SLURRY
THROAT
ADJUSTABLE PLUG
VENTURI SCRUBBER
WASH LIQUOR
WASH LIQUOR
INLET SLURRY
51
APPROX. SCALE
EFFLUENT SLURRY
Figure 3-1. Schematic of Venturi Scrubber and Spray Tower
3-3
-------
GAS OUT
MIST ELIMINATOR
WASH LIQUOR
CHEVRON MIST
ELIMINATOR
INLET KOCH TRAY
WASH LIQUOR
1
1
fcH
S
*R
r-^J
«. <. «x <
V V V
y
ip n n n n rt n
IV V y [l
^KOCH TRA1
'
d ^
1
STEAM SPARGE
RETAINING GRIDS ^
*»»* IU
A A A
' ~cf-0 —
O
0 o „
°°0°0
O O O
So o~
n
°00 °
v° 0 0 ° 0
ff^Q_Q_O_
o
o „ o
O O Of
00 o
AA&
INLET 5
/MOBILE
^r
* EFFLUENT KOCH
TRAY WASH LIQUOR
y
H
APPROX. SCALE
EFFLUENT SLURRY
Figure 3-2. Schematic of Three-Bed TCA Scrubber
3-4
-------
GAS OUT
MIST ELIMINATOR
WASH
INLET SLURRY
INLET SLURRY
GAS IN
MIST ELIMINATOR
WASH
CHEVRON MIST
ELIMINATORS
TURBULENT LAYER
GLASS SPHERES
EFFLUENT SLURRY
APPROX. SCALE
EFFLUENT SLURRY
Figure 3-3. Schematic of Marble-Bed Scrubber
3-5
-------
de-entraining slurry in the exit gas streams. The chevron mist elimin-
ators used during the testing on the three scrubber systems are depicted,
to scale, in Figure 3-4. The cross-sectional areas of the spray tower,
TCA, and Marble-Bed scrubbers are 50, 32, and 49 ft2, respectively.
3.2 SYSTEM DESCRIPTION
The Shawnee test facility contains five major areas:
(1) The scrubber area (including tanks and pumps)
(2) The operations building area (including laboratory area, elec-
trical gear, centrifuge, and filter)
(3) The thickener area (including pumps and tanks)
(4) The utility area (including air compressors, air dryer, lime-
stone storage silos, mix tanks, gravimetric feeder, and pumps)
(5) The pond area
The test facility has been designed so that a varied number of different
scrubber internals and piping configurations can be used with each
scrubber system. For example, the TCA scrubber can be operated
with one, two, or three beds of spheres or with only the support grids.
Solid separation can be achieved with a clarifier alone or with a clarifier
in combination with a filter or a centrifuge.
Some typical configurations for limestone testing with the venturi/spray
tower, TCA, and Marble-Bed scrubber systems are shown schematically
in Figures 3-5, 3-6, and 3-7, respectively. Such process details as
flue gas saturation (humidification) sprays are not shown.
3-6
-------
SPRAY TOWER
STAINLESS STEEL
SPRAY TOWER
POLYPROPYLENE
TCA
STAINLESS STEEL
MARBLE-BED ABSORBER
STAINLESS STEEL
(JO
I
-J
GAS FLOW
GAS FLOW
GAS FLOW
GAS FLOW
6 in.
Figure 3-4. Test Facility Mist Eliminator Configurations
-------
OJ
co
^> FLUE CAS J>- O -4S-)
VENIURI I
SCRUBBER
I.D. FAN
^ WATER ^~~1
1 . . 1
O Gas Composition
® Particulate Composition & Loading
® Slurrv or Solids Composition
_ _ Gas Stream
i Liquor Stream
PROCESS
WATER
HOLD
IANK
^
+1
I
I
VACUUM
FILTER
oT
STACK
Discharge
1
fJESLUi?RY
TANK
SETILING PONO
Figure 3-5. Typical Process Flow Diagram for Venturi/Spray Tower System
-------
bo
vO
TCA
SCRUBBER
To Effluent
Hold Tank
FLUE CAS J>- Q -®-»
»->v»v»1
--u-_T!_n_
A A A
••••••••
/fs,'Sf'f.
h • • ••
[>
I.D. FAN
L
Bleed
O Gas Composition
® Particulate Composition & Loading
® Slurry or Solids Composition
_ _ Gas Stream
__ liquor Stream
Discharge
RESLURRY
TANK
I
L,
SIACK
SHTLING POND
Figure 3-6. Typical Process Flow Diagram for TCA System
-------
LO
H-i
O
MARBLE-BED
SCRUBBER
FLUE CAS
^> LIMESTONE^
TANK
O Gas Composition
® Particulate Composition & Loading
0 Slurry or Solids Composition
_ _ Gas Stream
—. Liquor Stream
I.D. FAN
1
1
>
•MM
g2*«BQ
V V *•*
A J^^
" i ft -
y&ita
\^v^ w
l_
s^1
ill
SCRUBBER
EFFLUENT
HOLD
e
—
lea) .
4
CLARI
L^L
Discharge
STACK
SEHLINC POND
Figure 3-7. Typical Process Flow Diagram for Marble-Bed System
-------
For all systems, gas is withdrawn from the boiler ahead of the power
plant particulate removal equipment so that the entrained particulate
matter (fly ash) can be introduced into the scrubber. The gas flow rate
to each scrubber is measured by venturi flow meters and controlled by
dampers on the induced-draft fans. The concentration of sulfur dioxide
in the inlet and outlet gas streams is determined continuously by Du Pont
photometric analyzers. Inlet and outlet particulate ]oadings are measured
using a modified EPA particulate train.
The scrubbing systems are controlled from a central graphic panel-
board. An electronic data acquisition system is used to record the
operating data. The system is hard wired for data output in engineering
units directly on magnetic tape, and on-site display of selected infor-
mation is available. Also, important process control variables are
continuously recorded, and trend recorders are provided for periodic
monitoring of selected data sources.
Figure 3-8 is a view of the scrubber area looking toward the power
station. Figure 3-9 is a view of the operations building and thickener
area. Figure 3-10 is a view of the scrubber control room.
3. 3 EPA PILOT PLANT SUPPORT
Two smaller scrubbing systems (300 acfm each), which are capable
of operating over a wide range of conditions, have been installed at the
EPA facility in Research Triangle Park, North Carolina, in support of
the Shawnee prototype testing activities. The small pilot scale scrubber
systems are capable of simulating the TCA scrubber system and have
generated large quantities of limestone and lime wet-scrubbing data on
certain TCA configurations.
3-11
-------
Figure 3-8. Scrubber Area
3-12
-------
Figure 3-9. Operations Building and Thickener Area
3-13
-------
Figure 3-10. Control Room
3-14
-------
Section 4
TEST PROGRAM
This section contains a description of the Shawnee test program (the
Phase III program) which ran from March 1972 through October 1974.
As mentioned previously, an advanced Shawnee test program was begun
in October 1974 (see Reference 3).
The test program schedule is presented in Figure 4-1. Test results
are presented in Sections 5 through 9 of this report. Operating exper-
ience is summarized in Section 10. Results of particulate removal
tests, taken at various times during the program, are presented in
Section 11. The test data are analyzed in Sections 12 through 14. A
listing of the operating periods for the three scrubber systems during
reliability testing from March 1973 through October 1974 is presented
in Appendix B.
In this report, all gas velocities and liquid-to-gas ratios are at
scrubber operating conditions, i.e., saturated gas at scrubber tem-
perature. With flue gas operations, the scrubber temperature is
approximately 125 F. The gas velocities are all superficial velocities.
4. 1 TEST PERIODS AND TEST PROGRAM SCHEDULE
The following sequential test blocks were defined for the Shawnee test
program:
4-1
-------
I
tNJ
TEST PROGRAM FUNCTIONS
SYSTEM CHECK-OUT
AIR/WATER TESTS
SODIUM CARBONATE TESTS
LIMESTONE WET-SCRUBBING TESTS:
Factorial Tests
Reliability Verification Tests
Rel lability Tests (TCA)
LIME WET-SCRUBBING TESTS:
Reliability Tests (Venturi /Spray Tower)
1972
MAMJJASOND
1 23456789 10
BOILER OUTAGE
SYSTEM MODIFICATI
J F
1112
,J
1
!•
ONS
1973
MAMJJASOND
13 14 15 16 17 18 19 20 21 22
1
1
I
1974
J F M A M J J A S 0
23242526272829303132
Figure 4-1. Shawnee Test Schedule
-------
(1) Air/water tests
(2) Sodium carbonate tests
(3) Limestone wet-scrubbing tests
(4) Lime wet-scrubbing tests
4.1.1 Air/Water Tests
These experiments, which used air to simulate flue gas and water to
simulate alkali slurry, were designed to determine pressure drop model
*
coefficients and to observe fluid hydrodynamics (e.g. , Marble-Bed
turbulent layer) for all three scrubbers in clean systems. Pressure
drop tests are summarized in Section 5. 1, and fitted pressure drop
models are presented in Section 12.
4.1.2 Sodium Carbonate Tests
Two series of sodium carbonate tests were designed. The first, or
"gas-phase resistance" series, utilized water solutions of sodium
carbonate containing 0. 5 to 1. 0 wt % sodium ion to absorb SC>2 from
flue gas and from a synthetic flue gas composed of air and SC^- These
tests were designed to determine uncertain model coefficients for the
gas-side mass transfer resistance under conditions where gas-side mass
transfer is rate controlling. The second, or "gas/liquid-phase resis-
tance" series, used sodium carbonate solutions containing 0. 1 to 0. 5 wt %
sodium ion to absorb SO2 from flue gas and synthetic flue gas. For this
-••
Mathematical models describing pressure drop, particulate removal,
and sulfur dioxide removal for the three scrubber systems have been
presented in Reference 6.
4-3
-------
series, gas-side mass transfer was not rate controlling, and uncertain
model coefficients for the liquid-side mass transfer resistance could be
calculated using relationships for gas-side coefficients developed from
the "gas-phase resistance" tests. These runs also helped ascertain
the absorption capability of liquors associated with some variations of
the Double-Alkali scrubbing process over a useful range of operating
conditions. A summary of the sodium carbonate test results is presented
in Section 5. An analysis of the results and equations for predicting
SO2 absorption using the fitted gas and liquid-side resistances are pre-
sented in Section 13.
4.1.3 Limestone Wet-Scrubbing Tests
The primary objectives of the limestone wet-scrubbing test sequence
were:
(1) To characterize, as completely as practicable, the
effect of important independent variables on partic-
ulate removal and SOg removal.
(2) To identify and resolve operating problems, such as
mist eliminator scaling and plugging.
(3) To identify areas or regions for reliable operation
of the three scrubber systems, consistent with rea-
sonable SO2 removal, and to choose economically
attractive operating configurations from within these
regions.
(4) To determine long-term operating reliability with
attractive configurations for one or more of the
scrubber systems and to develop definitive process
economics data and scale-up factors.
4-4
-------
To accomplish the first objective, a large number of short-term
(< 1 day/test) limestone factorial tests were made on each scrubber
system. The test data for this series are presented in Section 6 and
are analyzed in Section 14.
To accomplish the second and third objectives, a relatively small num-
ber of longer term (~ 500 hour) limestone reliability verification tests
were made on each scrubber system. These longer term tests were
also useful in (1) obtaining reliable material balances and (2) quanti-
fying variations in SO2 and particulate removal and in system slurry
compositions with time. The results of the limestone reliability veri-
fication tests are given in Section 7.
The fourth objective was accomplished by running long-term limestone
reliability tests, lasting up to 3 months in duration, on the TCA system.
The results of these tests are given in Section 8.
4.1.4 Lime Wet-Scrubbing Tests
The objectives of the lime wet-scrubbing test sequence were identical
to the objectives for the limestone wet-scrubbing sequence just described.
As originally planned, the testing was to be divided into the same three
categories: (1) short-term factorial tests, (2) longer term reliability
verification tests, and (3) long-term reliability tests. Subsequently,
it was planned to begin the lime testing with long-term reliability tests
on the venturi/spray tower system and to perform the factorial and
reliability verification tests at a later date (after October 1974). The
results of the long-term lime reliability tests are given in Section 9.
4-5
-------
4. 2 TEST DESIGNS
The test sequences for the air/water, sodium carbonate, limestone
factorial, and limestone reliability verification experiments were all
j-
full or partial factorial designs based upon the chosen independent
variables, their levels, and the restraints of time (outlined in Figure
4-1). The choice of the independent variables and their levels was
based upon pilot plant test results, the restrains of the system, and
results from mathematical models which relate the dependent and
independent variables.
For the air/water testing, the primary dependent variable was pressure
drop and the controlled independent variables were: gas rate, liquor
rate, venturi plug opening, number of grids and spheres in the TCA,
and height of marbles in the Marble-Bed.
For the sodium carbonate testing, the dependent variable was SO2
removal and the controlled independent variables were: gas rate,
liquor rate, venturi plug opening, SO2 inlet gas concentration, height
of marbles in the Marble-Bed, scrubber inlet liquor pH, scrubber
liquor sodium concentration, and stoichiometry (moles sodium added
per mole SO2 absorbed).
A factorial experiment is the name commonly applied to an experi-
ment wherein the effects of several independent variables (factors)
on the dependent variables are determined at each of two or more
levels.
4-6
-------
For the limestone factorial testing, the dependent variable was
removal and the controlled independent variables were: gas rate,
liquor rate, venturi pressure drop, number of headers in spray tower,
scrubber inlet liquor pH, and number of grids and spheres in the TCA.
Non-controlled independent variables were SO2 inlet gas concentration
and scrubber slurry temperature.
For the limestone reliability verification testing, the dependent vari-
ables were scrubber system scaling and plugging potential, and the
controlled independent variables were: gas rate, liquor rate, scrubber
inlet liquor pH, effluent residence time, solids concentration in the
scrubber recirculation slurry, and solids concentration in the discharge
sludge. Non-controlled independent variables were SO2 inlet gas con-
centration and scrubber slurry temperature.
4. 3 ANALYTICAL PROGRAM
Samples of slurry, flue gas, limestone, lime, and coal were taken
periodically for chemical analyses, particulate mass loading, and
limestone reactivity tests during the wet-scrubbing experiments.
Locations of slurry and gas sample points are shown on Figures 3-5,
3-6, and 3-7. A summary of the analytical methods for determining
important species in the slurry solids and slurry liquor is presented
in Table 4-1. A listing of the compositions of the raw materials used in
the testing program is presented in Appendix C.
4-7
-------
Table 4-1
FIELD METHODS FOR BATCH CHEMICAL ANALYSIS
OF SLURRY AND ALKALI SAMPLES
SPECIES DESIRED
oo
Sodium
Potassium
Calcium
Magnesium
Sulfite
Total Sulfur
Carbonate
Chlorides
FIELD METHOD
SOLIDS
X-ray Fluorescence
X-ray Fluorescence
Amperometric Titration
X-ray Fluorescence
Evolution
LIQUIDS
Atomic Absorption
Atomic Absorption
Atomic Absorption
Atomic Absorption
Amperometric Titration
Ba(ClO4)2 Titration
Infrared Analyzer
Potentiometric Titration
-------
Six Du Pont photometric analyzers were utilized for continuous SO?
gas analyzing at the inlets and outlets of all three scrubbers. Values
of pH were monitored on a continuous basis using fifteen Universal
Interlox pH analyzers. Three Universal Interlox electrolytic analyzers
were used to monitor electrical conductivity. A modified EPA partic-
ulate train (manufactured by Aerotherm/Acurex Corporation) was used
to measure mass loading at the scrubber inlets and outlets.
4.4 DATA ACQUISITION AND PROCESSING
Operating and analytical data were recorded automatically onto magnetic
tapes at the test facility. These were sent to the Bechtel Corporation
offices in San Francisco for processing. Additional data was recorded
manually in operating logs and graphs by on-site personnel.
4.4.1 Operating Data (ScanData Acquisition)
Over 150 pieces of "scan data" (flow rate, temperature, pH, etc. )
were recorded automatically at fixed time intervals onto magnetic tape
at the test facility. The scan data acquisition system was designed
and installed by Electronic Modules Corporation, and the tape recorder
was supplied by Cipher Data Products Corporation. A backup printed
record on paper tape was available if the recorder malfunctioned.
The scan data tapes were mailed to Bechtel Corporation in San Francisco
for processing. Preliminary processing consisted of reading the tapes,
translating the coded data into comprehensible numbers, and preparing
a report of the data.
4-9
-------
4.4.2 Analytical Data
The analytical data acquisition system, which recorded the results of
laboratory analyses on magnetic tape, was designed and (in part) in-
stalled by Radian Corporation. A mini-computer received inputs,
either directly from laboratory instrumentation or indirectly by read-
ing cards. The mini-computer performed certain calculations and
entered the resultant data on magnetic tape. The system generated,
on-site, a printed summary sheet of analytical data for each sample.
In San Francisco, data on tapes received from the test facility was
entered into a data base. The data were sorted, further calculations
were made (e.g., percent sulfite oxidation, stoichiometric ratio), and
reports were prepared which present the data covering a specified
period for a given scrubber.
4.5 MATERIALS EVALUATION PROGRAM
TVA has conducted a study for the evaluation of corrosion and wear of
plant equipment and test specimens (coupons) at the Shawnee facility.
A summary of this study is presented in Section 10. 11 of this report.
TVA reports on materials evaluation are included in Appendices J and K.
4-10
-------
Section 5
AIR/WATER AND SODIUM CARBONATE TEST RESULTS
The results of initial testing with air and water and with sodium
carbonate (soda ash) solution are presented graphically in this
section and tabulated in Appendix D. Pressure drop data are
presented in Section 5. 1. SO2 removal data from sodium carbonate
tests are presented in Section 5.2.
5. 1 PRESSURE DROP DATA FROM AIR/WATER
AND SODIUM CARBONATE TESTS
The pressure drop data for the air/water and sodium carbonate
runs for the three scrubber systems are shown in Figures 5-1
through 5-6 and in Tables D-l through D-9 of Appendix D. Tests
with both air and flue gas were made in each of the scrubbers.
An analysis of these data, including equations fitted to the primary
variables, is presented in Section 12.
5. 1. 1 Venturi Scrubber
The effects of throat gas velocity (40 to 100 ft/sec), liquid-to-gas ratio
(15 to 50 gal/mcf), and plug opening (25 to 80 percent) on venturi pressure
*
drop are shown in Figures 5-1 and 5-2. The pressure drop is a strong
function of all three variables.
#
Measured from venturi inlet duct to spray tower inlet duct.
5-1
-------
PLUG OPENING = 60 percent
40
50
60 70 80
THROAT GAS VELOCITY, ft/we
100
Figure 5-1. Effect of Liquid-to-Gas Ratio and Throat Gas Velocity
on Pressure Drop for the Chemico Venturi
5-2
-------
LIQUID - TO • G AS RATIO - 25 pl/mcf
60 70 80
THROAT GAS VELOCITY, ft/we
100
Figure 5-2. Effect of Plug Opening and Throat Gas Velocity on
Pressure Drop for the Chemico Venturi
5-3
-------
3.6
3.0 •-
2.5 • -
J
.£
g 2.0
CO
c
\u
o
ee
0 1.5
in
C
Ul
oc
1.0 -
0.5 -
BED CONSISTS OF 2 GRIDS WITH 10 INCHES OF SPHERES
8 10 12
GAS VELOCITY, ft/MC
14
16
Figure 5-3. Effect of Liquid-to-Gas Ratio and Gas Velocity on Pressure
Drop per Bed for the TCA
5-4
-------
3.5
3.0 -
2.5 -
2 2.0
CO
O
oc
Q
1.5 -
1.0
0.5
1 1 1 T
LIQUID - TO - GAS RATIO = 50 gal/mcf
8 10 12
GAS VELOCITY, ft/sec
16
Figure 5-4. Effect of Internals and Gas Velocity on Pressure Drop
per Bed for the TCA
5-5
-------
12
ll.
e
of
ui
8 • -
CO
e
0 6
O
LU
a
O
C
a
UJ
cc
I
Ul
£
4 -
2 -
HEIGHT OF MARBLES - 3.5 in.
D
A
A
4-
456
GAS VELOCITY, h/sec
Figure 5-5. Effect of Liquid-to-Gas Ratio and Gas Velocity on
Pressure Drop across the Marble-Bed
5-6
-------
12
8 • -
ffi
ec
3
Q
1U
at
S 4
c
Q
Ul
C
i
6 -
2 -
LIQUID-TO- GAS RATIO = 30 gal/mcf
4-
4-
678
GAS VELOCITY, ft/we
10
Figure 5-6. Effect of Bed Height and Gas Velocity on Pressure
Drop across the Marble-Bed
5-7
-------
Plug opening affects both the throat area and the throat length. In
Figure 5-2 the increase in pressure drop with plug opening at constant
gas velocity is primarily the result of increase in throat length. The
relationships giving throat length and throat area as functions of plug
opening for the Chemico venturi are presented in Equations 12-2 and
12-3, respectively.
5.1.2 TCA Scrubber - Single Bed
The effects of superficial gas velocity (4 to 12 ft/sec), liquid-to-gas
ratio (0 to 95 gal/mcf), and scrubber internals (grids and spheres)
on pressure drop across a single TCA bed are presented in Figures
5-3 and 5-4.
In Figures 5-3 and 5-4, pressure drop is shown to be a strong function
of gas velocity, liquor rate, and scrubber internals. A single bed
consisted of 10 inches static height of 1 1/2 inch, 5 gram spheres
plus two wire mesh restraining grids. As seen in Figure 5-4, the empty
scrubber and wire mesh grids account for about 10 to 20 percent of the
pressure drop across the bed. Because of erosion problems with the
wire mesh grids (see Section 10. 3. 1), they were replaced with bar-
grids prior to limestone reliability testing. The bar-grids have a
lower pressure drop than the wire mesh grids.
Strictly speaking, single bed pressure drops are not additive for multi-
bed columns since there are not two grids for each bed (i. e. , three
beds consist of four grids and spheres), and entrance and exit effects
are not accounted for. Total pressure drops across the TCA scrubber
5-8
-------
for several internal configurations are tabulated in Tables D-4 through
D-6 of Appendix D. Total pressure drop was measured from the
entrance of the scrubber presaturation sprays to the scrubber exit
downstream from the mist eliminator and its associated wash headers.
5.1.3 Marble-Bed Scrubber
The effects of superficial gas velocity (3 to 8 ft/sec), liquid-to-gas
ratio (13 to 64 gal/mcf), and height of marbles (2 to 5 in. ) on pressure
drop across the marble-bed and the turbulent layer immediately above
the bed are shown in Figures 5-5 and 5-6. Pressure drop increases
with all three of these variables.
5. 2 SULFUR DIOXIDE REMOVAL DATA FROM
SODIUM CARBONATE TESTS
A summary of the SO2 removal data from the sodium carbonate runs is
shown in Figures 5-7 through 5-13 and in Tables D-10 through D-16
of Appendix D. The SO_ removals have all been corrected for the dilu-
£
tion effect of water vapor and reheater gas pickup by the flue ga.s.
Runs were made both with air containing injected SO_ and with flue gas
from Shawnee boiler No. 10.
Sodium carbonate tests were made at conditions in which gas-side mass
transfer resistance was controlling (gas side resistance tests) and at
*
These tests were designed, primarily, to determine uncertain coef-
ficients in correlation models where gas-side mass transfer resis-
tance is rate controlling.
5-9
-------
100
95 •-
90 •-
O
w
E
CM
80 •-
UJ
O
a
75 -
70 •-
65 --
60
0
O
SCRUBBER INLET LIQUOR pH = 9.5
SCRUBBER LIQUOR SODIUM CONC. = 1.0 wl %
S02 INLET CONC. = 600-3,300 ppm
(Air/SO2 & Flue Gat)
LIQUID-TO-GAS RATIO = 8-50gal/mcf
THROAT GAS VELOCITY = 41-105 ft/we
PLUG OPENING = 40-80 percent
-1 1 1 1
468
PRESSURE DROP. in. HjO
10
12
Figure 5-7. Effect of Pressure Drop on SC>2 Removal in the Chemico
Venturi (Gas-Side Resistance Tests)
5-10
-------
95
90 --
85 •-
80 •-
c
CM
8 75
K
IU
u
EC
70 •-
65 --
60 -
55
SCRUBBER INLET LIQUOR pH = 7.0
SCRUBBER LIQUOR SODIUM CONC. - 0.5 wt %
S02 INLET CONC. = 1200 ppm (Air/SO2)
THROAT GAS VELOCITY =• 41-83 ft/we
PLUG OPENING = 60 percent
468
PRESSURE DROP, in.
10
12
Figure 5-8. Effect of Liquid-to-Gas Ratio and Pressure Drop on
SO, Removal in the Chemico Venturi (Gas/Liquid-
Side Resistance Tests)
5-11
-------
90
85 —
80 -
75 •-
in
E
Ol
70 •-
ui
u
E
UI
o.
65 •-
60 •-
55 •-
50
SCRUBBER INLET LIQUOR pH = 7.0
SO2 INLET CONC. = 1200 ppm (Air/S02)
LIQUID-TO-GAS RATIO = 25 gal/mcf
THROAT GAS VELOCITY = 41-104 ft/sec
PLUG OPENING = 1-67 percent
D
468
PRESSURE DROP, in. H2O
10
12
Figure 5-9. Effect of Sodium Concentration and Pressure Drop on
SOo Removal in the Chemico Venturi (Gas/Liquid-Side
Resistance Tests)
5-12
-------
70
65 --
60 •-
55 --
Ul
K
M
8 *>•-
Ul
U
K
UJ
a.
45 •-
40 •-
35 --
30
O
>
o /
o /
0 £/ O
**/
*
v
f/
/°
SCRUBBER INLET LIQUOR pH = 6.75-7.0
SCRUBBER LIQUOR SODIUM CONC. - 0.125-0.15 wt %
LIQUID-TO-GAS RATIO = 16-36 gal/mcf
THROAT GAS VELOCITY = 77-118 ft/tee
PLUG OPENING = 0-67 percent
-\ 1 1 1
8 10 12 14 16
PRESSURE DROP, in. HjO
Figure 5-10. Effect of Inlet SC>2 Concentration and Pressure Drop on
SOo Removal in the Chemico Venturi (Ga s /Liquid-Side
Resistance Tests)
5-13
-------
100
95 •-
90 • - A'
85 --
UJ
oc
B 80
tr
UJ
0.
75 --
70 •-
65
20
D
SCRUBBER INLET LIQUOR pH = 9.5
SCRUBBER LIQUOR SODIUM CONG. = 0.5 wt %
SO2 INLET CONC. - 900 ppm (Air/SO2)
D GASVELOCITY= 6.2 ft/sec
O GAS VELOCITY = 9.2ft/iec
A GAS VELOCITY = 12 ft/sec
4-
4-
40 60 80
LIQUID-TO-GAS RATIO, gal/mcf
100
120
Figure 5-11.
Effect of Gas Velocity and Liquid-to-Gas Ratio on SO^
Removal for the TCA Operated as a Spray Tower (Gas-
Side Resistance Tests)
5-14
-------
100
95 •-
90 •-
85 --
iu
-------
100
95 •-
90 •-
85 •-
I
c
N
8
8
ec
8!
80 •-
75 - -
70 •-
60
SCRUBBER INLET LIQUOR pH = 9.5
SCRUBBER LIQUOR SODIUM CONC. - 1.0 wt%
S02 INLET CONC. - 1200 ppm (Air/S02)
MARBLE BED HEIGHT = 2 in.
a GAS VE LOCITY - 5.3 ft/we
O GAS VELOCITY - 8 ft/sec
1 1 1
10
20 30 40
LIQUID-TO-GAS RATIO, gal/mcf
50
GO
Figure 5-13.
Effect of Gas Velocity and Liquid-to-Gas Ratio on SO2
Removal in the Marble-Bed Scrubber (Gas-Side
Resistance Tests)
5-16
-------
conditions in which both gas-side and liquid-side mass transfer resis-
tance were important (gas/liquid-side resistance tests). Data from the
sodium carbonate tests indicated that gas-side resistance is rate con-
trolling at an inlet pH of 9. 5 and Na concentration of 0. 5 wt % or
higher, and at an inlet pH above 8. 5 and Na concentration of 1. 0 wl %.
Below these limits of pH and Na concentration, both gas-side and liquid-
side mass transfer were controlling. (See Runs 202-1A through 202-ID
in Appendix D, Table D-10. )
The gas-side resistance tests came to steady-state within a few minutes
after the gas or liquor flow rates, plug positions (or pressure drops),
and inlet SO2 concentrations were changed. The gas/liquid-side resis-
tance tests had to be run over longer periods of time (greater than
six hours) because of the apparent large variations in SO- removal,
L*
due to variations in inlet liquor pH, Na+ concentration, and stoichiometry.
An analysis of the data from the soda-ash tests for the three scrubber
systems is presented in Section 13 of this report. For the gas-side
resistance tests, the analysis includes equations representing SO-,
removal for all three scrubbers as a function of the independent vari-
ables. The gas/liquid-side resistance tests have been analyzed rigorously
only for the venturi scrubber.
5. 2. 1 Venturi Scrubber
Percent SO? removal versus venturi pressure drop for different liquid-
to-gas ratios (12 to 50 gal/mcf), liquor sodium concentrations (0. 125
5-17
-------
to 0. 5 wt %) and inlet SO? concentrations (1200 to 3300 ppm) are shown
in Figures 5-7 through 5-10. Figures 5-1 and 5-2 show venturi pres-
sure drop as a function of throat gas velocity (40 to 100 ft/sec), liquid-
to-gas ratio (15 to 50 gal/mcf), and plug position (25 to 80 percent open).
The percent SO- removal for the gas-side resistance tests is shown in
Figure 5-7. The SO. removal increases with pressure drop and is
independent of inlet gas SO? concentration, which indicates gas-side
control of SO_ transfer.
Lt
Low sodium concentration (0. 125 to 0. 5 wt %) and low inlet liquor pH
(6. 75 to 7. 0) data are shown in Figures 5-8 through 5-10. Here SO_
removal is shown to be a function of venturi pressure drop, liquor rate,
gas rate, sodium concentration, and inlet gas SO? concentration. These
data indicate that both gas-side and liquid-side mass transfer resistance
is important.
5.2.2 TCA Scrubber as a Spray Tower
The effects of liquid-to-gas ratio (25 to 100 gal/mcf) and gas velocity
(6.2 to 12 ft/sec) on SO- removal for the gas-side resistance tests
are shown in Figure 5-11. The data are for the TCA with no internals
*
(TCA operated as a spray tower). The SO_ removal at higher values
of removal (90 to 100 percent) depends on both liquor rate and gas velocity.
*
Gas-side resistance tests with the TCA in Lts normal three-bed con-
figuration resulted in SO, removals greater than 99 percent.
5-18
-------
5.2.3 Marble-Bed Scrubber
The effects of liquid-to-gas ratio (8 to 27 gal/mcf), marble height (2 and
5 inches), and gas velocity (5.3 and 8 ft/sec) on SQ_ removal for the
gas-side resistance tests are shown in Figures 5-12 and 5-13. The
SO7 removal at higher values of removal (90 to 100 percent) depends
on liquor rate and marble height, but is independent of gas velocity at
constant L/C.
5-19
-------
Section 6
LIMESTONE FACTORIAL TEST RESULTS
The significant SO2 removal data from the limestone short-term
(< 1 day per test) factorial testing on the three scrubber systems are
presented graphically in this section. A complete chronological tabular
listing of the factorial data is presented in Appendix E. Properties of
coal and limestone used during the tests can be found in Appendix C.
The factorial tests were designed to determine the effects of the primary
independent variables (e. g., gas and liquor flow rates) on SO2 removal
for the scrubber systems. An analysis of the data is presented in
Section 14 of this report where closed-form equations, compatible with
boundary restraints, are presented for predicting SO2 removal.
Variables which were found to be significant by a statistical analysis
of the data were introduced into the closed-form equations.
The initial block of limestone factorial testing on the three scrubber
systems was made from August 1972 through January 1973 (Tables E-1
through E-3, Appendix E). During this period, it was not possible to
operate the test facility in a totally closed liquor loop without facility
*
modifications. In closed liquor loop operation, the raw water input
*
The modifications were completed during a five-week boiler outage
in February and March 1973 (see Figure 4-1). These modifications
are discussed in Section 10. 1.
6-1
-------
to the system is equal to the water normally exiting the system in the
humidified flue gas and in the settled sludge. Settled sludge concentra-
tions in lime/limestone -wet-scrubbing systems are normally equal
to or greater than 38 percent by weight of solids. During the factorial
testing, water input was excessive, and sludge with less than 38 wt %
solids had to be discharged from the systems.
A second block of limestone factorial testing was made with the spray
tower in September 1973, under closed liquor loop operation (Table
E-4, Appendix E). The spray tower system had been modified during
the February 1973 boiler outage to increase the maximum slurry flow
to the spray headers from 600 to 1200 gpm. For the spray tower,
only the closed liquor loop factorial data will be discussed in this report.
The earlier open liquor Loop data (Table E-l, Appendix E) have been
discussed in Reference 2.
A comparison between the open liquor loop factorial data for the scrubber
systems and longer term closed liquor loop replicate runs has shown
that SO, removal is not significantly affected by liquor composition
within the region investigated. Also, models developed for predicting
SO2 removal have shown that, at a specified scrubber inlet liquor pH,
the SO£ removal efficiency is not significantly affected by liquor com-
position within the region investigated (see Section 14). It is presumed,
therefore, that the factorial data generated during open liquor loop
operation is applicable for systems operating with closed liquor loops.
Although satisfactory material balance closures could not be obtained
during the limestone factorial testing, confidence in the generated data
is based on the following:
6-2
-------
Wet chemical analyses for SO- in the inlet and exit gas streams
repeatedly corroborated Du Pont SO, analyzer measurements.
Sulfur removals in longer term closed liquor loop limestone
runs, with excellent material balance closures for sulfur
(see Sections 7 and 8), were in close agreement with factorial
replicate runs for the scrubber systems.
6. 1 SO2 REMOVAL RESULTS
For the data presented graphically in this section, replicate runs have
been drawn as single data points, with the average value and range of
values for SO, removal indicated. All of the replicate runs are listed
in Appendix E.
6. 1. 1 Venturi Scrubber (Table E-l, Appendix E)
The effect of gas and liquor flow rate on SO£ removal for the venturi
scrubber with 9 inches of pressure drop is shown in Figure 6-1. The
data indicate that SO£ removal is a function of liquor rate but is only
slightly affected, if at all, by gas rate within the region investigated.
SO-> removal was not significantly affected by pressure drop within
the region investigated (6 to 12 inches H_O).
6.1.2 Spray Tower (Table E-4, Appendix E)
The effect of gas and liquor flow rate and inlet liquor pH on SO? re-
moval for the four-header spray tower is shown in Figure 6-2. The
data indicate that SO7 removal is a significant function of liquor rale,
L*
gas rate (gas velocity), and inlet liquor pH within the region investigated.
6-3
-------
60
50 ••
40 --
O
CO
I-
z
LLI
U
20 ••
$
LIQUOR FLOW RATE = 600 gpm
n LIQUOR FLOW RATE - 300 gpm
SCRUBBER INLET LIQUOR PH = 6.0-6.3
SO2 INLET CONCENTRATION = 2200-3000 ppm
PERCENT SOLIDS = 5-8%
HOLD TANK RESIDENCE TIME > 30 min.
SCRUBBER OUTLET LIQUOR TEMP.= 107-120 °F
15,000
1
20,000
25,000
30,000
GAS FLOW RATE, ocfm (a 330°F
Figure 6-1. Effect of Gas and Liquor Flow Rates on SC^ Removal in
the Chemico Venturi with Nine Inches of Pressure Drop
6-4
-------
90 --
80 --
_, 70 ••
O
z
UJ
u
60 ••
50 -•
40 •-
O LIQUOR RATE = 1,200 gpm (4 HEADERS)
O LIQUOR RATE = 900 gpm (3 HEADERS)
D LIQUOR RATE = 600 gpm (2 HEADERS)
PERCENT SOLIDS = 10.5-12.5%
RESIDENCE TIME > 18 min.
SO2 INLET CONC. = 2,900-3,500 ppm
SCRUBBER OUTLET LIQUOR TEMP. = 126-129° F
4 HEADERS
-------
Figure 6-3 is a cross-plot of Figure 6-2, showing the effect of liquid-
to-gas ratio and gas velocity on SO2 removal for an inlet liquor pH
of approximately 6. 0. The effect of liquid-to-gas ratio on SO2 removal
(for a gas velocity of 8. 0 ft/sec) at liquor inlet pH ranging from approx-
imately 6. 0 to 5. 8 is shown in Figure 6-4.
6.1.3 TCA Scrubber (Table E-2, Appendix E)
The results of the EPA TCA limestone runs are summarized in Figures
•jf
rt*
6-5 through 6-7.
Figure 6-5 shows the effects of spheres versus no spheres and gas flow
**
rate on SO? removal in the six-grid, three-bed TCA system. The
data indicate that SC>2 removal is significantly affected by the presence
of the spheres and is only slightly affected by gas rate within the region
investigated.
The liquor and gas rate effects on SC^ removal in the four-grid, three-
bed TCA system are presented in Figure 6-6. As shown from this data.
""From November 4, 1972, to January 15, 1973, TVA conducted a spec-
ial series of tests with the TCA scrubber to provide process and equip-
ment scale-up and design information for the 550 Mw coal-fired TVA
Widows Creek Unit 8 retrofit limestone scrubbing system. The results
shown on Figures 6-5 through 6-7 do not include the TVA tests.
*
For the six-grid, three-bed configuration, spheres were placed between
the first and second, third and fourth, and fifth and sixth grids. Sub-
sequent to the initial factorial testing of the TCA in the six-grid con-
figuration, all testing has been done with the TCA in the "normal"
four-grid, three-bed configuration (see Figure 3-2).
6-6
-------
100
90 •-
80 -•
o
CM
70 --
z
LLJ
u
60 -•
50 ••
40
20
SCRUBBER INLET LIQUOR PH « 6.0
PERCENT SOLIDS = 10.5-12.5%
RESIDENCE TIME > 18 min.
SO INLET CONCENTRATION = 2,900-3,500 ppm
SCRUBBER OUTLET LIQUOR TEMP. = 126-129° F
4,7 ft/sec
6.7
8.0
30 40 50 60 70 80
LIQUID-TO-GAS RATIO, gol/mcf
90
100
Figure 6-3. Effect of Liquid-to-Gas Ratio and Gas Velocity on SO2
Removal in the Spray Tower
6-7
-------
90
80 ••
70 •-
O
LU
OC
u
O£.
60 ••
50 •-
40 •-
30
PERCENT SOLIDS = 10.5-12.5%
RESIDENCE TIME > 18mm.
SO2 INLET CONCENTRATION = 2,900-3,500 ppm
SCRUBBER OUTLET LIQUOR TEMP. = 126-129° F
GAS VELOCITY = 8.0 ft/sec
SCRUBBER INLET
LIQUOR PH« 6.0
SCRUBBER INLET
LIQUOR pH *5.8
10 20 30 40 50 60 70
LIQUID-TO-GAS RATIO, gol/mcf
BO
90
Figure 6-4. Effect of Scrubber Inlet Liquor pH and Liquid-to-Gas
Ratio on SO2 Removal in the Spray Tower at 8. 0 ft/sec
Gas Velocity
6-8
-------
100
95 --
90 --
- S5
|
£
Cf80
i-
B
75 -•
70 -•
65 •-
60
102-1 18 °F
{5.5in.H20)
6* I] f\\
in.H.O)
D
(2.0in.H20)
Li
(2.5in.H20)
](3.6in.Hr
+
LIQUOR RATE = 1,190-1,210 gpm
SO2 JNLET CONCENTRATION = 1,700-2,950 ppm
SCRUBBER INLET LIQUOR pH = 6.0-6.3
PERCENT SOLIDS = 7.5-11.5%
HOLD TANK RESIDENCE TIME = 4.6 min.
SCRUBBER OUTLET LIQUOR TEMP. = 110-120° F (EXCEPT AS NOTED)
HEIGHT OF SPHERES
O 5 INCHES/BED (3 BEDS)
D NO SPHERES
NUMBERS IN PARENTHESES REPRESENT TOTAL PRESSURE DROPS
(EXCLUDING MIST ELIMINATOR & KOCH TRAY).
-I
-f-
+
•4-
+
+
+
+
+
+
15,000
20,000
25,000
GAS FLOW RATE.acfm <& 280 F
Figure 6-5. Effect of Spheres versus no Spheres and Gas Flow Rate
on SO, Removal in the Six-Grid, Three-Bed TCA
6-9
-------
100
95 -
90 -•
85 . .LIQUOR RATE=900 gpm
80 +
z
LU
u
70 ••
65 --
60 •-
55 --
50
LIQUOR RATE=1200 gpm
LIQUOR RATE=600 gpm
(3.0in.H_O)
. in.
- n(7.0fn.H20)
(3.8in.H20)
<£>(3.5in.H20)_
>(4.4in.H,0)
-^ L
H - 1
SO INLET CONCENTRATION = 1,800-2,700 PPm
SCRUBBER INLET LIQUOR PH = 6.0-6.3
PERCENT SOLIDS = 6- 11%
HOLD TANK RESIDENCE TIME >18 min.
SCRUBBER OUTLET LIQUOR TEMP. = 111-123° F
HEIGHT OF SPHERES = 5 INCHES/BED
NUMBERS IN PARENTHESES REPRESENT TOTAL PRESSURE DROPS
(EXCLUDING MIST ELIMINATOR & KOCH TRAY).
1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 -
15,000
20,000 25,000
GAS FLOW RATE, acfm @ 280°F
Figure 6-6. Effect of Gas and Liquor Flow Rates on SO2 Removal in
the Four-Grid, Three-Bed TCA
6-10
-------
100
95 -.
90 -•
85 -
< 80
O
CM __
O 75
70 ••
65 ••
60 ••
55 ••
50
10.5 ft/a
3 ft/J
sec
SO2 INLET CONCENTRATION = 1,800-2,500 ppm
SCRUBBER INLET LIQUOR pH = 6.0-6.3
PERCENT SOLIDS = 6-11%
HOLD TANK RESIDENCE TIME > 18 min.
SCRUBBER OUTLET LIQUOR TEMP. = 111-123° F
HEIGHT OF SPHERES = 5 INCHES/BED
20 30 40 50 60 70
LIQUID-TO-GAS RATIO, gal/mcf
80
90
Figure 6-7. Effect of Liquid-to-Gas Ratio and Gas Velocity on SO2
Removal in the Four-Grid, Three-Bed TCA
6-11
-------
SO? removal is a significant function of liquor rate and is only slightly
affected, if at all, by gas rate within the region investigated. Figure 6-7
is a cross-plot of Figure 6-6 showing the effect of liquid-to-gas ratio
and gas velocity on SO? removal.
6.1.4 Marble-Bed Scrubber
Figure 6-8 shows the effect of gas and liquor flow rates on SO2 removal
in the Marble-Bed system with five inches of marble-bed height. The
data indicate that SO- removal is a function of liquor rate but is only
Li
slightly affected, if at all, by gas velocity within the region investigated.
Figure 6-9 is a cross-plot of Figure 6-8 showing the effect of liquid-
to-gas ratio and gas velocity on SO? removal.
6.Z ANALYTICAL RESULTS
As mentioned previously, a majority of the limestone factorial tests
with the three scrubber systems were made during open liquor loop
%
operation. The average concentration of total dissolved solids in the
scrubber inlet liquor during these tests was about 3800 ppm. The
++ + +
average species concentrations were: 1000 ppm Ca , 70 ppm Mg ,
40 ppm Na"1", 50 ppm K+, 250 ppm SO3~, 1200 ppm SO4 = , 100 ppm
CO3~, and 1100 ppm Cl". The chlorides in the liquor are attributable
to chlorides present in the coal which are converted to HC1 and absorbed
from the flue gas.
Analytical data for closed liquor loop limestone testing are presented
In Sections 7 and 8.
6-12
-------
100 --
<
I
I
80 ••
60 -•
20 -•
H 1
TOTAL LIQUOR RATE = 400 gpm
TOTAL LIQUOR RATE = 600 gpm
TOTAL LIQUOR RATE = 800 gpm
SO. INLET CONCENTRATION = 2,400-3,200 ppm
SCRUBBER INLET LIQUOR pH = 6.0-6.3
PERCENT SOLIDS = 5-7%
HOLD TANK RESIDENCE TIME = 50 mm.
SCRUBBER OUTLET LIQUOR TEMP. = 115-125° F
(9-11 in.H20)
'(8-10in.H20)
)(10-12 in.H2O)
(8-9in.H20)
(9-10in.H2O)
NUMBERS IN PARENTHESES REPRESENT MARBLE-BED
PRESSURE DROPS (EXCLUDING MIST ELIMINATOR)
IN A SCALE-FREE BED.
20,000
1 - 1
25,000
1
-I 1-
30,000
GAS FLOW RATE,ocfm (« 330 F
Figure 6-8. Effect of Gas and Liquor Flow Rates on SO2 Removal in
the Marble-Bed Scrubber with Five Inches of Marbles
6-13
-------
100
80 •-
LLJ
ae
e>
O
i/)
60 ••
40 ..
20 ••
10
8.2 ft/sec
5.5 ft/tec
SO2 INLET CONCENTRATION = 2,400-3,200 ppm
SCRUBBER INLET LIQUOR pH = 6.0-6.3
PERCENT SOLIDS = 5-7%
HOLD TANK RESIDENCE TIME = 50 min.
SCRUBBER OUTLET LIQUOR TEMP. = 115-125° F
1 1 1 1 1 1 1
20 30 40 50
LIQUID-TO-GAS RATIO, gol/mcf
60
70
Figure 6-9. Effect of Liquid-to-Gas Ratio and Gas Velocity on SO2
Removal in the Marble-Bed Scrubber with Five Inches
of Marbles
6-14
-------
The composition of solids in the shirry is fixed by the moles CaCCK
added per mole SO-, absorbed (stoichiometric ratio), the overall per-
cent oxidation of sulfite to sulfate within the system, and the percent
of fly ash. The mole percent oxidations averaged approximately 30
percent during the open liquor loop factorial testing and the fly ash
comprised from 30 to 50 wt % of the solids for the scrubber systems.
6-15
-------
Section 7
LIMESTONE RELIABILITY VERIFICATION TEST RESULTS
Performance data from limestone reliability verification testing at
the Shawnee facility are presented in this section, along with an evalua-
tion of each reliability verification test. Operating experience assoc-
iated with specific system components (e.g., mist eliminators, reheaters,
SOg gas analyzers) will be discussed in detail in Section 10. Properties
of coal and limestone used during these tests can be found in Appendix C.
As part of the analysis of the data, the scaling potential of scrubber
internals has been correlated with the calculated scrubber liquor sulfate
(gypsum) saturation. This is discussed in Section 7. 3.
7. 1 RELIABILITY VERIFICATION PERFORMANCE DATA
The major objective of the closed liquor loop limestone reliability veri-
fication tests was to identify areas or regions for reliable long term
(4 to 6 months) operation consistent with reasonable SO? removal.
A majority of the reliability verification tests were on-stream for ap-
proximately 500 hours (3 weeks). It should be noted that it is difficult
to assess long-term reliability from runs lasting 500 hours, especially
7-1
-------
when small quantities of scale or soft solids are present on system
components.
Summaries of the limestone reliability verification test results for the
venturi/spray tower, TCA, and Marble-Bed systems are presented
in Tables 7-1, 7-2, and 7-3 and evaluated in Tables 7-4, 7-5, and 7-6.
respectively. Complete operating data for selected Runs 506- 1A
(venturi/spray tower), 510-ZA (TCA), and 506-3B (Marble-Bed) are
graphically presented in Appendix F.
The major system problems addressed at the test facility are assoc-
iated with scaling and plugging of the equipment. A majority of the
component problems can be solved by improved design. The major
variables affecting scaling and plugging tendencies are: (1) effluent
residence time, (2) percent solids recirculated, (3) percent oxidation
of sulfite to sulfate, (4) gas velocity, ("5) liquid-to-gas ratio, (6) scrub-
ber pH, and (7) concentration of solids in the discharge sludge.
The limestone reliability verification tests were run at reduced scrub-
ber inlet liquor pH (5. 6 to 5. 9) to decrease the potential for sulfite
scaling and to increase limestone utilization. A modest reduction in
51";';
SO? removal, from high-pH "' performance, is the price of the increased
system reliability and limestone utilization.
*
In this report "scale" refers only to crystalline hard solids, and
"solids" or "soft-solids" refer to mud-like slurry solids. "Plug-
ging" refers to the accumulation of mud-like slurry solids. Also,
scale refers to sulfate base scale, unless otherwise noted.
The limestone short-term factorial tests were run at a scrubber inlet
liquor pH range from 6.0 to 6.3 (see Section 6).
7-2
-------
The test conditions for the initial reliability verification runs were
selected in order to give maximum probability for reliable operation
consistent with reasonable SO- removal. Subsequent tests were made
to observe the effects of reduced effluent residence time, reduced
percent solids recirculated, increased gas velocity (at constant liquor
rate), and increased scrubber inlet liquor pH on system reliability,
In addition, the effects of mist eliminator type (polypropylene vs,
stainless) and mist eliminator wash location (bottomside vs. combined
bottomside and topside washing) were investigated in the venturi/spray
tower system.
7.1.1 Venturi/Spray Tower System
Results of the venturi/spray tower reliability verification tests are
reported in Table 7-1 and evaluated in Table 7-4. The initial venturi/
spray tower test Run 501-1A was conducted, as mentioned previously,
under conditions selected to maximize the probability for reliable
operation (i. e. , an effluent residence time of 20 minutes, a percent
**
solids recirculated of 15-16 percent, and a spray tower gas velocity
of 5.4 ft/sec). As expected, the relative condition of the system at the
end of the test was good. Subsequent venturi/spray tower runs were
made at more economically attractive operating conditions. Run 507-1A
indicated relatively good system condition at the end of 434 operating hours
Minimizing effluent residence time and percent solids recirculated
and maximizing gas velocity is, of course, economically attractive.
*.
Approximately 40 percent of solids is fly ash.
7-3
-------
Table 7-1
SUMMARY OF LIMESTONE RELIABILITY VERIFICATION TESTS:
VENTURI/SPRAY TQWER SYSTEM
Ran No.
Test Objectives
Start -of-Run Dalr
End-of-Run Dah*
On Stream Hours"1
Gas Rale. acfm@ 330"F
Spray Tower C.ai Vrl . fpi @I25°F
Venturi/Spray Tower
Liquor Rates, gpm
Spray Tower L/C, gal/mcf
Percent Solid* Recirculated
Efnuent Residence Time, nun.
Stotchiometric Ratio,
moles Ca/tnoles SGj absorbed
Average % Limestone Utilization.
IDOx moles SOj absorbed/mole Ca
Inlet SO2 Concentration, ppm
Percent SO? Removal
Scrubber [nki pH Range
Scrubber Outlet pH Range
Percent Sulfur Oxidized
Solids Disposal System
Loop Closure, % Solids Disch.
Clear Liquor to Mist Elim. , gpm
Make-Up Water to MistElirn., gpm
Dissolved Solids, ppm
Total 6P Range, in. H2O(bl
Mist Elim^P Range, in HZO
Mist Eliminator Condition
al End of Run <<=> I'1
Venturl and Spray Tower
Conditions at End of Run
501-IA
Reliability verifi-
cation test @ low
pH with Chevron
316 5 S mist
eliminator.
4/9/73
5/9/73
645
20,090
5.4
600/600
37
15-16
20
.4-1. 6(4/9-4/27)
.9-Z. l(4/27-5/9l
2,400-3.100
70-75
5.8-6.0
5.4-5.7
5-25
Cla rifle r
20-26
14-20
12-14
9,000-8,000
10-11
O.<0-0.65
Scattered 1/8"
scale on top and
20 mil scale on
bottom
Thin peattered
scale and eroded
gutdevane bolts in
venturl section
Scattered 15-25
mil scale on after-
scrubber walls
above trapout tray.
9 of 28 slurry
ST4BFCN spray
nozsleo in after-
scrubber were
plugged
502-M
Same as 501-IA
with Chevron
jlastlc milt
eliminator.
kl 13/73
6/26/73
278
20.000
5.4
600/600
37
14-16
20
1.5.1.9
59
2,200-3,000
07-73
5.7-5.9
5.3-5.5
15-35
Clarifier
21-39
14-20
12-14
-
10.0-10.5
0.40-0.55
1/16" ecale on top.
Light scale and
solids between
vanes. Approxi-
mately 1/3 ft3
solids buildup at
4 locations (junc-
tion of support
bars).
5 mil scale on
walls below
plug and about
] >6 bolts heads on
venturl section
eroded, 10 mil
scale on after-
sc rubber walls
below trapoul tray
S01-IA
Same as S02-IA
with hiuht r liquor
rati and lower
porcrnL inlida
recirrulatcd.
6/29/73
7/11/71
zsr,
ZO.OQQ
5 4
(tOO/IZOO
75
8-9
20
1 4-1 6
67
2, 200-3. 000
74 -U
5 b-5.fi
5. 1-5. 3
20-40
Clarifier
27-41
27-33
10-12
7.300
10 4-11 6
0.45-0.55
No scale or solids
on top. 1/2 to 1"
L«r«d Ac-Lids de-
patit on lop of
on 2nd pas* of
vane. Center
portions clean
20 mil scale on
walla below plug
and noticeable
erosion of guide -
in venlun section
15 mil sra.e on
aftcr-tcrubber
walla below I rap-
out tray. 3 of ZA
• lurry op ray noz-
zles plugged.
SOt.-IA
Samr d*. MM-I \
with hmhi r t!«i*i
rail ..nH lower . t-
[lucni n sidonci
Mm*.' Top and
jotlcim misi chin.
wish.10
7/25/7?
H/lJ/75
417
10.000
8.0
(.00/1200
50
K-IO. 5
12
1.4-1 <' fl <>-! R
from 8/3-f,|l»lsl
67 159 from
8/3 to 8/6)t"'Rl
2,500-3.300(2,000-
2, 200 on 7/20 b 28)
U-71,
5.35-5.65
4 85-5. 1
20-35
Clarifier and
centrifuge
55 -h5
40-55
8-11
14, 9001'1
12 5-14 5
1 0-1.25 I"1
Some plastic vanes
damaged by chunks
from outlet duct
5 mil solids buildup
Moderate solids
buildup on dead
spots on support 1
beams & adjacent
vanes
15 mil scale on walls
of flooded elbon k
below plup. Conrd
erosion of suidevane
mil lisht scsttered
scale nn afler-
se rubber walls K
spray headers No
sigmf solids accum
above ^ below trap-
out Irsy Severe
solids deposits in
reheater initlel duel
U) Include* line-out
(b> Spray tower and venturi, excluding mial eliminator
U) Chevron plastic four-papa open mist ehm. in ill run*
except SOI-I A where Chevron 3165 S three-pass
open ml«t eliminator was used.
(d) Reacmuy of Limes tone decreased after 4/Z7 due la
larger average limes Ion*? particle §iz«.
(e) Mist tlim was washed from bottom only for all runs
except Run 506- IA where it waa waahed from both
top and bottom
If) The atoichiomeiry rangr was higher at l.i>-l H
(59% average limestone utilization! from KM to H/u
with correspondingly hip her scrubbi r inlri pH rdnjit
of 5 5 10 5.65
(gl As of 7^27, a new limrBioni. rontaintn^ ip)>rnx
1 25 mole % MR CO 3 v.aa used Prior i«> ihi» luiu
a li met tone having apprnx. ^ molr " \1«CO^ had
been uned
(hi Range given IB for period
steadily .ram 1 25 to 1 40 in 1!ZO afu.r S/h
(i) Increasing Steadily dunitu r
ppm.
frnni K. 000 lo M.100
7-4
-------
Table 7-1 (continued)
SUMMARY OF LIMESTONE RELIABILITY VERIFICATION TESTS:
VENTURI/SPRAY TOWER SYSTEM
Run No
Teat Objectives
Start -of-Run Date
End- of- Run Date
On Stream Hours'*'
GIB Rate. acfm@ 330° F
Spray Tower Gas VM. . fps @I25°F
Veniuri/SprJy Tower
Liquor Rates, gpm
Spray Tower L/C, gal/mcf
Percent Solids Recireulated
Effluent Residence Time, mm
Stoichiometric Ratio.
inolei Ca/moles SOj absorbed
Average % Limestone Utilization,
lOOx moles SOj absorbed/mole Ca
Inlet SO, Concentration, ppm
Percent 5OZ Removal
Scrubber Inlet pH Range
Scrubber Outlet pH Range
Percent Sulfur Oxidized
Solids Disposal System
Loop Closure, % Solids Ditch.
Clear Liquor to Mist Elim. , gpm
Make-Up Water to Mist Ehm . gpir
Dissolved Solid I r ppm
Total AP Range, in. H2O(t>1
Mist Elim.AP Range, m. H2O
Mist Elimuiator Condition
at End of Run(cl
Venturi and Spray Tower
Conditions at End of Run
507- IA
Same ai 506-1A
with chevron 31 &
S S mi at dim. with
bottom wash only
8/22/73
9/9/73
434
30. 000
6.0
600/1 ZOO
SO
B-10 5
12
1 2-1.4 (1 4.1 75
from 8/31 to 9/7)W)
77 [63 from
8/31 to 9/7)(dt
Z, 400-3. 400(1,400
1.750, 3/31-9/3)
67-77
5 3-5.65
4.9-5.2
25-45
46-60'BI
6-ll'B'
16. J00-I8.800tet
13. 5-14. 5
1 25-1 35
S mil solids deposit
on all bottom vanes
fc 10 mil on all lop
vane a. In NE sec-
tion 2 ft2 area 75%
plugged {top), An-
other 2 ft2 25%
plugged concentration dropped in
1600 ppm.
(g) The flow ranges for clear liquor and makeup
water were 34-53 and 15-21 gpm, respectively,
from 8/31 to 9/9. when clinfisr only was used
(hi System shut down after 28 hours of operation due
to system problems (i e , high «nl rain me nl from
mbtelim top flush, pluggagc of ourlel rXi Pont SOj
analyzer sample probe*)
7-5
-------
Table 7-2
SUMMARY OF LIMESTONE RELIABILITY VERIFICATION TESTS:
TCA SYSTEM
Run Ni>
Teal Obipc MM-8
5lart-of-Run Oalr
End-of.Run Date
On Stream Hours'"1
Cas Rate, acfmp 300°F
Cai Velocity, fps (• 125°F
Liquor Rate, gpm
L/C. gal/mcf
Percent Solid* Recirculaled
Effluent Residence Time, nun.
Sloichiometrir Ratio,
moles Ca/molei SOj absorbed
Average % Limestone Utilization,
lOOx moles SO2 absorbed/mole Ca
Inlet SOj Concentration, ppm
Percent SO, Removal
Scrubber Inlet pH Range
Scrubber Outlet pH Range
Percent Sulfur Oxidized
Solids Disposal System
Loop Closure, % Solids Disch.
Clear Liquor to Koch Tray, gpm
Make-Up Water to Koch Tray, gpm
Dissolved Solids, ppm
Total AP Range, in H2O
Mist Eliminator and Koch Tray
AP Range, in. HjO
Mist Eliminator Condition
at End of lun
Bed Condition
at End of Run
Inlet Duct Condition
at End of Run
Other Problems
or Comments
501- ZA
Reliability verifi-
ation test @ low
H.
3/22/73
4/2J/73
580
20, 000
8.3
1200
75
14-16
20
1. 1-1.4
80
2. 200- J. 300
80-86
5 6-6 0
5. 1.5.7
20-40
Clarifter
25-48
20-30
7-12
4.000-10.000
4. 5-5. 3
1.6-2.0
1/16" scale on
lottom vanes
only
Spheres In middle
bed fell down to
2 holes In bottom
grid Replaced 3
dozen collapsed
spheres.
Slight solids
milt-up up-
stream and heavy
solids buildup
downstream of
cooling nozzles.
9 intermediate
shutdowns due to
cooling nozzle
and Ventri-Rod
pluggage. Ven-
trt-Rod pluggage
ranged from 12-
70%. Replaced
Ventri-Rod with
4 ST24FCN SS
Bete nozzles on
4/16/75
502-2A
ami- as 50I-2A
with hi|th stoichi.
mi-try and pH.
4/27/73
5/21/73
557
20, 000
8.3
1200
75
14-16
20
5-1.9 (2. 1-2.7
from 5/5-l2llcl
59 (42 from
5/5-12lul significant
grid wire con-
tinued
About 60% of duct
s rea plugged.
Solids buildup at
and upstream of
nozzles
4 intermediate
shutdowns due to
cooling nozzles
pluggage Used
SpracoTLB 31 b
SS nozzles on
5/5/75.
50H-2A
[cpltcati uf
OI-2A
5/25/71
5/29/75
98
20,000
8.3
1200
75
15-lu
20
1.2-1.4
77
2,300.3,000
82-87
5.6
5 0-5.2
20-35
Clarifier
31-43
5-18
7-12
-
5.0.6 0
1 9-2.3
Clean
Replaced about
5% of collapsed
placed 3 damaged
grid sections
Solids buildup up-
stream of cooling
nozzles
509- 2A
Sami a> 501 -ZA
with lowi r pt r-
crnt solid* n » irr
f./5/71
W25/73
4(.5
20. 000
«. 3
1200
75
8-9
20
1.2-1.45
75
2,000-3. 100
80-8H
5.5-5.8
5 0-5.4
32-50
Clarifier
26-45
20-45
7-11
8.300-11.800
5.0-5 8
1 9-2 0
1/16" srali on
west quadrant.
Replaced the da-
maged SW section
placed about 20%
of collapsed
spheres
Clean
Modified suot-
blowc r brad on
5/29/73 to haw
2 lets blowinu. air
forward only
Capped bollorn
cooling spray
nozzlr
(..) Include* lin^-oul
(b) Total, excludmgniisl iliminator and Koch Tray.
(c) Reactivity of limestone decreased during the period
of higher Btoichiomelry range and lower average lime-
atone utilisation, due to larger average limestone
particle sue.
(d) Range piven it for period before 5/1 5 Incroa-o
gradually from 6 to ° in H2O from ^/) ^ to S/il
7-6
-------
Table 7-2 (continued)
SUMMARY OF LIMESTONE RELIABILITY VERIFICATION TESTS:
TCA SYSTEM
Run No
Teat Objerliit b
Start-of-Run Dat<
Cnd-of-Run Date
On Stream Hours'3'
Gas Rate, arfrnfe' 300° F
Gas Velocity, fps g 125°F
Liquor Rate, gpm
L/C, gal/mcf
Percent Solids Rccirculated
Effluent Residence Time, nun.
Stoichiometric Ratio,
molei Ca /moles SOj absorbed
Average & Limestone Utilization,
lOOx moles SO2 absorbed/mole Ca
Inlet SO2 Concentration, ppm
Percent SO2 Removal
Scrubber Inlet pH Range
Scrubber Outlet pH Ringe
Percent Sulfur Oxidized
Solids Disposal System
Loop Closure, % Solids Disch.
Clear Liquor to Koch Tray, gpm
Make -Up Water to Koch Tray, gpm
Dissolved Solids, ppm
Total &P Range, in. H2O(M
MiBt Eliminator and Koch Tray
AP Range, in HjO
Mi«l Fliminator Condition
at End of Run
Bed Condition
at End of Run
Inlet Duct Condition
at End of Run
Other Problems
5IO-2A
Same as 509-2A
with higher gas
rate
6/27/73
7/10/73
297
25,000
10 5
1200
60
7.1-9.5
20
1.2-1 5
74
2, 000-2, 700
73-89
5.4-5.5
4.85-5.2
35-55
Clanfier
26-44
25-45
9-13
8.800-11,300
6 6-7 6
2 2-2.5
60 mil scale on
most of mist elim
3 of 14 sections in
SW corner were
partially plugged
with 1/2" solids
between bottom
vanes.
Several loose grid
wires. No grid
replacement
needed.
Clean
SM-2A
Sami as 5IO-2A
uith lower of flu on
r«. siricnce lime
and higher percent
7/Z2/73
8/13/7J
493
25.000
10. S
1200
60
13 5-16
4.4
1.25.1 55(7/22-8/51
1 15-1 3(8/6- 13)(8'
71 (7/22-8/5)
82 (8/6- Ul'R*
2. 100-3.100(1,800-
2 100 7/24 26&281
77-89
$ 2-5 55
4.7-5 0
20-50
Clanfier
27-52
5-26
9-13
9.800-11.400
7 0-8 5
2 2-2 5(2.5-2 8
from 8/10 to 8/131
207* area plugged
with solids. NW
quadrant had higher
buildup (50% plug-
ged) wuh ha rd
crysi solids
Solids buildup
mainly on bottom
\anea Pitting
continued
14**. damaged
spheres in low IT 2
beds Light scale
on IV'i, of bottom
pr.d
7 ft3 solids build-
up upstream of
nozzli s
As of 7/27 a new
limrstont. hating -
1 25 molf*.
MpCOj v.as used
Prior to this time,
limestone contain-
ing * 5 mole \
MgCO] was used
5I5-2A
Same d*. 5N-2A
with lowi r
pure mi solids
rccirrulaiecl
8/K./7J
9/10/75
571
25,000
10 S
1200
60
7 0-h 5
4 4
1.2-1.4(1.4-1 55
from 8/31 to 9/3t'cl
77 (68 from
8/31 to 9/31(cl
2.400-3,300(1.450-
1,700, B/31-1/3)
80-88
5 2-5 4
4 9-5 1
25-50(dl
Clarificr(cl
34-44(el
36-50
10-12
11.000-13. 300m
7 0-8 S
2 2-2 5(2.5-2 9
from 9/6 to Q/10)
40f« area plugged
Solids buildup
mainly on bottom
2 vanes. Up to 1"
solids buildup on
underside of Koch
tray 6 tray xalvcs
partially plugged.
llrukcn uri.
(c) High stotchtometry range of I 4-1 55 (68rn average
limestone utilization! caused by excess limestone in
scrubber slurry during the period of low inlet SO^
concentration lav 1600 ppm) from 8/31 through 9/3
(d)
48-80*. oxidation from R/31 through 9/3 when a\erau<
inlet SO, concent ration dropped to 1600 ppm
With clarificr and centrifuge before IM*
hours on 8/20. Porctni solids dischart.ffl
from centrifuge was 58-5**°,
No analytical data before 8/20, whi-n clai HUM
and centrifuge, were used
Indicates effect of utilization of new limestone
IBLL Other Problems or Comment si
\bout f> in' of support arid for top hi d Itrnki it
Some of top bed sphert s dropped into nudtlli IM.
-------
Table 7-3
SUMMARY OF LIMESTONE RELIABILITY VERIFICATION TESTS:
MARBLE-BED SYSTEM
Run No.
Tret Objectives
Starl-of-Run Date
End-of-Run Date
On Si ream Hours'"1
Ca> Rate, acfm 6 3JO°F
Gas Velocity, (pi @ I25°F
Liquor Rale* to Top/Bottom
Sprays, gpm
L/C. gal/mcf
Percent Solids Rccirculaled
Effluent Residence Time, mm
Stoichtometric Ratio.
molea Ca/moles SO2 absorbed
Average T« Limestone Utilization.
lOOx molcfl SOj absorbed/mole Ca
Inlet SO2 Concentration, ppm
Percent SOg Removal
Scrubber Inlet pH Range
Scrubber Outlet pH Range
(Wetr/Downcome r)
Percent Sulfur Oxidized
Solids Disposal Syslem
Loop Closure, % Solids Disch,
Clear Liquor to Mist Elim. , gpm
Make-Up Water to Mist Elim..|ipm
Dissolved Solids, ppm
Total &P Range, in. HjO""
Mist Ehm.&P Range, in. H^O
Mist Eliminator Condition
Bed Condition
at End of Run
[nlct Duel Condition
at End of Run
Other Problems
or Comments
501-3A t, 3B
Reliability verifi-
cation lest @ low
>H
3/14/73
4/23/73
77]
20, 000
5 5
ZOO/600
50
10-12
JO
1. 15-1.45(3/14-4/71
1.3-1.6 (4/8-Z3|(Bl
77 (3/14-4/7)
69 (4/8-23)<8>
2.500-3.300
65-71
5. 6-6. 0
5.4-5 7/
5.4-5.7
15-35
Cla rifle r
20-29
10-22
8.12
6. 900-8, 900
8.5-10.5
0. 17-0. Z5
1/E" aolida de-
30% of bed either
plugged or mar-
>lea in stratified
pattern.
Z ft of solids de-
aosit between
spray header and
scrubber.
Both soot blower
airjets projecting
forwa rd Several
shutdowns due to
slugged cooling and
»ottom spray noz-
zles Swirl vanea
in 13 of 16 CE bot-
tom bed spray
nozzles eroded
away
50Z-3A
Sambas 501 -3A 1,
3B with high stoi-
chiometry & pH.
4/25/73
5/7/73
285
20, 000
5.5
200/600
50
11-14
10
1 5-2. I (4/25-29)
1.9-Z. 7(4/2 9-5/7|ld
5k (4/Z5-Z9!
43 (4/29-5/7|ld)
2,600-3.200
67-77
5 8-6. 1
5.4-S.7/
10-30
Clarifier
19-25
13-23
7-20
3,700-8.000
7 5-11.0
0. 16-0 35
1 /4" alurry scale
top vanes of dc-
mistcr.
60ft of marbles
stratified 1 ft2
a rea was plugged
with solids.
b ft of solids de-
posit blocking 60-
70% of duct between
leader and
scrubber.
4 ST20FCN cooling
spray nozzles re-
placed by ST24FCN
nozzles At start of
run Swi rl vanes
in all 16 CE bottom
bed nozzles dis-
appeared Swirl
vanea in all 6 CE
top bed nozzles
lightly eroded
503-3A 1 3B
Same as 501 -3A Si
3B with lower pcr-
5/11/73
5/22/73
267
20, 000
5 5
200/600
50
B-ll
30
1 8-2.4
48
Z. 500- 3, 500
67-7!
5 7-5.9
5.4-5 7/
5. 1-5 3
15-30
Clarif. Ei centrifuge
57>oO (used vpnturi
clarifier 5/16-17)
43-53
3-5
11.000(el
8 0-9.3
0 1S-O.ZZ
1/3" solidi dc-
Ltghl. dust dc-
WBlt on bottom
side of mist elim.
25ft of bed was
plugged with solids
and had stratified
rows of marbles.
1-1/2 ft3 of solids
deposit between
leader and scrub-
ber.
Z cooling spray
nozzles were found
plugged All CE
Bottom bed nozxles
operated without
swirl vanes
Swirl vanes in CE
lop bed nozzles
still intact
504 -3A I 505- 3A
Sam, ai 50I.3A t.
3B with Spraco bid
5/Z5/73
6/4/71
233
20. 000
5 5
200/600
50
10-12
30
1 5-2 0
57
2, 300-3.100
67-72
5 6-5.8
5. 3/
5 2-5.4
10-30
Centrifuge'*'
60-65 [23-24
from 5/30-31l(cl
20-30
3-4
10. 500">
8.3-9.7
0 15-0 17
50-60 mil scale on
12ft of bed plugged
with solids 60ra
of bed had stratified
rows of marbles.
1 ft3 of solids de-
posit between header
and scrubber
All ZZ CE bed spray
nozzles replaced by
Spraco No 1736
ramp bottom nozzle <
at start of run
fa] Includes line-out
(b) Total excluding misl eliminate) .
(cl .Increasing steadily during run from 4 000 lo 11 000
ppm except for a brief decreasing period caused by
alone from * 16 to 5/17
<«>
(11
(R>
Uifd dander along from 5/30 - A/11
Only nne sample WAS taken during run
Fliffh sloichiomci ry range of 1 3-1 i.
limestone utilization) caused by sysienr
bed olu|EB«Rrt
|i.9S. average
. degradation
. avrrage
limeatnnr utilization) caused by decreased limrainne
reactivity (i •? larger average particle and
7-8
-------
Table 7-3 (continued)
SUMMARY OF LIMESTONE RELIABILITY VERIFICATION TESTS:
MARBLE-BED SYSTEM
Run No.
Trst Object iv i g
Start-of-Run Dan-
End-of-Run Date
On Stream Hours1*1
Gas Rale, acfm 4§ 330°F
Cae Velocity, fps
-------
Table 7-4
LIMESTONE RELIABILITY VERIFICATION TEST RUN EVALUATIONS:
VENTURI/SPRAY TOWER SYSTEM
P \R\MCTCR
Mint Eliminator Scaling
or Plugging
\cnturi and Spra> To\vei
Mechanical Condition at
End of Run
\ cnturi Scaling or
Plunging
Spray Tower Scaling or
Plu|!i>inc
TEST RUN
501-1A (645 Operating Hours)
Comments
Light scale on bottom
vanes. Scattered scale on
top vanes
Ncplipible solids deposits.
•Minht erosion of (juicle vane
bolts and surrounding area
in vcntu n.
Scattered lipht scale on
walls below, plup. Moder-
ate scale on walls of Hood-
ed elbow
Nculi^iblc solids deposits.
Scattered light scale on
walls
Scattered moderate solids
deposits on top blurrj head-
er, on bottom mist elimi-
nator wash header, and on
Relative
Condition
at
End -of -Run
Fair
Fair
Good
Good
502-1 A (278 Operating Hours)
Comments
Moderate scale on top
vanes.
Scattered light solids de-
posits on bottom vanes at
support bar junctions.
Moderate erosion of guide
vanes, bolts and cross
braces in vcntun.
Negligible scale on walla
below plug. Moderate
scale on walls of flooded
elbow.
Negligible solids deposits.
Light scale on walls below,
trapout tray
Scattered light solids de-
posits on top slurry header,
on bottom mist eliminator
wash header, and on
bottom of trapout tray
Relative
Condition
at
End -of- Run
Fair
Fair
Good
Good
503-1 A (256 Operating Hours)
Comments
No scale.
Non -uniform, light, scat-
tered solids deposits on
bottom two rows of vanes
Slight erosion of guide vane
Light scale OR walls b«low
plug. Moderate scale on
walls of flooded elbow.
Negligible solids deposits.
Light scale on walls below
trapout tray.
Light solids deposits on
bottom of trapout tray.
Relative
Condition
at
End-of-Run
Goad
Fair
Good
Good
506-1 A (417 Operating Hours)
Comments
No scale. Moderate solid:.
deposits around support I
beams. About 10% of plas-
tic top vanes damaged by
solids dislodged from stack
(Solids due to high entrain-
ment of mist eliminator
top flush).
area of ventun
Slight erosion of top splash
seal flange in ventun
Light scale on walls below
plug and on walls of
flooded elbow.
Negligible solids deposits.
Light scale on all four
spray headers and on about
50% of wall area above
trapout tray.
Light solids on bottom of
trapout tray and adjacent
walls.
Relative
Condition
at
Lnd-of-Run
Poor
Fair
Good
Fair
-J
I
-------
Table 7-4 (continued)
LIMESTONE RELIABILITY VERIFICATION TEST RUN EVALUATIONS:
VENTURI/SPRAY TOWER SYSTEM
P\R \METFR
Mi-l Eliminator *calinp
or Pluccmi!
V cnturi and Spra> Tow-er
Mechanical Condition at
End of Run
V enturi Scaling or
PluUiMllf!
Spray Tower Scnhnu or
Pluumni.
TEST RUN
507- 1A (434 Operatiny Hours)
Comments
No scale
\cglipible solids do po flits
on vanes. Scattered par-
tial plugging of about 87" of
top vane flow area.
Slipht erosion of guide
vane assembly.
No scale.
Moderate solids buildup at
\\et-dry interface due to
discontinued soot blowing.
\ef>li|:ible scale and solids
deposits.
Relative
Condition
at
End -of- Run
Good
Fair
Good
Good
50H-1A (28 Operating Houri)
Comments
No scale.
Negligible solids deposits.
High entrainment of
Relative
Condition
at
End -of -Run
Poor
-------
Table 7-5
LIMESTONE RELIABILITY VERIFICATION TEST RUN EVALUATIONS:
TCA SYSTEM
PARAMFTFR
Mist Flimmator and Koch
Tray Scaling or Plugging
Scrubber Mechanical (al
Condition at End of Run
Scrubber Scaling or
Pluppinp
Inlet Duct Pluepinf!
TEST RUN
501 -ZA (580 Operating Hours)
Comments
Negligible scale and solids
deposits.
Spheres from middle bed
dropped to bottom bed
through eroded p nd wires.
Negligible scale
Scattered solids deposits
on -walls below Koch tray.
Slipht solids buildup up-
stream and heavy solids
buildup downstream of
Relative
Condition
at
End -of- Run
Good
Bad
Good
Bad
502-2A (553 Operating Hours)
Comments
Light scale on vanes.
About 1 5% of bottom vane
flow area plugged by solids.
Significant erosion of grid
wires
Negligible scale
Some so) ids deposits on
slurry nozzles only.
About 60% of duct area
plugged immediately up-
Relative
Condition
at
End-of-Run
Poor
Bad
Good
Bad
508-2A (98 Operating Hours)
Comments
Negligible scale and solids
deposits.
Loose, bent and eroded!
wires in two grids.
Negligible scale
Scattered moderate solids
deposits on walls immedi-
ately below Koch tray.
Moderate solids buildup
upstream of cooling
sprays.
Relative
Condition
at
End -of -Run
Good
Had
Fair
Poor
509-2A (465 Operating Hours!
Comments
two rows of vanes.
Negligible solid's deposits.
Broken and eroded *ires
in several grids
below bottom bed, light
scale on walls of bottom
two beds
Negligible solids deposits
Clean
Relative
Condition
at
End-of-Run
Goad
Bad
Excellent
V> attempt was made to modify run conditions in order to solve the continuing problem of
support p nd erosion The wire mesh pnds (0. 1 48 inch diameter wi res) were replaced with
sturdier 3/fl inch diameter rods (1 - 1/4 inch on center) prior to the long-term reliability test.
-------
Table 7-5 (continued)
LIMESTONE RELIABILITY VERIFICATION TEST RUN EVALUATIONS:
TCA SYSTEM
P\R*MTTrR
Mi»t Eliminator and Koch
Tray Scalinp or Plufipinp
Scrubber Mechanical'*1
Condition at End of Run
Scrubber Scaling or
Phi|!piinK
Inlet Duct Plumiini:
TEST RLN
51 0-2 A (297 Operating Hours 1
Comments
Moderate scale on bottom
vanes.
About 25*pr of bottom vanes
partially plugged with
solids.
Loose and bent wires in
several ends.
Scattered moderate to
heavy scale on walls below
bottom bud. Intermittent
fieav} «cale on about 30T. of
bottom arid. 1 ipht scale
on\iall» above bottom bed.
Neelimblc solids de DO sits
Clean
Relative
Condition
at
End -of- Run
Fair
Bad
Poor
Excellent
51 4-2 A 1493 Operating Hours)
Comments
Flow area of bottom two
vanes about 20% plugged
with scale and solids fone
quadrant about 50% plugged
with hard crystalline solids.
Loose, bent and broken
wires in two middle grids.
Light scale on bed walls.
Heavy scale on 75% of bot-
tom grid. Moderate scale
and heavy solids on v.alls
below Koch tray. Moderate
scattered solids on walls
below bottom bed.
Moderate solids buildup
Relative
Condition
at
End -of -Run
Poor
Bad
Poor
Fair
515-ZA (571 Operating Hours)
Comments
Flow area of bottom two
vanes about 40% plugged
with scale and solids. Mod-
erate solids buildup on
underside of Koch tray.
partially plugging several
valve s .
Spheres from bop bed
dropped to middle bed
through eroded grid wires.
Moderate scale between
bottom bed and Koch tray.
Heavy scale below bottom
bed and on bottom grid.
Intermittent heav> solids-
scale deposits below bot-
tom grid.
Clean
Relative
Condition
at
End -of -Run
Bad
Bad
Bad
Excellent
I
I—1
l*>
\o attempt «.aa made to modify run conditions in order to solve the continuing problem of
support f>nd erosion. The uire mesh finds (0 1-18 inch diameter uires) were replaced with
•sturdier 3/H inch diameter rods (1 - 1/4. inch on center) prior to the long-term reliability test.
-------
Table 7-6
LIMESTONE RELIABILITY VERIFICATION TEST RUN EVALUATIONS:
MARBLE-BED SYSTEM
PARAMETER
Mist Fhminator Scaling
or Plunging
Scrubber Mechanical
Condition at End of Run
Scrubber Scaling or
Plugging
Inlet fXiCt Plufiiiinj:
TEST RUN
501 -3A t JB (771 Operating; Hours)
Comment
Light scale on all \anea
Intermittent, moderate
solids deposits on bottom
vanes
Swirl vanes in 80% of bot-
tom slurry no z. tits com-
pletely eroded Nor&le
plugging by marbles drop-
ped through loose grid
Light scale on walls below
bed.
Intermittent, heavy solids
deposits on bottom spray
headers ft. bottom of bed.
About 30% of bed plugged
or in stratified pattern.
About 15% of duct plugged
downstream of cooJinp
sprays.
Relative
Condition
at
End -of -Run
Fair
Bad
Bad
Bad
&02-3A (28S Operating Hours)
Comment
Moderate scale and solids
deposits on top vanes
Light scale on bottom
vanes
without swirl vanes
and below bed and on all
spray headers.
About 2% o! bed plugged,
60% stratified
About 70% of duel plugged
immediately downstream
Relative
Condition
at
End -of -Run
Fair
Bad
Poor
Bad
503-3A £. 3B (267 Operating Hours)
Comment
No scale.
Light solids deposits on
top vanes
About 20% of bottom
slurry no 7 alts plugged
with debris.
Light, intermittent scale -
solids deposits on headers
and walls above bed. Mod-
erate scale- solids deposits
on bottom headers
About 25% of bed plugged
About 20% of duct plugged
downstream of cooling
sprays
Relative
Condition
at
End-af-Run
Good
Bad
Bad
Poor
5M-3A S. 505-3A (233 Ope rating Efourst
Comment
vanes.
Light solids deposits on
bottom vanes
About 35% of bottom
Spraco slurry noz?les
partially plugped with
marbles
above mist elin-i and bed,
Scattered. Light scale-
solids deposits on headers
below bed.
About 12% of bed plugged,
60% stratified.
About 30% of duct plupeed
downstream of coolmp
sprays
Relative
Condition
at
End -of -Run
Fair
Poor
Pad
Bad
I
t—
*.
-------
Table 7-6 (continued)
LIMESTONE RELIABILITY VERIFICATION TEST RUN EVALUATIONS:
MARBLE-BED SYSTEM
PARAMETER
t Eliminator Scaling
Scrubbing Mechanical
Condition at End of Run
Scrubber Scaling or
Plugging
Inlet Duct
TEST RLN
50b-3B (180 Operating Hours)
Light scale on bottom
vanes. Moderate scale on
top vanes.
About 30% of middle vanes
completely plugged. 30T-
partially plumped.
About 80£ of bottom Spraco
slurry no fries severely
eroded
Moderate scale on walls
throughout scrubber. Inter-
mittent, heavy scale on all
headers and walls below
bottom headers.
About 10£ of bed plugged,
% stratified
About 457. of duct plugged
downstream of cooling
sprays. No solids down-
stream of open no7zle.
Relative
Condition
at
End-of-Run
Bad
Bad
-------
at an effluent residence time of 12 minutes, a percent solids recir-
culated of approximately 9 percent, a spray tower gas velocity of 8. 0
ft/sec, and a liquid-to-gas ratio of 50 gal/mcf. Effluent residence times
below 12 minutes could not be obtained during the testing due to system
constraints.
During the venturi/spray tower runs, the underside (upstream) mist
eliminator wash was effective in reducing the rate of soft solids accumu-
lations on the lower mist eliminator blades at superficial velocities at
or below 8 ft/sec {see Runs 503- 1A and 507-1A), but topside plugging
was a problem. A topside (downstream) wash was helpful in reducing
plugging on the top blades, but there was evidence of droplet entrain-
ment in the exiting flue gas with resultant accumulation of solids on the
walls of the outlet duct (see Runs 506-1A, 507-1A, and 508-1A). More
definitive information was gathered on mist eliminator operability during
lime reliability testing (see Sections 9. 2. 2 and 10. 2).
The polypropylene chevron mist eliminator (see Figure 3-4), used during
Runs 502-1A through 506-1A, was discarded after it was damaged by
solids falling onto it from the outlet duct.
7.1.2 TCA System
TCA reliability verification tests are reported in Table 7-2 and evaluated
in Table 7-5. As expected, the relative system condition at the end of
the initial TCA test 501-2A was good as far as scrubber or mist elim-
inator scaling and plugging was concerned. There was, however,
difficulty experienced due to mechanical failure of a TCA support grid
7-16
-------
and plugging of the inlet duct at the hot-gas/liquid interface. During
subsequent tests (see Runs 509-2A through 515-2A), the problem of inlet
duct plugging was apparently solved, although there was still some
accumulation of solids in the inlet duct during Run 514-2A (the resolu-
tion of the inlet duct plugging problem will be discussed in Section
10.4). The continual problem of erosion of TCA support grid wires was
not solved during the remainder of the reliability verification tests.
Sturdier support grids (parallel 3/8-inch rods) were installed in the
TCA scrubber during subsequent long-term testing.
The results of the subsequent testing, under more economically attrac-
tive operating conditions, showed relatively good system condition
after 465 on-stream hours with an effluent residence time of 20 min-
utes, a percent solids recirculated of approximately 9 percent, a gas
velocity of 8. 3 ft/sec, and a liquid-to-gas ratio of 75 gal/mcf (see Run
509-2A). A subsequent test at a gas velocity of 10. 5 ft/sec and a liquid-
to-gas ratio of 60 gal/mcf (Run 510-2A) gave some indication of scale
buildup within the scrubber and partial plugging of the mist eliminator.
Two final test runs at an effluent residence time of 4. 4 minutes (Runs
514-2A and 515-2A) gave indications of severe scale buildup within the
V
scrubber and mist eliminator, and severe solids buildup in the mist
eliminator and on the underside of the Koch tray. Effluent residence
times between 4.4 and 20 minutes could not be obtained during these
tests due to system constraints (the larger effluent hold tank was used
for the 20 minute tests and a smaller recirculation tank for the 4.4
minute tests).
The maximum sulfate super saturation within the scrubber system
occurs at the scrubber effluent. Hence, scale formation is heaviest
on the bottommost grid of the TCA.
7-17
-------
The acceptable effluent residence time, therefore, is between 4.4 and
20 minutes at a recirculated solids concentration of approximately 9
percent (with 40 percent of solids as fly ash), a gas rate of approx-
imately 8 ft/sec, and a liquid-to-gas ratio of approximately 75 gal/mcf.
Tests at the EPA TCA pilot facility at Research Triangle Park have
indicated that an effluent residence time of 10 minutes is satisfactory
for a liquid-to-gas ratio equal to or greater than 65 gal/mcf and a per-
cent solids recirculated of 10 percent.
7.1.3 Marble-Bed System
The condition of the Marble-Bed scrubber at the termination of the
reliability verification tests was poor (see Tables 7-3 and 7-6). Prob-
lems associated with erosion of the Combustion Engineering slurry
spray nozzles directed toward the underside of the Marble-Bed resulted
in insufficient wetting and subsequent plugging of the bed. The use
of hollow cone Spraco nozzles also caused insufficient wetting of the
bed and subsequent plugging (see Runs 504-3A, 505-3A, and 506-3B).
7.2 ANALYTICAL DATA
A summary of scrubber inlet liquor analytical data for the limestone
reliability verification tests is presented in Table 7-7. Except where
noted, most of the dissolved species appear to have approached steady-
state concentrations for these runs. The liquid analytical data are tested
by inputting the measured compositions and pH's into the Bechtel Mod-
ified Radian Equilibrium Computer Program which then calculates the
ionic imbalances and sulfate (gypsum) saturations. A listing of this
7-18
-------
Table 7-7
AVERAGE SCRUBBER INLET LIQUOR COMPOSITIONS
FOR LIMESTONE RELIABILITY VERIFICATION RUNS
Run No
Venlurl
501-1A
50fc- 1A
507-IA(bl
TCA
501-2A
50Z-2A
SQQ-2A
51O-ZA
514-2A
5I1-2A
Marble-Bed
501-3A S, 3B
502-1A
SOS-3A(Cl
•iO(.-3B
Percenl
Solids
Rpeirculaled
15
8
8
IS
IS
8
8
IS
8
11
1 1
II
1 1
Effluent
Residence
Time, mm
20
12
12
20
20
20
ZO
4 4
4 4
30
10
30
30
Percent
Solids
Discha rged
20-28
55-65
93-68
Z5-48
31-19
26-45
ZI.-44
27-52
34-44
20-29
19-ZS
60-65
60-66
Percent
Sulfur
Oxidized
5-25
20-3;
21-45
20-40
17-35
32-50
35-55
20-50
25-50
15-35
10-30
10-30
20-40
5c rubbe r
Inlet pH
Range
5 8-6.0
5 4-5 7
5.3-5.7
5 7-6 0
5 8-6 1
5 5-5.8
5 4-5.',
5.2-5 6
5 2-5 4
5.8-6 0
5 6-6 1
5 6-5 8
1 5-5 8
Ca + t
ZOOO
4200
510
30O
200
350
400
3 SO
310
200
120
300
450
Liquor S
N.*
50
140""
140
50
100
100
100
100
120
50
50
150
ISO
K*
85<">
180
.
40
70
70
80
120
.
.
50
120
scv
zoo
200
120
100
150
220
130
190
210
250
200
200
200
SC4=
1300
2100
2500
1600
1250
1900
ZOOO
ZOOO
2500
1500
1000
1400
1800
CO,'
200
40
25
too
250
250
80
70
20
100
200
250
250
Cl" Total
Calculated Perc^nl
a, 50°C(dl
3000 7000 96
7800'*' 15,000(m| 167
10.200 18,800 204
2600 65OO 109
ZZDO 58OO 87
4800 10.400 138
5000 10.8OO 149
5000 10,800 1S2
5800 12.4OO 193
3500 7800 113
2200 5300 74
5500 10.600 106
9400 17.400 ISO
(a) Concentration at end of run Concentration increasing throughout run.
(b) Concentrations for first half of run are luted Percent solids discharged
u.*s 20-30% during second half (using clarifier only) and total dissolved
solids decreased gradually to 11, 300 ppm.
|d) Calculated SuKate Saturation = (activity Ca++) x (activity SO4~)/ (solubility
product at 50°C). A solubility product for CaSO4 2H2O of 2 2 x 10-S uas
used (Radian Corporation. "A Theoretical Description of the Limestone-
Injection Wet Scrubbing Process," NAPCA Report. June 9, 1970)
(c) Only one liquor analysis taken
-------
program is given in AppendixG. The original Radian program is des-
cribed in Reference 9. For the data shown in Table 7-7, the calculated
ionic imbalances were all less than 13 percent.
Venturi Runs 506-1A and 507-1A, and Marble-Bed Runs 503-3A through
506-3B demonstrate the higher degree of closed liquor loop operation
that is achieved by use of the clarifier and centrifuge, rather than the
clarifier alone, to separate solids (53 to 68 percent solids discharged
vs. 19 to 29 percent). The increase in dissolved solids concentration
at the higher percent solids discharge rates is due, primarily, to the
increase in liquor chloride concentration.
7. 3 SCALING POTENTIAL AS A FUNCTION OF LIQUOR
SULFATE SATURATION
The calculated values for the degree of liquor saturation at 50°C with
CaSOv 2H?O presented in Table 7-7 were made with the use of the
Bechtel modified Radian program. The calculated degrees of sulfate
saturations for the scrubber effluent liquors (which have not been
presented in this report) are, of course, greater than the predicted
saturations for the scrubber inlet liquors.
The major independent variables affecting the calculated sulfate satura-
tions are: (1) percent solids recirculated, (2) effluent residence time,
(3) scrubber inlet liquor pH, and (4) percent solids discharged. Oxida-
tion of sulfite to sulfate, although not an independent variable, has a
strong effect on sulfate saturation.
7-20
-------
Generally, the calculated sulfate saturations decrease with increasing
scrubber inlet liquor pH. Scrubber inlet liquor pH increases with
an increase in percent solids recirculated and/or an increase in
effluent residence time. Furthermore, the sulfate saturations tend
to decrease with decreasing oxidation of sulfite to sulfate. Oxidation
decreases with increasing liquor pH. In Figure 7-1, the calculated
degree of scrubber inlet liquor sulfate saturation for all of the relia-
bility verification tests is shown as a function of scrubber inlet liquor
pH. In Figure 7-2, the calculated sulfate saturations for the TCA
reliability verification tests are shown as a function of percent solids
recirculated and effluent residence time.
The calculated sulfate saturations increase with increasing dissolved
solids concentration, and, as discussed previously, the dissolved
solids concentrations increase with increasing percent solids dis-
charged. Hence, the "tighter" the closure of the liquor loop, the
greater the potential for sulfate scaling.
As shown in Figure 7-2, the degree of sulfate saturation of the scrub-
ber inlet liquor increased when effluent residence time decreased
from 20 minutes to 4.4 minutes (Run 515-2A vs. 509-2A and 510-2A)
and when the percent solids recirculated decreased from 16 to 8 per-
cent at 4. 4 minutes residence time (Run 515-2A vs. 514-2A). Sulfate
scaling of the bottommost TCA grid occurred when the effluent resi-
dence time was decreased from 20 minutes to 4.4 minutes, and in-
creased in severity when the percent solids was decreased from 16
to 8 percent at 4.4 minutes (see Table 7-2). From the data in Tables
7-2 and 7-7, it would appear that sulfate scaling is likely to occur in
7-21
-------
£IU
200-
190-
180-
0 170 -
S
@ 160-
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o
41 C/\
oc
w 140-
UJ
H
<
"• nn
_j 130 •
D
CO
1-
^~ i Zu *
III
o
c
Ul
o- 110-
100 i
90 •
80-
70
i i i i i i i i r i
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. ^>Y
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-
* ^^y ,~ ^^ • ,^^. j
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—
.
, S\^ t
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1 1 1 1 1 1 1 1 1 1
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6.0 6.1 6.
SCRUBBER INLET LIQUOR pH
Figure 7-1. Calculated Degree of Sulfate Saturation versus pH for
Limestone Reliability Verification Tests
7-22
-------
210
200 •
110 • •
100 •
90 • •
80
PERCENT SOLIDS RECIRCULATED - 8
PERCENT SOLIDS
RECIRCULATED = 15
LIQUID-TO-GAS RATIO = 60 gal/mcf
PERCENT SOLIDS DISCHARGED = 38
502-2A
501-2A
I I I I I I I I I I I I 1 I I I I
10 15
EFFLUENT RESIDENCE TIME. mm.
20
25
Figure 7-2. Calculated Degree of Sulfate Saturation for TCA Limestone
Reliability Verification Tests
7-23
-------
the TCA scrubber for a degree of sulfate saturation of the scrubber inlet
liquor greater than approximately 135 percent. The Radian Corporation
(Reference 10) has determined that the "critical" sulfate saturation at
45°C is approximately 130 percent.
A small amount of analytical data has been analyzed for the wash liquor
to the spray tower and Marble-Bed mist eliminators and to the TCA
Koch tray. The results showed that the inlet wash liquors, which are
composed of mixtures of clarified process liquor and available raw
water makeup, have approximately 60 percent of the degree of sulfate
saturation of the scrubber inlet liquor at typical conditions. Even though
the wash liquor may be less than saturated when introduced, SO-, absorp-
tion and oxidation in the liquor on the mist eliminator surfaces can cause
supersaturation and scaling.
7.4 LIMESTONE UTILIZATION
The results from the EPA TCA pilot facility at Research Triangle Park
have shown that limestone utilization (100 x moles SO? absorbed/mole
CaCO , added) is a strong function of limestone "reactivity" (i.e. , aver-
age particle size) and scrubber inlet liquor pH (see Reference 11).
For the limestone reliability verification tests (see Tables 7-1, 7-2,
and 7-3), average limestone utilizations for the venturi/spray tower,
TCA, and Marble-Bed scrubbers were 68 percent, 77 percent, and
67 percent, respectively. Not included in the above averages were
runs in which there was an apparent decrease in limestone reactivity
(due to larger limestone average particle size) and in which the effect
of "high pH" was being investigated (Runs 502-1A and 502-3A).
7-24
-------
An example of a decrease in limestone utilization and increase in SO^
removal due to an increase in inlet liquor pH can be seen by comparing
TCA Run 501-2A and 502-2A (see Table 7-2). An increase in average
scrubber inlet pH from 5. 8 to 6. 0 resulted in a decrease of utilization
from approximately 80 to 60 percent and an increase in SO_ removal
from approximately 83 to 93 percent.
An example of changes in limestone reactivity (and, hence, in lime-
stone utilization) due to changes in the average size of the limestone
particles can be seen in Runs 501- 1A (Table 7-1), 502-2A (Table 7-2),
and 502-3A (Table 7-3).
7.5 MATERIAL BALANCES
The results of material balances for calcium and sulfur for many of
the limestone reliability verification runs during continuous (uninter-
rupted) on-stream operating periods are given in Table 7-8. The SC^
absorbed was computed from the measured inlet gas rate, the inlet
and outlet gas SO- concentrations, and the estimated gas outlet rate.
Ct
The calcium added was computed from the measured volumetric rate
of limestone slurry additive and the solids concentration in the slurry.
The sulfur and calcium discharged were computed from the measured
rate of slurry discharged from the system and the concentrations of
sulfur and calcium in the discharge.
The computed inlet and outlet rates for calcium and sulfur are in good
agreement. The average stoichiometric ratios based on solids analy-
ses are probably more accurate than the values based on limestone
7-25
-------
Table 7-8
SUMMARY OF MATERIAL BALANCES FOR SULFUR AND CALCIUM
FROM LIMESTONE RELIABILITY VERIFICATION TESTS
Run No.
Veittun
501-1A
502-1 A
TCA
501-2A
502-ZA
509-2A
M-B
501-3A
501-3BU1
506-3B2 Absorbed
1.67
1.59
0.95
Z. 07
1.03
1.06
1.45
1.78
Based on
Solids
Analysis
1.73
1.8Z
1. 15
1. 77
1. 38
1.26
1.4Z
1.77
I
ro
(a)
Because of turbid clarifier overflew, some of the solids in the clarifier feed is returned to the scrubber.
discharged have been corrected for solids returned and are net discharge from the system.
The values for SOx and Ca
Ibl
The values for SOX and Ca discharged have been corrected for solids in the centrate returned to the scrubber.
-------
addition rate and SO, absorption, due to uncertainties in the measure-
ment of limestone slurry feed rate. The ionic imbalances for the bleed
stream solids analyses, from which the calcium and sulfur discharge
rates were calculated, averaged less than +5 percent (more cations than
anions).
The continuous operating periods shown in Table 7-8 were broken
up into "computational periods" of from 8 to 48 hours, material balances
were made for each computational period, and the results were summed.
The computed inlet and outlet rates for calcium and sulfur did not nec-
essarily balance during each computational period, due to the unsteady
conditions which prevail at any point in time (i. e. , changing percent
solids) and the resultant accumulation (or depletion) of the species
within the system. However, over a longer period of time (> 150 hours)
the accumulation term becomes negligible as compared to the total
input or output of species.
7-27
-------
Section 8
LIMESTONE RELIABILITY TEST RESULTS
Performance and analytical data from the TCA system limestone re-
liability testing at the Shawnee test facility are presented in this section,
along with an evaluation of each reliability test and the conclusions
drawn, to date, from the testing.
8. 1 PERFORMANCE DATA AND TEST EVALUATION
A summary of the test conditions and results for each of the TCA
limestone reliability tests is presented in Table 8-1, along with the
run philosophies. A summary of the scrubber inlet liquor analytical
data for a majority of the tests is presented in Table 8-2, along with the
calculated percent sulfate saturations. Properties of coal and limestone
used during these tests can be found in Appendix C. Essential operating
data for most of the TCA limestone reliability tests are graphically
presented in Appendix H. An evaluation and discussion of each test is
presented in the following sections.
8.1.1 TCA Run 525-2A
On October 24, 1973, the initial limestone long-term reliability test
(Run 525-2A) was begun on the TCA system. The objective of the test
8-1
-------
Table 8-1
SUMMARY OF LIMESTONE RELIABILITY TESTS ON TCA SYSTEM
Run No
Siarl-or-Run Dale
End-of-Run Date
In Stream Hour*
Cai Rale. *efm @ JOO°F
Gaa Velocity, rpa @ 1ZS°F
jquor Rale, gpm
L/C. gil/mcf
'erceni Sol id • Recirculated
tffluenl Residence Time mln
tolchlometrtc Ratio, ircles Ca
added/mols SOj absorbed
Avg % LI me it one Ut ill eat Ion. IQOx
mold SO2 abs /mole Ca added
nlet SOj Concrniratian. ppm
'ercent SOj Removal
Scrubber [nlet pH Range
crubber Outlet pH Range
Percent Sulfur Oxtdned
Solids Disposal System
•oop Closure. % Solids Dischg
Calculated % Sulfate Saturation in
Scrubber Inlet Liquor 0 SO°C
Total Dissolved Sol id a, ppm
Total &P Range Excluding Mist
Eliminator and Kocb Tray, in HjO
Mlit Eliminator and Koch Tray
A P Range. In HZ0
Mill Eliminator AP Range, ID HjO
Absorbent
Hist Eliminator /Koch Tray
Scrubber Internal!
System Changes Before
Stan-of-Run
Method of Control
Run Philosophy
Results
52*-ZA
10/24/73
11/15/73
51?
25.000
10.5
1200
60
14-16
10
1.2-1 6
71
1800-4000
73- SB
5 5-6 1
' 2-5 8
15-30
Clarlfler
31-4Z
140
7000-9600
5 5-6 5
Z 3-2 7 (10/24-11/12)
2 7.3 1 fll/IZ-ll/15)
—
Limestone slurried to 60 wt %
with makeup water and added
o EHT
No mi at eliminator wash
K T (2" weir height} irrigat-
ed with available makeup
waler (-9 gpm) and all avail-
able clarified liquor (-15 gpm)
Bottom of Koch tray aieam
sparged 1 mln/hr.
3 alagea (4 grids) with 5"
sphereg/Biige Top b«d-ne»
TPR spheres Middle L
bottom-new HDPE spheres
System (scrubber, Koch tray
and mist eliminator cleaned
!O2 removal controlled At
84 f 2".
Intended long-term Condi -
tiona chosen for long-term
reliability baaed on reliabil-
ity verification teats
Terminated due lo rapidly
increasing pressure drop
•cro*a mlat elim and Koch
tray Lirgr aolidi deposit a
on undf rude of Koch tray and
on scrubber walla between
Iray and mam slurry header
TPR half- apherei plugged
in let Blurry noiclea fbelfevad
lo br primary problem)
Bottom o( mitt eliminator
SB?, plunged
^2fe-lA
11/Z1/73
1/10/74
1190
zo. soo
fl 6
1200
73
14-15 5
10
1 I- 1 7
69
1600-4300
75-87
5 65-5 9
•i 1-5 5
15-35
ClarUier
35-47
130
7500-9790
4 3-4 7
1 9-Z 1
0 15-0 26
..(meitone ilurned to 60 wt
-------
Table 8-1 (continued)
SUMMARY OF LIMESTONE RELIABILITY TESTS ON TCA SYSTEM
Run No.
Start-of-Run Dale
Gnd-of-Run D«te
On Stream Houra
Gil Rale. «c(m § 300"F
Cae Velocity, {ft 0 I2S°F
Liquor Rite, gpm
L/C. gel/mcf
Percent Sollda Reclrculalcd
Effluent ReaMence Time, mm
Slolchlomelrlc Ratio molea Ci
added/moll SO2 ibiorbed
Avg % Limeetonn Utilization. lOOx
molee SOj aba /mole Ca added
Inlet SOZ Concentration, ppm
Percent SOj Removal
Scrubber Inlet pH Range
Scrubber Outlet pH Range
Percent Sulfur Oildlaed
Solida Dlepoaal Syalem
Loop Cloeure % Sollde Dlachg
Calculated % Sulfate Saturation in
Scrubber Inlet Liquor 9 50°C
Total Dleeolvod Sollde. ppm
Total 4P Range Excluding Mlal
Eliminator and Koch Tray. In HjO
Mlet Eliminator and Koch Tray
A.P Range. In HjO
Milt Eliminator OP Range. In H20
Ahanrbrnt
Mill Eliminator/Koch Trar
Scrubber Internal!
Syatem Change! Before
Start-of-Ruo
Method of Control
Run Phlloiophy
Reiulta
«.29-2A
2/26/14
3/7/74
211
20. WO
8 6
1200
7]
14 5-16
12
1 15-1 3S
80
2300-3900
70-89
5 7-5 9
S 2-5 5
IS- 30
Clarlfier
30-47
130
8400
4 9-5 3
1 9-2 1
0 19-0 23
Limettnn* «lurrl»«l tn ho wt ••
with makeup water and added
lo EHT
No milt eliminator waeh
K T <2" weir height) Irrigat-
ed with available makoup
wale r ( — 5 |pml and all avail-
able clarified liquor IMS gpm)
Bottom of Koch tray eteam
aparged 1 mln/hr.
3 bed! 14 grldel with 5"
ipherei/bed All beda-won
TPR apherei from prevloui
run
No cleaning
No change!
SO2 removal controlled at
8412*
Override!
Inlet pH i •, 9!
Stoleh Ration 1 65
Intended long-term Teat
condition! aame ai prevlou!
run except Koch tray Irri-
gated with all available
makeup water and clarified
liquor
Riwlmp inapection afler 213
'inuri repealed eome eoft
• olide and alight aeale buildup
nn the mill ellm lower vanea
Although amount of icale and
• olid! wai alight, it waa
conaldered 10 be aignlflcanl
after only 213 houra. and run
waa terminated Bottom of
mlat eliminator 19% plugged
«30-2A
1/28/74
4/17/74
476
20. 500
8 t
1200
73
14-16
12
1 2-1.55
73
2200-4200
78-89
5 75-S 95
5 1-5 4
I2-Z9
Clarlfier
(Centrllujr only after 4/10)
10.43
120
(300.8600
4 8-5.1
1 9-2 1
0 17-0 25
1 imnton*. «l«"-i led lo 1 0 wt 91
• ilh clarified procea! liquor
and added lo EHT
No mlat eliminator waah
K T (2"wrir height) Irrlgal-
ed with 8 gpm makeup water
and 7 gpm clarified liquor
Botlom of Koch tray etoam
aparged 1 mln/hr
3 beda (4 grlda) wilh 5"
ipherei/bcd. All bedi-won
TPR Ipherei from prevloua
run
Syatem cleaned Koch tray
periphery aealed PWHT
outlet (Koch tray inlet) pump
converted from Hydroieal to
Centrlaeal Provided clarlflei
liquor for llmealon* alurry
feed tank Modified piping lo
obtain conataal Koch tray
makeup waler/llquor ratio
Sealed lop of EHT
SOj removal controlled at
84127.
OverrUea
Inlet pH s 5 9!
Stoich Ratios 1 6S
Intended long-term EHT
aealed to reduce oxidation,
and Koch tray waah ratio held
constant to obaerve any effect
on lollda buildup
Unable lo aignlfieantly raduee
oxidation or lulfalt latura-
tlon Run terminated due lo
heavy aeale and aollda de-
poait! on lop of Koch tray.
poaalbly eauaed by low
(15 ipm) Koch tray fluah rate
and a Clarlfier rake malfunc-
tion on April 8 - 10. reeult-
ing In abnormal aolida carry-
over lo Koch tray BoTtorr
of mm ehminalor 44*.
plugged
53I-2A
5/10/74
6/21/74
1088
20 100
8 I.
1200
71
7-9
12
1 3-1 7 (5/10-26. 6/19-26)
1.0-1 2<«> (5/26-6/19)
67 (5/10-26. 6/19-2AI
91('> (5/26-6/191
1750.1750
71.96
5 4.1. 1
4 7-5 5
13-40
Clarlfier
IS. 42
100
25 000
4. 3-6 6
2 1-3 7
0 19-0 35
Llmeltone llurrted to 60 wl *•
with clarified proeeal liquor
and ended lo EHT
No miat eliminator waah.
K T ll weir helghtl irrigat-
ed wllh available makeup
water (-9 gpm) and all avail-
able clarified liquor (-30 gpml
aparged 1 mln/hr
3 beda (4 gridil with 5"
•pherei/bed. All bed i -worn
TPR apherea from prevloua
run
Syatem cleaned Inalalled
MgO add n ayalem Lowered
apray header 4' Leveled
Koch tray and further aealed
periphery Increaaed weir
height to 1" Inatalled inlet
weir EHT overflow line
blanked
SOj removal controlled at
5/10-5/21 8412ft
5/21-6/S 7812%
6/5-6/19 8412%
6/19-6/26 9512%
Intended long-term Attempt
to operate unaalurated wilh
MgO add'n to aealed EHT
Percent lolida lowered to 8%
to provide additional Clarlfier
liquor for Koch irrigation
Unable to maintain unaaturat-
ed aulfate operation with 5000
ppm Mg Steady elate oper-
ation waa not reached Run
terminated due to aollda and
aeale buildup on miat elim-
inator. Koch Iray and
bottom grid Botlom of
miat eliminator 757. plugged
Total aloich ratio for Ca
t Ma 11 1 08-1 28 (avg
alkali ulll 85«)
<12-2A
7/17/74
7/29/74
2 SB
20 500
8 i.
1700
104
7-1
12
o 88-1 za""
„<«
2000-1100
9A-99
1 (.-,, 0
S Z-', f.
7-Z*
Clariher
12-43
MO
44 000 -(.0 000
4 9-4 B
1 94-Z 1
0 15-0 19
Llmeltone .lurried to 60 wt%
with ell rifled proeeil liquor
•nd idiied to EHT
Recycle loop around mln
*llminiitor/K T Bottom of
milt dim wtahcd with fl gpm
makeup water plu> 7 gpm re-
cycle liquor K T (2 «nr
recycle liquor (plui IS gpm
mix ellm waih) Botlom of
{.T. cteam (p-irftcd 1 min/hr
3 bed. (4 grid*) with 5"
•phrm/bed All bedi-
u/orn TPR ipherei from
previoua run
Syitem cleaned Provided for
cloied-circuil recycle loop
around rnlit eliminator/Koch
tny. IncludmK mi it eliml-
nator underwaih Lowered
w«ir height lo 2" EHT and
PWHT icalrd with CO2 gaa
purge
Scrubber inlei pH controlled
at 5 8jO Z
Intended lonf|-term Attempt
lo oprrate unaai wilh MgO
add'n to EHT (10 000 ppm
Mgl 1700 gpm liquor rate
EHT b PWHT CO2 blanket.
miai eltm wa*h l> mitt ehm/
Koch iray recycle loop
Unable to attain unitttu rated
•ulfate operation wllh 10 000
ppm Mg Run t«rimnai*>d due
to •«*!« build* up on Koch tray
and Ion of 4000 {~l /2 bed)
•pherei through Rridi
Bottom of miit eliminator
1-Z« plugged
(b)
Total notch ratio for Ca
fc Mg ii 1 OS-I 45 (avg
alkali util ia 80%}
8-3
-------
Table 8-1 (continued)
SUMMARY OF LIMESTONE RELIABILITY TESTS ON TCA SYSTEM
Run No
Start-of-Run Date
End-of-Run Date
On Stream Hours
Cat Rale, acfm @ 300°F
Gaa Velocity (pi @ 125°F
Liquor Rate, gpm
L/C. gal/mcf
Percent Solids Recirculited
Effluent Reildence Time, mm
Stoichlometrlc Ratio, mole a Ca
added/mole SOj absorbed
Avg % Llmeiione Uliliiation, IQOx
mole a SO2 aba /mole Ca added
Inlet SOj Concentration, ppm
Percent SOj Removal
Scrubber Inlet pH Range
Scrubber Outlet pH Range
Percent Sulfur Oxidized
Solid! Disposal System
Loop Cloiure % Solids Diachg
Calculated % Sulfale Saturation in
Scrubber Inlet Liquor @ SO°C
Total Dinolved Sohdi. ppm
Total A P Range Excluding Mist
eliminator and Koch Tray. In HjO
Milt Eliminator and Koch Tray
&P Range, in HjO
Mist Eliminator AP Range, in H2O
Absorbent
Milt Elimlnaior/Koch Tray
Scrubber Internal!
Syatem Changes Before
Start-of-Run
Method of Control
Run Philosophy
Result!
5JJ-ZA
8/6/74
8/21/74
332
ZO. 500
8 6
1200
73
14 5-15 5
12
0 86-1 31(>l
wci
2000-3750
95-99
5 7-6 0
5 3-5 65
15-23
Clarlfler
29-38
135
53.000-53.000
4 60-4 95
2 05-3 85
0 17-0 25
Limestone slurned to 60 wt%
with clarified proceai liquor
and added to EHT.
Recycle loop around mlit
ehrmnator/K T Bottom of
mist elim washed with 8 gpm
makeup water plus 7 gpm re-
cycle liquor K T (2" weir
ht ) irrigated with 35 gpm
recycle liquor (plus 15 gpm
mist elim wash) Bottom of
K T steam a par Red 1 min/hr
3 stages (4 grida)with 5 inches
aphcres/atage All beds-
new TPR aphers
System cleaned Replaced
worn TPR apherea with new
TPR's
Scrubber inlet pH controlled
at 5 8 JO 2
intended long-term Attempt
o operate unaai with 10.000
ppm Mg cone in EHT 1200
gpm liquor rate 15% solids.
CO 2 blanket over EHT fc
PWHT. and milt elim /KT
ra cycle loop
Jnible to attain unaaturaled
sulfaie operation with 10 000
ipm Mg Run terminated due
o scale build-up on Koch tray
and ml»t eliminator Bottom
of mist eliminator 12%
plunged
Total Blotch ratio for Ca
k Mg is 1 03-1 48(Avg.
alkali util BOftl.
S34-2A
9/3/74
9/8/74
100
20. 500
8 6
1200
73
10-12.5
12
1 10-1.30
82
2700-3600
75-90
5 65-5 85
5 2-5 4
15-30
Clan fie r
30-40
130
7900-8500
4 30-4 35
1 85-2 00
0 15-0 20
-tmestone alurned to 60 wt%
with clarified process liquor
and added to EHT
bottom of mist elim. washed
cont with 15 gpm dll clar
liq. ("8 gpm makeup water +
~7 gpm clar liq ) K T
(211 weir ht Mrrfc with -8
gpm clar liq + 15 gpm mist
elim. wash Bottom of Koch
tray steam sparged 1 min/hr
> stages (4 grids) wdh 1 inchei
spheres/alage All beds-worn
'PR apheres from previous
run
iystem cleaned
Scrubber inlel pH controlled
t 5 8iO 2
Intended long-term Discon-
tinue use or MgO Teal con-
ditions chosen similar to
SZ6-2A
tun terminated due to scale
•uild-up on the Koch tray
iouom of mist eliminator
-2% plugged
535-2A
9/12/74
In Progress
948 (as of 10/22/74)
20. 500
a 6
1200
73
12-15
12(9/12-9/27). 15(after 9/27)
1 35-1 70
65
2000-4000
77-88
5 7-6 0
5 1-5 6
ln-30
Clarlfler
35-42
120 [after 9/27}
6000-8000
4 00-4 60
1 95-2 00
0 10-0 20
Limestone slurrled to 60 wt%
with clarified procesa liquor
and added to EKT
Bottom of miat elim waihed
cant with 15 gpm dll clar
liq. (-9 gpm makeup water 4
•6 gpm clar liq ) K T
irrig with «'9 gpm clar liq 1
15 gpm mist elim wash Total
clar liq tomiai elim & K T
15 gpm min Bottom of Koch
tray steam sparged 1 mln/hr
3 atages (4 grida) with 5 me he
apherea/stage All beds-worn
TPR spheres from previous
Syatem cleaned Seal water
removed from cooling spray
>ump
SOj removal controlled at
85 ±2%
Overrides
Inlet pH* 6 0
Stoich Ratio 4 1 7
ntended long-term Teat
conditions chosen similar to
526-ZA
[nsprction of aystcm at 786
!irs showed mist elim and
Koch tray to be essentially
clean Heavy solids buildup
on walla between steam
sparger and slurry spray
lieader 30 mils scale on
all grids
8-4
-------
Table 8-2
AVERAGE SCRUBBER INLET LIQUOR COMPOSITIONS AND CALCULATED
SULFATE SATURATIONS FOR TCA LIMESTONE RELIABILITY RUNS
Run No.
525-ZA
526-ZA
528-ZA
5Z9-ZA11"
S30-2A(b>
532-2A
533-2A
534-2A
535-2A(c|
Percent
Solids
Reeirculated
14-16
14-15.5
14-16
14.5-16
14-16
7-9
14.5-15 5
10-12.5
11.5-15.5
Effluent
Residence
Time, min.
10
10
12
12
12
12
12
12
15
Percent
Sollda
Discharged
31-42
35-47
25-33
30-47
30-43
32-43
29-38
30-40
35-42
Percent
Sulfur
Oxidized
15-30
15-35
10-30
15-30
12-25
7-Z5
15-Z3
15-30
15-25
Scrubber
Inlet pH
Rang*
5.5-6.1
5.65-5.9
5.7-5.95
5. 7-5. 9
5.75-5.95
5.6-6.0
5.7-6.0
5.65-5.85
S. 8-6.0
Inlet Liquor Species Concentrations, mg/1 (ppm)
Ca 1 Mg
2100 250
2300 34O
1400 ZOO
1900 330
1730 34O
570 10. 500
715 11.800
2220 170
1850 290
Na1"
80
60
30
120
50
60
60
40
50
K* | S0j=| S04= |C03°| Cl- [ Total
50 BO 2000 70 3200 7900
140 BO 1900 210 3700 8700
120 ISO 1600 260 1600 5400
520 30 ZOOO 180 3300 8400
1ZO 1ZO 1900 320 2790 7370
110 3000 38.700 30 2400 56.900
110 2570 37.200 200 3100 55.750
180 70 1730 90 3540 804D
70 60 1800 80 3060 7260
Calculated Percent
Suliate Saturation
at SO°cW
140
130
110
130
120
145
135
130
120
oo
i
in
Note; Average concentration* are for ateady-atate operating per lode.
Solida diaposal system: Clarifier only.
(a) Only one sample waa taken during ateady-atate operation.
(b) Sollda diapoaal ayatema* Clarifier only for flral two-third a of
teat, then centrifuge only.
(c) Teat run was started on 9/12/74 with 12 mlnutea residence time. Residence
time was Increased to 15 minutes on 9/27. The run is still In progress as of
10/16. The values given In the table are for period 9/27 through 10/16.
(d) Calculated Suliate Saturation = (activity Ca+t) x (activity SOH= (/(solubility
product at 50°C). A solubility product for CaSO4- 2H2O of 2. 2 X 10-5 was
used (Radian Corporation, "A Theoretical Description of the Limestone-
Injection Wet Scrubbing Proeeas. " NAPCA Report. June 9. 1970).
-------
was to operate continuously for from four to six months. The operating
conditions selected for the run were based on the results of the relia-
bility verification tests (see Figure 7-2) and the tests conducted at the EPA
pilot facility at Research Triangle Park . The major test conditions
were {see Table 8-1):
Gas Velocity 10.5 ft/sec
Liquid-to-Gas Ratio 60 gal/mcf
Percent Solids Recirculated 15
Effluent Residence Time 10 min.
Percent SC^ Removal (controlled) 84
During this test, the Koch Flexitray was irrigated with the available
raw water makeup plus all the clarified liquor at an approximately one
to two ratio, and the effluent irrigation liquor was routed to the scrubber
effluent hold tank. The mist eliminator, at that time, had no provision
for independent underside wash and was washed only with liquid entrain-
ment from the Koch tray.
For the first time, thermoplastic rubber (TPR) spheres, purchased from
UOP, were tested in the scrubber. They were used in the top bed while
the bottom two beds were charged with high density polyethylene (HDPE)
spheres, also purchased from UOP. The original wire mesh grids (which
eroded during the limestone reliability verification runs) had been
replaced by sturdier bar-grids for the long-term reliability runs.
After 517 hours of operation the run was terminated due to unusually
heavy solids buildup on the underside of the Koch Flexitray and scale
and solids buildup on the bottom vanes of the mist eliminator (about 60
percent of the free area was plugged). Numerous (over 200) half-spheres
8-6
-------
of the TPR type were found in the scrubber and slurry circulating system.
TPR half-spheres were also found lodged in two of the four inlet slurry
spray nozzles. It should be noted that the scrubber beds (and bottom-
most grid) were essentially free of scale after the 517 hour operating
period. The calculated scrubber inlet liquor sulfate saturation of 140
percent (see Table 8-2) was only slightly higher than the 135 percent
estimated from the limestone reliability verification tests to be required
for scale-free operation.
It Ls hypothesized that the accumulation of soft solids below the Koch
tray was due, primarily, to the partial blockage of the slurry inlet noz-
zles, resulting in excessive entrainment of the fine slurry droplets.
This excessive entrainment and the high gas velocity (10. 5 ft/sec) most
probably contributed to the mist eliminator pluggage.
8.1.2 TCA Run 526-2A
Run 526-2A was begun on November 21, 1973. The TPR spheres in
*
the top bed had been replaced with HDPE spheres , and the accumulated
scale and soft solids from Run 525-2A had been removed. The run
conditions were identical to those for Run 525-2A, except that the gas
velocity was reduced to 8.6 ft/sec. The velocity was reduced because
more detailed investigation of previous reliability verification runs
(see Section 7) indicated that long-term reliability for the present Koch
tray/mist eliminator configuration could not be expected at a gas velo-
city of 10. 5 ft/sec.
*
It was planned to use TPR spheres in all three stages following the
installation of strainers in the inlet slurry piping.
8-7
-------
On January 10, 1974, the run was interrupted after 1190 hours of on-
stream operation to check the wear of the HDPE spheres in the three
beds (HDPE sphere life had been estimated to be less the 2000 hours).
The average percent weight loss for the HDPE spheres in the bottom
two beds was found to be approximately 32 percent for 1707 hours of
use (Runs 525-2A and 526-2A).
Pressure drop across the chevron mist eliminator had increased slightly
during the initial 800 hours of operation, and during the last 400 hours,
increased more rapidly to a final level about 1. 5 times the initial value
of 0. 18 inch H2O.
The general appearance of the system was good. Scattered solids
deposits (up to 1 inch) and light scale (about 1/16 inch) was found on
the scrubber walls below the bottommost grid and on the wall areas
not in contact with the spheres. The four bar-grids were covered with
10 to 14 mil scale on the inactive surfaces (i.e., surfaces not in contact
with spheres).
A heavy, relatively uniform solids layer covered the underside of the
wash tray. All four inlet slurry spray nozzles were partially plugged
with debris, primarily with plastic covering from pipe insulation.
The flange of the steam sparger underneath the wash tray was found to
be leaking. Mist eliminator plugging was confined to the bottom two
passes only, reducing the free flow area by about 15 percent. Several
small pieces of solids fell from the outlet gas duct and rested on top of
the center section of the mist eliminator. The area restricted by these
pieces was insufficient to affect the pressure drop across the mist
eliminator.
8-8
-------
As with Run 525-2A, it is hypothesized that the solids accumulations
on the slurry inlet spray nozzles and header, on the adjacent scrubber
walls, and on the underside of the Koch wash tray were primarily caused
by partial blockage of the TCA slurry inlet spray nozzles by debris,
which changed the spray pattern and caused excessive entrainment of
fine slurry droplets. Also, the blocked nozzles may have been a major
factor contributing to the mist eliminator pluggage observed. It should
be noted that the accumulation of sulfate scale on the bottommost bar-
grid (10 to 14 mils) was not excessive after the approximately 1200 hours
of operation. This was to be expected, since the scrubber inlet slurry
was only 130 percent saturated with respect to calcium sulfate (see
Table 8-2).
After inspection of the scrubber, it was decided not to restart Run 526-2A,
but to conduct a short-term test with certain changes in the scrubber
internal configurations before attempting a new long-term reliability test.
8. 1. 3 TCA Run 527-2A
Run 527-2A commenced on January 18, 1974, following the removal of
the soft solids from the walls (inlet slurry spray nozzles area) and from
the bottom of the Koch tray {the mist eliminator was not cleaned). It
was a scheduled short-term run to determine whether certain changes
in the scrubber internal configurations could minimize the mist elim-
inator plugging problem and to observe the effect of the changes on
SO? removal and limestone utilization. The modifications included
raising the Koch tray outlet weir height from 2 to 3 inches, using two
beds (3 grids) with 7 1/2 inches of spheres per bed, and removing the
four inlet slurry spray nozzles to minimize spray generation (slurry
was introduced through the open nipples of the existing spray header).
8-9
-------
The results of the changes were inconclusive and the run was terminated
after 133 operating hours. The slurry carryover to the Koch tray and
the mist eliminator appeared to be equal to or greater than the carry-
over observed during Run 526-2A.
The mist eliminator plugging continued on the lower vanes, and the free
flow area was reduced by an additional 50 percent (for a combined total
of 65 percent for Runs 526-2A and 527-2A). It should be noted that
the Koch tray, inadvertently, was not irrigated for a 2 hour period
during the run.
An additional 20 mils of scale formed on the scrubber walls below the
bottommost grid.
8.1.4 TCA Run 528-2A
Run 528-2A was started on February 6, 1974, following a complete
cleaning of the system. The run was intended to be of short duration
and was made using raw water only for Koch tray irrigation. The
Koch tray effluent was routed to the sewer. The purpose of the run
was to observe the effect of irrigation with raw water, versus raw
water plus clarified liquor, on the mist eliminator scale and solids
deposition. Scrubber internal configurations were returned to Run
526-2A conditions (2 inch Koch tray outlet weir height, use of inlet
slurry spray nozzles, three-bed operation). The HDPE spheres were
replaced with new, improved TPR spheres with reinforced seams and
with 5 inches of spheres in each bed. A dual strainer (by Elliot Co. )
was installed in the scrubber feed slurry loop to prevent the inlet spray
nozzles from plugging by debris.
8-10
-------
The run was terminated on February 26 after 425 hours of operation,
and the appearance of the system was generally good. The top of the
Koch Flexitray was covered with approximately 20 mils of dust type
solids. The mist eliminator was free of scale and solids with only a
slight film of dust covering the inlet vanes. The pressure drop across
the mist eliminator and Koch Flexitray had not increased during the
test. The bottom of the wash tray was relatively clean.
Evidence from this test showed that the potential for scale and solids
deposits on the mist eliminator is decreased when the degree of sulfate
saturation of the Koch Flexitray wash liquor is reduced.
It should be noted that excessive weepage from the Koch tray irrigation
water caused the test to be made with a slightly open liquor loop (average
discharged solids of 29 percent). This explains the relatively low cal-
culated scrubber inlet liquor sulfate saturation of 110 percent (see
Table 8-2).
8.1.5 TCA Run 529-2A
Run 529-2A was started on February 26, 1974. The test conditions
were the same as for Run 528-ZA, except that the Koch tray was ir-
rigated with the available raw water makeup plus all clarified liquor
at an approximately one to three ratio. The run was initially intended
to be a long-term limestone test. However, an inspection on March 7
revealed that the lower vanes of the mist eliminator were approximately
19 percent plugged with scale and soft solids. This was considered to
be significant after the relatively short period of time, and the run
was terminated after only 213 operating hours.
8-11
-------
Nearly all the TPR spheres were dimpled. Eight spheres had failed
{filled with slurry) in the bottom bed.
8. 1.6 TCA Run 530-2A
Run 530-2A was started on March 28, 1974, after a thorough cleaning.
The Koch tray was irrigated at a constant rate of 15 gpm, consisting
of about 8 gpm makeup water and 7 gpm clarified liquor, with the
purpose of achieving a high dilution of Koch tray irrigation liquor and,
hence, minimizing the mist eliminator and Koch tray scaling potential
(see Run 528-2A).
The run was originally intended to be a long-term reliability test.
However, it was terminated after only 476 operating hours when a
rapid increase in pressure drop across the Koch tray occurred. An
inspection revealed heavy scale and solids deposits on top of the Koch
tray. A clarifier rake malfunction (which was not discovered until
April 10) caused heavy solids carryover in the clarifier overflow for
about two days. The solids carryover and the lower (15 gpm) Koch
tray flush rate probably resulted in the settling of solids on the Koch
tray. Subsequent use of the centrifuge for slurry dewatering resulted
in centrate containing about 0. 5 wt % of solids, which may have con-
tributed to further settling of solids on the Koch tray.
;
This partially collapsed condition is considered normal by the supplier
due to pressure and temperature cycling between operating periods
and shutdowns.
8-12
-------
The mist eliminator was heavily plugged. Inspection on April 9 (after
290 hours of operation) showed an estimated overall restriction of 8
percent which then increased rapidly in 186 hours to 44 percent at the
end of run.
Approximately 100 TPR spheres (0.4 percent of the total inventory of
the system) failed at the seams during the run.
8.1.7 TCA Run 531-2A
Run 531-2A was begun on May 10, 1974, after a thorough cleaning.
Magnesium oxide was added to the effluent hold tank in an attempt to
*
operate in the sulfate unsaturated mode. Also, the TCA slurry header
was lowered four feet in an attempt to reduce the amount of slurry
droplet entrainment to the Koch tray.
Results from the EPA pilot facility at Research Triangle Park (Re-
ference 12 )have shown that it is possible to operate limestone and
lime wet-scrubbing systems with liquors "unsaturated11 with respect
to calcium sulfate, thereby completely eliminating the potential for
gypsum scaling. This is accomplished by controlling, within given
limits, the total oxidation of sulfite to sulfate and the amount of dis-
solved sulfate. Under these limits, the sulfate formed by oxidation is
purged, without crystallization, as a "solid solution" within the pre-
cipitated CaSC>3. The amount of sulfate which can be purged in this
manner is related to the sulfate activity in the scrubbing liquor, which
can be increased by addition of magnesium ion. The required mag-
nesium addition for unsaturated operation appears to be higher for
limestone systems than for lime systems and also increases as the
concentration of chlorides in the process liquor increases.
8-13
-------
The run was terminated after 1088 operating hours due to increasing
pressure drop across the mist eliminator, Koch tray, and bottommost
TCA bed. Inspection revealed considerable scale and solids deposits
on the Koch tray, mist eliminator, and bottom grid. The mist eliminator
was 75 percent plugged at the inlet edge and within the first pass. Scale
deposits were limited to the first two passes.
Heavier than usual solids buildup was observed on the walls between
the slurry spray nozzles and the steam sparger. This could be due to
insufficient wetting of the walls by entrained slurry resulting from the
lowering of the slurry spray header.
The run had never attained steady state (i. e., the desired magnesium
ion concentration of 10,000 ppm was not reached), and the final mag-
nesium concentration of 5,000 ppm in the process slurry was insuf-
ficient to attain unsaturated operation.
A total of 638 TPR spheres (2.4 percent of the starting inventory)
failed at the seams during the run. The wear of the intact spheres
varied from no measurable loss in the top bed to a 6. 5 percent weight
loss in the bottom bed for over 2000 hours of operation.
8. 1. 8 TCA Run 532-2A
Run 532-2A was begun on July 17, 1974, after the system was cleaned.
Again, magnesium oxide was added to the effluent hold tank in an attempt
to operate in the sulfate unsaturated mode at a 10, 000 ppm level of
magnesium ion in the process slurry. The scrubber recirculation
liquor rate was increased from 1200 to 1700 gpm.
8-14
-------
Also, a closed recycle irrigation liquor loop was provided for the Koch
tray/mist eliminator system, which included provision for mist elim-
inator underwash (v-8 gpm fresh water plus "^7 gpm recycle liquor).
The Koch tray recycle irrigation rate was set at 35 gpm. The clari-
fier liquor, which had been used for Koch tray irrigation during the
previous tests, was routed directly to the effluent hold tank.
Because of relatively high saturation (140 percent) of the inlet scrubber
slurry and the liquor in the wash tray loop, an inspection was made on
July 29, after 258 operating hours. About 200 mils of thick scale cov-
ered the walls below the bottommost grid, and the top of the Koch tray
was covered with 12 mils of scale. The free flow area of the mist elim-
inator was 1 to 2 percent plugged with solids within the first and second
passes.
About 4000 TPR spheres (15 percent of the total inventory) were found
*
floating in the downcomer. They had passed through the bottom grid.
In view of the above problems, the run was terminated. Note that the
SO2 removal efficiency for this test averaged about 98 percent, as com-
pared with 84 percent for the previous test, due to the addition of mag-
nesium (see Table 8-1).
The 1-1/2 inch TPR spheres can pass through the bar-grids supplied
by UOP when they become dimpled on both sides.
8-15
-------
8.1.9 TCA Run 533-2A
Run 533-2A was started on August 6, 1974, after a thorough cleaning
of the system. The recirculating slurry rate was reduced from 1700
to 1200 gpm, the used TPR spheres in the three beds were replaced
with new ones, and the percent solids recirculated was increased from
8 to 15 percent. The Koch tray/mist eliminator system was the same
as in the previous test, with a closed recycle irrigation liquor loop
for the Koch tray and mist eliminator underwash. The scrubber slurry
magnesium ion concentration was maintained at 10, 000 ppm. The
scrubber inlet liquor, however, remained supersaturated with respect
to sulfate (see Table 8-2).
The run was terminated after 332 operating hours when an inspection
showed that the underside of the wash tray was covered with up to 60
mils of scale over 40 percent of the tray area. The top surface of the
tray was coated with from 50 to 100 mils of scale. The mist eliminator
was 12 percent plugged with scale/solids deposit, primarily in the
second and third passes. Also, the walls between the steam sparger
and the slurry spray nozzles had up to 2 inches of solids deposit.
8.1.10 TCA Run 534-2A
Run 534-2A was started on September 3, 1974, after the system had
been cleaned. It was decided to abandon, for the time being, attempts
The liquor rate was reduced because of increased erosion of steel
piping during the previous test and because the high liquor rate may
have contributed to forcing the dimpled spheres through the bar-grids.
8-16
-------
to operate in the sulfate unsaturated mode with the addition of mag-
nesium oxide until further exploratory tests were conducted at the
*
EPA pilot facility in Research Triangle Park. Therefore, conditions
for Run 534-2A were chosen similar to those of Run 526-2A, which had
been in operation for 1190 hours with no apparent scaling problem on
the top of the Koch tray. The underside of the mist eliminator was
washed continuously with 15 gpm diluted clarified liquor (»^8 gpm
makeup water plus ^ 7 gpm clarified liquor), while the Koch tray was
irrigated with the remaining ^-8 gpm of clarified liquor plus the 15 gpm
mist eliminator wash. The main differences between Runs 534-2A
and 526-2A were, therefore, the addition of direct mist eliminator
underwash and the four feet lower elevation of the inlet slurry spray
header. In order to reach the expected steady state chloride concen-
##
tration quickly, CaClo was added to the system before startup.
Run 534-2A was terminated after 100 on-stream hours due to scale
buildup on the Koch tray. The top of the tray, including the valve caps,
was almost completely covered with from 10 to 15 mils of scale. About
2 percent of the mist eliminator flow area was restricted by solids.
Also, about 30 percent of the Koch tray underside surface was covered
with solids, reaching a maximum thickness of 1 1/2 inches.
*
Further testing at the EPA pilot facility (see Reference 12) has indi-
cated that a decrease in scrubber effluent residence time (i. e. , an
increase in solid solution precipitation rate) from 12 to 5 minutes
would result in unsaturated operation for the conditions tested.
**
It normally takes a number of weeks for the chloride level in the pro-
cess slurry to reach a steady state value when beginning a run with
raw water. The process slurry was dumped at the beginning of Run
534-2A to dispose of the large quantity of magnesium ion in the system.
8-17
-------
As in the previous run, the walls between the steam sparger and the
slurry spray nozzles had up to 2 inches of solids deposit.
8.1.11 TCA Run 535-2A
Run 535-2A was begun on September 12, 1974, after the system had
been cleaned. The test conditions were nearly identical to Run 534-2A,
with the added condition that a minimum clarified liquor return flow rate
of 15 gpm was to be maintained for Koch tray irrigation and mist elim-
inator wash. In maintaining this rate, the fluctuating bleed flow to the
clarifier resulted in, at times, only 12 to 13 percent solids (as com-
pared with the desired 15 percent) in the recirculating slurry. Therefore,
the effluent residence time was increased from 12 to 15 minutes, in order
that the sulfate saturation of the scrubber liquor remain below 135
percent at all times (see Figure 7-2). Also, about 12 percent more
make-up water was available for mist eliminator/Koch tray irrigation
because of the elimination of seal water from a flue gas cooling spray
pump.
After 158 hours of operation, an inspection showed about 15 mils of
scale covering about 25 percent of the top of the Koch tray and rela-
tively heavy solids accumulation (up to two inches thick in some areas)
on the underside of the tray. The mist eliminator was about 5 percent
plugged with solids (mostly fly ash) on the lower vanes. The walls
between the steam sparger and the slurry spray nozzles had up to 4
inches of solids deposit. The run was continued.
After 316 hours of operation, a second inspection revealed that the
scale had disappeared from the top of the Koch tray and that the mist
8-18
-------
eliminator was only 1 to 2 percent plugged with scattered solids (mostly
fly ash) on the lower vanes. The bottom of the Koch tray, however,
still had heavy solids accumulation. At this time, it was found that
the steam pressure in the Koch tray steam sparger (see Figure 3-2)
had drifted to 50 psig from an original setting of 125 psig. The steam
pressure was reset and the run continued.
After 431 hours of operation, a third inspection showed that the top
of the Koch tray was still clean and that the mist eliminator was prac-
tically clean (approximately one percent plugged with scattered solids
on the bottom vane). The solids accumulation on the underside of the
Koch tray had been substantially reduced, with 30 percent of the under-
side clean to metal. However, solids buildup on the walls between the
steam sparger and the slurry spray nozzles had increased to a max-
imum thickness of 8 inches in some areas.
After 786 hours of operation, a fourth inspection showed that the top
of the Koch tray was still clean and the mist eliminator again prac-
tically clean (approximately one percent plugged with scattered solids
on the bottom vane). The solids accumulation on the underside of the
Koch tray was slightly increased, with 20 to 25 percent of the under-
side clean. The solids buildup on the walla between the steam sparger
and the slurry spray nozzles had further increased. The maximum
deposit in one area had reached 15 inches in thickness. Approximately
30 mils of scale had accumulated on the grids during the 786 hours of
operation. There was no measurable increase in pressure drop across
the beds, Koch tray, or mist eliminator. The run was continued fol-
lowing the 786 hour inspection.
8-19
-------
The average wear of the TPR spheres, for 1200 hours of operation,
was about 4 percent.
8.2 MATERIAL BALANCES
The results of four material balances for calcium and sulfur during
limestone reliability testing calculated over continuous on-stream
operating periods are given in Table 8-3. The method of calculation
is identical to the method used during reliability verification testing
(see Section 7. 5).
The computed inlet and outlet rates for calcium and sulfur are in good
agreement. The average stoichiometric ratios based on solids analyses
are probably more accurate than the values based on limestone addition
rate and SO^ absorption, due to uncertainties in the measurement of
limestone slurry feed rate. The ionic balances for the bleed stream
solids analyses, from which the calcium and sulfur discharge rates
were calculated, averaged less than +4 percent (more cations than
anions).
During Run 531-2A, when magnesium oxide was added in an attempt to
achieve unsaturated operation, the stoichiometric ratio values reported
include sulfur in the liquid but not magnesium since the material balance
is only for calcium and sulfur. Stoichiometries based on both mag-
nesium and calcium are reported in Table 8-1.
8-20
-------
Table 8-3
SUMMARY OF MATERIAL BALANCES FOR SULFUR AND CALCIUM
FROM LIMESTONE RELIABILITY TESTS
Run No.
5Z6-ZA
531-ZA
531 -2A
535-ZA
Material
Balance
Period.
hours
43Z
35Z
563
47Z
Sulfur Balance
S02
Absorbed,
Ib-moles/hr
5. 1
4.7
4.9
5.8
SOX in Slurry
Discharged.
Ib-moles/hr
5. 5
5. 1
4.3
6. 1
Percent
Error
+ 7
+ 8
-14
+ 5
Calcium Balance
Ca in Lime-
stone Feed,
Ib-moles/hr
8.1
7. 1
4.5
8.5
Ca in Slurry
Discharged,
Ib-moles/hr
8.0
7.4
4. 5
9. 1
Percent
Error
-1
+4
0
4-7
Average Stoichiometric Ratio.
Moles Ca Added/Mole SO, Absorbed
Based on Lime-
stone Added
and SO2 Absorbed
1. 60
1.50
0.93(a)
1.47
Baaed on
Slurry
Analysis
1.4f,
1.45(a)
1 05(al
1.49
00
ro
{a) Does not include magnesium.
-------
8. 3 CONCLUSIONS
8. 3. 1 Scrubber Internals Operability
Both the limestone reliability verification and reliability test results
have shown that scrubber internals can be kept relatively free of scale
if the sulfate (gypsum) saturation of the scrubber liquor is kept below
about 135 percent. This can be accomplished with the proper selection
of percent solids recirculated, effluent residence time, and liquid-to-gas
ratio (see Figure 7-2). The data indicate that, at approximately 15 per-
cent solids recirculated, 10 minutes effluent residence time, and 73
gal/mcf liquid-to-gas ratio, the scaling of the TCA internals will not
become a problem in maintaining long-term system operation. For
example, the four bar-grids in the TCA were covered with only 10 to 14
mils of scale after 1190 hours of operation in Run 526-2A.
A significant recent problem in the TCA has been associated with solids
buildup on the walls between the steam sparger and the slurry spray
nozzles (see Runs 531-2A through 535-2A), which originated after the
slurry spray nozzles had been lowered by four feet. It is hypothesized
that the solids buildup is due to insufficient wetting of the walls by en-
trained slurry. The problem may be corrected, therefore, by wash-
ing the walls between the tray and nozzles or by raising the nozzles to
their original position. Such a wash system will be tried, and, if
*
unsuccessful, the slurry nozzles will be raised.
*
During the later portion of Run 535-2A, which was in progress at
this report writing, a single nozzle Koch tray underwash utilizing
the Koch tray effluent was installed and the steam sparger was
removed. The single nozzle underwash has been successful in
keeping the underside of the Koch tray as well as the scrubber walls
below the tray free of solids buildup.
8-22
-------
HDPE spheres had an operating life of about 2000 hours before eroding
through and filling with slurry. TPR spheres showed a weight loss of
only six percent after 2500 hours. At this erosion rate, a service life
approaching one year would be anticipated for the TPR spheres. The
TPR spheres tend to dimple, however, and can slip through the sup-
porting bar-grids. This can be corrected by respacing the bar-grids.
There has been no measurable erosion of the bar-grids in the TCA
after more than 5000 hours of operation.
8. 3. 2 Koch Tray/Mist Eliminator Operability
The most significant reliability problem encountered during the TCA
limestone reliability tests has been associated with scaling and/or
plugging of the Koch Flexitray and bottom vanes of the chevron mist
eliminator (see Figures 3-2 and 3-4).
Run 528-2A showed that the mist eliminator and top surface of the
Koch tray can be kept relatively free of scale if the irrigation liquor
is low in sulfate saturation.
Run 526-2A showed that the top of the Koch tray can be kept relatively
free of scale if it is irrigated with the available raw water makeup and
clarified liquor, provided the mixture is maintained below the critical
sulfate saturation level of approximately 135 percent. The run was
terminated prematurely, after 1190 hours, due to excessive wear on the
HDPE spheres and plugging (with debris) of the scrubber slurry nozzles.
8-23
-------
The present Run 535-2A has been in operation for over 900 hours with-
out any significant scaling or plugging of the top of the Koch tray or
mist eliminator surfaces. The test conditions for this run are similar
to those for Runs 5Z6-2A and 529-2A, with the exception of direct mist
eliminator underwash with raw water. It is likely that long-term relia-
bility of this mist elimination system would be realized at the run condi-
tions tested. Efforts to simplify the mist elimination system and to
achieve reliability operation at higher gas velocities will be made during
the Advanced Test Program.
8-24
-------
Section 9
LIME RELIABILITY TEST RESULTS
Performance and analytical data from the venturi/spray tower system
lime reliability testing at the Shawnee facility are presented in this
section, along with an evaluation of each reliability test and the con-
clusions drawn, to date, from the testing.
9. 1 PERFORMANCE DATA AND TEST EVALUATION
A summary of the test conditions and results for each of the venturi/
spray tower lime reliability tests is presented in Table 9-1, along with
the run philosophies. A summary of the scrubber inlet liquor analy-
tical data for a majority of the tests is presented in Table 9-2, along
with the calculated percent sulfate saturations.^ Properties of coal and
lime used-during these tests can be found in Appendix C. Essential
operating data for all of the venturi/spray tower lime reliability tests
are graphically presented in Appendix I. An evaluation and discussion
of each test is presented in the following sections.
The sulfate saturations and analytical data are for an average inlet
gas SO2 concentration of 2800 ppm. The effect of inlet gas SO£ con-
centration on sulfate saturation is discussed in the following sections.
9-1
-------
Table 9-1
SUMMARY OF LIME RELIABILITY TESTS
ON VENTURI/SPRAY TOWER SYSTEM
Run Mi
Stan-or-Run IXtr
End -of- Run Dair
In Stream Ihiuri
Gal Heir ICIrr n iJOT
Spray Tower Gai Vel. fee @ I25T
Vanluri'Spray Tower
.Iquor Hale a gpm
pray Tower LtC gal/mcf
'erecnl Solldi Recirculaled
;ffluenl Realdenc* Time min
Solid* Dlapoaal Syetem
Stolchlomet rie Ratio, motet Ca
added/mole SOj ibaorbed
Avg *j Lime Utilization, IGOa-
molea SO2 abi /mole C* addrd
nlet SOj Concentration, ppm
Percejii SOz Removal
Scrubber Inlet prl Binge
Scrubber Outlet pH flange
Percent Sulfur Ondlied
»oop Cloiure, H Solid! Duchg
Calculated % Sulfale Saturation In
Scrubber Inlet Liquor 9 fO°C
DlaaolvtdSollda ppm
Total iP Ring* Excluding
Miet eliminator in. r^O
Veaturi O.P, In HjO
Mill Ellminelor&P. In HjO
Abiorbenl
Milt Ellmlnalor
Scrubber Inurnale
Syitem Change* Before Sun
of Run
Melhod of Conlrol
Sun Philosophy
Reaulle
1.01. 1 A
IOfl/73
l/R/74
2151
21. 000
6 1
1.0071100
60
7.9
12
Clarlfler Only Clirll It IiuetmiKent Clartflf r i Filter
IIO/5-1I/3- Filler I1I/7.I2JISI {IZ/Li-l/91
1 01. 1 21 1 02-1 IB 1 04-1 \1
at 11 9»
lfcOO.3900 lbDO-4000 i!00.«00
68.91 '5-«5 «-?S
14-85 1 5-> 5 71-84
4 7.5 5 4 7-5 5 « «-5 3
10-30 10-30 10-30
20-26 ZO-27 42-52
ISO 120 110
5700-7100 4i00.7300 HBOO-1J.1W
11 0.11 5 11 0-12 0 II '-12 3
9 9 '
0 S5-0 70 0 60.0. TO 0 f 0- 1 6]
jime (lurried lo 20 wlti with makeup water end added
loEHT
10/9 - 12/15. Bottom wuhed with tvillible makeup water
1-14 gpm) plu> available clarified liquor (-It, gpm) Con-
llnuoue walh rale o> 0 g gpm/fl2 12/15 . 1/8 Bottom
•wiahed with available makaup water [MS gpm) plua available
cycle of 1- 1/2 mlM ontl-tfi rnlnofl Alea. top waa iMianed
once/wk with freah water for 5 mln during laat 4 wka
All eo»ltf CT/hoaderl on top 3 header* tprayed dmmward
itrttom header noxalei (7) aprayed upward
Syjtem (aerubber and mlat ellntiMtor) cleaned
Scrubber inlet pH controlled at 8 0 i 0 2
Initially atarled aa lime reliability verification teat Sllb-
• aeuently, due to apparent reliability of the run. declilon
we* mace thai teal continue ai long-UTm reliability teal
Routine Inapeclion on 11/7/74 allowed ayatemwaa generally
clean after bb6 hour* of operation with clarifier only for
aollda fflavoaal Run waa terminated on l/B/74 due to ID
fan vibration and rapidly Increaaing preaiure drop acroll
mlaE (Km Sulfati- baaed acale lormrd on moil acrubbwr
walla ana in eturry piping Top of miat «limvnfcle.r 69^
plugged with aollda that fell from outlet duet-work Mlat
eliminator top vane* heavily acaled (300 rmla avg I
L02.IA
j.'iim
4/1/74
391
it. too
«. 7
'.DO /1 200
60
7 5-9 t
12
Clarlfler 1 Filter
1 02-1 18
91
2100-3100
87-97
1 6-8 1
4 9-J 4
5-28
42-48
its
?!«>
11 0-12 0
9
0 65-0 73
Ume alnrrlad to 20 wt*. with
makeup water and added lo
EHT
Bottom waahed with available
makeup water 1-5 gpm) plua
available clarified liquor
1 ~34 awn) VTaih rate of I
ont 1 mln off
All noxalei on 4 header*
aprayed downward 7 noz-
±lea/neader on top 3 headera.
b noiBle* on bottom header
Syatom cleaned chemically
(NajCOs / auga r/llmeatone /
fly* ah loin ) followed by
mrch cleaning EHT aealed
Initallad cKlernal combuation
rehealer Changed neazlet
on bottom iprey header to
apray downward inetead of
upwaid Capped middle
noealei on bollonn neadrr
Scrubber inlet pH controlled
at 8 0 i 0 Z
Intended Long-term Sraled
EHT In attempt lo reduce
aulfite oxidation and thereby
degree of aulfale aaturalion
Run trrmlnaled due to acalr
[125 mil. avp>l and aolidl di.
poalta on miat rllmlnator lop
vaitca. Sulflte oaldation and.
aulfale aatvration were not
rc plua
available clarified liquor
(~M gjim) Waah rate of 1
mln. on/t-1/2 mln off
All nozilei on 4 neaden
aprayed downward 7 noa-
zlea/header on top ) neadera
6 noazlea on bottom header
« 8 0 1 0 I
Intended long-lrrm Reclr*
culaled 1 5£ aolid* in atlempl
lo reduce dearer of lulfatr
aaluration CUT lealed
ual reduced but run »ai
lerminaled due to icale (fiO
,-ill.j.r land n>lil a buildup
an the niiBI eliminalnr rop
hanei
9-2
-------
Table 9-1 (continued)
SUMMARY OF LIME RELIABILITY TESTS
ON VENTURI/SPRAY TOWER SYSTEM
Run No
Siart-of Run Date
End -of -Run Dalr
On Stream Hour*
Gai JUtc ic(m0 130DF
Spray Tower Gil Vcl. fp» @ I2*°F
Ventun/Spray Tower
Liquor R*te« gpm
Spray Tower L/C gal/mcf
Percent Solids RrcircuUted
Effluent Residence Tim*, mfn
Solidi Dupoial Syitem
Sio-ichiometrlc Ratio molea Ca
added/mole SOj ibaorbed
Avg % Lime Utilizalien, 10 Ox
molei SO2 ab! /mole Ca added
Inlel SOj Concent ration ppm
Percent SO; Removal
Scrubber Inlet pH Range
Scrubber Outlet pH Range
Percent Sulfur Oxldlied
Loop Cloiure. % Solid* Diachg
Calculated % Sulfal* Saturation in
Scrubber Inlel Liquor g 50°C
3i»»olvrd Solid • ppm
Total AP Range. Excluding
Mut Eliminator, in HjO
Ventun AP In H2O
Mlal Eliminator/* P. in H2O
Absorbent
Miit Eliminator
Scrubber Internal*
Syatem Change! Before Start
of Run
Method of Control
Run Philosophy
leaultB
f.04.1 A
4/26/74
7/15/T4
laza
25 000
6 7
mm MOOU1200
60
7 5-9 0
17
ClarUler t Filler
1 03-1 30
88
2000- 1BOO
70-«
7 7-8 4
4 5-5.4
8-30
50-40
ISO
11.600-11.700
3 a. a a
Plug 100% open
0 70-1 75
Lime ilurned to 20 wt *, with
makeup uaier Jnd added 10
•c rubber downcomer
Bottom waahed with available
makeup water (-"-5 Ipm) plus
available clarified liquor
<~J5 gpm) Waah rate of
1 gpm/ft2 on cycle of - 3 1/2
mln «n< 1 HZ mln off
All noztlei on 4 header*
•prayed downward 7no>-
clea/header on top 3 tieaderi
6 noiilei on bottom header
Miit eliminator and outlet
duct cleaned Sealed EHT
provided with Nj gaa purge
EHT over now blanked Lime
•lurry makeup added >o
•c rubber downcorner
Scrubber inlet pH controlled
at 8 0 1 0 2
Intended I wki To oburve
•ulJlte oxidation and degree of
• ulfate aaturailon with lime
•dd'n to downcorner minlrnuir
• lurry rale to venturl icaled
EHT purged with Nj gai. and
B% toLlda recirculated
Degree of aulfate eatu ration
wa* about 130% Solid • from
outlet duct fell to top of mix
eliminator Run wai termin-
ated due to heary icale <500
milB avg | and aolldi buildup
on mici eliminator
•-OS-IA
7/11/74
BSf/74
Ml
24 000
i. 7
mm MOOWIZOO
60
B 0-9 3
17
Clariher fa PUter
1.10-1 17
88
2500-3)00
73-61
B B-9 2
4 9-5 1
12-26
49-52
115
6.000-7.400
3 2-3 9
Plug 100% open
n AH.O 8t
Lime (lurried to 20 wi«i with
makeup wale r and added to
• c rubber downcomer
Bottom waihed with available
makeup water only (-5 ipm)
Waah rate of 0 4 gprn/ft* on
cycle of—I mm on/4 min
off
All nocxlei on 4 header*
•prayed downward 7 aoa-
alei/header on top 3 header!
6 noiilei on bottom header.
Syjtem cleaned
Scrubber Inlet pH controlled
at 9. 0 f 0 i
nlendeil ^ong-term Control
at higher pH In attempt to
reduce tulfite oxidation and
hereby degree of tulfate
•aluration Waih mi at ellm-
nalor with walar only
Run we • terminated due to
acale formation (up to ISO
million lop ml«t eliminator
vane*
•.O'-IA
R/7/74
B/14/74
170
25.000
6.7
mm f~100}mOQ
'•O
T 7-9 0
17
Cla rifle r
1 10-1.15
89
2400-3200
67-79
1 8-8 2
5 0-5 2
12-22
18-23
120
5.000-7,000
3 6.3 7
Plug 100% open
0 78.0 B6
Lime ilurried lo 20 wt% with
makeup water and added to
•c rubber downcomer
Bottom waihed continuously
with IS gpm (0.1 gpm/ ft2)
raw water only (Rate wap
greater than available makeup
water)
111 Docilei on 4 heideri
tprayed downward 7 noi-
ilei/beadcr on top 3 headera
Y noiclei on bottom header
Milt eliminator cleaned
Scrubber Inlet pH controlled
at 8 0 JO 2
Intended ahort-lerm Mtit
eliminator waahed contlnuoui-
y with raw water only (at rale
ircater than available makeup
water)
Run wae terminated due to
• cale formation (SO mils avg )
on top mill eliminator vanei
-.Oh-IA
Hf2W74
0/17/74
l'i
J-, ijnn
. 7
(.00/1200
fiO
7 7-9 4
12
Clarifier k Filter
1 05-1 2^
87
2000-3750
75-9S
7 6-8 4
4.8-5 1
12-28
48-58
130
7. 500-9. 500
II 5-12 0
9
0 75- 0 97
Lime alurricd la 20 wt% with
makeup water and added lo
• c rubber downcamer
Bon am wished with available
makeup water only V-5 5 gpml
Waah rate of 150 gpm (3 gpm/
ft*) for approx 9 mln every
4 houri
All noxilei on 4 header*
•prayed downward 7 noi-
zlei/header on top 3 header!
i nozKte* on bottom header
Miit eliminator cleaned
Provided for Freon gaa
blanket over EHT
Scrubber inlet pH controlled
at fl 0 i 0 2
Int'd 2 w\» 12 mln rri lime.
venturl In aervlce EHT ical-
ed with Freon Mill ellm on
4 hr waih cycle Obiervr
effect! of lime add'n to down-
comer and eealed EHT (com-
pare with Run 601 -!A)
tun terminated due to alight
increaie In mill eliminator
AP Inspection revelled
•cale buildup (88 mile avg )
on (he mlai rllmlnator lop
vanei
9-3
-------
Table 9-1 (continued)
SUMMARY OF LIME RELIABILITY TESTS
ON VENTURI/SPRAY TOWER SYSTEM
Stirt-of-Kun Date
End-of-Rot Dale
>n Stream Hour*
Cki Rile. »cfm£M00F
ipnyTow«r G»J Vtl,
Venturl/Sprty Tower
Jquor Raiei. gpm
Spray Towtr L/C. gtlJmcf
Percent Solid• Rectrculated
Efrhi.nl RaiLdene* Tim*r mln
Solldi DiipDMl System
SloleMometrlc Ratio, molei Ca
added/mole SO; abiorbed
Avg % Lime Utilization. IQDx
mole a SO; aba /mole Ca *itd«d
Inlet SOj Concentritlon. ppm
t SGj R«mo
Scrubbflr UUt pH R«ma
Serabh>r Pullet pH flinge
l Suliur 0*iJI»qd
-eop Clo«un, 4 Sfthdi DUchg
Cklculftted % Sulftti Stturttian In
bbftc Inl»t Ulqwr fl SO°C
Dl.iolv.d Solldl. ppm
. Excluding Mix
EUmtrutor. In H2O
in HZO
MUtElimitntorAP. in H2O
Abiorbcnt
Mill Eliminator
Scrubber Intcrmli
Before St»rt
Method of Contra]
Run Philosophy
9/20/74
1D/2/74
25,000
B.7
tOO/I200
1-9 0
Cbrlflerk Filler
1200
H.MO-10rCQD
Lime •lurried to 20 wtft with
lukeup witer (
icrubber dovacomflr
Botiom wmjhed witb makeup at
Z 7 gpnt/ft' for «-S mln erery
4 hre Slmu]ian«ov« lop waib
urllh remalnlitf makeup «1
1 (pm/ft2 throagh • eliigle
nofi»le coverlB| about H ftz
Total makeup«rS gym tug
All noivlei an 4 header*
•let/headcr on lop 3 hfcaderi
iUci on bottom header
MUl vllmiutor end outlet dvc
cleaned A jingle nozzle in-
•ulled to provide top weah foi
one acctl«n at mlit ellmlnaior
end ae»nl hdUi dTilltd I
ht top vanei of a ••cond
atrcllon
Scrubber Inlet pH controlled
,180102
Intended Z vfci To obaerve
the effect of rnUt gUmLjiator
lop wach fon on* vectionl and
the effect of iocreitcd tt»l-
dence time on •ulfeta aatura-
tion
Run terminated*! planned
Sulfate nhiraUen reduced to-
1 Mill elimlnaior lop
vanci clean whire top waehed
9-4
-------
Table 9-2
AVERAGE SCRUBBER INLET LIQUOR COMPOSITIONS AND CALCULATED
SULFATE SATURATIONS FOR VENTURI/SPRAY TOWER LIME RELIABILITY TESTS
Run No
601 lA|al
601-lA(bl
603-1A
604-1 A
605-1 A
60S-1 A
609- 1 A
Percent
Solids
Recirculated
7 9
7-9
13 5-16 0
7 5-9 0
8 8-9 2
7 5-9 0
8-9
Effluent
Residence
Time, rmn
12
12
12
17
17
12
24
Percent
Solid a
Discharged
20-26
42-52
46-54
50-60
48-52
48-58
46-52
Percent
Sulfur
Oxidised
10-10
10-30
12-22
8-30
12-28
13-24
15-25
Scrubber
Inlet pH
Range
7 4-8.6
7 5-8. 5
7 8-8 2
7 7-8 4
8 8-9 2
7 9-8.4
7 5-8 5
Inlet Liquor Species
Ca*+
190O
3100
2880
3200
2200
2220
2680
M."
140
200
190
400
50
320
310
N.*
60
80
90
80
60
60
60
K*
80
230
330
275
180
230
120
Concentrations, n
so3 =
90
60
60
50
50
45
40
S04*
2000
2300
1670
2000
1450
1920
1440
ig/1 (ppmt
cot-
20
25
5
30
5
10
20
Cl" Total
Calculated Percent
at S0°clel
-------
9.1.1 Venturi/Spray Tower Run 601-1A
On October 9, 1973, a test (Run 601-1A) was begun on the venturi/spray
tower system at the following major test conditions (see Table 9-1):
Spray Tower Gas Velocity 6. 7 ft/sec
Venturi Liquid-to-Gas Ratio 30 gal/mcf
Spray Tower Liquid-to-Gas Ratio 60 gal/mcf
Percent Solids Recirculated 8
*£
Effluent Residence Time 12 min.
Scrubber Inlet Slurry pH (controlled) 8
This test was initially intended to be a lime reliability verification test,
but due to apparently reliable operation, it was decided to continue
the run under these conditions as a long-term reliability test.
The pH control level for the scrubber inlet slurry was chosen based
on results of lime testing at the EPA pilot facility in Research Triangle
Park, which indicated reasonable lime utilization and SO2 removal at
that level.
During the test, the chevron mist eliminator was washed on the under-
side both continuously (at a rate of 0.8 gpm/ft^) and intermittently
O
(1 gpm/ft ,31/2 minutes on/1 1/2 minutes off) with the available raw
water makeup plus clarified liquor. Also, the mist eliminator was
washed on the topside once per week with fresh water for 5 minute
durations during the last four weeks of the test.
Twelve minutes was the minimum residence time obtainable in the
effluent hold tank for this run.
9-6
-------
Throughout the initial 666 hour portion of the run, the clarifier was used
as the final dewatering device and the average percent solids discharged
was 23 percent, which resulted in slightly open liquor loop operation.
An inspection after 666 hours on November 7 showed that the mist
eliminator bottom vanes were clean, while the top vanes were about 5
percent plugged with soft solids. The scrubbers were generally clean,
with only a thin layer of scale (20 mils) on the upper half of the spray
tower.
In order to operate under closed liquor loop conditions, the test was
continued with the clarifier plus vacuum rotary drum filter (o,r centrifuge)
in series. Problems with the filter cloth and mechanical difficulties
with the centrifuge, however, resulted in intermittent operation of these
pieces of equipment from November 7 to December 15. For the final
575 hours of testing (from December 15 through January 8), the filter
operated satisfactorily, the average percent solids discharged increas-
ed from 23 to 47 percent, and the total dissolved solids increased from
about 6500 to 10, 500 ppm (see Table 9-2).
Run 601 - 1A was terminated after a total of 2153 hours (3 months) of
operation, due to vibration in the ID fan and to rapidly increasing pres-
sure drop across the mist eliminator. An inspection showed that the top
of the mist eliminator was covered with solids that fell from the duct-
work above, restricting about 80 percent of the surface. In addition,
about 1/8 to 1/2 inch thick scale formed in the middle and top vanes
and about 5 percent of the bottom (inlet) vanes contained heavy (1/4 to
*
The venturi/spray tower system clarifier is undersized.
9-7
-------
to 3/4 inch) scale. It is hypothesized that the heavy accumulation nf
solids in the outlet duct occurred when slurry droplet entrainment through
the chevron mist eliminator wetted the duct walls during frequent reheater
flame- outs.
Heavy scale had accumulated on the wall of the spray tower below the
bottom header, while the middle section of the vessel was only slightly
scaled. The venturi wall above the throat was clean, but scattered
scale covered the plug. A light scale covered the venturi wall between
the throat and flooded elbow, and the entire flooded elbow was covered
with hea'vy scale. Also, the recirculating piping was scaled, with
heaviest scale deposits in the pump suction areas. Scale also formed
on the impeller eyes and tips of all the recirculating slurry pumps and
on the lining of the casing of some of the pumps. It should be noted that
scale formation in the scrubbers, circulating slurry piping, and pumps
did not prevent continual operation of the system or necessitate termina-
tion of the run.
The formation of most of the scale on the scrubber walls and piping
occurred between December 15 and January 8, when the system was
operating under closed liquor loop conditions. The calculated average
sulfate saturation of the scrubber inlet liquor during this period was
180 percent. This is contrasted with a calculated sulfate saturation of
150 percent for the inittial 666 hours of testing during open liquor loop
operation (see Table 9-2).
An analysis of the test data during the final 575 hours of closed liquor
loop operation shows that the calculated inlet liquor sulfate saturations
9-8
-------
are strong functions of inlet gas SO? concentration (or SO2 absorption
rate). For example, during test periods where the inlet gas SO- con-
centrations averaged 3200 and 2500 ppm, the calculated sulfale satura-
tions averaged 225 and 140 percent, respectively.
9.1.2 Venturi/Spray Tower Run 602-1A
In preparation for the second lime reliability run, the system was
partially cleaned chemically (Na2CO ,/sugar/limestone/fly ash solution),
followed by mechanical cleaning. All the stainless steel spray nozzles
were replaced with identical full cone, stellite-tipped Bete nozzles
(ST48FCN) and the original Hauck reheater, which had frequent
flame-outs throughout the previous run, was modified to incorporate
an external combustion chamber (designed by Bloom Engineering Co. ).
Results from the EPA pilot facility in Research Triangle Park had
indicated that sealing the effluent hold tank could reduce the sulfite
oxidation and, thereby, the degree of sulfate saturation of the scrubbing
slurry. In an attempt to duplicate this mode of operation, the effluent
hold tank in the venturi/spray tower system was sealed prior to the
start of Run 602-1A.
Run 602-1A was started on March 15, 1974. The mist eliminator was
washed on the underside with the available raw water makeup and clari-
fied liquor (in an approximately one to seven ratio) at a rate of 1 gpm/ft^
in an intermittent operation (4 minutes on/1 minute off cycle).
9-9
-------
After 393 operating hours, the run was terminated when it became
apparent that sealing the effluent hold tank in this facility was not
effective in reducing the degree of sulfate saturation of the scrubber
inlet liquor. Although the sulfite oxidation had dropped somewhat (from
about 20 to 17 percent), the calculated sulfate saturation at the termina-
tion of the test was 190 percent.
An inspection showed that a uniform (about 1/8 inch) scale covered most
of the top and middle vanes of the mist eliminator. The bottom vanes
were relatively clean. The walls of the spray tower were covered with
a thin scale. The wall of the venturi below the plug was generally clean
and no scale was deposited in the flooded elbow.
9.1.3 Venturi/Spray Tower Run 603-1A
Run 603-1A was started on April 2, 1974, after the mist eliminator was
cleaned. The solids content of the recirculating slurry was increased
from 8 to 15 percent in order to reduce the degree of scrubber liquor
sulfate saturation. The mist eliminator was washed on the underside
with the available raw water makeup and clarified liquor (in an approx-
imately one to four ratio) at a rate of 1 gpm/ft^ in an intermittent oper-
ation (1 1/2 minutes on/1 1/2 minutes off).
After 395 hours of operation, the run was terminated due to increasing
pressure drop across the mist eliminator (from 0. 55 inch H^O at the
start of the run to 0. 70 inch H^O). The mist eliminator had 50 to 70
mils of scale on the outlet edge and soft solids along the inlet edge of
the top vanes. The middle and bottom vanes had light deposits of scale
9-10
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and soft solids. The venturi scrubber contained about the same amount
of scale as before the start of the run, while there appeared to be slightly
less scale on the spray tower walls and in the suction piping of the slurry
pumps. The calculated sulfate saturation of the scrubber inlet liquor
was 135 percent. This was a significant drop from the previous run's
value of 180 percent saturation at 8 percent solids recirculated.
9.1.4 Venturi/Spray Tower Run 604-1A
In order to decrease the quantity of soft solids buildup on the mist elim-
inator, which had caused termination of the previous test, it was decided
to drop back the percent solids recirculated from 15 to 8 percent for
this run. To reduce the scrubber slurry sulfate saturation from the
expected level of 180 percent (see Run 601-1A), (1) lime was added to
the scrubber downcomer (vs. the effluent hold tank), (2) the effluent
hold tank was purged (blanketed) with N^, and (3) the venturi scrubber
was used only for gas cooling (venturi plug 100 percent open with 100
gpm liquor flow rate).
It was theorized that the addition of lime to the downcomer quickly
increases the pH of the scrubber outlet liquor, thereby precipitating
calcium sulfite before the sulfite can be oxidized to sulfate in the liquid
phase (the solubility of calcium sulfite is lower at higher pH). As
mentioned previously, a reduction of liquor phase sulfite oxidation
results in a reduction in sulfate saturation. It was further theorized
that reducing the liquor flow to the venturi with a minimum flue gas
pressure drop would minimize liquid atomization, oxygen absorption,
and, consequently, oxidation.
9-11
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Run 604-1A was begun on April 26, 1974, after the mist eliminator was
cleaned. The mist eliminator was washed on the underside with the
available raw water makeup and clarified liquor (at an approximately
one to seven ratio) at a rate of 1 gpm/ft in an intermittent operation
(3 1/2 minutes on/1 1/2 minutes off). The effluent residence time was
increased to 17 minutes, since this -was the minimum time obtainable
at the reduced total liquor rate of 1300 gpm (the venturi liquor rate had
been reduced from 600 to 100 gpm).
The run was terminated after 1828 on-stream hours due to (1) increas-
ing pressure drop across the mist eliminator (from 0. 62 inch H^O
at start of run to 1. 75 inches H2O) and (2) gas flow control problems
caused by solids accumulation on the ID fan inlet dampers. The top
of the mist eliminator was 75 percent plugged with 150 to 200 pounds of
loose solids which had fallen from the outlet duct. There was about
1/2 inch of scale on the top vanes and 1/4 inch of scale on the bottom
vanes. Up to 2 inches of solids had accumulated in the outlet gas duct
and six of the 14 fan damper blades were covered with 1 to Z inches of
solids.
The sulfite oxidation ranged from about 14 percent with N^ purge over
the effluent hold tank to about 19 percent without NZ purge (from May 29
*
to June 5). The calculated average sulfate saturation of the scrubber
inlet liquor, however, was 130 percent. This was a significant drop
from the saturation level of 180 percent during the closed liquor loop
portion of Run 601-1A.
;''
Oxygen concentrations in the effluent hold tank in the vicinity of the gas/
liquid interface ranged from 15 to 20 percent, as compared with 21 per-
cent for air. This suggests that sealing the tank and N2 purging were
not effective in reducing oxygen absorption in the effluent hold tank.
9-12
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As in Run 601-1A, an analysis of the data showed that the calculated
inlet liquor sulfate saturation was a strong function of the SO? absorp-
tion rate. For example, during test periods where the inlet gas
concentrations averaged Z700 and 2900 ppm, the calculated sulfate
saturations averaged 120 and 150 percent, respectively.
9.1.5 Venturi/Spray Tower Run 605-1A
Run 605-1A was started on July 31, 1974, after the mist eliminator
was cleaned. The scrubber inlet liquor pH was raised from 8 to 9
only for this run to observe the effect of pH on sulfate saturation. The
mist eliminator was washed intermittently with raw water makeup at a
rate of 0. 4 gpm/ft^ on a 1 minute on/4 minute off cycle. As before,
lime was added to the downcomer and the venturi liquor rate was set
at 100 gpm with the venturi plug 100 percent open.
An inspection after 141 operating hours showed relatively heavy (up
to 150 mils) scale on the top mist eliminator vanes and the run was
terminated. As observed in previous runs, there was a moderate
buildup of scale on the middle vanes (50 mils) and only a light dust film
on the bottom vanes. No additional scale had formed in the spray tower
during the run. The calculated average percent sulfate saturation of
the scrubber inlet liquor was 115 percent. This can be compared with
a level of 130 percent for Run 604-1A, which had a controlled scrubber
inlet liquor pH of 8. 0 (see Table 9-2).
9-13
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9.1.6 Venturi/Spray Tower Run 606-1A
Run 606-1A was started on August 7, 1974, after the mist eliminator
had been cleaned. The objective of the run, which was intended to be
of short duration, was to investigate scale formation on the mist elim-
inator vanes with continuous washing on the mist eliminator underside
with raw water at a rate of 0. 3 gpm/ft . This raw water rate (15 gpm)
is approximately three times the quantity normally used during closed
liquor loop operation, and, therefore, the test was made under open
liquor loop conditions (about 21 percent solids discharged). The scrub-
ber inlet liquor pH was reduced from 9 to 8 for this test.
The run was terminated after 170 on-stream hours. About 95 percent
of the trailing (top) surface of the mist eliminator vanes was covered
with 30 to 70 mils of scale. As usual, there was light soft solids accumula-
tion on the middle vanes and the bottom vanes were relatively clean. It
should be noted that the scale growth rate on the top vanes (~50 mils/
week) was about the same for this test as for all of the previous tests
in which mixture of clarified liquor plus raw water were used for under-
side washing.
9. 1. 7 Venturi/Spray Tower Run 608-1A
Run 608-1A was started on August 21, 1974, after the mist eliminator
had been cleaned. The main objective of the test was to investigate
scale formation on the mist eliminator vanes with intermittent under-
side washing at high perssure (45 psig) using the available raw water
makeup at a rate of 3 gpm/ft^ for about 9 minutes every 4 hours. Also,
9-14
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the venturi scrubber was put back in service (at 600 gpm and 9 inches
HpO pressure drop) in order to investigate the effect of venturi operation
(Runs 608-1A vs. 604-1A) and lime addition in the downcomer (Runs
608-1A vs. 601-1A) on scrubber liquor sulfate saturation.
The run was terminated after 610 hours of operation due to increasing
pressure drop across the mist eliminator (from 0. 75 inch I^O at
start of run to 0. 95 inch H^O). About 80 percent of the trailing sur-
face of the top vanes was covered with scale, averaging 88 mils in
thickness and resulting in approximately 3 percent pluggage of the
free flow area. The middle and bottom vanes were, as usual, essen-
tially clean (3 mils of dust coverage). Note that the average scale
growth rate on the top vanes for this test (24 mils/week) was essen-
tially half the average scale growth of the previous four tests.
The condition of the scale on the walls of the spray tower remained
essentially unchanged, but the spiral tips of most of the spray nozzles
were covered with 1/4 to 1/2 inch scale ("whiskers").
The calculated average sulfate saturation of the scrubber inlet liquor
was 120 percent (see Table 9-2). This is the same as the calculated
saturation for Run 604-1A and about 50 percent lower than the calculated
saturation for Run 601-1A. Therefore, it may be concluded that, for
these run conditions, venturi operation has little effect on sulfate
saturation and the addition of lime to the downcomer (vs. lime to the
effluent hold tank) significantly reduces the sulfate saturation of the
process slurry.
9-15
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9.1.8 Venturi/Spray Tower Run 609-1A
Run 609-1A was started on September 20, 1974, after the mist eliminator
had been cleaned. The primary objective of the test was to evaluate
the effect of topside mist eliminator washing on the formation of scale
on the top mist eliminator vanes. The entire underside of the mist
eliminator and a 14 ft^ area on the topside was washed at high pres-
sure (45 psig) with makeup water at a rate of 2. 7 gpm/ft^ for the under-
side and 1. 0 gpm/ftr for the topside for about 8 minutes every 4 hours.
Only a small section of the topside was washed-because it was felt that
water carryover from top sprays could possibly cause reheater over-
*
loading and fan problems. Also the effluent residence time was in-
creased from 12 to 24 minutes, for this test, in order to determine
the effect of residence time on scrubber liquor sulfate saturation
(Run 609-1A vs. 608-1A).
Run 609-1A was intended to be of short duration and was terminated
after 278 hours of operation. The topside spray had been successful
in drastically reducing the scale buildup on the top mist eliminator
vanes. The washed area was essentially clean, with less than 1 mil
of solids accumulation, compared with an average of 40 mils scale
buildup on the rest of the topside surfaces.
Procedures for minimizing these problems, such as use of a sequential
sectional wash of the topside of the mist eliminator or use of a second
mist eliminator downstream of the topside sprays, will be investigated
during the Advanced Test Program.
9-16
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The calculated average sulfate saturation of the scrubber inlet liquor
was 110 percent for the test {see Table 9-2). This value is about 20
percent lower than the calculated saturation for Run 608-1A. It may
be concluded, therefore, that the effect of effluent residence time on
sulfate saturation is similar for lime systems as for limestone systems
(see Figure 7. 2).
9.2 MATERIAL BALANCES
The results of five material balances for calcium and sulfur during
lime reliability testing calculated over continuous on-stream operat-
ing periods are given in Table 9-3. The method of calculation is
identical to the method used during reliability verification testing
(see Section 7. 5).
The computed inlet and outlet rates for calcium and sulfur are in
fair agreement. The average stoichiometric ratios based on solids
analyses are probably more accurate than the values based on lime
addition rate and SC^ absorption, due to uncertainties in the mea-
surement of lime slurry feed rate. The ionic balances for the bleed
stream solids analyses, from which the calcium and sulfur discharge
rates were calculated, averaged less than +2 percent (more cations
than anions).
9-17
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Table 9-3
SUMMARY OF MATERIAL, BALANCES FOR SULFUR AND CALCIUM
FROM LIME RELIABILITY TESTS
Run No.
601-1A
601-1A
602- 1A
604- 1A
606-1 A
Material
Balance
Period.
hours
400
456
317
894
168
Sulfur Balance
soz
Absorbed,
Ib-moles /hr
6.2
6.3
7.2
5 8
5.3
SOX in Slurry
Discharged,
Ib-moles/hr
5.9
5. 5
7.9
5.9
5.4
Percent
Error
- 5
-15
+ 9
+ Z
t- z
Calcium Balance
Ca in Lime
Feed.
Ib-moles /hr
6.4
5.7
6.7
5. Z
4.7
Ca in Slurry
Discharged,
Ib-moles/hr
6.7
6.0
8.6
7. 1
6. 1
Percent
Error
+ 4
+ 5
+ZZ
+Z7
+23
Average Stoichiomet ric Ratio.
Moles Ca Added/Mole SO2 Absorbed
Based on Lime
Added
and SO, Absorbed
1. 03
0. 91
0. 94
0. 91
0.88
Based on
Slurry
Analysis
1.13
1.09
1. 10
1.20
1. 13
sD
1
00
-------
9. 3 CONCLUSIONS
9. 3. 1 Scrubber Internals Operability
The lime and limestone reliability tests have shown that scrubber
internals can be kept relatively free of scale if the sulfate (gypsum)
saturation of the scrubber liquor is kept below about 135 percent.
As with limestone, this can be accomplished with increased percent
solids recirculated (Run 603-1A vs. 601-1A) and/or with increased
effluent residence time (Run 609-1A vs. 608-1A). Moreover, the
lime tests have shown that adding the lime to the scrubber downcomer
(which corresponds to a small residence time tank in series with the
larger effluent hold tank) can substantially reduce the sulfate saturation
(Run 608-1A vs. 601-1A), allowing for operation at reduced percent
solids and/or effluent residence time. Also, operating at higher
scrubber inlet liquor pH appears to reduce the scrubber liquor sulfate
saturation (Run 605-1A vs. 604-1A).
The lime tests have also shown that the sulfate saturation of the scrub-
ber inlet liquor is a strong function of the inlet gas SO- concentration
(SO2 absorption rate). The data have indicated that a 100 ppm increase
in SO? inlet concentration corresponds roughly to a 10 percent increase
in sulfate saturation at the run conditions tested.
It should be noted that the 27 full-cone, stellite-tipped Bete nozzles
in the spray tower have shown no signs of measurable erosion after
approximately 4000 hours in slurry service.
9-19
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9. 3. 2 Mist Eliminator Operability
The most significant reliability problem encountered, to date, during
the venturi/spray tower lime reliability tests has been associated with
scaling and/or plugging of the topmost vanes of the chevron mist elim-
inator (see Figures 3-1 and 3-4).
Runs 601-1A through 608-1A showed that the scale formation rate on
the top mist eliminator vanes (25 to 20 mils/week) was relatively unaf-
fected by the wash cycle, wash rate, or quality (sulfate saturation) of
the wash liquor. Run 608-1A showed that intermittent washing with
high pressure (45 psig) raw water at a rate of 3 gpm/ft2 for 9 minutes
every 4 hours gave results that were at least as good as results with
continuous washing with relatively low pressure raw water at 0. 3 gpm/ft
(Run 606-1A). Intermittent washing can be especially important if the
availability of raw water makeup is restricted (e. g. , at high percent
solids discharged and/or high pump seal water usage).
Run 609-1A showed that intermittent topside and bottomside washing
with high pressure raw water would most likely eliminate the scale
accumulation problem on the top vanes of the existing mist eliminator
(see Figure 3-4) and allow for long-term reliability of the system at the
run conditions tested (see Table 9-1). However, the problems caused
by entrainment of topside wash water will have to be evaluated.
The reliability of the mist eliminator with intermittent topside and bottom-
side washing using high pressure raw water has been further demon-
strated in a recently completed 253 hour test (Run 610-1A). The scrub-
ber and mist elimination systems were not cleaned before the test.
9-20
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After a total of 531 operating hours (Runs 609-1A and 610-1A), the
washed area of the top mist eliminator vanes was still clean compared
with about 70 mils scale buildup on the rest of the topside vane surfaces.
Further tests with topside and bottomside wash and tests at higher gas
velocities will be made during the Advanced Test Program.
9-21
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Section 10
OPERATING EXPERIENCE DURING LIME/LIMES TONE TESTING
In this section, the operating experience during lime/limestone wet-
scrubbing testing at the Shawnee facility is summarized. Also sum-
marized are the results of a materials evaluation program conducted
by TVA.
10. 1 CLOSED LIQUOR LOOP OPERATION
Results at the Shawnee facility have shown that scaling potential,
which is a primary factor affecting reliability, is significantly af-
fected by the quantity of raw water input to the system, i. e. , the
greater the raw water input, the lower the scaling potential (see
Section 7.3). To obtain significant and comparable reliability data,
therefore, the scrubber systems must be operated in a "closed liquor
loop" mode. Closed liquor loop operation is defined as operation in
which the raw water input to the system is equal to the water normally
exiting the system in the settled sludge and in the humidified flue gas.
For lime/limestone wet-scrubbing systems, the solids concentration
in the settled sludge is normally equal to or greater than 38 wt %.
Closed liquor loop operation was not achieved during the initial limestone
factorial test period. Water input was excessive and sludge with less
10-1
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than 38 wt % solids had to be discharged from the systems. This
was not considered a serious problem during factorial testing (see
Section 6), but little information was gained about the effect of scal-
ing potential on reliability during this period.
Sources of excessive water input included seal water used to flush
the stuffing boxes (Hydroseals) on the slurry pumps, water quench
sprays used to cool and saturate incoming gas, and water used to
dilute the limestone slurry feed (10 to 20 wt % limestone).
The absorbent feed system was changed in November 1972, to provide
slurry feeds with up to 60 wt % limestone concentration. During the
five week boiler outage in February and March 1973, the Hydroseal
slurry pumps were converted to a Centriseal type (stuffing box with
air purge), and the TCA and Marble-Bed scrubbers were provided
with process slurry gas cooling systems. As a result of these modi-
fications, closed liquor loop operation has been maintained at the facility
since the beginning of limestone reliability verification testing in
March 1973.
10. 2 MIST ELIMINATOR OPERABILITY
The most significant reliability problem encountered during the lime/
limestone wet-scrubbing tests has been associated with the scaling
and/or plugging of mist elimination surfaces.
It is hypothesized that mist eliminator scaling is caused predominently
by SO? absorption into process liquor adhering to the mist eliminator
10-2
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surfaces, subsequent oxidation of the absorbed SC>2 species to sulfate,
and the resultant precipitation of calcium sulfate. In addition, solids
adhering to the mist eliminator surfaces will cause plugging and may
also act as sites for additional scale formation. These problems may
be alleviated by: (1) reducing the sulfate saturation of the mist eliminator
wash liquor (e. g. , utilizing raw water or subsaturated process liquor),
(2) washing the mist eliminator at a sufficient rate to remove all im-
pacted solids, (3) utilizing a wash tray to reduce the suspended solids
concentration of the droplets impinging upon the mist eliminator,
(4) using mist eliminators with improved draining characteristics
(e. g. , sloped mist eliminators), and (5) addition of softening or de-
scaling agents. Most of these concepts have been tested to date at the
Shawnee facility during the lime /limestone reliability sequences.
These concepts will be discussed in the following sections.
10.2.1 Venturi/Spray Tower System
A three-pass, open vane, stainless steel, chevron type mist
eliminator (see Figures 3-1 and 3-4) was used in the venturi/spray
tower system during the latter half of the limestone reliability
verification testing period and during the entire lime reliability
testing sequence. A polypropylene chevron mist eliminator (see
Figure 3-4), used during the early part of the limestone reliability
verification testing period, was discarded after it was damaged by
solids falling onto it from the outlet duct.
10-3
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In the venturi/spray tower system, operating at a superficial gas
velocity of 6.6 ft/sec, there has been a continuing problem of scale
formation on the top mist eliminator vanes. A variety of washing
configurations have been tried in order to alleviate this problem.
Individual test runs are discussed in Section 9. 2. 2.
Underside washing only, either continuously with low pressure water
at 0. 3 gpm/ft2 or intermittently with high pressure water at 3 gpm/ft2
(9 minutes every 4 hours at 45 psig), was unsuccessful in eliminating
scale formation on the top vanes. It was encouraging, however, that
intermittent washing (0.1 gpm/ft2 average rate) was as effective as
continuous washing (0. 3 gpm/ft2) for removing soft solids. Inter-
mittent washing may be required in closed liquor loop operation due
to restrictions in the allowable raw water makeup to the scrubber
system.
A combination of intermittent high pressure topside wash at 1 gpm/ft
and bottomside wash at 2. 7 gpm/ft2 (simultaneous top and bottom wash
for 8 minutes every 4 hours at 45 psig) appeared to be successful in
eliminating the scale accumulation oh the upper mist eliminator vanes.
However, entrainment of the topside wash water may be a problem.
This will be investigated.
Future plans include testing a new sloped (cone-shaped) closed-vane
chevron mist eliminator with underside washing, and testing the
existing open-vane chevron mist eliminator with intermittent and
sequential topside washing and with intermittent bottomside washing.
A Koch Flexitray preceding the mist eliminator will be installed if
long-term reliability cannot be achieved with the use of sprays only.
10-4
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10.2.2 TCA System
The TCA mist eliminator system consisted of a Koch Flexitray in
series with a six-pass, closed-vane, stainless steel, chevron type
mist eliminator (see Figures 3-2 and 3-4) during both the limestone
verification and the reliability testing.
At this report writing, a TCA run (Run 535-2A, see Table 8-1),
operating at a superficial gas velocity of 8.6 ft/sec, has been in
operation for over 900 hours without any significant scaling or
plugging of the Koch tray or mist eliminator surfaces. It appears
that long-term reliability of this mist eliminator system can be
realized at the conditions used during this run.
For Run 535-2A, the underside of the Koch tray has been intermittently
steam sparged (125 psig) for one minute every hour. The underside
of the mist eliminator has been washed continuously with 15 gpm
diluted clarified liquor (^ 9 gpm makeup water plus ** 6 gpm clarified
liquor), while the Koch tray has been irrigated with the remaining
/v 9 gpm of clarified liquor plus the 15 gpm mist eliminator wash.
The main difference between Run 535-2A and earlier runs (in which
there was some scaling and plugging of the lower vanes of the chevron
mist eliminator) was that a minimum clarified liquor flow rate of
15 gpm has been maintained for Koch tray irrigation and mist elim-
inator wash, while recirculated solids concentration has been allowed
to fluctuate between 12 and 15 percent. Previously, the clarified
liquor rate had been allowed to fluctuate, while the recirculated solids
concentration was maintained at 15 percent. A discussion of previous
runs is presented in Section 8. 3. 2.
10-5
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Future plans include the testing of the TCA mist elimination system
at increased gas velocity (10 and 12 ft/sec) and testing of the 6-pass
chevron mist eliminator with the Koch tray removed.
10.3 SCRUBBER INTERNALS
10.3.1 TCA Grid Supports
The original wire mesh grids (0. 148 inch diameter stainless steel
wires) deteriorated considerably during the approximately 3000 hours
of operation in slurry service. Vibration caused by plastic sphere
activity resulted in the rubbing together of the grid wires at their
perpendicular junctions and the grids failed at several locations
due to subsequent erosion of the wires in slurry service.
The wire mesh grids were replaced with sturdier "bar-grids"
(3/8 inch in diameter stainless steel bars, 1-1/4 inch on centers)
prior to the long-term limestone reliability testing. There has
been no measurable erosion of the bar-grids in over 5000 hours of
slurry service.
10.3.2 TCA Plastic Spheres
Until recently, a significant limiting factor in the long-term reliability
of the TCA scrubber has been associated with the erosion and sub-
sequent collapse of the UOP supplied HDPE spheres (sphere life was
approximately 2000 hours). The collapsed spheres eventually filled
with slurry and settled to the bottom of the support grids. Starting
with Run 528-2A (see Section 8), an improved type of UOP supplied
10-6
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TPR sphere was used in the TCA beds. After approximately 2500
hours of operation, all the spheres were dimpled on one side, about
2. 4 percent failed at the seam, and the weight loss averaged about
six percent. It is estimated that these TPR spheres would not need
replacement until after about a year of service. The problem of
dimpled spheres falling through the bar-grids (see Run 532-2A in
Section 8) may be solved by respacing the grids or using heavier spheres.
10.3.3 Nozzles
Initially, nozzle reliability at the test facility was greatly reduced
by the frequent plugging of spray nozzles with foreign material
{TCA spheres, marbles, debris, etc. ) and the erosion of some
spray nozzles by the abrasive solids in the circulating slurries.
Nozzle plugging, however, was reduced substantially by placing
covers over the open vessels in the scrubber systems and installing
strainers in the circulating slurry lines.
Spray Tower. Limestone factorial testing in the spray tower started
with the use of spiral tip, 316 SS, full cone, Bete No. ST24FCN nozzles
(capacity: 12 gpm @ 10 psi) manufactured by Bete Fog Nozzles, Inc.
Because of frequent plugging with slurry and/or debris, these nozzles
were replaced in September 1972, with Bete No. ST32FCN nozzles
(capacity: 21 gpm @ 10 psi). Plugging of the larger Bete nozzles was
less frequent. Neither type of nozzle was in service long enough to
determine wear rates.
The original supply of TPR spheres was defective and many of the
spheres split at the seams. Subsequent batches were of much better
quality.
10-7
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To allow for increased liquor flow to the four-header spray tower,
Bete No. TF48FCN stainless steel nozzles (capacity: 47 gpm @
10 psi) were installed during the February 1973 boiler outage. Because
of severe erosion of the stainless steel tips (average weight loss of
approximately 28 percent in 4320 hours), they were replaced with
identical stellite tipped ST48FCN nozzles in March 1974. No erosion
of these nozzles has been noted after over 5000 operating hours.
Plugging of the spray nozzles with debris was greatly reduced by installing
dual strainers (manufactured by Elliot Co.) in the circulating slurry lines
in June 1973, and by sealing the effluent hold tanks in July 1974.
TCA. The large Spraco No. 19&9F, full cone, 316 SS, open type slurry
feed nozzles wure replaced on October 1973 and again in September 1974,
although erosion was only slight (no significant wear after 4900 hours at
5 psi pressure drop for the second set of nozzles).
Occasional partial plugging of the nozzles with large debris (half TPR
spheres, parts of plastic insulation cover) was alleviated with the
installation of a dual strainer (by Elliot Company) in the circulating
slurry line in February 1974 and the sealing of the effluent hold tank
in March 1974.
Marble-Bed. The 22 original slurry feed spray nozzles lined with
Solathane 291 and equipped with internal Adiprine LD3I5 swirl vanes
failed in various ways during the short-term limestone factorial testing.
The swirl vanes in all 22 nozzles eroded, the liners of four bottom
nozzles collapsed, and two bottom nozzles disintegrated. The nozzles
frequently became plugged with slurry and debris.
10-8
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The original slurry feed nozzles were replaced during the February
1973 boiler outage with improved nozzles supplied by Combustion
Engineering (stronger Adiprine LD3056 lining with improved bonding
using Thixon 1244 between the liner and the body of the nozzle and a
locking groove to hold the vanes in place). The diffusion vanes of the
16 bottom spray nozzles failed during the initial limestone reliability
verification test runs after 1060 hours of operation.
All 22 CE spray nozzles were replaced before limestone reliability
verification Run 504-3A with Spraco No. 1736 hollow cone nozzles.
These nozzles were in service for only 233 hours due to the discon-
tinuation of testing on the system.
10.4 HOT-GAS/LIQUID INTERFACE
The hot (300 to 330°F) flue gas feed must be humidified before
entering the neoprene rubber-lined TCA and Marble-Bed scrubbers
to reduce the gas temperature below 190 F, the maximum permissible
for liner protection. Normally, the gas temperature was reduced to
about 150°F. Cooling of the feed gas was not required at the venturi
scrubber inlet during normal operation since the venturi scrubber
itself is an efficient humidifying device.
During open liquor loop factorial testing, raw water humidification sprays
were used in the vertical duct leading down to the TCA and Marble-Bed
scrubbers. Sootblowers were used in the horizontal section of the
duct at the scrubber entrance. With this arrangement there was a
continual problem of soft solids buildup at the hot-gas/liquid interface.
10-9
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To facilitate closed-loop operation by minimizing raw water addition,
the TCA and Marble-Bed scrubbers were provided with process slurry
cooling systems during the boiler outage in February 1973.
The TCA system was equipped with a Venturi-Rod presaturator in
the horizontal gas duct two feet upstream of the scrubber entrance.
The performance of the Ventri-Rod was not satisfactory in the hori-
zontal flow configuration (rapid buildup of soft solids occurred both
on and downstream of the Ventri-Rod), and it was replaced during
reliability verification Run 501-2A with a humidification section
consisting of four full-cone Bete nozzles (ST24FCN) in the horizontal
duct.
By subsequent careful selection of the proper size, orientation,
location, and number of the spray nozzles, modification of the soot
blower head (both nozzles leading at 45 ), air blowing during forward
travel only, and installation of a Y-strainer in the process slurry line
to the cooling spray nozzles, the buildup of solids in the TCA inlet
duct was essentially eliminated. These improvements resulted in
the wet-dry interface being moved to within 12 inches of the scrubber
entrance, where the accumulated solids could be easily blown into
the scrubber and discharged through, the 36 inch downcomer for
reslurrying in the effluent hold tank.
On the Marble-Bed scrubber, modifications to the cooling slurry
system resulted in moderate but encouraging results. The effective-
ness of these modifications could not be verified due to the discontinuation
of testing at the end of Run 503-3B in July 1973.
10-10
-------
10.5 REHEATERS
Flue gas from the scrubber is reheated to prevent condensation and
corrosion in the exhaust system, to facilitate isokinetic and analytical
sampling, to protect the induced draft fans from solid deposits and
droplet erooion, and to increase plume buoyancy.
The reheaters originally employed (Hauck Manufacturing Co. ) were fuel
oil fired units with separate combustion air supply and with combustion
occurring in the flue gas stream. The reheaters were difficult to
start and operate, and the combustion was incomplete. The latter
resulted in a visible plume containing significant quantities of soot
that made the interpretation of the outlet particulate data difficult
and affected gas sampling by the Du Pont SC>2 photometric analyzers.
Moreover, significant quantities of oil-soaked soot accumulated in
the duct work which, on two occasions, resulted in fires. The
difficulty appeared to result from quenching of the flame by the cold
(128 F) flue gas before complete combustion could occur, and from
operating with the same fuel oil nozzles over a wide range of flow
rates.
As an expedience for operation, all three reheater systems were
modified during the scheduled boiler outage in early 1973, using
stainless steel sleeves (10 gage, 304 SS, 40 inches in diameter by
4 feet high) to provide approximately 50 cubic feet of isolated
combustion zone for each reheater. In addition, the original turbulent
mixing type fuel oil nozzles were replaced with mechanical atomizing
nozzles. These modifications were effective in achieving complete
combustion, but burner flame-out continued to be a problem.
10-11
-------
To maintain operation consistent with the requirements for long-term
sustained reliability, the reheater on the venturi/spray tower system
was modified in March 1974 to include a fuel oil fired external com-
bustion chamber (manufactured by Bloom Engineering Co. ). The
performance of this unit has been very satisfactory with excellent
equipment reliability (i.e. , minimal flame-outs and operating dif-
ficulties), essentially complete combustion, and improved fuel
economy for over 4000 hours of service. Procurement arrangements
have been initiated to provide an identical unit to reheat the outlet
gas from the TCA scrubber.
10.6 FANS
Initially, considerable difficulty was experienced with the induced
draft fans (manufactured by Zurn Industries). Some of the problems
included high fan vibration, fan motor failure, fan damper control
failure, and fan blade deformation. All of the problems, except for
blade deformation, required repeated shutdowns of the affected
scrubber systems.
The unacceptable high vibration problem of all three fans was
greatly reduced in June 1972, by insulating the fan housing, adding
additional bracing to the outboard pedestals, and welding balance
weights on the fan shrouds. However, occasional high fan vibration
continued to hinder scrubber operation, particularly on the venturi/
spray tower system.
Stable flue gas flow control was difficult to achieve until the "fully
open" to "full closed" fan damper response time was increased
from 10 to 100 seconds with new actuators.
10-12
-------
Erosion, corrosion, pitting, scaling, etc. have been negligible on
all three fans. However, past operation has been with 125 F flue
gas reheat to give a fan outlet temperature of 250 F. Future plans may
include operation with reduced reheat. Prior to the commencement
of the low reheat test runs, the outlet ducts and the stacks of both
the ventun/spray tower system and the TCA scrubber will be
insulated, and corrosion test coupons will be mounted upstream and
downstream of the respective fans.
10.7 PUMPS
The majority of the pumps used at the Shawnee test facility in alkali
slurry service are rubber-lined variable speed centrifugal pumps
manufactured by Allen-Sherman-Hoff. Most of the original pumps
had Hydroseals, but excessive consumption of seal water resulted
in upsetting the slurry liquor loop water balance. The pumps were
converted to air purged Centriseals during the boiler outage in
February 1973.
Except for excessive seal water consumption, the Hydroseal pumps
performed satisfactorily. When converted to Centriseal, however,
the smaller pumps (less than 100 gpm) required pump discharge-to-
suction recirculation lines to eliminate a vapor lock problem at low
flow rates. In addition, frequent replacement of packing material
and accelerated wear rates on shaft sleeves have been experienced
with pumps using Centriseals. A program of testing hardened 316
stainless steel sleeves is currently underway.
10-13
-------
In general, the rubber linings have shown excellent erosion-corrosion
resistance characteristics and have remained in good condition.
Bond failure between the metal casing and the rubber lining has
occurred only once since the commencement of testing. On two
occasions, the rubber lining was badly gouged by debris (in one
case part of a slurry spray nozzle) entering the pumps from the
suction tanks.
One stainless steel variable speed centrifugal pump was originally
used in the limestone slurry addition system. Severe erosion of the
housing and impeller were noted (with a corresponding loss of 20 percent
pumping efficiency) in only twenty days of actual operation. Sub-
sequently, this pump was replaced by individual Moyno pumps to
each scrubber system. Operation of the Moyno pumps (stainless
steel rotor and butyl rubber stator) has been satisfactory with only
normal maintenance required.
10. 8 WASTE SOLIDS HANDLING
The test facility is equipped to study alternative methods of waste
solids dewatering and disposal. Separate clarifiers were provided
for each scrubber system. A rotary drum vacuum filter and a
horizontal solid bowl centrifuge are common to the three systems.
10.8.1 Clarifiers
The clarifiers are conventional solids contact units {manufactured
by Dorr-Oliver) with a heavy duty rake and scraper mechanism
10-14
-------
supported from a bridge. The vessels are glassflake lined with a
stainless steel rotating mechanism. The venturi/spray tower and
Marble-Bed systems have 20-foot diameter units while the TCA unit
is 30 feet in diameter.
The concentration of solids in the underflow of the larger TCA unit
has approached the expected final settled concentration of the sludge
(approximately 40 wt %). The solids concentration in the underflow
streams from the smaller venturi/spray tower and Marble-Bed units,
however, has averaged only about 25 wt % indicating they are under-
sized. To achieve closed liquor loop operation (see Section 10. 1),
the smaller units had to be used in series with the filter or centrifuge.
10.8.2 Filter
The filter is a Maxibelt rotary drum vacuum filter supplied by Ametek.
Some modifications have been made to facilitate trouble free filter
cake discharge. Under normal operations, the filter cake contains
50 to 55 and 45 to 50 wt % solids from limestone and lime slurries,
respectively.
Filter operation has been significantly hampered by the short life of
the filter cloth. The useful life of the polypropylene, nylon, and
polyester filter cloths tested, to date, has been generally below 260
hours.
In order to improve cloth life, it is planned in the near future to
convert the existing filter to a single roll type with air blowback and
scraper discharge.
10-15
-------
10.8.3 Centrifuge
The centrifuge is a solid bowl continuous type manufactured by Bird
Machine Co. During the limestone reliability verification testing, the
centrifuge was used for solids dewatering in the venturi/spray tower
and Marble-Bed systems either directly or in series with a clarifier.
The cake solids content was satisfactory, at 55 to 65 wt %, and the
centrate solids averaged 0. 5 to 1. 0 wt %. However, a major repair
of the unit was necessary after about 1400 hours of operation due to
severe erosion.
1 0. 9 LININGS
Two types of lining material were used throughout the scrubber
systems. The TCA and Marble-Bed scrubbers, the venturi scrubber
downstream of the plug, the spray tower, the process water tanks, most
slurry pumps, the circulating slurry piping, and the tank agitator blades
were neoprene rubber lined. The effluent hold tanks and clarifiers
were glass flake lined.
The rubber linings have been found, generally, to be in excellent
condition. Essentially no erosion or deterioration has been noted.
However, slight wear was noted on some of the rubber-coated agitator
blades. This type of wear is believed to be caused primarily by
foreign objects striking the agitator blades (rubber lined pumps are
discussed in Section 10.7). One agitator blade neoprene lining was
successfully patched with epoxy.
10-16
-------
Hairline cracks have been noted on the surface of the glassflake lining
of the effluent hold tanks and clarifiers. The cracks did not appear to
penetrate the entire thickness of the lining. The cracks were more
prevalent at the junction between the baffles and the tank walls.
Isolated areas on the bottom of the TCA effluent hold tank also showed
wear by erosion. These areas were near the wall baffles where eddy
currents are formed.
Glassflake patching material is available for lining repair but has not
been used to date. The eroded areas on the bottom of the TCA effluent
hold tank were painted with epoxy.
Prior to starting the long term reliability run with limestone on the
TCA, the agitator in the effluent hold tank was lowered four feet.
AF a precautionary measure, a steel wear plate was installed on the
bottom of the effluent hold tank, covering the area under the agitator.
10.10 INSTRUMENT OPERATING EXPERIENCE
10.10.1 Sulfur Dioxide Analyzers
Essentially trouble-free operation was experienced with the Du Pont
Model 400 UV sulfur dioxide analyzers following the modification of
the sampling system and the replacement of interference filters in
November 1972. Initially, the sampling system was particularly
vulnerable to condensation, solid particulates, oil, soot, corrosion,
or the combinations of these factors which led to leakage or plugging
of the sampling lines, plugging of the filters, or coating of the
optical lens. All of these effects caused erroneous sulfur dioxide
analyzer readings.
10-17
-------
10.10.2 pH Meters
Two types of pH meters have been used in slurry service: (1) Uniloc
Model 320 in-line flow-through meters and (2) Uniloc Model 321 sub-
mersible electrode meters.
The performance of the in-line flow-through meters had been unsatis-
factory due to the erosion of the glass cells by the slurry, their high
rate of failure, and the frequent plugging of the sample lines. All
the in-line flow-through meters at the scrubber inlets and outlets
have been replaced by the submersible electrode pH meters.
For the submersible electrode pH meters, cell erosion, cell breakage,
and sample line plugging has been minimal during the approximately
9000 on-stream hours. Routine cleaning and calibration of the cells
that measure the slurry pH at the scrubber inlet are made twice a
week to maintain the desired meter accuracy of ± 0. 1 pH unit. How-
ever, routine calibration checks during the scrubber operation have
not been possible for the submersible cells located at the scrubber
outlets (inside the downcomers). Studies are being made to effect
the routine calibrations of the scrubber outlet pH meters during
operation of the scrubber systems.
10.10.3 Density Meters
Operating experience had been gained with three types of density
meters in slurry service: (1) Ohmart radiation meters, (2) differential
pressure (bubbling tube) meters, and (3) Dynatrol Model CL-10HY
vibrating U-tube meters.
10-18
-------
Experience with the radiation meter initially indicated a loss of
calibration in the range of about 1 to 2 percent per week, but subse-
quent circuit modification corrected the problem. The meter's ac-
curacy is affected however, by the accumulation of scale on the
inner pipe wall at the source probe and unexplained 1-2% instability
in periodic cycles.
The sample line and the probes of the differential pressure meter
plug frequently and require significant maintenance. However, the
meter is accurate when clean and can be used to check the calibration
of the Ohmart radiation meters.
The Dynatrol density cells (using the vibration principle of the U-tube
for continuous response to a density changes) were installed in September
1973, to measure the densities of the lime slurry feed to the venturi/
spray tower system and of the circulating limestone slurry to the TCA
system. This meter has also been used to measure limestone feed
slurry densities.
The performance of the two installed meters has been excellent with
no in-service problems except slugging at low flows (25 percent of
design) and loss of accuracy at 150 percent of design flows. The two
failures experienced to date resulted from accidents. There has
been no indication of any scaling in the sensing tube in either of the
three above mentioned services.
10-19
-------
10.10.4 Flowmeters
Foxboro magnetic and differential pressure (both orifice and Annubar)
flowmeters are used at the test facility.
Operating experience with the magnetic flowmeters has generally
been adequate. The main problem has been in obtaining accurate
flow measurements at very low flow rates with meters designed to
measure flow over a wide range. To assure accuracy, Foxboro
recommended a minimum linear velocity of 3 ft/sec through the flow
element.
The magnetic flowmeters smaller than 4 inches diameter have a
tendency to drift in calibration, and frequent flow checks are required
to verify the accuracy. Meters larger than 4 inches are more reliable.
However, scale accumulations on the electrodes influence the accuracy
and periodic cleaning is necessary.
The orifice flowmeters function well in slurry service {6 to 15 per-
cent solids by weight), provided that pressure taps are protected from
plugging by using diaphragms as close as possible to the slurry piping.
Inspection results of 304 and 316 stainless steel orifice plates indicate
little erosion after 7500 and 4500 hours of service, respectively. Es-
timated error in flow measurement due to erosion was less than 5 percent.
Experience at the test facility indicates that Annubar meters should
be used only in non-scaling, clear liquid service {containing a max-
imum of 0. 5 percent by weight of suspended solids) to prevent frequent
plugging and associated maintenance work.
10-ZO
-------
10.10.5 Control Valves
Operating experience with control valves in slurry service has gen-
erally been unsatisfactory. Severe erosion in a short time is caused
by the increased velocity during throttling operation. This deteriora-
tion has been observed in stainless steel plug valves, globe valves,
and rubber pinch valves. Satisfactory and trouble free flow control has
been experienced only with variable speed pumps.
10. 11 MATERIALS EVALUATION
TVA has conducted a study for the evaluation of corrosion and wear
of plant equipment and test specimens (coupons) at the Shawnee facility.
Two interim reports on the results of this study have been written
by G. L. Crow and H. R. Horsman. The first interim report is
presented in Appendix J and summarized in this section. The second
interim report was received only in time to include it in Appendix K.
Linings have been previously discussed in Section 10. 9.
10. 11. 1 System Components
A thorough inspection of all system components was conducted during
the extended February and March 1973 boiler outage. Each of the
three scrubber systems had been operated for about 1800 hours during
the limestone factorial tests.
Localized deposits of loose fly ash accumulated in the gas ducts between
the boiler and scrubber structure. The surfaces of the mild steel
10-21
-------
ducts were coated with a thin iron oxide scale. Moderate pitting had
occurred at the uninsulated connections apparently due to local con-
densation. The flanges and access doors have since been insulated
to avoid this problem.
The most severe corrosion was found on Type 316 stainless steel
surfaces, particularly on the mist eliminator blades in the TCA
system. In general, the corrosion was in the form of pitting with
some pits as large as 1/16-inch diameter and 30 to 35 mils deep.
Significant erosion was noted on the pump sleeves, at the intersections
of the wire of support grids in the TCA scrubber, and on the impeller
and casing of the 316 SS Gould limestone slurry pump.
10.11.2 Test Coupons
Test coupons of several different materials of construction, together
with stressed and welded specimens, were exposed for periods of
1700 hours or longer to various slurry and gas environments. The
corrosion rates observed are presented in Table 10-1.
With few exceptions, mainly in the TCA system, the greatest loss
of'weight from metal specimens occurred in areas where the velocity
of the unscrubbed, partially humidified flue gas was comparatively
high. Impingement on the specimens of the slurry caused erosion
and corrosion. Pitting and crevice corrosion were not important
factors where erosion and corrosion kept the specimens clean. In
other areas of the three scrubber systems where solids accumulated,
10-22
-------
Table 10-1
CORROSION TEST RESULTS
Metals (a)
1. Hastclloy C-276
2 Iconel 625
3. Incoloy 825
4. Carpenter ZOCb-3
5 Type 316L SS
6. Cupro-Nickel 70-30
7. Monel 400
8. HasteLLoy B
9. Type 446 SS
10. E-Brite 26-1
I 1 Incoloy 800
12. USS 18-18-2
13 Type 304 L SS
14. Type 410 SS
15 Aluminum 3003
16 Mild Steel A-283
17. Cor-Ten B
Corrosion,
mils/yr
Neg. to 5
Neg. to 5
Neg. to 7
Neg to 14
Neg. to 15
>l to 49
>l to 57
>l to 100
Neg. to «140
Neg. to <190
Neg. to<190
Neg. to >=200
Neg. to<:200
=•1 to<250
>1 to<500
» to <1400
=»1 to -=1400
Number of
Pitted
Samples'*5'
.
1
-
2
3
1
1
2
9
10
6
11
14
15
9
2
5
Pitted Depth, (c '
mils
Mm.
_
-
-
-
-
-
-
-
Minute
Minute
Minute
Minute
Minute
Minute
2
-
Minute
Max.
_
Minute
-
Minute
Minute
18
2
Minute
19
IS
19
16
25
16
70
Minute
5
Samples With Ni
Crevice Attack S
-
-
I
-
2
-
1
-
11
2
3
11
11
16
5
2
4
Other Types of Attack
inn be r of Area of
•amples'b> Attack
-
-
-
<"d>
1, 1 CIS, Weld
1 Weld
3 Weld
-
-
-
1 fe)
-
1 (e)
-
-
-
1 Weld
o
1
Non-Metals'"
Plastics
Rubbers
Ceramic
Bondstrand 4000
Flakelme 200
Qua -Corr
Butyl 1375
Natural 9150
Neoprene 26, 666
Transits
Evaluation, Number of Samples
Good
IZ
2
5
6
6
b
14
1 Fair |
14
2
Poor
9
5
1
5
Note Test samples of each material were tested for luSO hours, or more
(a) Metals are listed in approximate order of decreasing corrosion
resistance.
(b) Samples of each metal were tested in 21 locations.
(c) Depth of penetration in mils during total exposure period.
(d) Groove in parent metal is IB mils deep.
(e) Severe localized attack of parent metal.
(f) Samples of Bondstrand. Flakelme and Transite were tested in
21 locations. Samples of Qua-Corr and rubbers were tested in
6 locations.
-------
the frequency of localized corrosion was high. However, each of
the 17 alloys tested showed good corrosion resistance at one or more
test locations in each scrubber system.
Corrosion of Hastelloy C-276 was from negligible to 5 mils per year.
This alloy showed no evidence of localized attack in any test location.
Next in resistance to corrosion were Inconel 625, Incoloy 825, Carpenter
20 Cb-3, and Type 316L stainless steel alloys. The corrosion rates
for each material ranged from negligible to 5, 7, 14, and 15 mils per
year, respectively. These alloys had few minute corrosion pits and/
or crevice corrosion. Type 316L, the fifth alloy in corrosion resistence,
is the least expensive of this group of materials.
Three nonferrous alloys, Cupro-Nickel 70-30, Monel 400, and
Hastelloy B, each had minimum corrosion rates of less than 1 mil.
Maximum-corrosion rates were 49, 57, and 100 mils per year,
respectively. Only one or two specimens pitted. In three tests of
Monel and in one test of Cupro-Nickel 70-30, the welds were inferior
to the parent metal.
The corrosion rates of Type 446 stainless steel, E-Brite 26-1,
Incoloy 800, USS 18-18-2, and Type 304L stainless steel ranged
from negligible to values which indicated that the alloy specimen
•was completely destroyed at one or more test locations. The values
for the specimen failures ranged from greater than 140 mils per year
for Type 446 to greater than 200 mils for both USS 18-18-2 and Type
304L stainless steels. These five alloys were highly susceptible
to localized corrosion.
10-24
-------
Another group of alloys, Type 410 stainless steel, 3003 aluminum,
A-283 mild steel, and Cor-Ten B, had minimum corrosion rates of
less than 1 mil per year and maximum corrosion rates of greater
than 250 mils for Type 410 to greater than 1400 mils for A-283 and
Cor-Ten B. Pitting and crevice corrosion occurred on the four
alloys.
In general, the stressed specimens (five alloys only) were not cor-
roded at rates higher than their counterpart disk-type specimens.
Specimens of Bondstrand 4000, Flakeline 200, and Transite materials
were tested at 21 locations. Bondstrand 4000 showed good corrosion
resistance in 12 tests and poor resistance in nine tests. Only six
specimens of each of the following materials were tested: Qua-Corr
plastic, butyl natural rubber, and neoprene rubber. The results
showed five good specimens and one poor specimen for Qua-Corr
plastic, and six good specimens for each type rubber.
10-25
-------
Section 11
PARTICULATE REMOVAL TEST RESULTS
Overall particulate removal tests were conducted by the EPA on all
three scrubber systems during the limestone factorial testing (November
1972 to January 1973). Results of these tests are presented in Tables
11-1 through 11-3. During the limestone reliability verification test-
ing (May 1973), the EPA conducted both overall particulate removal
tests and particulate distribution tests on the TCA. These results
are presented in Table 11-4 and Figures 11-1 and 11-2. Results of
overall particulate removal measurements taken by TVA personnel
at various times (May through October 1974} during reliability testing
are presented in Tables 11-5 and 11-6 for the venturi/spray tower
and the TCA system, respectively.
11. 1 OVERALL PARTICULATE REMOVAL EFFICIENCIES
To obtain overall particulate removal efficiencies in the three
scrubber systems, a modified EPA particulate train (manufactured
by Aerotherm/Acurex Corporation) was used to measure mass
loading at the scrubber inlets and outlets. Only those data which
were taken at close-to-isokinetic sampling conditions are reported here.
All of the outlet particulate data obtained prior to the modification of
the reheaters during the 1973 boiler outage have been corrected for
11-1
-------
Table 11-1
OVERALL PARTICULATE REMOVAL IN VENTURI/SPRAY TOWER
DURING LIMESTONE FACTORIAL TESTS
Run No.
415-1A
414-1D
414-1D
414-1C
417-1A
414-1E
418-1C
453-1B
454-1B
456-1A
Date
11/09/72
11/1Z/72
11/14/72
11/15/72
12/22/72
12/25/72
12/27/72
12/31/72
1/04/73
1/05/73
Gas Rate,
acfm (sat. )
@ 125°F
23,800
23,800
23,700
23,700
23,800
23,800
11,800
11,800
11,800
11,800
Liquor Rate,
gpm
Venturi
305
305
305
305
605
300
600
12
12
12
Spray Tower
0
0
0
0
0
0
0
460
450
450
Pressure Drop,
in. HO
|laJ
Spray Tower
9.0 2.0
9.0 1.9
9.0 1.9
6.4 1.9
9.5 1.9
12.0 1.9
12.5 0.4
2.5 0.45
0.75 0.45
0.70 0.45
Grain Loading,
grains /scf
Inlet j Outlet
4.38 0.012
2.1 0.010
3.32 0.013
3.40 0.02
3.38 0.012
4.17 0.009
6. 39 0. 114
2.6 0.004
4.62 0.07
3.38 0.056
Percent
Removal
99. 7
99. 5
99.6
99.4
99. 6
99. 8
98. 2
99. 8
98. 5
98. 3
I
ro
(a) Including mist eliminator.
-------
Table 11-2
OVERALL PARTICULATE REMOVAL IN TCA SCRUBBER WITH FIVE GRIDS
AND NO SPHERES DURING LIMESTONE FACTORIAL TESTS
Run No.
Date
Gas Rate,
acfrn (sat. )
@ 125°F
Liquor
Rate,
gpm
Total
Pressure
Drop, in. H,
Grain Loading,
grains/scf
Inlet
Outlet
Percent
Removal
i
u>
WC-5
WC-5A
WC-5A
WC-11
WC-12
12/21/72
1/06/73
1/09/73
1/12/73
1/14/73
15,800
15,900
15,900
16,000
15,900
730
730
730
745
375
3.8
4.7
5.5
7. <>
«
1. 70
4.16
1.32
3.29
3.65
0. 004
0.029
0.019
0. 017
0. 022
99.8
99. 3
98. 6
99. 5
99. 4
(a) High total pressure drop (including Koch tray, mist eliminator, and inlet duct) due to plugging of
the inlet gas duct by solids deposit.
-------
Table 11-3
OVERALL PARTICULATE REMOVAL IN MARBLE-BED SCRUBBER
DURING LIMESTONE FACTORIAL TESTS
Run No.
427-3A
427-3A
426-3B
427-3C
427-3B
428-3A
428-3A
428-3A
438-3A
440-3A
440-3A
Date
11/13/72
11/16/72
11/28/72
12/02/72
12/24/72
12/28/72
12/29/72
12/30/72
1/07/73
1/11/73
1/13/73
Gas Rate,
acfm (sat. )
@ 125°F
15, 800
15,800
15,800
15,800
15,800
15,800
15,800
15,800
15,800
9,900
9,900
Liquo r
Rate,
gpm
810
810
810
800
805
810
810
810
400
600
600
Total
Pressure
Drop, in. f^O
12.2
12.2
10.2
12. 7
11.2
11.7
11. 7
11.7
7.2
6.9
6.9
Grain Loading,
grains/scf
Inlet
2.6
3.32
4.43
4.24
2.19
3.78
4.12
3.63
4.20
3.82
3. 59
Outlet
0. 030
0.035
0.032
0. 033
0.027
0.025
0.016
0. 035
0.020
0.042
0. 066
Percent
Removal
98.8
98.9
99.3
99.2
98.8
99.3
99.6
99.0
99.5
98.9
98.2
-------
Table 11-4
OVERALL PARTICULATE REMOVAL IN TCA SCRUBBER
DURING LIMESTONE RELIABILITY VERIFICATION TESTS
Gas Rate,
Run No. Date acfm (sat.
@ 1Z5°F
503-2A 5/22/73 20,600
506-2A 5/24/73 16,500
505-2A 5/23/73 16,500
Liquor Pressure Grain Loading,
) Rate, Drop/a) grains/ scf
gpm in. H20 Inlet Qutlet
1200 9.8 3.16 0.00852
3.00 0.00375
1200 7.5 2.89 0.0143
2.13 0.0152
600 5.6 2.34 0.031
2.61 0.020
2.28 0.010
Pe rccnt
Removal
99.7
99. 9
Q9. 5
99.3
98. 7
99. 2
99. 6
(a) For a TCA with 3 beds, 5 in. spheres/b-ed and inclxiding mis,t eliminator and Koch tray.
-------
Table 11-5
OVERALL PARTICULATE REMOVAL IN VENTURI/SPRAY TOWER
DURING LIME RELIABILITY TESTS
Run No.
Date
Gas Rate,
acfm (sat. )
@ 125°F
Liquor Rate,
gpm
Venturi ] Spray Tower
Pressure Drop,
in. H2O
Venturi j Spray Tower
Grain Loading,
grains/scf
Inlet 1 Outlet
Percent
Removal
604-1A 6/Z6/74 19,800 100 1200 1.9 3.0 2.52 0.024 99.1
608-1A 9/11/74 19,800 600 1200 9.0 2.2 2.28 0.023 99.0
610- 1A 10/10/74 19,800 600 1200 9.0 3.2 2.72 0.021
-------
Table 11-6
OVERALL PARTTCULATE REMOVAL IN TCA SCRUBBER
DURING LIMESTONE RELIABILITY TESTS
Run No.
531-2A
531-2A
532-2A
•53S-2A
535-2A
Date
5/15/74
6/12/74
7/24/74
9/27/74
10/30/74
Gas Rate,
acfm (sat. )
@ 125°F
16,900
16,900
16,900
16,900
16,900
Liquor
Rate,
gpm
1200
1200
1700
1200
1200
Pressure
Drop,(a)
in. H2O
6. 7
10. 0
6. 7
6.2
6.2
Grain Loading,
grains/scf
Inlet
2.82
3.47
3. 33
2.73
2.24
Outlet
0. 029
0. 010
0. 024
0. OH.
0.023
Percent
Removal
99.0
99.7
99. 3
99. 4
99.0
(a) For a TCA with 3 beds, 5 in. spheres/bed and including mist eliminator and Koch tray.
-------
soot-contamination from the flue gas reheaters. ' The soot amounted
to less than 30 percent of the total mass of the outlet particulates.
The overall particulate removal efficiencies measured in the three
scrubber systems appear to be higher than the efficiencies predicted
from "impaction theory". These improved efficiencies could be due
J-a-
to condensation of water vapor in the flue gas on the solid particles. '""
In order to verify the particulate removal results obtained, to date,
and identify the causes for the observed removals, EPA has planned
a new test series for the determination of size and overall removal
efficiencies in the TCA and venturi/spray tower systems.
11.1.1 Venturi/Spray Tower System
Results of tests conducted on the venturi/spray tower system by
the EPA during limestone factorial testing are presented in Table 11-1.
Tests were conducted with slurry to the Chemico venturi only (Runs
415-1A through 41 8-1C) and with slurry primarily to the spray tower
(Runs 453-1 B through 456-1 A). Overall particulate removal efficiencies
of 99.4 to 99. 8 percent*** were obtained for the venturi at a gas flow
rate of 24,000 acfm (125 F), liquid-to-gas ratios from 12. 5 to 25 gal/
»i»
'''See Section 10. 5 for a discussion of soot contamination from
the oil-fired reheaters.
"""* The condensation of water vapor per unit mass of inlet solids
has been estimated to be from 1 to 5 grains water/grain inlet
particulates within the scrubber.
!e*vFor an average scrubber inlet grain loading of 3. 5 grains/scf,
a particulate removal of 99. 0 percent would correspond to
0. 07 Ibs particulate discharged per 10 Btu.
11-8
-------
mcf (300-600 gpm), and venturi plug pressure drops from 6 to 1 2
inches H?O. For the spray tower, the removal efficiency was about
98. 5 percent at a gas velocity of 4 ft/sec and a liquid-to-gas ratio
of 37 gal/mcf (12, 000 acfm and 450 gpm).
Particulate removal tests by TVA during lime reliability testing
were made with the venturi and spray tower operating simultaneously.
These are reported in Table 11-5. Overall particulate removal
efficiencies of 99. 0 to 99.2 percent were obtained with a gas flow
rate of 20, 000 acfm (125°F), venturi pressure drops from 2 to 9
inches f^O, and Ixquid-to-gas ratios of 5 to 30 gal/mcf and 61 gal/
mcf for the venturi and spray tower, respectively.
ll.l.Z TCA System
The EPA measurements during limestone factorial testing on the
TCA scrubber with 5 grids and no spheres are presented in Table
11-2. Overall removal efficiencies were 98.6 to 99. 8 percent at a.
gas velocity of 8 ft/sec and a liquid-to-gas ratio of 46 gal/mcf
(16, 000 acfm and 730 gpm), with total pressure drops (including
Koch tray, mist eliminator, and inlet duct) of 4 to 7 inches P^O.
Further measurements by the EPA during limestone reliability
verification testing on the TCA scrubber with 3 beds and 5 inches
of spheres per bed are presented in Table 11-4. Overall removal
efficiencies of 98, 7 to 99.9 percent were achieved at gas velocities
from 8.4 to 10.4 ft/sec (16,500 to 20,600 acfm), liquid-to-gas
ratios from 37 to 75 gal/mcf (600-1200 gpm), and total pressure
drops from 5. 5 to 10 inches H2O. The higher pressure drops
generally gave higher overall removal efficiencies.
11-9
-------
TVA measurements during limestone reliability tests on the TCA
scrubber, again with 3 beds and 5 inches of spheres per bod, arc
presented in Table 11-6. Removal efficiencies were all Beater
than 99 percent. These data are in substantial agreement with the
EPA measurements.
11.1.3 Marble-Bed System
Measurements by EPA on the Marble-Bed scrubber during limestone
factorial testing are presented in Table 11-3. The Marble-Bed
scrubber gave an overall particulate removal efficiency range of
98. 8 to 99.6 percent at a gas velocity of 5. 5 ft/sec, a liquid-to-
gas ratio of 51 gal/mcf {15,800 acfm and 810 gpm), and 12 inches
HoO total pressure drop.
11. 2 PARTICULATE REMOVAL AS A FUNCTION
OF PARTICLE SIZE
During the limestone reliability verification testing, a special
series of tests using a Brink impactor were conducted by EPA to
measure the TCA inlet and outlet aerodynamic size distributions.
In order to utilize the Brink impactor at scrubber inlet mass
loading conditions, a modified EPA particulate mass sampling
train was used. The train was of 316 stainless steel construction
and consisted mainly of a heated sample probe (6 feet x 1/Z inch
outside diameter), a cyclone, and the Brink impactor with a 144 mm
glass fiber filter. The impactor drew a sample from the gas stream
exiting the cyclone. Previous work elsewhere by the EPA had
established that the particles collected in the cyclone had a mass
11-10
-------
mean diameter of approximately 5 microns at a flow rate' of ono
cubic foot per minute. At the scrubber outlet, the Brink impactor
was used directly in the flue gas duct (without sample probe: and
cyclone).
11.2.1 Particulate Size Distribution in the TCA
The particulatc size distributions at the TCA inlet and outlet were
measured by the EPA for the runs listed in Table 11-4. The
results are plotted in Figure 11-1 as cumulative weight percent
versus particle size.
As shown in Figure 11-1, the mass mean diameter of the inlet
solids was approximately 23 microns, which is slightly greater
than the "normal" range of 10 to 20 microns. The data for the
outlet size distribution shows some scatter. The mass mean
diameter ranged from about 0. 5 to 0. 75 micron for a total pressure
drop range of 5.5 to 10. 0 inches H^O. Generally, the higher
pressure drops give smaller outlet mass mean diameters.
11.2.2 Particulate Removal Efficiency in the TCA as a
Function of Particle Size
Based on the measured particulate size distributions, the particulate
removal efficiency as a function of particle size was determined by
EPA for the TCA runs shown in Table 11-4. In Figure 11-2 the
percent penetration (100 minus percent removal) is plotted versus
particle diameter in microns for different ranges of total pressure
drop.
11-11
-------
OUTLET PARTICLE DIAMETER, microns
TOTAL PRESSURE DROP = 5.5-10.0 in. Hj
GAS VELOCITY = 8.4-10.4 ft/*«c
LIQUID-TO-GAS RATIO = 37-75 gal/mcf
-t-
6 8 10 20
INLET PARTICLE DIAMETER, microns
-I—
40
—I 1—
60 80 100
Figure 11-1. Particle Size Distributions at TCA Met and Outlet
11-1Z
-------
Z
UJ
U
13
z
o
o
ii
Z
O
UJ
Z
Z
UJ
U
Of
LU
Q.
60
40 ••
20 -•
10
8
6
4 --
2 •-
1 •-
0.8
0.6
0.4 +
0.2 --
0.1
—O
TOTAL PRESSURE DROP:
O 9.7-9.9 in. H2O
A 7.4-7.7 in. HO
O 5.5-5.7 in. H20
GAS VELOCITY = 8.4-10.4 ft/sec
LIQUID-TO-GAS RATIO = 37-75 gal/mcf
4-
—i—
0.04 0.06 0.1
0.2 0.4 0.6 1
PARTICLE DIAMETER, microns
Figure 11-Z. TCA Particulate Removal Efficiency
as a Function of Particle Size
11-13
-------
As seen in Figure 11-2, the removal efficiency dropped rapidly
with decreasing particle diameter down to about 0. 5 micron and
then leveled off over the range of 0. 5 micron to 0. 1 micron. For
the submicron particles (0.1 to 1.0 micron), the removal efficiency
dropped rapidly with decreasing pressure drop. The efficiencies
were 94 to 98 percent at 9. 8 inches H^O total pressure drop, 92 to
95 percent at 7.6 inches H,O, and 71 to 90 percent at 5.6 inches
H2O. Because of the limited number of tests, conclusions regarding
submicron collection efficiency should be reserved until additional
testing can be carried out.
11-14
-------
Section 12
ANALYSIS OF PRESSURE DROP DATA
In this section theoretical equations were fitted to the pressure
drop data obtained during air/water and sodium carbonate testing
(see Section 5) for each of the three scrubbers.
12. 1 VENTURI SCRUBBER
In Reference 6 a proposed correlation was presented for fitting
venturi pressure drop. ^ A further analysis of the differential
equations which describe pressure drop for a venturi (see Reference
13) indicated that the ratio of throat length to plug diameter, ^L/H ,
v si-
should be included in the expression. The inclusion results in
a much improved fit to the data, especially at high gas velocities
and high liquid-to-gas ratios.
The following equation is a fit to the venturi air/water and soda-
ash pressure drop data (see Section 5. 1. 1 and Appendix D, Tables
D-l, D-2, and D-3):
*
The proposed correlation (Equation 3 of Reference 6) should
have shown the coefficient p3 multiplied by "T^3".
* '
Volgin (Reference 14) included a "throat length" term in his
venturi pressure drop correlation but gave no theoretical
grounds for the inclusion.
12-1
-------
5" 9. 38 O.S97
' (12-1)
with:
(12-2)
o.00n-8(% opening o-fu
-------
15
10 ••
o
Cs
X
Of
Q
iu
oi
cz
Q.
Q
LU
I—
5 5
5 10
MEASURED PRESSURE DROP, in. H
Figure 12-1. Comparison of Experimental Data and Predicted Values
of Pressure Drop in the Chemico Venturi from Equation 12-1
12-3
-------
in Figure 12-1, but not included in the fit of Equation 12-1, is the
pressure drop data for the limestone factorial runs (see Appendix E,
Table E-l).
The four coefficients in the second term on the right-hand side of
Equation 12-1 were also fitted to the limestone factorial data. The
resultant equation is:
0-tl. , ,^'^
(12-4)
The equation accounts for 92 percent of the variation of the data.
Measured and predicted values of pressure drop are compared in
Figure 12-2.
12.2 TCA SCRUBBER
The following equation was fitted to the TCA pressure drop data
for the air/water and soda-ash runs (see Section 5.1.2 and Appendix
D, Tables D-4, D-5, and D-6) and for the limestone factorial
*
runs (see Appendix E, Table E-2):
(12-5)
£3x/£> 'V9*(L/G) \np/df> + M
"Thirteen runs were eliminated from this analysis. These included
nine TVA grid-tower runs for which the inlet gas duct was partially
plugged and four runs operated under "flooding" conditions.
12-4
-------
15
CM
10 --
O.
o
OS
Q
D
00
00
UJ
y 5 ••
Q
UJ
ae.
a.
O LIMESTONE FACTORIAL DATA
5 10
MEASURED PRESSURE DROP, in. h
Figure 12-2.
Comparison of Experimental Data and Predicted Values
of Pressure Drop in the Chemico Venturi from Equation 12-4
12-5
-------
where:
&1P - pressure drop across TCA (excluding mist eliminator),
in. H2O
"V - gas velocity through scrubber, ft/sec
L/Q- ~ liquid-to-gas ratio through scrubber, gal/mcf
hn ~ total height of packing, in.
£tp = diameter of packing = 1.5 in.
A/S - number of grids (screens)
The data fitted to this equation were taken with wire mesh grids which
were subsequently replaced with bar-grids. Pressure drop across
bar-grids is slightly lower.
Equation 12-5 gives the best least-squares fit not only for the
combined air/water, soda-ash, and limestone data but also for the
limestone data alone. The equation accounts for 91 percent of the
variation of the combined data and for 94 percent of the variation of
the limestone data. Standard errors of estimate are 0. 70 inch
H_O overall and 0. 62 inch H^O for the limestone data. Measured
and predicted values of pressure drop are compared in Figure 12-3.
The pre-constant of 1.2 inches H,O on the righthand side of Equation
£
12-5 represents the average pressure drop for the TCA system when
operated as a "spray tower" (no grids or spheres). The second term
on the right-hand side represents the pressure drop across the TCA
bed of spheres. The form for this expression was obtained from the
work of Happel (Reference 15) and Leva (Reference 16) for pressure
:';
drop through a two-phase fluidized bed at high Reynolds numbers.
*
_. ., , (plastic sphere diameter)(gas velocity)(gas density)
Reynolds number = •"• *• B •—a J—
(gas viscosity)
12-6
-------
12
10
O LIMESTONE FACTORIAL DATA
O AIR/WATER & SODA-ASH DATA
8 -•
O
Q£
Q
i)
i/>
i/i
UJ
0.
Q
UJ
y
o
LU
6 --
2 --
-*-
+
+
468
MEASURED PRESSURE DROP, in. I
10
12
Figure 12-3.
Comparison of Experimental Data and Predicted Values
of Pressure Drop in the TCA from Equation 12-5
12-7
-------
12.3 MARBLE-BED SCRUBBER
«•*
The following equation was fitted'1" to the Marble-Bed pressure drop
data for the air/water and soda-ash runs (see Appendix D, Tables
D-7, D-8, and D-9):
+ O.Ci6(L/&) ' V1' (hM/d») (12-6)
where:
-------
a.
O
UJ
oe.
a;
a.
U
O
UJ
oe.
a.
14
12 --
10 ••
8 ••
4 ••
2 -.
O LIMESTONE FACTORIAL DATA
O AIR/WATER & SODA-ASH DATA
-I H
1
i 1 1 1 H
4 6 8 10
MEASURED PRESSURE DROP, in. HJ
12
14
Figure 12-4. Comparison of Experimental Data and Predicted Values
of Pressure Drop in the Marble-Bed Scrubber from
Equation 12-6
12-9
-------
Also shown in Figure 12-4, but not included in the fit of Equation 12-6,
is the pressure drop data for the limestone factorial runs presented
in Table E-3 of Appendix E. The equation is not a good representation
of the limestone data, perhaps due to an effect of percent solids in the
slurry and due to the gradual plugging of the marble bed during many
of the test runs (several runs whose pressure drops clearly indicated
plugging were omitted from the analysis).
The following equation, based on the form of Equation 12-6, was
fitted to the data from the limestone factorial runs:
= ff.J 4- 0.007*
Equation 12-7 accounts for 75 percent of the total variation of the
data with a standard error of estimate of 0. 8 inch r^O. The
equation does not hold for pressure drops less than six inches
Measured and,predicted values of Marble-Bed pressure drop for
Equation 12-7 are compared in Figure 12-5.
12-10
-------
O
O
0£
Q
UJ
Q.
Q
LLJ
y
o
LLJ
QC
o_
12
11 ••
10 ••
9 ••
8 -•
7 ••
6 ••
O LIMESTONE FACTORIAL DATA
7 8 9 10
MEASURED PRESSURE DROP, in. HJ
11
Figure 12-5.
Comparison of Experimental Data and Predicted Values
of Pressure Drop in the Marble-Bed Scrubber from
Equation 12-7
12-11
-------
Section 13
ANALYSIS OF SODIUM CARBONATE SCRUBBING DATA
In this section, the sodium carbonate (soda-ash) data are analyzed and
models are presented for predicting SO2 removal in sodium carbonate
systems. In Section 13. 1, models are fitted to the "gas-side resistance"
data where the gas-side mass transfer resistance is controlling. Equa-
tions are presented for predicting SO2 removal in (1) the Chemico ven-
turi, (2) the TCA operated as a one-stage spray tower, and (3) the Marble-
Bed absorber. In Section 13.2, a model is fitted to the "gas/liquid-
side resistance" data where both gas-side and liquid-side mass transfer
resistances are significant. An equation is presented for predicting SO2
removal under such conditions in the Chemico venturi. It should be noted
that none of these correlating equations are useful for lime/limestone
scrubbing systems where gas-side resistance is negligible and where the
dependence of the controlling liquid-side resistance on the operating
variables differs from a soda-ash system.
13. 1 GAS-SIDE RESISTANCE DATA
As mentioned previously, the gas-side resistance tests were designed,
primarily, to determine uncertain coefficients in models where gas-
side mass transfer is rate controlling. For gas-side controlling
mass transfer, the absorption efficiency is independent of both
13-1
-------
liquor composition and inlet gas concentration of the absorbed com-
:''
ponent. Data from these tests indicated that gas-side resistance
is rate controlling at an inlet pH of 9. 5 and Na+ concentration greater
than 0. 5 wt %, or at an inlet pH above 8. 5 and Na concentration of
1. 0 wt %. These results are, generally, in agreement with predictions
made with the use of the Bechtel modified Radian equilibrium computer
program (see Appendix G).
The following theoretical expression represents SO? absorption for
the condition of gas-side resistance being rate-controlling (Reference 17):
Fraction _ j _ eyp - ^&U • 2T / w I (13_D
S02 Removal f ^ ! ' '
where:
'*-'
-------
13.1.1 Venturi Scrubber
The following equations for predicting SO? removal in the Chemico
ji,
venturi were fitted to the data from the gas-side resistance tests:
Fraction j _ & - Q.OU'+V '
-------
Comparisons between measured and predicted SO2 removals from
Equations 13-2 and 13-3 are shown in Figures 13-1 and 13-2. Equations
13-2 and 13-3 account for 99 percent and 96 percent of the variation
*
in the data, respectively. The standard errors of estimate are 1.2
percent SO2 removal for Equation 13-2 and 1. 9 percent for Equation 13-3.
13.1.2 TCA Scrubber as a Spray Tower
Gas-side resistance tests in the TCA scrubber in its normal configura-
tion resulted in SC>2 removal in excess of 99 percent (Table D-13, Runs
201-2A and 201-2B) and no correlation was possible. However, in tests
with the TCA scrubber operated as a spray tower with no screens or
spheres (Table D-13, Runs 225-2C through 230-2C), SO2 removal
ranged from 90 to 96 percent. The expontential pre-constant in the fol-
lowing equation for predicting SO2 removal was fitted to this data:
where:
IF = gas velocity through scrubber, ft/sec
L./Q- = liquid-to-gas ratio through scrubber, gal/mcf
Coefficients for liquid and gas rates in the above correlation were
obtained from the equation developed in Reference 18 for spray towers,
which was based upon the work of Fair (Reference 19). The SO2 removal
fit explains 65 percent of the variation in the data with a standard error
of 1. 3 percent removal.
See Appendix L for definitions of statistical terms.
13-4
-------
70
MEASURED SO,
80
REMOVAL,
90
100
Figure 13-1.
Comparison of Experimental Data and Predicted Values
of SC>2 Removal in Chemico Venturi from Equation 13-2
(Gas-Side Resistance Tests)
13-5
-------
50
60
70
MEASURED SO,
80
REMOVAL, %
90
100
Figure 13-2.
Comparison of Experimental Data and Predicted Values
of SO, Removal in Chemico Venturi from Equation 13-3
(Gas-Side Resistance Tests)
13-6
-------
13.1.3 Marble-Bed Scrubber
The two pre-constants in the following equation were fitted to the data
from the gas-side resistance tests for the Marble-Bed scrubber (Tables
D-15 and D-16):
Fraction _ , „„ „ | ^ , ^ r ' /, i/^\'~z. . ^ .. ,v i r-^' /'i >^P't*'
SO2 Removal
[-<9J5> O. V- fO.AO O
-3.1 ^f (UG-) ^ + O.WV (Lie)
(13-5)
where:
IT = gas velocity through scrubber, ft/sec
L/G- = liquid-to-gas ratio through scrubber, gal/mcf
(includes both top and bottom sprays)
2|n = height of marble layer, ft
The coefficients for liquor and gas rates in the first term of the expo-
nential in Equation 13-5 were obtained from the equation presented in
Reference 6 for the •&&&- in the glass sphere region of the Marble-Bed
system.
The effects of the turbulent layer and of the upper and lower spray
zones on-fyjO. cannot be easily separated, as these effects show a
similar variation with liquor and gas rates. Hence, the spray and
turbulent layer effects have been combined into a single term (the
second term in the exponential of Equation 13-5), with the same
coefficients of gas and liquor rates as those developed in Reference
18 for a spray tower.
13-7
-------
The SO£ removal fit in Equation 13-5 explains 79 percent of the variation
in the data with a standard error of 1. 1 percent removal.
13. 2 GAS/LIQUID-SIDE RESISTANCE DATA
"Gas/liquid-side resistance" tests were made under conditions of sig-
nificant gas-side and liquid-side mass transfer resistance and of neg-
X
ligible equilibrium vapor pressure, U , of SO2 over the bulk liquid.
Such conditions existed at Na concentration less than 0. 6 wt % and
inlet pH greater than 8. 5. A correlation was made with the data from the
gas/liquid side tests for the Chemico venturi.
In the case of significant gas and liquid-side mass transfer resistance
and negligible equilibrium vapor pressure of SC>2 over the bulk liquid,
the following expression represents SOo absorption (Reference 17):
I"'_^«<&& ' g/ff
" P |_ , + ™.£<:.a/.£
Fraction __ -^- -• ^ /,, 6)
S02 Removal ' KXH I ,- ~ l^-oj
where/Wis Henry's law constant and^is the liquid-side mass transfer
coefficient.
For the venturi scrubber, the term 'fcgtt -?/G can be obtained from Equa-
tion 13-2 or 13-3. Using Equation 13-3:
13-8
-------
The following equation for predicting SC^ removal in the Chemico ven-
turi was obtained by combining Equation 13-7 with Equation 13-6 and by
fitting the term ^ ^frd'/ftiA to the gas/liquid-side resistance data:
Fraction = I -
SO2 Removal
where: (13_g)
= pressure drop across venturi, in.
= liquid-to-gas ratio through venturi, gal/mcf
= rnole fraction SO2 in inlet gas
= mole fraction Na in inlet liquor
= liquor pH a-t scrubber inlet
The proportionality between ^-«^fl-/«La and fy-sc-/XtfA. shown in
Equation 13-8 can be predicted theoretically. Also, ,M&GCt/£L&. is
expected to be a function of liquid-to-gas ratio and pH. The statistical
significance of j4-$jja /X'^ an{^ °* ^e interaction group (jL/Gy~ I Of
was verified by a linear regression model.
Measured and predicted values of SO2 removal from Equation 13-8
are compared in Figure 13-3. Equation 13-8 explains 85 percent of the
variation in the data with a standard error of estimate of 4. 1 percent
SO2 removal.
13-9
-------
O
90
80
70
60
y
o
g 50
30
O
O
O
O
O
CD
OO
30
40
50
60
70
80
90
MEASURED SO2 REMOVAL, %
Figure 13-3. Comparison of Experimental Data and Predicted Values
of SO7 Removal in Chemico Venturi from Equation 13-8
(Gas/Liquid-Side Resistance Tests)
13-10
-------
Section 14
ANALYSIS OF LIMESTONE FACTORIAL DATA
In this section, a theoretical approach is employed to relate SO? re-
moval to the measured parameters for the spray tower, TCA, and
Marble-Bed absorbers. A closed-form equation is developed for each
absorber, which is compatible with boundary constraints, and which
should permit reasonable extrapolations. Variables which were found
to be significant by a statistical analysis of the data were introduced
into the closed-form equations.
14. 1
THEORETICAL MODEL
Analysis of the limestone factorial data, using the Bechtel modified
Radian Equilibrium Computer Program (see Appendix G), has shown
that the equilibrium mole fraction of SO? over the bulk scrubber liquid,
jf.
u , is negligible with respect to the SO, mole fraction within the gas
d <• *
for the spray tower, TCA, and Marble-Bed scrubbers. For this con-
dition, Equation 13-6 represents SO_ removal:
Fraction
SO2 Removal
- ex
(13-6)
Due to low liquor residence times, the amount of limestone dissolved
within the venturi scrubber is relatively small. Hence, ty can be
significant.
14-1
-------
where:
•''••G ~ gas- side mass transfer coefficient
CL - gas-liquid interfacial area per scrubber volume
2 = axial distance in the scrubber
Q- = gas rate per cross-sectional area
/W, = Henry's law constant
_^L = liquid-side mass transfer coefficient
Also, scrubber computer models using previously fitted gas- side mass
transfer coefficients (see Section 13) have shown that liquid-side resis-
tance controls (i. e. , -^?L/W<< •& Q. ) for the spray tower, TCA, and
Marble-Bed scrubbers for a majority of the limestone data. For this
condition, Equation 13-6 can be written as:
Fraction _ [j£ z//m J
SO2 Removal / |_ J
The liquid- side coefficient can be written as:
where:
•KJ L ~ liquid film mass transfer coefficient for physical absorption
(Ti = average enhancement factor for mass transfer in the liquid
film due to chemical reaction within the scrubber
14-2
-------
o
It is assumed that the parameters -L u , & . and 2?- are functions of gas
rate, liquor rate, and scrubber internals (e.g. . number of stages in the
TCA), and that '/ is a function of the reactions within the scrubber liquor.
As an example of the approximation to the actual conditions encountered
during alkali wet-scrubbing of SO^f consider a very rapid pseudosecond
order irreversible reaction between the absorbed gas A (H_SO,) and
"reagent" B (bicarbonate and sulfite species). If the diffusivilies of
A and B in the liquid are equal, the following expression can be used
to predict the enhancement factor (see Equation 26 in Reference b):
(f -_- | + _*.!!_ (14-3)
VXA
where:
X|- = average concentration of dissoved reactant B (bicarbonate
and sulfite species) in the scrubber liquor
X^ = average concentration of dissolved A (H_SO,) at tlie gas-
liquid interface within scrubber
^/ - stoichiometric coefficient relating the number of moles
of B reacting with one mole of A
For liquid-side controlling mass transfer, X^ can be approximated by:
XA - y///i ii4-4)
where ift- is the SO., concentration in the scrubber gas phase.
An analysis of the limestone factorial analytical data with the use of the
Radian computer program has shown that X,. is inversely proportional
14-3
-------
to the hydronium ion concentration of the scrubber liquor:
in^ (i4-5)
where A is a constant and -ffi is the scrubber liquor pH.
The enhancement factor, therefore, may be written as:
where A is a constant equal to /Jtf/3/V-
Combining Equations 14-1, 14-2, and 14-6 yields:
/-H -1,
r.<"l£_ ) | (i4-7)
Fraction
SO2 Removal
The form of Equation 14-7 has been fitted by multiple regression to the
limestone factorial data for the spray tower, TCA, and Marble-Bed
scrubbers. For these fitted equations, the scrubber inlet liquor pH and
the scrubber inlet gas SO^ concentration have been substituted for the
average values of pH and SO- concentration in Equation 14-7.
It is assumed that the effect of scrubber inlet liquor pH and inlet gas
SO., concentration on SO_ removal is represented by the form of Equa
tion 14-7 for the three scrubber systems. However, the variation in
14-4
-------
scrubber inlet liquor pH (a controlled independent variable) was statis-
tically significant only for the spray tower tests, and the variation in
inlet gas SO? concentration (a non-controlled independent variable) was
statistically significant only for the TCA tests. Therefore, the effects
of pH and gas SO, concentration on SO, removal have been included only
£ £
in the fitted models for the spray tower and TCA, respectively.
14. 2 FITTED EQUATIONS
14. 2. 1 Spray Tower
JS
The following equation was fitted to 12 limestone factorial test runs
made with the spray tower (see Figure 6-2 and Table E-4):
-
\(
"]
(14-8)
where:
= superficial gas velocity at scrubber conditions, ft /sec
L/Q - liquid-to-gas ratio at scrubber conditions, gal/mcf
l - scrubber inlet liquor pH
Measured and predicted SO., removals from Equation 14-8 are shown
in Figure 14-1. Equation 14-8 accounts for 94 percent of the variation
Only data for runs with 300 gpm per header were included. The single
data point at 225 gpm per header (Run 523-1A) was omitted.
14-5
-------
80
70 -•
o
5
o
UJ
cc
(SI
8
Q
UJ
O
O
UJ
oc
0.
o
60 -•
O
00'
.00
50 -•
40 •-
30
40
50 60
MEASURED SO2 REMOVAL. %
70
80
Figure 14-1.
Comparison of Experimental Data and Predicted
Values of SO? Removal in the Spray Tower from
Equation 14-8 (Limestone Factorial Tests)
14-6
-------
in the data with a standard error of estimate of 3. 2 percent SO-
n5
removal.
14.2.2 TCA Scrubber
The following equation was fitted to 17 limestone factorial test runs
made with the TCA (see Figures 6-5 and 6-6 and Table E-2):
Fraction
SO, Removal
I i 2 J? ( )
i - e*p\-c.oo+t, L" \t f o. 10 (tL£ + Ms)
/ L dp
(14-9)
where:
L = liquor rate per cross-sectional area, gpm/ft
r'/p = total height of packing, in.
&p = diameter of packing = 1.5 in.
A/5 = number of grids (screens)
^ - scrubber inlet gas SO? concentration, ppm
Measured and predicted SO_ removals from Equation 14-9 are shown
£1
in Figure 14-2. Equation 14-9 accounts for 98. 5 percent of the variation
in the data with a standard error of estimate of 1. 3 percent SO? removal.
*
See Appendix L for definitions of statistical terms.
*
Runs 423-2A and 424-2A were excluded because of high values for solids
concentration in the recirculating slurry. Run 427-2A was excluded
because it was a limestone depletion run.
14-7
-------
100
90 -•
o
ui
cc
N
8
Q
LLJ
H
CJ
Q
UJ
CC
Q.
80 ••
70 ••
60 •-
50
50
60
70 80
MEASURED S02 REMOVAL, %
100
Figure 14-2. Comparison of Experimental Data and Predicted
Values of SO, Removal in the TCA from Equation
14-9 (Limestone Factorial Tests)
14-8
-------
14. 2. 3 Marble-Bed Scrubber
*'•
•f
The following equation was fitted to 27 limestone factorial test runs
made with the Marble-Bed scrubber (see Figure 6-8 and Table E-3):
Fraction = ( _
SO, Removal ;
L (L/Cr)
(14-10)
Measured and predicted SO- removals from Equation 14-10 are shown
in Figure 14-3. Equation 14-10 accounts for 95 percent of the variation
in the data with a standard error of estimate of 4. 1 percent SO, removal.
*
Runs 405-3A through 415-3A were excluded because of anomalously
low values for SO- removal. Run 431-3A was excluded because ol
unstable operation of the marble bed.
14-9
-------
100
80 --
a*
I 60
ui
c:
CM
8
o
111
U 40 --
Q
UJ
QC
O.
20 --
40 60
MEASURED SO2 REMOVAL, %
80
100
Figure 14-3. Comparison of Experimental Data and Predicted
Values of SO? Removal in the Marble-Bed Scrubber
from Equation 14-10 (Limestone Factorial Tests)
14-10
-------
Section 15
REFERENCES
1. Bechtel Corporation, EPA Alkali Scrubbing Test Facility: Lime-
stone Wet Scrubbing Test Results, EPA Report 650/2-74-010,
January 1974.
2. Bechtel Corporation, EPA Alkali Scrubbing Test Facility; Sodium
Carbonate and Limestone Test Results, EPA Report 650/2-73-013,
August 1973.
3. Bechtel Corporation, Test Manual for Advanced Test Program,
EPA Report, September 1974.
4. Universal Oil Products, Air Correction Division, Bulletin No. 608,
"UOP Wet Scrubbers," 1967.
5. National Dust Collector Corporation, General Catalog, December 23.
1968.
6. M. Epstein, et al. , "Mathematical Models for Pressure Drop, Par-
ticulate Removal and SOg Removal in Venturi, TCA and Hydro-Filter
Scrubbers, " presented at Second International Lime/Limestone Wet
Scrubbing Symposium, New Orleans, Louisiana, November 8-12, 1971.
7. E. L. Crow, et al. , "Statistics Manual, " Chapter 6, Dover, New
York, I960.
15-1
-------
8. R. If. Borgwardt, Limestone Scrubbing at EPA Pilot Plant. Prog-
ress Report No. 6, EPA Report, January 1973.
9. Radian Corporation, A Theoretical Description of the Limestone-
Injection Wet Scrubbing Process, NAPCA (APTIC No. 22709 and
26446) Report, June 9, 1970.
10. P. S. Lowell, "Use of Chemical Analysis and Solution Equilibria
in Predicting Sulfate/Sulfite Scaling Potential, " presented at
Second International Lime/Limestone Wet Scrubbing Symposium,
New Orleans, Louisiana, November 8-12, 1971.
11. R. H. Borgwardt, Limestone Scrubbing at EPA Pilot Plant, Pro-
gress Report No. 12, EPA Report, July 1973.
12. R. H. Borgwardt, "EPA/RTP Pilot Studies Related to Unsaturated
Operation of Lime and Limestone Scrubbers, " presented at Symposium
on Flue Gas Desulfurization, Atlanta, Georgia, November 4-7. 1974.
13. R. H. Boll and C. A. Leeman, "Particle Collection and Pressure
Drop in Venturi Scrubbers, " AIChE 69th National Meeting. Cincin-
nati, Ohio, May 16-19, 1971.
14. B. P. Volgin, et al. , Int'l Chem. Eng. , Vol. 8. No. 1, p. 113,
1968.
15. J. Happel, Ind. Eng. Chem. . Vol. 41, p. 1161, 1949.
16. M. Leva, "Fluidization, " McGraw Hill, New York, 1959.
17. Treybal. R. E. , "Mass-Transfer Operations, " Chapter 5, McGraw-
Hill, New York, 1955.
15-2
-------
18. Bechtel Corporation, Alkali Scrubbing Test Facility - Progress
Report: Mathematical Models for Venturi Scrubber and After-
Scrubbers, APCO Report, February 1971.
19. J. R. Fair, Petro. /Chem. Eng. , Vol. 33, No. 9, p. 57, August
1961.
15-3
-------
Appendix A
CONVERTING UNITS OF MEASURE
Environmental Protection Agency policy is to express all measurements
in Agency documents in metric units. When implementing this practice
will result in undue costs or lack of clarity, conversion factors are
provided for the non-metric units used in the report. Generally, this
report uses British units of measure. For conversion to the metric
system, use the following conversions:
To Convert From
scfm (60°F)
cfm
ft
ft/hr
ft/sec
ft2
ft /tons per day
gal/mcf
gpm
gpm/ft2
gr/scf
in.
in. H2O
Ib
Ib- moles
Ib-moles/hr
Ib-moles/hr ft2
Ib-moles/min
To
nm3/hr (0°C)
m^/hr
°C
m
m/hr
m/sec
m2
m /metric tons
per day
cm
mm Hg
gm
gm-moles
gm-moles/min
gm-moles/min/m
gm-moles/sec
Multiply By
1.61
1.70
subtract 32 then
-r 1.8
0. 305
0. 305
0.305
0.0929
0. 102
0. 134
3.79
40.8
2.29
2.54
1. 87
454
454
7.56
81.4
7.56
A-l
-------
Appendix B
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-------
SCRUBBER OPERATING PERIODS
tfl
i
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oo
-------
SCRUBBER OPERATING PERIODS
tfl
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9/30 |/0/I I IO/Z ||0/3
-------
SCRUBBER OPERATING PERIODS
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-------
SCRUBBER OPERATING PERIODS
IO/20'.IO/2I ilO/22'lO/Z3 1(0/2^/0/25 '. \0/2t, i|O/27 '> 10/20 ' 10/2.9 i IO/3O ' /O/3| ' 11/t 11/2 ' 11/3
-------
Appendix C
PROPERTIES OF RAW MATERIALS USED
DURING THE TEST PROGRAM
C-l
-------
Listed in this appendix are typical properties of the coal, alkaline
feeds, and makeup water used in this test program.
COAL
Supplier: Old Ben Coal Co. , Benton, Illinois
May 1972 through September 1973:
Type: Old Ben Mine 24
Analysis: 8.3 to 12.4 wt
3.0 to 4.5 wt
0. 18 to 0. 37 wt
15.8 to 20.7 wt
Approximate Ash Analysis:
50 wt % SiO2
18 wt % A12O3
16 wt % Fe2O3
7 wt % CaO
1 wt % MgO
1 wt % SO 3
2 wt % K20
1 wt % Na2O
3 wt % Ignition loss
% total moisture
% sulfur
% chloride
% ash
October 1973 through October 1974:
Type: Mixture of Old Ben Mines 24 and 26 either straight
from mines or reclaimed from plant coal storage pile
Analysis: 9.4 to 13.4 wt % total moisture
wt % sulfur
wt % chloride
wt % ash
9.4
2.3
0. 03
14.7
to
to
to
to
13.4
5.5
0.27
27.9
C-2
-------
Approximate Ash Analysis:
54 wt % SiO_
23 wt % A1263
12 wt% Fe 03
3 wt % CaO
1 wt % MgO
1 wt % SO
3 wt % K O
1 wt % Na2O
3 wt % Ignition loss
SODIUM CARBONATE
Supplier: Vol-State Chemical Co. , Chattanooga, Tennessee
Type: Soda ash, Grade 58 % light
Analysis: 58 wt % as Na2O
LIMESTONE
Supplier: Fredonia Quarries, Fredonia, Kentucky,
August 1972 through July 1973:
Type: Fredonia Valley Blue White
Analysis: 90 wt % CaCO-
5 wt % MgCO3
5 wt % Inerts
Nominal Grind:
90 wt % less than 325 mesh
81 wt % less than 30 microns
74 wt % less than 20 microns
48 wt % less than 6 microns
C-3
-------
July 1973 through October 1974;
Type: Fredonia Valley White
Analysis: 95 wt % CaCO.
1 wt % MgCO3
4 wt % Inerts
Nominal Grind:
97 wt % less than 325 mesh
92 wt % less than 30 mocrons
86 wt % less than 20 microns
53 wt % less than 6 microns
LIME
Supplier: Linwood Stone Co. , Davenport, Iowa
Type: Pebble lime, unslaked
Analysis: 97. 0 wt % CaO total
95. 5 wt % CaO available
0.28 wt % MgO
0.47 wt % Inerts
MAGNESIUM OXIDE
Supplier: Basic Chemicals, Ft. St. Joe, Florida
Type: MAGOX PG (pollution grade)
Analysis: 97. 6 wt % MgO
1. 5 wt % CaO
0. 5 wt % SiO2
0.4 wt % R,O,
C-4
-------
MAKEUP WATER
Source: Ohio River (filtered)
Typical Analysis:
pH = 7.8
Conductivity =190 micromhos/cm
Species ppm, wt
Ca 45
Mg 3
Na 22
K 3
Mo 1. 5
Al 0.9
Fe 0.6
Mn 0.06
Cr 0.04
so4= 10
CO3 18
cr 177
C-5
-------
Appendix D
TABULAR LISTING OF AIR/WATER AND
SODIUM CARBONATE TEST DATA
D. 1 PRESSURE DROP DATA FROM AIR/WATER AND SODIUM
CARBONATE TESTS
The pressure drop data for the air/water and sodium carbonate runs
for the three scr\abber systems are shown in Tables D-l through D-9.
The "total" pressure drops refer to pressure drops from the point of
gas entrance to the gas humidification sections to the point of gas exit
downstream from the mist eliminators and their associated wash headers.
The observed variations in the independent and dependent variables for
the presented air/water and sodium carbonate (soda-ash) runs were:
Gas flow rate +200 cfm
Liquor flow rate +10 gpm
Marble-Bed turbulent layer height ±20%
Total pressure drop ±3%
Mist Eliminator pressure drop ±8%
As can be seen from Tables D-l througli D-9. the replicate runs were all
in agreement to within the estimated experimental variations of pressure
drop.
D-l
-------
Table D-l
PRESSURE DROP DATA FROM
AIR/WATER RUNS: VENTURI/SPRAY TOWER SYSTEM
Date
Run
No
Air Flow
Rate, acfm
Air Temper-
ature. °F
Water Flour Rate, gpm
Venturi Spray Tower
Water Temper-
ature. °F
Plug Position,
% Open
Pressure Drop, in
Total Ventun Mist Elim.
Kcplicatu
K u n s
a
5/20
5/20
5/20
5/20
5/20
5/21
5/21
5/21
5/21
5/21
5/21
5/21
5/21
5/23
5/23
5/25
5/25
5/25
5/25
101-1B
103-IB
111-1A
119-1A
102-1B
104-1A
110-1A
112-1A
108-1A
109-1A
107-1A
113-1A
] 15-1A
120-1A
116-1A
106-1B
118-1A
114-1A
117-1A
23.000
13. 100
9,600
23.000
8.700
17.700
23.000
8.300
17.900
23.200
13, 300
13, 300
23,200
8, 300
8.700
8. 300
17,900
17. 600
13.100
89
88
86
96
91
87
85
87
95
98
100
100
96
87
91
89
87
90
90
0
0
0
0
405
200
0
0
0
395
Z05
400
200
0
200
580
395
595
595
390
0
ZOO
0
395
200
400
0
0
390
205
395
200
210
205
595
395
585
600
67
66
67
66
66
66
67
67
67
68
67
69
66
69
69
25
50
100
100
75
100
25
25
75
50
25
100
75
100
50
100
25
50
75
6.6
1. 5
. 7
2.9
1.6
3.0
6.6
.8
1.9
11. 2
4.0
2.5
5.8
.5
1. 3
2. 1
9 8
10.4
4.8
4.6
. 8
. 2
.9
1. 2
1.4
4.6
. 7
. 8
8.2
3. 4
1 6
3. 4
1. 4
8. 2
8. 1
3. 4
97
34
. 16
. 98
. 13
. 54
1. 00
. 12
. 60
1. 00
. 30
. 29
. 90
. 12
. 13
11
. 61
59
28
-------
Table D-2
PRESSURE DROP DATA FROM SO DA-ASH RUNS WITH
AIR AND S02 GAS MIXTURES: VENTURI/SPRAY TOWER SYSTEM
Date
Run
No.
Air Flow
Rate, acfm
Air Temper-
ature, °F
Ljiquor Flow
Rate to Venturi
gpm
Liquor Temper-
ature. °F
Plug Position,
% Open
Pressure Drop, in.
Total Venturi Mist Elim.
Replicate
Runs
a
i
OJ
7/6-7
7/7
7/9
7/9
7/9
7/9
7/10
7/10
7/10
7/10
7/10
7/10-11
7/11
7/11
7/11
7/11
7/11
7/11
7/11
7/11
7/11-1Z
7/12
7/1Z
7/12
7/1Z
7/13
7/13
7/13
7/13
7/13
7/13-14
7/14
7/14
7/14-16
7/16-17
7/17-18
7/18-19
7/19
7/20
202-1A
202-IB
202-1C
202-1D
208-1A
205-1A
201-1A
202-1E
203-1A
204-1A
205-1B
206-1A
207-1A
208-IB
209-1A
2SO-1A
251-1A
253-1A
250-1B
2S4-1A
255-1A
254-IB
256-1A
257-1A
258-1A
259-1A
260-1A
261-1A
262-1A
259-1B
260-IB
261-1B
262-1B
259-1C
241-1A
243-1A
243-IB
244-1A
260-1C
23,100
23,300
23. 300
23, 300
23,400
11,800
17.500
23,400
23,500
11.600
11.600
17.400
11.500
23.500
17.600
23, 300
23.400
11.800
23.400
23,400
11,500
23. 300
11,500
17,400
17,600
23,400
23.400
11.600
11,600
23,400
23,400
11,500
11.500
23,400
11,500
23, 300
23,300
23,300
23,400
93
97
97
101
104
105
99
103
105
106
104
102
102
100
101
105
107
107
105
103
102
100
99
100
99
102
99
102
105
103
104
101
101
105
85
105
106
108
103
200
200
200
190
580
565
185
190
385
180
580
385
370
595
595
395
385
380
355
590
215
590
580
230
385
280
570
585
305
290
590
575
310
280
390
380
380
380
385/600(<
71
70
73
74
76
77
77
76
78
79
79
79
79
79
78
78
78
79
79
79
79
79
79
78
78
78
76
78
79
81
79
78
78
80
75
79
80
80
78
59
80
40
40
60
40
40
40
80
59
81
60
60
60
60
60
1
67
SO
50
46
7.4
7.3
7.4
7. 3
10.0
5.2
5.9
7. 2
13. 5
2.5
5. 3
4 7
2.9
10.5
7.9
9.7
9.6
2.8
9.4
12.9
2.0
13.0
4.0
4.7
6. 1
8.7
12.7
3.9
2. 4
8.5
12.7
3.8
2.4
8.4
7.0
8.7
11.0
11.2
12.4
4 6
4 5
4. 7
4 6
6. 8
4. 5
4. 5
4. 5
10 4
2. 1
4.6
3. 2
2. 2
7. 1
6. 1
6.9
6.8
2. 3
6.6
9. 5
1. 6
9.6
3. 3
3.2
4.6
5.8
9. 2
3. 3
1. 9
5. 9
9.4
3. 2
1. 9
5. 7
6.4
6.0
8. 3
8. 6
9. 1
96
99
99
.98
.99
.22
.56
.98
.98
.23
. 23
50
.23
1.01
. 54
.98
.95
. 23
.97
.97
.23
.98
. 22
.54
.51
.92
1.00
.23
. 20
.98
1.02
. 22
19
.99
. 22
.99
.96
.99
1.04
C
C
D
E
D
F
C
H
I
J
C
H
I
J
C
K
K
(a) 385 gpm to venturi. 600 gpm to spray tower (single header).
-------
Table D-3
PRESSURE DROP DATA FROM SO DA-ASH RUNS
WITH FLUE GAS: VENTURI/SPRAY TOWER SYSTEM
Date
7/21-22
7/22
7/22
7/23
7/23
7/23
7/23
7/23
7/23
7/24
7/24-25
7/26
7/Z9
7/29
7/29-30
7/30
7/31-8/1
8/1-2
8/4
8/4-5
Run
No.
271-1A
270-1 A
273-IA
272-IA
275-1A
274- 1A
271-1B
274-1B
270-1B
281-1A
280- 1A
286- 1A
Z87-1A
288-1A
289- 1A
291-1A
Z9Z-1A
299- 1A
310-1A
311-1A
Gas Flow
Rate, acfm
14,800
30, 000
14,900
30, 000
14,900
30,000
15,000
30, 000
29, 900
29,700
14,800
20, 100
20. 000
20, 000
19,700
19.700
19, 90O
30,000
30,000
19.900
Gas Temper-
ature, °F
330
342
331
341
331
345
330
346
347
345
334
340
326
329
328
307
330
337
344
33Z
Liquor Flow Rate, gpm
^ °r Liauor Temper- Plu
Ventun 1 Spray Tower ature, °F
190 0 100
395
565
570
390
225
200
195
400 1
104
114
109
107
106
109
110
112
380 0 109
385
580
580
580
585
585
610
107
99
99
99
100
99
102
280 0 108
290 0 110
570 t 98
_ Pressure Drop, in. H,O „
ft Position. r ' Reolicate
'o Open Total Ventun Mist Elim. Runs
60 2.0 1.5 .20
10.3 7.7 1.00
4.2 3. 6 .19
13.7 10.8 .93
3.0 Z. 7 .19
8. 3 5. 7 .90
2.0 1.6 .19
7.6 5.3 .96
' 10.7 8.0 .92
52 11.8 9. 1 .92
0 8. 2 7. 7 .19
11 13.4 1Z. 6 .38 L
17 11.5 10.3 .40
Z9 9.9 8.8 .42
11 1Z.O 11.6 .39 M
10 12.4 11.6 .37 M
Zfa 10.8 10. 1 . 41
59 8.7 6.6 1.01 N
59 9.0 6.9 l.OZ N
10 12.6 11.8 .44 L.
u
-------
Table D-4
PRESSURE DROP DATA
FROM AIR/WATER RUNS: TCA SYSTEM
D.H.
i/lll
5/11)
5/11
5/12
5/H.
5/1..
5/17
5/17
I/IK
i/IH
I./2
i./2
•./!
N/l
i./t
l./f
••/•I
»/4
M/4
•./4
Kim
\..
IOI-2C
III2-2C
11U-.1A
105-2A
104 2A
IUI.-2A
ION-2A
1 10-2A
in-i.2A
1 I2-2A
107- 2 A
120- 2 A
1 II-2A
1 1 <-2A
1 I-4-2A
1 I5-2A
1 I7-2A
1 IK-2A
1 I«-2A
1 I..-2A
Air h lim
Kato , «ii Im
1h. 11)1)
IU. 01)1)
12. 800
22. "00
1 7. 700
IK. 100
1 3.400
22 KOO
17. i.OO
« 501)
K KOO
23. 500
1 1 201)
1 i. 21)0
IH 000
21. 500
•). 000
1 3. -100
IK 100
13. 200
Air I erupt1 r-
aluri- 'T
K4
Hi.
HH
HH
05
93
HG
«<)
Kf,
H4
<)0
IB
•>4
"3
10-4
102
100
•IP
-------
Table D-5
PRESSURE DROP DATA
FROM SODA-ASH RUNS WITH AIR AND SO2 GAS MIXTURES: TCA SYSTEM
Dale
6/21
6/23
6/28
6/30
7/3
7/3
7/3
7/3
7/3
7/4
7/6-7
7/7
7/7
7/8
7/8-9
7/9
7/11
7/11-12
7/12-13
7/13-14
7/14
7/15
7/15
7/15
Run
No.
20I-2B
20I-2C
20I-2H
20I-2L
225-2C
226-2C
227-2C
228-2C
229-2C
230-2C
231-2A
232-2A
233-2A
234-2A
235-2A
236-2A
241-2A
245-2A
248-2A
249-2A
250-2A
2AO-2A
261-2A
262-2A
Ai r Flow
Rate, acfm
23,000
17,400
17,700
17,400
17,700
11, 900
23,600
11,700
23,500
17, 600
23. 300
11,800
23, 300
23.300
23, 300
23,400
11,800
23, 300
21, 100
1 1 , 800
23,400
17.800
12.000
23, 300
Air Temper-
ature. °F
86
89
100
95
98
99
101
100
100
100
95
92
94
94
99
100
107
101
80
107
103
103
102
101
Liquor Plow
Rate, gpm
905
915
855
920
925
640
610
1. 180
1. 190
915
590
565
590
1. 190
540
1, 165
1, 180
610
1. 190
1. 190
615
860
615
595
Liquor Temper- Nui
ature. °F Sc
71
70
77
75
75
74
76
77
77
76
70
70
68
72
72
72
74
74
73
75
76
79
79
80
Tibet of
reens Spheres
yes
0 no
0 no
0 no
'
2 no
Ii
4 yes
11
*
no
no
2 yes
1 i
' T
Pressure Drop, in H_O
Total 1 Bottom Stage 1 Mist Elini.
18.4 2 22 26
3. 5 1.82 13
1 3 .23 12
1.4 .24 13
1.4 .26 12
08 .14 04
1.6 31 24
1.5 22 .05
2. 1 35 23
1.4 24 12
2.0 30 2K
1.0 .17 07
2. 1 .31 .26
3.2 .53 27
1.7 37 2 K
2.6 60 2K
5. 6 2 20 Ob
83 2 03 27
12 5 2 43 23
1.7 24 On
2.0 29 2t.
3.2 2.00 12
2 1 1.53 04
3. 6 1.82 . 21
Kcpl irate
Uuns
c
c
D
D
E
E
F
F
a
i
(a) Refers to screens for bottom and middle beds.
(b) Refers to screens for bottom bed.
(c) Static height of spheres - 10 inches/bed
-------
Table D-6
PRESSURE DROP DATA
FROM SODA-ASH RUNS WITH FLUE GAS: TCA SYSTEM
Date
7/20-ZZ
7/24-25
7/Z5
7/28-29
7/29-30
7/30
Run
No
27I-2A
272-2A
Z73-ZA
274-2A
Z78-2A
Z76-2A
Gas Flow
Rate, acfm
15,000
15.400
IS. 100
22.400
22.500
22, 500
Gas Temper-
ature, °F
306
311
299
295
299
284
Liquor Flow
Rate, gpm
585
580
1, ISO
1. 190
600
1, 182
Liquor Temper- Num
ature. °F Scr
10Z
99
103
361 °' <; v,
-------
Table D-7
PRESSURE DROP DATA FROM
AIR/WATER RUNS: MARBLE-BED SYSTEM
Date
3/31
5/9
5/10
5/10
5/12
5/16
5/16
5/l»
5/16
5/lc
5/16
5/17
5/17
5/18
1/1R
5/18
5/I9
5/19
5/19
5/19
Run
No
I01-3A
I01-3B
I03-3A
105-3A
I06-3A
107-3A
110-3A
10R-3A
I14-3A
I09-3B
I15-3A
I1I-3A
IK.-3A
119-3A
I20.3A
102-3C
117-3A
112. 3B
I03-3B
I1B-3B
Air Flo*
Rale, acfm
9.700
8.500
17.700
17.400
9.200
13.200
13.200
17.500
23. 100
22.900
17.700
8.400
8.400
23.200
1 3. ZOO
13.300
13.400
13.400
17.700
17.900
Air Temper-
ature. °F
70
71
81
84
90
85
84
83
96
83
96
88
87
87
85
92
90
90
87
91
Water Flow Rate, gpm
Bottom Sprays
0
0
405
280
155
405
ISO
270
400
0
265
280
405
275
150
275
150
0
400
0
Top Sprays
0
0
ISO
210
0
0
0
0
205
0
200
200
200
200
0
0
200
200
0
200
Water Temper-
ature. °F
.
60
60
64
64
64
64
67
_
67
66
66
66
66
68
67
67
66
66
Marble
Height.
in.
3.5
We,r Turbulent Pressure Drop, in 1I2O ^ (
Height, Layer Height, To(a, BeH and Tur- M,,I "RUH,
in, in. bulenl l-aver Eliminalnr
8 - 0.7 0.2 .On
06 0. 5 .07
14 7.0 6.3 .28
N.R. (al 6. 3 57 .26 A
0 10 0.8 OS
6 57 5.4 .15
1 2.9 2.6 IS B
5 60 5.0 2H
19 87 6.9 48
40 3.2 40
11 6.5 59 27 A
6 4. 1 40 OS
7 4.8 4.8 .OS
13 75 65 52
1 2.6 2.3 15 B
10 SO 4. 7 14
7 4.9 4.6 15
N.R. 4.9 4.6 .IS
10 6.7 6 2 29
9 5.7 5.1 .29
G
oo
(a) Not recorded
-------
Table D-8
PRESSURE DROP DATA FROM
SO DA-ASH RUNS WITH AIR AND SO2 GAS MIXTURES: MARBLE-BED SYSTEM
Dale
../29
"/JO
u/30
7/1
7/1
7/1
7/1
7/2
7/2
7/2-3
7/3
7/3
7/19
7/19
7/20
7/ZO
7/20
7/20
7/21
7/Z1
7/21
7/21-2
7/22
7/Z2
7/23
7/Zi
7/23
7/23
Run
No
20I-3A
2ZI-3A
ZZO- 3A
212-3A
ZZZ-3A
223-3A
214-3A
224-3A
21S-3A
225-3A
22&-3A
227-3A
228-3A
229-3A
230-3A
23I-3A
232-3A
Z33-3A
Z34-3A
235-3A
250- 3A
Z5I-3A
252-3A
Z53-3A
254. 3A
ZS5-3A
21i .\A
Z57-3A
'Kir Flow
Rate, acfm
19.400
19.400
19.400
15.600
23.500
15.900
15. 700
23 200
23. 300
15.700
23. ZOO
15.600
23.400
15.700
23.400
23.400
15.700
15.900
15.700
23. 300
23. 500
23.400
23.500
23. 500
23.300
23.400
23. 500
23 i.flO
Air Temper-
ature. °F
101
96
95
99
106
108
97
99
99
99
97
98
107
106
103
103
101
106
104
IOZ
109
107
10(.
108
100
107
110
110
Liquor Flow Rate, gpm
Bottom Spray a
390
305
605
190
605
MO
605
210
(.10
215
195
200
200
405
405
205
405
205
205
400
205
400
200
405
2O5
405
205
4OO
Too Sprays
195
0
0
195
0
0
190
0
215
0
0
0
0
195
185
195
0
0
195
0
0
0
195
190
0
0
190
195
Liquor Temper-
ature. °F
77
76
76
77
81
82
79
77
77
78
76
77
84
84
84
83
83
85
85
34
85
84
84
84
83
85
85
85
Marble
Height.
in.
5
1
f
2
2
5
Weir Turbulent
Height. Layer Height.
in. in
8 23
1 B , ,
1 N R. (1"
8 7
19
II
14
12
17
S
II
S
8 14
N.R.
N.R.
N.R.
N.R.
6
8
11
8 7
112
22
11 12
117
22
Pressure Drop, in HgO
_ , |B*H and Tur- N.isl ' '* 1Ci*11
T°lal jbulem Layrr Mnnii-.lnr n"ni
12.3 8.5 33
8. 1 7. 3 X,
12 4 8.6 37
50 45 20 C
7.3 5.8 49
6.8 58 20
7. 1 58 20
59 4.9 52 D
79 57 49
45 4. 1 22 E
59 49 53 D
4.8 42 21 E
63 5. 1 .49 D
64 5. 5 .19
74 58 49
6.5 5.2 .49
61 5.4 21
5 Z 4. 5 .19
56 4.9 .1° C
69 5.6 50
91 8.0 50
10 1 «.B 50
95 81 48
13.7 9. 1 i.O
94 81 50
11.1 S 9 4<»
10 2 8 i. 47
13 5 9.0 i.O
o
I
vO
la I "V>i recorded
-------
Table D-9
PRESSURE DROP DATA FROM
SODA-ASH RUNS WITH FLUE-GAS: MARBLE-BED SYSTEM
Dale
7/2B-30
7/30
7/31-8/1
8/1
o
1
Run
No
Z61-JA
263- JA
264-3A
262-3A
Gas Flow
Rate, aefm
20,000
20, 100
20, 100
20.000
Gas Temper-
ature. °F
315
306
323
309
Lfiouor Flow Rate, gprr
BnMnTn Sprays Top Spra
605 0
305 1
305 1
603 T
ys atur.. °F
102
100
97
103
Marble
Height
in
5
1
T
Weir
Height
in
11
1
1
Turbulent
Layer Height
in
19
N. R
N. R.
Pressure Drop, in. HgO
To.,1 I!',''"1? TUr1 Ml"
jbulrnt L»>fr| il,m1nalrr
12 6 8.4 ,20
74 65 .lo
74 64 15
12.9 8.1 22
Rrpl!cair
Runs
F
G
G
F
(at Nol recorded
-------
D. 2 SULFUR DIOXIDE REMOVAL DATA FROM SODIUM
CARBONATE TESTS
A summary of the SOo removal data from the sodium carbonate runs is
shown in Tables D-10 through D-16. The SO2 removals have all been
corrected for the dilution effect of water vapor and reheater gas pickup
by the flue gas.
The observed variations in SO2 removal for the sodium carbonate runs
•were as follows:
Inlet Liquor
pH
8.5-9.5
6.0-7.5
Percent SO2
Removal
85 - 100
50 - 80
90 - 100
50 - 80
Observed
Variation in. .
SO 2 Removal11'
±1%
±2%
±3%
±7%
(a)
See replicate runs in Tables D-10 through D-16.
The variations in replicate runs appeared to be a function ofpH level and the
magnitude of SO7 removal. The observed variations were also functions of the
scrubber system. For example, Na concentration was easier to control
on the venturi system than on the TCA and Marble-Bed systems. Con-
sequently, the variations in SO? removal were less for the venturi system
than for the other two systems for the gas/liquid-side controlled tests.
i-
At high concentration/pH, the interfacial vapor presssue of SO£ is
essentially zero and gas-side resistance controls. At low concentra-
tion/ pH, both gas and liquid-side resistances are important. Since
the liquid-side resistance is a function of pH (and Na+ concentration),
variations in inlet liquor pH may have caused the observed variations
of SO2 removal.
D-ll
-------
Table D-10
SODIUM CARBONATE RUNS WITH AIR AND SO2 GAS MIXTURES:
VENTURI/SPRAY TOWER SYSTEM (RUNS 202-1A TO 251-IB)
Dale
7/6-7
7/7
7/9
7/9
7/9
7'9
7/10
7/10
7/10
7/10
7/10
7/1D-1I
7/11
7/11
7/11
7/11
7/11
7/11
7/11
7/11
7/11
7/11-12
7/12
7/12
7/12
7/12
Run
No.
202- 1A
202-1B
202- 1C
202- ID
208- 1A
205-1A
201-1A
202-1E
203-1A
204-1A
205- IB
Z06-1A
207-1 A
208-1B
209- 1A
250-1 A
251-1A
252-1A
253-1A
250-1B
254-1A
255-1A
256-1A
257- 1A
2S8-1A
251-lB'bl
Nominal Run Specifications'9'
Air Flow . .
Rate, acfn-i
23. 100
23.000
11.550
17.320
23, 100
23, 100
11.550
11.550
17. 320
11.550
23, 100
17, 320
23. 100
23. 100
11, 550
11. 550
23. 100
23.100
11.550
11,550
17, 320
17.320
23, 100
Liquor Flow
Rate, gpm
200
600
600
200
200
400
200
600
400
400
600
600
400
600
Plug Position,
% Open
60
80
40
40
60
40
80
40
80
60
80
60
60
60
200
600
200
400
400
Caa Inlet SO2
Concentration, ppm
1200
1
1
1200
600
1200
1200
600
600
1200
— .. .1 , Average
Scrubber Inlet Liquor _ ~,^
pH 1 Na* Cone. , wtft Removal
9.5 0.5 80
8.5 0.5 75
8.5 1.0 80
9.5 1.0 80
9.5 1.0 90
82
79
79
94
66
83
76
73
92
87
9.5 1.0 90
90
70
70
90
9.5 1.0 94
64
80
75
82
90
Replicate
Runs
A
B
B
C
A
D
E
C
D
£
d
I
(a) See Table D-2 for actual (measured) air and liquor flow rates.
(b) Actual flow rates not available in Table D-2.
(c) At ambient conditions.
-------
Table D-ll
SODIUM CARBONATE RUNS WITH AIR AND SO2 GAS MIXTURES:
VENTURI/SPRAY TOWER SYSTEM SCRUBBER (RUNS 259-1A TO 260-1C)
Dale
7/13
7/13
7'13
7/13
7/13
7/13-14
7/14
7/14
7/14-16
7/16-17
7/17-18
7/18-19
7/19
7/20
Run
No.
259-IA
260- 1A
Z61-1A
262- 1A
2S9-1B
260- IB
261-13
zftz-is
259-1C
24I-1A
243-1 A
243-1B
244-1A
260-1C
Nominal Run Specifications 'a'
Air Flow ,,.
Rate, acfm
23. 100
23. 100
11.550
11.550
23. 100
23. 100
11.550
H.«Q
23, 100
11. 550
23, 100
23. 100
23, 100
Z3. 100
Liquor Flow
Bate, gpm
300
600
600
300
300
600
600
100
300
Plug Position. I Gas I
% Open | Concent
Scrubber Inlet Liquor T,*"'™8,^
.!_. 50 H P.rrrnt STl
ration, ppm pH | Na+ Cone. , wt % Removal
60 1200 7.0 0.5 74
400 Pressure
1 Pressure
Pressure
Pressure
400/600(<0 Pressure
88
73
59
63
83
72
58
69
-------
Table D-12
SODIUM CARBONATE RUNS WITH FLUE GAS:
VENTURI/SPRAY TOWER SYSTEM
Date
7/22
7/22
7/22
7/23
7/25
7/23
7/23
7/23
7/23
7/24
7/24-25
7/25
7/26
7/29
7/29
Run
No
271-1A
270-1A
273-1A
272-1A
275-1A
274-IA
271-1B
270-1B
274-1B
281-IA
280-1A
284-1A
286- 1A
287- IA
238-IA
Nominal Run Specifications **'
Gas Flow ..
Rate, acfm
15,000
30. 000
15.000
30, 000
IS. 000
30.000
15.000
30. 000
30.000
30, 000
15.000
30. 000
20. 000
1
Liquor Flow Plug P
Rate, acfm % O
,„,,,„„ ,,rn.vr. o.r T Scrubber Inlet L.quor S,o,ch,om.iry
pen Drop. in. HjO PH [ Na Cone. . «rt% mole g^ .fiiorbed
ZOO 60 - 95 1.0
400
600
600
400
200
200
400
ZOO
400
400
400/600
-------
Table D-13
SODIUM CARBONATE RUNS WITH AIR AND SO2 GAS MIXTURES:
TCA SYSTEM
Date
6/21
6/21
6/23
6/28
6/30
7/3
7/3
7/3
7/3
7/3
7/4
7/6-7
Til
7/7
7/8
7/8-9
7/9
7/11
7/11-12
7/12-13
7/13-14
7/14
7/15
7/15
7/15
Run
No
Nominal Run Specifications'2'
Air Flow ... Liquo
Rate, acfm Rate,
• Flow Gas In
gpm Concent ra
Scrubber Inlet Liquor „„„,... „,
tion. ppm pH | Na+ Cone., wt.% Screens *
201-ZA(el 17,320 900 900 9.
Z01-ZB
ZOI-ZC
201 -ZH
Z01-ZL
Z25-2C
Z26-2C
Z27-2C
22B-2C
Z29-2C
230-2C
Z31-2A
Z32-2A
233- ZA
Z34-ZA
Z35-2A
236-2A
Z41-2A
245-2A
248 -2A
Z49-2A
Z50-2A
260-2A
261 -ZA
262 -JA
23, 100
17,320
17.320
17,320
19.
9.
9.
7.
17,320 900 900 9.
11.550 600
23.100 600
11.550 1200
23,100 1200
17.320 900
23. 100 600 900 9.
11.550
23. 100
23.100 1200 900 7
1 600 1
1 1200 T
11.550 1200 1200 6
23,100 600
23.100 1200
11,550 1200
23. 100 600
k^,r
Percent SOj
heres's' Removal
Replicate
Runs
5 0.5 4(bl Yea 99+
5
5
5
0
4
-------
Table D-14
SODIUM CARBONATE RUNS WITH FLUE GAS:
TCA SYSTEM
Dare
7/20
7/20-22
7/Z-1-Z5
7/25
7/ZS-Z1
7/29-30
7/30
Run
No
270-2A(C)
E71-2A
272-2A
273-2A
274-2A
27B- 2A
276-2A
Gas Flow *
Rale, acTm
30.000
15.000
15.000
15.000
22.500
1
Liquor Plow
Rale, gpm
600
600
600
1200
1200
600
1200
Nominal Run Specifications '*
Scrubber Inlet Liquor Sloichio
pH I Na* Cone. , wt% mole SO2
6 75 0. 125
6. 75 I
7. 75 1
6.75 T
mpl ry.
- en l Number of _ ,
23 f opne
absorbed Screens
4 10 inches/bed.
-------
Table D-15
SODIUM CARBONATE RUNS WITH AIR AND SO2 GAS MDCTURES:
MARBLE-BED SYSTEM
Date
6/29
6/30
6/30
7/1
7/1
7/1
7/1
7/1
7/2
7/2
7/3
7/3
7/3
7/19
7/19
7/20
7/20
7/20
7/20
7/21
7/21
7/21
7/21-22
7/22
7/22
7/23
7/23
7/23
7/23
Run
No
201 -3A
221-3A
220- 3A
212-3A..
Nominal Run Specifications*8
Air
Rate.
Flow(c;
actm
19.250
19.250
19.250
. 15.400
213-3A(bl 23.
222- 3A
223-3A
214-3A
224- 3A
21S-3A
225-3A
226 -3A
227 -3A
228- 3A
229- 3A
230-3A
23I-3A
232-3A
Z33-3A
234- 3A
235-3A
250- 3A
251-3A
252-3A
253-3A
254- 3A
25S-3A
256-3A
257- 3A
23.
100
100
15.400
15.400
23.
23.
100
100
15.400
23.
100
15.400
23.
100
15.400
23.
23.
100
100
15.400
15.
15.
23.
23.
400
400
100
100
Liquor Flow Rate, gpm
Bottom Sprays 1 Top Sprays
400 200
300 0
600 0
200 200
200 200
600 0
600 0
600 200
200 0
600 200
200 0
200 0
200 0
200 0
400 200
400 200
200 200
400 0
200 0
200 200
400 0
200 0
400 0
200 200
400 200
200 0
400 0
200 200
400 200
Gas Inlet SOj
Concentration, ppm
1200
1200
1200
1200
Scrubber Inlet Liquor
pH | NaT Cone . wt.%
95 0.5
9.5 05
9.5 1.0
9.5 1.0
Turbulent
Marble Weir Layer
Height, ,n. Height, in H«'8hl- »"•
5 B 23
8
287
11
19
11
14
12
17
8
11
8
2 8 14
6
8
11
587
8 12
8 12
8 22
11 12
11 17
11 12
11 22
Average
Percent SO2
Removal
99*
91
98+
92
91
94
97
98+
85
96
91
81
86
90
97
95
92
95
93
94
93
93
96
95
98*
94
96
95
984
Replicate
Runs
E
C
A
B
A
B
A
C
B
E
a
I
(a) Sec Table D-8 for actual (measured) gas and liquor flow rates
(b) Actual flow rates not available in Table D-R.
fc) At ambient conditions.
-------
Table D-16
SODIUM CARBONATE RUNS WITH FLUE-GAS:
MARBLE-BED SYSTEM
Date
No.
Nominal Run Specifications'3'
Ga, Flow(b)
Rate, acfm
7/28-30 26I-3A 20,000
7/30 263-3A I
7/31 264-JA 1
8/1 262-JA I
Liquor flow Rate, gpm
Bottom Sprays 1 Top Sprays
600 0
300 I
300 1
600 1
Scrubber Inlet Liquor
PH I Na+ Cone., wt.%
0. 125
; I
Stoic biometry,
moles NazCOj/ Mar
mole SO£ absorbed Heigh
1.05 5
1.50 1
1.75 1
1. 30 1
ble Weir
t, in. Height, in.
Layer
Height, in.
Percent 5O2
Removal
11 19 72
19 SO
50
67
o
f—«
00
(a) See Table D-9 for actual (measured) gas and liquor flow rates.
fb) Hot. unsaturated.
-------
Appendix E
TABULAR LISTING OF
LIMESTONE FACTORIAL TEST DATA
E-l
-------
Table E-l
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: VENTURI/SPRAY TOWER SYSTEM
Date
9/6-9
9/9-10
9/21-25
9/25-26
10/2-3
10/3-4
10/4-5
10/6-7
10/7-9
10/10-12
10/13.16
10/17-20
10/20-22
10/22-23
10/23
10/23-24
10/25
10/25-30
11/8-12
11/12-15
11/15-16
12/21-22
12/23
12/23-24
12/24-25
12 725-26
12/26
12/26
12/26
12/26
12/27-28
Run
No
Gas Flow
Rate, acfrn
B 330 °F
401-lA(d) 20.000
401-IB 20.000
402-IA
402- IB
403- IA
404-1 A
40S-IA
406- IA
407-1 A
408- 1A
409-1 A
410-IA
411-1A
412-IA
412-IB
413- 1A
414-1B
414-1A
415-1A
414-1D
414-1C
417-IA
417-1B
419-IA
421-1A
4 14- 1 E
414-1H
414-1F
418- 1A
1 18- IB
418-1C
20. 000
19.800
10. 000
29,900
29, 900
30, 000
29, 900
30. 000
30. 000
29. 900
30. 000
29. 900
29. 900
30. 000
29. 900
30.000
30. 000
29.900
29.900
30,000
30. 000
15.000
15.000
30. 000
30.000
29. 900
15 000
14.800
14.900
Liquor Flow Rate.gpm (,)
i lr-.J ctM.-u
Venlun
520
565
560
560
560
280
270
550
545
540
260
560
555
545
545
555
280
275
305
305
305
60S
600
605
610
inn
tuv
300
305
300
600
600
Spray Tower gal/mcf tncR
ome- Percent Solids
alio'a' Recireulated
635 72 1 55-2.15 8-12
0 36 3.40
-4 75 8-10
nnfll.,
•Time,
, Preasure Drop , in. H?O
mln Venturi
65 -70 11.0-13 0
600 72 1 50-1.70 7-9
0 36 2 15-2 50 7-9
i
23 3 15
-3 80 7-9
11 4.70-5 30 5-7
11 2.90
22 2.85
.4 00 5-7
-3 25 4-6
22 2 65-3.00 6,8
22 3 35-3.75 6-8
11 3.05-3 50 5-7
23 2 75
•2 90 5-7
23 2 65-3.10 6-8
22 2 05-2 60 6-7
22 1 75
23 3 60
11 4 40
11 4.40
13 4 80
13 4 25
•2 35 5-7
.3 80 6-8
-4 70 6-8
30 5-7
• 60 5-7
- 85 5-7
13 4 80- 90 5-7
25 (
25
50
50
12
12
13
25
50
50
e 6-8
6-8
5-7
5-7
57
- 1
5-7
5-7
5-7
5-7
5-7
1
11.0-13 0
11.5-12.5
11. 5-12.5
8.8- 92
8.8- 9.8
8.5- 9 S
85-95
85-95
9.0- 9.4
82-98
8.5- 95
11 5-12.5
11.5-12 5
85- 9.5
85-95
8 5-10 S
11 5-12 S
8 5- 9. S
11 5-12.5
60- 6.8
9.0-10 0
60-64
90-94
8.9- 9 S
8 5- 9 S
5.7- 63
77-81
33 12.0-12 6
65 -70 12 0-13.0
Spray
Towrr (bl
10-17
0 2-0.6
I 0-1.7
0.2-0.6
0 8- .2
0 8- .2
0.8- .2
0.8- .2
0 8- .2
0 8- .2
0.8- 2
0.8- 2
0 8- .2
08-2
08-2
08-2
0 8- .2
08-2
08-2
08-2
08-2
0 8- .2
0.8- .2
0. 1-0 3
0. 1-0 3
08-2
0.8- 2
0.1-0 3
0 1-0. 3
0 1-0.3
InU-t SO2
Concentration, ppm
2300-3300
2800-3300
2200-2700
2400-2800
2600-2800
2400-2800
2500-2900
2600-3000
2500-3000
2500-3000
2600-3100
2700-3100
2800-3200
2800-3200
2900-3100
2900-3100
3000-3200
2700-3200
2300-2900
2200-3000
2400-3000
2300-2500
2300-2500
2400-2600
2200-2800
2200-2800
2700-2800
2700-2900
2700-2900
2700-2900
2300-2500
P4 rci nl
SO2 Uimoval
81 16
37 i6
88 ?3
60 is
41 t6
35 -6
36 i6
49 !6
47 it
51 '-6
46 iS
53 i4
53 !5
54 i4
49 -4
46 i3
33 i2
34 is
24ll3»>
33 -'S <'»
28 is ("
39 i3
35 i2
44 i2
39 i2
29 -2
26 i2
31 t2
44 i2
44 ±2
\uirtbe r of
Spray Headers
Used (cl
4
(g|
4
(8)
I
H
I
ro
NOTE: Footnote definitions are on the following page
(continued)
-------
Table E-l (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: VENTURI/SPRAY TOWER SYSTEM
Dal*
Run
No
12/31. 1/2 453-IB
1/2-3
1/3-4
1/4-6
1/6
1/6-7
1/7 -8
1/8-9
1/9
1/12-13
1/14-15
1/23-26
1/26-27
1/27
1/27-28
1/28
1/28-29
1/29-30
l/)0
453-IC
454-IB
4 56-1 A
458-1A
459-IA
461-IA
462-IA
460-1 A
•160- IB
4 60- 1C
fat Flnu
Hii it . Aclnt
m 340 "F
14.900
14 900
14.900
14 900
10.000
14.900
10.000
29.900
29.900
1 2 . 000
1 1 . 600
Liq'ior Flow Rate gpm
V L nltiri Spray Tnui r
0(hl 460
•I63-1A1" 20.000
•165- 1A
466. 1A
4f,7-]A
468-1A
469-1A
470. 1A
47I-IA
29.900
30 000
20 200
19. 400
19.400
20 200
20.000
450
450
450
455
300
450
450
295
320
390
450
455
300
295
300
250
300
310
uc"
gal /mcf
38
37
37
37
57
25
56
19
12
34
42
2B
19
12
18
ZO
16
19
20
Stonhionio- Percent Solids
Inc Ratio Recirculated
le) 5-7
5.7
5-7
5-7
5.7
5-7
5-7
5.7
7-9
2-3
3-4
6-9
7-9
7-9
7-8
6.8
6-7
7-8
1 6-8
EHT Residence
Time, mil*
40
65-70
56
70
106
106
106
127
106
106
Pregsure Drop . in H^O
V< niuri
2.2-2 8
0 6-0 9
0 6-0 9
0 6-0 9
0 4-0 6
0 6-0 9
0 4-0 6
1 4-1 6
1 3-1 7
0 5-0 7
0 6-0 9
0 7-1 5
1.4-1 5
1 4-1 5
0 1-1 2
0 9-1 !
0 5.0.9
0 6-0 8
0 6.0.8
Towrr""
01-04
01-04
0 1-0 4
01-04
01-02
0. 1-0 4
01-02
1.0-1 7
1 4-1 6
01-03
0 1.0 2
0. 1-0 5
1 3-1 7
1.2.1 6
01-03
01-05
0 3-0 7
0 4-0 9
0 7-0 9
[nl,, SO-.
Cone, n,ra.,Un. ppn,
2700-3100
2800-3000
2800-3200
3000-3400
3100-3300
3000-3200
3100.3300
3200.3400
3000-3400
2800-3200
2800-3200
2800-1200
2500-2900
3000.3100
2800-2900
2900-3000
2600-1200
2900-3100
3100-3200
ljt r«-i nl
Sn^ II. niiii.il
53*3
50±2
52*3
48*3
6613
3«i2
70*2
4 Ot2
2SA2
46±3
6113
42Jb2
32*2
2612
30*2
33*2
35*2
3942
39*2
Number nl
Sprai llradi r~
L^d""1
4
312.3 41
212.41
211.41
213 41
w
I
Limeatone Fine ground (87% through ZOO meflhl except where noted
la) D< firn H .15 moli b CaCO^ addi d/nioli B SOg absorbed
(bi Total pressure drop arroba tower, excluding mist rliininatur
^pra> irtwi r nrti m ust.
-------
Table E-l (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: VENTURI/SPRAY TOWER SYSTEM
Date Run Hot Vcnturi Spray Tower Ventun
\o Gas Inlet Tower Outlet Inlet
9/u-9 401-IA 320-340 305-325 117-123 134-130 115-121
1/9-10 401- IB 320-340 305-325 115-120 122-128 115-117
9/21-25 -402-1 A 320-345 300-325 115-125 120-130 11-4-122
0/25-2., 402-113 325-350 310-325 121-124 129-134 118-120
10/2-3 401-IA 325-345 310-325 III. -124 (O 114-117
10/3-4 404-IA J-15-350 325-330 119-122
10/4-5 405- IA J30-350 320-330 U9-'25
10/i. -7 40..-] A J30-350 320-330 117-120
10/7-9 407. IA 130-345 31H-327 117-122
10/10-12 40H-IA 117-350 317-327 117-123
10/13-1., 409-1 A 530-340 320-330 118-125
10/17-20 410-IA 320-330 308-325 112-121
10/20-22 411-IA 320-340 310-325 110-121
10/22-23 412-1A 330-345 313-325 11S-I21
10/23 412-in 125-335 315-325 1K.-121
10/21-24 413-IA 321-135 309-322 114-121
10/25 414-IB 325-333 312-319 106-124
10/25-30 414-IA 325-340 310-3Z5 llu-122
11/8-12 4I5-1A 320-345 305-330 115-124
11/12-15 4I4-1D 305-330 300-315 1K.-124
11/15-1,, 414-1C 315-323 304-311 108-120
1 10-112
110-114
114-118
113-1 17
113-119
1 11-115
97-1 14
107-114
114-llt,
1 14-1 15
108-115
106-109
106-109
108-113
108-113
88-103
12/21-22 417-lA'f' 315 310 300-315 65-107 104-120 70- 96
12/23 417. in"1 305-317 295-308 94.113 76- 91
12/23-24 4I9-1A 305-325 295-315 102-113 110-123 87-100
12/24-25 421 -IA« '. Ijl
!2'25-2i, 414- IE" '-'n1
12/2.. 414-Ul"1 319-322 310-312 100-101 119-121 84- 86
12/2,, 414-IF"'- 115-325 302-312 103-IOu 122-129 81- 92
12/2.. 41*. lA1'1-1"'
12/2.. 4IB-1B'"'"11
12/27-28 4IK-IC1'1 210-325 275-315 <>0-IO(, I10-I2H 75-109
Vcnturi
Outlet
118-128
115-122
117-12o
123-126
120-123
122-124
117-125
121-125
120-127
120-126
121-124
116-125
120-123
121-126
122-124
120-126
120-128
120-125
120-129
120-126
117-126
111-122
107-121
114-120
111-112
114-117
108-116
EHT'"
Outlet
115-118
-
120-123
114-120
113-115
115-117
116-121
116-119
116-121
115-119
107-116
115-117
117-119
117-118
111-118
111-112
112-114
113-117
112-118
104-113
107-114
110-113
100-113
112-113
112-114
102-110
Ambient
sP™y Temp..
Tower op>
Outlet
118-124 65-84
(d) 60-80
116-125 61-80
(d) 70-80
54-74
65-67
57-78
54-79
45-75
50-75
58-65
38-50
40-56
61-70
60-70
47-54
46-48
46-60
48-58
46-62
15-39
33-36
32-35
32-42
32-33
30-34
29-49
Liquor pH ""
Ventun
Inlet
6.2-6 9
6 2-6 4
6 1-6 4
b 1-6 4
u 2-6.4
6 2-o 4
6.4-0 5
6 3-6 4
6 1-6.3
5 9-u 4
u O-o 3
l> 2-6 8
6.2-6 4
6 2-6 3
6 1-6 2
6. 1-b 3
6 5
6. 1-6 3
6 0-6.3
5.9-6 2
6 0-6 3
6 2-6 4
6. 1-6 4
6 1-6.4
6. 1-6 4
6 1-6 3
6. 3-o 4
6 3-6.4
6 2-6 4
6. l-o.3
b. O-o. 4
Ventun EHf'1'
Outlet Outlet'"'
6.0-6 5 61-69
6. 1-6.2 6.2-6 4
5 8-6 2 61-64
5.8-6.0 6.0-6 4
(el u 1 - 6 2
6.2-u 5
u. 1-6 2
o l-o 2
ii. l-o 2
u !-<• 3
i>. 0- o 1
u 0-6 1
6.0-6 2
o.O-o 1
0.0-6. 1
b 9-1.. 0
5 9-6.0
5 9-6 1
5.8-0 0
5.8-5 9
5 9-6.0
6. 1
6 2
3-6 5
.0-6 1
.1-0.2
.1-6.2
l-o 2
9-u 2
.1-6.2
. 2-b. b
Spray
Outlet
6 0-6 8
Idl
5 9-o 2
(d)
"•«'"• Clar.f,,r
Tank . ,.
n underflow
Out i 1
6 l-o U
(dl I. 4-... 7
...4-7 0
(d) i. 4-7. n
i> i.-i. 7
i. i.-l> 7
o 5
,, 4
., 0-. h
. 2-, =,
„ ,.-,. 9
D ., -0. K
o 7-i. K
6 8
o 8-7 1
6.6
u 4-0 K
o 3 -t. 5
.. O-o =1
u 0- u 1
o 8
.
_
o 5-t. i.
.
.
_
.
-
Pl.,l
-------
Table E-1 (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: VENTURI/SPRAY TOWER SYSTEM
Dale
12/31-1/2
l/Z-3
1/1-4
1/4.6
l'6
1/6.7
1/7.8
1/8-9
1(9
1/12-13
1/14-15
1/23-26
1/26-27
1/27
I/27-Z8
1/28
1/28-29
1/29-30
1/30
Run
Mo
453-lB
453-IC
454-1B
456-IA
458-1 A
459-IA
Hl-lA
462-lA
460-1 A
460-IB
460-IC
463-IA
465-1A
466-IA
467-1 A
468- IA
469- IA
470-IA
471-IA
Gas Temperature. °F
lli.l
Gns
295-318
305-120
307.322
293-120
270-101
298-110
296-101
310-120
305-122
298-109
298.319
300-118
306-328
317-128
304-124
295-119
307-326
306-318
108-316
Inli I
10Z-I20
108-120
110-115
108-120
103-113
107-120
106-118
11Z.I21
111-123
101-1 16
105-115
110.118
107-121
1 1 1 - 1 20
107-118
108-120
110-122
1 12-120
110-116
Tov. r
101-133
127.163
125-144
100-134
114-138
100-148
113-146
S2-I07
79-97
132-170
128-147
107-124
117.127
118-127
117-127
105-128
97-138
99-112
108-118
Ouil< l
107.113
109.118
105-114
107.114
92-102
104-112
90- 100
105.117
113-119
96-109
100-108
112-115
112-121
119-126
I17-U4
110-121
111-119
111-117
112-113
Liquor Temperature.
Inlt t Outlet
Digital output in error
(d) Spray lower not in use
(e) Unable la sample
(O pH s taken from in-line meter* Laboratory pH not taken
(g> Magnetic tape records not available
(h) Ventun not in uae
(it effluent hold tank
-------
Table E-2
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: TCA SYSTEM
Date
10/9-17
10/17-20
10/ZO-Z1
10/71-22
IO/23-Z4
10/25-26
10/27-28
10/28-29
10/29-31
10/31-11/1
11/1-3
11/25-12/6
12/20-21
12/21
12/21
12/22
12/22
12/22
12/22-1/9
1/9-10
1/10
1/10
1/10-11
1/11
1/11
1/11-12
1/12-15
Run
No.
401 -2A
402-2A
404-2A
405-2A
408-2A
409-2A
410-2A
411-ZA
412-ZA
413-2A
414-2A
WC-ZA
WC-4
WC-5
WC-6
WC-7
WC-8
WC-9
WC-5A
WC-4A
WC-6A
WC-7A
WC-8A
WC-9A
WC-10
WC-11
WC-12
Gas Flow
Rate, acfm
@ 310 °F
20.000
15.000
20.000
15. 100
15, 100
20. 100
15.000
15. 100
27,500
27,400
20,100
20.000
19.500
19.200
19.450
19.300
30.050
30.050
19,300
19.100
19. 100
19, ZOO
25. 150
25. 100
2S.OOO
19.400
19.300
Liquor Flow
Rate, gpm
1180
585
1Z20
1180
1180
1180
1180
1180
1170
1220
1200
800
1030
730
515
370
570
815
730
1070
510
375
460
680
980
745
375
L/C""
gal/mcf
74
49
76
97
97
73
98
97
53
55
75
50
65
48
33
24
23
34
47
70
34
24
23
34
49
48
24
Stoichio-
metnc
Ratio'4)
1.54-1.96
2.09-2.44
1. 56- .72
1.26- .62
.51- .88
.65- .80
.94- .32
.41- .45
.27- .34
.72- .86
.56- .81
(e)
Percent
Solids
Recirc.
7.2-8.4
7.5-9.3
8.4-9.2
Effluent Tank
Residence
Time. mm.
4.
9.
4.
6.9-8.8
7.0-8.8
7.8-10.7
6.8-8.4
6.9-8.4
6.6-9.5
8.4-9.2
7. 1-9.Z '
12. 5-15.5
13. 1-15.8
13. 5-14.0
14.2-14.4
14.2-14.4
14.2-14.4
14.2-14.4
12.7-15.3
(b)
13 3-14.9
6.
5.
7.
9.
13.
8.
6.
7.
5.
10.
14.
11.
8.
5.
7.
14.
6
Z
6
8
3
5
5
2
5
0
5
1
7
6
4
1
6
5
6
Ht. of Spheres
per Bed. in.
10
5
0
No. of Pressure
Grids Drop, (cl
in. H2O
6 8.2-9.8
4. 3-5.5
9. 1-9.9
7. 1-7.9
7.2-7.6
5. 9-6. 8
4.5-5. 1
4.4-5.0
13-15
12-15
6. 1-7.7
5 1.4-1.9
1.9-2. 1
1.4-1.6
1.2-1.3
1.0-1. 1
2. 1-2.4
2.5-3.1
1.3-3.0(d|
3. 7-4.0
2.7-3.1
Z. 6-2.8
5. 5-5.8
5. 7-6.6
6.4-6.8
4. 1-4.7
3.8-4.5
Inlet SO2
Cone. . ppm
Z600-3300
2850-3250
Z650-2950
2800-3150
2950-3200
2800-3150
Z550-2950
ZSOO-31SO
2850-3150
2400-2900
2800-3250
2300-3300
1850-2600
2450-2600
2300-2450
2200-2400
2400-Z450
Z400-2450
2150-3350
3200-3250
3100-3ZOO
3050-3150
2800-3050
2950-3050
2800-2950
Z850-3100
2750-3150
Porcent
Removal.
S02
92 ±3
80 ±3
93 t3
94 ±3
93 ±3
89 -3
87 t4
86 i3
96 ±3
96 13
90 ±3
62 ±6
78 ?4
66 ±2
60 -2
52 ±3
63 -1
72 *'«)
72 ±7(d)
87 tl
73 1Z
69 tl
77 2
85 1
90 1
85 1
71 -1
H
i
(Continued)
NOTE Footnote definitions are on the following page.
-------
Table E-2 (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: TCA SYSTEM
Date
1/24-25
1/25
1/26
1/26
1/26
1/27
1/27-28
1/28
1/28-29
1/29
1/29-30
1/31-2/1
2/1
2/1
2/1
2/1
2/1
2/1-2
2/2
2/2
Run
No.
415-2A
416-2A
417-2A
418-2A
419-2A
420-2A
421-2A
422- 2A
426-2A
423-2A
Gag Flow
Rate, acfm
@ 310 °F
15,250
20, 000
25,200
15,000
19,300
24,650
20, 050
20, 100
20,050
20, 200
424-2A 20,000
427-2A
in. H20
6 5.0-6.0
5.8-6.6
9.4-9.7
1.9-2.0
2.4-2.6
3. 5-3.7
4 6.3-7.0
6.2-7.0
6.2.6.9
5.9-6.8
6.4-7.0
5.8-6.0
2.8-3.2
7.0-7. 1
4. 3-4.4
5. 3-5.8
3.4-3.6
3.6-3.7
3.7-3.8
5.5-5.7
Inlet SO2
Cone. , ppm
2250-2750
1750-2200
1700-1850
2350-2600
2500-2900
2850-2950
2600-2850
2550-2800
2700-2850
2750-3350
2900-3550
2200-2500
2300.2450
2250-2450
2050-2300
1950-2100
2000-2050
1800-1900
1800-2450
2450-2500
Percent
Removal,
S02
95*2
95*1
96*1
84*1
82»1
80*2
93*2
93*2
93*2
95*2
96*1
92*5
69*2
94*2
69*3
94*1
71*1
91*1
89*2
88*1
w
I
-J
Scrubber Internals* 3 beds when spheres were used.
Limestone. Fine-ground (87% through 200 mesh).
(a) Defined as moles CaCC>3 added/mole SO2 absorbed.
(bl Nominal percent solids was 14% for these runs. Density meter readings were 10-12%. Three laboratory samples taken at 1600 hours on 1/9. 1/1 I and 1/12
gave 13.9, 7.7, and 20.2%, respectively.
(c) Pressure drop across the scrubber, excluding mist eliminator and Koch tray (when used).
(d) SO2 removal increased steadily from 64-67% to 75-79%, pressure drop increased from I. 3-1. 6 to 2. 6-3. 0 in. H2O, during the 19-day run.
(e) Stoichiometries for this period of timeare all in excess of 1. 5 moles CaCO^/mole SO? absorbed.
(0 Limestone was not added to the system dunngthe run. SO^ removal dropped steadily from 97 to 36%, and scrubber inlet liquor pH dropped steadily from 6. 2 to 5.
during the entire run.
(gk At scrubber outlet conditions.
-------
Table E-2 (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: TCA SYSTEM
Date
10/9-17
10/17-20
10/20-21
10/21-22
10/23-24
10/25-26
10/27-28
10/28-29
10/29-31
10/31-11/1
11/1-3
Il/2. Q- 7 n
t.. 7-7 1
7 1-7 2
t, 5-7. 1
o 3-u S
t/. 4-u 6
Ci.i.-o 8
o.9-7 2
5 5-6 7 (b)
6 3
(a)
M
CO
Fool noli fit finitions art- on following
(Cuntinued t
-------
Table E-2 (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: TCA SYSTEM
Date
1 /24-2S
1/25
1/26
1/26
1/26
1/27
1/27-28
1/28
1/28.29
1/29
1/29-30
1/31-2/1
2/1
2/1
2/1
2/1
2/1
2/1-2
2/2
2/2
Kvm
\'o
415-2A
416. 2A
417-2A
418-2A
4I9-2A
420-2A
42I-2A
422-2A
420-2A
423-2A
424-2A
427-2A""
428-2A
429-2A
430-2A
431-2A
432-2A
433-2A
434-2A
43S-2A
Gas Temperature. °F R(irf Liquor Temp . F Liquor pH
Hoi
Ga»
252-294
273-292
276-306
274-282
280-301
280-293
284-302
265-288
274-280
275-285
276-283
256-262
276-292
285-295
265-289
284-299
278-286
277-289
278-284
Si rubber Scrubber oe> Scrubber Scrubber •-. or- Scrubber Sc rubln r Clarifn r
r l emp , r
Inlol Outlet Inlet Outh l Inlet OulUt I'ndi rflnu
107-131 (c) 93-116 90-116 102.118 33.62 6.0-f. 2 -
119-130
121-129
120-130
120-129
122-130
122-129
117-135
1 19-128
1 2 1 - 1 30
1 2 1 - 1 30
118-120
120-127
122-254
120-274
122-285
220-269
252-271
232-255
109-116 107-113 111-118 45-52 61 -
110-117 101-114 113-119 45-48 6.0-6 1 60 7.9
110-120 108.117 110-118 44-46 5.9-6.3 - -
112-121 108-115 110-118 45 6 1-6.3 - -
113-121 108-117 114-120 44-45 6.0 5.9 6.8
111-118 111-117 114-119 44-48 6.2 60
110-124 91-113 112-125 32-45 6.1 62 75
95-114 78-92 101-110 26-32 5.8
97-117 84-102 103-120 26-33 6.2 62 72
107-118 98-107 111-121 25-30 6.1 61 71
5.9-6 2 5 8-6 2
111-113 109-112 112-114 47-57 6.1-6 3 5 9-6 0 -
112-117 112-115 114-118 58-64 6 2 6.0 -
116-124 115-117 117-123 65-66 6.2 5.9 -
112-115 112-116 113-116 60-66 6.1-62 5.8-5.9
112-118 111-115 112-118 51-60 5.9-6.1 58-5.9 -
109-112 109-111 111-112 48-50 5.9-6.0 5.8-6.0 -
110-118 108-115 111-119 46-48 6 0-6 2 60 -
115-118 114-116 118-120 I>1> 61-62 u O-i. 1 -
M
lal Unable to samplt
(b) Laboratory pll not available.
let Digital output m error.
(dl No maunotir tape rlala
-------
Table E-3
TEST RESULTS FROM LIMESTONE FACTORIAL. RUNS: MARBLE-BED SYSTEM
Date
8/21-28
7/9-10
9/23-26
9/28-29
9/30-10/1
10/1-3
10/3-6
10/6
10/10-12
10/13-17
10/17-20
10/20.21
10/21-22
10/22-23
10/23-24
10/24-25
10/25-27
10/27-28
10/29
10/30-31
10/31-11/1
11/1-2
11/5
11/8-9
Run
No.
40.-3A«"
401-3B(d)
402-3A
403-3A
404- 3A
405- 3A
406- 1 A
407- 3 A
408- 3A
409-3A
410-3A
41I-3A
412-3A
413-3A
414-3A
4I5-3A
4I6-3A
4I8-3A
419-3A
417-3A
420- 3 A
421-3A
422- 3A
425- 3A
Gas How
Kali, acfm
(f 3300F
20. 000
20. 000
20. 000
20. 000
20. 000
20. 000
20. 000
20. 000
20. 000
20, 000
20. 000
20. 000
20, 000
20. 000
20. 000
19. 900
20. 000
30. 000
29. 900
30.000
20. 000
20, 000
20. 000
30, 000
Liquor Flow Rate, spm L/C
Top Sprays
200
200
205
200
205
200
Z05
205
200
205
200
200
200
205
200
200
195
205
210
205
205
200
205
205
gal/
Bottom Sprays
,. Sloiehiome-
mcf trie Ralio'al
410 38 2. |;.3 20
395 37 1 90-2 85
405 38 2 10-2 80
605 50 1 75-2.05
200 25 4.30-4.85
200 25 3. 30-3 85
600 SO 1 75-2 15
605 50
1 55-1.95
600 SO 2 15-2 65
205 25 4.15-5 85
605 50 2 05-2. 50
200 25 5 30-5 80
200 25 3 10-4 15
605 50 2 00-2 35
605 *0 2 45-2.90
600 50 2.20-2.40
205 25
205 17
210 IB
4 45-5. 30
7 30-7.70
4 30-4 80
605 34 1 60.1.85
6OO 50 1 7S-2 05
200 25
5.00-5 30
605 SO 1.55-1.65
605 J4
2 (.0-2.90
Percent
Solids
Recirculated
5-9
4-12
6-10
5-7
5-7
5-7
5-7
5-7
S-7
5-7
5-7
4-6
5-7
5-7
5-7
5-7
5-7
5-7
4-6
5.7
5-7
5-7
11-13
10-12
(Kl
EHT
Residence
Tune, mm.
50
Marble
Height,
in.
5
Weir Pressure
Height'"' Drop. in. HzOlc)
in.
3 8.0-10.0
6. 6- •». 6
6.5- 8.5
8.8-10.8
8.2-10.2
8.4-10.4
11.5-13.5
13.0-15.0
10.7-11.7
8. 2- 9.2
9. 5-10.5
8.8- 9.8
9.4-10.4
10.2-11. 2
10. 3.11. 3
10. 1-11. 1
8. 7- 9. 7
8.8- 9.8
8.8. 9.8
12. 7-13.9
9.8-11.0
8. 5- 9.5
9.0-10.0
10.0-12.0
Lnlet SO2
Cone . ppni
1800-2700
2100-2300
1700-2300
2500-3100
2500.2800
2200-2900
2300-2800
2500-2900
2500-3000
2400-2900
3200-2500
3000-3200
3000-3200
3000-3200
3100-3500
3000-3400
2800-3200
3000-3200
3100-3300
3100-3300
2900-3300
2900-3100
3300-3600
3000-3400
i'c n. nl
*iO;i Hi ivntal
5e • 7
63 i i
59 ,5
79,4
37 t 6
35 .6
77 ,6
75 > 6
75 .5
10 i 5
69 .3
32 • 5
35 ,5
58 .3
65 .5
65 t3
36 t 5
24 .5
28 ,4
73 ±3
79 |3
34 ,4
75 .3
ob • 5
M
I
Nttio Footnote definitions arc on following pagr.
(continued)
-------
Table E-3 (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: MARBLE-BED SYSTEM
Dale
11/11
11/12-16
11/28
12/1-6
12/20. Z6
12/26-1/3
l/J-4
1/5-6
1/6-7
1/7-8
1/8-9
1/9-16
1/20-22
1/31-2/1
2/1
Run
No.
426-3A
427-3A
426-3B
427-3C
427-38
428-3A
429-3A
Gas Flow
Rate, acfm
& 330°F
20.000
20. 000
20.000
20.000
20.000
20.000
20. 000
431 -3A(" 20,000
433-3A
438-3A
439-3A
440-3A
425-3B
441-3A
442-3A
20,000
19.900
12.600
12,500
30, 000
20, 000
20, 000
Liquor Flow Rate, gpm
Top
Sprays
200
205
200
200
200
200
0
0
0
0
0
0
200
200
0
Bottom
Sprays
600
60S
610
600
60S
610
605
60S
20S
400
40S
600
600
605
605
L/C""
gol/mcf
50
50
50
50
50
50
37
37
13
25
40
60
25
37
37
Stoichiome- Percent
trie Ratio'*' Sohds
Recirculated
1.85-2.00 5-7
1.40-1.90 5-7
(e) 5-7
5-7
5-7
5-7
5-7
5-7
5-7
5-7
5-7
6-8
10-14
9-11
7-9
EHT Marble Weir Pressure
Residence Height, Height"1' Drop, in HjO
Time, mm in. in.
50 5 3 9.4-11.4
3
100
50
11.0-13.0
8.9-10.9
11.9-12.7
10. 3-12. 3
11.0-12.0
9. 1-9.9
4.6-9. 1
5.5-6.7
6.8-7.2
6.0-6.8
6 6.6-7.0
i8. 1-8.5
6.9-7 1
' 6.8-7.2
Inlet SO2
Cone. . ppm
2600-3100
2500-2900
2800-3200
2800-3400
2200-2800
2500-3100
2600-2800
3000-3300
3000-3400
3300-3500
3300-3500
2900-3300
2900-3100
2600-2900
2600-2800
Prrcenl i
SO2 Removal
8114
79±5
82*3
78*4
80*2
78±4
63±2
48-73 "'
20±3
34*2
49*2
6 O*4
u7±2
73*2
69*2
w
I
Limestone Fine ground (87% through 200 mesh), except where noted
(a) Defined as moles CaCO. added/mole SO 7 absorbed.
(b) Weir height is measured from top of marbles
re) Total pressure drop across scrubber, excluding mist eliminator
(d) Limestone coarse ground (69% through 200 mesh)
(e) Stoichiomctnea for this period of time arc all in excess of 2 0 moles CaCOj/mole
ff) Unstable operation of marble bed
[R| At scrubber outlet conditions
(h) Effluent hold tank
absorbed because of limestone slurry addition problems.
-------
Table E-3 (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: MARBLE-BED SYSTEM
Date
8/21-28
9/7-10
9/23-26
9/28-29
9/30-10/1
10/1-3
10/3-6
IO/fc-8
10 '10- 12
10/13-17
10 17-20
10/20-21
10/21-22
10/22-23
10/23-24
10/24-25
10/25-27
10/27.28
10/29
10/30-31
10/3I-1I/
11/1-2
11/5
11/8-9
Run
No
401-3A1"1
401-3B)
Scrubber Trmp .
Outlet °F
124-
120-
123-
118-
120-
125-
(b
29 119-126
30 121-125
30 122-128
26 110-140
28 110-122
32 Uo-122
) 116-122
118-123
118-130
116-121
93-123
115-120
118-121
122-130
122-127
111-123
115-124
121-125
119-124
110-140
120-128
112-123
97-124
115-124
Liquor Ten
Top
Sprays
120-125
115-125
120-124
115-122
108-111
109-114
117-120
116-119
115-121
110-116
97-114
108-111
113-115
116-118
112-116
106-113
107-112
111-113
111-115
110-115
115-118
109-115
99-115
106-113
Bottom
Sprays
116-122
112-120
115-121
112-120
102-106
102-109
115-119
115-118
110-120
105-110
108-114
100-105
104-109
111-115
111-114
'08-113
99-104
100-104
103-110
110-115
114-117
101-107
108-115
99-114
nperature.
Weir
Outlet
119-122
118-122
120-124
118-122
114-118
111-118
115-122
116-122
114-125
116-122
115-121
113-120
117-120
116-120
115-119
113-119
114-120
116-122
117-121
110-120
116-121
114-119
113-119
115-120
°F
Down-
comer
119-125
120-128
120-127
120-125
114-118
113-119
120-126
121-125
116-127
115-120
117-126
111-120
116-120
117-125
121-123
118-125
113-119
116-125
118-123
115-122
115-125
113-117
117-122
120-126
Temp .
°F
65-87
60-87
67-77
48-85
44-61
53-77
57-80
53-80
60-75
58-76
38-50
46-56
57-67
59-65
47-56
46-51
37-59
53-59
52-59
54-61
63-73
52-81
40-61
43-56
Liquor pH 'c*
Top
Sprays
6 0-6.3
5 8-6 9
6.0-6.2
5 9-6 2
5 8-6. 1
7-6.3
1-6 2
. 1-6.4
.0-6 1
.0-6. 1
1-6 2
0-6.1
.9-6.1
6 1-6 2
6 0-6 3
Bottom
Sprays
6.1-6 5
6. 1-7 0
5.9-6 5
5 8-6 1
5 8-6 3
6 7
6. 1-6 2
6 2-6.3
61-62
6. 1-6 3
61-62
6 2-6 3
Weir
Outlet
5 6-5 8
5 4-5 6
5 6-5 8
5 2-5 9
5 4-5 5
5 6-5 7
5 5-5 7
5.6-6.2
5 4
5 4-6 2
Down-
comer
5 5-6 2
5 7-6.4
5 7-5 8
5 4-6 2
6 0
5 7-5
5 7-5.
S.5-1..
5 4
5 6-6 1
Clarifier
Underflow
6 5-6 6
5 9-6 4
6 1-6 7
6 1-6 8
6 1-6.5
6.4-6 8
6 3-6 5
6 4-6 8
6 3-6.6
6 3-6 4
6 3-0.5
Turbulent
Layer
Hmghl. in
6-8
3-0
7-11
11-17
3-5
10-13
12-15
11-17
3-5
1-3
2-3
11-13
7-9
5-9
2-3
2-5
3-5
19-21
8-9
10-15
M
Note Footnote dclinitions on following pap«
(continued)
-------
Table E-3 (continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: MARBLE-BED SYSTEM
Date
11/11
11/12-16
11/28
12/1-6
12/20-26
12/26-1/3
1/1-4
1/5-6
1/6-7
1/7-8
1/3-9
1/9-16
1/20-22
1/31-2/1
2/1
Run
426-3A
427-3A
426. 3B
427-3C
427-3B
428- 3A
429-3A
43I-3A
433. 3A
438-3A
439-3A
425-3B
441-3A
442-3A
Gas Temperature F
Hot
Gas
310-320
295-320
314-317
310-325
290-300
290-315
305-320
292-316
299-314
295-313
285-303
305-320
302-320
314-335
Scrubber Scrubber
Inlet Outlet
(1
)) (b)
1
1
115-120
112-118
116-122
110-121
114-122
115-124
110-118
113-128
118-123
119-124
Bed
Temp .
Op
118-121
122-135
94-107
116-128
118-125
105-113
112-119
115-152
114-139
113-12!
104-113
118-129
113-120
118-126
Liquor Temperature.
Top
Sprays
76-111
111-118
92-99
115-118
100-110
102-108
—
_
-
_
-
90-117
95-112
~
Bottom
Sprays
74-110
112-118
93-106
113-120
105-112
101-108
107-111
71-91
66-77
71-85
71-95
97-116
107-114
110-114
Weir
Outlet
72-114
115-120
112-128
118-120
113-117
108-111
110-118
104-118
89-114
106-118
106-112
108-121
112-118
112-128
°F
Down-
comer
110-120
121-126
111-122
115-120
115-125
115-119
119-123
93-105
92-103
35-104
77-93
117-127
115-122
116-122
Temp .
op
48-49
44-61
37-40
40-60
32-42
35-50
41-45
21-27
26-29
25-29
20-26
35-53
46-65
50-66
Liquor pH <= 1
Top
Sprays
60-62
—
—
-
—
-
5 9-6 2(a
6 1-6 2(a
~
Bottom
Sprays
61-62
6 2-6 3<"
6 2
6 5
6 1
6 3
1 6 0-6.2
'61-6 *<•
6 2-6 j'»
Wnr
Outlet
5 8-6 0
—
5.8
-
—
-
-
Down- Clam
comer Under!
59 63-6
58 6.9-7
56-61 6 2-6
— —
- 7 1
72
73
7 J
— —
~
Tprhulpnt
Layer
" Height in
low
7 9-18
0 10-11
4 9-11
3--I
0-3
2-0
2-5
0-5
11-22
6-10
9-16
M
I
(a) pH'B taken from in*lme meters.
(b) Digital output in error
(c) Single value• indicate only one pH reading taken
-------
Table E-4
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: SPRAY TOWER
Date
9/1J-14
9/14
9/14
9/14
9/14
9/14-15
9/IS
9/15
9/15
9/15
9/15-16
9/16
9/16
Run
No.
523-1A
520-1A
524-1A
526-1A
5ZI-1A
5Z7-1A
5ZZ-1A
5Z5-1A
5ZB-1A
5Z9-1A
530-1A
S3I-1A
53Z-1A
Gaa
Flow Rate.
acfm@ 330 F
30,000
30, 000
25, 100
IT, 500
Z9, 900
17, 500
30, 000
25, 000
IT, 400
Z9, 900
25, 000
30, 000
29, 900
Liquor
FlowRate.f'1
gpm
910
1195
1210
1195
905
905
600
600
600
1185
690
690
585
L/G.«"
gal/mcf
3T
50
60
85
37
64
Z5
30
4}
50
45
17
24
Stoich. Ratio,
molea Ca added/
mole SO2 aba.
Z. 4
1.9
2.0
Z. 1
2. 1
1.9
Z. 1
2.4
Z. 0
Z. 0
1.8
Z. 4
Z. 3
Percent Solids
Recirculated
12. Z
12.4
12. 5
12.0
11.6
11.1
11. Z
11.5
11.4
11.2
10.5
10.T
11.1
EHT Residence
Time.
nun.
27
20
18
18
24
24
35
35
35
18
24
24
35
Pretture
Drop.<»>
in. H2O
3.6
4.0
3.1
1.7
3.2
1.5
3.3
Z.o
l.Z
4.0
2.5
3.8
3. 1
Inlet SO2
Concentration.
ppm
3100-3300
2900-3300
3200-3300
3000-3200
3000-3100
3000-3200
3200-3500
3200-3500
Z900-3000
2900-3300
3300-3400
3200-3300
3200-3500
S02
Removal.
%
51 1
68 2
68
74
50
66
43
45
52
63
54
56
41
No. Spray
Headers Used'
4
4
4
4
3 (1.3.4)
3 (1. 3.4)
Z '3.4)
2 (3.4)
Z (3.4)
4
3 (1.3.4)
3 (1.3.4)
2 (3,4)
M
I
Note Footnote definitions are on the foil owing page
-------
Table E-4 (Continued)
TEST RESULTS FROM LIMESTONE FACTORIAL RUNS: SPRAY TOWER
Date
9/13-14
9/14
9/14
9/14
9/14
9/14-15
9/15
9/15
9/15
9/15
9/15-16
9/16
9/16
Run
No.
S23-1A
520-1A
524 -1A
526-1A
521-1A
527-1A
522 -1A
S25-1A
528-1A
529-1A
530-1A
S31-1A
532 -1A
Gas Temperature, °F
Hot
Gas
337-342
327-345
328-335
325-335
336-345
314-342
318-337
326-337
327-334
340-351
330-339
322-328
329-344
Venturi
Inlet
128-131
124-135
129-132
125-132
127-132
123-131
126-132
125-132
121-123
124-132
126-128
124-130
126-130
Spray
Tower
127-131
125-132
127-131
126-131
1Z7-132
124-129
124-130
126-132
125-128
126-132
124-126
124-127
126-128
Liquor Temperature, °F
Tower
Inlet
124-126
I
Tower
Outlet
126-129
Ambient
Temp. , °F
68-70
68-70
69-71
69-74
69-74
65-68
62-64
64-80
81-83
69-82
63-69
58-62
64-89
Liquor pH
EHTfe)
Outlet
5.9
6.0
6.0-6. 1
6.1
5.8
5.9
5.9-6.0
6.0-6. 1
5.9-6.0
5.8
5.8
5.9
5.8
Tower
Outlet
5.3-5.5
5.5-5.6
5.6
5.6-5.8
5.2
5.2-5.5
5.2
5.2
5.2-5.3
5.1-5.2
5.2-5.3
5. 1-5.2
5.0-5. 1
(a) 10 gpm of water was used in venturi saturation sprays. No slurry flow to venturi (venturi plug 100% open).
(b) Pressure drop across the 3pray tower, excluding mist eliminator.
(c) Numbers in parentheses refer to header positions, counting from bottommost header.
-------
Appendix F
SELECTED GRAPHICAL OPERATING DATA FROM LIMESTONE
RELIABILITY VERIFICATION TESTS
F-l
-------
GJ. flu.' 30.00(1 «lni I- 330 "I
Inuui Hiirtn Viiiiiin 600 inn
LiqiKH R»ttlnSpuy Town I.POO
Vtnluli L/C 27y*linil
Spny Tuwti KG bJjilm'l
SfHly Tin>« Gil Vjlueily ' '> M u
Vtnlini Preiam Unit 9 in HjO
E.M.T Rllidcra him 12 mm
No ofSpnyHudm 4
Gas Inlet SO; Com 2.bOO 3.200 n»n
12.000 2.200 pi-m duiim J/28 .i.cl ) 211
ScrubUi Intel Liqtwi Timp IK 131 "t
Louid Conductivity 3.SOO 21.MO u ml .n in.
Doch.10. ICIiiilici t Ctnl'itugtl Snliih
Clint S7tbwl\
Nott: Al ill July 27. • linwilunt conliit inf
»pp(0««™IHv 1 l;4mole% Mfl COj htibcen
um) at Ittf led Nciltly PIUI to ihu time • hmcfluii
hi>in« Kciininuicly b T.ok % M( CU3 I.M bnn u«
CMENDAI 0*V
TOTAl OliSEXVlD SCXIOi ^ MAG'-JtSIUM (Mg " I
CAICIUM >Ca " I A iOOWM (Ma ' I
lUlf*U (SO4 I ^ KMASSHJM >f ' I
CHlO«1DE (CI - I • SUlFlU fSOj 1
O CMIONATI (CO I
t.tm
6.000
,003
«
Figure F-l
OPERATING DATA FOR
VENTURI/SPRAY TOWER
RUN 506-1A
F-2
-------
h
89 '
- VfNIUtl L SHAV 1OWII INUI IIN-LINI Mini)
*/i I 1/6
TEST IIM(. t»m
I/I I l/» I I 10
CAlENOAI DAY
B/ll I 1/17
Git Rit. • 30.000 ictm * 330 °F
Liquor Rite to Vtnturi : 600 gprn
Liquor Rtli to Sprty Toww • 1.200 gpni
VmtuiiL/G*27gd/mcl
SpriyTomr L/G - S3f.il/md
Spray TOWH Cu Velocity - 7 b ft/»c
V*niun Priuurt Drop - 9 in H20
E.H.T. llitKMnnTrrnf 12 mm
No. of Sony Hudni • 4
Gil Inlil SO; Cone. • 2.600 3.300 ppm
Saubbtf InUrt lnuor Tlmp. • 128 132 °F
Liquid Conductivity = 22.000-27.000 A mhoi/cm
Dachiroi ICIirrfiir i Cinttilugil Solid!
Cone -5565 wl\
s'i
III
I >.
*
A
0
D
*
0
G
A
4>
A
7
O
A
0
0
TOTAi DlSSOtVlD SOtlOi
CALCIUM (Co " )
SUl»ATf (SO
CHIORICt (tl " 1
**»OM(S"JM
CAI10MAlf3[C03 1
]«) IK)
TEST TIME, torn
Figure F-l (Continued)
OPERATING DATA FOR
VENTURI/SPRAY TOWER
RUN 50A-1A
F-3
-------
KGlNHjN 110-?*
I 6.78 I t/7* I 4/30
100 120 140 1»
TEST TINK.tWi
7/S I 7/1 I
CAUNOAI DAY
no wo
7/4 t 7/7
GuRltt'2VOOOlclm»>300uf
Liquor Rite- 1.200Bpn<
L;G - M oii/md
Gil Velocity - S 8 H/*t
E.H.T. fletidence Time - 20 mm
Three Stigei. 5 in spheies/stigp
Git Inlet SOj Cone. - 2.000-2,700 ppm
Scrubber Inlet Liquor Temp ' 121 127 "F
Lrquri Conductiv.ly • 11,00020.000 II inhoi/tm
DiKhlnH ICIiriliirl Solids Cone 26 U «i %
O 6-000
• TOTAL DISSOLVED SOLIDS A CHLOSIDt iCl ' >
D SULFATf (SO4 ; I tl iOOIUM {No ' 1
7 POIAS&HJM .« • .
O CAMONAlf (CO-
VOOO
?,OOP
1.1 -
.'II' -
RQ '00
HIT IlMt. houn
7'J I
CALENOAK DAY
Figure F-2
OPERATING DATA FOR TCA
RUN 510-2A
F-4
-------
-- lOUi, OCIUDIN& Ofwinit t «OCM
- - ofousrtt 4 KOCH nuv
- INIIt IN [IN! Mltfll
- OUtUt IIAII
WO MO MO J«
ClllRllr A IKIII (, li. 300")
l.|...' H.,|. •Jllll,,,,.,
I'l. Mg«l,mil
G« Vfliiiitv 9811/vi
[ HI R™A.,,I, !,„» rein...
Tfii^St^-i b Misphi-rri/niv
Gnln!HSO,Cu..[ 2700? 600 ppm
Sciubhn Inhl liquni Temp 1J] 1?) "I
LquKl C>n«lurl»ily 11.000 32.400 u mh,ii/,n,
Dilcl>ir«r{ClmlKrlSoMiCi>ni 36 38 «t "
sii -
O? "1
m-
ili:
!i"
^— CAICIU* IC^DI
/ * TOi»i iui'm fK)j)
I )./» I
«X) 4JC
US! lIMl, teun
V1J 1 7
OlfNDAI OAv
r
I7.0M
lO.OOO
I.OB
"
?K) no
MO MD
•40 4«0
CAttNDAI OUT
Figure F-? (Continued!
OPERATING DATA FOR TCA
RUN 510-2A
F-5
-------
l""#
n
I ° K
'1
o'j;, ^
13 •
W •
2 £
« J
M
fc
^ i •••
TOIAl, EKCIUDtNG OtMlilf*
- INIEI (tN-UNf MCTBI)
HSTTIMt,
«/i; i t/H
CALfNDAR DAY
G«R»I» ?O.OUO«tm»'33ll"l
Liquor flali H00g|im linutl
L/C 53gil/M,c:l
G» Velocity S.lll/sei
f H T. Rnrtnicr 1 mn 30 mm
Mvbh Bed Hnighi V, ,r,
Sl!lnlrlS02 Cum ?,300 3,100 ppm
Scrublwr Intel l«)iiiii Imip 12? 129 "F
Liouid CDnduntviry 23,00032.000 u. mhlij/tm
Discharge (Ccmrilugrl Snlidi Cone EO 66 XI •-
Hi '
„
y
CAICNJM (CaOl
//
rri' TIM; ham
ft/It I 6/17 I 6/le
CALENDAR OAV
//
70 000
IB. 000
14,000
I""
1' U,000
10 000
5
9 8-°°°
E 4.000
J
- «.ooo
8
5 ?,oon
" 0
• TOTAL DISSOLVED SOl'DS A CHIOKIW (Cl ' ) y fOTAJSWM (K 4 ) • SUIHTI ISO,, )
- O C»LCIUM (C« ** \ + MAONfSUM (Mg ** 1 0 CAMONAIt (CQj )
D MJLfATE fiO \ A SODHJM (No * 1 •
-
• •
'
-
1- *
* *
O
0 0
n
8
w.ooo
!B,000
>6,000
14,000
12,000
10,000
8,000
4.000
2,000
D
-if-a
//
100 230
iOC no
6/li 1 6/14
Figure F-3
OPERATING DATA FOR
MARBLE-BED
RUN 506-3A & 38
F-6
-------
Ipl*l [XCLUOlNC DfMliTCI
\J
8 = '
3;
Bi •
Si?
. --o -o --- <
ci n a n
TO oa
11.000
tA I.'.
K.OOO
t?,000
10.000
- .Ttit:
4.000
4 rr.
.' W
0
£ wo
S
140 UO MO 400
tK MC S30 MO UO «0
4"74 I fc^J | i/7* I 47'
Figure F-3 (Continued)
OPERATING DATA FOR
MARBLE-BED
RUN 506-3A & 3B
F-7
-------
Appendix G
BECHTEL MODIFIED
RADIAN EQUILIBRIUM COMPUTER PROGRAM
G-l
-------
INTRODUCTION
The Bechtel Modified Radian Equilibrium Computer Program takes
as input the measured composition (g-mole/liter or ppm) and pH
(optional) of an aqueous liquor or slurry containing dissolved Ca, Mg,
Na, K, SO3, SO4, CO3, and Cl species. The partial pressures of
CO7 and SO? in equilibrium with the liquid may be input instead of the
concentrations of carbonate and sulfite species.
The program determines:
• Presence or absence of solid species (CaCO.j» CaSO,,
CaS04, Ca(OH)2, MgCO3, Mg(OH)2)
• Concentrations and activities of individual dissolved
ionic and molecular species
• Liquid pH (if unspecified)
• Ionic imbalance of dissolved species (if pH is specified)
• Equilibrium partial pressures of CC2 and SO_ gases
above the liquid (if unspecified)
• Degree of CaSO^ 21^0 saturation of liquid
For the program, the following sections of this appendix present:
• SUBPROGRAM DESCRIPTIONS
Includes file type and function for each subprogram
G-2
-------
• PROGRAM INPUTS
Shows the order of input data in data file
• TERMINAL RECORD
Gives example test cases showing the creation of
input data file and equilibrium program output
• PROGRAM LISTINGS
G-3
-------
SUBPROGRAM DESCRIPTIONS
Filename
BEQCALL
BEQ
BEQCON
BEQSOX
BEQPRINT
BEQ
BEQ
Filetype
FORTRAN IV (G)
FORTRAN IV {G)
FORTRAN IV (G)
FORTRAN IV (G)
FORTRAN IV (G)
EXEC
DATA
Function
*
CSS main program FORTRAN
file reads input data and calls
BEQ.
Modified Radian program;
determines aqueous solution
equilibria for the slurry system
Ca, Mg, Na, K, SO2, SO3>
CO2, Cl.
Calculates equilibrium constants
in BEQ.
Handles special cases of 803
and SO ^ solids not covered by
BEQ.
Prints output from BEQ.
*
CSS executive program for
operating BEQ.
Input data file for BEQ.
These files have been written for use only on the National CSS, Inc. ,
time-sharing system.
G-4
-------
PROGRAM INPUTS
Data is input to the modified Radian equilibrium computer program (BEQ
FORTRAN) through a BEQ DATA file. The format for this file is:
Line 1: Identification statement (up to 80 alphanumeric characters)
Line 2: JPRINT, JCONC, JS, TK, ppSO2, ppCO2, SSO3, SSO4, IPH, PH
Line 3: Ca, Mg, Na, K, SO3, SO4, CO3> Cl
Where:
JPRINT
JCONC
JS
TK
ppS02
ppC02
SSO3
SSO4
IPH
PH
Ca
Mg
Na
K
SO3
SO4
C03
Cl
Print flag = 1 or 2
Concentration flag = 1 or 2
Solids flag = 0 or 1
Liquor temperature, °K
Partial pressure SO2, atm
Partial pressure CO2, atm
Relative sulfite saturation
Relative sulfate saturation
pH flag = 0 or 1
Liquor pH
total amount of component (solid plus liquid)
in slurry, gmole/liter liquid or ppm
JPRINT - Print Flag
JPRINT
1 Use for long-form printout
2 Use for short-form printout
G-5
-------
JCONC - Concentration Flag
JCONC = 1 Concentrations are input in ppm
= 2 Concentrations are input in gmole/liter liquid
JS - Solids flag
JS =0 Use when no solids are present (i. e. , program assumes
all input species are in liquid]. This permits program
to predict the sulfate saturation of the liquor.
= 1 Use when there is the possibility of solids being pre-
sent. When JS = 1, the partial pressure of CO_,
ppCOo- must be specified rather than the total CO,
in the slurry.
ppSO-, ppCO, - Partial Pressure
Set pp SO, = 0 if SO, in slurry is specified. Set ppCO, = 0 if CO , in
slurry is specified. When JS = 1, ppCO-, must be specified rather
than COy When JS = 0, either ppCO2 or CO3 can be specified.
SSQ3, SSO4 - Relative Saturation
Set SSO., = 1 and SSO. = I (100% saturation) for normal Radian equili-
brium. Use of other values permits the program to predict up to the
specified degree of SOj or SO saturation before formation of solids
(e.g. , a value of SSO =1.4 allows for a SO. saturation of 140%).
The JS = 0 flag overrides the specified values of SSO and SSO ..
IPH, PH - Liquor pH
IPH =0 pH is not specified
= 1 pH is specified
PH = Specified liquor pH
If the pH is specified (e.g.: the measured pH of a liquor sample), the
ionic balance equation is discarded from the program, and the ionic
imbalance is printed out. For limestone and lime wet scrubbing liquids
it is generally better to input the pH when it is known.
G-6
-------
and COi Concentrations
Set 803 = 0 if ppSO2 is specified. Set CO3 = 0 if ppCO2 is specified.
When JS = 1, ppCOz must be specified rather than 003.
G-7
-------
TERMINAL RECORD
CREATION OF INPUT DATA FILE
AND EQUILIBRIUM PROGRAM OUTPUT
IBM 2741 Terminal
Input in Lower Case
Terminal Response in Upper Case
G-8
-------
^— CREATE INPUT DATA FILE
17.iJ2.23 oli t jjtq data
HEN FILE.
•MPUT:
ramp it point 2316 4 12 74 at Q80u
1 . 1 , iJ , 323, iJ , Li, ' . 1 , l.s-5
1:312. 333, 51, 118, 72, 1806. 353, 2SU1
sample point 2S16 4 12'.'4 at 0800
-2. 2. 0, 325, 0, 0, 1 , 1 , 1 . 5.75
0 . 0 4-521 , U. U « 370 . U. 0 0 222 , 0 . U 0 30 2 , 0. U U U *0 , U. 111 881" , 0 .0 U 597 , U. n 79"" I
.-amp Li poin* 2816 4 12 74 at IJ800
1 , i . 1 , 323, U, U.2151, 1 , 1 . U
1312, 333, 51, 118, 72, 1306. 0, 28u1
EDIT:
filt
17.1.18.18 print
^ PRINT FILE
Case
Case
Case
i
1 •
2 •
3
SfiMPLE PQIHT
' • I . ii. i23
•.'HI2, 333, 'i
SflMPLF. K»!HT
2 , 2 , U . J2 3
.1.1.1.1452' . U. U
'SflHPLE POIHT
1 , I , I . 523
t.'8<2, 333. 'J
17.d8.43 b£
EXECUTION:
28 'b 4 '.L1
, U . U , ! , ' .
! , il:3, 72, 10
28 1 6 41 2
, ii , u , i , 1 ,
! 370 , IJ.UU222,
28 '6 4 >2
, .2151 , 1
1 , \\\t, 72, 11=
•I
7't HT i'8uu
1 , 'i.75
U io , 358 , 28u '
74 rtT u8uO
I , 5.75"
U . U U 30 2 , U . U U 0 90 , U - U ' 880 , 0 . U 0 597 , U . U 7-:»U 1
74 flT 0300
, I . n
iih, M , 2801
< — EXECUTE PROGRAM
NOTE:
Case 1
Case 2
Case 3
LONG-FORM PRINTOUT
NO SOLIDS (JS = 0)
SHORT-FORM PRINTOUT
OF CASE 1
LONG-FORM PRINTOUT
SOLIDS (JS = 1)
G-9
-------
Case 1
SAMPLE POINT 2ai<>
INPUT DATA!
Kl JS
1 0
TK PPS02
323.0 0.0
AT OHDO
HF.CHTFL MOOIFIFD RADIAN
PPCd?
0.0
SS03
1.000
1.000
H PH
1 S.750
CONCENTRATIONSt OMOL/LITkB AND
CA *G NA K S03 SO* CO") n
0.0*531 0.01370 0.002?? 0.00302 n.0n090 n.nlflRO O.OOS97 0.079'U
1812. 333. SI. 118. 72. Ifl06. 3S«.
CALCULATED RESULTS!
COMPONFNT
M*
OH-
H2C03
HC03-
C03—
H?S03
HS03-
S03—
HS04-
SO*—
CA»*
CAOH*
CAHC03*
CAC03
CAS03
CASO*
MG + 4
MGOH*
MGHC03*
MGC03
M6S03
M6S04
CONCENTH4TION
0.4101L-U7
0.1593F-0?
0.806&t-07
0.4993E-03
0.3037E-04
0.1088F-OS
0.9U5E-02
0.3734t-0l
0.133t»-07
0.399bE-03
0.337^-03
0.713(JF-0?
O.lllnE-01
0.737bE-07
NAOH
NAHC03
NAC03-
NAS04-
CL-
0.3167E-04
0.245ZF-02
0.516JE-0?
0.3UHF-ln
0.2494E-OS
0.5150E-OH
0.7901F-D1
PH
•i.750
PPS02 = 0.lE)40F-Ob
PERCENT EHPOR i* IONIC H&LANCE = .s
PEWCENT SULFATE SATURATION = 117.7
TOTAL DISSOLVED SOLTYS
ANALYSIS OF SLURHYl
71S1. PPM
ACTIVITY COFFFTClE-r
O.H2?7
0.7336
0.?A96
1.H2H7
0.7336
O.PB96
0.7450
0.1137
0.74SO
l.n?87
1.0287
0.-JOH1
0.7450
l.n?87
1 .0287
0.
1.P297
1.0287
0.7450
fl.74Sf>
0.7237
fPCU?
CA
HG
NA
K
S03
S04
C03
CL
1 IUUID
GMOL/LITFH
0.4621F.-01
0.1370E-01
0.221HF-0?
0.3011E-02
0.8993E-03
0.1880F-01
0.596bE-0?
0.7V01F-01
PPM
1H12.
333.
SI.
lie.
72.
ian6.
JS8.
?ani.
soi. io
GMOL /LITER
o.n
0.0
0.0
0.0
0.0
0.0
o.o
0.0
AIM
PPM
n.
n.
n.
'i.
n.
n.
n.
o.
G-10
-------
Case 2
SAMPLE POINT 2si6 4/12/7* AT o«on
HECHTkL MODIFIFD PftOlftN EOUILIPHInM p.
INPUT DATA I
Kl JS TK PPSo? "PCO? ssoi «;sr.6 II>H
2 0 3/"3.0 0*0 0.0 1.000 l.Ofin i ^
CONCENTRATIONSi pMGL/LITeR ftNt) PH 1 ( • 1 1 :
CA MG NA K so3 so* ^03 ''i
0.0*521 0.01370 Q.002?2 0.00302 O.OnO<>0 O.OlflHO 0.nOS^7 O.Of9M
1812. 333. 51. 118. 72. 1806. 358. ?HOI.
PH a 5.750 PPCO* a 0.2151 «TM
PERCENT E«ROP IN IONIC BALANCE = <;.$
PERCENT SULFATE SATURATION = 117.7
TOTAL DISSOLVED SOLIDS " 7351. PPM
G-ll
-------
Case 3
SAMPLE POINT 2816
INPUT DATA)
Kl JS
1 1
4/12/74 AT OMOO
BECHTEL MOniFIFD HADIAN FOUR I ON In*
TK PPS02
323.0 0.0
ssm
i.non
TPM
1.000 0
PM
n.n
CONCENTRATIONS, GHOL/LITER AND PP»(«iT)l
CA MG MA K S03 S0« C03 :i.
0.04521 0.01370 0.00272 0*0030? 0.00090 0.01HAO fl.O O.nMynj
1812. 333. 51. 116. 72. l'<06. n. 2«n|.
CALCULATED HFSULTS: coNCf-ukaTiON
"P ACTIVITY CflFFFTCIF T
PH • 6.033
M*
OK-
H2C03
HC03-
C03—
H2S03
MS03-
S03--
HS04-
S04--
CA»«
CAOH*
CAMC03*
CAC03
CAS03
CASO*
MG**
MttOH*
MGHC03*
MGC03
MGS03
MGS04
Nft*
NAOH
NAHC03
NAC03-
NASO*-
ri-
Ci-COj (51
CASO* IS)
PPS02
-0?
0.303JE-D?
0.307PE-07
0.3613E-03
0.785i>t-02
0.348bE-Ol
0.2435F-07
0.72T6E-03
0.3726E-OS
0.45HE-03
0.6073F-0?
0.112»E-01
O.U50E-H6
0.1109F-03
0.1693F-OS
0.516ME-02
0.4B3DE-OS
0. flOl" -:>\
O.SHS3E-0' AIM
I.n267
0.73B7
n.?977
1.0267
0.7387
0.?977
O.?5l3
0.74R6
n.748f>
I.n267
1 .0267
1 .0267
0.1141
n.74fl6
0.74R6
I.n?h7
1.02fi7
0.761f>
1 .0267
1 .0267
C02
1 .'
1.noon
0.0083^3 fiMOL/i
PEHCENT SULFATE SATURATION = 100.0
TOTAL DISSOLVED SOLIDS = 7092.
ANALYSIS OF SLURRY:
( KSP = 0.2206F-0* )
Cfl
I'll
1 t
r
SO 4
SO*
C03
CL
LIQUID
TN'JL /L ! It-*
O.bc!] It-- i)
11. J J7 •>-- i)
titHSl •' - -7
O..i0l ">h -'1?
o.^qy 2St-Ol
0.780SF-0?
0.7V01F-01
PPM
IftPM.
.m.
«•. i .
11H.
7?.
I5f,l.
4 ^
'i.n
O.'i
n.r
o.r,
0,?5Ii3E-n
-------
PROGRAM LISTINGS
G-13
-------
BEQCALL FORTRAM P
VP/CSS
tOeBECCLl 07/PB/T5 I0.26.4R
NATIONAL CSS. INC. (SUNNYVALE OATA CFMTERI
C
C
C
THIS ROUTINE CALLS BE'J TO UETFRMTNF. AQUEOUS
SOLUTION EQUILIBRIA FOR THE SYSlpM CA,"G,NA,K,S03»S04ir03,CL.
(NITRATES ASSUMED ZERO FOR INPUT/OUTPUT CONVENIENCE)
FOR js«i AND SPECIFIED PPCOZ.
IDS APF ALSO DETERMINED.
C
C
C
C
C
C
C
C
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
100
c
no
c
C PROGRAM USES "BEO EXEC".
C»*»**»«*»«*»« •••••»»•••**••• •••«***»«*»e«»»»a «••«««•*»•««»«•••«»«**••
DIMENSION X(50) fCM(lO) .PP(2) tSS(3) ,XMW(jn|
COMMON /ID/IDENT<20), CCM(IO), C*(]0)
COMMON /INPUT/ PPS02, PPCO?. SSlt sS3. KK1, JJS, PPH
REAL'S CMP(IO) /'C***S 'M6«*«i «NH*», «K»»» «S03~t»
1 «SO*«t «C03», 'CL-». ••••«/
REAL'S DATE i HMS
DATA XHM /40.0«»2*. 31t a2.99»39.10»P.0.06««»h.06t60.0] «35.4^i
1 O.OiO.O/
01 MO PRINTOUT FHOH SURROllTTNE HPR
is FULL PRINTOUT
2: SHORT FORM
Kl
JS
TK
SS(l)
SS(3)
IPH
PH
21
0!
li
INPUT CONCS
INPUT CONCS
IN
IN
PPM
ITER
0!
i:
NO SOLIDS
SOLIDS MY Bt PRESENT. PPCO? SPECIFIED.
SLURRY TF.MPEHATUBE* HERRFES KELVIN
PARTIAL PHESSIIHES OF 502.002 IN HTM
RELATIVE SATUHflTiON OF CaS03 AT WHICH
CRYSTALLIZATION nCCURS. USE VftLUE OF 1.00
FOR NUWMAJ. R4DIAM Ellt/II
APPLIES TO CASfH
PH NOT SPECIFIED
PH IS SPECIFIED
LCA00010
LCA00020
LCA00030
LCA00040
LCA00050
LCA00060
LCA00070
LCA00080
LCA00090
LCA00100
LCA00110
LCA00120
LCA00130
LCAOOUO
LCA001SO
LCA00160
LCA00170
LCA00160
LCA00190
LCA00200
LCA00210
LCA00220
I.CA00230
LCAOO?40
LCA00250
LCA00260
LCA00270
LCAD0280
LCA00290
LCA00300
LCA00310
LCA00320
LCA00330
LCA003*0
LCA003"50
LCA00360
I.CA00370
LCA00380
ICA00390
I.CA00400
PH
INPUT. <;tr = o.
LCA00410
IF NOT sPEriFitnucA00420
LCAQ0430
TNPUT DATA CONCS OF CA,,Mfi,NAiK.Srt?.S04,COi.CL LCA00440
IN THAT OMOtrf. LCA00450
CONCS O
IN THAT
O«OE
CONTINUE
HFAD A MEW CASE
HfAU (^tllOi£Nr)=?UD>
FORMAT! 20A4>
CALL TIMFS (Ic»U«
WHITE (6.112) DATF,
INPUT L>4Ta FROM FILE 'MElJ OATA".
lOtNT
LCA00470
ICA004QO
LCA00490
LCA00500
LCA00510
LCA00520
LCAOOS30
LCAOOS40
LCA00550
G-14
-------
BEQCALL FORTRAN P
1D=BECCL1
12/13/74
13.19.01
112 FORMATJ 1H1, BOX, A8, « AT «• A5>
WRITE (6tll5) IDENT
115 FORMATUH , 5Xi 20A*)
READ <5»120»END=160> XPR, XK1, SJt TK, PP(D, PP(2), SS(D,
1 SS(3)t XIPH, PH
READ (5,120,END=160) (CCM(I),1=1,B)
120 FORMAT( 10699,0)
Kl = XK1
NOPR * XPR
C CHECK INPUT CONCNS:
DO 3 I « 1,8
IF (CCM(I).GE.O.) GO TO 3
WRITE <6il70) CMP(I), CCM(I)
170 FOf
PPC02 = PP(2)
SSI = SS(1)
SS3 5SS(3)
KK1 = Kl
JJS = JS
PPH = PH
IF(TK,GT,273.) GO TO 45
WRITE (6»175) TK
175 FORMAT< 1HO, "INPUT TEMP OF •
i • HADIAN CALC»' / 6x, «SKIP
GO TO 100
45 CONTINUE
CM(1) * CCM (5) *°*~
CM(2) = CCM(7)
CM(3) " CCM(6)
CM(4) = 0.
CM(5) = CCM(l)
CM(6) = CCM(2)
CM17) = CCM(3)+CCM(4)
CM(8) = CCM(8)
EPSNA = l.E-10
, F6.1,
TO NEXT
• K IS TOO
CAUC,«)
L"W FOR',
50, -
CJ2_~
LCA00560
LCA00570
LCA00580
LCA00590
LCA00600
LCA00610
LCA00620
LCA00630
LCA00640
LCA00650
LCA00660
LCA00670
LCA00680
LCA00690
LCA00700
LCA00710
LCA00720
LCA00730
LCA00740
LCA00750
LCA00760
LCA00770
LCA00780
LCA00790
LCA00800
LCA00810
LCA00820
LCA00830
LCA00840
LCA00850
LCA00860
LCA00870
LCA00880
LCA00890
LCAOU900
LCA00910
LCA009^0
LCA00930
LCA00940
LCA00950
LCA00960
LCA00970
LCA00980
LCA00990
LCA01000
LCA01010
LCA01020
LCA01030
LCA01040
LCA01050
LCA01060
LCA01070
LCA01080
LCA01090
LCA01100
G-15
-------
BEQCALL FORTRAN P ID*BECCL1 12/13/7* 13.19.01
IF(CM(T).6T.EPSNA) FNA a CCM(3)/CM<7) LCA01110
IOPT « 0 LCA01120
IF(PP(2).6T.EPS) IOPT * 2 LCA01130
IF(PP(1).GT,EPS) IOPT a IOPT«1 LCA01140
CALL BEO (NOPRtJS»lOPTiTK,XtCM.PPtSSiIPH,PH*FNA) LCA01150
60 TO 100 LCA01160
160 CONTINUE LCA01170
WRITE (6tl80) LCA01180
180 FORMAT! iHOi •INPUT DATA INCOMPLETE FOR THIS CASE.") LCA01190
200 CONTINUE LCA01200
NRlTE(6i2lO) LCA01210
210 FORMATtlHO.'END OF DATA*) LCA01220
1000 CONTINUE LCA01230
STOP LCA01240
END LCA01250
G-16
-------
BED
FORTRAN
VP/CSS
IDsHfcCCLl 12/19/7* !Q.57iS9
NATIONAL CSS* INCt (SUNNYVALf DATA CENTEH]
PAGE 1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(6)
(9)
(10)
(11)
(12)
(13)
( 14)
(lb)
(16)
(17)
(IB)
H»
OH-
H2C03
HC03-
C03--
H2S03
MS03-
S03--
HS04-
504—
CA»*
CAOH*
CAHC03
CAC03
CAS03
CAS04
MG**
MGOH*
•
(19) MGHC03*
(20)
(21)
(22)
(21)
(24)
(25)
(2b)
(27)
(2H»
(29)
(30)
(31)
(32)
<3J)
(34)
MGC03
H&S03
HGS04
N03-
CAN03*
NA»
NAN03
NAOh
NAHCU3
NAC03-
NASU4>
CL-
CACU3
CAS03
CAS04
(S>
(S>
IS)
<3S) CA10H12 IS)
(36)
(37)
MQC03
HG(OH)
(S)
2 (!»
LIQ00120
LIQ00130
LIOOOISO
LIW00150
LI000170
LIQ00180
LI000190
LIU00200
LI«00210
LI000220
LI000230
SUBROUTINF BFCi (NOP«» JSS, [OPT,TK»X, CM,PP,SS. IPH.P^.FNA) LIU00010
£•••••*••«*«•*««••••••*•«••***•»•*••••••••*****••••••••*••**•*•••••••• LJ QO 0020
(;•••••• THIS ROUTINE DETERMINES AOUEOU& SOLUTION EQUILIBRIA FOR THE LI000030
C SYSTFM S02tC02»Sn3tN2US.CAtMG.NAfCL. LIQ00040
C LIG00050
(;••»••• FOR JSS=1 AND SPFCIFIED PPCOZi bOLIDS ARE ALSO l>FTEP«INEDt LI000060
C LN0007U
C LIQ00090
C COMPONENTS LIU00100
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C LIU00530
C LTUOOS40
C LIQOOSSO
LI0002SO
LI000200
LI«)0027U
LIQ002UO
LIU00290
LIQ00300
LIQ00310
LIQ00320
LI000330
LI0003*0
LI000350
LI000360
LIU00370
LIQ003RO
LIU0039U
LI00040U
LIU00410
Ll«004ifO
LIU00440
LI000450
LIU00460
LIQ004rO
LI000480
LI000490
LI000500
IIU00510
G-17
-------
BEG
FORTRAN P
lO=ijECCLl
12/19/74 lfl.S7.59
PAGE 2
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
(4)
(5)
(6)
(7)
<8>
(9)
EQUATIONS
(1) (HO (Oh-) « K(l)
(?) (h2C03) = PPC02/K(2>
(3) (H*)(HCU3-» = (H2COJ)»K(J)
(H»)(C03— ) = = (CAOH»)»K<8>
(10) (CA+«)(C03— ) = 0*)«M17)
(16) 502 f'ATRRUL BALANCt
(19) so.i MATERIAL BALANCE:
(?0) CA MATERIAL HALANCt
(?1) Mb MflTEHlAL HALANCt
(22) CHAHGL RALANCF
(?3) (H2S03) = PPS02/K(2J)
(CA*«)(N03-) = (CANU3*) °K(2<»)
(NA«)(N03-> = (NAN03)«K(25)
(26) (NAO(OH-) = (NAOH)»K(2b)
LIQ00570
LI 00 0580
LIQ00590
LIU00600
LI000610
LIQ00620
LIQ00630
LI000040
LIQ00650
LHJ00660
LIU00670
LI000680
LIQ00690
LIQ00700
LIU00710
LI000720
LIQ00730
LIQ00740
LIQ00750
LIQ00760
LI000770
LI000760
LIQ00790
LIQ00800
LIOOOB10
LI000820
LIQ00830
LIQ00840
I.IQ00860
LIUOOB70
LIUUOHHO
LIQUOR90
LI000900
LI000910
LIQ00420
LICI00930
LIU00940
LI000950
LIG/00960
LIU00970
LIU00980
Liooinoo
LI001010
LI001U20
LIQ01030
LI001040
LIQ01050
LIU01060
LIU01070
LIU01000
LIQ01090
LIQ01100
G-18
-------
BEQ
FOPTRAN p
12/1V/74
iO.57.59
PAGE 3
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
(2tJ>
(?9)
MO)
(3D
(3?)
(33)
(34)
(35)
(36)
(37)
(36)
(NA*)(HCOJ-) = (OH-)»«2 L.F.
LI001110
LUU1120
LIQ01130
LIQ01140
LIU01150
LIU01160
LIU01170
Lioonao
LIQ01190
LIQ01200
LIOP1210
LIQ012ZO
LI001230
LIQ01240
LU01250
LIU012hO
LI001270
LIU01280
LIUU1290
LIU01300
LI001310
L]0013
-------
BCO
FOPTRAN P
lO*HtCCLl
12/1V/74 10.57.59
PAGE 4
DIMENSION X<50> •CM<10),PP(2).IFLAl>(10),SSO>
COMMON/CEE/Cl.C3,C5»C6tC7,Fl.F3
COMMON/GAMMA/GAM (50)
COMMON/TEMP/AC»BCtC»'K(2>iCK(50)
COMMON/COHP/LON
COMMON/PRFSS/PPltPP2
REAL K (50). LOW
JS a JSS
2 CONTINUE
X(l) n 0.
EPS a .00000001
IF(JS.NE.JSS) PP CM(?) = 0.
IF*U.5»CM(*)*0.5*CM = l.t-4
5 CONTINUE
IF(JS.^E.JSS) GO TO 3')
KOUNT = 0
KN = 0
KP = 0
00 10 1=1,7
IFLAfl(I) = 0
1F(CM(I).1 T.FPS) Rfi Tli 10
IFLAG(I) = 1
KOUNT = KOUNT»1
IF(I.nT.4) KP = KP»1
IFII.LT.5) KN = KN»1
1U CONTINUE
IFIKP.EU.O.OK.KN.FO.O) IT = 1
IS5 = I
IF(JS.EQ.O.OR.IFLfln0
LIU02100
LIQ02110
LIW02120
LIU02130
LIQ(i2140
LI0021bO
LIW02160
LIQ0217C
LIQ021«<
LIQ02191
LIOU2?OC
G-20
-------
BEG
FORTRAN P
IO=nECCLl
10.B7.59
PAGE 5
x
XU1 > = C«
xtl7) = O<6)
Xt2J) = CM14)
XtJU =
(;««»»»« OUTF.H
LICI02210
Kq-*-v
£• «.'
CUN^tHuE-NCF. tIF ACTIVITY COEFFICIENTS
LOUP FOU
?
lF
Cl = l.*>7Aa»Ab*rt
105 CONTlNut
IF (JFL«B(?) .FO.ll fiU ff) 110
X t*3 = K (3)*X (1) /< ( 1 I
X(5> = K U>«X(4) /K(l)
GO To US
110
X4XS = M 1
J)
lF(IFi /.:•.(.!) .t«.«| 1,0 T'> 120
X<*«iO = All) /K I n
rJ = i.*xoxio
CONTINUE
U UK AG(«i) .t U. D
-------
BEQ
FOHTHAN P
IU=HECCL1
10.57.59
PAGE t
130
135
UO
145
150
160
170
18(1
190
195
CONTINUE
IFtIFLA&(6).EQ.O( GO TO HO
X18X17 = X(2)/K<13I
If
IF(IFLAG<2).EQ.l) GO TO U5
X28X25 = X(4)/K<27)
X29X25 = X(5)/K(28)
C7 = l,*X27X25*X28X2l>«X29X?5
GO TO IbO
CONTINUE
C7 * l.»X27X25
CONTINUE
JF(JS.EU.O) GO TO 1SS
TF(IFLAG(S).EQ.O.OR./X(8>
lF(SCAC03.LT.SCAS01 RO To 170
SOL5 = SCflSOJ
ISOL5 = 1
GO TO 1HO
CONTINUE
SOLb s SCACD3
1SOLS = 2
GO TO 180
CONTINUt
SOL5 = SCflOH?
ISOL5 = 3
CONTINUE
IFUFLAGIM .CO.O) r,0 TO IMS
SMGOH? = ic(39)/X(?)/M?)
SMGC03 = K(i8)/X(c,)
IF(SMGOH2.LT.SM(jCi.M) bO To 190
SOL6 = S>MGC03
LIU02760
LI002770
LIU0278U
r,o ro
ISOL6 =
GO Tn IS 7
( IFLAO ,K.X,CM.FP,bOL6>
LlQ02bOO
LI00281U
LKJ02b20
LIQ02B30
LI002P«tO
LlQ028bO
LIU02860
LIQ02fl'0
LIQ02680
L.IU02U90
LIU02900
LIQ02910
I.1002920
LI00293U
LIU029«0
LIU()2S(bO
LI002960
LI002970
LI0029HO
LIU02SVO
LI003000
LIU03010
LIU03020
I 1003030
LIU03040
LICI03050
LKJ03060
L1UOJ070
L1D03080
LI003090
LIU03100
LI003110
LI00312U
LIOOJ13U
LIU03140
LIU031bU
LI
-------
BEQ
FORTRAN P
rl)=HECCLl
12/19/74
10.57.59
PASE 7
196
197
199
CONTINUE
CALL CASOfc HFLAG.KtXiCMtPP.SOLb)
60 TO 300
CONTINUE
CALL CASOX (IFLAG.KtXtCMiPP.SOLb>
60 TO 300
CONTINUE
CALCULATE BASE IONS (S03—»C03"«SO*--iN03-tCA**fM6*« »NA*)
IF(IFLAGM).L'Q.I) X(H) * 0.
!FdFLAG(2>.EQ.n X(5) - 0.
X(10)
X(23)
F51 =
F53 =
CSS =
C6S =
C7S s
0.
0.
0.
0.
C5
C6
C7
60 TO 200
CS
C6
C5S*X(5)/M10)*X514/K(9»
C6S*X(5)/M15>*X514/K<14>
C7S*X<5)/M2«)*X514/K<27)
00 255 1=1»IT
IF(IFLAG(2).EO.O)
X514 s X(5)«X4X5
1F(1FLAG(5>.E0.1)
IF(IFLAG(6).E0.1>
IF(IFLAG<7l.EQ.n
200 CONTINUE
IF(IFLAG(5).EO.O) GO TO 210
Xlll) = CM(5)/(C5«J(IB)/Ktll)*XtlO)/Kll2)«Xl23)/Ktii4)*F5l»F53)
IF(JS.NE.O) X(ll) = AMJN1(X(lll.SOLbJ
210 CONTlNUb
lF(IFLAG(6litO.O] GO fO 220
X!17) s CH(6)/(C6»X
IF(JS.NE.O) X417) = AMINHXUTUSOL6]
220 CONTINUE
IF(IFLAG(7).E0.1) X<25> = CMI7I/(C7»X(10J/K(29)*X(231/K(?5))
IF(IFLAG(1>.EQ.OJ GO TO 230
Fl = C1*X(11)/K(1U*X(17)/K(16I
XO) s CM(1)/F1
]F (IS5.EO.O) GO TO 230
X(8) s AMINKXIB),K(35>/X(11) )
XE8) s AM/tXl (X(B) tCHlS/Kl)
F51 = X(8)*(CM(1)-X(8>"F1)/K(35)
230 CONTINUE
lF(IFLAr,(21.EQ.H X(51 = CmZI / (Ca*X (11J /M 10 1 *X( ll I «X4X5/K (91
1 *X(17>/K<15)*X(17)4'X4X5/Kd4)*X<*X(25»»X4X5/K(27»
IF(IFLAGC3) .EO.O) GO TO 2»At25)/K129)
X(IO) = CM(3)/F3
lFdS5.bQ.OI fiO TO 240
X(IU) - AMl,Ml/X(ll»
X(10> = AMAX1(XUO)»CM35/F3)
F5J = X[10)*»F3>/K(3b>
240 CONTINUE
IF(IFLAG(4).E0.1) X<23> = CMI4»/(1.*«11)/K(24>+>
2St> COMTjNUt
256 CONTINUE
C«*««»« CALCULATE ALL UNObTERMINED
LI003310
LI003320
LI 00 3330
LI003340
LIU03350
LI003360
LI003370
LI003360
LI 00 3390
LI003400
LIQ03410
LI003420
LIU03430
LIQ03440
L1U03460
L1003470
LI003480
LI003490
LI803500
LI003510
LI003520
LI003530
LI003540
LI003550
LI003560
LIQ03570
I.IU03580
LI003590
LIU03600
LIQ03610
LIQ03620
I.IQ03630
UI003640
LI003650
LIU03660
LI003670
LI003680
LI003690
LIQ03700
LIU03710
LIQ03720
LIU03730
LICI03?40
L1U03750
LIU03760
LI303770
LI003780
LI003790
1.1003800
LI003H20
LIQ03B30
LIU03ii40
LIU03850
G-23
-------
BEfa
FORTRAN P
TU=HECCL1
12/19/7*
10.57.b9
PAGE
300 CONTINUE
IF(IFLAGM).EO.O) (iO TO 310
X(7) * X(B)»X7X8
310 CONTINUE
IF X(10)«X9X10
CONTINUE
IF(IFLAG(5).FO.O) C,fl TO 330
X(12) B X(11)«X12X]1
X(24) = Xni)*X(23)/K<24)
X(13) * X(11)«XU)/K(9)
CONTINUE
iFUFLAG(ft) .EO.O) 60 TO 340
X(1H) s X(17)«X18X17
X(19) a X(17)«X(4)/K<14)
CONTINUE
IF(IFLAG<7).E<).0> 60 TU 342
X(29) = X(25)«X(5)/K<28)
X(30) = X(25)«X(10)/K(29)
CONTINUE
IF(IPH.EU.l) 60 TO 500
CALCULATE NE* VALUE OF (H+»
PHIS a PHI
PHI a 2.«(X[17)*X(|l)-«i)-X«H)-A(10) ]*X(1)«X(12)»X(1J)*X(18)
1 »X(19)*X(24>«X(2S>-X(2)-X(<*)-X(7)-X(9>-X(23)-X(2y)-X(30>-X(31>
ITO = 1TO«1
IF(JJ.GT.1.AND.ITO.E0.1.ANO.AHS(PMD ,LT.?.«AHS(PHlS)) GO TO 500
IF(PHI.LT.O.) GO TO J<-0
L0i< B PM
IF(HI.LT.1V.) GO TO 3bO
PH = PM*1.
315
320
330
340
342
GO TO no
JSO CONTINUE
IF( (HI-LOW).LT.TOL) GO TO 500
PH = (Hl*LO«M/2.
XII) = l./GAM( n/(lU.**PH)
GO TO 100
360 CONTINUE
Hi = PH
IF90
LIU04300
LIQ04310
LIU04320
LIQ04330
L 1004 3*0
LIU04360
LIU04370
LIU043U(
LIQ043SH
LIQ0440C
G-24
-------
8EQ
FORTRAN P
IO=BECCL1
10.57.59
PAGE 9
520
5*0
CONTINUE
lF(IFLAG(2>.tD.O)
X(3) » X(5)»X3X5
PP(2) a X(3)«K(2)
CONTINUE
GO TO 540
X(H>
X(15)
K(lb)
K<20)
X(211
X(22)
X(26)
X(27)
X(11)*X(S1/KUO>
X(H)«X<10>/K(12>
XUT)*X<5»/KU5>
X(17)»X<8l/Kd6>
X(17)«X(10I/K(17)
X(25)*X(23)/K(25)
X(25)«X27X25
X(25)«X(4)/K(27)
IF(JS.EO.O) GO TO 1010
C*»»*»* CALCULATE SOL10S
EPS1 a l.F-6
IF(IFLAG(5).EO.O) pO TO
lF(dS.Etl.3) GO TO 600
lF(IFLAG(l),EQ.n X(33)
IFCJS.E0.2) GO TO 1001
600 CONTINUE
iFdFLAGOJ.EO.l)
IF(JS.NE.I) GO TO
F5
1001
= CM(1>-X(8»«F1
CM(3(-X(10)*F3
650
XI34)
1001
C5*X(8)/K(11)*X(]0)/K(12)»K(i3)/K(24)
s CM(5)-X(34)-X(11)«F5
IFU50L5.EQ.2) X(3?) = CM (5)-X (33)-X134)-X {11) ">F5
TF(ISnL5.FQ.3) X(3S) = CM<5)-X(33)-A(34)-X(11)»F5
!F(X(32).GT.FPS1.0R.X(3a).GT.EPSll GO TO 1001
IF(X(33).BT.EPS1I GO TO t-50
IF{X(34).LT.EPS1) r.O 10 1001
JS = 3
GO TO 2
CONTINUE
IF(ISOLS.EQ.I) GO
IF / K(35)
SS(3) = X(10) » X(ll) / K(J6)
c*"«««* *RITE OUTPUT
IP = NOPR
IFUP.NE.OJCALL BEOPKT(NOPRtIOPTiIFLAG,TK»X.CMiPPtsS«lPH.PHtFNA)
RETURN
END
LIQ04410
LIQ04420
LI004430
L.IQ04440
LIQ04450
LI004460
LI004470
LI004480
LIQ04490
LI004500
LI004510
L1004520
LI004530
LIQ04540
LI004550
LI004560
LIQ04570
LIQ045UO
LI004590
L1004600
LIQ04610
LIQ04620
LI004630
LIQ04640
LI004650
LIQ04660
LIU04670
LIQ04680
LIQ04690
LI004700
LIQ04710
LIU04F20
LIQ04730
LIQ04740
LIQ04750
LIOC4760
LIQ04770
LIQ047BO
LI004790
LI004800
LI004810
LIQ04820
LIQ04630
LI004640
L1004850
LI004860
L1Q04870
LI004680
LIU04B90
LI004900
LIQ04910
LI004920
LIQ04930
LIQ04940
LI004950
G-25
-------
BEQCOM FORTRAN P IO=HECC|_1 12/19/74 10.58.32
VP/CSS — NATIONAL CSS, INC. (SUNNVVALp DATA CENTER)
PAGE 1
SUBROUTINE KCALC fCKlSO)
COMMON/GAMMA/GAM(50)
COMMOM/COMP/LON
DIMENSION A(1DtB(ll>»C(31l»CC(llJ»U(ll),SS<3)
REAL K(bO)»X<50)
DATA A/b.»3.,3.,*.5»4.5,3,,4.5,3.,^.,5.»4./
DATA B/.4t.3f.3»0.«0.»0.,.li,3f-.2».l»0./
DATA C/l.»l.»0.,l.,4.,0.»l.»4.»l.»4.,4.»l.»l.»0.tO.»0.,
1 4.,l.,l.,0.,0.,0.,l.,l.,l,iO.,0.tO.,l.,l«,l./
DATA CC/1.,1.,0.,1.»4.»4,»4.,4.»1.»1.,1./
DATA U/0.,0.,.076,0.,0.»0.»0,,0.»0.»0.»0./
6AMU2) = 1.
IF(JS.NE.O.AND.JJ.EU.I) GO TO 42
FI = 0.
DO 20 1=1,31
FI = FI»X{I)»C(I)
20 CONTINUE
FI = FI/2. v^
SFI = SQKT(FI) Zt""1
IT2 r 11
IFILOK'.EU.O) IT2 = W
00 40 1=1,IT?
DNM = l.*BC»A(I)*SFI
ACF = AC*CC(I)
UM = 2.3f»?6»U(I)
GAM(I) = F.XP(ACF»(-SFI/DNM*B(I)*(H)*JM*FI)
40 CONTINUE
CO TO 50
4<2 CONTINUE v
CAM(l) = 0.8 "" _
n . A o «
50
GAMI2)
GAM(3)
GAM(4)
GAM (5)
RAM(6)
GAM (7)
GAM(B)
GAM!9)
GAM(ln)
RAM(ll)
CONTINUE
KID
K12)
G314
K(3)
G415
K 14J
KI5)
: O.S »J
=0.4 Ct
= 0.4 £,,
= 0.4 c
= 0.4
= 0.8
= 0.8
= 0.8 I
CK(1)/(GAM(1)<
GAM(3)/CPK(?)
CKOMG314
GAM(4)/ (GAM(l)*faAM(5)
KC200070
KC200080
KC200090
KC200100
KC200110
KC200120
KC2001JO
KC200140
KC200150
KC2001bO
KC200170
KC200180
KC200200
KC20021U
KC200220
KC200230
KC200240
KC2002bO
KC200260
KC200270
KC200280
KC200290
KC200300
KC200310
"KC200320
KC200330
KC200340
KC200350
KC200360
KC200370
KC20038U
KC2003VC
KC200400
KC200410
KC20U42D
KC200430
KC200440
KC200450
KC2004bO
KC200470
= CK(5)»G314
KC2004SO
KC200500
KC20051C
KC200520
KC200530
KC200540
KC200550
G-26
-------
BEQCON FORTKAN P
ID*HECC|_1
12/IV/74
In.58.32
PAGE 2
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
K(7) s CM7)»<,AM(?)/«JAM(1)«GAM<6>)
K(8) B CK(8)/GAH(7)
K«9) B CK(9)«GAM(?)/(fjAM(7)«GAM«4))
6375 B GAM(J)/(GAM(7)«bAM<5»
K(10) B CK(10)*G37«?
Kill) B CKUl^GS?*,
676 B GAM(7)«GAM(f,)
K(12) B CK(12)«GAM(3)/G7b
K(13) - CK(13)/GAM(8)
K(14) * CK<14)«GAM(2)/((JAM(8)«GAMUM
G3tf5 B GAM(3)/(GAM(tt)»GAM(5))
K(15) = CK(15)*G385
K(lb) = CK(16J*(>3BS
K(17) s CK(17]*GAM(3)/(GAM(8)«GAM(b))
K(23) = 6AM(3)/CPK<1)
IF(LON.EQ.l) 60 TO bO
DO 45 1=2*,29
K(I) B 1.
45 CONTINUE
GO TO 70
60 CONTINUE
KI24) = CK(18)<>GAM(2>/(GAM(7>«GA'4(()»
K(25) B CK(19)*GftM(J)/(GAM(10)«GAM(9))
K(26) s CK(20)«GAM{.')/(GAM(2>«GA»i(10)>
K(27) s CK(21)*(iAM(3)/(GAM(4)«GAM(10)}
K(28) s CK(22)*GAM(2)/(GAM(5)*GAM(10»
K(29) = CK(23)*GAM(2)/(UAM(fi)«GAM(10) )
70 CONTINUE
G7S = GAM(7)«GAM(5)
K(J4) = CK(24)/G75
K(35) = CK(25)«SS(D/G75
K(36) B CK(26)«SS(3>/G7b
622 B l./(GAM(2)«GAM(2)>
K(37) = CK(27)««22/GAM(7)
K(3B) = CK(2e)/(GflM(H)«GAM(5))
s CK(2AM(8)
RETURN
FNO
KC200B60
KC200570
KC20058U
KC200590
KC200600
KC200610
KC200620
KC200630
KC200640
KC200650
KC200660
KC200670
KC200680
KC200690
KC200700
KC200710
KC200720
KC200730
KC200740
KC200750
KC200760
KC200770
KC200780
KC200790
KC200AUO
KC200H10
KC200H20
KC200BJO
KC200B40
KC200850
KC200860
KC200870
KC200H80
KC200890
KC200900
KC200910
KC200920
KC200930
KC200940
KC200950
KC200460
KC200970
KC200980
KC200V90
KC201000
KC201010
KC201020
KC201030
KC201040
KC201050
KC2010bO
KC201U70
KC201U80
KC201090
KC201100
G-27
-------
BEQCON FORTRAN P ID»BECCL1 12/19/74 lQ.58.32 PAGE 3
SUBROUTINE TCON(JS.TK) KC201110
€••»«•• TEMPERATURE-DEPENDENT CONSTANTS ARE DETERMINED «EHE. KC201120
COHMON/COMP/LON KC201130
COMMON/TEMP/AC.BC,CPK(2>,CM50) KC201140
DIMENSION AI29)»B(29),C<29),D<29> KC201150
C . KC201160
DATA A/4470.99,0..3404.71,2902.39,-843.67,-633.8*,475.14. KC201170
1 -273..-301.85,-475.48.-S04.8,2572.1,-517.99,-235.08.-504.8. KC201180
2 -*32.5,-1057.86,-1245.tO.,0.»0.1-303.41,-241.,-1660.,0.,4944.0, KC201190
3 530.49,-955.14,-080.85/ KC201200
C KC201210
DATA B/0.«O..O..O.iO.,0.iO.,0*,0.«0.i0..23.l5,0.,o.,0.«0.,0., KC201220
1 O.,0..0..0..0..0..0.,0.«37.745,-12.9722,0.,0./ KC201230
C KC201240
DATA C/.01706.0...032786,.02379.O.»0.,.018222,0.iO.»0.»n., KC201250
1 0.,0.,0.,0.,0..0.,0..0.»0.«0.,0.«0.»0.,0.,0.,.032331.0.,0. KC201260
Z/ KC201270
C KC201280
DATA D/6.0875,0.,14.8435,6.4980,-4.7171,-9.3320,5.0435,-2.29. KC201290
1 -2.272,-4.7954,-5.091.63.60,-4.3223,-1.747.-5.091,-4.3715,-5.7y50KC201300
2 .-4.49».40,.57».25»-2.2852,-1.52*,-13.88,-6.147»105.36,-25.7085, KC201310
3 -7.871.-12.514/ KC201320
C KC201330
EPS * .OOnOOl KC201340
IF(jS.EQ.jSOLD.AND.LON.EQ.LONOLO.AiMD.AHS(TK-TOLD>.LT.EPS) HETUHN KC201350
TC = TK-Z73.16 KC201360
TC2 = TC«TC KC201370
^- DC = 87.740-0.40008»TC»9.398E-4*TC2-1.410E-6»TC2«[C KC201380
DCTK = DC*TK " KC20U90
SQOCTK = SORT(DCTK) KC201400
y ~~~ *c = 1.8246E6«2.3026/(DCTK«SQDCTK) KC201410
—•* 8C = 50.29/SUDC1K KC201420
DM » 2.3025851 KC201430
TL06 a ALOGIO(TK) KC201440
DO 10 1=1,29 KC201450
CK(I) = EXPtDM«(-A(I)/^^-B(I>«TLU^'-C(I)«TK»D(^))) KC201460
10 CONTINUE KC201470
CC« IF(JS.NE.l.ANn.rC.GT.40.) CK(26) = EXP(DM»(-1200.V/TK*6.648V«TLOG-KC201480
CC» 1 O.U3?057*TK-7.084)) KC2014VO
CPK(l) = EXP<0**M370./TK-4.51)) KC201500
CPKI2) = f!XP(OM»(10l5./TK-4.87) ) KC201510
TOLD = TK KC201520
JSOLD = JS KC201530
LONOLD = LON . KC2015VO
RETURN KC201550
END KC201560
G-28
-------
BEOSOX
FORTRAN
VP/CSS
IO«BECCU 12/14/74 10.b8.42
NATIONAL C!»St INC. (SUNNYVALE DATA CENTER)
PAGE 1
CM<4> / < 1 .*X ( 1 1 » /K (24) »X (?5) /K (25) )
C
C
C
C
SUBROUTINE CAS03( IFLAG»KtX»CM»PPtSOL6)
DIMENSION X(50)iCM(10).PP(2)iIFLAttUO)
COMMON/CEE/CltC3iC*»C6«C7*FltF3
REAL K(50)
IT « 5
IF(IFLAG(3).EO.O.AND.IFLAG<4).EG.O.ANO.IFLA6(6).E«.0
1 .AND.IFLAG(7).EO.O> IT B l
CM15 a A85(CM(l)-CM(5l)
CM15SO • CM15*CM15
IF(CM(5).GT.CM(1) ) GO TO 200
X(ll> B 0.
X(17) B 0.
X(25) B 0.
DO 100 I-ltIT
IF(IFLAGO).EQ.l) XllQl «= CM U)/ IC3*A< 1 U /K < 12) »X ( 1?) /K ( 17)
1 «X(25>/K(29I)
IF(IFLAG(4).EU.l) X(23»
Fl » C1*X(17)/K(16)
F5 • Cb*X(10l/K(12)*X(23)/K(24)
DISC s CM15SQ*4.«K(35)»F5«F1
X(8) B ISC))/(2.«Fl)
X(ll) > K(35)/X(8)
IF(IFLAG(6) .EO.O) GO TO 60
X(17) « CM(6)/(C6*X(a>/K(lb>«X(lO)/K(17»
XI17) = AMIN1 (XI171 »SOL6)
SO CONTINUt
IF(IFLAG(7)tEG.l) X(i!S) = CM (7) / *<2i>) = CM (7) / (C7*X 1 10) /K (20) *X (23) /K (?5) )
Fl = C1»X(17)/K(16)
F5 - C5*X(10)/K(1?)«A(^3)/K(24)
DISC = CM15SO**.«K(35)«Fb«Fl
X(ll) s (CM15*SQRT(OISC))/(2.«F5)
X(8) r K(35)/X(11)
IF(IFLAG(3) .EQ.l) X(10) = CM (3) / «C3*X ( \\ ) /K ( 12) *X ( 17) /K ( ] 7)
1 »X(25>/K(25»
250 CONTINUE
Fl = Cl*X(ll)/K(H)«X(l/)/K(l6)
RETUHN
END
CS200010
CS200020
CS200030
CS20004U
CS200050
CS200060
CS200070
CS200080
CS200090
CS200100
CS200110
CS200120
CS200130
CS200140
CS2001SO
CS200160
CS200170
CS200180
CS200190
CS200200
CS200210
CS200220
CS200230
CS200240
CS2002SO
CS200260
CS2002rO
CS200280
CS2002VO
CS200300
CS200310
CS200320
CS200330
CS200340
CS2003SO
CS200360
CS200370
CS200380
CS200390
CS200400
CS200410
CS200420
CS20043U
CS200440
CS200450
CS200460
CS200470
CS200480
CS200490
CS200500
CS200S1U
CS200520
CS200S30
CS200540
CS200550
G-29
-------
BEQSOX FORTRAN P
PAbF 2
SUBROUTINF CAS04 (JFLAGiK,XiCM,Pk,SOLfe)
niMENSION X(50) tCM(10)ffP(2).IFLAt>(10)
COMMON/CEF/Cl.C3»C«itCb.C7tFliF3
REAL K(50)
IT = 5
IF(IFLAG(l).EQ.O.AN[).lFLAG(4>.EQ.O.ANn.lF|_AG«6).fc'«,O.ANO,lFLAG(7)
l.EQ.O) IT s 1
CM35 a ABS(CM(3)-CM(b»
C*35SO = CM35*CM3S
IF(CM(b).GT.CM<3)| GO TO 200
X(U) = 0.
X(17) = 0.
X<25) = 0.
no loo l=itiT
1F/K(25K
F3 = C3*X(17)/K(17)*X<25)/K(29)
F5 » C5*X(8)/K(11)»X(23)/K(?4)
DISC « CM35SQ**.«K(36)»'rb«F3
XI10) = (CM35»SOPT(01SC)I/(2.»F3>
X(ll) = K(36)/X(10)
IF(IFLA&(((«>.EO.O) CO 10 50
X(17) * CM(6)/(C6*XI«)/'«16I*M1U)/M17))
X(17) s AMIN1(X(17).SOL6)
50 CONTINUE
IFIIFLAfam.FU.lJ X(^b> = CM<7>/(C7*X(10)/K(29)»X(?3)/K (25))
100 CONTINUE
F3 = C3+X<11)/K(1?)»X(1M/M17)*A(2?O/M?9>
RETURN
200 CONTINUE
X(8) s 0.
XtlO) =• 0.
X(23) ~ 0.
DO 250 1=1.IT
IF(IFLAG(6>.EO.OI fiO TO ?30
X(17J s Ct»{6l/(Ch»X(8)/K(lb)«X(10)/M17) J
X(17J = AMIN1(X(17)»SOL6)
230 CONTINUE
IFIIFLAGm.EO.l) X<25) = CM (7) / (C7*X (] 0 ) /K 129) »X (?3) /K (2S) )
F3 = r3*X(17>/Kll7)»A|?5)/K(29)
F5 = C'
OISC =
X(ll) = (rM35«SQiyT (OISCI
X(10) s K(361/X(11)
IFIIFLAG(l).LO.l) X(H) =
2SO CONTlNUt
F3 = C1*X (H)/K (12) *X(l7l/K( 17)
RETURN
F.ND
CS200560
CS200570
CS2005BO
CS2005SO
CS200600
CS200610
CS200620
CS200&30
CS200640
CS200bbO
CS200b60
CSP00670
CS200680
CS200690
CS200700
CS200HO
CS200720
CS200/JO
CS200740
CS200750
CSSOOYftO
TS200770
CS200780
CS2CI0790
CS200HOO
CS200810
CS200B20
05200830
CS200b*0
CS2008SO
CSlOOEibD
CS200H70
CS200880
CS200890
csaooyoo
CS20J910
TS200930
CS2009SO
cseoosro
CS200990
CS20LCOO
C52010iO
CS201020
CS2010JO
CS20in*0
CS20L060
CS201070
CS201080
CS201090
rs2ouoo
G-30
-------
BEQSOX FORTRAN P
12/19/74
10.58*42
PAGE 3
IT
SUBROUTINE C*SOX ( lFLAG»n»»«O,PPiSOL6)
DIMENSION X(SO)*CM(10)iPP(2)*lFLA6(10)
COMNON/CEE/Cl*C3«CStC6tC7,Fl*F3
REAL KC50)
IT • 5
IF.EO.O.ANO.IFLAG(6I.EQ.O.AND.IFUG(7).EW.O>
CM135 • ABS(CM(1)*CM(J)-CM(5»
C13SSO • CH135*CM135
IF(CM(5),6T. • 0.
X(17) • 0.
X(25) c 0.
00 100 I«ltIT
IF(IFLAGU).CO.l) XI23) = CM(4) / U.*X ( 1 1 )/K <24) *X (35) /K<25) >
Fl » Cl*X
F3 • C3*KU7]/K(17)«X{25I/K<29)
F5 • C*»X<23)/K(24>
THF • F1»F3«K(36)/K<35>
DISC • C13SS8*4.»K«3S)«F5»THF
X<8> = ICM]35*SQRT|OISC))/I2.«THM
Xtll) " K(3S)/X(8)
X<10) « K(36)/X(11)
IF(IFLAG(6).EQiO) GO TO bO
X(17) * CM(6)/»X*X(10>/K<17})
X(17] • AMINKXU7) tSOLbl
50 CONTINUE
[FUFLAGm.Ee.U X(2b) = CM(7)/ (C7*X 1 10) /K (29) +X (?3) /K<25) )
100 CONTINUE
Fl = C1*X(11)/K<11)*XU7)/K(16>
F3 = C3 + X»ll)/K(l?)*X(l7)/mlT)«*.<25>/K(?9)
RETURN
200 CONTINUE
X<8> = 0.
X(10) = 0.
X(23) = 0.
DO 2SO I=1»IT
lF(IFLAG(6).Eb.O) GO TO 230
X(17> a CM(6)/(C6»X(8)/K(lft)+X(10)/K(17))
X(17> = AHINHX(17>»SOL«»I
230 CONTFNUE
IFMFLAG(7).FQ.l) XI25) = CM (7) / (C7*X ( 10)/K (291 *X (23J /K (25) I
Fl = Cl*Xtl7>/K(l*»>
F3 = C3*X tl7)/K(17)+X(25)/K<2<»
C5»X(23)/K<24)
= C135SQ*4.»F5»(F1*M35»+F3»KO6M
= (CM135*SQRT(OISCn/<2.«F5)
= K<35)/X<11)
= M36)/A(11>
250 CONTIMUt
Fl = C1+X<11)/K(111 *X(l7)/K(l6)
F3 = C3*X(11)/K(12)*X{17)/K«17)*X(25)/K(29)
RETURN
END
F5 =
DISC
X(ll)
X(B)
CS201110
CS201120
CS201130
CS201140
CS2011SO
CS201160
CS201170
cs2
-------
BEOPHlNT FORTRAN P
IU=HECCL1
NATIONAL
U/1V/74 io.56.14 PAGE 1
INC. (SUNNYVALE DATA CENTErf)
c«»»»
SUBHOUTINF 8FOPHT (NUPM» IOPT« IFLAG, TK , X,CM,PP,SS. IPHtPH.FNA)
•««««««««*o«««« ««»•««•»«««»#«««•«««»»« «««»«*«»««««•»•»« *••••••••«
C«««««« THIS ROI'TINF WHITfrS OUTPUT FOR S>L"HHr E^UILIHRIA
C
C
f •• Att
I W W • w
C
C
C
C
C
100
IbO
OETFHMIMED HY SUH«OUTINF RLO.
.„..„„.„ » „ »».
DIMENSION X(50) tCM(10),ILA(B),CML(8),CMS(6)
niMENSION IC<37>( SM3). fWHRlt CWb(W)
COMMON/GAMMA/G AM ( 50 )
rOMMON/TEMP/AC»BC(CPK<2) .CKIbU)
COMMON /in/ Il)ENT(?0)t CCM(IO), CM10)
COMMON /INPUT/ PPSfl«!. Pt»C02i SS1» Sb3» KKlt jjSi ^PH
REAL'S CMP(IO) /• CA«.» Mb',1 MA't • K't
1 • S03»i« 504' t» C03'»' CL'»' •«' f/
HEAL»8 LR(74)
REAL MW(8)/40.08,24.31t«;2.99.39.10,bO.()b.<*6.06tb0.01«35.4b/
DATA LH/6HH* tf«M ,bHOH- tt>H .6HH2CQ3 |6H »
1 6HHCP3- »6H ,bMCOJ— ,bM «6Hn2S03 «bM »bHHSU3-
2 6H .6HS03-- »6H .bHHSUt- ,6H tbHSU4-~ *6H
J 6HCA«+ ,f>H ,f>HCAOH+ ,bH .6HC4HC03.6H* .6HCAC03
4 6H .6HCAS03 «6H .OHCAS04 .6h ,bHMO*» t6H
5 6HMQOH* ,6H ,6HMGHC03,bH* , 6MMGC03 «6H tbHMGSl)3
b 6H , 6HMGb04 tbH , bHNOJ- ,6.1 ,6HCAN03«.6H
f 6HNA* .6M .6HNAN03 »bM ibHNAOH »6H ,6HNftHC03
tJ fiH ,bHNAC01-t6H .bHNAisO*-.6H «6HCL- iAH
9 6HC^r03 ,6H(S) ,b)iCAS03 ,6H(S) «(SHC\SO'* »6H(b) .(.HCA(OH)
1 6H2 (S) «bHMGC03 ,bri(S) ,6HMG (OH) ,bH2 (S) /
BEAL»fl ILfl /•CA«,iMG».«NAi,>K«,«5>03l.«S04«,«C03"t'CL1/
DATA IC/l.?.3.4,S.3.<»i5«?,h»7.?fi;i3.3iJ.b»2.2.3'J.3»9.
1 2»10,3.3.3,2,2»11,1?,12.12,1?,UJ,12/
IP = NOPR
PP1 = PP(l)
PP? = PP(?)
WR I TE (6(100)
FORMAT (1MO,3?X. 'flFTHTLl. ^OOIFIER KAUlAN (UUILIBRIUM PKOGPAM1/
1 1H • ' INPUT OATA : • )
WHITF. (btlSO) KK1, JJSf TK. HPS02t PPfOc. SSI, SSJ, IHH, PPH
FORMAT (1M , 3Xt >K1'» 4At IJS*. *A, 10.4,2X, GlO.4,2*, F7 .3.2X.F7. 3 .
LPROOOIO
LPR00020
LPR0003U
LPR00040
LPHOOOSO
LPHOOOFU
LPR00080
LPH00090
LPkOOlOO
LPW00110
LPR00120
LPK00130
LPR00140
LPK00150
LPW00160
LPHOOlfO
LPR001MU
LPH00190
LPH00200
LPH00210
LPPOOc^O
LPH0023U
LPR00240
LPH00250
LPHo02bO
LPK002AQ
LPR00280
LPH00290
LPR00300
LPHOOJ10
LPR00320
LPW00330
LPM003*0
LPK003'jO
LPH003bO
LPKOO'3/0
LPK00380
LPH00340
LPK00400
LPH00410
LPt*00420
.LPH00430
LPR0044U
LPW00450
3 3*i IJ» IXt F7.3 )
WRITE (6.160) (CMP(I), 1=1,8)
160 FORMAT! 1HO» 3X» • cnNCKNTHA T I UNSt OMCJL/LITErt AMU
1 1H .7IA6.1X),A8)
WRITF (0.170) (CCM(I), I=lto)
170 FORMAT! IH ( 7Ci(?) .Fij.O) Crt-' = M3) »X (4) *A (S) »A f 1.1) »X ( 1») »X ( 19) «
I PhtOObUO
LPHUOblO
LPW00520
LPM00530
G-32
-------
BEOPKlNT
II)=RECCL1
12/19/74 10.58.14
PAGF 2
»X(29)*X(32)*X(Jb)
IFdP.NE.ll 60 TO 1220
WRlTE(hil)OO)
1100 FORMAT! / 1M . 'CALCULATED RESULTSl'. 12X. 'CONCENTRATION'
1 1M »UXt'COMPONENT'.BA»' LH(IS).LB(IS+1).X(I).GAM(I6)
CONTINUE
FORMATUbX.Ab,A6.Fl5.4.13X.F7.4)
60 TO 1304
CONTINUE
IF PH.PP2
FOHMATI/lH »'PH = • »F6 . 3 »8X , 'PPCU«! = ',610. 4, i ATMi/)
GO TO 2300
CONTINUE
WRITE(6il?80> PH.CM2
FORMATI/lH »»PH s i iF6.3f8Xi "C02 B 'tF9.6i' GMOL/Li/)
fiO TO 2300
CONTINUE
IF(IOPT.EO.I) hO in 13JO
IFdOPT.EO.2) fiO TO 13bO
IF (IOPT.tO.3) GO TO 2100
WRITEJ6.1310) PH.PPl.HP^
FORMAT (/1H f*PH = •,F6.Jt6X,»PPSU2 = '.blU.4,i ATM. .fix t 'PPC02
1 GlO.4. • ATHi/1
SO TO 2JOP
PH.fPl.CM2
/)
= '.mo.4.* ATM«,ax»'co2 = ••
1340
1 G10.4.
RO Tn 2300
1350 CONTINUE
WRITE <6f1400)
1400 FORMATI/lH
1 F9.6«
GO TO ?30n
2100 CONTINUE
WRITF{6.2P001
22HO FORMAT(/lH «'MH = •.Ffi.JtflX.•S02 = '.F9.6.' GMOL/L'.8X1'C02 = '
J F9.b, • GMOL/l.1/)
2300 CONTINUE
TFUPH.ECJ.O) ft" TO »X(l3)«X(iy)»X(24)«X<2b)
1 -2.»0) PCTfc
2360 FOHMAT( IH ."PEKCFwT E««UR IN IONIC BALANCE = ».K>.1)
23RO
LPR00900
I.PR00910
LPR00920
I.PR00930
LPR00940
LPR00950
LPR00960
LPH00970
LPR00980
LPHOU940
LPH01000
LPR01010
LPR01020
LPH01030
IPR01040
LPR01050
LPR01060
LPROioro
LPR01080
LPM01040
LPR01100
G-33
-------
FORTMAN P
IO=HtCCLl
12/1^/74
in.
PAOE 3
SS13] = 100. « SSI.1)
SS(l) = 100. * SSlD
IF(IP.EG.l) 60 TO ?395
WRlTF(6t23B5) SS(3I
238b FORMATUHOi'PEHCFNT bULF'ATL SA'TIJHATION =
GO TO 239fl
2395 CONTINUE
WRITE <6, 23 SS(3)i CM2fr>
2390 FOHMATUMO* "PERCENT bULFATE SATURATION =
1 tE10.4, « J • )
2348 CONTINUb
00 t F6.1*
( KSP = '
[ = 1.8
P.
0.
239V CONTlNUt
EPS s l.E-6
CMLU) = X
CMS(l-) = X(32)+Xm>*X(J4)»X(35)
CMLl?) = X ( 17)+X (1«)*X(19)
CMLJ3) = FNA«SUMX
CMLI5) = x<6)*M7)
'•>) = XI33)
it s X(9)*X I 10)«X(16)#X<2?)»A130)
MM ( I )
C«"L<
CMSJ6) =
CMH7) =
CMS(7> =
CML(8) = X(31)
CMLTOT = 0.
CMSTOT = 0.
CWLTOT = 0.
CUSTOT = n.
DO 2410 I site
CMLTOT = CMLTOf + C^L(I»
CMSTOT = TMSTOT *
) = 1000. *
> = 1000. *
CWLTOT = r**LT()T «
CWSTOT = CWSToT «
2410 CONTlNUt
CWTOT = 0.
IF(IOPT.GT.I) C*(
IFdOPT.E
no 2420 ]=i,a
2420 CWTOT = CriTOT + Cw(I)
TOS = CVfTOT - C*STOT
24bO FOHMftTUHO, 'TOTAL UISSOLVfcD
IF(IP.Mt.l) GO TO 2600
WHITF. (6.2100)
2400 FOHMflTllHOi "ANALYSIS U^ SLURPY:(» 11X.
1 «SOLIO« /
2 IH , 30A. 'OMOL/LlTE^1» 7Xf
(5)
Frt.O. •
LPR01110
LPH01120
LPR01130
LPi<01140
LPH01150
LPH01160
LPH011TO
LPMOllflO
LPH01190
LPH01200
LPR01P10
19X.
«bMOL/Ll TtR« , lOXt «PPM«I
LPR01240
LPH01?feO
(_PH01<270
LPROU90
I.PH01300
LPH01310
I.PH01J20
LPR013JO
LPH013bO
I.PH01370
LPK013dO
LP«01 J90
L PK01400
LPR01410
LPR01420
LPH014JO
I.PH014SO
IPH01/«60
LPR0147U
LPHOl't'lO
LPW01500
LPHOlblO
LPH015JO
LPH01540
LPROlbSO
LPHOlbbO
LPH01b7Q
LPH01600
LPHOlhlO
LPW01630
LPH01640
G-34
-------
BtOPHlNT FO"TRA'J P
TD=HFCCI_1
12/1S/74
10.56.14
PAGE 4
DO 2440 1=1.fl
IF(CML.LT.l.E-?n.AKjD.CMS
-------
Appendix H
GRAPHICAL OPERATING DATA FROM
LIMESTONE RELIABILITY TESTS
H-l
-------
J-
III "
s »
Ms-
I
Ih.
5 S« .
- INiOlUUCS (ASH)
- CALCUM (C.O)
10/73 I 10 7*
BO 100 1% 140 140
IEST TIM, houn
I 10/M I 10/?« I lO.To I 1M)
CALENCMt DAY
100 WO 2*0
Gil Riti-26,000 lefni* 300 °F
Liquor Ritt" 1200gpm
L/G • 64 oil/md
G M Vtlodty • 9.8 ft/m
EHIutnt RHtonct Tinw • 10 min
ThrM Stifn, 5 in vhffn/rt*t
Saubbtr Inltt Liquor Ttmp. - 112-126 °F
LiquU ConduclMtv • 3,200-7,500 u mhoi/cm
Diuh«fft (CUrrtiff) Solidl Cone. • 2741 wt %
• TOTAl NSSCXVEO SOLIDS
O CAlCWMfC.")
Q SUIFATI (SO/ I
A CHiOIlDf (C< - )
+ MAGN(SUM IMfl" .
A SODIUM (N.+)
V FCTASSIUM IK * )
• SULFITE OO.' )
O CAMONATI (CO. ' )
10 40 U 10 100 IM
TESITIME, ho»n
w/» i lo/i* i w/17 i n/n i to/M I H
CALINDAI DAV
iu IN too no 1*0
Figure H-l. Operating Data for TCA Run 525-2A
H-2
-------
•UN SM-1A CONTIMUf D
CAIENWI 0*V
• TOTAL DISiOlVID JOUOS
O CALCIUM (Co ** t
* CHLORIDE (Cl • >
4 MAGNESIUM (M,**)
A SOOHM (No * }
V FOTASSUMfK *l
• SULFITf K03 )
0 CAtlONATI (CO.J' }
MO MO HO 310 MO MO 400
IEST HMf . h
11/B I
OUMDAI DAV
MO 4M
MX* f II/M I
H/U I tl/IJ
GII RIM - 25,000 Kim * 300 ° F
Liquor Rut = 1200 gpm
L/G-Mgil/mcf
CB Velocity = 9.8 WMC
Efftuint R«id»nce Tim* • 10 min
Thru SligH, 5
Scnibbtr Inin Liquor Ttm«. • 119-1 23 °F
Liquid Conductivity - 7,500-9,300 u mho/cut
Oiichirjt (Cliriflerl Solldi Cone. • 31-42 M K
Figure H-l. Operating Data for TCA Run 525-2A (continued)
H-3
-------
EMDIUNSIS-1A '
0 n j
-
\l
H "
2 * '
5y '•»
^ 8 :.«o
TQTAI , EXCIUPINO MltT EKM k KOCH TKAV
•UTittW.iKOCMTMV
INLET (IN-IINI WCIER)
INLEI n AH
<.
N - OUTUTfl
4*0 SOD » MO M 9B W 130
ItSI 1IM(, hour!
I n/u I 11/15 I llfl* I 11/17 1 11'ii I 11/19
CAIENDAI OAY
MO 660
tl/SO I 1111
«0 7W''
i.ntn
I.MO
1.000
J.500
2 ? '
2 2 i «
I
* (SOJ
mMHOMMfitDMOMB
no ?»
CALENDAR OAV
n/w t n/»
i.,
• TOTAL DISSOLVED SOI IDS
O CALCIUM (Co +* )
Q HJIFATi (J04 t
A CHLOtiH fCI • i
• MAGNESIUM [M« ** }
& SODIUM (M0 * )
V roTASiw* I* * t
• suifin po, *)
O CAItONATf (CO, )
MO MO
I 11/14 1 11/11 I 11/1*
ti/io I ii/ii I \\flt i
CALtNMI DAY
G» Piti- 25,000 Kfm* 300 °F
Liquor Rite = 1200 gpm
L/G • 64 Ml/mcf
0« VelocitY - 9,8 ft/we
Effluint RMidinc* Time » 10 min
Thiw Staow, 5 in iphem^iip
Scrubbtr Inltt Liquor Temp. 122-124 °F
Liquid Conductivity • 9,200-10,900 u. mhoi/cm
Diichiroe (Clirtfier) Solids Cone. = 4042 wt Ii
Figure H-l. Operating Data for TCA Run 525-2A (continued)
H-4
-------
- TOTAL, EXCLUDING will ELIM t KOCH TB*'
FUN » KOCHTttAV
TEST TIMt, hnn
11/7* I
CALENDAR DAY
/» I 12/1
• TOTAL DISSOLVED SOLIOS
O CALCIUM (C* ** )
O SLILFATE (1O4 • 1
A CHLC«1DC Kl - 1
• MACNfSILIM (MgM
& SODRJM (No * )
T7 POIASSUM pi * )
• SUlFITf t5O3T )
0 CAMONATE(C
-------
' KIN JU-ZA CONTINUED
TUT TIME . hM,
«/5 I 12/4 I
CAIENOAI OAV
40 MB
Ifr I \t/9
I ,„
• TOTAL DISSOLVED SOLIDS
O CALCIUM (Co ** 1
Q SULFAIE (SQ^ - )
A CHiOIIDt tCI - 5
• MAGNtSHJM (Mg **)
£t SODIUM (N« * )
V PO1ASSUM [K * )
• SULFITE [SO * )
O CAWONAT! (CO., = )
•
A
a
o
-
-
-
-
-
II/J I ll/J I
11/10 I 11/11
OK Hiu • 20.500 icfm e 300 ° F
liquor Bin « 1 200 gpm
UG = 78 jil/mcf
Cu Wlocity • 8.0 ft/m
Efflutnl Rnidinci Tim • ID min
•Hint Sujti, S in i
Sctubbir Inlit LiquoiTimp. - 118-123 °F
liquid CoiducHvltY • 6,000-9.900 M. mhos/em
Oiiehir,. (d.rifiirl Solids Cone. • 35-44 wt S
Figure H-2. Operating Data for TCA Run 526-2A (continued)
H-6
-------
s' «
HJN 51*-!*. CONTINUED
TQML. ntCUJMNG MUT ELIM * KOCM ruv
ITILHH ftKOCMTNAV
I 12/12 I U/13 I 11/14 I 11/13 I 11/14 I 12/17 I 11/1
• TOTAL USSOLVfO SOLIDS
O CALCIUM f C* **)
D SULFATE K0t ' )
* otomoc rcr>
» MAGNESRJM (Mo ** )
A SODIUM (Mo *)
^7 WTASSWM (K *)
• SULFITl BO." 1
O CAttONATl [CO ' )
10,000
B.OOC
ManSKMMDMIBIIH
12/14 I 11/13
TEST TIME, hwn
1Z/1* I
lALfNDM BAY
TOO 720
I 11/91
GH RIM - 20,500 «rfm • 300 °F
Liquor Riti = 1200 gpm
UG • 78 gil/mcr
Gn Vslocity • 8.0 fi/m
Effluent Rnidence Tirm • 10 min
ThrM Si«ojw, 5 in *pherw/«ag«
Scrubbir inlet LJquor Temp. - 120-124 °F
Liquid Conductivity- 7,400-11,500 jimhot/cm
OiKhirpe (drift*) Solidt Cone. - 37-45 M%
Figure H-2. Operating Data for TCA Run 526-2A (continued)
H-7
-------
G« Km • 20,500 Kim * 300 °F
Liquor R.1.-1200 spm
L/G • 78 jal/mcl
G« V.locity • 8,0 fl/m
Eftlutni Rnidmu Tinw • 10 mln
Thru SlajM, S in iph«r«/itiji
Scrubbtr Inlit Liquor Temp. - 118-126 °F
Liquid Conductivity • 7,00-11,100 jtmhot/cm
DiKhirgt (Qirifiwl Soil* Cone. • 37-47 wt X
• TOTAL aSSOlVtDSOltOS
O CAICUM (C. ** )
a 5UIFATE (SO4 ' 1
A CHLOtiM (Cl * )
• MACNISUM (M! **
& SODIUM (N**)
V POTASSUM (It + )
• SULFHt (SO. " )
A
a©
O CAMONATI (CO.•
n/t4 i IVM
TEST TIME, r
IM4 I
CALtNDAR D
MO MO
IV* I "VSt
Figure H-2. Operating Data for TCA Run 526-2A (continued)
H-8
-------
6« Rite - 20,500 tcfm * 300 °F
Liquor Rue" 1200 gpm
L/G - 78 gtl/mcf
G« Velocity - 8.0 ItAtc
EHtutflt Reiidence Time - 10 min
Three Stages, S in ipherw/H»9«
Scrubbtr Inlet Liquor Temp. - 118-125 °F
Liquid ConductMiy - 7,100-10.400 H mhoi/cm
Discharge (Clarifier) Solids Cone. • 3846 wl %
^ 10,DO
* 1,000
• TOIAl DtiSOlVtO SOIID
O CALCIUM (O, " I
O SUlFAIf BO4 1
A CmotlM (Cl - \
TO IDOC 1010 I0« ID60
1/1 I \n
1.-7 I 1/1
Figure H-2. Operating Data for TCA Run 526-2A (continued)
H-9
-------
BEGIN RUN UO-ZA
END RUN WO-2A
TEST TIME, houn
I 3/» I 3/M I 3/31 I 4/1 I 4/2 I 4/3 I 4/4 I 4« I 4rt I 4/7 ( 4/1 I 4/1 I 4/10 I 4/11 I 4/12 I 4/13 I 4/14 I 4/16 I 4/11 I
CALENDAR DAY
12.000
1 11.000
t 10.000
! i.ooo
£ '•""
5 7,000
S «.noo
g 5.000
z
8 4.000
8 3.000
q
> 2.000
1.009
0
• NOTE SWC1ES WHOSE CONCENTRATIONSARELfSS
THAN MM ppm ARE NOT PLOTTED
. • TOTAIDISSOLVEDSOUDS
O CALCIUM 1C***)
O SULPATE (3O| ") -
A CHLORIDE ICI "I •
e
• •
*
CLARIFIER CENTRIFUGE
- ONLV ONLY
r | »•
-
A A
A
* on Qo o° 4VD Qo Do
nO ^
I I I i I I I I _i 1 1
11.000
11.000
10.000
0.000
1.000
7,000
1.000
5,000
4,000
3.000
2.000
1.000
0
MO 200 240
TEST TIME, howl
I 3f» I 3/30 I 3/31 I 4/1 I 4/2 I 4/a I 4/4 I 4A I 4/0 I 4/7 I 4/1 I 4/9 I 4/10 I 4/11 I 4/12 I 4/13 I 4/14 I 4/15 I 4/14 I
CALENDAR DAV
CD Ran • 20,500 tcfm * 300° F
Liquor Roti • 1200 gpm
L/G • 78 gri/mcf
GK VoJocity - 8.0 fl/uc
EHT (Stilid) Rnid.nct Timi - 12 min
Irino Sum, S in iphern/iaot
Pircmt Solids Bscirculjted - 14-16 wl S
Tool Pmwn Drop, Excluding Mist Eliir.
md Koch Triy - 4.8-5.1 in H20
Otmiittr mt Koch Troy Prnun Drop - 1.9-2.1 In HjO
Scrubbir Inlit Liguoi Ttmpintun-119-12S°F
Liquid Conductivity - 5,200-8.300 JL mhoi/cm
Oochmjo ICIirifi.r .nd Cintrifugol Solid)
Cannntnti on-30-43 wtK
Figure H-3. Operating Data for TCA Run 530-2A
H-10
-------
FUNNEL SAMPLER REPAIR AND INSPECTION —j
TEST TIME. hour.
S/19 I 5/20 I 5/21 I 5/22 I 5/23 I 5/24 I S/25 I 5/26 I 5/27 I 5/2S t 5/29 I
CALENDAR DAY
2*1
ill "
i a f '••
ill '•"
i 1.1
; *
111
J3 U >•
s*i
u> O ^
5^£
X Z
o ~
1
i
1
z
oc
i
s
—
i
>
i
5
X)
10
0
/\/^J\/\ r\ A / \ /\ A
•"x, /\ \/\ /\x'\_ \/ \ Av •
v/ V V ^ ^ ~~^ V v V
•
30
M
10
0
12.000 r- * -> 12,000
11,000
10.000
9.000
7.000
1.000
5.000
4000
3.000
2.000
1.000
• TOTAL DISSOLVED SOLIDS NOTE: SPECIESWHOSE CONCENTRATIONS ARE LESS
O CALCIUM ICi **1 THAN 500 pon. ARE NOT PLOTTED.
O MAGNESIUM IM,**!
. Q JULFATEISO,"]
A CHLORIDE (a ~) f>
•
• ^ 1^ ATOMIC ABSORPTION UNIT ^
t • OUT OF SERVICE
a
a A
° o o D a. * 3203004004M4IO
TEST TIME, houn
1 5/11 | 6/12 t 6/13 1 i/14 1 5/15 1 5/16 1 5/17 1 5/11 1 fi/11 1 G/20 1 5/21 1 5/22 1 5/23 1 5/24 1 S/ZS 1 ft/2* 1 VZ7 t V2t 1 (VTt t
CALENDAR OAV
- IZOOipm
l/G " 71 jol/md
6nVl(MllY-M
-------
HUN Ml ZA CONTINUED
TEST TIME, hqun
I 6/31 I I/1 I «/Z I I/I I 1/4 I 07S I IV« I 6/7 I 8/8 I 6/9 I 6/10
CALENDAR DAY
90,000
I »ooo
f 20.000
(C
2 15.000
2 10JW
* s.ooo
• TOTAL DISSOLVED SOLIDS
O CALCIUM IC« **l
O MAGNESIUM [M| «|
•
0
A SULFITE ISO, 'I
D SULFAT6(S04'*(
A CHLORIDE ICI "I
NOTE. SftCIES WHOSE CONCENTRATIONS ARE LESS
THAN 500 pgm ARE NOT PLOTTED.
•I o
30.000
K.OOO
1 20.000
15.000
10.000
1000 .
2.000 - O
'•««• • o O
410 WO
>*• cf °* °*
A
1 A A
5 O O
540 000
A
0* A°
&
O C^ C^
040 HO
0 AO °
2 A *2
a
0 ^> 0 0 OQ
720 TOO HO
0
« * 2
* A
A
A
0 0 & 0
•40 MO K
ju.
A *'-~>
- 3.000
A 1000
O C ''"*
10 Ml
TEST TIME. IMMH
u I in I I/I In I i/w I 1/11 I i/i! I «m I vi4 I v» I •/« I vi? I vn
CALENDAR DAV
Liquar Rato- 1200 gpm
L/G - 78 jil/mcf
On Viloeiw • 8.0 Wnc
EHT (Suloc) Rltidonco Timi- 12 min
ThrH Stlgn. 5 in soharaffaagl
P«rc«nt Solidi Rociralatot) • 7-3 v« %
Total Pressure Drop, Excluding Mift Elim.
and Koch Tny - 6.0-6.6 in HjQ
Scrubbir Inlet Liquor Tomponturi - 122-128 °F
Liquid Conductivity - 10,000-20,000 u. mhr
Oiicliargo (Clirifiirl Solidi
Concintratlon - 35-12 ot %
Figure H-4. Operating Data for TCA Run 531-2A (continued)
H-12
-------
ENORUNUV2A '
1
i* .
-S *
i n
s
•*>
r.
'I
— -_ KOCH TflAY OUTLET CLEANING
t- LIMESTONE FEED OFF
L- INSPECTION
A \A r-xx-V^
1 ' V
-
•/^
si
U
3.500
3.WW
> -- OUTLET
M
45
3.500
3,000
2.500
2000
1.000 1.040 1.010
I ft/20 I 6/21 I 6/22 I 6/Z3 1 6/74 I i
1.170 1 160 1.200 1740 1.290 1.320 1.900 1.400
TEST TiME.houn
i I ft/28 I »/27 I 8/28 I 8/2fl t 0/30 I 7/1 I 7/2 I 7/3 I 7/4 I 7/5 I 7/i I 7/7 I
CALENDAR DAV
1.8
9 3 1 ' •
< 8 J
HJ "
iff "
1.0
40
slj „
is
K Z 20
S2
0
10.000
1 25.000
%
E 10.000
S 15.000
5
? 5.000
£
| o
E
K 5.000
S 4-°°°
a tow
a
» i.»o
§ 1.000
a
0
»
-
*-" "^'^A -A ._* A
/^ V' \ f ^^ \
A^
-
•\ \A N
•\-A ^ A A
v ^ V\
V ;
.
•
r €
• • TOTAL DISSOLVED SOLIDS
• 0 O CALCIUM (Cj *41
O MAGNESIUM (Mg " t
.0nnOQDo a -jLnnno,.,
D SULFAT£|SOj-|
A CHLORIDE (Cl ~)
NOTE: SPECIES WHOSE CONCENTRATIONS ARE
LESS THAN 500 ppm ARE NOT PLOTTED.
0
o °
* • * * A » t
.
A
A A A
M 1.000 1.040 1.0*0 1.120 1.160 1.200 1.240 1.210 1.320 KWO 1,400 1.4
TEST TIME, houn
1 1/20 1 6/21 I 6/22 I 1/23 1 1/24 1 I/2S 1 «/7§ 1 «/27 1 *-T1 | VT» 1 »V» t 7/1 | 7/2 1 7/3 1 7/4 1 W» I 7/1 1 7/7 1 7/1 1
U
1 >
1 4
1 J
1 0
40
30
W
10
0
30.000
ZS.OOO
20.000
15.000
10,000
S.OOO
0
S.OOO
4.000
3.000
2,000
1.000
n
CALENDAR DAY
Gn Rm- 20.500 Kim* 300 °F
Liquor Rite • 1200 gpm
L/G • 78 til/mtf
Gn Vtlocity - 8.0 ft/nc
EHT (Solid! flnldlnci Timi « 12 min
Thrvt Snon, 5 in i
Percent Sclidl Rtcirtulllld = 7-9 wt %
Total Prmurt Drop, Excluding Mitt Elim.
and Koch Tray - 6.6-9.5 in HjO
Scrubber Inlet Liquor Temperature • 122-128 °F
Liquid Conductivity • 22,000-27,500 A mhos/cm
Discharge (Clirlfiir) Solids
Concentration - 35-42 wt S
Figure H-4. Operating Data for TCA Run 531-2A (continued]
H-13
-------
BEGIN RUN 532-ZA
END HUN U2 2A
is
52
SS
100
* *
Sl' »
I
85
00
U
-• ui 2* °-<
™ i *• ° 3
»*f 0.!
O.I
M
e.o
Hi »
8*
5.0
- ~s\ rf/^^-^^ r<^^ r^ / .^\ s-^s~
\ /' -^ " ^"/x—" ^Y-A A
yvy1 "^ \ '""" ^ " •*' \ /
\ / V — OUTLET "*
.
I J*\l\
• i / 1 N^ NX n ^ l '' "i / ^ "X
- /i/w ^ \ j /
.v v
IQB
*
90
as
ao
0.8
04
0,3
02
0.1
IS
B.O
5.6
5.0
4 S
1 WM
3.000
2.600
2.000
'•""o «o • MI Mt at ia at ' ~ ' ' at at ta MI
-------
BEGIN RUN S33-ZA
END RUN 533 2A
la
<2
M
100
H
Sfl* "
8
•
BO
OS
is 3- "
si* ° j
' ^ o °*
0.1
M
1.0
lit «
I*
5.0
4 5
3 WO
r, g I000
58 2,000
1 WO
1,1
Ml "
R X 1
: 1 0
40
Iff X
£ - I w
a N t-
i 9 j
0
70.000
1 80.000
5
| 50,000
0 40.000
• 30.000
z 20.000
a
i 10.000
1
s °
z
U)
o
o 3000
o
"• 2.0OO
§ 1.000
a
(
INSPECTION — j REINSTALL G-201 STRAINER — ^
REMOVAL OF ELIIOT STRAINER J T— COOLtNQ S^RAY HEADER KEPAIfl
• — y v-^j-v — \A/~X_^^VT ,v> -\ A~~Sr^
r ^rw\H^ " v-^^
.
.
j
•
-
-
^-^ ^ — ^_^-v_ -*
r
r~ INLET
"y^^^^^^v^^-'-^-^V.^X - ^v-v'SVA'^NV^— *^ ^^**
•^'"*^^^^^^v^-^ ^ V/N/^^"^-^^- ^ ^^
\_ OUTLET *^^
"
-
-| (vA n
//\flA HA^ A IA/lr\
•'J UY^^VTA n/ ^ N/Arv W^
\A / 1
WV J IvJ
J 40 80 1M 160 200 240 280 320 360 400 440 41
TEST TIME houi
CALENDAR DAY
: r^ ,--S\ \
-•'N/ ^^_— - ^^v__^
"*"^
,
A,
-\Ai — ^ — \ // \_. N / \
V- •-*' \ / s/ *" " "~
•J
-
•
• roTAL DISSOLVED SOLIDS
• • •
• • 00 O CALCIUM ICi "i
_ O MAGNESIUM (Mg "l
:•• 0°° DD 0 * * SUL.TE.S03-,
O SULFAT€ IS04'|
0 4 CHLORIDE ICI ~)
- LJ LJ -
NOTE SPECIES WHOSE „
_ A THAN 500 pom ARE NOT
PLOTTED.
A
A
A A A ^-^
4 A A* "
A A A
A A A
A
O^O,^ " ii? i i i i
40 BO 110 100 200 240 200 320 340 400 440 41
TEST TIME, liourt
1 8,7 I 8,» 1 8/9 1 i-;'0 1 1/11 1 kV12 1 a/13 1 >V14 1 S/15 1 8 IS 1 I/1T 1 8 1B I 8/19 1 S/20 1 B'JI 1 1/17 1 0/23 1 6/24 1 §'25 1
CALENDAR DAY
Gas Rate = 20,500 acfm 9 300 °F Percent Solids Recirculated - 14.4-5.5 wt %
Liquor Rate = 1200 gpm Total Pressure Drop, Excluding Mist Eli m.
L/G = 78 gil/mc) and Koctl Tr"Y - 4.6-4.95 in HjO
150
96
90
•
80
05
04
03
02
0.1
at
"
55
SO
45
3.500
3,000
2.500
1.000
1500
10
1 8
1.8
14
l 2
1 0
40
30
21)
10
0
70.000
00.000
50.000
40,000
30.000
20.000
10.000
0
4,000
3.000
2.000
inoo
0
Gat Velocity * 8.0 It/sec
EHT (Sealed) Residence Time = 12 min
Three Staget. S in spheres/stage
Scrubber Inlet Liquor Temperature
Liquid Conductivity -27.00D-39.000 u. mhos/tm
Discharge (Clarifier) Solidi
Concentration = 29-38 wt %
Figure H-6. Operating Data for TCA Run 533-2A
H-15
-------
Is
|S
i
$i*
a
M1
si*'
iil
I6t
si1
SI
So-
il
M
10
71
70
0-4
11
f.2
01
0
11
10
1.0
4.1
i.m
2.0W
1 VW
•MM RUN WIA END j
PUMP J MEHEATEfl *^1
REPAIR PROOLEm
AACV A/
" i/"!/
u
..
•
• _--^
•~~
•
•
f~ WLET
. ^— OUUiT
•
\ (i^A
n . \n \ /
[lAV\ ^ V
K
K
78
70
0.4
03
07.
01
0
It
10
S.O
4.5
J.SOO
1.000
2500
2.000
i wn
0 40 M lit HO 200 MO 200 320 HO 000 409 400
I 0/4 I M I M I t/7 I M I M I 0/10 I 0/11 I 0/1J I OV11 1 1/14 I 0/10 I 0/10 I 1/17 I 1/10 I W10 I W30 I l/» | 0/12 I
CALENDAR DAY
l.B
is! 1.4
ill
i a J '•»
il»
gl| «
1.1
sli "
Is! -
ip ,,
*S5 .
11.000
i-
y 11.000
I 10.000
a looo
*-
J 1,000
i ;™
• 6.000
1 4,000
! J000
>
8 2,000
I/MM
.
'^\ ^ '.
\
. /»
AX V^-
.
-
r -,
• TOTAL DISSOLVED »LIOS
O CALCIUM ICi »»l
D OULFATE l«O4->
A CHLORIOi ICI -1
• NOTt: SPECIE! KHOSE
0> CONCEI1TRATIOHS ARE LESS
THUIIMpMliMIWT
PLOTTED.
•
•
•
i * *
' ° D 8 &
•
iiiiiiiiiii
1.4
1,3
I.I
1.1
10
•
10
0
11000
12.000
11,000
10.000
0,000
0,000
7.000
0.000
1000
4.000
3,000
1000
1,000
0
I M I M I W I 1/7 I Ml t/t I W10 I W11 I oVlt I t/IJ 1 tVU I tVlS I tVIt I tV17 I t/1t I t/lt I MO I «V21 I trtl I
CALENDAR DAY
,-20,500 tclmS 300°F
Liquor Rate = 120Qapm
L/G • 73 yol/mcf
Gn Vtloclty • 8.6 ft/toe
EHT (Snlldl Resilience Time • 12 mm
Three Sttgtt, 5 in cphirn/ttogt
Poreont Solid! Rtclrculiud • 10-12.5 wt %
Totll Pronuro Drop, Excluding Mitt Elim.
tnd Koch Troy • 4.04.3 In H20
Scrubb.r Inlit Liquor Timpontun • 123-127 °F
Liquid Conductivity • 6,300-3,000 u mhos/cm
Ditch.rge (Clarilier) Solidl
Concenlration • 30-40 wt K
Figure H-7. Operating Data for TCA Run 534-2A
H-16
-------
21
Is
BEGIN RUN 5*2*
.CANING -, INSPECTION-
V.
1%
4.5
3,500
3000
2.500
2000
1,500
TEST TIME. houM
I 9/13 I 9/14 I 9/15 I 9/16 I 9/17 t 9/18 I 9/19 I 9/20 I 9/21 I 9/22 I 973 I 9/24 I 9/25 I 9/Z6 I 9/27 I 9/28 I
CALENDAR DAY
45
3.SM
3.000
2,500
2.000
1.503
9/29 I 9/30 I 10/1 I
13.000
12.000
11.000
10.000
9.000
8,000
7.0OO
6.000
5.000
4,000
3.000
Z.OOO
1.000
• TOTAL DISSOLVED SOLIDS
O CALCIUM (Ci*+)
O SULf ATE (SO3-)
A CHLORIDE ICI I
NOTE. SPECIES WHOSE
CONCENTRATIONS ARE LESS
THAN 500 ppm ARE NOT
PLOTTED
8
G
. ***
8 8 fi 9 g
8 d
*.
a
t 09
12.000
11,000
10.000
9.000
8.000
7.000
«,000
3000
2.001
1000
TEST TIME, haun
I 9/13 I 3/14 I 9/15 I 9/tl I 9/17 I 9/11 I 9/19 I 9/20 I 9/21 I 9/22 I 9/23 I 9/24 I tIK I
CALENDAR DAY
9/26 I 9/27 I 9/2* I 9/29 I 9/30 | 10/1 I
Gal Rate = 20.5M «cf m @ 300 °F
Liquor Rate- 1200gpm
L/G - 73 plfaicf
Gai Velocity - 8.6 ft/sec
EHT (Sealertl Residence Time • 12 min (9/12-9/271,
15 min (after 9/271
Three Stages, 5 in spheres/stage
Percent Solidi Ricirculated = 12-15 wt %
Total Pressure Drop, Excluding Mist Elim.
and Koch Tray - 4.M.6 in HjO
Scrubber Inlet Liquor Temperature =120-126 °F
Liquid Conductivity = 4,800-10,000 u mhos/cm
Discharge (Claritier) Solidi
Concentration • 35-42 wt S
Figure H-8. Operating Data for TCA Run 535-2A
H-17
-------
I 10/3 t 10/4 I 10/5 I 10/6 I 10/7 I 10/1 I 10/9 I 10/10 I 10/11 I 10M2 f 10/13 I 10/14 I 10/1S I 10/W I 10/17 I 10/11 I 10/1) I 10/20 I 10/21 I
CALENDAR DAY
11.000
10.000
9.000
8.000
7,000
G.CXXJi
5.000
NOTE: SPECIES WHOSE
CONCENTRATIONS ABE LESS
THAN GOO ppm ARE NOT
PLOTTED
§ fi.
• 13.000
• 12.000
• 11.000
10,000
1.000
1.000
7.000
6,000
5,000
4.000
1,000
2,000
1.000
UOMOMOMOMOTZOTflOHOMOMOnO
TEST TIME. Kmin
10/3 I 10/4 I 10/5 I 10/6 I 10/7 I 10/1 I 10/9 I 10/10 I 10/11 I 10/11 I 10/13 I 10/14 I 10'15 I 10/16 I 10/17 I 10/18 t 10/19 I 10/10 I 10/21 I
CALENDAR DAY
G«H««- 20,500 acini* 300° F
Liquor Ratt * 1200 gpm
L/G • 73 sal/mcf
Gas Velocity = 8.6 ft/set
EHT (Snlid) Residence Time • 12 min (9/12/27),
15min(after9/27l
Three Sng«. 5 in tphms/mgl
Percint Solids Recirculated - 12-15 wt %
Total Prtisure Drop, Excluding Mitt Elim.
and Koch Tray * 4.04.6 in HjO
Scrubbir Inlet Liquor Timpenture • 121-128° F
Liquid Conductivity-6,500-11,800 u mhoi/cm
Discharge (aarifierl Solids
Concentration > 3542 wt X
Figure H-9. Operating Data for TCA 535-2A (continued)
H-18
-------
Appendix I
GRAPHICAL OPERATING DATA FROM
LIME RELIABILITY TESTS
1-1
-------
WGlN HJN 401-IA
I 10/10 I 10/11 I 10/12 I 10/13
TEST TIME,
I 10/14 I 10/15
CALENDAR DAY
770 MO '
10/16 I lO'l? I 10/18
10/10 I 10/11
nST TIME, twin
10/11 I 10/13 I 10/H I 10/15
CALENDAR DAY
• TOTAL OlSSOLVtO SOLIDS
O CALCIUM 'Co ** I
O SULFATE (5O4 )
A CHLOUDE (Cl ' I
^ MACMESIUM (Mj *"
A SODIUM (Nn - 1
V POTASSIUM (K ' ]
O CAMONATE (CO |
Ne«: Voluti lo. Co" ind Total Diuoltd Solid*
100 1»
TEST TIME, how,
10/1] I 10/14 1
CALfMDAI DAY
Q5
IftO ISO 700 :
10/17 I 10/18
CM Rin-25,000«cfm*330»F
Liquor Km to Vtnturi • 800 K>m
Lipuor Dm to Sony TONtr * 1200 K>n
Vlnluri L/G • 32 gil/rncf
Sptl» Town L/G • 64 Oll/rocf
Sony Tram G>> Viloclty • 6.3 Wm
Vtnuti Prraura Drop • 9 In. H20
E.H.T. RwdtnctTiiM-Umin
No. of Sptiy Ht>dm = <
Scnjbkv Inltt Liouor Ttmo. -.128-121°F
Liquid Comhjctrvity - 3,700 5,200 Jl mhoi/cm
Doctor* ICIvifM Solidi Cone. - 21-26 wl %
Figure 1-1. Operating Data for Venturi/Spray Tower Run 601 - 1A
1-2
-------
UN tGl-U CONTINUED
GH Riti • 25,000 «cfm * 330 °F
Liquor Rite to Venturi * 600 gpm
Liquor Rite to Spny TOMf • 1200 gpm
Vintufi L/G = 32 jil/mct
Spriy To** L/G » 64 jil/mcf
Spny Tower Gn V.lotity • 6.3 (l/«c
Vlnturi Prtgun Drop - 9 in. r^O
E.H.T. Rniihnw Ti™ * 12 min
No. ot Spny HtlfJmi • 4
Scrubbtr Inln Liquor Temp. • 123-126 °F
Liquid Conductivity • 5,200 8.600 11 mhoi/cm
Ditch»m I Chrifitrl SnlMi Core. • 22-26 M %
5 >.»
a
I »
:;
O CALCIUM (Cn ** < & SOCUM (No * 1
D SULFAIE RO4 I V fOTASSIUW IK ' )
* CHLOtiDf tCI • ) • SULFITE (SO3 ' i
0 CA«»ONATE (CO3 ' )
•
•
° 8 =*
-------
G«fliti-2b,OOOicfm»330°F
Liquor Rtu to Vinturi = MM jpm
Liquor DM to Spny TOMC • 1200 gpn
VttituriL/0-32nl/mct
SBnyTl»MtL/G-64ljl/iKf
Spny TOM 6n Vdodty • U ft/K
Vnuri Pmura On» • I In. N]0
E.H.T. Buldinci Tinn • 12 ™
No.ofSpnyH«dm>4
I Inltt Lkluor Twip. • 123-121 °F
LlquU Conductivity • 6,60M,«IO M. n
DWMIO ICWtkrl SoMl Cone. - 20-26 wt %
CALEMDA« [MY
• TOTAL OlSSOlVtO SOLIDS
O CALCIUM (Co ** }
O SULf ATE SO( ' )
A CHORIDE (Cl - )
* MAGNESIUM (Ma "
A SODDM (Mn *
V POTASSIUM (It * )
• So»i
11/3 I
CALENDAR DAY
Figure 1-1. Operating Data for Venturi/Spray Tower Run 601-1A (continued)
1-4
-------
HINMl-IA CONTINUED
s >••
• TOTAL DISSOLVED iOUOS
O CALCIUM (Co'" \
a suture rso4 )
A CHLO«tO€ (Cl- )
* MAGNfSNJM IMgH 1
A SOOIUM (No * )
V K3IASSIUM (K *)
• SJIFITl (SOj )
O CAHOMTE (CO3 )
h h
h-
TEST TIMf. hauti
It/JO I 11/11 I 11/12 | ll/lj |
CALENCM* Mr
I 11/16 | 11/17
G« • 25,000 Kfrn* 330'F
Liquor Rile to Venluri - 600 gptn
LiquoT Rill In Spny TOWUT - 12001pm
Vmturi L/C • 32 Jil/mcf
Sony Trair L/G 64 gtl/mcl
Sony Tonnr G« Viloclty * 6.3 ft/HC
Vmturi Pmsun Drop - 9 in HjO
Etflumt Rnlitonci Tim • 12 tnln
No. of Spny H«!din • 4
Sciubbir Inlil Liquor Ttmp. -122-121 °F
Uquld Conductjnty • 6.900-10,300 u. mhoi/ccr
Diitliirgi Solids ConctTitnUon (SM liquid dita
plot for dispowl iyitem u»d.l
O.ritlt. Only: 20-J6 »1X
Cl.rltier SFilrer: 44-51 wl«4
Figure 1-1. Operating Data for Venturi/Spray Tower Run 601-1A (continued)
1-5
-------
7 * i-
2 8 I
MJNU1-IA CONTINUED
1 \fl1 I 11/M
• TOTAL DI5SOI Vf D SOLIDS
O CALCIUM (c« M )
O SUIMTE (SO4 ' )
A CHLOHIDt (Cl - 1
»o°
+ MAGNESHIM (Mg** 1
6 SODIUM (No ' |
*? FOTASS1UM (K * )
• SULFITE {SOj ' }
0 CAMONATE IC03= )
11
0*
s
a
I -
G«-25,000 «lm* 330 °F
Liquor Ritt to Vtnturi • BOO gpm
Liquor Rm to Spny Ta
-------
Ig f
UJNttl-IA CONTINUED
• TOTAL OIllOLVtD SOLID
O CALCIUM (&•**)
A CHLOtlOC (CI - )
• MAGNIS'UM (Mf ** )
Ct SOOfUW (K. * !
9 POTASSIUM (K * )
• winnso^-)
o CAwwiAn (CGj •)
Jo
10.000
9,000
4,000
2,000
•
_i_a_
ixo i»o
n/lt I 11/30 I ii/t I
1320 iwo
rtSf TtM£. Inn
I IV3 I 11/4
CAICNOM MY
IMO i«o I4» |4«
I IV* i iz" I '•'/•
G« RIM-25.000ocfro»3M°F
Liquor Rlti to Vmturi • 600 jpm
Uquor RIII to Sony Tnw • 1200 gem
V«ituril/G-32ji/iraf
Spr.y To»,r L/G - 64 ^l/mcl
Sony TOMF Gn VHodly • 6.3 fttec
Vwturl Pmuro Drop"9inH,D
Efflu.ntKHKl.nci Tim,-12 mir
Nc.ofSpnyHHdn-4
ScnibbM Inlrt Liquor Timp. • 121-121 °F
Liquid Conducli«ity • 5.000-7,000 M.mhM/cm
OiKhirji Solidi ConcintnHon (SM liquid dm
plot for diipool lytttn u»dl
a»il»r Only: 21-27 WI%
Qltitwi FiltK:4S-SOwtS
Figure 1-1. Operating Data for Venturi/Spray Tower Run 601-1A (continued)
1-7
-------
HUN U1-1A CONTINUED
I-
M! "
o - «
I iiy» i 12/10 I iz'i
">"•
ia,noe
10,000
•r ».ooo
8 i.om
C 4,000
I
| i.ODO
" 0
* TOTAL DISSOLVED 50UDS * WAGHESIUM (Mg **)
O CALCIUM (G> ** ) A SODWM (No * )
D SULFATffSO *) 7 HOTASSRJM(lt* 1 9
A CMtoiioe KI - > • suLFirt (so, s )
O CAWONAn (COj • )
.
» 00 .
A O
.;
u.oon
17.000
10,000
8.000
t.aoo
3.000
0
?440 IWC
A,
IJ/10 I 11/11
.•-*) IUO
Itil 11 Ml. h.un
12/12 1 12/11 I 12/H
OlENDAK DAY
Ij/ttl I 1V17
G« Din • 25,000 Kim * 330 ° F
Liquor RIM to Vmturi » BOO gpm
Liquor Dili to Spny ToMr • 1200 gprn
Vtnturi L/C • 32 gil/mcf
Spny Tower L/C • H gil/mcl
Sony Tomr Oi, Vilodty - 6.3 ft/at
Vtnturi Prtnure Drop = 9 in H,0
Etflutnt B«iiHnc« Tim • 12 mta
No. of Sony H«.dm > 4
Scnibter Inlit liquor Timp. • 122-125 °F
Liquid Conductivity - 6,20r>9,700 u.mho>/tm
Oischiroe Solids Concintntfon ISn liquid dm
plot for dhpoal tysnm usfdl
ainfl«r Only: 21-26 W1K
drifieiS Film: 42-50 wt%
Figure 1-1. Operating Data for Venturi/Spray Tower Run 601-1A (continued)
1-8
-------
ENTUM t SHAY TOWR INIIT (UM)
5
VINTUII i SWAY TOWH ,NLH JIN-UNE MCTIM
Gu Rm • 25,000 Kfm * 330 °F
Liquor Ran to Vinluri • 600 gpm
Liquof ftitt to Spny Towvr • 1 200 gpm
Vintufi L/G-32gil/mcf
Sony Towtr Co Vtloclty • 6.3 It/He
Vlntun Pntun Drop • 9 It HjC
Efflu.nl RriiiJinti Time • 12 min
No. of Sprty H..d«n - «
ScnibbH Inlft Liquor I.mp. * 122-1 M °F
Liquid CondiKtMty - 1,100-12,000 umhoi/tm
DiKhrgt (Dirillir & Film I Solid!
Conctntr«fon-4MlMK
• TOTAL 0«OIV10 iCXIW
O CALCUMIC***)
D lULFAff (JO4 ' I
A CMIO«1W (Cl • I
o'
0
• MA&NCSIUM [M, " )
A tOMUM (N«*)
7 KJTAiSWMflt »)
• fULFIT! (SO * )
0 OHOMATt (CO, ' )
iiw ir» inn i7*c
ii/t* I >3/» I >2Al t
LOW
4.000
t» wo KM IMO two IMB
mi TIUI. t— -,
I 11/U I ll/M I 11/15 I 12,^* I '*/"
CAUNOU MV
Figure I-1. Operating Data for Venturi/Spray Tower Run 601-1A (continued)
1-9
-------
tUNttl-lA CONTINUED
W 1MB IMO I9» MOO KIK TOtO TO40 ?CBO J100
G«Rati = 25,000 a
Liquor Ran lo Venluri = 600 gpm
Liquor Rate lo Spray Tower • 1200 gpm
Venluri L/G = 32 qal/mcf
Spray Tower L/G = S4 gal/mcf
Sony Tower Gas Velocity - 6.3 ft/sec
Venturi Prtssuie Drop = 9 in HjO
Effluent Rrtidence Time = 12 min
Nu. of Spray Headers = 4
Scrubber Inlet Liquor Tamp. = 118-126 °F
Liquid Conductivity - B.400-10,700 u mhot/cm
Discharge (Clarifier & Filler) Solid)
Concentration - 44-52 wt H
ill'
^ J n™
131
- INSOLUIIES (ASH)
is1."
z e u
JOffl ."if 3060 20BO
2130 JI40 JIM)
I 12/39 I 17,00 I I7'll I I/I I
1/3 I 1/4 I 1/S
_ to.oc
TOrAL DISSOLVED SOLIDS
OICIUM (Co H |
SULFATE (SO, )
CHIOHIDE (Cl ' 1
MAGNESIUM (Mg " 1
A SODIUM (NB • i O CA«ONATE (CO}
7 TOTASSIUM (K ' I
• SUlFirt (SO. )
12/yt I 12/30
2000 »2D -")*) 2MO 20BO
TtSTTIME, hwn
I I/I I 1/2 I 1/3 I 1'*
CALENDAR DAY
7170 11*0 7160
Figure 1-1. Operating Data for Venturi/Spray Tower Run 601-1A (continued)
I-10
-------
VfNIUII A SftAY TOWN INIIT (IN-LINt Mtltl)
-
^ - vtNWf 1 4 JHAY
TO*«I IN4II :L*I)
r.1 l.SM
s *
K w J.8*
HI.
t V
"
ii«o nw n»
TUT TIMI, >«un
I 1/11 I 1/11 I
CALENDAR DAV
1130 2MC UtO 3310
1/14 I I/I) I l.'l* t
if::
ir.ooo
r io.oco
I 1.000
• TOTAL OlSSOLVtOSOlKK
O CALCIUM {Cm ** )
O JVLFAT! I5O4 ' )
A CMlCtt'OE (CO
• MAGNtSIUM iA.\i " )
& SODIUM (N. ' )
7 POTASSIUM (R ' )
• sjif IT! fiOj • >
O CAtto^4Are (co • i
5 300
I m
3.00T
:,soo
I *
i!
H
31
21
30
II
^7
•-£
<.
TOTAL ULfUl nOj)
CALCIUM (C.O)
SUUIT1 (JOj)
11*0 JIM MOD HJO »« 1MO JIM JJOB JMO 7)40 1MO MM
TfST TIMt, Scun
I I/I 1 I/V 1 1/IB 1 1/M 1 1/12 1 I '1 1 1/14 1 l.'l 3 t I'U 1
CALENDAR DAY
-
•
Ml
En Hit! • 25,000 Kim f 330 °F
Liquor Rite to Vcnlurl • 600 gpm
Liquor RIM n Spny Twwr • 1200 jpi>
Venturi L/G • 32 jel/mtl
Sony Tower L/C • 64 jil/mcf
Spriy Town GH Vtloclty • 6.3 It/we
Vinturi Pmwn Drag • 9 In HjO
Efflutnt Retidertce Time • 12 mln
No. ol Spr.y Hetdtn • 4
Strubb«r Inlet Liquor Temp. • 123-124 °F
Liquid Conductivity • 8.900 ji mhm/cm
DiKhHgt >'Clirillir a Filter) Solids
Contintritlon • 46 wt H
7i« nn noo mo nw TMO z»o 2300 ii» IMO ;JM ino two
TtlTTlMf, ^n
I 1,1 I }fl I 1/10 I '/I t I 1/11 I 1/13 I 1/14 I 1/13 I I-'U I t/17
CAUNDAI DAY
Figure I-1. Operating Data for Venturi/Spray Tower Run 601-1A (continued)
I-11
-------
BEGIN RUN M2 1A
END RIM MM 1A
d* *
TEST TIME. noun
I 3/19 | 3/17 | 3/11 | 3/19 | 3/20 I 3/21 I 3/22 | 3/23 | 3/24 | 3/25 | 3/26 | 3/27 | 3/28 | 3/29 | 3/30 | 3/31 | 4/1 | 4/2 | 4/3 |
CALENDAR DAY
12.000
S 11.000
1 10.000
! 9.000
9
K 8.000
i
7.000
| 9.000
3 5.000
1
g «00
S 1,000
i
3 2.000
8
1.000
0
• MOTE SPECIES WHOSE CONCENTRATIONS ARE LESS
THAN 500 ppm ARE MOT PLOTTED.
• TOTAL DISSOLVED SOLIDS
O CALCIUM 1C* **) 0
_ Q SULFATE (SO, ")
A CHLORIDE (CI ~)
•
• ^
"CLARIFICBONLV 1 CLARIFIEH ONLY
: .
A *
• 4 * ° 0 S
• ftp a a
A 0 a
12.000
11.000
10.000
9,000
B.OOO
7.000
9.000
b.OOO
4.000
3.000
2,000
1.000
TEST TIME, heun
I 3/10 | 3/17 | 3/19 | 3/1* I 3/20 I 3/21 I 3/Z2 I 3/23 I 3/24 I 3/75 I 3/20 I 3/27 I 3/29 I 3/70 I 3/30 I 3/31 I 4/1 | 4/2 | 4/3 |
CALENDAR DAY
Gas Ran • 25,000 acfm * 330 °F
Liquor Roto to Venturi - 600 gpm
Liquor Rate to Spray Tower = 1200 gpm
Venturi UG - 32 gal/mcf
Spray Tower L/G = 64 gal/mcl
Spray Tower Gn Velocity = 6.3 ft/sec
EHT (Senled) Retldancg Time - 12 min
No. o( Spray Headm = 4
Pircent Solids Rgcirculated - 7.5-9.5 wt %
V9nturi Pressure Drop - 9 in ^20
Total Presnire Drop, Excluding Mist Elim. = 11-12 in H?[)
Scrubber Inlet Liquor Temperature - 124*130 °F
Liquid Conductivity . 6,800-9,200 Jt mhos/tm
Discharge (Clarifiei and Filter) Solid!
Concentration - 42-48 wt S
Figure 1-2. Operating Data for Venturi/Spray Tower R,un 602-1A
1-12
-------
40 M1M1M2M>24e200320»M40D4M
TEST TIME, haurt
4/3 I 4/4 I 4A I 4* I */7 I 4* 1 4* I 4/10 I 4/11 I 4/13 I 4/13 I 4/14 I 4/1S I 4/1« I 4/17 I 4/10 I 4/tt I 4/20 I 4/71 I
CALENDAR DAY
12,000
I-
f 10.100
I 9000
t 1.000
I 1.000
5 5.0M
i
g 4.o"
a 1.000
9
2.000
1,000
0
• TOTAL DISSOLVED SOLIDS NOTE: SPECIES WHOSE CONCENTRATIONS
O CALCIUM 1C* **)
O SULFATE ISO< '!
A CHLORIDE
-------
TEST TIME, houn
I 4/27 I 4/21 I 4/29 I 4/30 I &/I I fi/2 I 5/3 I 5/4 I 6/5 I 5/8 I 5/7 I 5/i I 5/9 I 5,'10 I 5/11 I 5/12 I 5/13 1 5/14 I
CALENDAR DAY
N2 PURGE
OVER EHT
LOST Nj PUFGE
' tMSCFH I PURGE I 330SCFH
— - K- H*
12.000
I ,1,000
f 10,000
i 9i°°°
H 8.000
2 7.000
• e.ooo
y 6.000
1
i •••"•
S 3'°°°
S 2.000
Q
1.000
2
0
• TOTAL DISSOLVED SOLIDS NOTE: SPECIES WHOSE CONCENTRATIONS
O CALCIUM 1C. **> ARE LESS THAN 500 pern
0 SULFATE 1S04 "1 AfiE NOT PLOTTED.
* CHLORIDE ICI -J
* *
^
• • •
•
*
• A
A 4 *
A O O
A - 0 0 00
00 DO 0
D 0
17.000
11.000
10.000
9.000
8.000
7,000
1.000
5,000
4.000
3.900
2.000
1.000
n
TEST TIME, houn
I 4/77 I 4/21 I 4(79 1 4,'M I 5/1 | 5/2 | 5/3 I V4 I S/S I 6/6 I R7 I W I Ml I 5,'10 I 5/11 I ft/12 I 5/13 I 6/14 1 5/15 [
CALENDAR DAY
G.i H.I. 26.0M icfm » 330 °F
Liquor Rnt to Vmtnrl - mimmum (100 jpml
Liquor flitt to Spray Towtr " 1200 gpm
V«nturi L/C = 5 )il/mcf
Sony Tamr L/C = 64 jil/mcf
Spny Towor G« Votodty • 6.3 ft/at
No. of Sony HOKjtn - 4
EHT (Solid with N} Pur9«) RoiUtiici
TirM<17min
r%nm Solids R«ircul.t«l - 7.5-9.0
Vonturi Hug Position 100% Open
Total Prusinri Drop. Excluding Milt Elim. - 3.3-3.9 in H.O
Scnillw Inl.t Lkllioc Timplntur. = 125 129 °F
Liquid Conduclivity - 4,900-9,500 IL mhoi/tm
Dlteborgi (CIvrHor ind Filtor) Solids
ConcMtrmon - 50-M wl S
LilM Addition to Scrubbir Oowncom.i
Figure 1-4. Operating Data for Venturi/Spray Tower Run 604-1A
1-14
-------
RUNHM.1A CONTINUCD
I S,'l7 t
TEST TIME, houn
I 5/1* I 5/20 I S/21 I S/Z2 ! 5/23 I 5/24 t 6/25 I 5/28 I 5/27 I 5/28 I 5/29 I 5/30 | HH I W1 I M I IO I IM
CALENDAR OAV
12.000
| 11,000
I 10.000
g
1
6 '•"*
1 7.000
1 (.000
I
Jj 9.000
*
& **»
8 3.000
Q
> 2.000
8 ,00,
5
0
• «
•
• TOTAL DISSOLVED SOLIDS
O CALCIUM (Ct **(
O SULFATE
DO Q Q
0
' 1 1 I 1 l | | [ | i _
12.000
11.000
10.000
1,000
•.000
7.000
6,000
5,000
4.000
3.000
2,000
vooo
i an? i vn i iro i m I MI I ra i m i im I MB I B/M'I u? I Mt I SVM I MO | MI I vt I w I M I w I
CALENDAR DAY
Ga Ritt • 25,000 trim 1330 °F
LiquiK Km to VMtwi • minimum (100 gpm)
Liqyoc Rid to Spr.v To«M • 1200 gpm
V.nturi L/C • 5 Jil/mcf
Spriy Tow L/6 - M fjl/ncf
Sony Tomr Ots VriocMy • 6.3 ft/s«
No. of Spny H«din « 4
EHT (S«l«l with N2 Potil! fteUMCO
Tim • 17 mm
hrcom Solids Ricirciiloud • 7.5-9.0
Venturi Plug Position 100K Opir
Totil PtBjute Drop, Exdudini Mist Ellm. • 3.3-3.1 in H.,0
Saubb.r Inllt liquor Tempwituft • 12H32 °F
Liquid Conductivity - 7.400 12.000 X mini/Cm
Diichirgt (CbriFtof ind Filltf I Solid;
ConcMtntion - 50-JO m %
Limi Addition to Seiibbir Downeomc
Figure 1-4. Operating Data for Venturi/Spray Tower Run 604-1A (continued)
1-15
-------
HUN MM-tA CONTINUED
INSTRUMENT
CHANGE
I M I t/7 I ft I W I V10 I a/11 I
TEST TIME, how*
8/14 I 6/16 I 6/li
CALENDAR DAY
1.290 1,320 1.360 1.400 1
I 0/1* I 6/19 I V20 I B/Z1 I 6/22 I 1/23 I 1/24 I
nl
lif
1.000
1.040
1.060
1.120
1.200
1.320
1.360
1.400
10.000
| 15000
i KOOO
13.000
3 11,000
|u 10000
1 9,000
| 1,000
§' 7,000
z 6000
g 5,000
n 4,000
2 M0°
>
1,000
a
"• TOTAL DISSOLVED SOLIDS Q SULFATE tSO4 ') NOTE SfFCIFS WHOSE CONCENTRATIONS ARE
-0 CALCIUM I0"| A CHLORIDE (Cl-l , LE« THAN EM pp. ARE NOT HOTTED. .
• • *
* * * * -
•
A
O ° o
: D ° ° ° o ° ° ° ° Q o ° Q ° o ° Q
16.000
19,000
14.010
1X000
12.000
11.000
10.000
a.ooo
e.ono
1.000
6.000
S.OOD
4.000
1.000
2.000
1.000
1.180 1,200 1,2
TEST TIME, how*
1 vi I a/T I •/• I V9 I a/io I 1/11 I a/i2 I a/i3 I tm I a/it I «/K I tm I a/ia I a/» I 1/20 I a/2i t a/xa I a/23 I V24 I
CALENDAR DAV
Go> R6«- 25.000 acfm * 330 °F
Liquor Rato to Venturi - minimum (100 gpml
Liquor Rate to Spray Tonwr "1200 gpm
Vonturi L/G • 5 jal/mcf
Spray Tontr L/G - 80 jil/mct
Sony TOMK Gai Vilociry • 6.7 Him
No. of Spn» He.d.n - 4
EHT IS66lad with Nj Purgal Reiidtncl
Tiim-17mln
Percent Solidi Roclrcunnod • 7.6-9.0 wt S
Venturi Plug PoiiHon 100S Open
Total Pranura Drop. E«dud!rn Mlrt Ellm. • 13-3.8 in H,0
Scnibow Inlit Liquor Timpinnin - 126-132 °F
Liquid Conductivity - 10,000-24,000 u. mhoa/cm
Diichirja (Claritiot and Filter) Solids
ConcantnrJon - 5040 «rt %
Lima addition to Scrubber Downcomtr
Figure 1-4. Operating Data for Venturi/Spray Tower Run 604-1A (continued)
1-16
-------
RUN 604-1A CONTINUED
INSTALL NEW FUNNEL SAMPLER
END RUN 604-1A
«
•EX
J2 £
ai
3.500
3,000
- INSPECTION AND CLEAHUF
i
-1 3.500
- 3,000
) 1,410 1520 1,500 1,000 1,640 1.680 1.720
TEST TIME. hour.
I e/26 I 6/27 t tin I 6/29 I 6,30 I 7/1 I 7/2 I r:t I 7/4 I 7/5 I 7/6 I 7/7
CALENDAR DAY
I 7/13 I 7/14 I
rl"
1520
1.760 1.800
1 840
1 880
18.000
^ 15,000
% K.WO
. 13,000
§ 12.000
J 11.000
j 10.000
K 9.000
3 8.000
H
? 6.000
3 sooo
8 4,000
g 3.000
1 !«
n
• TOTAL DISSOLVED SOLIDS O SULFATE (804") NOTE- SPECIES WHOSE CONCENTRATIONS ARE
LESS THAN 500 ppm ABE NOT PLOTTED.
O CALCIUM (C* **) A CHLORIDE ICI )
-
-
* • • • • • *
• • • • • •
-
O o ^ ^
- ^^^oOO^OQ^ ^O"
-a D° nnoDQ OOQD-
0 D D D 0 o
1 I 1 1 1 1 1 1 1 L__ 1
16.000
15.000
14.000
13,000
12.000
11.000
10,000
9.000
1,000
7.000
ft.OOO
b 000
4.000
3.000
2.000
1.000
0
MO l.BOO 1.640 1.680 1.720
TEST TIME, houn
I 6/26 I 6V27 I 6/26 I 6/29 I 6/30 I 7/1 I 7/2 I 7/3 I 7/4 ! 7/5 I 7/6 I 7/7 I 7/8 I 7/9 I 7/10 I 7/11 I 7/12 I 7/13 I 7/14
CALENDAR DAY
G« R8i6- 25.000 «cfm» 330 °F
Liquor Riti to Vtnturi - minimum (100 aoml
Liquor Rsti to Spray Tovwr - 1200 gpm
Vtntirri L/C • 5 pl/mcf
Spray TOINT L/G « 64 gri/mcf
Spray TOMT Go Vtlocrty • 6.3 ft/itc
No. ofSprayHHiltn-4
EHT (S«il«d «th Nj Purje) R«.id«r.et
Timi-17min
Pemnt Solids Ricirculitld • 7.5-9.0 wt %
Vinturi Plug Position 100% Open
Totil Prnvin Drop. Excludinj MM Elim. • 3.7-4.0 in H?0
Scfubbif Inltt Liquor Temperature * 126-132 °F
Liquid Conductfvity * 10.000-31,000 n mhos/cm
Oisctierae tClaritier ind Filter) Soli*
Concentr«don • 50-60 Ml S
Lime addition to Scrubber Downcnmer
Figure 1-4. Operating Data for Venturi/Spray Tower Run 604-1A (continued)
1-17
-------
UHMftUNMtU ENO DUN IOH«
IWOTMN-i i
M
„
i
n
70
1.1
HJ- i.
O.I
10
1
£> "
I'1 :
4
1800
fi *~
u o
(9 U>
ft
•1
• V
. NA/WV /
u
•
•
a
p\ <—>
\VINTURI • SWAY TOWtH INLET
. \ , VfNTURI * SPftAV TOWER OUTLET
L
- r\
v^l/W^^^
w
0 40 • " 120 ' ~ 1H ' " no MO MO HO HO 4« 440 «
TEST TIMC. houri
K
B
10
7»
70
u
10
0 1
34
10
1
P
1
5
1
HIM
3.000
two
UOO
,'**
7/11 1 VI 1 M 1 VI 1 V4 1 M 1 VI 1 V7 1 i/l 1 I/I 1 V10 1 Vtl 1 V12 1 VII 1 V14 1 VII 1 VII 1 1/17 1 VII 1 VII 1
1.4
Sil 'J
* <3 ™ 1-*
tif "
1.0
CALtKOAH BAY
'.
K Y^^
• ^-^ "*^-
L
p..
13
M
1.1
10
5 * A\
111
3!| *
Sgi „
IBS
gi o
1UOD
| 15.000
| 14.000
| 13.000
D 12,000
j 11.000
J 10.000
flt 9.000
| 1.000
5 7.000
* 6.000
| 5,000
8 4.000
§ 1.000
O 2.000
1,000
0
. /
•v-A/1
V^ ' V^
• TOTAL DISSOVED SOLIDS ^
O CALCIUM IC«**J
Q SULFATE IIO4 ")
A CHLORIDE ;ci !
MOTE: IKCIU WHOSE CONCENTBATIONS
ARE LESS THAN 500 ppm ARE NOT nOTTEO.
•
^ *
•
•
• A A » »
0 0 0 0 0*
Q D D o D
30
.
10
0
11.000
15.000
14.000
1X000
12.000
11.000
10.000
i.OOO
1.000
7.000
8.000
5000
•,000
1,000
1,000
n
120
IK
240
TEST TIME, houn
7/31 I VI I V2 I 1/3 I 1/4 I I/B t ft* I V7 I |/| | I/I I 1/10 | I/11 I S/12 | VU I VM I V1B I VII I V17 I VII I Vlt
CALENDAR DA v
Gil Riti • 26.000 Kim f HO °F
Liquor Rill to Vmtiirl - minimum 1100 gpml
Liquor Riti to Spray Toww -1200 gpm
Vmturl UG • 5 gil/md
Spray Tmw Gn Vilochy • 8.3 ft/ac
No. ol Sony Hnderj • 4
EHT I3e.l.d with N? Purgol RnidHKl
Timt • 17 min
Pirctnt Solid. RKiiculiud - 8.0-9.3 M %
Vinturl Plug Position 100% Optn
Tool Praun Drop, Excluding MM Elim. • 12-3.9 In HjO
Scrubber Inltl Liquor Timpntura - 121-130 °F
Liquid Condunlvity • 5.SOO-IO.OOO M. mhot/cm
Diichiroj (Clirifhr and Filter) Solldi
Concintntion - 48-52 wt %
Limi iddition to Strubbir Downcomir
Figure 1-5. Operating Data for Venturi/Spray Tower Run 605-1A
1-18
-------
li
as*
MOINKUNIOI-U ENO «Utl IW1 A 1
t Si
SIJ
40 SO 120 180 ZOO 240 280 320 360 400 440
TEST TIME, town
I •/! I l/t I 1/10 I 1/11 I t/12 I 1/13 I 1/14 I 1/15 I kVIt I i/17 I 1/11 I S/1ff I 1/20 I 1/21 I 1/22 I 1/23 I 1/24 I 1/76 I |/2t I
CALENDAR DAY
111 ."
lif ::
1.0
A\ *
*Ui "
111 10
1C 5 "J
*§* .
16,000
1 1S.OOO
? i«,ooo
I 1)-°°°
12.000
3 11.000
5 10.000
a »-«»
8 1.000
g T.OOO
Z 6.000
9 s.ooo
S 4.000
o
« 1.000
0 2.000
1.000
•
.
•
r___/^> ^^^\/\
^-^
•
• TOTAL DISSOLVED SO LIDS
O CALCIUM Id " ;
D SULFATE (S04-l
4 CHLORIDE ICI H
NOTE: STECIESWHOSE CONCENTRATIONS
ARE LESS THAN 500 oon, ARE NOT PLOTTED
-
* 0
•0* * 5 ,9 i ^ :
,.0o^^>6oo
V4
1.3
u
1.1
1.0
"
n
10
0
11.000
11.000
14.000
13,000
12.000
11.000
10.000
i.on
1.000
7.000
1.000
5000
4.010
1.000
2,000
1.000
I I/I I I/I I 1/10 I 1/11 I 1/12 I V13 I 1/14 I I/I! I 1/10 1 1/17 T 1/11 I W1I I MO I 1/21 I I/2Z I 1/2] I I/W I I/2S I 1/21 I
CALENDAR DAY
GM Rile • 25,000 icfm * 330 "F
Liquor Ren to Vtnturi ' minimum (100 gpm)
Liquor Reti to Spray Tower • 1200 gpm
Vmturi L/G - 5 gll/mcf
Spny Toww L/G - 64 g.l/mc(
Sony Tomr Gn Velocity - 6.7 ft/MC
No.ofSpr.yH(id«n-«
EHT (Sealed with N, Purge) Resident!
Tim«-17mln
Percent Solid. RicireuliMd - 7.7-9.0 wt S
Vmturi Rug Position 100% Open
Totll Pmnin Drop, Excluding MM Elim. • 3.6-3.7 in HjO
Scrubbir Inltt Liquor Timpmituri • 130-132 °F
Liquid Conductivily - S.tOO-10,000 Jl mhoi/cm
Diaherge (ClHilitr) Solidi
Connntratlon - 11-23 wt S
Lime iddition to Scrubber Downcomer
Figure 1-6. Operating Data for Venturi/Spray Tower Run 606-1A
1-19
-------
IIQIN RUN MIA
TEST TIME, h
I 8/23 I 1/23 I 8/24 I 8/25 I 8/26 1 8/27 I 8/28 I 8/29 1 3/30 I 8/31 I 9,1 I 9/2 I 913 f 9/4 I Ml t 9t* I 917 \ 9/9 I 9/9 \
CALENDAR DAY
ALEO EHT
• TOTAL DISSOLVED SOLIDS
O CALCIUM (Ci **)
NOTE: SPECIES WHOSE
CONCENTRATIONS ARE LESS
ie.ouo
•s
1 15.000
3
«= 14.000
. 13, WO
| 12,000
j 11.000
§ 10.000
1 ••-
1 0.000
S '•°°°
z o.ooo
5 l.ooo
8 4.000
3 1.000
0 2.000
1 i.ooo
0
. THAN 500 pcmAfll NOT
• Q SULFATE
-------
INOMUMM11A
I Ml I W1I I mi I VM I VW I KM I i/i i I Vll I .if I ml Ml I M I MM I KM I Ml I Mi I HI I Ml I Ml I
CALENDAR DAY
,) ,4
l] ,,
jff '-«
1.0
fi i
if „
P .
n.ooo
1 £
. 13.000
| 11.000
5 11.000
fc
3 ».~
: ..ooo
I ,-.
5 '•**
I 1000
S s.ooo
8 4.000
| J.OOO
I *""
IJ«
e
; ;
J^-^*/*\y\ "
^V ^^ _-^-^*~*^^ ^^*
•
i/X/X^ -
.
• TOTAL OlStOtVfDlOLin
O CALCIUM IC»**I "
D SULFATE 1904'}
A CHLORIDE (Cl "I
" NOTE SPECIES WHO«
. CONCCNTRATIOMS ARE LESS
THAMWOf^ittAniNOT
PLOTTED.
- _ -
•
• •
•
-
-A A
- 8 g e $ 8 D
i •
14
1]
U
1 '
10
«0
JO
to
1
1.000
li.000
M.goo
11,000
11000
11,000
W.OOO
1.000
.000
J.OOO
.000
Mil
4JOO
1000
1000
•
TECT TIME houn
VII I I/I) I V14 I VII I V1« I 1/17 I VII I VII I MO I V>1 I VZt \ Vn I VM
CALfMOAR DAY
I MI I VM I vn I m I no I
On RIM- 25.000Kim » 330 °F
Liquor Ran to Vanturi • 600 opm
Liquor Ran to Sfiny Towtr - 1200 opm
Venltti L/G 33 gjl/mcf
Spray Towir Gat V(lo:ity - 6.7 ti/»c
No. of Spray Haulm • I
cHT ISuM) Rnldmct
PlfCint Solid! (trcirculil.d - 7.7-9.4 wt %
Vinturi Pntaura Drop • 9 in HjO
Tool Pruwn Drop. Excluding Mtt Ellm. • 11.5-15.0 in H.O
Scrubbar Nit Liquor Tinpiralurl • 128-132 °F
Uquld Conductivity - 7,10M.200 11 mhovcm
Dischatj. (Clirlfiir and Filt.rl Solid.
Concintratlon • 48-58 M %
Umi addition to Scrubbir Downcom.r
Figure 1-7. Operating Data for Venturi/Spray Tower Run 608-1A (continued)
1-21
-------
PRESSURE TAP!
CLEANED
SI
il
I «i I tva I
TUT TIME, Mutt
I W4 I MS I vat I «r I v» I w» I no I ion I i
-------
Appendix J
FIRST TVA INTERIM REPORT OF CORROSION STUDIES:
EPA ALKALI SCRUBBING TEST FACILITY
by
G. L. Crow
H. R. Horsman
October 1973
J-l
-------
NOTE: The Hydro-Filter scrubber has been renamed
the "Marble-Bed Absorber". It is referred
to, however, as "Hydro-Filter" in this appendix.
J-2
-------
EPA ALKALI- SCRUBBING TEST FACILITY—SHAWHEE POWER PLANT
Interim Report of Corrosion Studies
Identification and solution of corrosion and erosion problems
associated with construction materials are important goals in a program
for the design and evaluation of limestone - wet-process systems for
removing sulfur dioxide from stack gas at coal-fired power plants. The
program at the Shawnee Power Plant is a cooperative effort among the
Environmental Protection Agency (EPA), Bechtel Corporation, and TVA.
Earlier corrosion tests made in pilot-plant studies by the
Process Engineering Branch of limestone - wet-scrubbing systems at
Colbert Power Plant showed that some materials of construction were
durable while others were severely attacked under plant operating
conditions (Process Engineering Branch reports—Sept. 1971* Dec. 1971*
July 1972, and Aug. 1972).
At the request of the EPA in 1972, the Process Engineering
Branch of TVA started corrosion tests of 17 alloys and 7 nonmetals at
21 strategic locations in three parallel scrubber systems at the Shawnee
Power Plant. The systems were the venturi, the Turbulent Contact
Absorber (TCA), and the Hydro-Filter; each of these had the capacity
to handle 30*000 acfo of gas.
After the systems had been operated from 1700 to 2200 hours,
the results of corrosion tests and of plant inspections showed that
greatest corrosion had occurred in areas such as inlet ducts and venturi
where wetted gas or gas and slurry flowed at high velocity. Typically,
the stack gas contained 0.3$ SOs and 3 to 5 grains of fly ash per cubic
foot. Deposits of solids, such as limestone and fly ash, prevented
erosion but caused corrosion of the concentration cell type in some
areas. The most resistant alloys tested were Hastelloy C-276, Inconel 625,
Incoloy 825, Carpenter 20 Cb-3, and Type 3l6L stainless steel. Hastelloy
C-276 was the most durable and also the most expensive; Type 316L stain-
less steel ranks fifth in durability but eleventh in cost of the alloys
tested. Rubbers, such as butyl, natural, and neoprene, showed good
resistance. With some exceptions, units of plant equipment made of
Type 316L stainless steel or lined with neoprene or with polyester
inert flake material were durable. Testing work is being continued.
*Process Engineering Branch of the Tennessee Valley Authority.
J-3
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Program and Plans
Program; The limestone - wet-scrubbing program for sulfur
dioxide removal at Shawnee is funded and directed by EPA. The Bechtel
Corporation designed the plant facility and TVA built it. TVA is operating
the plant under a test program developed and directed by Bechtel. Evalua-
tion of construction materials by exposure of test specimens at strategic
locations and by inspection of the plant equipment is an important goal in
the program.
Plans; Responsibility for conducting the evaluation program
at Shawnee was assigned TVA in March 1972. /Report to Air Pollution
Control Office, EPA (Contract No. PH 22-68-6?, June 28, 1968), by Bechtel
Corporation (March 2, 1972) J The Process Engineering Branch of the
Division of Chemical Development was given this task. /Informal memo-
randums—H. W. Elder to R. D. Young (April 5, '1972) and Ronald D. Young
to H. W. Elder (April 7, 1972)^7 'stiis VOT]li includes procuring test
materials, making test specimens, fabricating suspension1 equipment for
spools and racks of specimens in the plants, and reporting test results.
Also included are periodic inspection and evaluations of plant equipment
for corrosion and wear.
Bechtel Corporation specified 20 materials of construction that
consisted of 17 alloys and 3 nonmetals to be tested at 24 designated loca-
tions in the three plants, ^teterial List of Corrosion Coupon Test Rack
(2/15/72) and Drawings SK-M-102 through 109 and SK-M-111 (Job 6955),
Bechtel Corporation./
Plant Facility; Figure 1 is a view of the plant showing the
three parallel scrubbing systems—the venturi, the TCA, and the Hydro-
Filter.
Power plant stack gas at an average temperature of 320 °F (300°-
350°F) flows through a 1*0-inch duct to a system where it is sprayed for
humidification and for cooling. It then passes through limestone slurry
in a particular type of test scrubber for sulfur dioxide removal.^ After-
ward, it is freed of mist in a separator, reheated to between 235° and
265°F to vaporize mist and eliminate a plume, and discharged through a fan
and duct to the atmosphere. Scrubber effluent is clarified to remove
solids which are discarded and the liquor is then recirculated.
Some features common to all the systems are described below. A
40-inch duct is used to carry the stack gas at 320°F from the Ho. 10 boiler
of the power plant to a test system; each duct is made of 10-gage carbon
steel, ASTM A-283, and is insulated except at flanged Joints. The 40-inch
duct connects to another gas duct made of Type 316L stainless steel. This
duct is equipped with two sets of spray nozzles (the first for humidifying
and the second for cooling the gas) and an air-operated soot blower.
J-4
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Downstream from each sulfur dioxide absorber and mist eliminator unit
there are a stainless steel duct, a refractory-lined reheater fired with
fuel oil, an induced-draft fan of stainless steel, and a stack of stain-
less steel. For liquor handling there are a slurry recirculation tank,
a scrubber effluent tank, and a liquor clarification system. The effluent
hold tank and a clarifier tank are made of carbon steel A-28J and coated
inside with Flakeline 103 which is a Bisphenol polyester resin-fiber glass
coating manufactured by the Ceilcote Company. The recirculation tank,
clarified water storage tank, and reslurry tank are made of carbon steel
and lined with neoprene.
Distinguishing features of the systems are as follows. In the
venturi scrubber system shown in Figure 2, the gas is scrubbed in a venturi
unit made of Type 316 stainless steel and then passed through a neoprene-
lined spray tower (afterscrubber) with a chevron-type separator in the top
for mist recovery. In the TCA system, shown in Figure 3; 6as i-s scrubbed
in a mobile bed of wetted balls, and the mist is removed in a Koch
FlexiTray and chevron-type separator in a tower lined with neoprene. In
the Hydro-Filter system shown in Figure 4, gas is scrubbed in a flooded
bed of marbles, and the mist is removed in a chevron-type mist separator
in a neoprene-lined scrubber tower.
Preparations for Corrosion Tests
With Bechtel's approval, several improvements were made in plans
for the design, preparation, and installation of test specimens. Non-
metallic materials added to the test materials list included Qua-Corr, a
fiber glass-reinforced furan resin, and the rubbers—butyl, natural, and
neoprene. Stressed specimens of five alloys were also added to detect
stress-corrosion cracking under plant operating conditions.
Disks: Disk-type specimens, 2 inches in diameter, were prepared
from the 17 metals. A weld was made (according to manufacturer's recom-
mendations) across the diameter, and after being welded, the metal was
cooled slowly in still air to simulate conditions of constructing or
repairing large equipment. Whenever it was available, metal stock of
1/8-inch minimum thickness was used, and the surfaces were machined
smooth after the welding. Some alloys available only in thinner gages
could not be machined, so the weld beads were smoothed by grinding. A
hole, 23/64 inch in diameter, was drilled in the center of each disk for
mounting.
J-5
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Three nonmetallic materials, Bondstrand ^00, Flakeline 200,
and Transite, were also prepared as 2-inch disks and mounted on spools
along with the metal disks. Flakeline 200, a coating material, was
applied on mild steel disks by the manufacturer. Bondstrand l&OO and
Transite are self-supporting materials and are obtained in sheet form
for disk preparation.
Stressed; A strip approximately 1/8 by 1 by 5-1/2 inches was
welded at midlength, machined to smooth all the surfaces, and formed into
a U shape. One-half-inch holes were drilled in each end of the strip to
accommodate a bolt (Type 316 stainless steel, 1/4 inch) fitted with
Teflon insulators for applying static stress in the specijnen.
Coated; Because of their large sizes of approximately U-l/2 by
U-l/2 inches, the plate specimens of Qua-Corr plastic and the butyl,
natural, and neoprene rubbers were mounted on a separate rack. Qua-Corr
is a self-supporting material; the rubbers were applied on mild steel
specimens by the manufacturer. The durometer "A" hardness values of the
rubber-coated specimens as received were as follows: natural, 3^-37;
butyl, 5^-56; and neoprene,
Mounts and Suspensions; Spools and racks for mounting the test
specimens and also the suspension equipment for installing them in the
plants were constructed mainly of Type 316 stainless steel. Bolts and
nuts were annealed to remove stresses caused by cold-working in threading
operations. To prevent loss of fasteners through vibration of equipment,
two nuts were locked by forcing them together.
At some test locations inside plant equipment, brackets were
attached as permanent fixtures by welding, and then the spools of specimens
were bolted to them. In other locations, spools were fastened to existing
pipes by the use of band- type clamps. In a tank, spools were suspended by
means of a 1/8-inch strip or a 3-inch pipe that was bolted to the top.
Sleeves (3/8- inch wall by 6 inches long) of soft butyl rubber were placed
around the 3- inch specimen support pipe as cushions to prevent abrasion
damage to the Flakeline coating or neoprene lining on a tank wall. No
specimens were installed inside pipelines or fittings.
Figure 5 shows the three types of assemblies used for mounting
the corrosion test specimens. These were:
(A) Stressed— with 5 U bends
(B) Rack—with three rubber- coated plates and one plastic plate
(C) Spool — with 20 disks consisting of 17 alloys and 3 nonmetals
J-6
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A Teflon sleeve was used to insulate the specimens from the supporting
stainless steel bolt, and Teflon spacers or washers were used to prevent
contact of the dissimilar materials.
Figure 6 shows prepared specimens and support equipment before
shipment from the Office of Agricultural and Chemical Development (OACD)
to Shawnee in August 1972. A few racks of specimens are shown attached
to 3-inch pipe and to 1/8-inch-thick strap.
Test Exposures, Conditions, and Procedures
Test specimens of materials listed in Tables I, II, and III were
installed in the three plant systems in August 1972. Table IV gives the
analysis of each of the 17 metals tested. Specimens were exposed at test
locations identified by series 1000, 2000, and 5000 as shown in Figures 2,
3, and k; however, specimens (1004-6) were omitted in the venturi after-
scrubber tower that was to be modified. All specimens remained in the
scrubber systems from August 12, 1972, to February 3, 1973, except those
in the TCA system which were temporarily removed for preliminary
evaluation in November 1972.
Plant Operation: Usually, one system was operated at a time,
although all three could be operated simultaneously. Operating hours
in the exposure period are shown below.
Hours
System _ Idle Operated
Venturi
Turbulent Contact Absorber 2535 1667
Hydro-Filter81 1950 2203
a
Also called marble bed.
Plant Process Materials and Deposits: Typical compositions
of inlet and outlet gas at the scrubber systems are tabulated below.
Scrubbed
Component gas gas
0.05-0.2
12
69
k
, * 8 15
Fly ash, gr/std ft 3-5 0.02
J-7
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Temperature of the inlet stack gas from unit 10 boiler averaged 320°F
(300°-350°F) and that of the exhaust gas after being reheated was 235°
to 26"5°F.
Ranges in properties of liquor in the different tanks of the
three scrubber systems are summarized below.
Liquor in tanks
Recycle Effluent Clarifier
Temperature, °F 70-125 75-130 70-100
Solids, # by weight Ij-lJ U-IQ 0-30
pH 5-3-6.1* 5-6-6.8 6.0-7-6
Composition, % by weight
CaS04-2H^O 1.0-3.0 1.0-2.0 0-6
CaS03-l/2Hj0 1.5-5.0 1-5-3-5 0-10
Unreacted limestone plus
fly ash 1.5-7-0 1-5-U.5 0-15
Water 85-96 90-96 70-100
Table V shows analyses of deposits from the three systems in
the plant. These scale and solid deposits from tanks and scrubber equip-
ment exposed to the limestone scrubbing liquor in the three systems were
composed mainly of calcium, sulfite, sulfate, and carbonate in the ranges
of percentages shown below.
Percent
Component by weight
CaO 26-lH
SO 2 9-18
S03 2lf-ltf
C02 0.5-6
Soot that deposited in stacks above the gas reheater contained the
following on a dry basis: 27 to 6U$ ash and 36 to 73$ hydrocarbon.
Moist soot contained 2 to 13$
Exposed Specimens: Pictures were made of specimens when removed
from the plant as shown in Figures 7-12. Then the specimens were cleaned
and their corrosion rates and physical condition were determined as shown
in Tables I through III along with properties of gas and liquor at various
test points.
J-8
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Inspections of Plant: Equipment in the plant systems was
inspected for corrosion and erosion damage during the first week of
February 1973-
Barometer "A" hardness values of rubber lining on equipment
and on test specimens were measured with a Shore instrument—Type "A-2,"
ASTM 22^tO. Unfortunately, hardness of most lined plant equipment was not
determined before plant operation; so data from the rubber vendors were
ordinarily used as reference values. Temperature of the atmosphere varied
from 35° to 60°F as did the temperature of equipment during the plant
inspection. A decrease in temperature would be expected to increase
rubber hardness. Values for neoprene linings are summarized in Table VI
for the plant equipment and in Table VII for test specimens after exposure
to plant operating conditions.
Results of Plant Inspections
and Corrosion Tests
In this section, plant inspections are described first, and
then the results of corrosion tests under different exposures in equip-
ment are given. Some of the observations on plant equipment were made
by or in collaboration with R. E. Wagner and R. C. Tulis, engineers with
TVA at Shawnee Power Plant.
Carbon Steel Ducts for Inlet Stack Gas—Plant Equipment; A
product of general corrosion thinly coated the inside walls of these
ducts where they had been insulated. A thicker corrosion product covered
inner walls of uninsulated duct sections (at flanges) because heat loss
through bare metal to air cooled the stack gas and condensed corrosive
liquid containing carbon dioxide, oxygen, and sulfur oxides. Such
localized corrosion was pronounced in the Hydro-Filter duct; and subse-
quently in February 1975, the plant personnel fully insulated this duct
as well as those to the other systems.
Small quantities of fly ash had deposited in ductwork areas
where the gas flow changed directions, but this caused no apparent
problem.
Stainless Steel Ducts for Inlet Stack Gas—Plant Equipment;
In each duct between the carbon steel section and the scrubber unit
there are: three nozzles of Type 316 stainless steel for spraying
liquid to humidify gas, and one nozzle of Type 309 stainless steel
for blowing air to dislodge soot. At the TCA and the Hydro-Filter
(but not the venturi) scrubbers, there are four nozzles of Carpenter
20 alloy for spraying recycle slurry to cool the inlet gas.
J-9
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The ducts, in general, vere not appreciably corroded. Slight
abrasion occurred in areas which vere not coated "by solids, but corrosion
of the concentration cell type was present under the accumulations of
solids.
Spray nozzles for gas humidification in these ducts were operated
for the number of hours shown below.
Percent of
Duct to Spray hours operating hours
Venturi 56? 31
TCA 0 0
Hydro-Filter 2203 100
The conditions of the soot blower nozzles were as follows: at TCA—good,
and at Hydro-Filter—severely corroded. (The nozzle in the venturi system
was not inspected.) Nozzle corrosion at the Hydro-Filter was attributed
to the use of the water sprays for gas humidification upstream which would
yield hot corrosive mist containing carbon dioxide, oxygen, and sulfur
oxides.
Two of the four nozzles of Carpenter 20 stainless steel used
for cooling gas to the TCA scrubber were plugged and two were severely
eroded internally. Erosion was caused by high-velocity flow of cooling
clurry consisting of water, limestone, and fly ash.
Stainless Steel Ducts for Inlet Stack Gas—Corrosion of Test
Specimens: Specimens located in ducts below gas humidifier sprays
corroded as follows in mils per year: 1 to more than 330 in venturi
system, 1 to 17 in TCA, and 1 to more than 300 in Hydro-Filter. (See
points 1002, 2002, and 3002 on Figures 2-4.) The high rates in ducts to
the venturi and Hydro-Filter systems are attributed to previously men-
tioned hot corrosive spray from humidifier spray operation. (Compare
1002, 2002, and 3002 on Figures 7, 9, and 11, respectively.) Type 3l6L
showed good resistance in the venturi and TCA ducts but had localized
attack (l8-mil groove and minute pits) in the Hydro-Filter duct. Other,
more expensive alloys, such as Hastelloy C-276 and Inconel 625, showed
good resistance in the ducts to the three systems as well as in other
parts of the systems as described later.
In the duct to the TCA system where no humidification was used,
the temperature of the gas was 260° to 330°F, and the conditions of the
nonmetal specimens were: Transite—good, Flakeline 200—fair, and
Bonstrand—poor. All three of the materials were in poor condition in
humidified gas to the venturi and Hydro-Filter units.
J-10
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Venturi Scrubber—Plant Equipment: Bolts and nuts of Type
stainless steel used to assemble internal parts of the venturi scrubber
had failed twice in plant operation before they were replaced with ones
of fully annealed Type Jl6 stainless steel.
The neoprene-lined duct between the venturi unit and the after-
scrubber tower was in good condition. Durometer A hardness of the lining
was 67.
Venturi Scrubber—Corrosion of Test Specimens; The specimens
were installed directly below the vertically mounted venturi as shown at
point 1011 of Figure 2. Gas and slurry (laden with compounds of sulfur
oxides) at a high velocity caused more severe corrosion and erosion
damage to specimens in this location than in any other in the three
systems. Specimens of nine alloys and three nonmetals failed. Figure 7
shows that spool 1011 was clean and only 8 of the 20 test specimens
remained at the end of the 181*0-hour test period. The five alloys that
showed the lowest corrosion in mils per year were: Hastelloy C-276—5 mils,
Inconel 625—5 mils, Incoloy 825—7 mils, Carpenter 20 Cb-3— Ik mils, and
Type 316L stainless steel—15 mils.
The other three remaining alloys and their corrosion rates
were: Cupro-nickel 70-30—^9 mils, Monel hOO—57 mils, and Hastelloy B—
100 mils.
The three rubbers (butyl, natural, and neoprene) were in good
condition, but the plastic Qua-Corr failed as shown fourth from the left
on 1011 in Figure 8. Both Figures 7 and 8 show severe erosion damage to
the chemically resistant Teflon spacers on the spools at location 1011.
Towers in the Venturi, TCA, and Hydro-Filter Systems—Plant
Equipment: In general, the neoprene lining on the wall of each tower
was in good condition (Table VI). Hardness values and comments are
listed below.
J-ll
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Tower
Venturi
(afterscrabber)
Barometer hardness
Original8- Measured*3
60-65
52-60
TCA
Hydro-Filter
60-65
60-65
53-63
65-72
Comment
Wear was apparent in a small area
near a nozzle. The highest hard-
ness was near the top and the
lowest was near bottom of the
tower.
Highest hardness was in the mid-
section and the lowest was near
bottom and top of the tower.
Slight impact damage was probably
caused by foreign sharp objects.
Highest hardness was in the mid-
section and the lowest was near
the top of the tower.
a From vendor's data—hardness was not measured in the plant before tower
operation.
Measurements in plant were not made at same temperature because of
weather changes.
Solids deposition in the towers varied as described below:
Venturi
(afterscrubber)
TCA
Hydro-Filter
A heavy deposit was present as follows: on the walls
below trapout tray in bottom; on a 30-inch-wide band
of the wall below the mist eliminator (chevron); and
on bottom (1/2 the area) of the mist eliminator near
top of tower.
Multilayered deposits of solids covered the walls of
the tower. These decreased in thickness from 1 inch
at bottom to 1/16 inch at top. The mist eliminator
(chevron) was partly clogged. No loose solids were
present because the unit was cleaned 2 weeks before
the inspection.
Scale, 1/16 inch thick, was on walls, piping, and
spray nozzles. Slurry deposit was 1/U to 1/2 inch
thick on a narrow band of wall below and adjacent
to the mist eliminator and on the bottom of the mist
eliminator.
J-12
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Corrosion of Type J16 stainless steel components of the towers
ranged from mild to severe as described below.
Venturi Surfaces under solid deposits had generally developed
(afterscrubber) small pits. The wall of the outlet duct below the
gas reheater, although clean, was pitted.
TCA Grids that supported packing showed negligible corrosion,
but their top surface showed some abrasion from the
moving bed of wetted balls. The Koch FlexiTray was
clean and showed no apparent corrosion after 985 hours'
service. However, the top side of the mist eliminator
(chevron) had undergone severe general corrosion and
pitting after 1667 hours' service.
Hydro-Filter Corrosion of the mist eliminator (chevron) and other
components of Type 316L stainless steel in this tower
was not detected.
Spray nozzles of Type 316 stainless steel were generally in good condition
after handling slurry in the venturi afterscrubber and the TCA towers, but
nonmetal nozzles in the Hydro-Filter tower were damaged. Four of 16 nozzle
locations had been previously blanked when nozzles had failed and no spares
were available. Some of the plastic nozzles beneath the glass sphere bed
in the Hydro-Filter were damaged and had been replaced with nozzles of
improved design. The remaining original nozzles were badly worn, and two
of four improved design nozzles had failed. Of six soft rubber nozzles
at a higher level in the Hydro-Filter, four were badly eroded; in one,
the lining of the whirl chamber had torn so as to plug the outlet, and the
casing was cracked.
Towers in the Venturi, TCA, and Hydro-Filter Systems—Corrosion
of Test Specimens: In the afterscrubber of the venturi system, specimens
were not installed because of plans to alter the arrangement of sprays.
In the TCA scrubber tower, test specimens were mounted at three
elevations (see Figure 3 and Table II). Those above the third grid for
holding mobile packing hollow plastic spheres at location 2006 were
exposed to gas and liquor. Those below the FlexiTray at 2005 were
exposed to gas and droplets, and those below the chevron mist eliminator
at 200k were exposed to gas and mist. Figure 9 shows that spools of
specimens which had been exposed at 2006 and 2005 were partly covered by
solids, but those at 200^ were clean. In the period August 12 through
November 3> 1972, movement of the mobile bed had caused some erosion at
2006. The eroded specimens were replaced with new ones that were placed
within a wire mesh container to protect them from erosion by the balls.
At all three locations, the corrosion rates were 1 mil per year or less
for Carpenter 20 Cb-3, Hastelloy C-276, Incoloy 825, Inconel 625, and
J-13
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Type -jLdl, GtainlccG steel. Gac and mif.t at 200Ji below the mict eliminator
caused crevice corrosion on Incoloy 025 an(i minute pitting on Type 3l6L
utninlecn steel. It also caused the greatest corrosion of mild steel
(250 rails) and Cor-Ten B (268 mils per year). Pitting and/or crevice
corrosion occurred on most of the other alloys exposed in this tower.
The corrosion of stressed specimens 200k shown in Figure 10 was about
equal to that of the counterpart disk specimens in Figure 9-
The condition of the nonmetallic materials tested in the TCA
tower ranged from poor to good. The three specimens of rubber and two
of the three specimens of Bondstrand were in good condition.
In the tower of the Hydro-Filter system, tests of corrosion
specimens were conducted at two locations (see Figure k and Table III).
One was in the liquor and inlet gas at 5006 below the marble support grid,
and the other was in the gas and liquor at 3005 above the marble bed (see
Figures 11 and 12). All of the test specimens were coated with scale and
deposit. The following alloys were corroded at rates of 1 mil per year
or less: Carpenter 20 Cb-3, cupro-nickel 70-30, Hastelloy C-276, Incoloy
825, Inconel 625, and Type 3l6L stainless steel. Mbnel 1*00 and Hastelloy B
had rates of less than 1 to k mils per year in the two locations. Mild
steel and Cor-Ten B had the greatest rates—37 and 1*0 mils per year,
respectively, above the marble bed; and Ik and 13, respectively, below
the bed. Pitting and/or crevice corrosion occurred on the other alloys.
In the liquor and inlet gas at 3006, Bondstrand was good, and the Flakeline
and Transite were fair. In the gas and liquor at 3005, Bondstrand Qua-Corr,
and the three rubbers were good, and the Flakeline was fair.
Exhaust Gas Systems—Plant Equipment: Each exhaust gas reheater
for heating the scrubbed gas to between 235° and 265°F is identical in the
three systems (Figures 2, 3, and k). The refractory lining, 3 inches
thick, in all the reheaters had cracked, mainly near the burner ports.
The lining of the venturi reheater had the largest cracks and was coated
with fuel oil.
In the venturi stack, soot saturated with oil had deposited, and
on two occasions such a deposit had ignited and burned. In the TCA exhaust
stack, soot saturated with oil was also found, but no fires had occurred.
In the Hydro-Filter system, the soot deposit in the exhaust duct was
thinner, indicating that combustion of fuel oil in the heater had been
more efficient than in the other two systems.
Downstream from the reheater in each system, there was no
apparent corrosion of the stack made of Type 316 stainless steel.
J-14
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At the induced-draft (I. D.) fan of each system, soot and fly
ash accumulated on the fan "blades and housing to depths of 1/16 to 1/4 inch.
In ceneral, the thickest deposits were on stationary parts, and the trailing
faces of the "blades accumulated a thicker deposit than other areas of moving
parts. Deposits were smallest in the fan for the Hydro-Filter where no oil
was detected. Measurements of the blades and shrouds of Type 316 stainless
steel showed only slight variation in thickness from the original values
determined before the plants were operated. Slight bends on the periphery
of two blades on the fan for the Hydro-Filter and one blade on the fan for
the TCA system probably occurred because of stress relieving, but these
bends caused no apparent problems.
A stainless steel sleeve (l*0-inch diameter by k feet high) has
subsequently been installed in each reheater. Also, burner nozzles of
different design and having much better atomizing characteristics were
installed. The sleeve and nozzles should promote essentially complete
combustion of oil before hot combustion gases combine with the scrubber
exhaust gas and thus should minimize problems with oil and soot deposits
in the stack and fan.
Exhaust Gas Systems—Corrosion of Test Specimens; Corrosion
test specimens were mounted in the exhaust stacks in each system 8 to 10
feet downstream from the reheater as shown at points 1007, 2007, and 3007
(Figures 2, 3, and 4). Temperature of heated exhaust gas in contact with
the specimens was usually between 235° to 265°F. Tables I, II, and III
give corrosion data. Figures 7 through 12 show the soot- and ash-covered
specimens after exposure.
In the stack of the venturi system, the corrosion of the test
specimens was slightly more severe than in other systems. Oil-saturated
soot had caught fire and destroyed the Teflon insulators and spacers.
(See item 1007 on Figures 7 and 8.) Five of the highly alloyed materials
and Type 316L stainless steel were durable, however, corroding at rates
of less than 1 mil per year. Five other alloys had corrosion rates of
1 to 5 mils per year, and the rates for mild steel and Cor-Ten B were 16
and 18 mils. Aluminum 3003 was pitted to a depth of 70 mils during the
exposure period. Transite was in good condition after the test, but
Bondstrand and Flakeline failed apparently because of overheating.
In the TCA exhaust stack, the corrosion rate was either
negligible or less than 1 mil per year for eight alloys including
Type 316L. (See item 2007 on Figures 9 and 10.) Cor-Ten B and mild
steel had rates of 2 and 3 mils per year with minute pits. Pitting of
other alloys ranged from minute to depths of 12 mils. Flakeline 200
and Transite were in good condition but Bondstrand failed.
J-15
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In the stack of the Hydro-Filter system, corrosion of specimens
was slightly greater than in the TCA system but less than in the venturi
system. (See item 3007 on Figures 11 and 12.) Five alloys, including
Type 316L stainless steel which had minute pits, were corroded at rates
less than 1 mil per year. Several alloys were pitted, and the deepest
pit was 18 mils in E-Brite 26-1. Attack of mild steel, Cor-Ten B, and
aluminum 3003 was k to 5 nils per year with crevice corrosion under the
Teflon insulator. Flakeline and Transite were in good condition, but
Bondstrand failed.
Corrosive attack of the stressed specimens by reheated stack
gas was about egual to that of the counterpart disks in each test.
Effluent Hold Tanks—Plant Equipment; An effluent hold tank
20 feet in diameter and 21 feet tall is located directly under each
scrubbing tower: MOl for the venturi, D-201 for the TCA, and I>-301
for the Hydro-Filter systems. The shells are made of A-283 carbon steel
coated inside (80 mils minimum thickness) with Flakeline 103 manufactured
by the Ceilcote Company. This coating is a Bisphenol-A type of polyester
resin filled with flake glass (25-35$).
Each tank was in good condition except for minute cracks at the
junction of some baffles with the tank walls. Stains of iron rust indi-
cated that the cracks penetrated the Flakeline coating. All cracks were
within 8 feet of the bottom of a tank. The neoprene-lined agitators were
in good condition, and only slight wear was noted on the leading edge of
the blades. The hardness of the neoprene had changed little if any (see
Table VI). The Bondstrand 5000 and the Type 316L stainless steel down-
comers showed no evidence of attack in either tank. In tanks D-101 and
D-301 there were slightly worn areas where the butyl rubber insulator on
the specimen suspension pipe (15 feet long) had rubbed the wall.
Effluent Hold Tanks—Corrosion of Test Specimens: Corrosion
test specimens were mounted in the effluent hold tanks 15 feet below the
top. Figures 2 through k identify the locations and Figures 7 through 12
show pictures of test specimens by numbers—1008 for the venturi, 2008 for
the TCA, and 3008 for the Hydro-Filter systems. Tables I through III show
that corrosion was less than 1 mil per year for several alloys in the
three tanks.
In the venturi system tank, nine alloys, including Type 316L
stainless steel, had corrosion rates of 1 mil per year or less without
localized attack. The eight other alloys were attacked locally and had
corrosion rates of 1 to 18 mils per year. Four specimens were pitted
up to 2k mils deep. Crevice corrosion occurred on eight specimens. The
rate for mild steel was 18 mils and that for Cor-Ten B was 1^ mils per
year, both with crevice corrosion.
J-16
-------
The TCA effluent hold tank was in use only during the last
^5 hours of the 1667-hour operating period, so corrosion rates are less
representative than those at the two other tanks which were used con-
tinually during operating periods. Corrosion was less than 1 mil per
year for nine alloys. Appreciable corrosion in mils per year occurred
to several metals as follows: aluminum 3003, 20; Cor-Ten B, 170; and
mild steel, 210. Apparently significant general corrosion of these
alloys occurred during the extended period that the tank was idle,
but there was only minute pitting and no crevice corrosion.
In the Hydro-Filter tank, corrosion was less than 1 mil per
year for 10 alloys, including Type 316L stainless steel, without
localized corrosion. Aluminum 3005, mild steel, and Cor-Ten B were
corroded at the greatest rates~2 to 5 mils per year. Pitting occurred
on three alloys, and the deepest pit was 5 mils on Type 304L stainless
steel. Crevice corrosion occurred on 7 alloys.
In all three of the effluent hold tanks, the following showed
good resistance: the butyl, neoprene, and natural rubbers; the Bondstrand
and Qua-Corr plastics; and the Transite. Because of abrasion on one face,
the specimens of Flakeline 200 were in only fair condition. Flakeline 200
is similar to Flakeline 103 except that it is formulated for application
by "brush or spray" instead of by "trowel or spray." Apparently, the
application of Flakeline 103 coating inside the effluent tanks was
superior to that of Flakeline 200 on the test specimens.
Recirculation Tanks—Plant Equipment: Each of the scrubbing
systems has a recirculation tank 5 feet in diameter by 21 feet tall as
follows: H-lOk for the venturi, D-20^ for the TCA, and D-30^ for the
Hydro-Filter. These tanks were lined with neoprene sheet 1/4 inch thick,
and the blades and shaft of their agitators were also lined with neoprene.
The linings on all of the tank walls and the agitators were in
good condition. A thin scale had deposited that would protect the surface.
IXirometer A hardness values for the neoprene linings, however, were not
consistent (see Table VI). The hardness values were higher than the
original for the lining in Hydro-Filter tank D-304, and they were lower
for the agitator blades in TCA tank ]>-204.
Recirculation Tanks--Corrosion of Test Specimens: Corrosion
test specimens were suspended 8 feet below the top in recirculation tanks
D-10U (venturi) and D-30^ (Hydro-Filter); they were 15 feet below the top
in D-204 (TCA). See Figures 2, 3, and h. Corrosion was negligible or
less than 1 mil per year for several alloys in the three tanks (Tables I
through III). The greatest attack occurred on Cor-Ten B and mild steel.
Items 1012, 2012, and 3012 on Figures 7, 9, and 11, respectively, show
the spools of specimens after exposure.
J-17
-------
In venturi tank D-104, the rate for Cor-Ten B was 12 and that
for mild steel was 19 mils per year. The rate of attack on the other
alloys was less than 1 mil per year. Pitting and crevice corrosion
occurred only on Type ^10 stainless steel.
In TCA tank 2Qk, the corrosion rate was 5 mils per year for
Cor-Ten B, 5 mils for mild steel, and 2 mils for aluminum. Pitting
occurred on seven alloys with the maximum depth of 10 mils on Type 304L
stainless steel. Crevice corrosion occurred on four alloys.
In Hydro-Filter tank D-JO^, the corrosion rate was 10 mils for
Cor-Ten B and 11 mils per year for mild steel. Type ^10 had pits 7 mils
deep and three alloys underwent crevice corrosion. The other alloys were
attacked less than 1 mil per year.
In general, localized attack was less prevalent in the recircula-
tion tanks where agitation was more vigorous than in the effluent hold tanks
(except in D-201 that was used only lj-5 hours).
Bondstrand and Transite were in good condition after the test in
each tank, but Flakeline 200 was only fair because of abrasion on one face
of each specimen.
Clarifier Tanks—Plant Equipment; Clarifier tanks D-102 for the
venturi and D-302 for the Hydro-Filter are 20 feet in diameter and 15 feet
tall; and tank D-202 for the TCA is 30 feet in diameter by 15 feet tall.
Each tank has a coned bottom that is positioned 3 "to 5 feet above the
foundation elevation (Bechtel drawings M-8 and M-9)- The tanks are of
A-283 carbon steel coated inside with Flakeline 103- Mechanical equip-
ment inside the clarifiers is made of Type 316L stainless steel. Tank
D-302 was not inspected because it was in use for testing filter
equipment.
The Flakeline 103 coating in tanks D-102 and D-202 was in good
condition except for cracks at the junction of the overflow weir and the
wall. Iron rust had bled through the cracks. The stainless steel equip-
ment had not been attacked. However, four carbon steel bolts used to
anchor the underflow cone at the bottom of the two tanks had rusted.
Clarifier Tank—Corrosion of Test Specimens: A spool of corrosion
test specimens was suspended in the fluid 5 feet below the weir in clarifier
tanks D-102, D-202, and D-302. These tanks are not shown in Figures 2
through h (see Bechtel drawings M-8 and M-9). Items 1013, 2013, and 3013
in Figures 7, 9, and 11 are pictures of specimens after exposure. Tables I
through III show corrosion data.
J-18
-------
In the venturi tank D-102, seven alloys including Types
and 316L stainless steel showed negligible corrosion, and two other alloys
had rates of 1 mil per year or less without localized attack. Cor-Ten £
and mild steel had rates of 5 mils per year. Pitting occurred on four
alloys, and the greatest depth was 12 mils on aluminum 3003- Five alloys
had undergone crevice corrosion.
In the TCA tank D-202, six alloys including Type JO^L and
Type 316L stainless steel showed negligible attack and seven other alloys
had rates of 1 mil per year or less without localized attack. Cor-Ten B
and mild steel were corroded at rates of 6 and 8 mils per year. Two
alloys were pitted; the deepest pit was h mils on Type ^10 stainless
steel. Localized corrosion occurred on Cor-Ten B and Type ^10 stainless
steel.
In the Hydro-Filler tank D^302, a total of nine alloys including
Type 304L and Type 316L stainless steel corroded at less than 1 mil per
year without localized attack. The rates were 7 and 9 mils for Cor-Ten B
and mild steel. Four alloys were pitted; Type 410 stainless steel had the
deepest pit, 16 mils, and four alloys had undergone crevice corrosion.
Transite was in good condition in the three clarifier tanks;
Bondstrand was good in the venturi and the TCA tanks but poor in the
Hydro-Filter tank because of spalling; Flakeline 200 was fair in the
three tanks.
Clarified Process Water Storage Tanks—Plant Equipment; Clarified
water storage tank D-103 for the venturi and D-303 for the Hydro-Filter
systems are 10 feet in diameter and 9 feet tall. Tank D-203 for the TCA
system is 13 feet in diameter and 9 feet tall. Each tank has four baffles
and a shell of carbon steel lined with 1/h inch of neoprene of durometer A
hardness of 55-60. Each tank has a three-blade agitator with diameter as
follows: Ik inches in D-103 and D-303 and about fe inches in D-203. The
agitators and shafts are lined with neoprene.
Conditions of linings in the clarified water tanks are described
below.
J-19
-------
Tank Tank No. Condition of lining on
Venturi D-103 Tank; Excellent
Agitator: Noticeable wear
TCA D-203 Tank: A lap joint, 8 inches long, was
loose where bottom liner extends upward
1-1/2 inches to make overlap on wall
liner near a baffle on west side.
Agitator: Slight wear
Hydro-Filter D-30J Tank: Good
Agitator: Noticeable wear. Cuts at
several places were possibly made by sharp
foreign objects.a
a Two pieces of thin gage metal were on floor of tank.
It appears that the durometer A hardness of the neoprene might
have increased slightly up to 11 units above 60 as shown in Table VI.
However, the temperature (60°F) of the linings during the inspection was
lower than the standard (73°F) specified in the ASTM designation, D22*K)-68.
Reslurry Tank—Plant Equipment: Tank D-itOl is used for reslurrying
waste solids removed in the clarifier. It is identical in size and in con-
struction to storage tank D-103 already described. All the neoprene linings
were in good condition and hardness tests were not made.
Neoprene-Lined Centrifugal Pumps—Plant Equipment: During the
corrosion tests in the scrubbing systems, Hydroseal pumps were in service;
impeller diameters were 12, 17, or 20 inches. These centrifugal pumps were
manufactured by the Allen-Sherman-Hoff Company. All wetted parts were
lined with neoprene of a durometer A hardness specified to be 5U to 56.
When the pumps were dismantled, inspection showed that the linings
were not damaged severely in any except pumps discussed later. However,
wear of varying degrees was found. The grooving of neoprene linings on
impellers and casings was least in the TCA system and greatest in the Hydro-
Filter system. General wear of the linings was slight, but a little more
noticeable in the Hydro-Filter system. A durometer A hardness of the
liners ranged up to 16 above the specified maximum; this was fairly general
for the three systems. (The temperature of the linings when tested was
below the standard of 73°F; this would cause higher values.)
J-20
-------
Packing glands caused severe vear on the stainless steel
components of pumps G-102 and G-202; these are the thickener underflow
pumps for slurry containing about J0$ solids.
The output of slurry feed pumps, G-108 and G-208, had decreased
over a period of weeks. These are rotary screw- type pumps (Moyno) used
for pumping limestone slurry containing about 60$ solids. Inspection
revealed that increased clearance between the stator and the rotor,
because of wear of the rubber lining of the stator, allowed excess
leakage. This was corrected by replacement of worn parts.
Pump G-tol, reslurry tank pump, was dismantled for modification.
The rubber-lined impeller and casing were neither grooved nor worn
appreciably. Hardness values of the linings were not determined.
Some of the Ifydroseal pumps have been replaced since February
with Centriseal pumps produced by the same manufacturer. Sealwater
required at the Hydroseal pumps had added more water to the system than
could be tolerated for closed- loop operation.
Valves — Plant Equipment: The stainless steel check valves at
the discharge of several pumps for each scrubber system were inspected.
These valves are ASTM A- 351, Grade CF-8M body, Type 316 plate, and
neoprene seal. Generally, these valves had worn slightly and their
surfaces were smooth and polished.
The H-inch neoprene pinch valve upstream (of FE 106l) from the
bottom slurry header in the afterscrubber tower of the venturi system
showed no signs of chemical attack and only slight evidence of wear.
Piping — Plant Equipment: Neoprene- lined piping was inspected
at the inlet to all pumps that were dismantled for inspection or seal
modification in the three scrubber systems. Elbows, tees, and open ends
of the piping showed no evidence of wear or deterioration. The neoprene
lining 3/16 inch thick with a specified durometer A hardness of 50 plus
or minus 5 was applied by the Rubber Applicators, Houston, Texas.
Hardness values were not determined during the inspection.
Discussion
Process Materials: In the S02 removal plant, the inlet stack
gas, the limestone absorbent, and their reaction products are corrosive
or abrasive.. Components of stack gas, such as COa, 02, and S02, dissolve
sparingly to make condensate or water corrosive. Fly ash in stack gas
J-21
-------
and the limestone in absorbent slurry are abrasive, especially in high-
velocity streams. Slurry containing limestone, sulfite, sulfate, and fly
ash forms deposits on metal to cause localized corrosion, (in future
tests, chloride in gas or in makeup water should be considered along with
compounds of sulfur as a likely corrosive in areas where it might be
concentrated in a residue.)
Materials of Construction: Materials in the plant consist mainly
of: carbon steel in the inlet duct for stack gas from the power plant;
stainless steel, [type 516L in the scrubbing system ducts, the venturi
scrubber, removable internal parts of scrubber towers, the outlet gas
duct, the fans, and stack; neoprene-lined carbon steel in the venturi
afterspray, TCA, and Hydro-Filter towers; neoprene-lined carbon steel in
the recirculation, clarified process water, and reslurry tanks; Bondstrand
and Type 316L stainless steel downcomers to the effluent hold tank;
Flakeline 103-lined carbon steel in the effluent hold and clarifier tanks;
refractory-lined gas reheater; and neoprene-lined pumps and piping.
Corrosion—Plant Equipment; In general, materials used in
construction of the three scrubbing systems showed good resistance to
attack. Carbon steel ducts were slightly attacked by inlet stack gas
when at temperature below the dew point.
Inlet stack gas, after being humidified by spray water, attacked
stainless steel ducts and nozzles as follows: slight erosion of bare duct
surfaces; concentration cell-type corrosion (pitting and crevice) of
surfaces underlying deposits; and severe corrosion and erosion of surfaces
(nozzles or projections) subjected to impingement.
In the venturi scrubber, the limestone slurry and gas discharging
at high velocity corroded and eroded stainless steel parts, but apparently
did not damage neoprene lining in the duct.
In the towers of the three systems, slurry and gas flowing at
low velocity caused only slight corrosion and erosion of bare removable
parts of stainless steel, such as packing supports and FlexiTrays.
Movement of the mobile packing (hollow plastic spheres similar to Ping-
Fbng balls) caused some erosion of grid wire in the TCA absorber.
Cause for severe corrosion on the top surface of a chevron-type
mist eliminator in the TCA tower is not known. However, it is likely
that some mist passing through a Koch FlexiTray located below would collect
on the chevron mist eliminator and evaporate to form a residue high in
compounds of chlorine and sulfur which would be corrosive. Pits observed
in the outlet duct from the venturi afterserubber might also have been
caused by such a residue of chlorine and sulfur compounds. Periodic
washing to remove residue might decrease the corrosion.
J-22
-------
Nozzles of stainless steel were more durable than those of
rubber or plastic for spraying limestone slurry in the towers.
Rubber lining on the tower shells, though coated usually with
slurry solids, was generally in good condition.
Exhaust gas stacks of Type J16L stainless steel were apparently
in good condition after exposure to gas reheated to between 235° and 265°F.
Sleeves and improved burner nozzles installed at the gas reheaters should
improve fuel oil combustion and thereby minimize troublesome soot deposi-
tion and a potential fire hazard in exhaust gas stacks.
Flakeline 103 linings in the effluent hold tanks and clarifier
tanks were generally in good condition except for cracks near attachments,
such as baffles and weirs, to the walls. Bondstrand downcomers were in
good condition to effluent hold tanks.
Neoprene linings were in good condition in the recirculation,
clarified water, and reslurry tanks. Slight to noticeable wear was
apparent on neoprene-lined agitators in these tanks. Neoprene-lined
piping was inspected near pumps and it appeared to be in good condition.
The neoprene linings of casings and impellers in centrifugal pumps were
not severely damaged, and the least wear was on those in the TCA system
and the greatest on those in the Hydro-Filter system. Decreased output
of limestone slurry (60$ solids) by two rotary screw-type pumps (Moyno)
required that neoprene-lined stators be replaced. The rotors are of
stainless steel.
Corrosion—Test Specimens; In general, the least attack occurred
to test specimens in the TCA system and the greatest to those in the venturi
system. With few exceptions, the greatest loss of weight from metal speci-
mens occurred in inlet duct areas exposed to wetted flue gas and in venturi
outlet area exposed to slurry and gas at comparatively high velocities.
Damage to some nonmetallic materials occurred in these areas also. Slurry
impingement on the specimens caused erosion and corrosion. Pitting and
crevice-type corrosion were minor where erosion and general corrosion
kept the specimens clean. Generally, in most areas where solids accumulated
in the three scrubber systems, the surface of the underlying specimens
showed localized corrosion. However, each of the 1? alloys tested showed
good resistance at one or more test locations in each scrubber system.
The three rubbers were tested at only six locations; they showed good
resistance in all tests. The maximum service temperature was exceeded
for some nonmetallic materials in the inlet gas duct and exhaust gas duct.
J-23
-------
Table VIII is a summary of data from all the corrosion tests
conducted in the three different scrubber systems. It shows the com-
parative resistance of the materials tested without identifying the test
conditions. The metals are grouped into four categories with respect to
decreasing corrosion resistance. The evaluation is based on corrosion
rates determined by weight loss and/or resistance to pitting, crevice
corrosion, and other types of localized attack.
Corrosion of Hastelloy C-276 was negligible to 5 mils per year;
this alloy showed no evidence of localized attack in any test location.
Next in resistance were the alloys Inconel 625, Incoloy 825, Carpenter
20 Cb-3 and Type J16L stainless steel with corrosion rates ranging from
negligible to 5, 1, Ik, and 15 mils per year, respectively. These alloys
had very few pits and/or corrosion crevices. One specimen of Type 316
stainless steel was grooved and the weld of another was attacked.
Three nonferrous alloys, cupro-nickel 70-30, Monel kQO, and
Hastelloy B, had minimum rates of less than 1 mil and maximum rates of
U9, 57, and 100 mils per year, respectively, with one or two specimens
pitted. In three tests of Monel and in one test of cupro-nickel 70-30,
the welds were inferior to the parent metal.
A group of five alloys that included Type kh6 stainless steel,
E-Brite 26-1, Incoloy 800, USS 18-18-2, and Type 30^ stainless steel, had
rates that ranged from negligible to a "greater than" value which indicates
that the specimen was completely destroyed at one or more test locations.
The values for failures ranged from greater than ihO mils per year for
Type W6 to greater than 200 for both USS 18-18-2 and Type 30to stainless
steels. These five alloys were highly susceptible to localized corrosion.
Another group of alloys which consisted of Type UlO stainless
steel, aluminum 3003, mild steel A-283, and Cor-Ten B had minimum rates
of less than 1 mil per year and maximum rates of greater than 250 for
Type klO to greater than' ikOO for mild steel and Cor-Ten B. Pitting
and crevice corrosion occurred on these four alloys.
In general, the stressed specimens (5 alloys only) were not
corroded at rates higher than their counterpart disk-type specimens,
and no cracks were observed.
Of all the alloys tested, Hastelloy C-276 was the most durable
and also the most expensive. Type 316L ranked fifth in durability and
about eleventh in cost. The values for cost comparison are based on
costs of tubing and sheet with Type 30^ stainless steel as unity (l.OO).
(See Table VIII.)
J-24
-------
Specimens of Bondstrand kOOO, Flakeline 200, and Transite were
tested at 21 locations. Bondstrand showed good resistance in 12 tests
and poor in 9 tests. The evaluations for Flakeline were: 2 good, lU
fair, and 5 poor; and those for Transite were: 1^ good, 2 fair, and
5 poor. Only six specimens of each of the plastic Qua-Corr and of the
rubbers, butyl, natural, and neoprene, were tested. The results were
five good and one poor for Qua-Corr and six good for each of the rubbers.
Summary
Test specimens and equipment exposed for about 6 months in three
test SOa removal systems at Shawnee Power Plant were evaluated for corrosion
and wear.
The most severe damage occurred in plant areas exposed to
humidified stack gas containing fly ash, CQz, 02, and S02 at elevated
temperature and high velocity; to gas and slurry discharging at high
velocity from the venturi; and to gas and mist leaving an absorber.
Metals covered by limestone-fly ash deposits were not eroded
but were subject to corrosion of the concentration cell type.
Neoprene-lined towers, ducts, and tanks, as well as rubber-lined
test specimens, were durable. Some wear was apparent on neoprene linings
of pumps and agitators.
In limited tests, reinforced plastics, such as polyester, epoxy,
and furan, were less durable than rubber as lining materials.
Seventeen alloys were tested in twenty-one exposure areas in
three systems of the plant. The maximum corrosion rates in mils per year
for the five most durable specimens were as follows: Hastelloy C-276,
5 mils; Inconel 625, 5 mils; Incoloy 825, 7 mils; Carpenter 20 Cb-5, lU
mils; and Type J16L stainless steel, 15 mils. Hastelloy C-276 is the
most durable and expensive of all the alloys tested; Type J16L stainless
steel ranks fifth in durability and about eleventh in cost.
This corrosion study is being continued on materials of
construction for the S02 removal test facility at Shawnee Power Plant.
G. L. Crow
H. R. Horsman
J-25
-------
TAJIK I
Cuiiunluii Teatu Condui'u-d In the Vanlurl Syulen of Uie Ltmegtonr - We I-Scrubbing
Piui-L'Bi) lui Suirur Plunlile Removal ftum Slack Pan at Shaunci. Pnncr Plant
pri lud—AUK. 12, 1972, u> Feb. 2, 197}, operating tlne--l8l>0 huura or 76.7
days, and Idle Llne--2}l<0 hours or 97.3 dayn)
CorruBiun upi-diii..utf
Expudcd In
Lorallona (See Klrf. 2), Reference NO.
Exhuuat Liquor
Oae and gaa Effluent Recycle In
Inlet BUS "iprajL (healed) llauor liquor clarlfler
10)1 lOOb 1012 101}
Inlet gaa epray
1002 10U
Qaa
Wlorlty, ft/ore
Composition, £ by volume
S08
COB
NB
08
Liquor
Sulldn, t by vltfhi
Corapot. 1 1 1 on , * by might
Cono'.lon ihir ol milnlj , mllt.yjM
Aluntnun }00}, wul.I ER1IUO
Coii,. til. i .\iCb- ^ t. U • •iirpv.iiii.r ?l»:b-J, mn-aaad
Cor-Tun D, vil.1 ttiUJtf-Cj
Cupru-iUck.'l /0-W, w. Id 1»2>9 RCuNl
E-Biltu r
Inroloy B^5, uelil ln>.oloy 6'^, atr«.i.iied
Mild utc.'l A-PB}, uclJ tf.012
Typi }0< , wt Id Typi. }W
Evnluiillr.n '.f iiuiimfUillli- miiii rlnl j*
Plniillfii
bonduliunU '.OHO (Flbti rtlHuu-ielnlorced epoxy),
Fluki lln^ ,'Txi (Iiu n ] luki n mid polyeulei rcaln) .
4uu-Cun (Flln.1 gliuu-n Inlon id i\iren reoln)...
Hubbi. i n
Bui y I .'V//, (C..polym^i "I 1 ...Uiiylune-laoprene) .
Ce noti 1 >
2f5-}}0°
20-60
10- X>
0
71-
"•.5
B
-
_
-
> 160
< l
_
> 290
1}
> ito
-
26
< 1
'< 1
< 1
10
1
> 1}0
> 10}
> no
Poor
Pooi
i
Poor
80-170 £
0.2
12
69
It
15
0.02
-
_
:
>550
it
-
> ll<00
1.9
> 190
-
100
5
> 190
7
5
> I'.OO
57f
> 200
15, -r
> 250
> HO
> 200
Poor
Poor
Foot
Good
Good
Good
Poor
!}5-2o5
20-60
10-JO
0.2
12
69
i.
15
0.02
-
.
_
m
P70
c 1
< 1
l8. -
'ill; -*
< i
.d
< 1
< 1
1
< 1
16, -«
1.
1
< 1
2
Poor
Poor
•
Good
-
90-1W
I.-10
5.6-6.8
1.0-2.0
1.5-}. 5
90-96
P2U, -c
Neg
Neg .
IS -c
i
< i
Neg.
2, Pm
Neg.
< 1
< 1
Neg.
< 1
18, -c
1
< 1 -c
Neg.
Neg.
P12, -c
< 1 -c
n'. -c
Good
Fair"
Good
Good
Good
Good
Good
-
70-125
1.-10
5.6-6.}
1 ,0-2 0
1 5-J.5
1.5-". 5
90-96
< 1
Ne|j.
-
12
< 1
Neg.
-
< 1
< 1
< 1
< 1
Neg.
19
< 1
Neg.
< 1
P}, -c
Neg.
Full-6
-
CuoJ
-
70-100
0-20
6.0-7.0
O-l.
0-7
0-10
80-100
P12, -c
Meg.
5, -
1
Ne8.
-
< 1, Pn
Neg.
Hug
< 1
Neg.
5
1, K
N.*.
Netf.
< 1, -c
< 1 -c
PIO! -c
Good
Fair"
-
,1-jJ
•Jdl Imuni win n i|'i'.y unit i ««" u.,.'J
b llb. V ..... i. r limn" (>) i Irtii 1" u»cd «'"•-•'• «• "I"-''- ^n -..« .onplelcly deal.oyed. "P" preceding « nujiiLc, lii,ll-
,Bl,,. I.IIIIM
-------
TABIS II
Corrosion Testa Conducted In the 1CA System of the Unegtone - Wet-aerubbing
Proceaa for Sulfur Dioxide Removal from Stack das at flhavner Power
(Teat perlod-Aug. 12, 1972, to Feb. 3, 1973J operating llme--lD6?
houm or 69.$ daye; and Idle tlne--2535 hour* or 105.6 days)
Corroalon anaelaena
la
Inlet
Location* (to* rig. 3), Reference Ho.
Oaa and Oaa and
droplet*
«65
Liquor
Sxhauat In
gaa affluent Recycle clarl-
mlat (heated) llauor llq.uor fler
SdoT WoB* 2012 2013
Temperature, t 260-310
Velocity, ft/a«c 25-^0
Flow raw, 1000'a of actual ft»/Bla 15-30
Composition, £ by volume
30, 0.3
CO, 13
o»
BiO
Liquor
Mb, gr/atandard ft*
3-5
70-125
6-12
11-28
0.05
12
15
0.09
70-120 70-120 235-865
5-10 »-8 25-60
11-22 11-22 15-30
0.0)
Ifi
69
15
o.oe
0.05
12
15
0.02
0.05
IB
15
0.02
Temperature, *F
Bolide, % by weight
pH
ComposUIon, t by weight
CaSO,'2HfiO
at
-
2
1
ta
2
^
1
1
1
1
m
1
17
l
ta
—
1
Ik
1
1
-
-
It •
Beg.
13
< 1 -«
P2, -«
6
Reg.
< 1, -*
—
'16
1
P6. -«
Reg.
Pa, >
pit) -•
•
•
*.
< 1
m
21, P3h
P6
_
6
Pfl -e
Beg.
Reg.
23
1
PIS, -•
< 1
K, >
P19, -e
-
-
26, P20
< 1
1
268
17
1, Pa
fm
13
Beg.
P19, -°
"BJ
1, -'
Reg.
650
15, -J
kf -®
Pto
A
< i, -
P12 -
Pl8, -
P16, -8
-
-
i, n
< i
< i
2, PB
< 1 '
K
Pa
< 1
Beg.
Pa
Beg.
< 1
< 1
3, P»
< 1
F16
< 1
< 1
«£ 1
P12, -e
P6
P5
110-125
6-10
5.9-6.3
1.0-2.0
2.0-3.5
3.0-lt.5
90-91.
20
leg.
2
170, PB
3
Beg.
< 1
2
Beg.
Heg.
Heg.
< 1
Beg.
210, Pa
2
Pa
Heg.
< 1
< 1
PB
< 1
- 1
85-125 85-100
7-15 0-30
5. 6-6 .a 6.3-7.6
1.5-3.0 0-6
2.5-5.0 0-10
3.0-7.0 0-15
85-93
2, PS
< 1
•
5, PB
< 1
Beg.
-
< 1
< 1
PE
Heg.
•
Beg.
3
< i
P10, -"
-
< 1
v
*, -:
Pa| -•
70-100
1
Heg.
-
6. -f
< 1
Heg.
-
< 1
Heg.
Pa
Heg.
•
< 1
8
< 1
Heg.
-
(leg.
.
P4, -e
< 1
< 1
Unreacted llaeetone plua fly ash
Hater
Corroalon rate of metala . Bila/yr
Aluminum 3003, veld BR1100
Carpenter ZOCb-J, veld Carpenter 2OCb-J
Carpenter 20Cb-3, veld Carpenter 20Cb-3, etreaaed
Cor-Ten B, weld EoOl8-CJ 15, Fa
Cupro-nlckel 70-30, weld B259 RCuJB
B-Brlte 26-1, veld B-Brlte 26-1
B-Brite 26-1, veld B-Brlte 26-1, stressed
Rkjielloy B, veld Baatelloy B
Bnatelloy C-276, veld Raatelloy C-276
Incoloy 800. veld Inconel 82
Incoloy 835, veld Incoloy 65
Incoloy 825, veld Inooloy 65, etreaaed
Xnconel 625, veld Inconel 625
Mild ateel A-28}, veld E6012
Monel IK», veld Monel l«0
Type JOltL, veld Type 308L < 1, Pa
Type JO«L, weld Type }08L, stressed
Type M6t, veld Type 316L <
Type 316L, weld Type 316L. stressed
Type 1)10, veld Type 309 1,
Type W. weld Type 309 <
UBS 18-16-2, veld Inconel 82 <
Condition of nometalllc materials'1
Pleatics
Bondatrand UOOO (Fiber glass-reinforced epcoey). Poor Poor Oood Oood Poor Oood Oood Oood
Flakellne 200 (Inert flakes and polyester reata). Fair Poor Fair Fair Oood Fair Fair Fair
Qua-Corr (Fiber glass-reinforced furan realn).. ... Oood - Oood
Rubbers
Butyl 85,666 (Copolyner of laobutylene-laoprane). ... Oood - Qood
natural 1375 (Polylaoprene) ... Oood - Oood
Reoprene 9150 (Cbloroprene polyner) - - - flood - Oood
Ceramic
TransIte (Portland cement and asbestos) Oood Poor Fair Poor Oood Oood Oood Oood
* Ho apray water vaa uaad at teat location ?002 during the corrosion teat period to humidify the gaa
b Becauae teat apeclaena uere worn by movaecnt of plaatlc balls during the period 8/12 to 11/3/7?, new specimens were
Installed 11/17/72. The iiata given were determined from the laat 995 hours of operation.
c The apaolaana were limeraed In the slurry only during the laat tU. 5 hours of operating tine, and the oorroalon rate waa
determined on ihla basis. However, the high rates for aluminum, Oar-Ten B, and mild ateel Indicate that theae alloya
were corroded during Idle lime alao
d The "greater than" (-•) sign la uead vh.-n a apeoloen waa completely destroyed "P" preceding a nunber Indicates pitting
during exposure period to depth In mils shown by number, and "Pm." minute pita. "Heg.," negligible, no velght loss or
localized attack
8 Crevice corrosion at contact with Teflon Insulator.
f dncalirMi attack o) hrbl-al!'ected zone of weld.
g Wear ou eilgo ol apculnr.n >tue to muvement of plaatic tails. '
n Edge of specimen uamaeM) liy impact of sharp object.
1 Attack nf well
1 Eval\ia<.l.«i. 'looil. lit i le ir no Lhunije in condition of specimen; fair, dellnlte change, probably ,-ould be ut.id,
poor, fail ml or severely 'lamagud
J-28
-------
TAHIS 11[
n 'ft nin rumluiiij In lln ByUm-Hller lfrnliin »r IJii- Mm nl nu- - u«t-3eniliblng
_Kiiin lur null\ir nionlili' liiBnuiil li'tn SlurX (JH.I m 'ihii«in » I'""- r Pluui
(Ti in pi riud--Aug. IV, I'Jf?, UP F-;h ], W7J; xpHrnMnK I In--?:'0'<
hiiurw nr 91." days] *nd Idle HJoo--!yXl tiuurn >ir Hl.J d«j«)
C<-i rviit.ui i m-i; linum. Llriuor
and Inlet. Ois and HUH KfTlurnt RpLyHv Ltquur In
J.*]uinnl In Inlet aaa gag llnuuc (hound) llqu-ir MIJU'.I n^rlfliT
LKintliwi (Hre ttB. '<). RFfrranre Ho 3002» 3006JOO1! 300f 50* W12 5OU~
CoaiiLinltlan, i by vulunr*
CO
., p
-p
HaO
rijt »(Oi. gp/n tandard fl3
LI quor
Cmpo-in ion, 3& by uMfth1
, * !*
Ullim Crl HjvMi.nl*> p)uB fly ll h
Cm rvt-l'ti inir «>f iii-i n | R'' f mllR/^T
Aluminum W- , wi»M F.HI 10O ...
Cuip^iti'M rOCb-', ui^M rni-jiPiiU-r ^ 160
». Pn
> 300
35*
71
< 1
93
2
< 1
30^d
> 140
01&, PB
> 100
> 90
> 120
Poor
Poor
Poor
}-8
10-2}
0.1
12
69
ti
15
0.02
Reg
1.0
1
< 1, PI
z
Beg.
< 1, P19
Beg.
•eg.
37
< 1
P12, -c
Heg.
P8, -c
3' '•
Oood
Fair
Fair.
J-8
10-23
0.1
12
69
L
15
0.02
P18
Neg.
< 1
13
1
< 1?>
li
Keg.
< 1
< 1
< 1
< 1
ll
2
PIO
pie, -c
Heg.
< 1, -"
PJ, -c
P10, -|
Ooodf
ralr
Ooodr
OoodJ
Ooodr
Qoodf
c$j*2bj
?5~60
12.5-W
0.1
12
69
I
15
0.02
5,-c
Pa
< 1
». -c
i
P7
vl, PlB
2
< 1
1
< 1
1
5
1, PB
< 1, Pa
< 1
< 1, Pa
>, -c
1, PB
2
Poor
Good
Cool
75-125
5.6-6 !>
1.0-2.0
1.5-3.5
1.5-&.5
P. -c
Hen.
< 1
5, -r
< l
< 1
< 1
< 1
< 1
< l
< 1
"W -r
< 1
< 1
<*;:=
B.', -r
Rood
Fair
Oood
Oood
Oood
Oood
Good
75-125
1"-10
1 0-?.0
1.5-3.5
1 V"- 5
< 1
10
< 1
< 1
< I
Me,.
Hsg.
Keg
Beg.
11
< 1
Beg.
•eg
rr, -c
.c
< ll -e
Good
Fair
Gnod
75-100
0-20
o-u
0-,'
0-10
8o-irx)
RI
Meg.
7
1
< 1
•• l
< 1
Heg.
< 1
dee-
<3
< 1
Heg.
P16, -«
P9, -c
P5, -c
PI}, Poor
Fair
Good
ay water IBB uncrt at all 1 1"":» at teat point J002 to humidify the gas .....,.,..
",r"a"r "han" (?) tlgn I, uaert -hen a apeelmen was completely destroyed. "?" preceding a number Indica « p ti ng
rlii Ita TOW pirlnd lo th. drplh In Jli shown by the number, and "Fa" Indicate. Unto pit.. "»,S . r,eFHRJM.
no »<-J
-------
TABLE IV
Allovs Tested In the Limestone - Vet-Scrubbi
Checieal analysis, ?
1.
2.
3.
i*.
5.
6.
7.
8.
9.
10.
11.
12.
13.
11*.
15.
16.
17.
Allovs
Alualcun 3003
Carpenter 20Cb-3
Cor -Ten 3b
Cupro-nlckel 70-30
E-Brlte 26 -lb
Haatelloy 3b
Hastelloy C-276b
Incoloy 8oob
Incoloy 82 5b
Inconel 625
Mild Steel A-283b
Monel U00b
Type 30l*L
Type 316L
Type UlOb
Type W*6b
USS l8-l3-2b
C
_
0.07*
0.066
-
< 0.001
< 0.01
0.002
o.ok
o.ok
0.1*
0.17
0.09
0.030*
0.030*
0.062
0.10
0.065
Cr
_
19-21
0.52
-
26.17
0.19
15-87
21.11
22.28
20-23
-
-
18-20
16-18
12.7
21* .6
18.2
'.U
m
32-33
0.018
31.00
0.08
Bal.
Bal.
31-32
1*2.22
Bal.
-
6U .66
8-12
10-11*
0.16
0.50
18.0
Fe
0.7a
Bal.
Bal.
0.53
Bal.
5.75
5-96
1*5-01
28.30
5.00*
Bal.
1.00
Bal.
Bal.
Bal.
Bal.
Bal.
Cu
0.2*
3-*
0.31
67.79
0.01
-
-
0.1*0
2.12
-
0.037
33.06
-
-
0.03
0.01*5
0.03
Mo
_
2-3
0.010
-
1.00
26.20
l£.32
-
-
8-10
-
-
-
2.0-J.O
0.05U
0.10
O.OlS
J'-T.
1.0-1.5
2.00*
1.20
0.52
0.01
0.53
0.1*9
0.81.
0.56
0.5*
0.118
1.03
2.00*
2.00*
0.1*3
0.71
1.50
S:
0.6*
1.00*
0.29
-
0.19
0.01
< 0.01
0.31
0.31*
0.5*
0.070
0.08
1.00*
1.00*
0.1*0
0.37
1.9»
P
_
0.035*
0.012
O.OO3
O.010
0.005
0.012
-
-
0.015*
0.015
-
0.01*5*
0.01*5*
0.011*
0.018
O.OC7
S
_
0.035*
0.031
0.005
0.012
0.006
0.010
0.007
O.OO7
0.015*
o.ceu
0.008
0.030*
0.030*
o.oiS
O.O10
0.009
Al Tl
Eal.
-
0.056
-
-
-
-
0.1*3 0.1*6
0.06 0.66
0.1** O.I**
0.005
0.001*
-
-
0.069
0.008 < 0.02
O.O01
Ctr-.-s
a
Zn 0.1 , To^al C.15
Cb + Ta 3 x C
V 0.05
Zn O.O3U , Pb CJOCS
N 0.010
Co 0.95, V 0.26
Co l.BU, W 3.51, V C.25
Co 1.0*, Cb + Ta 3.i; - L.15
N O.G3U, V < 0.05
N C.18, V < 0.03
S O.Oi*
, bxmuz.
° Analysis vas supplied with the material received for use in corrosion tests.
-------
Table V
Aaalvses* of riewssits in I i zest one - Vet-Scrubtinp Svsteca for
Date Sueber
Veaturl Systen
2/1/73 VD 2175
2/23/73 VD 2 2J73
TCA System
2/3/73 TCA D 1237)
2/3/73 TCA D 22373
2/5/73 TCA D 1257}
2/5/73 TCA D 22573
2/22/73 TCA D 122273
2/12/73 TCA D 120273
2/12/73 TCA D 221273
Hydro-Filter System
2/2/73 HFD-2273
2/3/73 HTD-2373
2/23/73 HFD-22373
Identification of sample
Location
Scale trm recirccJ.at.ion t&nn D-lOt.
Soot "TOO gas duct about 25 feet sbove reheater.
Scale free recirculation tank D-20u (Test 2012} .
Scale frca spool of corrosion specimens (Test 2006)
Scale fron scrubber vail below and near Koch tray.
Scale from grid -wall junction, elevation 396 feet
1-1/2 Inches.
Rust-colored scale froo corroded denister.
Tar -like material from duct 25 feet downstream
froa reheater.
Tar -like material dovnstream fron and Dear reheater.
Scale free corrosion spool above marble bed.
Deposit fron bottoa slurry nozzle.
Soot fron gas duct about 25 feet above reheater.
Sulfur
CaO
25.1*
-
31-8
23.5
39.T
U.2
3-6
-
-
29-5
23. a
-
Dioxide Removal from Stack OS
Corsositlon,
Sra.e or slu30e deposit
SOp SU C3a Xrfl
3.0 37.3 1.3
-
lO.i 23.7 6.3
17.6 27.U 0.5
16.8 25.9 2.0 0.22
15.8 2b.fc 6.2 0.21
b.2 33.2 0.0
.
-
17.6 27.1* 0.5
9.6 Ul.7 2.2
-
at Stavnee Power Plant
by weight
Soot aa'ierlalD
Criers Ash feC Hydrocarbon
25-5
- 56.0 12. 8 31.2
(6U.2) . (35.3)
23.l«
25.9
is.fc
12.5
9.0
25.2 7.8 67.0
(87.3) . (72.T)
39-3 1.7 59.0
(to.o) . (60.0)
2V. 9 -
17.T -
- 36-1 11. T 51-9
(M..2) - (58.8)
General Operation Equipnent
3/1/73 3173
Scale from re slurry pump G-fcOl.
59.3
0.5l4 12.3 20.1
26.7
Information tal'-en froa reports dated "arch and May 1975 by H. E. Wagner of inspections made February 1, 2, and 3, 1973 of the Hydro-Filter, tj,e venturl,
and the TCA scrubber systems.
Values la parentheses are on a dry basis.
-------
TAinj; n
Himlnpaii rl H"«pii-iu' Lliilnan of Eaulpaunt in ihi- Three l,lm>i)U.nc - Wei-Scrubbing Syaieaa
fui Suirui Dlotldr Remuvul fum Sl.iu-k flnn - PJUIT Plnnl
(K«po»ure prrlod! Avi«. 1?, W?, lo Feb. J, 19?M
Teat
temp., Diipjni-ter "A" hirdneaa
__^^__^^_^^^^^__ U'C"Uon of hardnena toot T* Original Flnal^
Verlinl fyotrm (11^0 cyi-intlng llCTirn)
Imhpn helcu Typi' ,M('L r.tnlnleaR nteel nl vynturl nectlcm ............. - fid tra 65 67
linpoui irny (npproiliniiiu elevnt.lon J88 IOM ) ....................... ,. - 60 to (,'j 5} to 60
Thii'i1 Inrhm hrliw nlit cllnlnnior ........................................... - 6010*55 51' to 60
Ttin-o fool n\>o»c nlHt cllmlnntoi ............................................... . 60 to 65 5) to 55
Four liK-hro lie low type >U>L utnlnJena eleel duct, to rehe>it.er .................... - 60 to 65 52 to 51"
Clnrlflfd Pnvrni Wnli-r RtoniR" Tiuik, D-10>:
Above ll<]ulj 1-vf] [[[ 60 55 lo 60 6* to 65
Bulov iiiiuld it- vi l [[[ 60 55 lo 60 61 to 6}
Reuliculntlnn Tnnk;
Fl« fcci nl>.wi> I'oUom [[[ - 55 to 60 65 to 69
PI Oder) at nullnliu [[[ - 60 lo 10 6} 10 6f
Blml<'n if Aftllnl'u In:
ElTlu.-nl hold n.nk D-101 [[[ - 60 to 70 6S to 66
Pn-lrruLnllnn imiti D-101' .............. . ........................................ 60 i 59 to fcj
F«ui irt-t H.-liw K."h liny ............................. , ....................... 60 to Si 59 to 60
•No fret nbnv.' Ki«-h trny ................................ , . . ..................... - 60 to 65 55 to 55
Clnrlllcd Procoi.n Unicr Slorigc Ank, D-20J:
Above liquid I i-w 1 [[[ 60 55 to 60 62 to 71
Bolew liquid luui-1 [[[ 60 55 to 60 6 uliM«r «rvl (, In-hui, b.-Low reducer ....................................... X> fiO to 65 6' ' to 6 f
Tlirur. Inrhcn union Tvjx- >l6L olwlnleon eteel atack ............................. J6 60 Lo b5 oi to 10
S'';:-'';r":°i ••::::::::::::::::::::::•.::.:::::••:::: 8 3 = 8 8S8
n, . ii niniiiii, T-ink, n-'X)'1
Hv, u,.i ...«,.. lutiw
bl«d,M Ul
,, uli.M..n i»nk a-iO'' I.............................. - 60 lo 70 67 to fO
n-JOl, 0-X)>A, R-.JOW, snd C-yfi: -
-------
TABLE VII
Hardness6 of Rubber Lining** Specimens Tested in the Limestone - Wet-Scrubbing
Systems for Sulfur Dioxide Removal from Stack Gas at Shavnee Power Plant
(Exposure period—Aug. 12, 1972, to Feb. 5, 1975)
Barometer "A" hardness
Location of Butyl Natural Neoprene
specimens0 (26.666) (1575) (9150)
As received 54-56 (55) 34-37 (35) 64-65 (64)
Venturi System (1840 Operating Hours)
1008
ion
TCA System
56-58 (57)
5^58 (56)
(1667 Operating Hours)
2004 56-59 (57)
2008 5lt_58 (56)
Hydro-Filter System (2203 Operating Hours)
3005
3008
55-58 (57)
54-58 (56)
39_4o (4o)
41-43 (42)
38-42 (40)
36-39 (38)
35-39 (38)
37-40 (38)
60-63 (61)
62-63 (62)
59-61 (60)
59-64 (62)
58-62 (60)
61-65 (63)
a Four tests were made of each specimen in the laboratory at 78°F with a
durometer type "A2," AS3M D2240, manufactured by The Shore Instrument and
Manufacturing Company. Values in parentheses are averages.
b Specimens of butyl, natural, and neoprene liners were applied on mild steel
coupons by the Gates Rubber Company.
c See reference numbers on Figures 2—4.
J-33
-------
TAM.E VIII
Coronation of Corrosion Data of Materials Tested in tlie Three Limestone - Vet-Ocrubblng Systems
for Sulfur Dioxide Removal froo Stack Cas at Shavnea Power Plant
Metals'1
1.
2.
3.
Ii.
6.
7.
a.
9.
10.
11.
12.
13.
lU.
15.
16.
17.
llastelloy C-276
Inconel fe'j
Incoloy tt25
Carpenter 20Cb-3
Type MfiL Rfl
CupronlcKel 70-30
Monel 1*00
llastelloy n
Type W» SS
E-Urite 26-1
Incoloy 800
uss 18-18-2
Type 30kL SS
Type It 10 SS
Aluminum 3003
Ml Id Steel A-883 C
Cor -Ten B
Cost comparison
A B
9.29
6.59*
l..'.6f
k.21
1.39
2.9V
9.'.7
2.5*
•
1.11
1.92
O-Skf
fi.05
5.73
3.73
1.61
3.61
1.85
2.TO
1.11
0.93
Condition
Honaetalllc Materiala Good Fair Poor
Plastics
1. Rondatrand dOOO
2. Flakellne 200
3. Qua-Corr
9
5
1
Corrosion*
On basis of
weight loss,
mils/yr. range
Neg. to 5
Neg. to 5
Neg. to 7
Neg. to lU
Reg. to 15
< 1 to U9
< 1 to 57
< 1 to 100
Neg. to IbO
Neg. to 190
Neg. to 190
Neg. to 200
Neg. to 200
< 1 to > 250
< 1 to > 550
< 1 to > ibOO
< 1 to > ibOO
Specimeni pitted
No.
—
1
.
2
3
1
1
2
9
10
6
11
1U
15
9
2
5
Depth.
Minimum
—
.
.
-
m
.
-
Minute
Minute
Minute
Minute
Minute
Minute
2
.
Minute
mils'"
Maximum
m
Minute
.
Minute
Minute
18
2
Minute
19
18
19
16
23
16
70
Minute
3
Specimen*
with crevice
attack. No.
M
-
1
2
_
1
-
11
2
3
11
11
16
5
2
ii
Specimen with other
types
No.
-
-
IF 1
1
3
-
.
-
1
-
1
-
-
-
1
of attack
Area
.
-
-
Olfl8, weld
Weld
Weld
-
-
h"
_
H™
-
-
-
Held
1. Hutyl 26,«>6
2. Natural 1)75
3. Neoprene 9150
Ceramic
1. Transite
° The compilation is based on 21 tests of each material except for Qua-Corr and the three rubbers (butyl, natural, and
tots, ,/lnrorm.tlon from J. M. Tull, Atlanta, Georgia, by telephone (JuUr 2, 1973)i7
c The actual depth of penetration in mils during exposure periods Is Indicated In Tables I, II, and III.
d Metals are listed In their approximate order of decreaelng corrosion resistance.
" Welded.
Seamless.
g A groove In parent metal was ifl mils deep.
" Severe locallied attack of parent metal.
J-34
-------
HYDRO-FILTER
(FLOODED-BED
OF MARBLES)
TCA
(MOBILE BED OF
PING-PONG BALLS)
VENTURI
(FOLLOWED BY
AFTER-SCRUBBER)
FIGURE I
THREE PARALLEL SYSTEMS OF LIMESTONE-WET-SCRUBBING
TEST FACILITY AT SHAWNEE POWER PLANT
J-35
-------
TOP or STACK
LEGEND:
OZX LOCATION Or TEST
x— r— SPECIMENS
o (RACK, SPOOL OR STRESSED)
0 SPECIMEN OMITTED IN CURRENT RUNS
(AUO 8. 1972--- FEB 2. 1973)
" CARBON STEEL ASTM A -263
e TEST 1015 WAS CONDUCTED IN
CLARIFIER TANK 0-102 NOT SHOWN
CATWALK
(TO POWER
BUILDING)
OAS INLET DUCTMO'DIA . IOGA O 'TWO'
CARBON STFFI k>i , ra mi.:
CARBON STEEL
EL
NtOPRENE LINED
(CARBON STEEL, B-C
REClRCULATION
TANK (0-104,
NCOPRENC LINED
CARBON STEEL)
GROUND LEVEL
EL. 34S'-01'
FIGURE 2
VENTURI SCRUBBER SYSTEM, (C-IOI)
J-36
-------
,TOP Or STACK
LEGEND:
OCX LOCATION OF TEST
^7-- SPECIMENS.
0 (RACK, SPOOL OR STRESSED)
* C AMBON STEEL ASTM A -28 3
> TEST too WAS CONDUCTED IN
CLARIFIER TANK o-toz NOT SHOWN
1
•VI
HEHEATER (F-20I.REFRACTORY
LINED CARBON STEEL \s |
SHELL. INSULATED) "1
T3VOD ,67V2ID I
MIST ELIMINATOR (CHEVRON) y
FLEXITRAY \1
OAS INLET DUCT (40* ^"X.
DIA., 10 GA. CARBON ~\ *
STEEL) ° \ffi ]
EL 397 '-10" ^ ®vUl
TYPE 316 L S.S •
I A TO 8)
ACCESS OOOR~
gggjo".-
SPOOL ,
1
(B)-
MIXER (i
(Y-204)^
JPOOL-
KEClHCULATION — *
TANK (0-204.
NEOPRENE LINED
CARBON STEED
o;
i
5
^
@
^01:
r
N
1
t
*
,1
>^-5J
-?i\
^' t
i i '
i
1 'S
1
1'
J
\ '4 ,
:i|
' .1.0. FAN
S-f(TYPE 316 LSS)
1
r
DUCT-40"DIA
'(TYPE 316 LSS)
1 .SPOOL
i *^5B)
J 1 II.1 STRESSED ""*"
P
Kr|f'[T¥PE 316 L SS)
TT^*,' XRACJL— -^"'
31^^^
~~^** ^ —
11r*i"A'fxx_ GRIOS
! /— (BALLSUPPO
JuJUl 1
i a MIXER
1 1 TK
i N _,--[
" \^\
:y
^STRESSED
'Ik SPOOL
t* RACK | .
! . O
K
L
*;*•
1
To-
6-1 l"SO INSIDE
.-RUBBER LiNtNO
«• SCRUBBER
'STRUCTURE
(NEOPRENE LINED
CARBON STEEL) ,
jLj'-T'SO INSIDE
II'-
' DOWNCOMER(4'0(A.,
TYPE 316 L SS)
HOLD TANK
-- (0-201 FOR
SCRUBBER
EFFLUENT ZZ
FLAKELINE
103 COATING
ON CARBON
STEEL")
IS
o-
6'
1 „
o'-o'
yGROUNO LEVEL
EL. 34»1-0"
FIGURE 3
TURBULENT CONTACT SCRUBBER SYSTEM. TCA-(C-20I)
(MOBILE BED. "PING-PONG BALL)
J-37
-------
. /TOP OF STACK
LEGEND
CTT\ LOCATION OF TEST
-^—--•SPECIMENS
0
-------
FIGURE 5
TYPICAL ASSEMBLIES OF CORROSION TEST SPECIMENS
-------
-
'
,
•
- . 'at •
FIGURE 6
CORROSION TEST ASSEMBLIES AND SUPPORTS READY FOR INSTALLATION IN PLANTS
-------
IOOT
EXHAUST] GAS (HEATED)
mum
RECYCLE LIQUOR
LIQUOR IN CLARIFIER
EFFLUENT LIQUOR
•r, ••—
INLET GAS (HUMIDIFIED)
FIGURE 7
DISK SPECIMENS AFTER EXPOSURE IN VENTURI. SYSTEM (AUG. 12, I972--FEB. 2, 1973)
-------
FIGURE 8
STRESSED AND COATED SPECIMENS AFTER EXPOSURE IN VENTURI SYSTEM
AUG. 12, 1972-'- FEB. 2, 1973
-------
FIGURE 9
DISK SPECIMENS AFTER EXPOSURE IN TCA SYSTEM (AUG. 12, 1972--FEB. 3, 1973)
-------
GAS AND MIST
BAS AND MIST
EFFLUENT LIQUOR
FIGURE 10
STRESSED AND COATED SPECIMENS AFTER EXPOSURE IN TCA SYSTEM
AUG. 12, I972--FEB. 3, 1973
-------
01
FIGURE II
DISK SPECIMENS AFTER EXPOSURE IN HYDRO-FILTER SYSTEM (AUG. 12, 1972—FEB. I, 1973)
-------
•-t
I
4-
0-
GAS AND LIQUOR
EXHAUST G
(HEATED)
EFFLUENT LIQUOR
GAS AND LIQUOR
EFFLUENT LIQUOR
FIGURE 12
STRESSED AND COATED SPECIMENS AFTER EXPOSURE IN HYDRO-FILTER SYSTEM
AUG. 12, 1972-FEB. I, 1973
-------
Appendix K
SECOND TVA INTERIM REPORT OF CORROSION STUDIES:
EPA ALKALI SCRUBBING TEST FACILITY
by
G. L. Crow
H. R. Horsman
May 1974
K-l
-------
EPA ALKALI-SCRUBBING TEST FACILITY—SHAWNEE POWER PLANT
Second Interim Report of Corrosion Studies
The first interim report of corrosion tests conducted at the
EPA alkali-scrubbing test facility at the Shawnee Power Plant vas com-
pleted October 1, 1973. That report covered tests conducted during the
period August 8, 1972, to February 3, 1973.
The current report gives results of the second series of
tests. These tests were conducted during the period June 5 to Sep-
tember 16, 1973.
Results from the two series of tests and from inspections of
equipment were comparable in most respects; however, comparisons of
corrosion resistance of materials were more difficult to make in the
second series of tests because the spools of specimens were not identical.
Hastelloy C-276 and Inconel 625 showed good resistance to corrosion at all
test locations in both series. Corrosion of Type 3l6L stainless steel on
the basis of weight loss was moderate (< 1 to 7 mils/yr), but localized
attack was prevalent, especially under deposits of solids. Armco 22-13-5
tested only in the second series (at nine locations) was highly resistant
to general and to localized attack. Neoprene-lined towers, tanks, and
pipelines were in good condition; however, several neoprene-lined cen-
trifugal pumps were damaged and wear was apparent on the leading edge of
neoprene-covered agitator blades. The polyester inert flake material
used for lining several tanks was in good condition except for minor
cracks. Corrosion tests are being continued.
Program and Facilities
Program; The experimental program for removing sulfur dioxide
and particulate from stack gas at the coal-fired Shawnee Power Plant is a
cooperative effort among the Environmental Protection Agency (EPA), Bechtel
Corporation, and TVA. The limestone - wet-scrubbing program for sulfur
dioxide removal is funded and directed by EPA. The Bechtel Corporation
designed the plant facility and TVA built it. TVA is operating the plant
under a test program developed and directed by Bechtel. Identification
and solution of corrosion and erosion problems associated with construction
materials are important goals in a program for the design and evaluation of
limestone - wet-scrubbing systems. At the request of EPA in 1972, the
Process Engineering Branch of TVA started corrosion tests in the three
scrubber systems.
K-3
-------
Plant Facility; Much of the information about plant equip-
ment, process flow, and preparation of corrosion test specimens was
given in the report on the first series of tests but is repeated here
for convenience.
The test facility at Shawnee consists of three parallel
scrubber systems: (1) a venturi followed by a spray tower, (2) a
Turbulent Contact Absorber (TCA), and (3) a marble-bed absorber.
Each of these systems has the capacity to treat 30,000 acfm of gas
containing 1800 to 1*000 ppm of sulfur dioxide and 2 to 5 grains per
standard cubic foot of particulates. Figures 1, 2, and 3 are schematic
views of the venturi, TCA, and marble-bed scrubbing systems.
Power plant stack gas at an average temperature of 320°F
(300°-350°F) flows through a ^40-inch duct to a system where it is
sprayed for humidification and for cooling. It then passes through
limestone slurry in a particular type of test scrubber for sulfur
dioxide removal. Afterward, it is passed through a mist eliminator,
reheated to between 235° and 265"F to vaporize any residual mist and
eliminate a plume, and discharged through a fan and duct to the atmos-
phere. Scrubber effluent is clarified to remove solids which are dis-
carded and the liquor is then recirculated.
Some features common to all the systems are described below.
A l*0-inch duct is used to carry the stack gas at 320°F from the No. 10
boiler of the power plant to a test system; each duct is made of 10-
gage carbon steel, AS1M A-283, and is insulated. The 4o-inch duct
connects to another gas duct made of Type 3l6L stainless steel. This
duct is equipped with two sets of spray nozzles (the first for humidifying
and the second for cooling the gas) and an air-operated soot blower.
Downstream from each sulfur dioxide absorber and mist eliminator unit
there are a stainless steel duct, a refractory-lined reheater fired
with fuel oil, an induced-draft fan of stainless steel, and a stack
of stainless steel. For liquor handling there are a slurry recirculation
tank, a scrubber effluent tank, and a liquor clarification system. The
effluent hold tank and a clarifier tank are made of carbon steel A-283
and coated inside with Flakeline 103 which is a Bisphenol polyester
resin-fiber glass coating manufactured by the Ceilcote Company. The
recirculation tank, clarified water storage tank, and reslurry tank are
made of carbon steel and lined with neoprene.
Distinguishing features of the systems are as follows. In
the venturi scrubber system shown in Figure 1, the gas is scrubbed in
a venturi unit made of Type 3l6L stainless steel and then passed through
a neoprene-lined spray tower (afterscrubber) with a chevron-type separator
in the top for removal of mist. In the TCA system, shown in Figure 2, gas
is scrubbed in a mobile bed of wetted balls, and the mist is removed in
K-4
-------
a wash tray and chevron-type separator in a tower lined with neoprene.
In the marble-bed system shown in Figure 3, gas is scrubbed in a flooded
bed of marbles, and the mist is removed in a chevron-type mist eliminator
in a neoprene-lined scrubber tower.
Current Corrosion Tests
The second series of corrosion tests was conducted during
the period June 5 to September 16, 1973. Only spools containing 2-inch
disks were exposed in the second series. Eight spools of specimens
were tested in the venturi system, 8 in the TCA, and 7 in "the marble bed.
Twenty-two alloys and 6 nonmetals were tested, but all materials were
not exposed at the 23 test locations. Alloys that showed poor resist-
ance to attack at some locations in the first series of tests were not
retested at every location in the second series of tests. Stressed
specimens were not included in the current tests.
Tables I, II, and III list the materials tested and identify
the filler metal used in preparing welded specimens of the alloys.
Alloys not included in the first series of tests but were added in
the current tests follow: Armco 22-13-5, red brass, Crucible 26-1,
and Types 201 and 317 stainless steel. The nonmetallic materials
added in the second series of tests were Lucoflex (PVC), polyethylene
Type III, and polypropylene. Test specimens of butyl, natural, and
neoprene rubbers were not included in the current tests; these materials
showed good resistance to attack in the previous tests.
Preparations for Corrosion Tests
Disks ; Disk-type specimens, 2 inches in diameter, were
prepared from the 22 metals. A weld was made (according to manufac-
turer's recommendations) across the diameter, and after being welded,
the metal was cooled slowly in still air to simulate conditions of
constructing or of repairing large equipment. Whenever it was available,
metal stock of 1/8-inch minimum thickness was used, and the surfaces were
machined smooth after the welding. Some alloys available only in thinner
gages could not be machined, so the weld beads were smoothed by grinding.
A hole, 23/6U inch in diameter, was drilled in the center of each disk
for mounting.
Specimens of six nonmetallic materials, Bondstrand
Flakeline 200, Lucoflex (PVC), polyethylene, polypropylene, and Transite,
were also prepared as 2-inch disks and mounted on spools along with the
metal disks . Flakeline 200, a coating material, was applied on mild steel
disks by the manufacturer. The other materials are self-supporting and
were obtained in sheet form for disk preparation.
K-5
-------
Vear Bars: Wear-bar test specimens were prepared to monitor
erosion-corrosion of the Type 3l6 stainless steel sliding guides in the
venturi cone nozzle and to evaluate other alloys for use in this service.
These guides are located immediately below the venturi throat where maxi-
mum gas-slurry velocities are attained. The specimens were of Type 316
stainless steel and of Haynes alloy 6B. The bars were lU inches long by
approximately 1/U-inch wide and either 1/8- or 1/k-inch thick depending
on the stock available from which the bars were sheared. Each specimen
was fastened to a specimen holder of Type Jl6 stainless steel by a clamp
at each end.
Mounts and Suspensions; Spools for mounting the test speci-
mens and also the suspension equipment for installing them in the plants
were constructed mainly of Type Jl6 stainless steel. Bolts and nuts were
annealed to remove stresses caused by cold-working in threading operations.
To prevent loss of fasteners through vibration of equipment, two nuts were
locked by forcing them together.
At some test locations inside plant equipment, brackets were
attached as permanent fixtures by welding, and then the spools of speci-
mens were bolted to them. In other locations, spools were fastened to
existing pipe by the use of band-type clamps. In a tank, spools were
suspended by means of a 1/8-inch strip or a 3-inch pipe that was bolted
to the rim at the top of the tank. Sleeves (3/8-in wan by 6 in long) of
soft butyl rubber were placed around the 3-inch specimen support pipe as
cushions to prevent abrasion damage to the Flakeline coating or neoprene
lining on a tank wall. No specimens were installed inside pipelines or
fittings.
Figure k shows the type of spool assemblies used for mounting
the corrosion test disks. Teflon insulators were used to prevent contact
of dissimilar test materials.
Each wear-bar specimen was mounted by clamping both ends to a
holder which was placed on one of four sliding guides at the venturi cone
nozzle. The test bars were not insulated from the Type Jl6 stainless steel
specimen holders.
Test Exposures, Conditions, and Procedures
Test specimens of materials listed in Tables I, II, and III
were installed in the three scrubber systems in June 1973- Table IV gives
the analysis of each of the 22 metals tested on the spools. Specimens
were exposed at test locations identified by series 1000, 2000, and 3000
as shown in Figures 1, 2, and 3.
The wear-bar specimens were in the venturi system from
August 29 to September 16, 1973.
K-6
-------
Plant Operation; Early in the exposure period, all three
systems were operated simultaneously, but during the latter part of
the period, only the venturi and the TCA systems were operated. Infor-
mation pertinent to the current exposure periods and to the accumulative
operation time since the original starting date for the three systems
follows.
Current test
Hours
Operation of system since
End of
first test Original start
Hours
Operated Idle Date Hours Date
1516
1861
757 2/2/73 2161 9/5/72 Uooi
463 2/3/73 3160 8/17/72 1*827
1560 2/1/73 1969 8/21/72
Exposure
period
Venturi 6/13-9/16/73
TCA 6/5-9AV73
Marble bed 6/5-8/30/73
The coal used at Shawnee Power Plant contained an average of
k% sulfur (2.0 to 5.5# S) and 0.2# chlorides (trace to O.U# Cl).
Plant Process Materials and Deposits: Typical compositions
of inlet and outlet gas at the scrubber systems are tabulated below.
Stack
Component
Scrubbed
gas
S02,
C02,
Fly ash, gr/std ft3
0.3 0.05-0.1
9.8-12.3 7.^-15.0
6.0-6.3 4.2-8.8
8 15
3-5 0.02
a Taken from unit 10 ahead of mechanical
dust collectors.
Temperature of the inlet stack gas from unit 10 boiler averaged 320°F
(3000-350°F) and that of the exhaust gas after being reheated was 235°
to 265°F.
Ranges in properties of liquor in the different tanks of the
three scrubber systems are summarized below.
K-7
-------
Liquor in tanks
Temperature , 8F
Solids, % by weight
Undissolved
Dissolved
PH
Ionic composition, ppm
S03=
co3a
soiT
Caff
Mg"
Na+
If
Cl"
Effluent
75-130
7-16
0.7-2.0
5 .2-6 .2
120-600
20-500
900-2500
2200-5500
220-550
60-200
1*0-180
3000-11,000
Recycle0
85-125
7-16
0.8-l.U
U.7-5A
180-220
20-250
1900-2500
2700-3300
310-1*00
100-120
70-120
1*800-5800
Clarifier
70-100
0-35
0-2.0
5.6-7.0
120-600
20-500
900-2500
2200-5500
220-550
60-200
1*0-180
3000-11,000
a The values given are for recycle liquor in the TCA system;
the recycle tanks in the two other systems were not used
during the corrosion test period.
Table V shows analyses of deposits from the venturi and the
TCA systems. The scale and solid deposits from scrubber equipment
exposed to the limestone scrubbing liquors were composed mainly of the
materials listed below and in the ranges of percentages shown.
Component
CaO
CaS03
CaS04
CaC03
MgO
Cl
Acid insoluble
Percent
by weight
2U26
Trace-l*8
16-72
Trace-19
0 .OQl*-l .21
11.6a
0.13-60
Only one specimen.
Exposed Specimens; Photographs were made of the spools of
disk-type specimens when removed from the plant as shown in Figures 5-7.
Then the specimens were cleaned and their corrosion rates and physical
conditionswere determined as shown in Tables I through III along with
properties of gas and liquor at various test points.
K-8
-------
The wear-bar specimens are shown in Figure 8 as they appeared
after the tests and before they were cleaned. Figure 9 shows new and
used specimens. Results of the tests are given in the section "Venturi
Scrubber—Corrosion of Test Specimens."
Inspections of Plant; Equipment in the plant systems was
inspected for corrosion and erosion damage during the period September 18-20,
1973. Also, R. C. Tulis contributed information compiled from his observa-
tions and inspections throughout the test periods. Some of his observations
have been included in this report.
Durometer A hardness values of rubber lining on equipment and on
test specimens were measured with a Shore instrument, Type A2, ASTM 22bQ.
Unfortunately, hardness of most lined plant equipment was not determined
before plant operation; so data from the rubber vendors were ordinarily
used as reference values. Temperature of the atmosphere varied from 5U°
to 73°F as did the temperature of equipment during the plant inspection
made by the authors September 18-20, 1973- A decrease in temperature
would be expected to increase rubber hardness. Values for neoprene lin-
ings for the plant equipment are summarized in Table VI. The current
hardness values range from slightly lower to slightly higher than those
accepted as original values (determined at 73% ASTM D22k)-68). In
general, the neoprene linings showed good resistance to deterioration.
Results of Plant Inspections
and Corrosion Tests
In this section, plant inspections are described first, and
then the results of corrosion tests conducted in some equipment are given.
All corrosion rates were calculated on the basis of weight loss of speci-
mens during the period of plant operation, rather than the overall exposure
period.
Carbon Steel Ducts for Inlet Stack Gas—Plant Equipment; A
product of general corrosion deposited a thin coating on the inside walls
of these ducts. Small quantities of fly ash had deposited in ductwork
areas where the gas flow changed directions, but this caused no apparent
problem.
Stainless Steel Ducts for Inlet Flue Gas—Plant Equipment; In
each duct between the carbon steel section and the scrubber inlet there
are three nozzles of Type 3l6 stainless steel for spraying water to
humidify the flue gas; some nozzles were plugged with solids. Only small
deposits of solids were present in the Type 3l6L stainless steel ducts
of the humidification sections, and only slight abrasion was noted of
areas not coated with solids. However, pitting had occurred under deposits
of solids during previous periods of operation.
K-9
-------
Spray nozzles for gas humidification in these ducts were
operated for the number of hours shown below.
Percent of
Duct to Spray hours operating hours
Venturi 80 5
TCA 0 0
Marble bed 4jl 100
At the TCA and the marble-bed (but not the venturi) scrubbers,
there are four nozzles for spraying recycle slurry to cool the inlet gas.
Because of their eroded condition, the original nozzles of Carpenter 20
alloy had been replaced with new nozzles of Type 516 stainless steel;
some of these were plugged with solids. Internal erosion of the nozzles
was caused by high-velocity flow of cooling slurry consisting of water,
limestone, and fly ash. Modification of equipment since February 1975
almost eliminated buildup of solids in this area.
The soot blower nozzle of Type 509 stainless steel in the TCA
system was in good condition, but that in the marble-bed system (which
was corroded severely) had been replaced with one of a different design.
The new nozzle was in good condition.
Stainless Steel Ducts for Inlet Flue Gas — Corrosion of Test
Specimens; Specimens located in ducts below the gas humidifier sprays
corroded as follows in mils per year: less than 1 to 15 in venturi
system, less than 1 to 8 in TCA system, and less than 1 to 13 in marble-
bed system. (See Figs. 1, 2, and 3 for test locations 1002, 2002, and
3002; also, compare spools of specimens in Figs. 5, 6, and 1, respectively.)
Tables I, II, and III list the materials tested (not identical at every
test location) and their corrosion rates. Corrosion was considerably less
severe in the inlet gas to the venturi (< 1 to 15 mils/yr) than it was in
the previous test (1 to more than 330 mils/yr). The reason for this was
that the humidification sprays were used only 5$ of the time in the current
tests compared with 31$ previously. In the TCA inlet gas the rates were
comparable in the two series of tests but not so in the marble-bed system;
the reason for the difference is that the alloys that corroded severely in
the first tests were omitted from the second. Several alloys, including
Type 3l6L stainless steel, had low corrosion rates (< 1 mil/yr) in the
inlet gas ducts of the three systems . This was true also in other tests
which will be described later.
In the duct to the TCA system where no humidification was
used, the temperature of the gas was 260° to 330°F, and the conditions
of the nonmetal specimens were: Transite—good, Flakeline 200~fair, and
Bondstrand — poor. All three of the materials were in poor condition in
humidified gas entering the venturi and Hydro-Filter units during the
previous tests, so they were not tested further in the inlet flue gas.
K-10
-------
Venturi Scrubber—Plant Equipment; Pitting and severe erosion
had occurred on the 1/^-inch-thick plates of Type 316L stainless steel
mounted edgewise to support the sliding guides for the venturi cone
nozzle. There are four equally spaced guide supports; two of these (north
and east positions) were eroded to depths of 1-1/U inches. Nuts and bolts
in this area were worn badly and required replacement several months later.
Fully annealed Type 3l6 stainless steel bolts have given better service in
the venturi area than did Type 30U stainless steel bolts. Erosion of the
venturi cone was less severe than that of the guide supports and bolts.
A test wear bar of Haynes alloy 6B mounted on the north guide
support and one of Type 316 stainless steel on the east guide support had
erosion-corrosion rates of 162 and 3280 mils per year, respectively,
during an operation period of 580 hours (see Figs. 8 and 9). Pitting of
the Haynes 6B test bar occurred only on the cold-worked (sheared) edges;
the maximum depth was 27 mils. The Type 3l6 test bar was pitted in all
areas that were not severely eroded; the maximum pit depth was JO mils.
The neoprene-lined duct between the venturi unit and the spray
tower was in good condition. Durometer A hardness of the lining was 60
(at 61°F).
Venturi Scrubber—Corrosion of Test Specimens; The specimens
were installed directly below the vertically mounted venturi as shown at
point 1011 of Figure 1. Gas and slurry (laden with compounds of sulfur
oxides) at a high velocity caused more severe corrosion and erosion
damage to specimens in this test location than in any other in the three
systems. None of the specimens were destroyed completely. The erosion-
corrosion rates ranged from 13 mils per year for Hastelloy C-276 to 1^5
for red brass. Alloys with rates of 20 to 3^ mils per year listed in
the order of increasing attack were: Crucible 26-1, Armco 22-13-5*
Inconel 625, Type 3l6L, and Type 317 stainless steel. Monel UOO and red
brass had rates of 122 and 1^5 mils per year, respectively.
The specimens of plastic-base materials Lucoflex (PVC), poly-
ethylene, and polypropylene were in poor condition.
Figure 5 shows that spool 1011 was clean. Severe erosion of
the Teflon insulators had occurred and two spacer rods on the spool had
failed.
Towers in the Venturi, TCA, and Marble-Bed Systems—Plant
Equipment; In general, the neoprene lining on the wall of each tower
was in good condition; impingement of slurry from sprays caused slight
erosion in a few small areas. Also, slight mechanical damage, possibly
due to impact by foreign objects, had occurred in a few areas mainly in
or near manways. The original durometer A hardness (taken from vendor's
K-ll
-------
data) of the neoprene liners was 60-65.- The current range of hardness
values for the venturi, the TCA, and the marble bed were: 1*6-62, ^5-65,
and 66-75, respectively. All measurements were not made at the same tem-
perature (range was 57°-72°F) because of weather changes. The hardness
is expected to increase with a decrease in temperature.
Solid deposits were noted in the towers as follows (approximate
thickness): venturi~0 to 1/8 inch, hard: TCA--0 to 1/2 inch, hard; and
marble-bed~0 to 1/32 inch, soft.
In general, the various pieces of stainless steel hardware,
such as manway deflector plates, header pipes for water and slurry, tem-
perature probes, overflow weirs, sampling equipment, and suspension
brackets were pitted in the three systems. Many spray nozzles were in
good condition, some were plugged with solids, and a few were worn badly.
Hew spray nozzles of a different design replaced the old nozzles in the
marble-bed system. The Type Jl6L stainless steel mist eliminator in the
TCA system was severely corroded, but that in the marble-bed system was
affected very little.
The condition of grids in the TCA and the marble-bed towers
ranged from good to poor and from clean to 50$ plugged with hard solids.
The greatest corrosion of grids occurred at points of contact where wires
crossed; this was mainly pitting and/or crevice corrosion. Abrasion from
the moving bed of wetted balls in the TCA caused failure of one grid.
(Other wire grids failed after Sept. 1973 and have been replaced with
rod-type grids.)
Towers in the Venturi- TCA, and Marble-Bed Systems—Corrosion
of Test Specimens; Corrosion tests were not conducted in the tower of
the venturi system during the previous series of tests because of plans
to alter the arrangement of sprays in the tower. Consequently, the three
spools (each containing 20 specimens) originally prepared for testing in
that unit were exposed during the second series of tests at locations
1006, 1005, and ICOU as shown in Figure 1; the test conditions are given
in Table I with the corrosion rates. Tables II and III give similar
information for tests conducted in the TCA and the marble-bed towers,
respectively.
Figures 5, 6, and 7 show the spools of specimens as they
appeared when the tests were completed. The test medium for each spool
in the three towers and the approximate amount of solids deposited on
the spool are given below.
K-12
-------
System
Venturi
TCA
Marble bed
Spool No.
1006
1005
100^
2006a
2005
200k
3006
3005
Test medium Amount of solids on spool
Gas and liquor
Gas and liquor
Gas and droplets
Gas and liquor
Gas and droplets
Gas and mist
Gas and liquor
Gas and liquor
Covered
Little
Partially covered
Thin deposita
Covered
None (clean)
Thin deposit
Little
a Movement of plastic spheres caused erosion on periphery of test
specimens.
In the venturi tower the specimens tested at the lowest eleva-
tion (spool 1006) had the lowest corrosion rates, less than 1 to 18 mils
per year; and those at the highest elevation (spool 100*0 had the greatest
rates, less than 1 to U2. Hastelloy C-276, Incoloy 825, and Inconel 625
had rates of about 1 mil per year at the three locations. Type 316L
stainless steel had rates of less than 1, 1, and 7 mils per year at these
three test locations. Pitting and crevice corrosion occurred on several
alloys.
The condition of the nonmetallic materials ranged from good to
poor—Bondstrand UOOO, 1 good and 2 fair; Flakeline 200, 3 fair; and
Transite, 1 good, 1 fair, and 1 poor.
Some of the alloys tested in the TCA and the marble-bed towers
during the first series of tests were replaced in the second series by a
few other alloys. Therefore, only a partial comparison of corrosion of
the specimens in the three towers can be made.
Specimens at test location 2006 in the TCA tower were damaged
because of abrasion on the periphery of the specimen by movement of the
plastic spheres (see Fig. 6). (A wire mesh container has been installed
to prevent such damage in subsequent tests.) However, a trend' in resist-
ance to corrosion in the TCA tower is evident. Alloys with corrosion rates
of about 1 mil per year were Hastelloy C-276, Inconel 625, Incoloy 825,
E-Brite 26-1, Crucible 26-1, Carpenter 20Cb-3, and Armco 22-13-5. Types 5\6l
and 317 stainless steel had rates of less than 1 to 5 mils per year. The
greatest attack (11 to 122 mils) was of mild steel, Cor-Ten B, Monel ^00,
cupro-nickel 70-30, and red brass.
K-13
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The condition of nonmetallic materials was: Bondstrand 4000,
2 good; Flakeline 200, 2 fair; and Transite, 1 fair and 1 poor.
With respect to corrosion only (omitting spool 2006 because
of abrasion damage), the most severe conditions in the TCA system were
at the uppermost test location, 200*1, in the tower near and below the
chevron mist eliminator.
Only two spools of specimens were tested in the marble-bed
tower. One of these was at location 3006 below the marble support grid
in the liquor and inlet gas; the other was at location 3005 above the
marble bed (see Fig. 3 and Table III). During the test period the system
was operated only ^31 hours compared with 1516 hours for the venturi and
1861 for the TCA.
At test location 3006 the corrosion rates ranged from less
than 1 to 12 mils per year, and at 3005 they were less than 1 to 26
which show the conditions at the uppermost test location were more
severe. Alloys that had corrosion rates of about 1 mil per year in
both test locations were: Hastelloy C-276, Inconel 625, Carpenter 20Cb-3,
Type 3l6L, and Type 317 stainless steel. Also, there were other alloys
that were tested at only one of these two locations; some of these showed
good corrosion resistance. Even though the period of operation was short,
pitting and crevice corrosion had progressed appreciably on other alloys.
The condition of nonmetallic materials was good to poor;
Bondstrand ^000, 1 good and 1 poor; Flakeline 200, 2 fair; and Transite,
2 good.
Exhaust Gas Systems—Plant Equipment; Each exhaust gas
reheater for heating the scrubbed gas to between 235° and 265°F was
identical (inline, oil-fired heater) in the three sytems (Figs.l, 2,
and 3) throughout the second series of corrosion tests. (Recently, an
external reheater manufactured by the Bloom Engineering Co., Inc.,
Pittsburgh, Pennsylvania, has been installed in the venturi system.)
The 3-inch-thick refractory lining in the venturi reheater had cracked
badly and was being replaced with a new lining. The lining in the TCA
reheater had small cracks, but it was in good condition; this unit had
been relined in February 1973. An inspection was not made of the marble-
bed reheater.
A stainless steel sleeve ko inches in diameter by k feet tall
and burner nozzles with better atomizing characteristics had been installed
in each of the reheaters since February 1973. The sleeves and new nozzles
improved combustion of oil before the hot combustion gases mixed with
scrubber exhaust gas. Consequently, this reduced soot deposits in the
stack and fan; also, oil-soot deposited in the stack was less as a result
of fewer flameouts caused by quenching the flame with scrubber gas.
K-14
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The Type 30^ stainless steel sleeve in the venturi reheater
had failed because of warpage and perforation; the sleeve in the TCA
reheater was warped, but it was useable. Replacement sleeves of Type 310
stainless steel, which has better heat resisting properties than the
Type 30^, were being fabricated as needed; Type 310 was not available
when the original sleeves of Type 30^ were installed.
A heavy buildup of solids in the form of globules (some were
1 in thick by ^ in long) occurred in the stack between the reheater,
and the induced-draft fan of the venturi system. The TCA stack had a
dry, nonuniform deposit of solids; the maximum thickness was about 3A
inch. A small deposit of dry solids was noted near the vacuum breaker
valve of the marble-bed system.
Thickness measurements were made of the blades and the shrouds
of the induced-draft fans for each system. Only slight variations
(reduction of only 1 to 3 mils) were noted from the original values
determined before the plants were operated. Pitting was not detected
on either the moving or the stationary components of the fans. The fan
for the TCA system contained the smallest volume of solids; previously,
the smallest volume had been in the fan for the marble-bed system.
In the venturi system, the Type 3l6L stainless steel duct
near the induced-draft fan cracked at the junction of the duct with the
expansion bellows. One crack was 1/8-inch wide by k inches long. A
specimen (VD-5) containing solids and liquids taken September 10, 1973,
from the crack was analyzed for several compounds but not for chlorides
(see Table V). However, a sample (VD-l) of solids taken earlier (Aug. 13,
1973) from the Type 3l6L stainless steel stack downstream of the reheater
contained 11.6$ chlorides. Chlorides are known to cause stress corrosion
cracking of austenitic stainless steel.
Deterioration of similar equipment in the TCA and the marble-
bed systems has not been noted. However, efforts will be made to detect
hairline cracking (if present) during future inspections of the stainless
steel equipment, especially in the areas of welds.
Exhaust Gas Systems—Corrosion of Test Specimens; Corrosion
test specimens were mounted in the exhaust stacks in each system 8 to 10
feet downstream from the reheater as shown at points 1007, 2007, and 3007
(Figs.l, 2, and 3). Temperature of heated exhaust gas in contact with
the specimens was usually between 235° to 265°F. Tables I, II, and III
give corrosion data. Figures 5 through 6 show the soot- and ash-covered
specimens after exposure. The greatest deposit of solids occurred on
the spool (3007) in the venturi system.
K-15
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The corrosion rates of test specimens in the heated exhaust
gas were: in the TCA stack, 1 to 2 mils per yearj in the venturi, 1 to
16; and in the marble-bed, 1 to 18. Alloys that had rates of about 1 mil
per year in each of the three systems were: E-Brite 26-1, Hastelloy C-276,
Inconel 625, and Type 317 stainless steel. Several other alloys had low
rates in the TCA and marble-bed systems . The range of rates for mild
steel and for Type 3l6L stainless steel in the three exhaust gas systems
were 2-l8 and 1-3, respectively. Pitting depth in mils ranged from minute
to 13 for specimens in the three exhaust gas systems .
The condition of the nonmetallic materials was: Bonds trand
1 poor; Flakeline 200, 2 poor; and Transite, 3 good. In some cases, tests
of materials that failed in the first series of tests were not repeated.
The condition of the Teflon insulator and spacers on spool 3007
(marble-bed system) indicates that the stack had been heated well above
the normal operating temperature at least for a short time during the test
period .
Effluent Hold Tanks— Plant Equipment; An effluent hold tank
20 feet in diameter and 21 feet tall is located directly under each
scrubber tower: D-101 for the venturi, D-201 for the TCA, and D-301 for
the marble-bed systems . The shells are made of A-283 carbon steel coated
inside (80 mils minimum thickness) with Flakeline 103 manufactured by the
Ceilcote Company. This coating is a Bisphenol-A type of polyester resin
filled with flake glass (25-35$) .
Each tank was in good condition except for minute cracks at
the junction of some baffles with the tank walls and for damage due to
abrasion of small areas in the TCA tank. The 15-foot-long specimen
suspension pipe was not anchored securely, and this allowed the turbulent
slurry to move the pipe enough to cause the butyl sleeves (cushions) to
abrade through the top coat of the Flakeline. Damage to another small
area of the lining was done by similar motion of a temporary downcomer
of bare U-inch carbon steel pipe which was installed after February 1973-
Stains of iron rust indicated that the cracks penetrated the
Flakeline coating. Rust stains were noted on the wall above the immersion
line; apparently these stains were carried by fluids dripping from mild
steel equipment located above. Scale about 1/32-inch thick was flaking
off the walls.
In general, the downcomers of Bondstrand (8-in diameter)
showed no evidence of attack, but those of Type 3l6L stainless steel
(k-ft diameter) were pitted. The neoprene -covered agitator blades showed
some wear on leading edges and in some cases, slight impact damage was
noted; apparently this was caused by sharp foreign objects. The hardness
of the neoprene had changed little if any (see Table VI). The covering
on the agitator shafts was in good condition.
K-16
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Effluent Hold Tanks--Corrosion of Test Specimens: Corrosion
test specimens were mounted in the effluent hold tanks 15 feet below the
top. Figures 1 through 3 identify the locations and Figures 5 through 7
show photographs of test specimens by numbers—1008 for the venturi,
2008 for the TCA, and 3008 for the marble-bed systems. Tables I through
III show that corrosion was less than 1 mil per year for 12 alloys in the
venturi tank, 16 in the TCA, and 8 in the Marble-bed tank; Type 3l6"L stain-
less steel was one of these in each tank.
The rates in mils per year for Cor-Ten B and mild steel in the
effluent hold tanks were 7 and 10 in the venturi, less than 1 for both
alloys in the TCA, and 79 and 99 in the marble bed, respectively. Red
brass, cupro-nlckel 70-30, and Hastelloy B had rates of 21, 26, and 13
mils in the marble-bed tank; these alloys were not attacked appreciably
in the venturi and the TCA tanks. The temperature and the pH of slurries
in the three tanks were comparable. However, their ionic composition as
tabulated below shows that_the marble-bed effluent slurry had an appreci-
able higher content of C03=, Ca"^, Ha+, and Cl" than the effluent slurry
of the two other systems.
To evaluate the effect of any and all of these components in
the slurry on corrosion of materials of construction, a daily analysis,
such as the one on the following page, would be necessary. Not only is
the range in composition important, but also the composition with respect
to time (weighted analysis) is of importance, especially if there are
areas of composition that are critical with respect to corrosion.
Ionic Composition of Effluent Slurry in System, ppm
Ion
S03
COa8
S04
Venturi
120-600
25-70
900-2500
2200-5100
220-510
KT
Cl"
ItO-lflO
TCA
180-220
20-250
1900-2500
2700-3300
310-UOO
100-120
70-120
Marble bed
150-250
180-500
1800-2000
4200-5500
450-550
130-200
90-160
3000-10,000 4800-5800 • 9000-11,000
The condition of the nonmetallic materials tested in the
effluent hold tanks for the three systems was: Bondstrand 4000, 3 good;
Flakeline 200, 3 fair; and Transite, 3 good.
K-17
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In comparing the results of the first series of corrosion
tests in the effluent liquor with the results from the second series,
the maximum rates for metals were higher in the venturi and the TCA
systems and much lower in the marble bed in the first series than in
the second. Pitting and crevice corrosion were common in both. The
condition of the nonmetallic materials tested was about the same for
both series of tests.
Recirculation Tanks—Plant Equipment; Each of the scrubbing
systems has a recirculation tank 5 feet in diameter by 21 feet tall.
These are designated as D-101* for the venturi, D-20U for the TCA, and
D-30U for the marble-bed systems. These tanks were lined with neoprene
sheet 1/^-inch thick, and the blades and shaft of their agitators were
also covered with neoprene.
The recirculation tank for the venturi system and that for
the marble-bed system were not used during the second series of
corrosion tests. However, this equipment was used during the interval
between the first and the second series of tests. The linings on all
of the tank walls and the agitators were in good condition. A thin
scale had deposited that would protect the surface. Durometer A hard-
ness values for the neoprene linings were fairly consistent (see Table VI),
although they were higher than the original hardness values. The coating
on the agitator blades in the TCA tank (D-20U) had lower hardness values
than those in tanks D-1C4 and D-301* (53 to % vs. 66 to 73).
The wire cage over the slurry outlet line in the TCA tank was
plugged with solids so it was removed later.
Recirculation Tanks—Corrosion of Test Specimens; Corrosion
test specimens were not installed in recirculation tank D-10^ (venturi)
in the second series of tests. Specimens were suspended 15 feet below
the top in tank D-201)- (TCA) and 8 feet below the top in tank D-301*
(marble bed). However, tank D-30^ was not used during the test period
and the exposure of specimens in that tank was nothing more than a plant
atmospheric test (test location 3012, see Fig. 3 and Table III).
All alloys exposed in the atmospheric test in recirculation
tank D-30U had corrosion rates of less than 1 mil per year except for
Cor-Ten B and mild steel which had rates of 11 and 12, respectively.
The nonmetallic materials Bondstrand ^000, Flakeline 200, and Transite
were in good condition.
Corrosion rates were low for specimens in recirculation
tank D-20U; mild steel had a rate of 1 mil per year and rates for the
other alloys were less than 1. Crevice corrosion and pitting occurred
on some materials. The condition of nonmetallic materials Bondstrand 1*000
and Transite was good, but because of erosion damage, Flakeline 200 was
only fair.
K-18
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Clarifier Tanks—Plant Equipment: Clarifier tanks D-102
for the venturi and D-302 for the marble-bed systems are 20 feet in
diameter and 15 feet tall; and tank D-202 for the TCA system is JO
feet in diameter and 15 feet tall. Each tank has a cone-shaped bottom
that is positioned 3 to 5 feet above the foundation elevation. The
tanks are of A-285 carbon steel coated inside with Flakeline 103.
Mechanical equipment inside the clarifiers is made of Type Jl6L stain-
less steel. Tank D-101 had not been drained, and therefore was not
inspected.
Small defects common to both D-202 and D-302 tanks were
cracks in the Flakeline 103 coating evidenced by rust bleeding through
at the junction of the tank wall with the cone bottom and under the
launder. This condition was noted at the end of the first test
(Feb. 1973).
In the TCA tank (D-202) a scratch through the top coat of
Flakeline 103 nad been cut on the inside periphery 1 foot above the
bottom by the stainless steel plow. The tip of the plow has since
been trimmed to prevent further damage. In the marble-bed tank (D-302)
rust spots were found at levels of 3 and 6 feet above the bottom on the
northwest wall. The stainless equipment in both tanks showed no evidence
of attack.
Clarifier Tank—Corrosion of Test Specimens; A spool of
corrosion test specimens was suspended in the slurry 5 feet below the
launder in Clarifier tanks D-102, D-202, and D-302. These tanks are not
shown in Figures 1 through 3. Items 1013, 2013, and 3013 in Figures 5,
6, and 7 are photographs of specimens after exposure. Tables I through
III give corrosion data.
The corrosion rates were less than 1 mil per year for most
alloys tested in the three Clarifier tanks. The highest rates were for
mild steel and Cor-Ten B; these were, in mils per year, 1 and 2 in the
venturi; 2 and 2 in the TCA, and 6 and 7 in the marble bed, respectively.
The higher rates in the marble-bed clarifier tank were probably caused
by the long period of idle time (1560 hr idle vs.^31 hr of operation).
jfln another test (3012, see Table III) conducted in atmospheric conditions
throughout the exposure period, the corrosion rates were 12 and 11 mils
per year for mild steel and Cor-Ten ~&J These results show that corrosion
of the two alloys was greater under atmospheric conditions than it was in
either the recirculation tank or the clarifier tank. Pitting and crevice
corrosion had progressed more on specimens in the venturi clarifier than
on those in the TCA and marble-bed clarifier tanks.
The condition of the nonmetallic materials was: Bondstrand '+000,
1 good and 1 fair; Flakeline 200, 3 fair; Transite, 3 good; and polypropylene,
1 good.
K-19
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Clarified Process Water Hold Tanks—Plant Equipment; Clari-
fied water hold tanks D-103 for the venturi and D-303 for the marble-bed
systems are 10 feet in diameter and 9 feet tall. Tank D-203 for the TCA
system is 13 feet in diameter and 9 feet tall. Each tank has four ver-
tical baffles welded to a shell of carbon steel and lined with 1/k inch
of neoprene of durometer A hardness of 55-60. Each tank has a three-
blade agitator with diameter as follows: 1^ inches in D-103 and D-303
and about k-2 inches in D-203. The agitators and shafts were covered with
neoprene.
In general the neoprene tank linings were in good condition;
the partial separation of a lap joint (8-in section) in the TCA tank as
noted in the previous report had not progressed further. The covering
on the agitator shaft and blade assembly was in good condition except
for moderate wear on the leading edge of the blades and minor Impact
damage on some blades. These exceptions were also reported previously.
The durometer A hardness of the linings (see Table VI) are
consistent for the three tanks and agitator assemblies, but these values
are higher than the original hardness values. However, the temperature
of the liners was l8°F lower than that specified (73°F) in the standard
for testing the hardness of rubber, ASTM designation 022^*0-68.
Reslurry Tank—Plant Equipment; Tank D-^K)! is used for
reslurrying waste solids removed in the clarifier. It is identical in
size and construction to storage tank D-103 already described. The tank
was half full of water when inspected. The neoprene lining above the
liquid line was in good condition and its durometer A hardness was 65 to
71 (at 55°F).
Neoprene-Lined Centrifugal Pumps—Plant Equipment: During
the first series of corrosion tests in the scrubbing systems, Hydroseal
pumps were in service; their impeller diameters were 12, 17, or 20 inches.
The centrifugal pumps were manufactured by the Allen-Sherman-Hoff Company.
All wetted parts were lined with neoprene. In February 1973 some of the
Hydroseal pumps were converted to Centriseal, which has air instead of
water for a seal. Seal water required by the Hydroseal pumps added more
water to the system than could be tolerated in closed-loop operation.
Conversion of Hydroseal pumps to Centriseal pumps requires replacement
of (1) the shell half-suction side, (2) the shell half-engine side,
(3) the impeller, and (k) the stuffing box. In addition, an adjusting
plate must be added, the lantern ring has to be moved to a new position,
and the pump has to be repacked.
The pumps that were converted from Hydroseal to Centriseal
are listed below.
K-ZO
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Pumps converted from
Scrubber system Hydroseal to Centriseal
Venturi G-101, G-103,
TCA G-201, G-203, G-204
Marble bed G-301, G-303A, G-30^
Only pumps in the TCA system were inspected (Sept. 18-20,
1973)' The pumps inspected that had not been converted were G-202
and G-206. Those inspected that had been converted to Centriseal
were G-201, G-203, and G-20U. The durometer A hardness of the
neoprene linings ranged from 59 "to 68 except for pump G-206 where
it was 51 to 55.
The damage observed in the Hydroseal and in the Centriseal
pumps was common to both. However, greater sleeve wear resulted when
using Centriseal because solids were completely washed back into the
pumps; thus sleeves on several pump shafts had been worn by the packing.
The neoprene liners of several pumps had been damaged by some hard object
that caused grooving j impact damage, and/or wear.
Piping — Plant Equipment; Neoprene -lined piping was inspected
at the inlet and the outlet of the pumps that were dismantled. All visi-
ble areas of the linings were in good condition. The hardness values
of the neoprene linings were not determined.
Valves— Plant Equipment; The stainless steel check valve
at the discharge of pump G-201 was inspected. The body of the valve
is of cast stainless steel ASTM A-351, Grade CF-8M. The plate (hinged
vertically at the center of the cavity) is of Type 316 stainless steel,
and it seats on a neoprene ring. The valve was in good condition; the
surface of the plate was smooth and polished.
Discussion
Process Materials; In the SOg removal plant, the inlet gas,
the limestone absorbent, and their reaction products are corrosive
and/or abrasive. Components of gas, such as C02) 0^, and SOg, dissolve
sparingly to make the condensate or water corrosive. Fly ash in stack
gas and the limestone in absorbent slurry are abrasive, especially in
high-velocity streams. Slurry containing limestone, sulfite, sulfate,
fly ash, and chlorides forms deposits on metal to cause localized
corrosion.
Materials of Construction; Materials in the plant consist
mainly of: (1) carbon steel in the inlet duct for stack gas from the
power plant; (2) Type 3l6L stainless steel in the scrubbing system
ducts, the venturi scrubber, the removable internal parts of scrubber
K-21
-------
towers, the outlet gas duct, the fans, and the stack; (3) neoprene-
lined carbon steel in the venturi afterspray and the TCA and marble-
bed towers; (4) neoprene-lined carbon steel in the recirculation,
clarified process water, and reslurry tanks; (5) Bondstrand and
TJrpe 3l6L stainless steel downcomers to the effluent hold tanks;
(6) Flakeline 103-lined carbon steel in the effluent hold and clari-
fier tanks; (7) refractory-lined gas reheater, and (8) neoprene-lined
pumps and piping.
Corrosion—Plant Equipment; In general, materials used in
construction of the three scrubbing systems showed good resistance to
attack. Carbon steel ducts were corroded slightly by inlet stack gas
when at temperatures below the dew point.
Inlet stack gas, after being humidified with spray water,
attacked stainless steel ducts and nozzles as follows: slight erosion
of bare duct surfaces; concentration cell-type corrosion (pitting and
crevice) of surfaces underlying deposits; and severe corrosion and
erosion of surfaces (nozzles or projections) subjected to impingement.
In the venturi scrubber, the limestone slurry and gas dis-
charging at high velocity corroded and eroded stainless steel parts,
but apparently did not damage neoprene lining in the duct.
In the towers of the three systems, pitting and crevice
corrosion were common types of attack of stainless steel removable
parts; this occurred in stagnant areas (under deposits of solids).
Movement of the moMle packing (hollow plastic spheres) caused erosion
failure of grid wire in the TCA absorber.
Severe corrosion occurred on the. top surface of a chevron-
type mist eliminator of Type 3l6L stainless steel in the TCA tower. It
is likely that mist passing through a wash tray located below collected
on the chevron mist eliminator and evaporated to form a residue high in
compounds of chlorine and sulfur which are corrosive. Pits observed in
the outlet duct from the venturi afterscrubber might also have been caused
by such a residue of chlorine and sulfur compounds. Frequent washing to
remove residue might decrease the corrosion.
The demister in the marble-hed tower was clean and was not
pitted.
A polypropylene four-pass vane-type mist eliminator purchased
from Chemico was used in the venturi tower for about ho days of operation.
During this period the unit showed no evidence of chemical attack, but the
top side was damaged severely by impact of heavy solids that fell from the
K-22
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duct above. Also some damage was caused by rough handling of the unit.
Perhaps further testing of plastic mist eliminators is justified.
Subsequently, the plastic unit was replaced by one of stainless steel.
Nozzles of stainless steel were fairly durable for spraying
limestone slurry in the towers, although replacement nozzles will be
required occasionally.
Rubber lining in the tower shells, though coated usually
with slurry solids, was generally in good condition.
Exhaust gas stacks of Type Jl6L stainless steel exposed to
gas reheated to between 235° and 265°F were not attacked by general
corrosion. However, cracking occurred near an expansion joint down-
stream from the I.D. fan in the venturi system. Stress corrosion might
have caused this damage.
Sleeves and improved burner nozzles installed at the gas
reheaters did improve fuel oil combustion and thereby minimize trouble-
some soot deposition and a potential fire hazard in exhaust gas stacks.
Flakeline 103 linings in the effluent hold tanks and clari-
fier tanks were generally in good condition except for cracks near
attachments (such as baffles and weirs) to the walls and for abrasive
damage caused by auxiliary equipment that had been improperly anchored
or adjusted.
Bondstrand downcomers to the effluent hold tanks were in good
condition; downcomers of Type Jl6L stainless steel were pitted.
Neoprene linings were in good condition in the recirculation,
clarified water, and reslurry tanks. Slight to noticeable wear was
apparent on neoprene-covered agitators, and impingement damage caused
by hard, foreign objects had occurred to the covering of a few agitator
blades. Neoprene-lined piping was inspected near pumps and it appeared
to be in good condition. The condition of linings of casings and coverings
on impellers in centrifugal pumps of the TCA system ranged from good to
poor. (Pumps in other systems were not inspected by the authors.)
Corrosion—Test Specimens; Because identical spools if disk-
type specimens were tested in the first series of corrosion tests, a
realistic comparison could be made of their corrosion resistance at each
test location in the three scrubber systems. However, in the second
series of tests the spools were not identical. Several materials that
showed poor resistance to corrosion at some locations in the previous
tests were omitted or replaced with a few other materials at these test
locations. The alloys added were Armco 22-13-5, red brass, Crucible 26-1,
and Types 201 and J17 stainless steel. The nonmetallic materials added
were Lucoflex (PVC), polyethylene Type III, and polypropylene.
K-23
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Although a clear-cut comparison of corrosion resistance
offered by these materials cannot be made, the following tabulation
lists the number of alloys with corrosion rates (on the basis of
weight loss only) within a few arbitrary ranges for each scrubber
system. The tabulation does not include results fron specimens that
were eroded severely at test locations 1011 and 2006. Those results
are shown in Table VI.
Number of alloys tested in
Range of corrosion rates Venturi TCA Marble bed
< 1-7 9 15 I1*
< 1-21 7^5
< 1-71 510
< 1-122 Oil
1-21 112
5-99 002
In general, corrosion was least severe in the TCA system
(15 alloys in the lowest range) and most severe in the venturi system
(only 9 alloys in the lowest range). This was also the trend in the
first series of tests. The nine alloys with corrosion rates of less
than 1 to 7 mils per year in the three systems were: Armco 22-13-5,
Carpenter 20Cb-3, Crucible 26-1, E-Brite 26-1, Hastelloy C-276,
Incoloy 825, Inconel 625, Type Jl6L, and Type 317 stainless steel.
Tables I, II, and III list the corrosion rate for each
alloy and identify localized attack, when it occurred, in each
scrubber system.
Table VII is a compilation of data for all materials tested
in the three systems without identifying the test conditions. This
table summarizes information on pitting, crevice corrosion, and other
types of attack in addition to corrosion on the basis of weight loss.
Alloys that showed good resistance both to pitting and crevice corro-
sion were Armco 22-13-5, red brass, cupro-nickel 70-30, and Hastelloy C-276 .
Alloys Hastelloy B and Inconel 625 each had only one minute pit. The 16
other alloys were definitely susceptible to localized attack.
Because the copper-bearing alloys cupro-nickel 70-30 and
Monel 1*00 showed resistance to pitting and crevice corrosion in the
first series of tests, red brass, which costs less, was included in
the second series of tests. The corrosion rates for red brass were
1 to 21 mils per year (only 10 specimens tested) with no pitting or
crevice corrosion. However, the weld was attacked enough to indicate
that perhaps a different filler metal and/or a modified welding proce-
dure might improve the corrosion resistance of red brass.
K-24
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The corrosion rate of Type 201 stainless steel was about
the same as that of Type 30^L; both alloys are highly susceptible to
localized corrosion in the scrubber systems.
When Type 317 stainless steel was tested, it was expected
that the greater molybdenum content of this alloy as compared with
that of Type 316 (3-^ vs. 2-3#, respectively) would reduce the fre-
quency of pitting and crevice corrosion compared with that of Type
stainless steel. However, the current tests show no definite improve-
ment on the basis of 8 and 23 specimens tested of alloy Types 317 and
3l6L, respectively.
Each of the 22 alloys tested showed good resistance at one
or more test locations in each scrubber system. Table VIII gives the
approximate comparative cost of most of the alloys based on the cost
of common Type 30^ stainless steel as unity (1.00).
The condition of the nonmetallic materials tested with
respect to the number of specimens in good, fair, and poor condition
were: Bondstrand ^tOOO, 10, 3* and 3; Flakeline 200, 1, 15, and 2; and
Transite, 15, 2, and 2. Only one specimen each of Lucoflex (PVC) and
polyethylene were tested; both specimens were poor. The three specimens
of polypropylene were two good and one poor.
This corrosion study is being continued on materials of con-
scruction for the SOg removal test facility at Shawnee Power Plant.
Summary
Test specimens exposed for about 3 months in three test
removal systems at Shawnee Power Plant were evaluated for corrosion and
wear.
The most severe damage occurred in plant areas exposed to
humidified stack gas containing fly ash, COa, Oa, and SOg at elevated
temperature and high velocity; to gas and slurry discharging at high
velocity from the venturi; and to gas and mist leaving an absorber.
Metals covered by limestone-fly ash deposits were not eroded
but were subject to corrosion of the concentration cell type.
Twenty-two alloys were tested either at all or at some of
the twenty-three exposure areas in the three scrubber systems. The
maximum corrosion rate in mils per year for the five most durable alloys
exposed at all the test locations were: Hastelloy C-276, less than 1;
Inconel 625, 1; Incoloy 825, 2; Carpenter 20Cb-3, 2; and Type 3l6L, 7«
K-25
-------
Nine specimens tested of Armco 22-13-5 and 8 of Type 317 stainless steel
gave rates of 1 mil per year or less; alloy 22-13-5 showed good resist-
ance to pitting and crevice corrosion, but Type 317 was affected by both
types of attack.
Of the alloys that showed great resistance to corrosion,
Hastelloy C-276 is the most durable and the most expensive. Type 3l6L
stainless steel ranks fifth in durability and about twelfth in cost
(considering all alloys tested). Comparative evaluations are difficult
to make for the second series of tests because all spools of test speci-
mens were not identical.
Neoprene-lined towers, ducts, and tanks were durable. Some
wear was apparent on neoprene linings of pumps and agitators.
Plastics, such as polyester and epoxy, were less durable
than rubber as lining materials.
In general, less corrosion was observed in the second series
of tests than in the first series; no specimens were completely destroyed
in the second series.
This corrosion study is being continued on materials of con-
struction for the S02 removal test facility at Shawnee Power Plant.
G. L. Crow
H. R. Horsman
K-26
-------
TAjl* 1
Curn- Ion Tento Cundii'-ted In the Venturl a/ntarn or toe Lines ton« - Wet-aerubMia
Proi-eae for Sulfur Dlonlde Removal fnn Slack flea at Bhiiwoea fever Plant
(Toet period.-June 15 to Sept. 16, 19731 operating tlae-.151i houn or 6}.8 dey»;
•nd Idle tlae--757 hnuri or 51-5 dayi)
Coriualon Bpeclneno
E«po»ed In
Loc-tUonn (lie* rig. O,
FeOrenre No
Eihauit
Inl«t Oai MI! Ou and Qu and Gu ud «»• Effluent Liquor In
»s «D»T llauor liquor dronletB (heated I liquor clarlfler
100?
1011
1006
1005
lOOd
1007
1008
101)
(inn
Temperature, *F . . .
VeloMty, ft/Mr .
Flow rate,
!OCO'« acfm lit 330'F
rcopOBltlon, t by volu
KjO ........
Fly nsh, gr/etd ft'
F5-«0
•0-60
20-50
0.3
12.3
6.3
a
3-5
60-170
30-50
15-25
0.2
12.0
6.3
15
0.02
60-160
5-7.5
15-25
0.2
12.0
6.3
15
0.02
flo-150
5-7.5
15-25
0.2
12.0
6.3
15
0.02
flo-ik)
5-7.5
15-25
0.2
12.0
6.3
15
0.02
235-265
20-30
0.1
11.7
6.3
15
0.02
Temperature, *F
Solldn, undlBBOlved,
* by vt
Solid*, dlseolved, I by vt .
Ionic composition, ppm
SOj-
COj'
so,
c.*
cr
Corrosion rate of metals . mtle/yr
AluBlnun 3003, «ld ER1100 . . .
Arnco 22-13-5,
veld Aroco 22-13-5
Brass, red, weld Oxveld 25H . .
Carpenter 20Cb->,
weld carpenter 2OCb-J ....
Cor-Tea B, weld E&018-C3 . . •
Crucible 26-1,
weld E-Brlte 26-1
Cupro Nickel 70-30,
weld B259 Ht-ulU
E-Brlte 26-1,
weld E-Brlte 26-1
KaateLloy B,
weld HBGtelloy B
Kaatelloy C-876,
weld Knstelloy C-276 ....
Inroloy BOO, veld Inconel 82 .
Incoloy R25, veld Inroloy 65 •
Inconel 635, urld Inconel 625
HI Id Bieel, A-2B), weld B6012
Honel kW, veld Monel 60 . . .
Type 201, veld Type }l6 ...
Typ* 30&L, veld Type 308L . .
Type 31«L, veld Type 316L . .
Type 317, veW Type J17 ...
Type MO, veld Type 309 ...
Typo kMi, weld Type 309 • . •
U3S lfl-]8-2, veld Inronel 8? .
Evaluation of nenmetnlllc materials
BondMrnnd 'OOO (Fiber glnan-
relnforrRd epoiy]
Flnkellnr POO (inert flakes
and polyenter reola)
tucoflei, polyvlnyl chloride . .
Polyethylene Type III
(high density) . ......
Polypropylene
< 1
7
Cernalc
Tmruilte (Portlnml ••»
nni) in.lieuton) . . .
90-130
70-100
8-16 0-35
0.7-1.9 0-2.0
J.J-6.2 5.8-T.O
120-600 120-600
25-70 25-70
900-2500 900-2500
2200-5100 2200-5100
220-510 220-510
60-1>« 60-1>>0
bQ-ldO bo-l&O
3000-10,000 3000-10,000
is te, p8b
16
lr
15r,
15,
< 1
< 1
3
-
•
^ l
. P9
« 1
< i
2
P16
P2O,
< 1
< \
.
Ud
-
20='*
71
-
90*
13d
55*
SB*
122*
Hi4
M*C*^
-
<
< i
18*
.
1
1, Plk
1
< 1
: lc, P3
< l
< I .
H*
2
1C, P10
1
_
tl«. P7
lc, P7
lc, P10
< ie, ris
»
.
6
2% P2.
e
. < 1
1 . H9t
< 1
37
10
2°, P16
< lc, Pll
.
f'»
r, PIS
3°, P13
2C, P17
51
-
y"
lc, P«
11
< 1
2ic, no,
i
< i
60
»e,e
17, Pl>
7*. PM
_
2ie, rao
17°, P30
l8e, P15
2, P3
e
-
5'
1, P3
2
C 1
2, PI
a
< i
11, P7
16
3, P«
3
'• 2
1, P6
t
5, P12
2
< 1
< 1
7
1
< 1
1
< 1
1, PI*
< 1
lc, Pll
lc, P12
< 1
< lc
Fair
Fair
Fulr
Fair
Good
Fair
c, P2"l
Good
Fair
1'. P9
a",
< 1
1, p»
< 1
< 1
< 1
< 1
< 1
< 1
< 1
c, P25
Pair
Fair
Poor
Poor
Poor
Ccxjd
Poor
Rood
Good
Good
* Durlnv llv- lor.t perlf«l, I He humid Iflcntlon apmyn vere uacd flO hours (5* of operntlng tl»e)i the gnu temperature wa>
nlKitu I?>*F "hiIf nprny vnler vnH uaed.
b "P" pn>. pilliw ii riomhfr Imlloilcn pitting during the exponure period to the depth la alia ebovn by the number, and
"Pm" Lnrll-ntei> nLnute pltii.
•.revue rorronlon nt Tttfloo Inoulotor.
11 gronlon nnd i-orroalon.
• nenl. Krlll L.-ntlun.
l7^il MtlH. k of parent nv*
i ol w
Kinliil.Moii'" ^'ml. llll lc ->r no olMn«e In ronrtltlon of op-H-lnifni rnLrp deflnlle chnn«e-pr6bribljr could be used; poor.
Cut led or n*vci''ly (tmnnr.e'1.
K-27
-------
TABU II
Corrosion Teata Conducted la the TCA Byiitem of the Unastone - Vet-Benibbing
Process for Sulfur Dioxide 1
(Teat
Corrosion operlnene
Locntlono (aee Fig. 2),
0«a
Velocity, ft/eec
Flow rnte,
1000'B arfn nt 500'P . . .
^onpoaltlon, % by volume
SO.
C08
Os
Fly nnh, gr/atd ft3 ...
Liquor
Sol Ida, undlseolved, f by ut
Solldn, dissolved, % by vt
Ionic conpoaltlon, ppn
SO,'
C03
S04'
Ca**
•a*
K*
Cl"
perlod-^JUne 5 to Sept
d«y»| Hnd Idle
Inlet Qaa and
BBB llouor ]
200? 2006
260-310 70-125
J5-50 8-9
20-25 15-16
0.) 0.05
9.8 7.'
6.3 8.8
8 15
3-5 0.02
lanoval fni
. Ik, 197)1
tIae-M)
Oaa and
Iron lota
2005
70-120
7-8
15-16
0.05
8 is
15
0.02
B Stack oa,
i at Shawnei
operating tl»e--l86l
bourn or 19.) daya)
Enhauat
Oaa and gaa
mtat, (heated)
200« 2007
70-120 2)5-265
6-7 )5-50
15-16 20-25
0.05 0.05
e!e sis
15 15
0.02 0.02
Corrosion rate of metnls/ mlle/yr
Aluminum }003, wold ER1100.
Armro ??-15-5
weld Araco 22-13-5 ....
Bmso, rod, weld Oxveld 25M
Carpentor POCb-3
weld Carpenter 20Cb-3 • •
Car-Ten B, wold EflOlfl-CS .
Crucible 26-1
weld E-Brlto 26-1 ....
Cupro Nickel 70-30
weld B?59 RCuHl
E-Brlt,e c^-1
wold E-Brlte P6-1 ....
Han le Hoy B
Hanlclloy C-276
wold lino to Hoy C-?7n . . .
Incoloy flOO,wcld Inconcl 82
Incoloy 825, ""Id Incoloy 65
Inconol f»?5t weld Incitiel 6?5
Mild nipol,A-?8\wolrt BS01?
H»ncl ''00, Moncl 60 ....
Type Ml, wold Type Mfi . .
IVpo 3O''L, wold Type JOML .
lype MfiL, wid Tyjn- Hfir. .
Typo 11 f, wold Tyjo )\J . .
Type ''10, vi-id Typo W9 . .
Typi- 'iVi, wi-ld Typo -ff) . .
Uf.3 Ifi-lB-P.wfld Inuinel fl?
Rvnluntlon of nonmclnlllc mini'
Roniliil rind *'OOO (FUw Plian-
Flnkolln.- TOO (Im-rl flnken
nrwl pulyo'.li-i p'l.ln) . . .
Trnnnltr (Pnrtlnntl ' ••nw-nt
" 'T" pn-i'i-illnif M nilinh'T Inill'-
< l
< 1
B
1
< l
< i
< i
< 1
< i
< 1
7
< l
< i
< i
< l
< l
< 1
j Inln
Poor
Fnlr
r.oc.i
nlcn pllilnif
60b'c
71b't
1? Plk
5C
k,b>eP7
Poor
ilurliut th*
8
< 1
' *21
< lb PIS
6
< lb P8
5
2,bP22
< 1
< 1
2, pro
Good
Fnlr
Full
• rxpotturo
1, PD
< It
lld 2
< 1 < 1
1, P)
< 1
«9 . 2
Pm, -b < l,b P2
< 1 < 1
l,bPl* <1%,ft"
< lb < 1?P7
< 1 < 1
J?2 2, P9
19* 1
?,bP?9
?,bpi?^ < i, ri
Sb nhovn by
Recycle
liquor
2012
85-125
7-16
0.8-1.1)
M-5.ii
180-220
20-250
1900-2500
2700-3)00
310-1(00
100-120
70-120
< 1, P5
< 1
< 1
< 1
< 1, PB
< 1
< &
< 1
< 1
1
< 1
'< 1
< lJ>Pm
< 1, Pa
Cood
Fnlr
Rood
the number,
Liquor In
clarlfler
2013
85-100
0-35
0.8-1.1)
5.6-7.0
lBO-220
20-250
1900-2500
2700-3300
310-1)00
100-1?0
70-120
1)800-5800
,li
-------
TABU III
Corrosion Tests Conducted in the Marble Bed System of the Limestone - Wet-Scrubbing
ProceBB for Sulfur Dioxide Bemoval from Stock Oae at Shawnee Pover Plant
(Tent, period.-Jun« B to Aug. JO, 1973; operating tlme—ltjl hours or 18 days;
and Idle tlne--1560 boura or 65 days)
Corrosion opeclpene
In
Locations (aae Fig. 3_),
Reference No ......
Inlet
«•»
3002
Gaa
Uquor and Oaa and
inlet gaa liquor
5006
5005
Recycle
liquor
3012s
Liquor In
clarlfler
5013
Temperature, t ........
Velocity, ft/gee ........
Flow into, lOOO'o acm at 330'F
Ccmpoaltlon, t by volume
SO, .............
COB .............
08 .............
riy ash, gr/atd ft'
Liquor
120-150
30-kZ
15-21
0.3
16.0
6.0
15.
5-5
Temperature, *F
Solids, undlaaolved, % by vt
Solids, dissolved, % by wt .
P«
Ionic composition, ppn
80s'
S0«"
if
ci"
Corrosion rate of metals, nlls/yr
Aluminum 3003, veld EH1100
Arnco 22-13-5, veld Armco 22-13-5 .
Brass, red, veld Oxveld 25f ....
Carpenter 2OCb-}, weld Carpenter
20Cb-3
Cor-Ten B, veld E8O1B-C3
Crucible 26-1, veld E-Brlte 26-1 . .
Cupro-Nlckel 70-30, veld B259 RCuHl
E-Brlte 26-1, weld E-Brlte 26-1 . .
Haatelloy B, veld Hastelloy B . . .
Rastelloy C-276, veld Haatelloy C-276
Incoloy 800, veld Inconel 82 ....
Incoloy 625, veld Incoloy 65 ....
Inconel 625, veld Inconel 625 ...
Mild steel, A-28}, veld B6012 . . .
Monel Uoo, veld Henel £0
Type 201, veld Type }l6
Type 30ltL, veld Type 308L
Type 316L, veld Type 3l6L
Type 317, veld Type 317
Type ItlO, veld Type 309
Type 'iii6, veld Type 309
USS 18-18-2, veld Inconel 82 ....
Evaluation of nonnetelllc materials.
Bondatrand "<000 (Fiber glass-
reinforced epoxy)
Flakellne 200 (inert flakes and
polyenter rcnln)
Polypropylene
< 1
13
< 1, Pa
1
< 1
< l
< 1
< 1
-------
TABLE IV
l*>
O
Alloys
Aluainua 3003
Arico 22-13-5
Brass, red
Carpenter 2OCt>-3
Cor -Tea 3°
Crucible 26-1
Cupro-:dciel 70-30b
E-Brite 2o-lb
Kastellcy Bb
Xastellcy C-276b
Incoloy 300b
lacoloy 52 5b
Incocel 525
Mild Steel, A-2S3b
Konel «OCb
Type 201
Type 30M,
Type Jl6l
Type 317°
Type -10°
Type 1A6°
USS 15-13-2"
C
.
0.06s
_
0.07*
0.066
O.O2
-
< 0.001
< 0.01
0.002
0.0k
o.d.
0.1*
0.17
0.09
0.15*
0.03s
0.03*
0.06
0.062
0.10
0.065
Alloys Test
Cr
.
20.5-23.5
19-21
0.52
26
-
26.17
0.19
15-37
21.11
22.23
20-23
.
_
16-13
13-20
16-13
13.6
12.7
2k .6
13.2
ted in the LJ
ill
.
11.5-13-5
32-33
0.013
.
31.00
0.03
Bal.
Bal.
31.32
12.22
Bal.
_
6k. 66
3-5-5.5
3-12
10-lk
12.6
0.16
0.50
15.0
Lnestone
Fe
0.7*
Bal.
0.05*
Sal.
Bal.
Bal.
0.53
Bal.
5-75
5-96
U5.01
23.30
5.00"
Bal.
1.00
Bal.
Bal.
Eal.
Bal.
Bal.
Bal.
Bal.
Cu
0.2
-
3k -86
3-k
0.31
67.79
0.01
.
-
O.kO
2.12
.
0.037
33.06
.
.
0.1L
0.03
O.OU5
0.03
Mo
.
1.5-3-0
_
2-3
0.010
1.0
-
1.00
26.20
16.32
_
_
8-10
_
.
_
.
2 .0-* .0
3.0
0.05k
0.10
0.013
Chealcal anal!
>5o
1.0-1.5
k. 0-6.0
_
2.00*
1.20
0-35
0.52
0.01
0.5?
O.k9
0.3k
0.56
0.5"
O.kE
1.03
5.5-7.5A
2.00*
2.00*
1.3
O.k3
0.71
1.50
Si
0.6"
1.0*
_
1.00*
0.29
0.25
0.19
0.01
<: 0.01
0.31
0.3k
0.5"
0.070
0.08
1.00s
1.00s
1.00s
1.90
O.kO
0.37
1.9k
axide Removal frog
raia, %
y
.
o.oC*
_
0.035*
0.012
0.025
0.003
0.010
0.005
0.012
—
_
0.015a
0.015
—
0.06*
O.OU5*
0.0k5s
0.01J
0.01k
O.OlS
0.007
s
0.03*
.
0.035*
0.031
0.010
0.005
0.012
0.006
0.010
0.007
0.007
0.015*
o.oek
0.008
0.03*
0.03*
0.03*
0.010
O.OlS
0.010
0.009
i Stack C
Al
Bal.
.
_
»
0.056
.
-
.
.
-
O.kS
0.06
O.k*
0.005
0.00k
.
.
_
0.069
O.OOS
0.001
ta« at Shi
Tl
_
_
m
m
0.35
_
.
-
O.kS
0.66
O.ka
_
_
_
.
.
_
_
< 0.02
-
ivnee Power Plant
Ctters
Zn, 0.1*; total 0.15
S, 0.2-0. k; Cb, 0.1-0.3; V, 0.1-0.3
Zn, Bal.; Pb, 0.05s
Cb+Ta, 8xC
7, 0.05
H, 0.03
Za, 0.03k; Pb, O.OO2
S, 0.010
Co, O.d5i V, 0.26
Co. 1.8k; W, 3-51; V, 0.25
.
_
Co, 1.0a; Cb*Tttf 3-15-^.15
_
_
H, 0.25s
.
_
rr, o.osk, v, < 0.03
M, 0.13; V, < 0.03
H, O.Ok
.".ajdaiun.
supplied
In corrosion
-------
TABL2 V
Analyses of Deposits in luestoae - «et-Scrubbing Systeas for Sulfur Dioxide Removal from Stack Gas at ghavnee Power Plant
Identification of saegle
Date
:."u=ser
Iccacioc CaC
Ye=v-ri System
3/17/75
3/SC/^
9/1C/73
3/L-/T3
5/-:/"3
i/a?£J
3,ic/73
5/10/73
i/13/73
9/10/73
7CA Syste
f/15/73
2/15/73
3/13/73
3/13/73
3/13/73
3/1-/73
3/1-/7J
W'Z
3/17/73
7D-1
VD-1
VD-1
VD-1
TO-2
V3-i
-.3-5
VD-^
VD-1
VD-5
91
No. 7
No. 6
ao. 3
3o. 1
:io. s
no. 5
:io. u
FHD-l
TCAD-1
l/c^-iach solids from wall of flooded elbow
20-iil scale from spray ceader la bottom of afterscrubber
Solids fron top of demster
Li sat -colored deposit free :o? spray at deals ter
Solids f-on scrubber cutlet at |tO-inch stainless steel duct
Solids fron scrubber outlet at ^0-inch stainless steel duct
••iterial free cracs in stacx below bellows Joint
Solids froc TE-1C13 at receater discharge
Solids from above the reheater
Vet, blacX solids from ID fan discharge duct
Deposit free inlet flue-gas duct near soot blower
Deposit from bottom (first) grid 2U.31
Deposit from door at elevation of 376 feet 26. 03
Deposit from wash tray weir 25.29
Deposit from wall between wash tray and demister 25,63
Deposit free bottoa of iecastsr
Deposit from Uo-incb duct at reheater outlet
Deposit in the line to pH aeter AH-2026
Deposit from strainer in tank D-20U
CaaOq
19.27
5. as
27.29
27.37
Trace
3-^0
11.95
U7.32
.
3- OB
35-90
3.39
at .01
2.56
1.60
O.W.
1.13
5-1*7
9.62
CaSC.
17.07
73-71
15-5*
Wt.23
kO.hk
60.16
U5 .20
25^3
_
70.39
32.50
71.71
87.76
5S.*7
60.39
50-37
53. "«8
50.16
51-99
CaCOg
3.60
0.10
12.29
0.70
0.17
0.35
O.blt
3.U8
0.199
9.75
O.i»3
5.3
trace
Trace
0.27
0.3
19O6
Trace
MgC Otners Acid insoluble
O.U)
O.OVT
0.21
C.007
0.013
O.Ob
0.75
0.90
Cl, 11.6
1.21 (Probably
carbonaceous)
o.oou
0.013
0.05S
0.022
0.022
O.OH
1.16
0.32
0.11
60.06
20>5
W.37
27.21
59.33
35- 13
Ul. 6i»
23.22
25.17
22.20
0.13
lo.lli
13-67
12.36
U3.63
U5.62
2k. 70
37.96
Infonaation taken from reports by J. B. Berkley to P. E. Stone and/or J. K. Metcalfe during the period 3/16/73 to 9/13/73.
-------
TABLE VI
Hanliii'ini of Heopn-ne Llnlngn of gquliwnt In thi- Three Limestone - H«t-Benibbln« Bystata
for Sulfur Dioxide Baauml from BiafK One at Shswne« Power Plant
(Exposure period: 6/5 to 9/l6/73--dates Inclusive for the three systems)
Durcneter "A" hardneae
_ Location of hardness tact _ Original" Current11 At 'T
Venturl ayoten (1516 operating boure)
After-Scrubber Hover!
Elgin Inches belun Type J16L 8.8. at vmturl lection ............................ 60-65 58-61 61
Sldeualla mar cone-nlwped button (approx. aleratlon, 371 feet) .................. 60-65 53-62 61
At approximate elevation, )8f feet .............................................. 60-65 54-60 5T
At approilnte elevation, 392 feat .............................................. 60-65 52-56 57
Three Inchon belov mlet eliminator (approx. elevation. 596 feet) ................ 60-65 5"t-59 55
Three feet above nlot eliminator (approx. elevation, «03 feat) .................. 60-65 *6-50 55
Beelreulatlon Tank. D-lQli!
rive feet above bottom [[[ 55-60 65-72 7)
Blades of agitator [[[ 60-70 66-71 7)
Clarified Process Water Storage Tank. D-103;
Above liquid level [[[ 55-60 67-72 5k
Belov liquid level [[[ 55-60 67-72 5*
Healurry Tank. D-lt03:
Above liquid level [[[ 65-71 55
Blades of Agitator In!
Effluent hold tank, D-101 ........ .. .............................................. ^-"W 58-*11 7J
TCA Braten [1661 oieratlng houra)
Scrubber Toner;
Four Inches above Inlet gaa duct (approx. elevation, J76 feet) .................. 60-65 55-62 68
Six Inches above boltcn (rid (approx. elevation, 380 feet) ...................... 60-65 57-oz TZ
Three feet above the second grid, near Test 2006 (approx. elevation, 386 feet) .. 60.65 57-61 72
•our feet belov Koch tr«y (appro*, elevation, »6 feet) ......................... 60-65 55-61 78
Tvo feet above Koch tray (approx. elevation, fcflk feet) .......................... 60-65 <>5-5J 72
Six Inches below 8.8. duct to reoeater (approx. elevation, W feet) ............ 60-65 53-65 72
jeelreulatlon TanX. P-2Qli!
Five feet above botton [[[ 55-*> 59-67 73
Blades of agitator [[[ 60-70 53-56 73
Clarified Proeeea Water Storage Tank. D-20V
Above liquid level [[[ 55-60 fe.JO 55
Belov liquid level [[[ 55-60 68-73 55
Blades of Agitator IB;
Effluent hold lunk, D-W1 [[[ &>-1° 65-TO 73
Pimps;
Impeller 0-201, 0-208, 0-SOJ, 0-205 ............................................. 5]>-56 59-«7 73
Liner 0-201, G-202, 0-203, 0^05 ................................................ 5k-56 - 73
Impeller 0^06 [[[ 5J-5J 51-55 73
Liner 0-206 [[[ 5»-56 51-55 73
Marble-Bed System («31 operating hours)
acmbber Tover;
Five Inches above bottom cone (approx. elevation, 370 feet) ..................... 60-65 66-73 68
81. inches above marble bed (approx. elevation, 377 feet) ....... .......... 60-«5 67-75 68
Above demlater and 6 Inches belov reducer (approx. elevation, 383 feet) ......... 60-65 66-72 6B
Three laches belov S.S. oo-lneh stack (approx. elevation, 385 feet) ............. 60-65 66-75 «>
Beelrculatlon Tank. D-»li!
-------
TABLK VU
lion of CorroHlon DuU of Haterlnle Trated In the Three Llmeo I one - Wet-Scrubbing Syntemn
for Sulfur Dioxide Removal from Stark Gas at 3hawnee Power Plant.
(Test period, Inclusive: June 5 to September 16, 1973)
Corrosion*
On baaIs w
No. of
specimens
Alloy tested
17
9
10
23
19
7
23
20
23
23
20
23
23
20
23
19
23
8
10
16
Aluminum 3003
Armco 22-1J-5
Brass, red
Carpenter 20Cb-3
Cor-Ten B
Crucible 26-1
Cupro Nickel 70-X)
E-Brlte 26-1
Hantelloy B
Kastelloy C-276
Incoloy 800
Incoloy 825
Inconel 625
Mild steel, A-28J
Monel >iOO
Type 201
Type yobi
Type }16L
Type 317
Type tlO
Type kli6
USS 18-18-2
On baa Is
of
wt. loss,0
mlls/yr
< 1-92
< 1
1-21
< 1-2
< 1-79
< 1-1
< 1-71
< 1-2
< 1-13
< 1
< 1-21
< 1-2
< 1-1
< 1-122
< 1-33
< 1-15
< 1-17
< 1-7
< 1-1
< 1-21
< 1-17
< 1-18
h
Specimens pitted'
No.
9
0
0
6
2
3
0
11
1
0
13
3
1
14
1
10
lit
7
1
8
12
11
Depth.
Mln.
H
0
0
H
H
It
0
H
0
0
H
H
0
H
0
H
H
H
0
M
H
H
mile
Max.
8l»
0
0
18
3
1U
0
2k
M
0
22
7
M
9
M
29
20
11
8
20
30
25
Specimens
with crevice
attack, No.
6
0
0
3
3
k
0
7
1
0
9
7
0
5
3
7
11
8
3
8
9
10
Specimens with other t/pep
No.
2
1
U
2
3
1
14
1
2
1
1
2
2
2
7
3
1
3
2
1
0
1
of at.tnrK
Identification
ld, le
lf
1 2e 1
id! if,' „
if if i
if
ld, le, 2n
a f
ld, lr
if
I*
ld l'
l*i if.
1
l"»e, li", 1 '
1« lf, I1
1
ld, if'1, I1
ld- *
ld
od
ld
h f
f 1
Evaluation of nonmetalllc materials^
Bondstrend UOOO (fiber glnos
reinforced epoxy)
Flakellne 200 (Inert flakes and
polyester resin)
Lucoflex, polyvlnyl chloride . . .
Polyethylene Type III (high density)
Polypropylene
Condition
Good Fair Poor
11
1
0
0
2
15
0
0
0
Ceramic
TransIte (Portland cement and
asbestos)
15
n Tables I. II, and III give corrosion data for the materials tested In the venturl, the TCA, and the marble-bed
scrubber aystems, respectively. Because the number of specimens tested of alloys ranged from 7 to 23, an order
of decreasing corrosion resistance could not be established.
b M, minute pit; the numerical values show the actual depth of penetration In mils during test period.
0 The rnnge of corrosion rateo does not Include severe abrasion which is Identified under "other types of attack.'
d Specimen worn by movement of plastic balls at test location 2006.
" Attack of weld.
Erosion and corrosion of specimen at test location 1011.
8 Attack of heat-affected zone of weld.
n Drnlokellflcntlon.
1 Localized attack of parent metal.
J Evaluation: good, little or no change In condition of specimen; fair, definite change—probably could be
uncd; poor, failed or severely damaged.
K-33
-------
TABLE VIII
Cost of Alloys Tested in the Three Limestone - Wet-Scrubbing Systems for
Removal of Sulfur Dioxide from Stack Gases at the Shavnee Power Plant
(Test period inclusive: June 5 to Sept. 16, 1973)
Cost ratioa
3/4-inch tubing 1/8-inch sheet
Source of infonnation : A _B _B _C _D
Aluminum 3003 - 0.85 0.79 0.79
Annco 22-13-5 - -
Brass, red - - 2.99 2.99
Carpenter 20Cb-3 4.21 - - 3.73
Cor-Ten B 0.22
Crucible 26-1 - - - - 1.66
Cuprc-Wickel 70-30 1.8oc - - - 2.28
E-Brite 26-1 - - - 1.85
Hastelloy B 9.47 - _
Hastelloy C-276 9.29
Incoloy 800 2.54 - - 2.70 2.86
Incoloy 825 4.46° - - 5.73
Inconel 625 6.59d - - 6.05
Mild steel, A-28J 0.3^, 0.8oc - - 0.19
Monel bOO 2.93d - - 3.6l 3.45
Type 201 _____
Type 304L 1.11 - - 1.11
Type 316L 1.39 - 1.6l 1.66
Type 317 1.8o - - -
Type 410 1.92 - -
Type 446 - -
USS 18-18-2 - -
Cost ratio values (as of reference date) are based on Type 304 stain-
less steel having a value of 1.00. The ratios are for commercial
quality 3/4-inch tubing of 0.065-inch wall which is cut to 20-foot
0-inch lengths and quantity of 10,000 feet or for (approx.) 1/8-inch
sheet in 20,000-pound lots.
A, Carpenter Technology Corporation, August 7, 1973-
B, J. M. Tull, Birmingham, Alabama, by telephone March 8, 1974.
C, J. M. Tull, Atlanta, Georgia, by telephone July 2, 1973.
D, Crucible Stainless Steel Division, Colt Industries, Pittsburgh,
Pennsylvania, from a representative visiting at TVA February 22, 1973-
Seamless.
d Welded.
K-34
-------
TOP OF STACK
LEGEND:
(SPOOL)
o. CARBON STEEL A8TM A-2B3
b TEST 1013 WAS CONDUCTED IN
CLARIFIER TANK 0-102 NOT SHOWN
OAS INLET OUCT(40"DIA., I06A. 0
CARBON STEEL0)
EL
B
xOUCT-40"DIA.
(TYPE 3I6L SS)
.1.0. FAN
'(TYPE 3I6LSS)
1 PRESSURE
SAFETY
VALVE (PSV.
24" BUTTERFLY)
"SPOOL
REHEATEWF-WlJ
| REFACTORY LINE
I«-CARBON STEEL
f SHELL. INSULA1
1 73%'O.D.,67T£
(TYPE 3W L SS)
37!
n
7-1
'ED) 13
•k-
-6*
k-
\
\
-•"
•-SCRUBBER
STRUCTURE
SCRUBBER TOWER
(NEOPRENE LINED
CARBON STEEL)
13-e"
INSIDE
NEOPRENE LINED
(CARBON STEEL. B-C -
ll'-3^
RECIRCULATION -*
TANK (0-104,
NEOPRENE LINED
CARBON STEEL)
OOWNCOMER
<4rDIA TYPE 3I6LSSJ
HOLD TANK
4f(D-IOI FOR
SCRUBBER
EFFLUENT,
FLAKELINE
103 COATING
ON CARBON
STEELb)
GROUND LEVEL
EL. 345-0'
FIGURE 1
VENTURI SCRUBBER SYSTEM (C-lOl)
K-35
-------
LEGEND:
CEDs. LOCATION OF TEST
*•?'•• SPECIMENS.
0 (SPOOL)
• CARBON STEEL ASTM A-283
* TEST 1013 VIMS CONDUCTED IN
CLAR1FIER TANK D-t08 NOT SHOWN
KEHEATER (F-201, REFRACTORY
LINED CARBON STEEL
SHELL.INSULATED)
73VOD..67'/il.D
MIST ELIMINATOR (CHEVRON)
I.D.FAN
TYPE SI6LSS)
DUCT-40 DIA
'(TYPE 3I6L SS)
(TYPE 316L SS)
6-11 SO. INSIDE
RUBBER LINING
to. SCRUBBER
rSTRUCTURE
SCRUBBER TOWER
(NEOPRENE LINED
CARBON STEED
LL SUPPORT .
3'-7'SO. INSIDE
MIXER
^(Y-201)
I
DOWNCOMERH'DIA.,
TYPE3I6L S3)
HOLD TANK
«H- (D-201 FOR
SCRUBBER
EFFLUENT. 22-8 =
FLAKEUNE
103 COATING
ON CARBON
STEEL")
RECIRCULATION
TANK(0-204,
NEOPRENE LINED
CARBON STEEL)
TOP OF STACK
OASINLET DUCT(40*
DIA., 10 GA. CARBON
STEEL)
EL. 3»7'.|Q'< ^
TYPE 316 L S.S
'(A TO B)
ACCESS DOOR
190-0'
(GROUND LEVEL
EL. 3«9'-0"
FIGURE 2
TURBULENT CONTACT SCRUBBER SYSTEM, TCA-(C-20l)
(MOBILE BED —PING-PONG BALL)
K-36
-------
TOP OF STACK
LEOEND:
OCX LOCATION OF TEST
^•••.•SPECIMENS.
a (SPOOL)
* CARBON STEEL ASTM A- 283
b TEST 30I3WAS CONDUCTED IN
CLAMFIER TANK 0-302 NOT SHOWN
10 FAN
(TYPE 3I6L SSI
REHEATERIF- 301, REFRACTORY
LINED CARBON STEEL
SHELL INSULATED)
DUCT 40"OIA
r«TYPE 316 L
SS)
GAS INLET DUCTC40
._ SCRUBBER
STRUCTURE
DIA..IOGA. CARBON
STEEL-,
TYPE 316 L SS
TO ®)
ACCESS DOOR
SPOOL
SCRUBBER
(NEOPRENE LINED
CARBON STEEL)
GRID
(MARBLE SUPPORT)
OOWNCOMER
14'OIAJYPE 3I6L SS)
LINE 103 COAT-
ING ON CARBON
STEEL0)
GROUND LEVEL
RECIRCULATION
TANK (0-304,
NEOPRENE-LINED
CARBON STEEL)
EL. 349-0"
FIGURE 3
MARBLE-BED SCRUBBER SYSTEM, MB-(C-301)
(FLOODED BED OF MARBLES)
K-37
-------
00
OO
FIGURE 4
TYPICAL SPOOL ASSEMBLY OF CORROSION TEST SPECIMENS
(2-INCH DISKS)
-------
I
OJ
.0
.
• >" •» IF til
FIGURE 5
DISK SPECIMENS AFTER EXPOSURE IN VENTURI SYSTEM (JUNE 13-SEPT. 16, 1973)
-------
ri ,
FIGURE 6
DISK SPECIMENS AFTER EXPOSURE IN TCA SYSTEM (JUNE 5-SEPT. 14, 1973)
-------
FIGURE 7
DISK SPECIMENS AFTER EXPOSURE IN MARBLE-BED SYSTEM (JUNE 8-AUG. 30, 1973)
-------
I
FIGURE 8
WEAR-BAR TEST ASSEMBLIES EXPOSED ON THE SLIDING GUIDES AT
THE VENTURI CONE NOZZLE (AUG. 29-SEPT 16, 1973)
-------
NEW SPECIMENS
HAYNES ALLOY B6 ('/8" x '/4"x 14 ")
TYPE 3I6S.S.C/4 x'/4xlO
•
<*>
SPECIMENS EXPOSED 380 HOURS
HAYNES ALLOY B6 WEAR RATE * 162 MILS/YR.; PITS ON CUT EDGE = 27 MILS DEEP
TYPE 316 S.S. WEAR RATE = 3280 MILS/YR.; PITS ON UNWORN AREA =3OMILS DEEP
FIGURE 9
NEW AND EXPOSED WEAR-BAR SPECIMENS FOR
TESTING IN THE VENTURI CONE NOZZLE
-------
Appendix L
DEFINITION OF STATISTICAL TERMS
The fraction of variation that is explained by a correlation is equal to
^*, where ^ is the correlation coefficient. Thus (Ref 7, P 175):
Fraction of Variation * ^ (y. - ^/
Explained = K = ' -
where:
= value of the independent variable for a particular data point
ti. = predicted (correlation) value of the independent variable
" for the same data point
M. = arithmetic average of all values of the independent variable
^ in the correlated set of data
The standard error of estimate is determined from the following equa-
tion (Ref 7, P 174):
Standard Error
of Estimate = V (L-2)
where:
/V7 = number of data points in the correlated set of data
•^ = number of dependent variables fitted with coefficients
L-l
-------
TECHNICAL REPORT DATA
(Please read/attractions on the reverse before completing}
i REPORT NO.
EPA-650/2-75-047
2.
3. RECIPIENT'S ACCESSION>NO.
4. TITLE AND SUBTITLE
EPA Alkali Scrubbing Test Facility: Summary of
Testing Through October 1974
5. REPORT DATE
June 1975
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO
Dr. Michael Epstein, Project Manager
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Bechtel Corporation
50 Beale Street
San Francisco, CA 94119
10. PROGRAM ELEMENT NO.
1AB013; ROAP 21ACY-032
11. CONTRACT/GRANT NO.
PH 22-68-67
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
NERC-RTP, Control Systems Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final: Through 10/74
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
6. ABSTRACT
The report describes test results through 10/74 from a lime/limestone
scrubbing test facility for removing SO2 and particulates from flue gases. The facility
consists of three parallel scrubbers--a venturi/spray tower, a Turbulent Contact
Absorber (TCA), and a marble-bed absorber—each able to treat a 10 Mw equivalent
(30,000 acfm) of flue gas from a coal-fired boiler at TVA's Shawnee Station. Lime-
stone factorial tests were conducted on all three scrubbers to determine the effects of
the independent variables on SO2 and particulate removal. Limestone reliability veri-
fication tests were conducted on all three scrubbers to define regions for scale-free
operation. Lime and limestone reliability tests were conducted on the venturi/spray
tower and TCA systems, respectively, to demonstrate long-term reliability,
primarily of the mist elimination systems. The TCA mist elimination system (a Koch
Flexitray in series with a chevron mist eliminator) has remained essentially clean
over a 1000 hour period at a superficial gas velocity of 8. 6 ft/sec. A recent test of
the spray tower mist elimination system (a chevron mist eliminator with provision for
underside and topside washing) at a superficial gas velocity of 6. 7 ft/sec indicated
that long-term operability of this system may be expected.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Air Pollution
Calcium Oxides
Limestone
Scrubbers
Absorbers
Washing
Sulfur Dioxide
Flue Gases
Spray Tanks
Coal
Boilers
Test Facilities
Prototypes
Air Pollution Control
Stationary Sources
Particulates
Venturi/Spray Tower
Turbulent Contact
Absorber
Marble-Red Absorber
13B
7B
7A
13H
2 IB
2 ID
13A
14B
8. DISTRIBUTION STATEMENT
Unlimited
19 SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
489
20 SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
------- |