SUMMARY REPORT • FLUE GAS DESULFURIZATION SYSTEMS • JANUARY - FEBRUARY 1976
Table
1 Summary List of F6D Systems
2 Status of FGD Systems
3 Performance Description for Operational FGD Systems
4 Number and Total MW of FGD Systems
5 Summary of FGD Systems by Company
6 Summary of FGD Systems by Vendor
7 Summary of New and Retrofit FGD Systems by Process
8 Summary of Operating FGD Systems by Process and Generating Units
9 Summary of Sludge Disposal Practices for Operational FGD Systems
10 Summary of FGD Systems by Process and Regulatory Class
11 Summary of Operational FGD Systems
12 Summary of FGD Systems Under Construction
13 Summary of Planned FGD Systems
14 Summary List of1 FGD Systems in the Early Planning Stages
15 Status of FGD Systems in the Early Planning Stages
16 FGD System Operations That Have Been Terminated or Shut Down Indefinitely
Definitions
Prepared by
PEDCo-Environmental Specialists, Inc.
Suite 13, Atkinson Square
Cincinnati, Ohio 45246
Page
3
9
33
129
133
137
141
145
149
153
159
163
167
175
179
185
203
Prepared for
Division of Stationary Source Enforcement
and
Industrial Environmental Research Laboratory
U.S. ENVIRONMENTAL PROTECTION AGENCY
Research Triangle Park,
North Carolina 27711
Contract No. 68-02-1321
Task No. 28
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Table 1
SUMMARY LIST OF FGD SYSTEMS
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TABLE 1
SUMMARY LIST OF FGD SYSTEMS
FGD STATUS REPORT 03/76
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
9
10
1 ALABAMA ELLC1RIC COOP
2 ALABAMA ELECTRIC COOP
3 ALLEGHENY POWER SYSTEM
I* ALLEGHENY POWER SYSTEM
5 ARIZONA ELECTRIC POWER COOP
6 ARIZONA ELECTRIC POWLR COOP
7 ARIZONA PUBLIC SERVICE
6 ARIZONA PUbLlC SERVICE
ARIZONA PUbLIC SLKVICE
AKIZONA PUbLIC SERVICE
11 ARIZONA PUBLIC SERVICE
12 BASIN ELECTRIC POWER COOP
13 BASIN ELECTRIC POWER COOP
m BASIN ELECIKIC POWER COOP
15 BASIN ELECTRIC POWER COOP
16 EiASlN ELECTH1C POWER COOP
17 CENTRAL ILLINOIS LIGHT CO.
16 CENTRAL ILLINOIS LIGHT CO.
19 CENTKAL ILLINOIS LIGHT CO.
20 CENTRAL ILLINOIS PUBLIC SEKV
21 CINCINNATI GAS £ ELECTRIC CO.
22 CINCINNATI bftS & ELECTKIC (.0.
23 COLUMBUS & SOUTHERN OHIO ELEC.
2<* COLUMBUS & SOUTHERN OHIO ELEC.
2b CULUf-iLtUS & SOUTHERN OHIO ELEC.
26 COLUMBUS £ SGUTHErtN OHIO ELEC.
27 COMtiOUWEALTH EDISON
26 COMNOiMWEALTH EDISON
29 DETROIT EDISON
30 UUQUESNE LIGHT
31 DUQUESNE LIGHT
32 GENERAL MOTORS
33 GULF POWER CO.
ZH GULF POWER CO.
35 GULF POWER CO.
TOMBIGBEE NO. 2
TUMU1GBEE NO. 3
PLEwSANTS NO. 1
PLEMSANTS NO. 2
APACHL NO 2
APALHE NO 3
ChOLLA NO 1
CHOLLA NO 2
FOUH CORNERS NO. H
FOUK CORNERS NO. 5A
FOUR CORNERS NO. SB
BEJLAH I\i0. 1
BtULAH NO. 2
MISSOURI BASIN NO 1
MISSOUK1 BASIN NO 2
MISSOURI BASIN NO 3
DUCK CREEK NO.l
DUCK CREEK NO.2
E.D.EDwAKDS NO.3
NLWTON NO.l
EAST E3END NO 2
MIAMI FONT NO 6
COULSVILLE NO 5
CUNCSVILLE NO 6
POSTON NO. 5
FUSION NO. 6
UILL COUNTY NO 1
PUWE.RTON NO. 51
ST.CLAIR NO 6
ELRAMA
PHILLIPS
CHEVROLET PARMA 1 2 3 &
SCHOL2 NO. 1A
SCHOLZ NO. 2A
SCHOLZ NOS. IB & 2B
JACKSON ALABAMA
JACKSON ALABAMA
BELLMONT W VIRGINIA
HELLMONT W VIRGINIA
COCHISE ARIZONA
COCHISE ARIZONA
JOSEPH CITY ARIZONA
JOSLPH CITY ARIZONA
FARMINGTOU NEW MEXICO
FAkMlNGTUN NEW MEXICO
FARMINbTON NEW MEXICO
BEULAH NORTH DAKOTA
BEULAH NORTH UAKOTA
WHEATLANO WYOMING
WHEATLAUO WYOMING
UHtATLAND WYOMING
CANTON ILLINOIS
CANTON ILLINOIS
BAKTONVILLE ILLINOIS
NEWTON ILLINOIS
RABBIT HASH KENTUCKY
NOKTH BEND OHIO
CONESVILLE OHIO
CONESVILLE OHIO
ATHLNS OHIO
ATHENS OHIO
ROftLOVILLE ILLINOIS
PEKIN ILLINOIS
BELLE RIVER MICHIGAN
ELRAMA PENNSYLVANIA
SOUTH HEIGHT PENNSYLVANIA
PAKMA OHIO
CHATTAHOOCHEE FLORIDA
CHATTAhOOCHEE FLORIDA
CHATTAHOOCHEE FLORIDA
1. OPERATIONAL UNITS "».
2. UMTS UNDER CONSTRUCTION 5.
3. PLANNED - CONTRACT AWARDED 6.
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
CONSIDERING ONLY FGD SYSTEMS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT To STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
0. OTHER
E. REGULATORY CLASS UNKNOWN
3-78
3-79
3-79
3-bO
6-79
6-79
10-73
6-77
0- 0
2-76
0- 0
0-61
0-61
1-60
6-60
6-63
6-7&
1-61
7-79
12-77
1-60
1-76
6-76
1-78
0-ttl
0-63
2-72
12-79
3-76
10-75
7-73
3-7H
2-75
2-76
3-75
3
3
6
6
-------
TABLE 1
SUMMARY LIST OF FGO SYSTEMS
FGD STATUS REPORT 03/76
I.D. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
36 INDIANAPOLIS POWER * LIGHT CO.
37 KANSAS CITY POWER i. LlbHT
36 KANSAS CITY POWER & LIGHT
39 KANSAS CITY POWER g LIGHT
HO KANSAS POWER * LIGHT
41 KANSAS POWER & LIGHT
HZ KANSAS POWER * LIGHT
43 KANSAS POWLR X LIGHT
44 KENTUCKY UTILITIES
H5 KEY WEST UTILITY UOAKU
46 LOUISVILLE GAS & ELECTRIC
47 LOUISVILLE GAS & E.LECTKIC
46 LOUISVILLE GAS & LLECTHIC
49 LOUISVILLE GAS & ELECTRIC
50 LOUISVILLE GAS 8 ELECTRIC
51 LOUISVILLE GAS & ELECTRIC
52 LOUISVILLE GAS & ELECTRIC
53 LOUISVILLE GAS & ELECTRIC
54 M1NNKOTA POWER COOPERATIVE
55 MONTANA POwER CO.
56 MONTANA POWER CO.
57 MONTANA POWER CO.
56 MONTANA POWER CO.
59 NEVADA POWER
60 NEVADA POWER
61 NEVADA POWER
62 NEVADA POWER
63 NEVADA POWER
64 NEVADA POWER
65 NEVADA POWER
66 NEVADA POWER
67 NEVADA POWER
66 NEVADA POWER
69 NEW ENGLAND ELEC SYSTEM
70 NORTHERN INDIANA PUB SERVICE
UNITS 1 AND 2
PETERSBURG NO 3
HAWTHORN NO 3
HAWTHORN NO 4
LA CYGNE NO 1
JLFFEKY NO. 1
JEFFERY NO. 2
LAWKENCE NO 4
LAWRENCE NO 5
GREEN RIVER
STOCK ISLAND PLANT
CANE RUN NO 4
CANE KUN NO 5
CANE KUN NO 6
MILL CREEK NO 1
MILL CREEK NO 2 ,
MILL CREEK NO 3
MILL CREEK NO 4
PADDYS RUN NO 6
MILTON R. YOUNG NO. 2
COLSTRIP NO 1
COLSTRIP iMU 2
CULSTRIP NO.3
COL5.TRIP (MO.4
HArtKY ALLEN STATION NO. 1
HARRY ALLEN STATION NO. 2
HARKY ALLEN STATION NO. 3
HARRY ALLEN STATION NO. 4
REIU GARDNER NO 1
REIU GARDNER NO 2
REIU GARDNER NO 3
REID GARDNER NO 4
WARNER VALLEY STATION NO. 1
WARNER VALLEY STATION NO. 2
BRAYTON POINT NO.3
BAILLY NO. 7
PETERSBURG INDIANA
KANSAS CITY MISSOURI
KANSAS CITY MISSOURI
LA CYGNE KANSAS
ST MANY KANSAS
ST MARY KANSAS
LAWRENCE KANSAS
LAWRENCE KANSAS
CENTRAL CITY KENTUCKY
KEY WEST FLORIDA
LOUISVILLE KENTUCKY
LOUISVILLE KENTUCKY
LOUISVILLE KENTUCKY
LOUISVILLE KENTUCKY
LOUISVILLE KENTUCKY
LOUISVILLE KENTUCKY
LOUISVILLE KENTUCKY
LOUISVILLE KENTUCKY
CENTER NORTH DAKOTA
COLSTRIP MONTANA
coLSTRiH MONTANA
COLSTRIP MONTANA
COLSTRIP MONTANA
E. LAS VEGAS
E. LAS VEGAS
E. LAS VEGAS
E. LAS VEGAS
NEVADA
HOAPA NEVADA
HOAPA NEVADA
MOAPA NEVADA
ST. GEORGE UTAH
ST. GEORGE UTAH
SOMERSET MASSACHUSETTS
CHESTERTON INDIANA
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
I*.
C.
D.
E.
PLANNED - LETTER OF INTENT SIGNED
PLANNED > REQUESTING/EVALUATING BIDS
CONSIDERING ONLY FGD SYSTEMS
4.
5.
6.
BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
BOILEK SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
BOILER SUBJECT To STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
OTHER
REGULATORY CLASS UNKNOWN
4-77
11-72
6-72
2-73
6-76
6-79
12-66
11-71
9-75
10-72
6-76
12-77
9-76
1-62
1-61
7-77
7-79
4-73
6-77
10-75
7-76
7-60
7-81
6-62
6-63
6-64
6-65
4-74
12-73
6-76
0- 0
6-61
6-62
0- 0
0- 0
2
1
1
1
3
3
1
1
1
1
2
2
5
6
6
2
3
1
2
1
2
6
6
6
6
6
6
1
1
2
4
6
6
6
6
A
B
B
C
B
B
D
0
C
C
C
C
C
C
C
A
A
C
B
C
A
A
A
B
B
B
B
B
B
B
B
B
B
C
C
PEDCo-ENVIRONMENTAL,
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TABLE 1
SUMMARY LIST OF FGO SYSTEMS
FGD STATUS REPORT 03/76
I.D. NUMBER AMU COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
71 NORTHERN INDIANA PUD SERVICE
72 NORTHERN INDIANA PUU SERVICE
73 NORTHERN STATES POWER CO.
7«» NORTHERN STATES POUER CO.
75 PENNSYLVANIA POWER CO.
76 PENNSYLVANIA POWER CO.
77 PENNSYLVANIA POWER CO.
76 PHILADELPHIA ELECTRIC CO.
79 PHILADELPHIA ELECTRIC CO.
80 PHILADELPHIA ELECTRIC CO.
81 PHILADELPHIA ELECTRIC CO.
82 PUBLIC SERVICE CO OF NEW MEX.
83 PUBLIC SERVICE CO OF NEW MEX.
84 PUBLIC SERVICE CO OF NEW MEX.
85 PUBLIC SERVICE CO OF NEW MEX.
86 PUBLIC SERVICE CO. OF COLORADO
87 PUBLIC SERVICE INDIANA
88 PUPLIC SERVICE INDIANA
69 hICKENBACKER AFU
90 S. CAROLINA PUB SERV AUTHORITY
91 S. MISSISSIPPI ELEC PWK ASSOC
92 S. MISSISSIPPI ELEC PWK ASSOC
93 SOUTHLRN CALIFORNIA EDISON
94 SOUTHERN CALIFORNIA EDISON
95 SOUTHERN CALIFORNIA EDISON
96 SOUTHERN CALIFORNIA EDISON
97 SOUTHERN CALIFORNIA EDISON
98 SOUTHERN CALIFORNIA EDISON
99 SPRINGFIELO LITY UTILITIES
100 TENNESSEE VALLEY AUTHORITY
101 TENNESSEE VALLEY AUTHORITY
102 TENNESSEE VALLEY AUTHORITY
103 TEXAS UTILITIES CO.
104 TEXAS UTILIT1F.S CO.
105 TEXAS UTILITIES CO.
BAILLY NO, 8
MITCHELL NO 11
SHERUURKE NO 1
SHERliURNE NO 2
BKUCE MANSFIELD NO* 1
BKUCE MANSFIELD NO. 2
BRUCE MANSFIELD NO. 3
CROliBY
EDIJYSTONE NO 1A
EUDYSTOWE NO IB
EUDYSTONE NO 2
SAN JUAN NO. 1
SAN JUAN NO. 2
SAN JUAN NO. 3
SAN JUAN NO. 4
VALMONT NO. 5
GIBSON NO. 3
GIBSON NO. i»
RICKENdACKER
W1NYAH NO, 2
R.D. MORROW NO.l
R.O. MORROW NO.2
KAIPAKOWITZ NO. 1
KAIPAKOWITZ NO. 2
KAIPAROWITZ NO. 3
KAIPAHOWITZ NO. I*
MOHAVE NO IB
MOHAVE NO. 2
SOUTHWEST NO. 1
SHAWNEE N0.10A
SHAWNEE NO.lOB
WIDOWS CREEK NO 8
MARTIN LAKE NO. i
MARTIN LAKE NO. 2
MARTIN LAKE NO. 3
CHESTERTON INDIANA
OAKY INDIANA
BECKER MINNESOTA
BECKER MINNESOTA
SHIPPINliPORT PENNSYLVANIA
SHIPPINGPORT PENNSYLVANIA
SH1HPINGPORT PENNSYLVANIA
PHOLNIXVILLE PENNSYLVANIA
EDDYSTONE PENNSYLVANIA
EUDYSTONE PENNSYLVANIA
EDDYSTONE PENNSYLVANIA
UATERFLOW NEW MEXICO
WATERFLOW NEW MEXICO
WATERFLOW NEW MEXICO
WATERFLOW NEW MEXICO
VALMONT COLORADO
GIbSON COUNTY INDIANA
GIBSON COUNTY INDIANA
COLUMBUS OHIO
GEORGETOWN SOUTH CAROLINA
HATTIESBURG MISSISSIPPI
HATTlESBURG MISSISSIPPI
UTAH 35 MI. NW OF PAGE
UTAH 35 MI. NW OF PAGE
UTAH 35 MI. NW OF PAGE
UTAH 35 MI. NW OF PAGE
LAUGHLiu NEVADA
LAUGHLIN NEVADA
SPK1NO.FIELU MISSOURI
PAUUCAH KENTUCKY
PADUCAH KENTUCKY
BRIDGEPORT ALABAMA
TATUM TEXAS
TATUM TEXAS
TATUM REXAS
ARIZ
ARIZ
ARIZ
ARIZ
1.
2.
3.
A.
B.
C.
D.
E.
OPERATIONAL UNITS 4.
UNITS UNDER CONSTRUCTION 5.
PLANNED - CONTRACT AWARDED b.
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
CONSIDERING ONLY FGD SYSTEMS
0- 0
4-76
5-76
5-77
4-76
4-77
4-79
10-78
9-75
10-78
10-78
7-77
7-77
5-79
5-61
10-74
0-78
0-79
3-76
5-77
11-77
6-78
0-82
0-83
0-64
0-65
6-77
6-77
7-76
4-72
4-72
2-77
9-76
6-77
12-76
6
2
2
2
2
2
5
6
1
4
6
3
3
4
4
1
6
6
2
3
3
3
6
6
6
6
6
6
2
1
1
2
3
3
4
C
C
B
B
B
B
B
C
B
B
C
B
B
B
B
D
A
A
E
A
A
A
A
A
A
A
E
E
A
C
C
C
A
A
A
BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
BOILER SUBJECT To STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
BOILER SUBJECT To STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
OTHER
REGULATORY CLASS UNKNOWN
PEDCo-ENVIRONMENTAL
-------
TABLE 1
SUMMARY LIST OF FGO SYSTEMS
FGD STATUS REPORT 03/76
I.D. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
106 TEXAS UTILITIES CO..
107 UNITED POWER ASSOCIATION
106'UNITED POWER ASSOCIATION
109 UTAH POWER ft LIGHT CO.
MAKTIN LAKE NO. t
COAL CREEK NO. 1
COAL CREEK NO. 2
HUNTINGTON NO.l
TATUM KEXAS
UNUEKWOOD NORTH DAKOTA
UNDERWOOD NORTH DAKOTA
PRICE UTAH
12-79
11-76
11-79
6-77
5
5
A
A
A
E
1. OPLKATIONM. UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTKACT AWARDED
!'
I'.
D.
E.
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
CONSIDERING ONLY FGD SYSTEMS
5.
6.
ln SUECO STRINGENT THAN THE FEDERAL NSPS
mill* SSK1S 10 UTE STANDARD THAT is EQUAL TO OR LESS STRINGENT THAN NSPS
OTHER
REGULATORY CLASS UNKNOWN
PEDCO- ENVIRONMENTAL
8
-------
Table 2
STATUS OF FGD SYSTEMS
-------
COMPANY
TABLE 2
STATUS OF FtiU SYSTEMS DURING 03/76
POWER STATION
CURRENT MONTH
I.D. NUMBER 1
ALABAMA ELECTRIC COOP
TOMBIGBEE NO. 2
225 MM - NEW
COAL 0.8- 1.5 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/78
PEABOOY ENGINEERING WAS AWARDED CONTRACT TO INSTALL FGD SYSTEM ON
TOM8IGBEE NO.2. SYSTEM WILL BE LIMESTONE SCRUBBING.
I.D. NUPBER 2
ALABAMA ELECTRIC COOP
TOMBIGBEE NO. 3
225 MW - NEW
COAL 0.8- 1.5 PERCENT SULFUR
PEABOOY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/79
PEABODY ENGINEERING WAS AWARDED CONTRACT TO INSTALL FGD SYSTEM ON
TOMBIGBEE NO.3. SYSTEM WILL BE LIMESTONE SCRUBBING.
I.D. NUMDER 3
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 1
625 MW - NEW
COAL 2.0- 5.0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 3/79
THE THREE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM HAVE CONCLUDED A LONG-TERM AGREEMENT WITH THE DRAVO LIMt CO. TO
SUPPLY THIUSORBIC LIME FOR THE PLANNED Su2 SCRUBBERS AT PLEASANTS NOS. 1
AND 2. THE SYSTEM SUPPLIER HAS NOT YET BLEN OFFICIALLY ANNOUNCED. THE
GUARANTEED PARTICIPATE. AND S02 REMOVAL EFFICIENCIES FOR THIS EMISSION
CONTROL SYSTEM ARE. 99.55 AND 90 PERCENT RESPECTIVELY
1.0. NUMBER
-------
TABLE 2
STATUS OF FGU SYSTEMS DURING
COMPANY
POWER STATION
I.D. NUMltLR f>
ARIZONA ELECTRIC POWER COOP
APACHE NO 3
205 MW - NEW
COAL O.b- 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/79
I.D. NUNbER 7
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
115 MW - RETROFIT
COAL 0.<*«*-! PERCENT SULFUR
RESEARCH COTTKELL
LIMESTONE SCRUBBING
STARTUP 10/73
I.D. NUMbER 6
ARIZONA PUBLIC SERVICE
CHOLLA NU 2
250 MW - NEW
COAL 0.«Ht-l PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/77 : [
03/76
CURRENT MONTH
"rrTTPR~OF~INTENT~TO~INSTALL~AN FGD SYSTEM WAS ISSUEU TO RESEARCH COTTRELL,
ENG!NEE«NG uEsIbi WORK is PROCEEDING. GUARANTEED so2 AND PARTICULATE
REMOVAL EFFICIENCIES ARE 50 AND 99.H PERCENT RESPECTIVELY.
IN TABLE 3 OF J^u^^F ™IS
crn «Y*TI.M HAS BLEW OPERATIONAL SINCE NOVEMBER 1973. RELIABILITY FOR
MODULES' i AND B SS SS^ED IN EXCESS OF 90 ANO 83 ""CENT RESPECTIVELY
SuRlNG THE PAST TEN OPERATING MONTHS. RELIABILITY FOR MODULES A AND B
?N JANUARY WAS 99 PERCENT. MODULE A WAS IN SERVICE 714.5 HRS. AND MODULE
B fa5i.7 HRS. DURING THIS PERIOD.
^SUBSTANTIALLY COMPLETE. CONSTRUCTION iS
UNDERWAY
I.D. NUMUER 9
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. "»
755 MW - RETROFIT
COAL. 0.7 - 0.758 SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
I.D. NUMBER 10
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. SA
160 MW - RETROFIT
COAL. 0.7 - 0.75. SULFUR UVG)
SCE
LIME SCRUBBING
THIS
MAO?
MW~UNIT~WILL''BE~CONTROLLED PENDING THE OUTCOME OF TESTS TO BE
THE PROTOTYPE 160 -MW FGD MODULE NOW BEING INSTALLED ON UNIT 5.
"THls"Ibo"Mw"sYSUN"HAs"BEEN"MOVEo"FKOM THE MOHAVE STATION OF SOUTHERN
CALIFORNIA EDISON WHERE THE SYSTEM WAS PREVIOUSLY TESTED. THE SYSTEM
TA DTAlA trMwTNETr'THE'ENG^^^
MMPLE?EO! ?H£ S?S?E; IT^TEO UP IN LATE FEBRUARY ANU THE UTILITY is
CURRENTLY IN THE PROCESS OF CONDUCTING TESTS.
PEDCo-ENVIRONMtNini.
11
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COMPANY
POWER STATION
TABLE 2
STATUS OF F6D SYSTEMS DURING 03/76
CURKENT MONTH
1.0. NUMBER 11
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. SB
595 NW - RETROFIT
COALt 0.7 - 0.75, SULFUR (AV6)
NOT SELECTED
NOT SELECTED
STARTUP . O/ 0
THE BALANCE OF THIS 755 MW UNIT MILL BE CONTROLLED PENDING THE OUTCOME
OF TESTS TO BE MADE ON THE PROTOTYPE 160 MW FGD MODULE NOW BEING INSTALLED
NO START-UP DATE HAS BEEN SCHEDULED.
I.D. NUMBER 12
BASIN ELLCTRIC POWER COOP
BEULAH NO. 1
450 MW - NEW
COAL 1.0 PERCENT SuLFuR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
THE UTILITY IS WOW
INVESTIGATING VARIOUS FbU PROCESSES. THIS NEW STATION IS CURRENTLY CALLED
THE BEULAH PROJECT AND WILL INCLUDE TWO NEW COAL-FIKED POWER-GENERATING
BOILERS WHICH WILL BE REQUIRED TO COMPLY WITH AIR EMISSION STANDARDS VIA
THE BEST AVAILABLE TECHNOLOGY.
I.D. NUMbER 13
BASfN ELECTRIC POWER COOP
BEULAH NO. 2
450 Mn - NEW
COAL 1.0 PERCENT SuLFuR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
THE UTILITY IS NOW
INVESTIGATING VARIOUS FGD PROCESSES. THIS NEW STATION IS CURRENTLY CALLED
THE. BEULAH PROJECT AND WILL INCLUDE TWO NEW COAL-FIRED POWER-GENEKATING
BOILERS WHICH WILL BE REQUIRED TO COMPLY WITH AIR EMISSION STANDARDS VIA
THE BEST AVAILABLE TECHNOLOGY.
I.D. NUMBER 14
BASIN ELLCTRIC POWER COOP
MISSOURI BASIN NO 1
550 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 1/80
BECAUSE OF THE STRICT WYOMING EMISSION STANDARDS OF 0.2LBS PER MILLION
BTUtLOU SULFUR COAL ALONE WILL NOT MEET STANDARDS. BASIN ELECTRIC IS NOW
INVESTIGATING VARIOUS FGD PROCESSES.
I.D. NUMBER 15
BASIN ELECTRIC POWER COOP
MISSOURI UASIN NO 2
550 Mb - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/80
BECAUSE OF THE STRICT WYOMING EMISSION STANDARDS OF 0.2LBS PER MILLION
BTU.LOW SULFUR COAL ALONE WILL NOT MEET STANDARDS. BASIN ELECTRIC IS NOW
INVESTIGATING VARIOUS FGO PROCESSES.
12
PEDCo-ENVIRONMENTAL
-------
COMPANY
TAULE 2
STATUS OF FGD SYSTEMS DURING
03/76
POWER STATION CURRENT MONTH
I.D. NUMBER 16
BASIN ELECTRIC POWER COOP
MISSOURI UASIN NO 3
550 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/83
BECAUSE OF THE STRICT WYOMING EMISSION STANDARDS OF 0.2LBS PER MILLION
BTU.LOW SULFUR COAL ALONE WILL NOT MEET STANDARDS. BASIN ELECTRIC IS NOW
INVESTIGATING VARIOUS FGD PROCESSES*
I.D. NUMUER 17
CENTRAL ILLINOIS LIGHT CO.
DUCK CKELK NO.l
100 MW - i\EW
COAL 2.5-3.0 PERCENT SULFUR
RILEY STOrtER/ENVIRONEERING
LIMESTONE SCRUBBING
STARTUP fa/76
THE UNIT IS NOW UNDER CONSTRUCTION AND IS SCHEDULED FOR COMPLETION IN
JUiME 1976. STATION CAPACITY IS HQOMW, BUT FLUE GAS FROM ONLY 100 MW
WILL BE TREATED INITIALLY.
.1.0. NUMBER 18
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO.2
i+OO MM - NEW
COAL 2.5-3.0 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 1/01
THIS PROPOSED LIMESTONE UNIT IS DUE TO BEGIN OPERATION JANUARY 1901
1.0. NUMJER 19
CENTRAL ILLINOIS LIGHT CO.
E.D.E.UWAKUS NO.3
357 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 7/79
LOW SULFUR COAL TO BE USED FROM 6/76 UNTIL STARTUP.
I.D. NUMbER 20
CENTRAL ILLINOIS PUBLIC SERV
NEWTON NU.l
600 MW - NEW
COAL 2.8-3.2 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 12/77
THE UTILITY IS NOW IN THE PROCESS OF EVALUATING BIDS FOR LIME/LIMESTONE
AND DOUBLE ALKALI SCRUBBING. A DECISION CONCERNING THE PARTICULAR PROCESS
AND VENDOR WILL BE ANNOUNCED SHORTLY.
PEDCo-ENVIRONM&WTAt
13
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING 03X76
POWER STATION CURRENT MONTH
1.0. NUPLiER 21
CINCINNATI GAS & ELECTRIC CO.
EAST OENU NO 2
600 MM - NEW
COAL
NOT SELECTED
NOT SLLECTED
STARTUP - 1/80
UTILITY WILL GO OUT FOR BIDS IN EARLY 1976. THE COMPANY IS PRESENTLY OB-
TAINING CONSTRUCTION AND OPERATIONG PERMITS. STARTUP DATE HAS BEEN MOVED
BACK TO JANUARY i960. THE COAL SOURCE FOR THIS UNIT HAS NOT YET BEEN SE-
LECTED.
I.D. NUMBER 22
CINCINNATI GAS S ELECTRIC CO.
MIAMI FOKT NO 8
300 MW - NEW
COAL 1.3 PERCENT SULFUR
NOT SELECTED
LIME/LIMLSTONE SCABBING
STARTUP 1/78
THE UTILITY HAS SIGNED A CONTRACT FOR THE PURCHASE OF LOW SULFUR COAL
(APPROXIMATELY 1.3 PERCENT SULFUR). THE COAL BED FOR THE NO.8 UNIT IS NOW
IN THE PROCESS OF BEING REDESIGNED TO ACCEPT THE LOWER SULFUR COAL. CGSE
NOW PLANS TO INSTALL A LIME/LIMESTONE FGD UNIT TREATING 60 PERCENT OF THE
TOTAL bOO MW CAPACITY. NEW BIDS ARE NOW BEING REQUESTED AND ACCEPTED ON
THIS SMALLER UNIT.
I.D. NUMBER 23
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE NO 5
HOO M«l - NEW
COAL 4.5 - «t.9 PERCENT SULFUR
UNIVERSAL OIL PROUUCTS
LIME SCRUBBING
STARTUP 6/76
THE UTILITY SIGNED LONb-TERM CONTRACTS WITH DRAVO FOR THE PURCHASE OF
THIOSORBlC LIME ANH WITH IUCS FOR THE PURCHASE OF SLUDGE FIXATIVES. THE
BOILER ANU FGD SYSTEM ARE STILL UNOER CONSTRUCTION. THIS MINE MOUTH PLANT
PLANS TO BURN COAL WITH 17 PERCENT ASH CONTENT AND 4.5 TO 4.9 PERCENT
SULFUR CONTENT. AN ELECTROSTATIC PKECIPITATOR WILL BE INSTALLED UPSTREAM
OF THE FbD SYSTEM.
I.D. NUMbER 24
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLL NO 6
loo MW - NEW
COAL <*.£> - 4.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRL-HBING
STARTUP 1/78
THL UTILITY SIGNLD LONb-TERM CONTRACTS WITH DRAVO FOR THE PURCHASE OF
THIOSORBlC LIME AND WITH IUCS FOR THE PURCHASE OF SLUDGE FIXATIVES. CON-
STRUCTION ON THIS UNIT IS CURRENTLY SCHEDULED FOR 1977 WITH COMPLETION
EXPECTED BY JANUARY 1978. SIMILAR TO CONESVILLE NO.5, THIS MINE MOUTH
PLANT WILL BURN COAL WITH 17 PERCENT ASH CONTENT AND 4.5 TO 4.9 PERCENT
SULFUR CONTENT. AN ELECTROSTATIC PRECIPITATOR WILL BE INSTALLED UPSTREAM
OF THE FGD SYSTEM.
I.D. NUMBER 25
COLUMBUS & SOUTHERN OHIO ELEC.
POSTON NO. 5
375 MW - NEW
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
UNIT WILL BURN 2.5 PERCENT SULFUR OHIO COAL.
PEDCo-ENVIRONMENT AL-
14
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
09/76
CURRENT MONTH
1.0. NUMBER 26
COLUMBUS H SOUTHERN OHIO ELEC.
POSTON NO. 6
375 HW - NEW
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/63
UNIT WILL BURN 2.5 PERCENT SULFUR OHIO COAL.
I.D. NUMbLR 27
COMMONWEALTH EDISON
WILL COUNTY NO 1
Ib7 MW - RLTROFIT
COAL - 9<*b3 BTU. 2.IK SULFUR
DAOCOCK & WILCOX
LIMESTONL SCRUBBING
STARTUP 2/72
REFEK TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGU SYSTEM HAS BLLN OPERATIONAL SINCE FEB. 1972. MOUULES A AND B WERE IN
SEKVICE A TOTAL OF 3214 AND 2580 HhS. RESPECTIVELY DURING 1975, THUS AT-
TAINING ANNUAL AVERAGL OPEKABlLlTlLS.OF 52 AND 12 PERCENT RESPECTIVELY.
UNIT NO.l CAME DOWN FOK A BOILER. TURBINL AND GENERATOR OVERHAUL IN MID-
OCTOBER 1975, RESULTING IN AN OUTAGE THAT LASTED FOR MORE THAN H MONTHS.
SYSTLM RESTART IS CURRENTLY SCHEDULED FOR MID-MARCH 1976.
I.D. NUMBER 26
COMMONWEALTH EDISON
POWERTON HO. bl
H25 Mw - RETROFIT
COAL 3.6 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 12/79
THE. CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO UNIVERSAL OIL
PRODUCTS. THIS SYSTEM WILL BE A LIMESTONE CLOSED-LOOP SCRUBBING SYSTEM
BACKFITTEO TO BOILER 51i WHICH IS ONE OF TWO IDENTICAL BOILERS SUPPLYING
STEAM TO AN 650 MW TURBINE-GENERATOR.
I.D. NUMBER 29
DETROIT EUISON
ST.CLAIR NO b
160 MW - RETROFIT
COAL 3.7 PERCENT SULFUR
PEABOOY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/76
THE UTILITY REPORTED THAT THE FGD SYSTEM WAS DOWN THROUGHOUT THE ENTIRE
REPORT PERIOD IN PREPARATION FOR AN UPCOMING 30 DAY VENDOR QUALIFICATION
OPERATION TEST RUN.
I.D. NUMBER 30
DUQUESNE LIGHT
ELRAMA
510 Mta - RETROFIT
COAL 1.0 - 2.8 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 10/75
THE FGO SYSTEM WAS PLACED IN SERVICE ON OCTOBER 26, 1975. INITIAL
OPLRATION PROCEEDED WITH FLUE GAS FROM ONE BOILER BEING TREATED BY THE
SCKUBBING SYSTEM. A SECOND BOILER WAS TIED INTO THE SYSTEM ON FEBRUARY «f,
1976. TO DATE (JAN. 31,1976) •» OF THE 5 SCRUBBER VESSELS HAVE BEEN IN
SERVICE IN VARIOUS COMBINATIONS FOK A TOTAL OF HH91 HRS. THE FIFTH VESSEL
HAS NOT BEEN PLACED IN SEKVICE BECAUSE IT IS BEING REVISED FOR THE TRIAL
INSTALLATION OF RUBBER-LINED RECYCLE PUMPS.
15
PEDCo- ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS L.UKING 03/76
CURRENT MONTH
I.D. NUMBER 31
OUOUESNE LIGHT
PHILLIPS
«HO MW - RETROFIT
COAL 1.0- 2.8 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 7/73
HEFEK TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS KEPURT. THIS
FGO SYSTEM HAS BLEW OPERATIONAL SINCE JULY 1974. THL UTILITY HAS RECENTLY
TERMINATED A TWO AND A HALF MONTH TLST PROGRAM EMPLOYING THlOSORBlC LIME
IN THE SINoLE STAGE. SCRUBBING MODULES. 1612 OPERATING HOURS WERE LOGGED
BY ONE SCRUBBING TRAIN AND 1309 HOURS WERE LOGGED BY ANOTHER TRAIN. RE-
SULTS INDICATE THAT THL .REQUIRED DEGREE OF S02 REMOVAL (63 PERCENT) CAN
BE OUTAINED WITH SINGE STAliE SCRUBBING, EMPLOYING LIME WITH A MGO CON-
TENT OF 6 TO 10 PERCEM.
I.D. NUMBER 32
GENERAL MOTORS
CHEVROLET PARMA 1 2 3 & H
32 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
KOCH
DOUBLE ALKALI
STARTUP 3/7<»
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGU SYSTEM HAS BEEN OPERATIONAL SINCE MARCH 197t. SYSTEM OPERAUILITY HAS
AVERAliCD OVER 59 PERCENT DURING THE PAST 6 MONTHS. SYSTEM OPERAUILITY WAS
«»o PLRCLNT DURING THE REPORTING MONTHS. GM is CURRENTLY CONTINUING THEIR
STUDY PROGRAM OF HIGH SOLIDS CARRYOVER IN THE SCRUBBING SOLUTION.
PRLSENTLY THE COMPANY IS EVALUATING THE SETTLING OF SOLIDS IN THE SCRUB-
BER SYSTEM CLARIFILR AND ANALYZING THE SOLIDS CONTENT OF THE CLARIFIER
UNDERFLOW.
1.0. NUMBER 33
GULF POWER CO.
SCHOLZ NO. 1A
20 MW - RETROFIT
COAL 3.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI
STARTUP 2/75
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGU SYSTEM HAS BEEN OPERATIONAL SINCE FEB. 1975. THE PROTOTYPE SYSTEM
OPERATED A TOTAL OF H7W HRS. DURING 1975« TRANSLATING INTO AN ANNUAL
AVLRAGL OPERAB1LITY OF 89 PERCENT. THL SYSTEM WAS DOWN THROUGHOUT THE RE-
PORT PERIOD DUE TO A SCHEDULED PLANT BOILER OVERHAUL. SYSTEM RESTART IS
SCHEDULED FOR MID-MARCH 1976. THE SYSTEM IS SCHEDULED TO RUN THROUGH TO
JUNE 197b.
I.D. NUMbER 34
GULF POWER CO.
SCHOLZ NO. 2A
20 Ml« - RETROFIT
COAL 3.0 PERCENT SULFUR
FOSTER WHEELER
ACTIVATED CARBON
STARTUP 2/7fa
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. SYSTEM
MOUIFICATIONS AND PRE-STARTUP CHECKOUTS WERE COMPLETED. A SUCCESSFUL
THREE DAY DRY RUN FOLLOWED. REINTRODUCTION OF FLUE GAS INTO THE SYSTEM
COMMENCED IN FEBRUARY AND A FOUR MONTH TEST PROGRAM IS NOW IN PROGRESS.
DURING THIS TEST PROGRAM S02. NOX. AND FLYASH REMOVAL PERFORMANCE. SYSTEM
ECONOMICS ANU SYSTEM RELIABILITY WILL BE ANALYZED.
I.D. NUMbER 35
GULF POWER CO.
SCHOLZ NOS. IB * 2B
23 MW - RETROFIT
COAL 3.0 PERCENT SULFUR
CHIYODA INTERNATIONAL
THOROUGHBRED 101
STARTUP . 3/75
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF REPORT. THIS FGD
SYSTEM HAS BEEN OPERATIONAL SINCE MARCH 1975. THE TOTAL SYSTEM OPEKABILI-
TY» INCLUDING SYSTEM COMMISSIONING, EXTENDING FROM FEB. 11.197&, To
DECEMBER 31, 1975, WAS 60 PERCENT. SYSTEM OPERABILITY FOR THE MONTH OF
JANUARY 1976 EXCEEDED 66 PERCENT. THE SYSTEM DID NOT OPERATE DURING THE
MONTH OF FEBRUARY.
PEDCo-ENVIRONMENTAL
16
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 04X76
CURKENT MONTH
1.0. NUMBER 36
INDIANAPOLIS POWER & LIGHT CO.
PETERSOUKG NO 3
530 Mm - NEW
COAL 3.U-3.5 PERCENT SULFUR
UNIVERSAL OIL PROUUCTS
LIMESTONE SCRUBBING
STARTUP . 14/77
UNIVERSAL OIL PRODUCTS HAS BEEN SELECTED To BUILD THE LIMESTONE SCRUBBING
SYSTEM. THE ENTIRE 530MW UNIT WILL BE TREATED BY FOUR MODULES. CONSTRUC-
TION HAS BEGUN ON ALL FOUR MODULES AND IS PROCEEDING ON SCHEDULE. WORK
ON THE FOUNDATION AND INSTALLATION OF THE RECYCLE TANKS IS CURRENTLY IN
PROGRESS.
I.D. NUMUER 37
KANSAS CITY POWER & LIGHT
HAWTHORN 140 3
1«*0 Hta - RETROFIT
COAL O.b- 3.0 PEhCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION £WET SCRUB
STARTUP 11/72
REFEK TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGL) SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 1972. BOTH MODULES WERE
DOWN THE ENTIRE MONTH OF JANUARY BECAUSE OF FKOZEN EQUIPMENT ANQ LINESi
ANU A MANPOWER SHORTAGE. OPERABILlTY FOR MODULES A AND B DURING THE MONTH
OF FEBRUARY WAS 37 AND 1 PLKCENT RESPECTIVELY.
I.D. NUMBER 38
KANSAS CITY POWER & LIGHT
HAWTHORN NO 4
100 MW - RETROFIT
COAL 0.6- 3.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION *W£T SCRUB
STARTUP B/72
REFER TO BACKGROUND INFORMATION-SECTION IN TABLE 3 OF'THIS REPORT. FGD
SYSTEM HAS BEEN IN.OPERATION SINCE AUGUST 1972. BOTH MODULES WERE DOWN
THE ENTIRE MONTH OF JANUARY BECAUSE OF FROZEN EQUIPMENT AND LINESi AND A
MANPOWER SHORTAGE. OPERABILITY FOR MODULES A AND B WAS 0 AND 76 PERCENT
RESPECTIVELY. MODULE A WAS INOPERATIVE ALL OF FEBRUARY BECAUSE OF THE
CONTlNUTATION OF A PROBLEM WITH LOSS OF DRAFT THROUGH THE
CONNECTING UUCTWORK.
I.D. NUMBER 39
KANSAS CITY POWER £ LIGHT
LA CYGNE NO 1
620 MW - NEW
COAL 5.2 PERCENT SULFUR
BABCOCK £ WILCCX
LIMESTONE SCRUBBING
STARTUP 2/73
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGU SYSTEM HAS BEEN OPERATIONAL SINCE FEB. 1973. THE ANNUAL AVERAGE
AVAILABILITY FOR ALL 7 MODULES DURING 1975 WAS IN EXCESS OF 63 PERCENT
(INCLUDING GENERATOR REPAIR OUTAGE TIME). THE UTILITY IS CURRENTLY PLAN-
NING THE INSTALLATION OF AN EIGHTH MODULE, SCHEDULED TO BE PLACED IN
SERVICE SOMETIME DURING THE SUMMER OF 1977.
I.D. NUMBER HO
KANSAS POWER & LIGHT
JEFFERY NO. 1
660 MW - NEW
COAL 0.32 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/76
THE UTILITY HAS PURCHASED AN AIR QUALITY CONTROL SYSTEM FROM COMBUSTION
ENGINEERING FOR PARTICIPATE AND S02 REMOVAL. THE SYSTEM WILL CONSIST OF
AN ESP DOWNSTREAM OF THE AIR HEATER PLUS ID FANS AND SPRAY TOWERS. AN
OVERFIRE AIK SYSTEM AT THE TANGENTIAL FIRED PULVERIZED BURNERS WILL CON-
TROL THE NOX EMISSIONS. THE CLEANED GASES WILL BE VENTED TO A 600 FOOT
STACK.
PEDCO- ENVIRONMENTAL
17
-------
COMPANY
POWLR STATION
TABLE. 2
STATUS OF FGD SYSTEMS UUhING
03/76
CURKENT MONTH
i.u. NUMBER 41
KANSAS POWER S LIGHT
JEFFERY KO. 2
600 MW - NEW
COAL 0.32 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/79
THE UTILITY HAS PURCHASED AN A1K QUALITY CONTROL SYSTEM FROM COMBUSTION
ENGINEERING FOR PARTICULAR AND S02 REMOVAL. THE SYSTEM WILL CONSIST OF
AN ESP UOWNSTREAi"i OF THE AIR MEATLR PLUS ID FANS ANU SPRAY TOWERS. AN
OVt-RFIRE AIR SYSTEM AT THE TANGENTIAL FIRED PULVERIZED BURNERS WILL CON-
TROL THE NOX EMISSIONS. THE CLEANED GASES WILL BE VENTED TO A 600 FOOT
STACK.
I.D. NUMUER 42
KANSAS POWER 8 LIGHT
LAWRENCE NO 4
125 MW - RETROFIT
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONt INJECTION *U£T SCRUB
STARTUP 12/66
REFER TO BACKGROUND INFORMATION SECTION IN TABLE a OF THIS REPORT. THIS
FGu SYSTEM HAS BEEN OPERATIONAL SINCE DECEMBER 1966. THIS UNIT IS CUR-
RENTLY BURNING LOW SULFUR WYOMING COAL. THE OPERATION OF THE SCRUBBER HAS
BEEN MORE EFFICIENT AND ECONOMICAL FOR THIS COAL TYPE BECAUSE A LESSER
OEiiREE OF S02 REMOVAL IS REUUIRED FOR COMPLIANCE. THE UTILlTy PLANS TO
REPLACE THIS SCRUBbING SYSTEM WITH A VENTRI-ROO AND SPRAY TOWER SCRUBBING
SYSTLM.
I.D. NUMBER 43
KANSAS POWER * LIGHT
LAWRENCE NO 5
400 Mw - NEW
COAL 0.5 PERCENT SuLFUR
COMHUSTIOU ENGINEERING
LIMESTONE INJECTION &WET SCRUB
STARTUP 11/71
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGU SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 1971. THIS UNIT IS CUR-
RENTLY BURNING LOW SULFUR WYOMING COAL. THE OPERATlON OF THE SCRUBBER HAS
BEEN MORE EFFICIENT AND ECONOMICAL FOR THIS COAL TYPE BECAUSE A LESSER
DEbHEE OF S02 REMOVAL IS REQUIRED FOR COMPLIANCE. THE UTILITY PLANS TO
REPLACE THIS SCRUBBING SYSTEM WITH A VENTRI-ROD AND SPRAY TOWER SCRUBBING
SYSTEM.
I.D. NUMBER 44
KENTUCKY UTILITIES
GREEN RIVER UNITS 1 AND
64 MH - RETROFIT
COAL 3.6 PERCENT SULFuR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 9/75
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
SYSTEM BECAME OPERATIONAL SEPTEMBER 13,1975. OPERATION IS CURRLNTLY
BEING CONDUCTED ON A HALF-LOAD BASIS BECAUSE OF A TURBINE REPAIR.
OPERATIONAL DATA AVAILABLE FOR THE HAST THREE MONTHS SHOWS THAT SYSTEM
AVAILABILITY. OPERABILITY AND UTILISATION HAVE AVERAGED 62, 39. AND 25
PERCENT RESPECTIVELY. SYSTEM OUTAGES HAVE RESULTED FROM MINOR MECHANICAL
STARTUP PROBLEMS AND COMPONENT CLEANOUTS. THE SYSTEM IS NOW BEING PRE-
PARED FOR AN EXTENDED RELIABILITY TEST PROGRAM.
I.D. NUMBER 45
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
37 MW - NEW
OIL 2.4 PERCENT SULFUR
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
STARTUP 10/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTEM HAS BEEN OPERATIONAL SINCE OCTOBER 1972. THE FGD SYSTEM HAS
BEEN OUT OF SERVICE SINCE JANUARY 28.1975. MODIFICATIONS AND REPAIRS ARE
CURRENTLY IN PROGRESS. SYSTEM RESTART IS AT LEAST A MONTH AWAY. CHECKOUT
OF ALL SYSTEM MOTORS AND PUMPS MUST BE COMPLETED BEFORE STARTUP CAN
COMMENCE.
PEDCo-ENVIRONMENTAL
18
-------
COMPANY
TABLE 2
STATUS OF F6D SYSTEMS DURING
03/76
POWER STATION
CURRENT MONTH
I.D. NUHBE.R 16
LOUISVILLE GAS & ELECTRIC
CANE RUN NO t
178 MW - RETROFIT
COAL 3.5-I4.0S PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 6/7fa
THE. UTILITY HAS SIGNLD A CONSENT AGKEEKENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGD EQUIPMENT ON THIS UNIT BY JUNE 1,1976. THE
CONTRACT HAS UEEN AWARoEU TO AMERICAN AIR FILTER. THE SYSTEM WILL OPERATE
ON A CLOSED WATER LOOP AND THE SLUDGE WILL BE STABILIZED. THIS SYSTEM IS
PRESENTLY UNDER CONSTRUCTION.
I.D. NUMBER «»7
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 5
163 PW - RETROFIT
COAL 3.5-4.U5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 12/77
THE UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGD EQUIPMENT ON THIS UNIT BY DECEMBER 1,1977.
THE. CONTRACT FOR THIS LIME SCRUBBING SYSTEM HAS BEEN AWARDED TO
COMBUSTION ENGINEERING. THE UNIT IS PRESENTLY UNDER CONSTRUCTION.
I.D. NUMBER <»8
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 6
277 MU - RETROFIT
COAL 3.5- f.O PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 9/70
THE UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGD EQUIPMENT ON THIS UNIT BY SEPTEMBER 1,1978.
THE UNIT IS PRESENTLY OUT FOR BIDS.
I.U. NUMbER 49
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 1
330 MW - RETROFIT
COAL 3.5- "*.0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 1/82
A COMPLIANCE SCHEDULE HAS BEEN SUBMITTED TO THE JEFFERSON COuNTY AIR POL-
LUTION CONTROL DISTRICT WITH 1/62 ESTABLISHED AS THE STARTUP DATE FOR AN
FGO SYSTEM.
I.D. NUMBER 50
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 2
330 MW - RETROFIT
COAL 3.5- 4.0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 1/81
A COMPLIANCE SCHEDULE HAS BEEN SUBMITTED TO THE JEFFERSON COUNTY AIR POL-
LUTION CONTROL DISTRICT WITH 1/81 ESTABLISHED AS THE STARTUP DATE FOR AN
FGO SYSTEM.
PEDCo- ENVIRONMENTAL
19
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS uURING 03/76
POWER STATION ' CURRENT MONTH
I.D. NUMULR 51
LOUISVILLE GAS X ELECTRIC
MILL CREEK NO 3
i»25 MW - NEW
COAL 3.5- H.O PERCENT SULFUR
AMERICAN AIK FILTER
LIME SCRUBBING
STARTUP 7/77
THE UTILITY HAS SIGNLD A CONSENT AGREEMENT WITH THE LPA FOR TH£ INSTAL-
LATION AND OPERATION OF FGU EQUIPMENT OiM THIS POwEK GENERATING UNIT BY
JULY 1,1977. THIS NEW FACILITY WILL BE REQUIRED TO MEET FEDERAL NSPS FOR
THE LIMITATION OF S02 LMISSIONS. CONTRACT HAS bEEN AWARDED TO AMERICAN
AIK FILTER. THE SYSTEM WILL OPERATE ON A CLOSED WATER LOOP AND THE SLUDGE
WILL BE STABILIZED. CONSTRUCTION HAS BEGUN ON THE FGD SYSTEM.
I.D. NUMBER 52
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO H
<«25 MW - NEW
COAL 3.5- "».0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 7/79
THE UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE LPA FOR THE INSTAL-
LATION AND OPERATION OF FGD EQUIPMENT ON THIS POWER GENERATING UNIT BY
JULY 1,1979. THIS NEW FACILITY WILL BE REQUIRED TO MEET FEDERAL NSPS FOR
THE LIMITATION OF S02 EMISSIONS. THE CONTRACT HAS BEEN AWARDED TO
AMERICAN AIR FILTER FOR A LIME SCRUBBING SYSTEM.
I.D. NUMBER 53
LOUISVILLE GAS & ELECTRIC
PADDYS RUN NO 6
65 MW - RETROFIT
COAL 3.b-<».0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUbBlUt
STARTUP
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS DURING
03/76
CUKKENT MONTH
I.D. NUMBER 56
MONTANA POWER CO.
COLSTRIP NO 2
360 MM - NEW
COAL O.B PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
LIME SCRUUBING
STARTUP 7/76
THE FGD SYSTEM IS CURRENTLY UNDER CONSTRUCTION. TURBINE ROLL AND SYSTEM
CHECKOUT HAS BEEN DELAYED A MONTH AND A HALF TO MID-JUNE 1976. NO DELAYS
IN THE JULY 1976 STARTUP DATE ARE FORESEEN AT THE PRESENT TIME.
I.D. NUMIJER 57
MONTANA POWER CO.
COLSTKIP NO.3
700 MW - NEW
COAL 0.7 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 7/80
THE UTILITY IS CURRENTLY WAITING FOR APPROVAL OF A CERTIFICATE TO
CONSTRUCT BOILERS 3 AND <+ BEFORE PROCEEDING WITH ORDLRS TO INSTALL FGD
SYSTEMS. THE FGD PROCESS BEING GIVEN PRIME CONSIDERATION FOR UNITS 3 AND
4 IS THE CEA LIME SCRUBBING SYSTEM NOW OPERATING AND BEING INSTALLED ON
UNITS 1 AND 2 RESPECTIVELY.
I.D. NUMBER 58
MONTANA POWER CO.
COLSTRIP NO.i*
700 MW - NEW
COAL 0.7 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 7/81
THE UTILITY IS CURRENTLY WAITING FOK APPROVAL OF A CERTIFICATE TO
CONSTRUCT BOILERS 3 AND H BEFORE PROCEEDING WITH ORDERS TO INSTALL FGD
SYSTEMS. THE FGD PROCESS BEING GIVEN PRIME CONSIDERATION FOR UNITS 3 AND
<* IS THE CEA LIME SCRUBBING SYSTEM NOW OPERATING AND BEING INSTALLED ON
UNITS 1 AND 2 RESPECTIVELY.
I.D. NUMBER 59
NEVADA POWER
HARRY ALLEN STATION NO. 1
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/82
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM.
TIONS HAVE NOT YET BEEN PREPARED.
SPECIFICA-
I.D. NUMBER 60
NEVADA PUrfER
HARRY ALLEN STATION NO. 2
500 MM - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/83
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
21
PEDCo-ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 03/76
CUKRENT MONTH
1.0. NUMBER 61
NEVADA POWER
HARRY ALLEN STATION NO. 3
500 MW - NEW
COAL"
NOT SELECTED
NOT SELECTED
STARTUP 6/81
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
1.0. NUMBER 62
NEVADA POWER
HARRY ALLEN STATION NO. H
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/85
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM.
TIONS HAVE NOT YET BEEN PREPARED.
SPECIFICA-
I.D. NUMBER 63
NEVADA POWER
REID GARDNER NO 1
125 Mh - RETROFIT
CO«L 0.5- 1.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
SODIUM CAKBONATE SCRUBBING
STARTUP t/7<»
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGU SYSTEM HAS BEEN OPERATIONAL SINCE APRIL l97«t. THIS SYSTEM WAS ON-LINE
186 HRS. IN JANUAKYt WHICH EQUATES INTO A 29 PLRCfNT OPERABILHY FACTOR.
THKCE FORCED SCRUbBER OUTAGES OCCURRED DURING THIS PERIOD DUE TO REHEATER
STLAM LEAKS, A VENTURI STRAINER COLLAPSE AND A FROZEN CARBONATE LINE.
TOTAL OPERATING TIME LOGGED BY THIS SCRUBBING SYSTEM TO DATE IS 6
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
03/76
CUKKENT MONTH
1.0. NUMbER 66
NEVAOA POWER
REID GARUNER NO 4
125 Mh - NEW
COAL 0-5- 1.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
STARTUP ' O/ 0
NEVAOA POWER COMPANY HAS SIGNED A LETTER OF INTENT WITH COMBUSTION EQUIP-
MENT ASSOCIATES FOR THE CONSTRUCTION OF AN FGD SYSTEM ON REID GARDNER NO.
-------
COMPANY
POWER STATION
TABLE: 2
STATUS OF FtiU SYSTEMS DURING 03/76
CURRENT MONTH
I.D. NUMbER 71
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 8
- 400 MW - RETROFIT
COAL 3 PEKCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
CONSIDERING A LIME OR LIMESTONE SCRUBBING UNIT. ALSO WAITING FOR PERFOR-
MANCE OF UELLMAN LORD/ALLIED CHEMICAL UNIT UNDER CONSTRUCTION AT THEIR
D. H. MITCHELL NO. 11 UNIT. LOW SULFUR COAL MAY BE BURNED TO COMPLY WITH
S02 EMISSION REGULATIONS.
I.D. NUMbER 72
NORTHERN INDIANA PUB SERVICE
MITCHELL NO 11
115 MW - RETROFIT
COAL 3.2- 3.5 PERCENT SULFUR
DAVY POWEKGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 1/76
THE ENGINEERING AND CONSTRUCTION PHASES OF THE S02 EMISSION CONTROL
SYSTEM AT THIS STATION WILL BE COWLETLD IN MARCH. PREPARATIONS FOR START
UP AND OPERATION OF THE SYSTEM ARE NOW WELL ADVANCED. THE STARTUP DATE IS
SET FOR APRIL I2t 1976. THL FGD SYSTEM IS AN INTEGRATION OF THL WELLMAN-
LORD S02 RECOVERY PROCESS OF DAVY POwERGAS AND ALLIED CHEMICAL'S SQ2
REDUCTION TO SULFUR PROCESS. DAVY HOWERGAS IS THE ENGINEER AND CONSTRUC-
TOR OF THE ENTIRE FACILITY AND ALLIED CHEMICAL IS THE SYSTEM OPERATOR AND
PRODUCT MARKETER.
1.0. NUMBER 73
NORTHERN STATES POWER CO.
SHERBURNt NO 1
680 Mw - NEW
COAL 0.6 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 5/76
FGD SYSTEM IS STILL UNDER CONSTRUCTION. PURCHASE ORDERS FOR SCRUBBERS
WERE PLACED IN EARLY 1971. DESIGN MODIFICATIONS CAUSED EQUIPMENT DELIVERY
DELAYS,HOWEVER THE OVERALL SCHEDULE HAS NOT BEEN UPSET. PROBLEMS ENCOUN-
TERED bY THE UTILITY THUS FAR HAVE UEEN DUE TO OBTAINING SOME ELECTRICAL
CONTROLS, A RELENT CONSTRUCTION STRIKE, AND A BOILER MODIFICATION INVOL-
VING GREATER NEGATIVE PRESSURE TOLERANCE. THE UTILITY IS NOW BEGINNING A
PRELIMINARY SYSTEM CHECKOUT.BY PASSING AIR AND CLEAR WATER THROUGH THE
FGD UNIT. A MAY STARTUP OF THIS SYTCM IS STILL ANTICIPATED.
I.D. NUMBER 71
NORTHERN STATES POWER CO.
SHERBURNE NO 2
660 Mw - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 5/77
FGU SYSTEM UNDER CONSTRUCTION WITH NO MAJOR DELAYS. PURCHASE ORDERS FOR
SCRUBBERS WtlRE PLACED IN EARLY 1971. RECENT SCRUBBER DESIGN CHANGES HAVE
CAUSED EQUIPMENT DELIVERY DELAYS BUT THE OVERALL SCHEDULE HAS NOT BEEN
UPbET. PRObLLMS HAVE ARISEN IN OBTAINING SOME ELECTRICAL CONTROLS.
CONSTRUCTION IS bEHIND SCHEDULE AND SOME DELAY OF STARTUP DATE MAY BE EX-
PECTED DUE TO RECENT STRIKE. THE EXTENT OF THE DELAY CANNOT BE DETERMINED
AT THE PRESENT TIME.
I.D. NUMBER 75.
PENNSYLVANIA .POWER CO.
BRUCE MANSFIELD NO. 1
635 MW - NEW
COAL t.3 PEKCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP H/76
THE UTILITY BEGAN A SHAKEDOWN AND DEBUGGING PHASE OF OPERATION FOR PART
OF THE SYSTEM IN DECEMbEK 1975. CONSTRUCTION IS STILL IN PROGRESS ON THE
REMAINING MODULES OF THIS SYSTEM. FULL COMMERCIAL STARTUP IS PRESENTLY
PROJECTED FOR APRIL 1976.
24
PEbCo-ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 03/76
CURRENT MONTH
I.D. NUMBER 76
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 2
835 Mb • NEW
COAL <*.3 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP • «»/77
FGU SYSTEM UNDER CONSTRUCTION. BUT ENCOUNTERING LONG DELAYS IN MATERIAL
DELIVERIES. STARTUP DATE HAS BEEN DELAYED 1 YEAR UNTIL 4/77.
I.D. NUMbER 77
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 3
635 Mb - NEW
COAL t.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP <»/79
FGD UNIT IS PLANNED. PRESENTLY REQUESTING AND EVALUATING BIDS.
I.D. NUMbER 76
PHILADELPHIA ELECTRIC CO.
CROMBY
150 MW - RETROFIT
COAL 2-t PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
STARTUP 10/70
COMPANY PLAN TO RETROFIT ONE OF THE TWO BOILERS AT"CKOMbY BUT HAVE NOT
MADE A FINAL DECISION ON THIS POINT. THE FGD PROCESS SELECTED WILL VERY
LIKELY BE AN MGO PROCESS DESIGNED JOINTLY BY UNITED ENGINEERS AND PHILA-
DELPHIA ELECTRIC. ENGINEERING DESIGN WORK IS SCHEDULED FOR JAN 76.
STARTUP NOW SCHEDULED FOR OCT 76.
I.D. NUMBER 79
PHILADELPHIA ELECTRIC CO.
EODYSTONE NO 1A
120 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUh OXIUE SCRUBBING
STARTUP 9/75
THE S02 SCRUBBER HAS BEEN TEMPORARILY SHUTDOWN BECAUSE THE ACID PLANT RE-
GENERATION FACILITY AT THE OLIN CHEMICAL SULFURIC ACID PLANT IN PAULSBORO
NEW jEKbEY HAS PERMANENTLY CEASED OPERATIONS. CONSIDERATIONS A«E NOW
BEH'Jfa GIVEN TO THE RELOCATION OF THL REGENERATION FACILITY. ONCE THIS DE-
CISION is MADE A MINIMUM PERIOD OF six MONTHS WILL BE REQUIRED TO RELO-
CATE THE REGENERATION FACILITY, THL PARTICULATE SCRUBBERS ARE CONTINUING
TO OPERATE. THE UTILITY IS STILL EXPERIENCING PROBLEMS WITH THE FANS, RE-
HEAT BURNERS, DAMPERS, AND EXPANSION JOINTS.
1.0. NUMbER 80
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO ID
2tO MW - RETROFIT
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
STARTUP 10/78
THE RETROFITTING OF SECOND STAGE SCRUBBERS ON THE BALANCE OF THE FLUE GAS
FROM EDDYSTONE 1 IS AWAITING PERFORMANCE OF THE EXISTING 2-STAGE UNIT
WHICH IS TREATING ONE THIRD CF THE BOILER FLUE GAS. THIS UNIT CONSISTS
OF A AND B PARTICULATE SCRUBBING TRAINS, EACH ARE 120 MW. CHECK VALVE
FAILURE ON A TRAIN HAS BEEN CORRECTED. FAN ON B TRAIN IS STILL AT THE
FACTORY FOR REPAIR.
PEDCo-ENVIRONMENTAL
25
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
03/76
CURRENT MONTH
I.D. NUMbER 61
PHILADELPHIA ELECTRIC CO.
EODYSTONE NO 2
336 MW - KETROFIT
COAL s.t PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXIPE SCKUBBING
STARTUP 10/78
COMPANY IS AWAITING PERFORMANCE OF FGD SYSTEM ON UNIT 1 BEFORE PROCEEDING
WITH DESIGN OF FGD SYSTEM ON THIS BOILER. HOWEVER ENGINEERING PHASE IS
TENTATIVELY PLANNED TO START IN JAN 76t AT WHICH TIME EVALUATION OF
DATA FROM UNIT 1 SHOULD BE COMPLETE.
I.D. NUMBER 82
PUBLIC SERVICE CO OF NEW HEX.
SAN JUAN MO. 1
375 Mw - NEW
COAL 0.8 PERCENT SULFUR
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 7/7?
THIS FGD SYSTEM IS AN INTEGRATION OF THE WELLMAN-LORD S02 RECOVERY PRO-
CESS OF DAVY POWLKGAS AND ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR PRO-
CESS. OAVY POWERGAS IS THE ENGINELK AiJU CONSTRUCTOR OF THE FGD SYSTEM
WHILE ALLIED CHEMICAL WILL BE THE SYSTEM OPERATOR AND PRODUCT MARKETER.
CURRENTLY THE FGD PROJLCT IS. PROcEEDfNG ACCORDING TO PLAN WITH NO MAJOR
PROBLEMS. EQUIPMENT IS NOW BEING PROCURED. CONSTRUCTION IS SCHEDULED TO
BEGIN IN MARCH OK «PRIL OF 1976.
I.D. NUMBER £3
PUBLIC SERVICE CO OF NEW HEX.
SAN JUAN NO. 2
3"*0 PW - RETROFIT
COAL 0.8 PERCENT SULFUR
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 7/77
THIS FGD SYSTEM IS AN INTEGRATION OF THE WELLMAN-LORU S02 RECOVERY PRO-
CESS OF OAVY POWERGAS AND ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR PRO-
CESS. DAVY POWERGAS IS THE ENGINEER AND CONSTRUCTOR OF THE FGD SYSTEM
WHILE ALLIED CHEMICAL WILL OE THE SYSTEM OPERATOR ANU PRODUCT MARKETER.
CURRENTLY THE FGU PROJECT IS PROCEEDING ACCORDING TO PLAN WITH NO MAJOR
PROBLEMS. EQUIPMENT IS NOW BEING PROCURED. CONSTRUCTION IS SCHEDULED TO
BEGIN IN MARCH OR APRIL OF 1976.
1.0. NUMBER 84
PUBLIC SERVICE CO OF NEW MEX,
SAN JUAN NO. 3
500 Mw - NEW
COAL 0.8 PERCENT SULFUR
DAVY POWERGAS
UELLMAN LORD
STARTUP 5/79
A LETTER OF INTENT HAS BEEN SIGNED WITH DAVY POWERGAS FOR A WELLMAN
LORD UNIT. THE PROJECTED STARTUP DATE OF THIS SYSTEM HAS BEEN DELAYED ONE
YEAR TO HAY 1979.
I.D. NUMBER 85
PUBLIC SERVICE CO OF NEW HEX.
SAN JUAN i'JO. t
500 MM - NEW
COAL 0.8 PERCENT SULFUR
DAVY POWERGAS
WELLMAN LORD
STARTUP 5/61
A LETTER OF INTENT HAS BEEN SIGNED WITH OAVY POWERGAS FOR A WELLMAN
LORD UNIT. THE PROJECTED STARTUP DATE OF THIS SYSTEM HAS BEEN DELAYED ONE
YEAR TO MAY 1981.
26
PEDCo-£NVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 03/76
CURRENT MONTH
I.Ot NUMBER 66
PUBLIC SERVICE CO. OF COLORADO
VALMONT NO. 5
50 MW - RETROFIT
COAL 0.72 PENCENT SULFUR
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
STARTUP . 10/Tt
KEFEK TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 197"». THE FGD SYSTEM CURRENTLY
OPERATIONAL AT THIS STATION IS AN EXPERIMENTAL UNIT, ORIGINALLY DESIGNED
BY UNIVERSAL OIL PRODUCTS FOK PARTlCULATE REMOVAL ONLY. ONE OF THE TWO
PARALLEL SCRUBBING MODULES WAS CONVERTED TO LIMESTONE SCRUBBING FOR
EXPERIMENTAL PURPOSES ONLY.
I.D. NUMbER 87
PUBLIC SEKVICE INDIANA
GIBSON NO. 3
650 Mb - NEW
COAL, 3.3% SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/78
BID EVALUATION IS UNDERWAY.
1.0. NUMbER 88
PUBLIC SERVICE INDIANA
GIBSON NO. H
650 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 0/79
BID SPECIFICATIONS ARE BEING PREPARED.
I.D. NUMBER 89
RICKEMBACKER AFU
RICKENBACKER
20 MU - RETROFIT
COAL 5.0 PEKCENT SULFUR
RESEARCH COTTRELL
LIME SCRUBBING
STARTUP 3/76
CONSTRUCTION OF THE SYSTEM IS NOW VIRTUALLY COMPLETE. THE SYSTEM STARTUP
DATE WAS SET BACK ONE MONTH DUE TO DELAYS OF SOME MATERIAL DELIVERIES.
THE SYSTEM IS NOW SChEDULEU TO BE PLACED IN SERVICE IN MID-MARCH, 1976.
I.D. NUMBER 90
S. CAROLINA PUU SEKV AUTHORITY
WINYAH NO. 2
140 MW - NEW
COAL 1.0 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 5/77
THE CONTRACT HAS BEEN AWARDED TO B&W FOR CONSTRUCTION OF A LIMESTONE SYS-
TEM TREATING 50 PERCENT OF THE GAS FLOW FROM A 280 MW BOILER. THIS UNIT
WILL FIRE 1 PERCENT SULFUR COAL AND THE GUARANTEED REMOVAL EFFICIENCY IS
69 PERCENT. DIFFERENT METHODS OF SLUDGE DISPOSAL ARE CURRENTLY BEING EX-
AMINED BY THE UTILITY.
PEDCo- ENVIRONMENTAL
27
-------
COMPANY
TABLE 2
STATUS OF KGD SYSTEMS DURING
03/76
POWER STATION CURRENT MONTH
I.D. NUMBER 91
S. MISSISSIPPI ELEC PWR ASSOC
R.D. MORROW NO.l
180 MW - NEW
COAL 1 PERCENT SULFUR
RILEY STOKEK/ENVIRONEERING
LIMESTONE SCRUBBING
STARTUP 11/77
THE CONTRACT FOR THIS LIMESTONE SYSTEM HAS BEEN AWARDED TO RILEY
STOKER/ENVIRONEERING. GUARANTEED S02 REMOVAL EFFICIENCY IS 85 PERCENT.
I.D. NUMbER 92
S. MISSISSIPPI ELEC PWR ASSOC
R.D. MORKOW NO.2
180 MW - NEW
COAL 1 PERCENT SULFUR
RILEY STOKEK/ENVIRUNEERING
LlMLSTONt SCRUBBING
STARTUP 6/7B
THE CONTRACT FOR THIS LIMESTONE SYSTEM HAS BEEN AWARDED TO RILEY
.STOKER/ENVIRONEERING. GUARANTEED S02 REMOVAL EFFICIENCY IS 85 PERCENT.
I.D. NUMUER 93
SOUTHERN CALIFORNIA EDISON
KAIPAROvJITZ NO. 1
750 MW - NEW
COAL lO.fiUOiBTUi 0.5S S
NOT SELECTED
LIME SCRUBBING
STARTUP 0/02
THIS NEW STATION IS ANTICIPATED TO INCORPORATE FGD, BUT A SPECIFIC
PROCESS HAS NOT BEEN SELECTED. THE STARTUP DATE FOR THIS UNIT HAS BEEN
DELAYED ONE YEAR PENDING THE ASSEMBLY ANU EVALUATION OF DATA FOR ENVIRO-
MENTAL CONSIDERATIONS AND SUBSEQUENT APPROVAL PROCESSES.
I.D. NUMDER 9«»
SOUTHERN CALIFORNIA EDISON
KAIPAROWITZ NO. 2
750 MW - NEW
COAL 10.800.BTU* 0.5S S
NOT SELECTED
LIME SCRUBBING
STARTUP 0/83
THIS NEW STATION IS ANTICIPATED TO INCORPORATE FGD, BUT A SPECIFIC
PROCESS HAS NOT BELN SELECTED. THE STARTUP DATE FOR THIS UNIT HAS BEEN
DELAYED ONE YEAR PENDING THE ASSEMBLY AND EVALUATION OF DATA FOR ENVIRO-
MENTAL CONSIDERATIONS AND SUBSEQUENT APPROVAL PROCESSES.
I.D. NUMuER 95
SOUTHERN CALIFORNIA EDISON
KAIPAROWITZ NO. 3
750 Mh - NEW
COAL 10.800.BTUt 0.5X S
NOT SELECTED
LIME SCRUBBING
STARTUP 0/8t
THIS NEW STATION IS ANTICIPATED TO INCORPORATE FGD, BUT A SPECIFIC
PROCtSS HAS NOT BELN SELECTED. THE STARTUP DATE FOR THIS UNIT HAS BEEN
DELAYED ONE YEAR PENDING THE ASSEMBLY AND EVALUATION OF DATA FOR ENVIRO-
MENTAL CONSIDERATIONS AND SUBSEQUENT APPROVAL PROCESSES.
PEDCo-ENVIRONMENTAL
28
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGU SYSTEMS OUKING 03/76
CUKKENT MONTH
I.D. NUMBER 96
SOUTHERN CALIFORNIA EDISON
KAIPAKOWITZ NO. H
750 KM - NEW
COAL 10.800.BTUt 0.5K S
NOT SELECTED
LIME SCRUBBING
STARTUP ' 0/85
THIS NEW STATION IS ANTICIPATED TO INCORPORATE. FGO, bUT A SPECIFIC
PROCESS HAS NOT BEEN SELECTED. THE STARTUP DATE FOR THIS UNIT HAS BEEN
DELAYED ONE YEAR PENDING THE ASSEMBLY AND EVALUATION OF DATA FOR ENVIRO-
MENTAL CONSIDERATIONS AND SUBSEQUENT APPROVAL PROCESSES.
I.D. NUMBER 97
SOUTHERN CALIFORNIA EDISON
MOHAVE NO IB
620 MW - RETROFIT
COAL 0.5- 0.8 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP 6/77
THE TOTAL CAPACITY OF BOILER IS 790 MW. EXISTING EXPERIMENTAL FGD MODULE
WILL TREAT ONLY 170 «W. FINAL SELECTION OF THE PROCESS HAS BEEN POST-
PONED. SEE MOHAVE 1A.
I.D. NUNbtR 90
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2
790 MW - RETROFIT
COAL 0.5 TO 0.8 % SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP 6/77
A PROTOTYPE 170 MW LIME SCRUBBING SYSTEM (HORIZONTAL MODULE) ON THIS UNIT
WAS OPERATED FROM NOVEISBER 1973 UNTIL FEBRUARY 1975. AVAILABILITY FOR THE
PERIOD 1/16/7H TO 2/9/75 AVERAGED 73.5». THIS SYSTEM IS TO BE REINSTALL-
ED Al THE FOUK CORNERS PLANT, OPERATED BY ARIZONA PUBLIC SERVICE.
I.D. hUP-iGLR 99
SPRINGFIELD CITY UTILITIES
SOUTHWEST NO. 1
200 Mb - NLW
COAL 3.5 PERCLNT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 7/7b
CONSTRUCTION ON THE BOILER AND FGD SySTEM IS CURRENTLY BEHIND SCHEDULE.
COMPLETION IS NOW SCHEDULED FOR MID-SUMMER 1976. THE SCRUBBER. ESP, AND
I.b. FANS ARE CURRENTLY BEING INSTALLED.
I.D. NUMBER 100
TENNESSEE VALLEY AUTHORITY
SHAWNCE NO.10A
10 MW - RETROFIT
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
STARTUP 1/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
TURBULENT CONTACT ABSORBER(TCA) LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN
OPERATIONAL SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA.
TVA IS THE CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN
FRANCISCO IS THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER.
29
PEDCO- ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 03/76
CURRENT MONTH
I.D. NUMBER 101
TENNESSEE. VALLEY AUTHORITY
SHAWMEE NU.10B
10 MW - RETROFIT
COAL 2.9 PERCENT SULFUR
CHEMICO
LIME/LIMESTONE SCRUBBING
STARTUP "1/72
REFER TO BACKGROUND INFOKMATIION SECTION IN TABLE 3 OF THIS REPORT. THIS
VEIMTURI/SPRAY TOWER LIME/LIMESTONE SCRUBBING SYSTEM HAS BELN OPERATIONAL
SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA. TVA IS THE
CONSTRUCTOR AND FACILITY OPL'KATOR. THE BECHTEL CORP. OF SAN FRANCISCO IS
THL MAJOR CONTRACTOR!TEST DIRECTOR. AND REPORT WRITER.
I.D. NUMBER 102
TENNESSEE VALLEY AUTHORITY
WIDOWS CKEEK NO 8
550 Mw - RETROFIT
COAL 3.7 PERCENT SULFUR
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
STARTUP 2/77
CONTRACTS HAVE BEEN LET ON ALL MAJOR PKOCESS EQUIPMENT INCLUDING THE
SCKUSBER, MIST ELIMINATOR. PIPING. INSTRUMENTATION, HOT AIR INJECTION
SYSTLM AND AIR HEATER FANS. THE ID FANS ARE NOW BEING INSTALLED AS IS THE
LIMESTONE CRUSHER. THE. LAST EQUIPMENT REQUISITION WILL BE COMPLETED BY
JUNE 1976. THE SCHEDULED STARTUP DATE OF FEBRUARY 1977 IS STILL OPERA-
TIVE.
•1.0. NUMBER 103
TEXAS UTILITIES CO.
MARTIN LAKE NO. 1
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 9/76
NEW SYSTEM, ERECTING BOILER. CONTRACT FOR FGD SYSTEM AWARDED.
ENGINEERING DESIGN WORK IS PROCEEDING. FABRICATION OF THE TOWER HAS
BEEN COMPLETED.
I.D. NUMBER 101*
TEXAS UTILITIES CO.
MARTIN LAKE NO. 2
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTHELL
LIMESTONE SCRUBBING
STARTUP 6/77
NEW SYSTEM, ERECTING BOILER. CONTRACT FOR FGD SYSTEM AWARDED.
ENGINEERING DESIGN WORK IS PROCEEDING. FABRICATION OF THE TOWER HAS
BEEN COMPLETED.
I.D. NUMBER 105
TEXAS UTILITIES CO.
MARTIN LAKE NO. 3
793 MW - NLW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 12/75
UTILITY HAS SIGNED A LETTER OF. INTENT WITH RESEARCH COTTRELL. THE BOILER
IS CURRENTLY BEING ERECTED AT THIS NEW FACILITY.
30
PEDCo- ENVIRONMENTAL
-------
COMPANY
POWER STATION
1.0. NUMbER 106
TEXAS UTILITIES CO.
MARTIN LAKE NO. H
793 Mta - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 12/79
1.0. NUMBER 107
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
5<«5 MM - NEW
LIGNITE - 0.63 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE
STARTUP 11/78
1.0. NUMBER 108
UNITED POWER ASSOCIATION
COAL CREEK NO. 2
5
-------
Table 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
33
-------
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUUGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
JOSEPH CITY ARIZONA
115 MW
COAL O.HH-1 PERCENT SULFUR
RESEARCH COTTRELL
LlhESTONE SCRUBBING
RETROFIT
10/73
OPERATIONAL
99.7 PERCENT
65 PERCENT
733 GAL/LB MOLE S02 REMOVED
UNSTAB1LIZED SLUDGE UISPOSE.D IN UNLINED POND
S&7/KW CAPITAL * 2.2 MILLS/KWH ANNUALIZEU
KEFER TO BACKGKOUNO INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPLRATIONAL SINCE NOVEMbER i97*' ^LXWXLXTY FOR
MODULES A AND B HAS AVERAGED IN EXCESS OF 90 AND 83 PERCENT RESPECTIVELY
XING T£E PAS? TEN OPERATING MONTHS. ^LIABILITY FOR MODULES A AND B
IN JANUARY WAS 99 PERCENT. MODULE A WAS IN SERVICE 71H.5 HRS. AND MODULE
B 653.7 HRS. DURING THIS PERIOD.
PEDCo-ENVIRONMENTAL
35
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BACKGROUND INFORMATION
ON
THE CHOLLA POWER PLANT
THE CHOLLA POWER STATION IS LOCATED NEAR JOSEPH CITY. ARIZONA. IT HAS ONE 115 MW COAL-FIRED BOILER IN SERVICE
AND TWO 250 MW UNITS UNDER CONSTRUCTION.
UNIT 1 IS A DRY BOTTOM PULVERIZED COAL-FIRED UNIT DESIGNED BY COMBUSTION ENGINEERING. THE COAL PRESENTLY BEING
BURNED HAS AN AVERAGE HEATING VALUE (DRY BASIS) OF 12,146 BTU/PER POUND AND ASH AND SULFUR CONTENTS OF 12.3 PERCENT
AND 0.44 PERCENT, RESPECTIVELY.
THE FGD SYSTEM AT THE CHOLLA PLANT WAS MANUFACTURED BY RESEARCH-COTTRELL AND INSTALLATION WAS COMPLETED ON DECEMBER
3, 1973. S02 REMOVAL EFFICIENCY IS REPORTED TO BE 85 PERCENT.
THE FGD SYSTEM CONSISTS OF TWO SCRUBBING MODULES (A AND B). EACH MODULE IS DESIGNED FOR 240,000 ACFM THROUGHPUT
AT 276°F, AND HANDLES 50 PERCENT OF THE BOILER'S FLUE GAS LOAD. MODULE A HAS A VARIABLE THROAT FLOODED DISC SCRUBBER
(FDS) FOLLOWED BY A PACKED TOWER; MODULE B IS SIMILAR BUT THE TOWER IS NOT PACKED AND SLURRY IS NOT CIRCULATED THROUGH
IT. EITHER ONE OR BOTH OF THE SCRUBBERS CAN BE BYPASSED. GAS LEAKAGE AROUND EACH TRAIN IS ESTIMATED TO BE ABOUT 4.52
OF THE GAS BEING TREATED. THE TOWER PACKING WHICH IS ABOUT 2 FEET THICK IS MADE OF POLYPROPYLENE CORRUGATED SHEETS
JOINED TOGETHER IN CRISS-CROSS PATTERNS SIMILAR TO HONEYCOMBS. THE TOWER DEMISTERS ARE MADE OF POLYPROPYLENE AND THE
REHEATERS ARE SHELL AND TUBE TYPE AND CONSIST OF THREE TUBE BUNDLES.
LIMESTONE FOR THE FGD SYSTEM IS PURCHASED IN GROUND FORM SUITABLE FOR SLURRYING. THE MAIN SOURCE OF SUPPLY IS
FROM THE NELSON MINES OF U.S. LIMESTONE IN PEACH SPRINGS. NEAR KINGMAN, ARIZONA.
THE PLANT DOES NOT HAVE A SLUDGE TREATMENT OR FIXATION SYSTEM. THE SLUDGE IS PUMPED TO THE FLY ASH POND ON AN
INTERMITTENT BASIS USING A COMMON PIPING SYSTEM WITH THE FLY ASH. NO POND WATER IS RECYCLED TO THE FGD SYSTEM.
PROBLEMS AND SOLUTIONS
DECEMBER, 1973 TO APRIL 2, 1974 - DUE TO THE SIZE DIFFERENCE BETWEEN MAIN DUCT AND REHEATER TRANSITION DUCT, THE
GAS FLOW PRODUCED HARMONIC VIBRATIONS IN THE REHEATER. THE VIBRATIONS WERE PARTIALLY DAMPED BY INSTALLATION OF BAFFLES,
PEDCo-ENVIRONMENTAL
36
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CHOLLA POWER PLANT (continued)
ONE OF THE REHEATER TUBE BUNDLES WAS BADLY CORRODED BY ACID WHICH CONDENSED IN THE UNINSULATED DUCT UPSTREAM OF THE REHEATERS. THE TUBE
BUNDLE WAS REPLACED AND A BAFFLE WAS INSTALLED TO DIVERT CONDENSED ACID AWAY FROM REHEATER TUBES. THE DUCT UPSTREAM OF THE REHEATER WAS
ALSO INSULATED. THE ACID CONDENSATION PROBLEM ONLY OCCURED IN THE MODULE WITH NO TOWER PACKING AND HENCE LOW SOg REMOVAL EFFICIENCY.
ANOTHER PROBLEM WAS DUE TO SOLIDS BUILD UP IN THE FDS STUFFING GLAND BOX AND ON TOP OF THE SPRAY DOME. ALSO, SOME LINES PLUGGED
PARTICULARLY WHEN THE SYSTEM OPERATED AT LOW FLOW RATES, SOLIDS SETTLED OUT IN STANDBY PUMPS AND EXCESSIVE FAN VIBRATIONS OCCURRED DUE
TO AN ACCUMULATION OF SCALE BUILD UP WHEN IT WAS IDLE.
TO SOLVE PROBLEMS, PACKING GLAND POSITION WAS REVERSED (INSTALLED UPSIDE DOWN). THE FAN WAS SANDBLASTED, THE PIPING MODIFIED TO
ELIMINATE STAGNANT POCKETS, AND PUMPS WERE FLUSHED IMMEDIATELY AFTER REMOVAL FROM SERVICE.
MORE RECENT PROBLEMS EXPERIENCED WITH THE UNIT ON CHOLLA 1 INCLUDE SIGNIFICANT CORROSION ATTACK IN THE VESSEL WALLS OF THE FLOODED
DISC PARTICULATE SCRUBBER OR MODULE. ACID CORROSION IN THE REHEATER HOUSING OF MODULE B IS ATTRIBUTED TO THE LACK OF PACKING OR CIRCULATION
IN THAT MODULE.
37
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RELIABILITY (X)
Month
Jan.
Feb.
Mar.
Apr.
May.
Jun.
Jul.
Aug.
Sept.
Oct.
Nov.
Dec.
Jan.
Feb.
Mar.
Apr.
May
Jun.
Module A
74
74
74
74
74
74
74
74
74
74
74
74
75
75
75
75
75
75
July. 75 •
Aug.
75
97
100
100
66
98
100
97
97
95
83
100 '
100
98
96
88
48
100
97
95
Module B
90
94
66
57
99
100
92
97
99
68
98;
100'
99
99
65
40
100
98
100
FGD SYSTEM RELIABILITY
CHOLLA UNIT NO. 1
COMMENTS
Annual boiler and FGD System overhaul,
Modules were both off-line for most of month for scheduled repairs and cleaning.
Substantial plugging of packing and mist eliminators was observed.
No problems reported.
Modules were shutdown to clean flow restrictions In flooded disc reclrculation lines.
Module A was down for Inspection one time.
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38
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FGD SYSTEM "RELIABILITY
CHOLLA UNIT NO. 1 (continued)
RELIABILITY (X)
Month Module A Module B COMMENTS
Sep> 75 98 97 Minor outage due to flooded disc, lines.
Qct „ 84 55 outages resulted from scheduled equipment overhauls and recoatlng of vessels.
Nov. 75 100 80 No major outages or problems occurred during the report period. Minor problems
Dec ?5 100 100 encountered during the month of December Included the rebuilding of a recycle
pump and malfunctioning of the B-s1de reheater coil.
Jan 76 „ 99 Module A operated 715 hours during the report month and Module B operated 654 hours. Module
A experienced some minor valve and line plugging problems. Module B operating hours were lower
due to system requirements.
*Note: The reliability factors displayed for Modules A and B are determined by computing
the ratio of the number of hours the module operated to the number of hours the system
was called upon to operate.
PEDCo-ENVIRONMENTAL
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PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATEK MAKE UP
SLUUGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
27
COMMONWEALTH EDISON
WILL COUNTY NO 1
ROMEOVILLE ILLINOIS
167 MW
COAL - 9*63 8TU, 2.IX SULFUR
OABCOCK ft WILCOX
LIMESTONE SCRUBBING
RETROFIT
2/72
OPERATIONAL
96 PERCENT
82 PERCENT
106 GAL/LB MOLE S02 REMOVED
STABILIZED SLUUGE DISPOSED IN CLAY LINED POND
S96/KW CAP. W/NO SLUDGE TREAT.fa.9 M1LLS/KWH AT 6bK BLR. CAP.
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTLM HAS BEEN OPERATIONAL SINCE FEB. 1972. MODULES A AND B WERE IN
SERVICE A TOTAL OF 3213 AND 2580 HRS. RESPECTIVELY DURING 1975, THUS AT-
TAINING ANNUAL AVERAGE OPERABILITIES OF 52 AND -»2 PERCENT RESPECTIVELY.
UNIT NO.l CAME DOWN FOR A BOILER, TURBINE AND AERATOR OVERHAUL IN MID-
OCTOBER 1975. RESULTING IN AN OUTAGE THAT LASTED FOR MORE THAN * MONTHS.
SYSTEM RESTART IS CURRENTLY SCHEDULED FOR MID-MARCH 1976.
40
PEDCo.-ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
THE WILL COUNTY POWER STATION
IN 1970, COMMONWEALTH EDISON CONTRACTED WITH BECHTEL CORPORATION TO INVESTIGATE THE SULFUR REMOVAL SYSTEMS THEN
AVAILABLE HAVING A SUFFICIENT DEGREE OF DEVELOPMENT TO WARRANT A LARGE SCALE INSTALLATION ON WILL COUNTY STATION'S UNIT #1.
AFTER DECIDING UPON A WET SCRUBBER SYSTEM USING LIME OR LIMESTONE. A SPECIFICATION WAS THEN PREPARED BY BECHTEL AND
RELEASED FOR BID. FROM THE NINE BIDDERS THAT WERE SOLICITED, SEVEN PROPOSALS WERE RECEIVED. AFTER DETAILED STUDY AND
BID EVALUATION WITH SPECIAL CONSIDERATION OF THE PROJECT SCHEDULE, BABCOCK AND WILCOX WAS GIVEN AUTHORIZATION, IN SEPTEMBER
1970, TO BEGIN THE DETAILED ENGINEERING FOR A LIMESTONE SLURRY SYSTEM. THE PROJECT HAD A COMPLETION DEADLINE OF DECEMBER
31, 1971 WHICH WAS ESTABLISHED BY THE ILLINOIS COMMERCE COMMISSION AS PART OF A RATE CASE.
THE BABCOCK AND WILCOX DESIGNED PROCESS WAS GUARANTEED TO REMOVE 98% OF THE FLY ASH AND 76* OF THE SULFUR DIOXIDE. THESE
EFFICIENCIES WERE BASED ON A DUST INLET LOADING OF 1.355 GRAINS PER STANDARD CUBIC FOOT AT 70°F AND BURNING 4% SULFUR ILLINOIS
COAL.
THE WILL COUNTY POWER STATION IS LOCATED NEAR ROMEOVILLE, ILLINOIS. THE PLANT HAS FOUR ELECTRIC POWER GENERATING UNITS
WITH A TOTAL RATED CAPACITY OF 1147 MW. ONLY UNIT #1 IS RETROFITTED WITH AN FGD SYSTEM.
UNIT #1 IS A WET BOTTOM COAL-FIRED BOILER AND PRODUCES 167 MW OF ELECTRICITY. THE BOILER WAS MANUFACTURED BY BABCOCK
AND WILCOX AND WAS INSTALLED IN 1955. THE PLANT NOW BURNS WESTERN COAL. THE GROSS HEATING VALUE OF THE COAL IS ABOUT 9500
BTU/LB. ITS AVERAGE SULFUR AND ASH CONTENTS ARE 1.3 PERCENT AND 10 PERCENT RESPECTIVELY.
THE WET LIMESTONE FLUE GAS DESULFURIZATION SYSTEM AT WILL COUNTY WAS PLACED IN SERVICE ON FEBRUARY 23, 1972. THE SYSTEM
CONSISTS OF TWO FGD MODULES (IDENTIFIED AS A AND B). LIMESTONE HANDLING AND MILLING FACILITIES AND SLUDGE TREATMENT AND
STABILIZATION UNIT. S02 REMOVAL EFFICIENCY IS REPORTED TO BE 82 PERCENT. SHORTLY AFTER STARTUP AND DURING THE INITIAL
DEBUGGING STAGE, NUMEROUS PROBLEMS WERE ENCOUNTERED. THIS PROMPTED COMMONWEALTH EDISON TO SHUT DOWN MODULE B IN MAY 1973 AND
TO CONCENTRATE ON SOLVING THE PROBLEMS OF MODULE A. MODULE B WAS NOT RESTARTED UNTIL MAY 1975.
PEDCo-ENVlKONMumL
41
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WILL COUNTY (continued)
THE LIMESTONE GRINDING FACILITIES CONSISTS OF TWO WET BALL MILLS. EACH RATED AT 12 TONS PER HOUR OF LIMESTONE. THE
LIMESTONE IS 97.5 PERCENT CALCIUM CARBONATE, AND CONTAINS 0.99 PERCENT MAGNESIUM CARBONATE AND 0.48 PERCENT SILICA. IT IS
RECEIVED IN COARSE GROUND FORM (ABOUT 1/2 INCH OR LESS) AND IS FINELY GROUND TO 95 PERCENT THROUGH 320 MESH.
THE SLUDGE FROM THE SYSTEM IS SENT TO A CLARIFIER. THE 'OVERFLOW IS RETURNED TO THE PROCESS WHILE THE UNDERFLOW IS
STABILIZED BY MIXING IT WITH LIME AND FLY ASH. ABOUT 200 LBS OF LIME AND 400 LBS OF FLY ASH ARE USED PER TON OF DRY SOLIDS
OF SLUDGE. THE FIXED SLUDGE IS TRANSPORTED BY CONCRETE MIXING TRUCKS TO A SMALL POND ON SITE FOR SOLIDIFICATION. THE
STABILIZED SLUDGE USUALLY SOLIDIFIES IN ABOUT ONE WEEK AFTER WHICH IT IS HELD ON-SITE.
PROBLEMS AND SOLUTIONS
1972 - DEMISTER PLUGGING WAS A CONSTANT PROBLEM, MAINLY BECAUSE OF HEAVY LIMESTONE ACCUMULATIONS ON THE BOTTOM OF THE
DEMISTER AND PARTLY DUE TO LOW WASH WATER PRESSURE CAUSED BY LEAKS IN THE POND RETURN BYPASS. THESE PROBLEMS KEPT MODULES A
AND B OUT OF SERVICE FOR SEVERAL DAYS EACH MONTH DURING MARCH, APRIL, JUNE AND JULY 1972. THE MODULES WERE ALSO OUT OF
SERVICE FROM SEPTEMBER 26 TO NOVEMBER 21, 1972, DUE TO THE BOILER BEING DOWN DURING THAT PERIOD.
IN ORDER TO SOLVE THE DEMISTER PROBLEM, THE SCRUBBERS' SLURRY NOZZLES WERE LOWERED AND THE SLURRY CIRCULATION SYSTEM WAS
LEFT OUT OF SERVICE TO KEEP THE DEMISTER CLEAN. SINCE THIS DID NOT IMPROVE THE SITUATION, THE DEMISTER ELEMENTS WERE HAND
WASHED. THIS SOLVED THE PROBLEM PARTIALLY, BUT ALSO INCREASED THE VENTURI NOZZLE PROBLEM BECAUSE THE BROKEN ELEMENTS FROM
THE DEMISTER GOT INTO THE SLURRY SYSTEM.
DURING HIGH GAS FLOW RATES. THE REHEATER OF MODULE B VIBRATED EXCESSIVELY. THEREFORE, MODULE B WAS TAKEN OUT OF SERVICE
IN APRIL TO CARRY OUT REHEATER MODIFICATIONS. THESE MODIFICATIONS INCLUDED REBRACING OF THE REHEATER TUBES AND THE INSTALLATION
OF A BAFFLE PLATE TO REDUCE THE VIBRATIONS.
OTHER REASONS FOR THE'MODULES' OUTAGES WERE, "EROSION AND PLUGGING OF SPRAY NOZZLES, INTERNAL AND EXTERNAL BUILD UP OF
DEPOSITS ON VENTURI NOZZLES, CORROSION, SULFITE BLINDING PROBLEMS AND FAN'S VIBRATIONS.
1973 - DEMISTER PLUGGING CONTINUED TO BE A PROBLEM. FURTHERMORE, THE DEMISTER ON MODULE B BROKE LOOSE FROM ITS MOUNTINGS
AND THE RESULTANT CARRYOVER WASH WATER PLUGGED THE REHEATER. THIS REHEATER ALSO EXPERIENCED LEAKS DUE TO CHLORIDE PITTING
CORROSION. MODULE A WAS DOWN FROM APRIL 24 TO MAY 24. 1973. AND MODULE B WAS DOWN FROM APRIL TO DATE. THERE WAS NO SCRUBBER
PEDCo-ENVIRONMENTAL
42
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MILL COUNTY (continued)
OPERATION DURING AUGUST 27 TO SEPTEMBER 26. 1973.
IN ORDER TO SOLVE THE OUTSTANDING DEMISTER AND REHEATER PROBLEMS, A CONSTANT UNDERSPRAY AND AN INTERMITTENT OVERSPRAY
WERE USED TO WASH ALL THE DEMISTER COMPARTMENTS OF MODULE A. EXTRA NOZZLES WERE ADDED AND A CLEAN WATER SUPPLY WAS MAINTAINED.
THE REHEATER UNIT HAS ALSO RETUBED.
1974 - ONLY MODULE A OPERATED DURING THE YEAR. PROBLEMS WERE MAINLY FREEZE UP TO VENTURI THROAT DRIVE MECHANISM, TANK
SCREEN BLINDING, DUCT CORROSION AND VIBRATIONS. LOSS OF BUILDING HEAT CAUSED EXTENSIVE DAMAGE AND KEPT THE SYSTEM DOWN FOR
THE ENTIRE MONTH OF JANUARY 1974.
1975 - ENTERING 1975 A-MODULE WAS OPERATIONAL AND B-MODULE WAS STILL UNDERGOING MODIFICATION. DURING THE FIRST QUARTER
OF 1975 THERE WERE 8 A-MODULE OUTAGES, WITH ONLY ONE BEING A FORCED OUTAGE DUE TO THE SPLITTING OF A SLURRY VENTURI SUPPLY
HOSE. B-MODULE WAS RETURNED TO SERVICE ON MAY 20, 1975. THE UTILITY DECIDED TO OPERATE THE SCRUBBER ON ILLINOIS HIGH SULFUR
COAL. UPON INCEPTION OF THIS PROGRAM A MULTITUDE OF PROBLEMS OCCURRED. THESE OCCURRED IN THE FORM OF LOWER PARTICULATE
REMOVAL EFFICIENCIES, HIGH SLURRY CARRYOVERS, DEMISTER PLUGGING, REHEATER COIL FOULING AND LEAKS. MODULE A WAS TAKEN OUT OF
SERVICE IN MID-JUNE FOR THE REMAINDER OF 1975. BY MID-SEPTEMBER 1975 B-MODULE WAS TAKEN OUT OF SERVICE DUE TO MASSIVE SCALING
IN THE ABSORBER SYSTEM. 'FINALLY. UNIT #1 CAME DOKN FOR A BOILER, TURBINE AND SCRUBBER OVERHAUL IN MID-OCTOBER FOR AN OUTAGE
THAT LASTED MORE THAN 4 MONTHS.
THE OPERA8ILITY FACTORS FOR EACH MODULE AND THE CORRESPONDING COMMENTS FOR THE REPORT PERIOD ARE PRESENTED IN THE
FOLLOWING TABLE.
PtDCo-ENVIKONMENUL
43
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FGD SYSTEM AVAILABILITY
WILL COUNTY UNIT NO. 1
PERIOD OPERABILITY (X)
Month/Year Nodule A Module B
Mar. 72 0
35
Apr. 72
34
14
May. 72
70
32
Jun. 72
31
July. 72
79
21
COMMENTS
Module A down for repair and modification to demister wash piping
assembly. During this period, Module B was taken out of service
every 2 or 3 days to hand wash the demister. Other problems,
vibration of reheater tubes bundle, rapid erosion of scrubber
spray nozzles, pluggage of venturi nozzles.
Module A out of service for 6 days due to a near repture of a
venturi pipe expansion joint. Heavy buildup of solids on demister.
Module B out of service most of the time for similar repair to
venturi pipe expansion joint, and_for modification to reheater unit
and demister wash system.
A few week outage of Module B to rebrace the reheater unit, tp_
Install underspray nozzles on demister and to use heavier screens
in the sump. Reheater pluggiNb caused additional outages. _ _
Both Modules were out of service due to high differential
_pressure across the demisters. Leakage of pond return bypass
valve caused demisters pluggiNti. Also during this period, repairs
were made to the rubber lining of scrubber A.
Plugging of venturi nozzles and demister paused Module A to be down
_fgr..2 days for repairs. Module B was put of service for 22 days to
PEDCo- ENVIRONMENTAL
-44- --
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WILL COUNTY UNIT NO. 1 (continued)
PERIOD OPERABILITY (X)
Month/Year Module A Module B
COMMENTS
Sept. 72
Oct. 7r
Nov. 72
Dec. 72
Jan. 73
Feb. 73
Mar. 73
22
0
22
65
30
30
0
24
11
Clean the demister and the reheater unit as well as to Install overhead
spray nozzles, and to replace sections of the demister. The boiler was
down for 2 days to repair the generator.
Boiler down Sept. 1-5 because of no demand. I.D. fan problem caused
unstable operation of the boiler most of the month. Module A was down
for modifications to reheater unit and repairs to reclrculatlon tank
screens.
Boiler and scrubbers were down. Outstanding modifications which were made
Included installation of reheater baffle plates to dampen vibrations and
Installations of an experimental demister wash system.
Boiler problems which caused unstable operation kept both modules down
during this month.
Modules operated intermittently due to electrostatic predpitator testing
and miscellaneous instrument problems.
Both Modules were down for repairs and modifications.
Modules were out of service due to cracks in the Inlet ductwork of the
booster fan. Improper installation of demister caused plugging of Module B
reheater unit.
Module A was out of service for 5 days due to demister plugging. Boiler
was down for 4 days of inspection. Module B was down due to leaks from
reheater tubes.
PEDCo-ENVIRONMENTAL
45
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MILL COUNTY UNIT NO. I (continued)
PERIOD OPERABILITY(X)
Month/Year Module A Module B
COMMENTS
Apr. 73
Hay. 73
Jun. 73
Jul. 73
Jul. 73
Sep. 73
Oct. 73
Nov. 73
Dec. 73
0
16
51
19
32
51
13
0
0
0
0
Persisting problems with demlster and deposits of calcium sulfate scale
on reheater tubes of Module A.
Both modules were out of service during this month.
Module B was kept down In order to concentrate on solving the problems
encountered In Module A. Boiler related problems were responsible for
most of the outages of Module A.
Module A problems: reheater tubes leaks and high fan vibrations.
More reheater tubes leaks on Module A attributed-to chloride corrosion
attack.
Modules were down. During this month, Chicago Fly Ash Co. finished
cleaning and treating the northeast half of the sludge pond.
Module A tripped several times this month due to bad limit switches
in the bypass and block dampers. Unit was also taken down to balance
the booster I.D. fan.
Routine inspection of Module A revealed some plugging. Module was kept
down for cleaning and some modification work. Poor gas distribution in
module suspected to contribute to demister problems.
Modules were down and the whole month was spent doing modifications
and maintenance, mostly to demlster, venturi throats, pumps and
Isolation valves.
PERCo- ENVIRONMENTAL
46
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_WILL COUNTY UNIT NO. 1 (continued)
PERIOD ..... OPERABILITV (*)
Month/Year Module A Module B
Jan. 74 0 0
Feb. 74
Mar. 74
21
Apr.... 74 72 0.
93
Jun. 74
55
96
COMMENTS
Modules were down due to freezing problem In the 10" 4400 ft. line
between modules and pond. Some damage to sump pumps occured. Freezing
weather also caused damage to some Instruments.
..The frozen pond pipe line was thawed, reanchored and returned to
service. The Instruments damaged by freezing were also repaired.
Module A kept down until arrival of second stage demlster. _
Module A was ready for service March 20 but was not returned to
service till March 27 because boiler was down.
Module A continued to operate until April 19 (except for two short
.Inspection outages) for 23 .consecutive days. Run was made on low
sulfur coal. Sump screens from Module B was substituted for damaged
one 1n Module A.
Module A operated for the whole month except.for_short outages for
Inspection. A good portion of this run was made with high sulfur coal.
Module A operated for about 300 hrs. The system was off for 2 wks.
.to repair venturl throat, drive.
Module A operated for the ihole month except for one Inspection outage
.and twice when boiler was down. Modu.le._B_1s_Jc_ept_dqwn__unt1l...satisfactory
_9P.er.ai.1 on.of_Hodu,le A 1s achieved.
PEDCo-ENVIRONMENTAL
47
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HILL COUNTY UNIT NO. 1 (continued)
PERIOD OPERABIUTY (X)
Month/Year Module A Module B
Aug. 74 91 0
COMMENTS
Sep. 74
Oct. 74
Nov. 74
Dec. 74
Jan. 75
Feb. 75
Mar. 75
85
94
97
99
99
99
99
Module A was'down six times this month, three times due to boiler "no
demand" outages, twice to repair leaks 1n steam piping and once to
balance a rough fan.
Module A was off three times this month: once to clean deposits
from the ventuM throat, once to fix a desuperheater leak, and once
because boiler was down.
Module A was down four times: once because of boiler outages, once
for Inspection and twice to fix reheater leaks.
Module A was out of service three times: twice because of no demand
and once for inspection.
Module A was down twice: once for Inspection and once for repair
of valve In spent liquor line to pond.
Module A was down twice: once for Inspection and once for no
demand. Modification of module B is continuing.
Module A was out of service twice this month, once for inspection and
once for no demand. One small reheater leak In a stainless steel bundle
was blanked-off on-line. During the inspection, demister underwash nozzles
were cleaned and a small section of demister was replaced. Inspection showed
conditions inside the scrubber to be about the same as before. Coal burned tht
month averaged less than 1% sulfur. Modifications of Module B is continuing.
Chicago Fly Ash 1s treating material from the scrubber with portland cement
and fly ash and dumping into the north half of the holding basin.
Module A was down four times: twice for no demand, once for a venturi
hose leak, once for an accidental 50-m1nute trip.
48
PEDCo-ENVIRQNMENT£L
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WILL COUNTY UNIT NO.1(continued)
PERIOD OPERABILITY («)
Month Module A Module B Comments
Apr. 75 40 0 Sludge pond was overburdened by near-continuous operation of Module A so that the
FGD system had to be shut down until sufficient water could evaporate from the pond.
The following modifications were made. Pump gland water flows were reduced from 10 to
5 gpm. Filter backwash was routed out of system. Continuous demlster underspray was
charged to Intermittent.
May. 75 84 37 The "A" Module remained out of service until May 5, when it was determined that there
was enough freeboard In the pond to start operating. During the month, there were two
more outages, one for 45 minutes, the result of a damper trip, the other to clean
underspray nozzles.
The "B" Module was In service 10:20 A.M., May 20, for the first time since noon, April
13, 1973. The start-up which was routine, was delayed until the 20th because of two
broken oil pumps on the recirc. tank mixers. Since the start-up, "B" has been out of
service twice, once for a venturl pump trip, and once for a recirc. tank level trip.
The total outage time was only 1 hour, 40 minutes.
Jun. 75 . '61 85 Module A sustained 5 outages during month. Module Is presently out of service to
install new demisters and to replace the reheater. Module B was out of service 8 times
during month. Longest outage was for 95 hours to clean booster fan and demlster. Booster
fan vibrations caused a shutdown on June 30.
jul. 75 o 79 Module A cannot be returned to service unMl the new reheater, ordered 1n April, Is
received and Installed. Module B sustained four outages. Reheater failures at 1000
hours seem to be a result of vibration fatigue. One minor steam header leak also occurred.
Aug. 75 0 100
PEDCo- ENVIRONMENTAL
49
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WILL COUNTY UNIT NO. 1 (continued)
OPERABILITY (%)
PERIOD
Month Module A Module B COMMENTS
Sep. 75 0 63 Module A remained out of service all month due to a delay on the new reheater order.
Module B was down 3 times during September due to massive absorber scale, demlster and 1.0.
booster fan cleaning, balancing I.D., booster fan and absorber pump screen plugging. Total
outage time was 238*40".
Oct. 75 0 100 On October 11, 1975, the Will County Unit No. 1 started its boiler, turbine and scrubber
overhaul. Module B experienced two minor outages during the 11 day period prior to the
overhaul. Module A was down during the entire period waiting for a new reheater.
Nov. 75 0 0 During the month of November the boiler, turbine, and scrubber modules were out of service for a
scheduled overhaul. Major maintenance areas included: module reheaters, pond return pump,
t
• venturi spray nozzles, venturl and absorber modules, pump valves, and sumps.
Dec. 75 0 0 Module B reheater returned from manufacturer after repairs and revisions. Scrubber reheaters could
be installed and operating by the end of January.
Jan- 76 The unit remained out of service during the report period for completion of the boiler, turbine,
Feb- 76 0 0 and scrubber overhaul which commenced on October 11, 1975. System restart Is now scheduled for
sometime In mid-March 1.976.
PEDCo- ENVIRONMENTAL
50
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 03/76
IDENTIFICATION NO. 30
UTILITY NAME OUflUESNE LIGHT
UNIT NAME ELRAMA
UNIT LOCATION ELKAKA PENNSYLVANIA
UNIT. RATING 510 MM
FUEL CHARACTERISTICS COAL 1.0 - 2.6 PERCENT SULFUR
FGD VENDOR CHEMICO
PROCESS LIME SCRUBBING
NEW OR RETROFIT RETROFIT
START UP DATE 10/75
FGD STATUS OPERATIONAL
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDUE DISPOSAL
UNIT COST
OPERATIONAL THE FGD SYSTEM WAS PLACED IN SERVICE ON OCTOBER 26. 1975. INITIAL
EXPERIENCE OPERATION PKOCEEUCD WITH FLUL GAS FKOM ONE BOILER BEING TREATED BY THE
SCRUBBING SYSTEM. A SECOND BOILER HAS TIED INTO THE SYSTEM ON FEBRUARY
-------
BACKGROUND INFORMATION
ON
ELRAMA POWER STATION
DUQUESNE LIGHT COMPANY, AN'INVESTOR-OWNED ELECTRIC UTILITY, SERVES ABOUT ONE-HALF MILLION CUSTOMERS IN SOUTHWESTERN
PENNSYLVANIA AND HAS A NET GENERATING CAPABILITY OF APPROXIMATELY 2500 MW. THIS CAPABILITY IS GENERATED BY COMBUSTION
TURBINES IN SIMPLE AND COMBINED CYCLE .MODES, BY NUCLEAR PLANTS, AND BY COAL FIRED POWER STATIONS. THE COMPANY IS SOLE
OWNER AND OPERATOR OF THREE COAL FIRED STATIONS. TWO OF WHICH HAVE BEEN RETROFITTED WITH WET SCRUBBERS USING LIME AS A
REAGENT.
THE SCRUBBER FACILITY AT THE 494 MW ELRAMA STATION IS ALMOST IDENTICAL TO THE PHILLIPS STATION. GIBBS & HILL IS THE
ARCHITECT-ENGINEER AND CHEMICO SCRUBBERS HAVE BEEN INSTALLED WITHIN THE SAME DESIGNATED BATTERY LIMITS. MECHANICAL AND
ELECTRICAL DUST REMOVAL EQUIPMENT REMOVE MOST PARTICULATES FROM THE BOILER EMISSIONS, AND THE GAS TO AND FROM THE SCRUBBERS
IS HEADERED IN THE SAME WAY. UNLIKE PHILLIPS, HOWEVER, THERE ARE FOUR BOILERS, EACH WITH ITS OWN TURBINE GENERATOR. FIVE SIN-
GLE STAGE SCRUBBERS WERE INSTALLED, WITH THE INTENTION THAT THE KNOWLEDGE GAINED FROM THE TEST PROGRAM AT PHILLIPS WOULD BE
APPLIED TO ELRAMA TO ENABLE COMPLIANCE WITH AIR EMISSION REGULATIONS.
THE FIRST ELRAMA SCRUBBED WAS NOT PLACED IN SERVICE UNTIL OCTOBER 26, 1975. IT HAD BEEN SCHEDULED FOR AN EARLIER
STARTUP DATE; HOWEVER, DUE TO THE SEVERITY AND NUMBER OF PROBLEMS ENCOUNTERED AT PHILLIPS, IT WAS NECESSARY TO DELAY STARTUP
UNTIL MANY OF THE PROBLEMS AT PHILLIPS WERE RESOLVED AND THE MODIFICATIONS COULD BE INCORPORATED AT BOTH STATIONS.
BOILER NO. 2 WAS INITIALLY CONNECTED TO THE SCRUBBING SYSTEM ON OCTOBER 26, 1975. THIS BOILER HAS AN EQUIVALENT CAPACITY
OF APPROXIMATELY 100 MW, AND THE EMISSIONS ARE HANDLED BY ONE SCRUBBER. IN ORDER TO INSURE RELIABILITY IN THE CASE OF A
SCRUBBER MALFUNCTION, TWO SCRUBBERS ARE OPERATED AT PARTIAL LOAD TO PROTECT THE BOILER AND TURBINE GENERATOR AGAINST A TRIP-OFF.
THE BOILER OPERATED CONTINUOUSLY ON THE SCRUBBER SYSTEM THROUGH JANUARY 1976. TWO MINOR OUTAGES OCCURRED DURING THIS
PERIOD, ONE BEING CAUSED BY INOPERATIVE THROAT DAMPERS AND THE OTHER INVOLVED THE FAILURE OF A LIME FEEDER BELT.
TWO BOILERS ARE THE MAXIMUM NUMBER THAT CAN BE TIED INTO THE SCRUBBING SYSTEM, PENDING COMPLETION OF ADDITIONAL CONSTRUC-
TION. TO DATE THE UTILITY HAS ENCOUNTERED THE USUAL NUMBER OF MINOR START UP PROBLEMS AND SOME MAJOR PROBLEMS AS WELL.
PEDCo-ENVIRONMENTAL
52
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ELRAMA POWER STATION (continued)
THE MAJOR PROBLEMS HAVE BEEN FROZEN PIPES AND THICKENER PROBLEMS. THE LATTER IS A HARDWARE AND DESIGN PROBLEM ASSOCIATED WITH
RECIRCULATION OF THE SLUDGE WITHIN THE THICKENERS TO ATTAIN 30-40 PERCENT SOLIDS CONCENTRATION.
THE SLUDGE BEING GENERATED AT THIS STATION IS TREATED BY THE IUCS METHOD, WHICH EMPLOYS A VACUUM FILTER, THUS IN-
CREASING THE SOLIDS IN THE UNDERFLOW TO 50 TO 60 PERCENT, THEREFORE REQUIRING LESSER AMOUNTS OF DRY FLY ASH TO BE MIXED
WITH THE SLUDGE.
53
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Elrama Power Station
Period
Oct. 75
To
Jan. 76
Feb. 76
Operating Hours
Boiler Scrubber Vessels
12 1- 2 3 4
1169 1508 976 838
Remarks
One boiler was connected to the scrubber system on October 26,
1975. A second boiler was connected on February 4, 1976. Four of
the scrubber vessels have been In service In various combinations,
the service hours to January 31, 1974 are posted 1n the ac-
companying table. The fifth vessel has not been 1n service
because it 1s being revised for the trial Installation of rubber-
lined recycle pumps.
PEDCo-ENVlKONtotNTAL
54
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TABLE 3
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY MAME
UNIT NAME
UNIT LOCATION
UNIT RATING
31
DUUUESNE LIGHT
PHILLIPS
SOUTH HEIGHT PENNSYLVANIA
mo MU
FUEL CHARACTERISTICS COAL i.O- 2.8 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICIPATES
CHEMICO
LIME SCRUBBING
RETKOFIT
7/73
OPERATIONAL
SOS
60 PERCENT
UATCK MAKE UP
SLUDGE DISPOSAL
STABILIZED SLUDGE DISPOSED IN UNLINEO POND
UNIT COST
OPERATIONAL
EXPERIENCE
S6<4/KW CAPITAL * b.8 MIULS/KWH ANNUALIZEU
KLFEH TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTLM HAS BEEN OPERATIONAL SINCE JULY 1973. THE UTILITY HAS RECENTLY
TEKMIHATED A TWO AND A HALF MO*TH TEST PKOGKAf. EMPLOYING THIOSORBIC LlHE
IN THE SINGLE STAGE SCRUBBING MODULES. 1812 OPERATING HOUKS WERE LOGGED
BY ONE SCRUBBING TRAIN AND 1309 HOURS WERE LOGGED BY ..MOTHER TRAIN. RE-
SULTS INDICATE THAT THE REQUIRED DEGREE OF S02 REMOVAL (63 PERCENT) CAN
BE OBTAINED WITH SINGE STAGE SCRUBBING, EMPLOYING LIME WITH A NGO CON-
TENT OF 6 TO 10 PERCENT.
55
PEOCo- ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
PHILLIPS POWER STATION
THE PHILLIPS POWER STATION IS LOCATED ON THE OHIO RIVER ABOUT 20 MILES NORTHWEST OF PITTSBURGH. THE POWER STATION
CONSISTS OF SIX COAL-FIRED BOILERS HAVING A NET GENERATING CAPABILITY OF 307 MW. THE RESULTANT FLUE GASES ARE DISCHARGED TO
A COMMON HEADER, TO WHICH THE FGD MODULES ARE CONNECTED THROUGH ISOLATION VALVES. THE BOILERS ARE CURRENTLY BURNING COAL
WITH A HEATING VALUE OF 11,350 BTU PER POUND AND A SULFUR AND ASH CONTENT OF 2.2 AND 18.2 PERCENT RESPECTIVELY.
THE FGD SYSTEM WHICH SUPPLEMENTS THE EXISTING MECHANICAL AND ELECTROSTATIC DUST COLLECTORS, CONSISTS OF FOUR TRAINS OF
WET VENTURI-TYPE SCRUBBERS WHICH HAVE BEEN INSTALLED AT A COST OF APPROXIMATELY $103/kW. GIBBS & HILL, INC., WAS ENGAGED
AS THE A-E FIRM FOR THE ENTIRE PROJECT WITH THE BATTERY LIMITS OF THE CHEMICO CORPORATION CONFINED TO THE SCRUBBERS AND
ASSOCIATED PUMPS AND CONTROLS BETWEEN THE INLET HOT GAS DUCT MANIFOLD AND THE EXIT WET GAS HEADER (INCLUDING THE REHEATER,
EXCLUDING THE NEW ID FANS).
THE FOUR TRAINS ARE LOCATED DOWNSTREAM OF EXISTING IN SERIES MECHANICAL COLLECTORS AND ESP'S INSTALLED ON EACH OF THE
SIX PULVERIZED COAL-FIRED BOILERS. THREE OF THE TRAINS ARE SINGLE STAGE VENTURI SCRUBBERS ORIGINALLY INTENDED FOR PARTICULATE
REMOVAL. THE FOURTH TRAIN IS A DUAL STAGE VENTURI SCRUBBER-ABSORBER AND IS THE PROTOTYPE FOR DETERMINING THE FEASIBILITY OF
TWO STAGE SCRUBBING FOR COMPLIANCE WITH S02 EMISSION LIMITS.
EACH TRAIN IS EQUIPPED WITH A NEW WET-TYPE ID FAN. A NEW COMMON DUCT DIRECTS EMISSIONS FROM AIR BOILERS TO THE SCRUBBER
SYSTEM WHERE THEY CAN BE SENT TO ANY OR ALL OF THE TRAINS. THE SCRUBBED GAS IS EXHAUSTED THROUGH A COMMON DUCT AND AN OIL-FIRED
REHEATER TO A NEW GROUND SUPPORTED STACK WHICH CONTAINS AN INNER ACID-RESISTANT BRICK STACK. •
SLAKED QUICKLIME IS ADDED TO THE LOWER CONE OF EACH OF THE SCRUBBER VESSELS TO NEUTRALIZE THE RECIRCULATING LIQUOR, WHICH.
IN SINGLE-STAGE SCRUBBING WITH HIGH CALCIUM LIME, REACTS WITH APPROXIMATELY 50 PERCENT OF THE S02 IN THE FLUE GAS. A LIQUOR
BLEED FLOW OF APPROXIMATELY 4 PERCENT IS SENT TO ONE OR BOTH OF THE THICKENERS FOR SOLIDS REMOVAL. THE OVERFLOW IS RETURNED
TO THE SYSTEM AND THE UNDERFLOW IS PIPED TO THE SLUDGE TREATMENT SYSTEM. THE UNDERFLOW IS STABILIED BY THE ADDITION OF 200
POUNDS OF CALCILOX PER TON OF DRY SOLIDS IN THE SLUDGE. THE FIXED SLUDGE IS TRANSPORTED TO EXPERIMENTAL PLASTIC LINED PONDS
PEDCo-ENVIRONNltrtfAL
56
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PHILLIPS POWER STATION (continued)
LOCATED ABOUT ONE MILE FROM THE STATION, WHERE THE MATERIAL SOLIDIFIES.
THE FLUE GASES FROM THE BOILERS ARE ACCELERATED TO A HIGH VELOCITY IN THE SCRUBBER. AT THE THROAT. THE GASES COLLIDE
WITH THE SCRUBBING LIQUID ATOMIZING IT INTO SMALL DROPLETS. THE FLY ASH AND THE SULFUR DIOXIDE IN THE GAS ARE PICKED
UP BY THE SLURRY DROPLETS AND EXIT AT THE BASE OF THE TOWER. THE GAS THEN REVERSES DIRECTION AND FLOWS UP THOUGH THE MIST
ELIMINATOR WHERE FINE DROPLETS ARE REMOVED BEFORE THE GAS LEAVES THE SCRUBBER.
STARTUP OF A PORTION OF THE PHILLIPS SCRUBBER SYSTEM BEGAN JULY, 1973. SEVERAL PROBLEMS THEN DEVELOPED IN THE FORM
OF EROSION PROBLEMS TO THE FANS AND THE LIME FEED SYSTEM, CAUSING OUTAGES OF THE SCRUBBER SYSTEM, AND AFTER AN EXTENDED
OUTAGE, THE SCRUBBER SYSTEM WAS RETURNED TO SERVICE IN MARCH. 1974. THE SYSTEM HAS BEEN OPERATING CONTINUOUSLY SINCE THAT
TIME WITH A VARYING NUMBER OF BOILERS CONNECTED TO THE SCRUBBER SYSTEM, AND -WITH A VARYING'NUMBER OF SCRUBBER TRAINS IN
SERVICE.
DETERMINATION OF THE AVAILABILITY OF THE PHILLIPS SCRUBBER HAS BEEN A DIFFICULT AFFAIR DUE TO THE NATURE OF THE
SCRUBBER SYSTEM DESIGN. UNTIL ALL BOILERS WERE CONNECTED TO THE SCRUBBERS, THERE WAS AT LEAST ONE SPARE TRAIN AND AS
MUCH AS 100X SPARE SCRUBBER CAPACITY. THEREFORE, HAVING A TRAIN OUT OF SERVICE FOR MAINTENANCE DID NOT REDUCE THE
CAPABILITY OF THE SCRUBBER PLANT. UNTIL ALL SIX BOILERS WERE CONNECTED, MEANINGFUL AVAILABILITY FACTORS WERE NOT AVAILABLE.
ON MARCH 17, 1975, THE LAST BOILER WAS CONNECTED. AND ALL FOUR SCRUBBER TRAINS WERE REQUIRED TO BE IN SERVICE. OPERATION
IN THAT MODE CONTINUED UNTIL AUGUST 4, 1975 WHEN IT WAS NECESSARY TO REMOVE THE NO. 6 BOILER FROM THE SCRUBBER SYSTEM
BECAUSE THE pH IN THE SYSTEM COULD NOT BE MAINTAINED AND DEPOSITS WERE BECOMING UNMANAGEABLE TO THE POINT WHERE SCRUBBER
OUTAGES WERE REDUCING THE STATION GENERATING CAPABILITY.
PEDCO-ENVIRONMENTAL
57
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Phillips Power Station
Month
Jul. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Jan. 76
Boiler
234
Operating Hours
5 6
Scrubber-Absorber
1A IB 2 3 4
83 644 703 349 605 643 400
180 537 723
Aug. 75 354 701 454 457 517 445 478 0 682 323 319
Remarks
Fourth FGD train and sixth boiler were tied in on March 17, 1975.
Particulate tests In May showed outlet loadings of 0.04 lb/
million Btu.
The two-stage train has been out of service from June 19 for
general cleaning and to repair a leak in the first-stage scrubber.
Scrubber unavailability has forced returning Boiler No. 6 to the
scrubber bypass gas path in order not to lose boiler capacity.
Plugging and maintenance problems have been encountered in
scrubbers. An evaluation of various recycle pumps 1s continuing.
As of October, 1975, Phillips initiated thiosorblc lime scrubbing in their
single stage modules on an experimental basis. The purpose of this pro-
gram is to study compliance feasibility, S02 removal efficiency, and the
quality of the sludge generated by the single stage modules.
The utility concluded the thiosorblc line testing program which commenced
October 1, and terminated in mid-December. A total of four boilers were
coupled to the scrubbing system during the run. The utility is now in the
progress of analyzing the data generated during the test run. The scrubbers
have been put back on regular lime. No unusual problems were encountered
during the test run.
The two and a half month test program with thlosorbic lime resulted
1n 1612 service hours on one train and 1309 hours on another train.
Results indicate that the required degree of SO- removal (83 per-
cent) can be obtained with an MgO content of 8-10 percent in the
lime with single stage scrubbing.
PEOCo-ENVIRONMENTAL
58
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TABLE 3
PERFORMANCE DESCRIPTION FUK OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
32
GENERAL MOTORS
CHEVROLET PARMA 1 2 3 &
PARMA OHIO
32 MU
FUEL CHARACTERISTICS COAL 2.5 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
KOCH
DOUBLE ALKALI
RETROFIT
3/7H
OPERATIONAL
OPERATIONAL
EXPERIENCE
REFEK TO UACKGROuND-INFORMATION SECTION IN TABLE. 3 OF THIS REPORT. THIS
F&O SYSTEM HAS BELN OPERATIONAL SINCE MARCH 1974. SYSTEM OPERAB1LITY HAS
AVERAGED OVER b9 PERCENT DURING THE PAST f> MONTHS. SYSTEM OPERAB1LITY WAS
-------
BACKGROUND INFORMATION
ON
THE CHEVROLET PARMA STEAM PLANT
THE CHEVROLET PARMA PLANT OF GENERAL MOTORS IS LOCATED NEAR CLEVELAND, OHIO. THE PLANT HAS FOUR SPREADER
STOKER BOILERS FIRED BY TRAVELING GRATES AND PRODUCES A TOTAL RATED CAPACITY OF 32 MW. THE BOILERS ARE RETROFITTED
WITH A SOLUBLE ALKALI FGD SYSTEM. THE COAL BEING BURNED AT THE PLANT CONTAINS ABOUT 2.5 PERCENT OF SULFUR.
THE FGD SYSTEM WHOSE SIZE IS 32 MW, WAS DESIGNED BY KOCH ENGINEERING AND WAS COMPLETELY INSTALLED ON FEBRUARY
28, 1974. THE SYSTEM CONSISTS OF FOUR SCRUBBERS OPERATING IN PARALLEL. EACH SCRUBBER IS MADE OF THREE ABSORPTION
TRAYS AND A MESH MIST ELIMINATOR. CONSTRUCTED OF ALL ELEMENTS ARE OF NO. 316L STAINLESS STEEL.
SODA ASH, THE PRIMARY REACTANT OF THE SYSTEM, IS MIXED WITH THE OVERFLOW FROM THE REACTOR CLARIFIER AND PUMPED
TO THE SCRUBBER SYSTEM. CAUSTIC. SOLUTION IS REGENERATED BY ADDING LIME SLURRY TO A PORTION OF THE ABOVE LIQUID
AFTER NEUTRALIZING IT WITH CaC03- THIS REGENERATED CAUSTIC SOLUTION ENTERS THE REACTOR CLARIFIER WHERE ADDITION
REACTION TAKES PLACE AND THE CALCIUM SULFITE AND OTHER SOLIDS ARE PRECIPITATED.
THE SOLIDS FROM THE CLARIFIER CONTAINING 20 PERCENT SOLIDS ARE PUMPED THROUGH A BLEND TANK TO A 500 SQUARE
FOOT ROTARY DRUM FILTER. THE FILTER CAKE IS DEWATERED TO 50 PERCENT SOLIDS.
!
PROBLEMS AND SOLUTIONS :
THE INSTALLATION WAS STARTED UP ON FEBRUARY 28, 1974 AND BY APRIL 31, 1974, IT OPERATED FOR 624 HOURS. THERE
WERE TWO SCHEDULED SHUTDOWNS DURING THIS PERIOD FOR EQUIPMENT INSPECTION. THE SECOND SHUTDOWN REVEALED THAT SOLIDS
WERE NOT BEING DISCHARGED FROM THE PRIMARY CLARIFIER RAPIDLY ENOUGH. AS A RESULT, THE CLARIFIER RAKE JAMMED. A
PIPING CHANGE WAS MADE TO BLEND THE CAUSTIC FEED IN WITH THE RECYCLE LIQUOR. THIS HAS IMPROVED BUT NOT COMPLETELY
ELIMINATED THE PROBLEM. NO PROBLEMS HAVE BEEN ENCOUNTERED WITH THE MESH MIST ELIMINATORS. THE VACUUM FILTERS
CAUSED PROBLEMS DUE TO PREMATURE CAKE CRACKING NECESSITATING AN OPERATOR ON HAND DURING OPERATION. G.M. ANTICIPATES
THAT THE CHANGE TO NYLON FROM POLYPROPYLENE WILL SOLVE THIS PROBLEM.
PEDCo-ENVIRONMENTAL
60
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CHEVROLET PARMA (continued)
CAKE WASHING TO REDUCE SODIUM LOSSES MAS NOT INITIALLY SUCCESSFUL DUE TO THE TENDENCY OF THE SPRAY WATER TO
KNOCK THE CAKE OFF THE DRUM. ALTERATIONS IN SPRAY PATTERN AND OTHER MEASURES HAVE NOW APPARENTLY SOLVED THIS
PROBLEM.
THERE HAS BEEN NO EVIDENCE OF CORROSION OR ABRASION IN THE PUMPS OR PIPING.
THE SYSTEM WAS SHUTDOWN FROM MAY 1 TO MAY 28, 1974 DUE TO THE UNEXPECTED BUILD-UP OF SOLIDS IN THE CLARIFIER
WITH SUBSEQUENT OVERFLOW INTO THE SCRUBBER. THE PROBLEM WAS SOLVED BY 1) USING A POLYMERIC FLOCCULATION AGENT TO
ATTAIN BETTER SETTLING AND 2) WITHDRAWING SLUDGE FROM THE CLARIFIER AT MORE FREQUENT INTERVALS. THE SYSTEM
AVAILABILITY TO THE BOILER HAS BEEN 87 PERCENT IN APRIL 1974, LESS THAN 10 PERCENT IN MAY AND 100 PERCENT IN JUNE,
JULY AND AUGUST 1974, AFTER THE SYSTEM WAS RESTARTED. PLUGGING BY CaCO-j DEPOSITS IN THE OVERFLOW LINE BETWEEN THE
CLARIFIERS AND IN THE LINE FROM CLARIFIER #2 TO THE MIX TANKS HAS BEEN A PROBLEM THAT HAS BEEN CORRECTED BY RELOCATING
A CHEMICAL FEED LINE AND REPLACING SOME PIPING. THE SYSTEM WAS DOWN THROUGHOUT THE MONTHS OF JULY AND AUGUST TO
REPLACE GRAVITY FLOW LINES WITH AN OPEN FLUME THAT CAN BE EASILY CLEANED.
PEDCo-ENVIRONMENTAL
61
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Chevrolet Parma
Operating hours
Month
Jun. 75
FGD system
2 3
Qperab.nity (X)
Remarks
Recent operation has been Intermittent 1n
nature. Tests by manufacturing development
and Chevrolet central office to determine
boiler outlet participate loading parameters
have been conducted. System was restarted In
May but had to be shut down because of plugged
chemical feed line to clarlfler. System re-
started about June 10 and had to be shut down
because of similar plugging in another part of
the line. Unit ran for about two weeks In June.
Jul. 75
Aug. 75
Sep. 75
Oct. 75
2331*
00000000 Down for July to August for revisions to system.
00000000 Replacing gravity flow lines with an open flume.
Will restart In September.
FGD System restarted September 8, 1975, operated during
1848* 79 this period at an availability factor of 80 percent.
*Note: The figures given for September and October
represent the operation hours for the period of
September 8 to November 9. Inclusive.
PEDCo-ENVIRONMENTAL
62
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Chevrolet Parma (continued)
Operating hours
Month
Nov. 75
Dec. 75
2135
FGD System
2 3
1250
Availability (*)
23 4
59
Jan. 76
Feb. 76
2997
1196
40
Remarks
The FGD System operated during the report
period with the exception of a scheduled
holiday shutdown (extending from 12/23 to
1/4). The FGD System experienced some
problems with solids and solids carryover.
G.M. conducted stream tests during the
month of December in an effort to de-
termine if the solids carryover problem
is due to a high solids recirculation
rate. The FGD system was down most of
December because of these tests.
The low operability factor was not due to
system unavailability but to the continuation
of a study program concenred with high solids
and solids carryover. G.M. is examining the
settling of solids in the system clarifier as
a possible solution to the problem. To date
the company has found the solids concentra-
tion in the clarifier too high for efficient
system operation. A.D. Little is scheduled
to conduct tests on the system in April as
part of an EPA evaluation nf the
63
PEDCo-ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 03/76
IDENTIFICATION NO. 33
UTILITY NAME GULF POWER CO.
UNIT NAME SCHOLZ NO. 1A
UNIT LOCATION CHATTAHOOCHEE FLORIDA
UNIT RATING 20 MM
FUEL CHARACTERISTICS COAL 3.0 PERCENT SULFUR
FGO VENDOR ADL/COMBUSTION EQUIP ASSOCIATE
PROCESS DOUBLE ALKALI
NEW OK RETROFIT RETROFIT
START UP DATE 2/75
FGO STATUS OPERATIONAL
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL KEFEK TO BACKGROUND INFORMATION SECTION IN TAULE 3 OF THIS REPORT. THIS
EXPERIENCE FGO SYSTfc.M HAS BEEN OPERATIONAL SINCE FEB. 197&. THE PROTOTYPE SYSTEM
OPERATED A TOTAL OF <*7tt HRS. bURING 1975, TRANSLATING INTO AN ANNUAL
AVLKAGt OPERAB1LITY OF 89 PERCENT. THE SYSTEM WAS DOWN THROUGHOUT THE RE-
PORT PERIOD DUE TO A SCHEDULED PLANT BOILER OVERHAUL. SYSTEM RESTART IS
SCHEDULED FOR MID-MARCH 1976. THE SYSTEM IS SCHEDULED TO RUN THROUGH TO
JUNE 1976.
64 PEDCO-.ENVIROPENTAL
-------
BACKGROUND INFORMATION
ON
SCHOLZ NO. 1A - DOUBLE ALKALI
THE SCHOLZ STEAM POWER PLANT OF GULF POWER COMPANY IS LOCATED IN CHATTAHOOCHEE. FLORIDA. UNIT NO. 1 IS A COAL-FIRED
BOILER DESIGNED FOR NOMINAL LOAD OPERATIONS OF 40 MW AND PEAK CAPACITY OPERATION OF 47.5 MW. THIS UNIT WAS SCHEDULED TO BURN
VARIOUS TEST COALS WHICH HAVE AN AVERAGE HEATING VALUE OF 12,400 BTU/LB., 14 PERCENT ASH CONTENT AND SULFUR RANGING AS HIGH
AS 5 PERCENT.
A 20 MW PROTOTYPE DUAL ALKALI SYSTEM WAS JOINTLY DEVELOPED, DESIGNED AND INSTALLED BY COMBUSTION EQUIPMENT ASSOCIATES AND
ARTHUR D. LITTLE.
THE PROTOTYPE SYSTEM AT THE SCHOLZ STEAM PLANT IS INSTALLED ON BOILER NO. 1, A BABCOCK & WILCOX PULVERIZED COAL-FIRED
BOILER. THE SYSTEM IS DESIGNED TO HANDLE 50 PERCENT OF >HE FLUE GAS FROM THE BOILER. THE BOILER HAS BEEN RETROFITTED WITH
A SECTIONALIZED, HIGH EFFICIENCY ESP CAPABLE OF 99.7X PARTICULATE REMOVAL. THE ESP CAN BE SELECTIVELY DE-ENERGIZED FOR STUDY
OF PARTICULATE IMPACT ON THE FGD PROCESS OPERATION.
THE PROTOTYPE UNIT INCORPORATES A HIGH DEGREE OF FLEXIBILITY FOR THE MAIN PURPOSE OF GENERATING DESIGN AND OPERATING
INFORMATION FOR A WIDE VARIETY OF APPLICATIONS. ALTHOUGH THE BASIC MODE OF THE SYSTEM OPERATION IS DUAL ALKALI WITH LIME
REGENERATION THE SYSTEM WAS DESIGNED TO ACCOMODATE LIMESTONE REGENERATION AND LIME/LIMESTONE COMBINATION REGENERATION.
THE SYSTEM PROPER INCLUDES A VENTURI SCRUBBER AND AN ABSORPTION TOWER. AN ADDITIONAL STORAGE SILO FOR LIMESTONE, A MIX
TANK. AND OTHER ASSORTED TANKS, PUMPS, CONTROLLERS AND PIPING ARE ALSO INCLUDED IN THE SYSTEM.
THE PROTOTYPE SYSTEM WAS COMPLETED AND PUT IN OPERATION BY CEA/ADL IN EARLY FEBRUARY 1975. IN MID-MAY AN EPA DUAL
ALKALI TEST PROGRAM WAS INITIATED BY SOUTHERN SERVICES. CEA AND ADL. THE SYSTEM WAS OPERATIONAL THROUGH EARLY JANUARY 1976,
WHEN THE BOILER WAS SHUT DOWN FOR A SCHEDULED OVERHAUL. THE BOILER AND PROTOTYPE SYSTEM ARE SCHEDULED TO BE PLACED BACK
IN SERVICE EARLY MARCH 1976.
PEDCO-ENVIRONMENTAL
65
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Scholz 1A - Double Alkali
Ing hours FGD system
FGE
Boiler FGD sysTem OperabilUy (%) Comments
Unit was placed 1n operation Feb. 5, 1975, and operated
through to July 18, 1975, When the system was shutdown
'2,600 83 for a two-month period for modifications, repairs and
replacement parts. - The system was unavailable'to the
boiler for a 491 hour period because of necessary 'ao-
justments and modifications required for Initiation of
the formal EPA test program In mid-May.
Jul. 75 The system was shutdown from mid-July'to mid-September.
To Repairs and revisions effected were of a mechanical
Sep. 75 nature, Involving replacement parts for valves that had
failed.
Sep. 75 44 The system was put back in operation on September 'l6,
Oct. 75 100 1975. From mid-September to mid-October, repairs were
made to the air preheater and adjustments were made in the
boiler operation, reducing flue gas oxygen levels down to
5-6 percent range. The system operated approximately 800
hours during this period.
66
-------
Scholz 1A - Double Alkali (continued)
Operating hours FGD system
Period BolleF FGD system OperablHty (%) Comments
Nov. 75 620 560 90 The system ran continuously for the remainder of the test
Dec. 75 732 732 100 period through January 2, 1976. S02 levels during this
period were In the 800 to 1700 ppm range. The system
operated in the concentrated mode throughout the remainder
of the test period. Covering the period from mid-
September to January 2, 1976, the system operated a total
of approximately 2,100 hours, equaling an- operabtlIty
factor of 97 percent.
Jan. 76 The FGD system and boiler were inoperative during the
Feb. 76 report period due to a scheduled overhaul.
System restart is scheduled for mid-March 1976, with
operation continuing to June 1976. During this opera-
ting period high sulfur coal will be used at Scholz
(3.5-4.0 percent), enabling evaluation of system per-
formance on high sulfur coal application.
67
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT.RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
34
GULF POWER CO.
SCHOLZ NO. 2A
CHATTAHOOCHEE FLORIDA
20 MM
COAL 3.0 PERCENT SULFUR
FOSTER WHEELER
ACTIVATED CARBON
RETROFIT
2/76
OPERATIONAL
S02
60 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
REFER 10 BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. SYSTEM
MODIFICATIONS ANU PKE-STARTUP CHECKOUTS WERE COMPLETED. A SUCCESSFUL
THREE UAY DRY HUN FOLLOWED. REINTROOUCTION OF FLUE GAS INTO THE SYSTEM
COMMENCED IN FEBRUARY AND A FOUR MONTH TEST PROGRAM IS NOW IN PROGRESS.
DURING THIS TEST PROGRAM S02, NOX, AND FLYASH REMOVAL IERFORMANCEt SYSTEM
ECONOMICS AND SYSTEM RELIABILITY WILL BE ANALYZED.
68
PEDCo- ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
SCHOLZ NO. 2A - FWBF SYSTEM
IN JANUARY, 1973. THE SOUTHERN SERVICES COMPANY OF GULF POWER AWARDED A CONTRACT TO THE FOSTER WHEELER CORPORATION
TO BUILD A 20 MW PROTOTYPE DRY ADSORPTION SYSTEM FOR FLUE GAS DESULFURIZATION. CONSTRUCTION ON THE FOSTER WHEELER PROCESS
STARTED FEB. 15, 1974 AT THE SCHOLZ STEAM POWER PLANT LOCATED IN CHATTACHOOCHEE. FLA. CONSTRUCTION WAS COMPLETED AND A
TESTING PROGRAM WAS INITIATED IN MAY, 1975.
THE SYSTEM AT THE SCHOLZ PLANT CONSISTS OF A 20 MW ADSORBER SECTION AND A 47.5 MW REGENERATION AND REDUCTION SECTION.
THE 20 MW ADSORBER IS DESIGNED TO ACCEPT HALF OF THE MAXIMUM FLUE GAS FLOW FROM UNIT NO. 2. THE COAL FIRED BOILER IS RATED
AT 40 MW (NOMINAL) AND FIRES COAL WITH A HEATING VALUE OF 12,400 BTU/LB. ASH CONTENT IS 14Z, AND SULFUR CONTENT RANGES
AS HIGH AS 5%.
THE PROCESS CAN BE DIVIDED INTO THREE BASIC SECTIONS: ADSORPTION, REGENERATION AND REDUCTION.
THE PURPOSE OF THE ADSORPTION SECTION IS TO REMOVE SOg, AND NOX AND PARTICULATE MATTER ON THE FLUE GAS WITH ACTIVATED
CHAR, CONVERTING THE CAPTURED POLLUTANTS TO SULFURIC ACID. THE REGENERATION SECTION PROVIDES CONTINUOUS ON-SITE REGENERA-
TION OF THE CHAR WHICH HAS BEEN LOADED WITH S02 IN THE FORM OF H2S04- THE CHAR IS REGENERATED AND A LOW VOLUME SOg RICH
OFF-GAS STREAM IS FED FORWARD TO THE RESOX REACTOR WHICH REDUCES THE S02 STREAM TO GASEOUS ELEMENTAL SULFUR WHICH IS COLLECTED
AND STORED IN AN INSULATED TANK.
THE DEMONSTRATION UNIT HAS TWO ROWS OF MODULES, EACH ROW CONSISTING OF SIX MODULES. THE ADSORPTION SECTION IS A TWO STAGE
DESIGN CONSISTING OF VERTICAL COLUMNS OF PARALLEL LOUVER BEDS WHICH SUPPORT AND CONTAIN THE ACTIVATED CHARCOAL. SULFUR
DIOXIDE, OXYGEN. WATER VAPOR, AND THE OXIDES OF NITROGEN ARE ADSORBED BY THE CAR PELLETS FROM THE CROSS FLOWING FLUE GAS
AT 250 - 300° F. THE S02 THEN REACTS WITH 02 AND HgO FORMING H2S04 WHICH IS FIRMLY RETAINED IN THE INTERIOR PORE SYSTEM OF THE
CHAR PELLETS. THE CHAR IS THEN REGENERATED IN THE REGENERATOR VESSEL BY HEATING TO 1200°F. DRIVING OFF THE ENTRAINED GASES
AND REDUCING SULFURIC ACID TO SOg. THE SOg-RICH GAS IS THEN PASSED THROUGH A VESSEL CONTAINING CRUSHED COAL RESULTING IN
REDUCTION TO GASEOUS ELEMENTAL SULFUR AND CARBON DIOXIDE. THIS LATTER PROCESS IS CARRIED OUT AT 1200° - 1500°F.
PEDCO-ENVIRONMENTAL
69
-------
SCHOLZ NO. 2A - FUBF SYSTEM (continued)
THE UNIT'S INITIAL SHAKE DOWN RUN ON FLUE GAS BEGAN AUGUST 11. 1975 AND PROCEEDED ON A CONTINUOUS BASIS FOR TEN DAYS.
THE REGENERATION SECTION WAS OPERATIONAL ABOUT 60X OF THE TIME. HOWEVER, THE RESOX SECTION HAS NOT YET BEEN COUPLED INTO FULL
SYSTEM OPERATION. S02 REMOVAL WAS WELL ABOVE EXPECTATIONS AND PRESSURE DROP ACROSS THE ADSORBER WAS WELL BELOW DESIGN LEVELS.
THE SYSTEM WAS SHUTDOWN PENDING CORRECTION OF SEVERAL OPERATING PROBLEMS. EQUIPMENT MODIFICATIONS AND EVALUATION OF THE INITIAL
OPERATING DATA. OPERATION WAS RESUMED AGAIN IN OCTOBER 1975, WHEN TWO CONSECUTIVE OPERATIONAL RUNS WERE CONDUCTED ON THE
RESOX PORTION OF THE SYSTEM. PROCESSING FRONT-END OFF-GAS AT FULL OPERATING TEMPERATURES. A MODIFICATIONS PROGRAM WAS
COMPLETED ON THIS SYSTEM IN EARLY JANUARY L976. REPRODUCTION OF FLUE GAS INTO THE INTEGRATED SYSTEM COMMENCED IN FEBRUARY
1976. THE SYSTEM IS CURRENTLY OPERATING THROUGH A FOUR MONTH TEST PROGRAM SPONSORED BY SOUTHERN SERVICES AND FOSTER WHEELER.
PEDCo-ENVIRONMENTAL
70
-------
FWBF System Operating History
Comments
Initial construction of the system was completed and a t
three month commissioning period followed. Various pieces
of equipment In the system were operated individually
and then in combinations to simulate sub-system operation.
"9' Sub-system operations were integrated into section opera-
tions and flue gas was passed through the adsorber and
regenerator for a 10-day period beginning August 11.
RESOX construction was incomplete at this time.
Two consecutive operational runs were conducted on the
RESOX portion of the system on front-end process off-gas
at full operating temperatures. This operational period
lasted 5 days.
A modifications program on the system commenced in late
August 1975 and continued through January, with the
*"' ?6 exception of the 5 day RESOX operation in October.
Modifications were completed and pre-startup testing
program was conducted in late January and early February.
A three-day continuous dry run was successfully com-
pleted. All materials handling loops and RESOX loops
were operated at full operating temperatures and pres-
sures. Following this reintroduction of flue gas into
the system commenced and a four month formal test program
conducted by Southern Services and Foster Wheeler is now
in progress.
PEDCo-ENVIRONMENTAL
71
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
35
GULF POWER CO.
SCHULZ NOS. IB & 2B
CHATTAHOOCHEE FLORIDA
23 MW
COAL 3.0 PERCENT SULFUR
CHIYODA INTERNATIONAL
THOROUGHBRED 101
RETROFIT
3/75
OPERATIONAL
S02
90 PERCENT
WATER MAKE UP
SLUUGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
REFLR TO BACKGKOuND INFORMATION SECTION IN TABLE 3 OF REPORT. THIS FGD
SYSTllM HAS BEEN OPERATIONAL SINCE MARCH 1975. THE TOTAL SYSTEM OPERABILI.
TY. INCLUDING SYSTEM COMMISSIONING! EXTENDING FROM FEB. 11.1975. TO
DECEMBER 31. 197&. WAS 60 PERCENT. SYSTEM OPERABILITY FOR THE MONTH OF
JANUARY 1976 EXCEEDED 66 PERCENT. THE SYSTEM DID NOT OPERATE DURING THE
MONTH OF FEBRUARY.
72
PEDCo ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
SCHOLZ UNITS 1 AND 2 - CHIYODA
THE SCHOLZ POWER PLANT IS LOCATED IN CKATTAHOOCHEE, FLORIDA, ABOUT 50 MILES WEST OF TALLAHASSEE. THE FGD SYSTEM WAS
DESIGNED BY CHIYODA INTERNATIONAL CORP. FOR TESTING AND PROCESS DEMONSTRATION ON A COAL-FIRED BOILER. THE PORCESS IS IN USE
IN JAPAN. BUT ONLY ON OIL-FIRED AND GAS-FIRED BOILERS.
THE SYSTEM CAN HANDLE ONE-HALF THE LOAD (53.000 SCFM) FROM EITHER OF. TH1 47 MW BOILERS. DESIGN ABSORBER INLET SOg
CONCENTRATION IS 2250 PPM. VARIOUS TEST COALS WITH SULFUR CONTENTS RANGING UP TO 5 PERCENT ARE SCHEDULED FOR BURNING.
THE PARTICULATE LOADS FROM NEWLY INSTALLED ELECTROSTATIC PRECIPITATORS ON THE TWO UNITS RANGE FROM 0.02 TO 0.1
GR/SCF. FLUE GAS FROM THE PRECIPITATORS IS QUENCHED WITH COOLING WATER TO REMOVE ADDITIONAL FLY ASH AND TO COOL THE
GAS BEFORE IT ENTERS THE S02 ABSORBER.
S02 IS ABSORBED IN WATER AND CATALYTICALLY OXIDIZED WITH AIR TO FORM SULFURIC ACID. THE DILUTE ACID IS RECIRCULATED
THROUGH THE ABSORBER. A PORTION OF THE ACID IS NEUTRALIZED WITH LIMESTONE TO PRODUCE GYPSUM AS A BY-PRODUCT.
BREAK-IN TESTS WERE INITIATED IN FEBRUARY 1975. DURING THESE TESTS SEVERAL MINOR PROBLEMS WERE ENCOUNTERED. AFTER
THESE PROBLEMS WERE CORRECTEDiTHE SYSTEM WAS SUBJECTED TO A SIX MONTH RELIABILITY TEST PROGRAM.
PEDCo-ENVIRONMENTAL
73
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Schloz IB and 2B - Chlyoda
Operating hours FGD system
Month BoilerFGD system Operabilfty (%) Comments
This Is a pilot plant size demonstration unit. Engineering
design began sept. 73. Startup occurred In March 1975. After
Initial operation for break-In tests, unit will be shutdown
for Internal Inspection. Reliability tests will then followed.
starting June 1975. Chemical performance was satisfactory.
Emission terts have not been performed. Some pump and
Instrument failures have occurred.
Jun- 75 100 Unit has been out of service for minor repairs throughout
July 75 0 July.
Aug. 75
Sept. 75 45 Unit operated at a 95 percent S02 removal efficiency during
Oct. 75 100 this period. Gulf Power Is attempting to upgrade this value
to a higher efficiency level. Waste water discharge from
this unit still a problem area.
Nov. 75 100 Outage time was less than one hour during November operation
due to a broken flue gas blower inlet vane and repair of a
plnhole 1n the prescrubber FRP lining.
Dec- 75 98 Scrubber outages during December resulted from continuing
repairs to a plnhole in the precrubber FRP lining.
» 76 66 The scrubbing system was in service 450 hours during this
month. Outage time was caused mainly by repairs to cracks in
the oxidizing tower.
. 76 0 System inoperative; down for repairs.
PEDCo-ENVIRONMENTAL
74
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TABLE 3
PERFORMANCE DESCRIPTION FuK OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
37
KANSAS CITY POWER & LIGHT
HAWTHORN NO 3
KANSAS CITY MISSOURI
140 MW
COAL 0.6- 3.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION SWET SCRUB
RETROFIT
11/72
OPERATIONAL
99 PERCENT
70 PERCENT
WATER MAKE UP
SLUUGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
UNSTABILIZED SLUUGE UISPOSED IN UNLINED POND
$1V/KW CAPITAL*2.S MILS/KWH OP
REFER TO BACKGKOUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
F&O SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 1972. BOTH MODULES WERE
DOWN THE ENTIRE MONTH OF JANUARY BECAUSE OF FROZEN EQUIPMENT AND LINES,
AND A MANPOWER SHORTAGE. OPERAblLITY FOR MODULES A AND B DURING THE MONTH
OF FEBRUARY WAS 37 AND 1 PERCENT RESPECTIVELY.
75
PEDCo-ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE HAWTHORN POWER STATION: UNIT #3
THE HAWTHORN POWER STATION IS LOCATED ON THE NORTH BANK OF THE MISSOURI RIVER IN EAST KANSAS CITY, MISSOURI. THE
PLANT HAS FIVE ELECTRIC GENERATING UNITS WITH A TOTAL RATED CAPACITY OF 980 Ml/. ONLY UNITS #3 AND #4 ARE RETROFITTED
WITH FGD SYSTEMS.
BOILER #3 IS A DRY-BOTTOM PULVERIZED-COAL-FIRED UNIT. MANUFACTURED BY COMBUSTION ENGINEERING AND INSTALLED IN EARLY
1950. THE PLANT BURNS TWO GRADES OF COAL: THE COAL WITH HIGHER ASH CONTENT TYPICALLY CONTAINS 14 PERCENT ASH AND 3
PERCENT SULFUR, WITH A HEAT CONTENT OF 11,400 BTU/LB; THE LOWER ASH COAL HAS 11 PERCENT ASH, 0.6 PERCENT SULFUR, AND
A HEAT CONTENT OF 9800 BTU/LB.
THE BOILER'S FGD SYSTEM OPERATES ON LIMESTONE FURNACE INJECTION FOLLOWED BY A FLUE GAS WET-SCRUBBING SYSTEM IN
WHICH BOTH THE SOg AND THE FURNACE CALCINED LIMESTONE ARE SCRUBBED AND ALLOWED TO REACT IN A REACTION TANK.
THE FGD SYSTEM CONSISTS OF TWO IDENTICAL MODULES, EACH CAPABLE OF TREATING 500,000 ACFM OF FLUE GAS AT 300'F.
BYPASSING OF THE MODULES IS POSSIBLE THROUGH A SYSTEM OF DUCTWORK AND DAMPERS AROUND EACH MODULE. EACH MODULE CONSISTS
OF A GLASS MARBLE BED, A CHEVRON TYPE FIBER GLASS DEMISTER AND A FINNED TUBE REHEATER. THE DEMISTER WASH SYSTEM USES
A SET OF EIGHT WATER LANCES THAT TURN ON AUTOMATICALLY TO WASH MUD FROM THE DEMISTERS WHENEVER THE DAMPERS CLOSE.
THE SPENT LIMESTONE SLURRY FROM THE MODULES IS DISCHARGED INTO A CLARIFIER TANK, AND THE UNDERFLOW IS PUMPED. UNSTA-
BILIZED, TO A 160-ACRE UNLINED POND, WHICH IS ALSO USED FOR DISPOSAL OF FLY ASH FROM THE OTHER BOILERS.
PROBLEMS AND SOLUTIONS
THE MAJOR PROBLEMS ENCOUNTERED WITH THE TWO FGD SYSTEMS ON UNITS #3 AND #4 AT THE HAWTHORN POWER STATION HAVE BEEN
IDENTICAL.
MAINTENANCE OF SOLIDS IN THE REACTION TANKS IN SUSPENSION WAS DIFFICULT AND CREATED BUILD UP OF MUD IN THE CORNERS
OF THE REACTION TANK. THE PROBLEM WAS SOLVED BY ROUNDING OF THE BOTTOM CORNERS, INSTALLATION OF FRESH WATER FLUSHING
PEDCo-ENVIKUWttltNTAL
76
-------
HAWTHORN UNIT #3 (continued)
NOZZLES ON EACH WALL AND INCREASING THE HORSEPOWER OF THE TANK MIXERS.
SEDIMENT BUILD UP WAS EXPERIENCED IN THE DRAIN POTS HORIZONTAL HEADERS. ALSC DISLOCATION OF THE MARBLE BED DRAIN
POT COVERS AND THE LOSS OF MARBLES WAS A FREQUENT PROBLEM WHICH WAS SOLVED BY INSTALLATION "OF NEW STAINLESS STEEL DRAIN-
POTS WITH EXPANDED METAL COVERS AND MODIFYING THE DRAIN PIPING. OTHER MODIFICATIONS INCLUDED THE INSTALLATION OF A NEW
DEM1STER WASH SYSTEM TO CONTROL DEMISTER PLUGGING. CHANGING THE FLUSHING SEQUENCE WITHIN THE WATER SEAL TO ELIMINATE
BYPASS SEAL PLUGGING. AND REPLACEMENT OF SPRAY NOZZLES. THESE MODIFICATIONS WERE COMPLETED BY FEBRUARY 1974.
PEDCo-ENVIRONMENTAL
77
-------
Hawthorn #3
Month
Jul. 75
Aug. 75
Sept. 75
Oct. 75
Jan. 76
Feb. 76
358
180
503
Operating hours
Module 3*Module 3B
247
117
148
247
81
145
FGD OperabHlty (»)
Module A Module JB
69
65
37
42
23
81
Nov. 75
Dec. 75
0
0
0
0
0
0
0
0
0
0
Comments
3A - leak In city water line. Plugged duct to
I.D. form. Couldn't open outlet damper from
scrubber.
Last marbles 1n bed and sustained broken spray
header.
l.ost I.D. fan for half of boiler. Carryover of
July problems.
Outage due to cleaning and mechanical repairs. The
pots, covers, and marbles In the marble bed of module
3B were replaced during this period.
Module 3A outage due largely to replacement of a re-
cycle pump motor. Boiler operation hours low due
to a scheduled boiler overhaul.
Boiler and scrubbers shutdown during the report
period for a scheduled turbine overhaul. The system
1s scheduled to go back on-line in January 1976.
System was down all month because of frozen equipment
and lines and a manpower shortage due to a boiler
and turbine overhaul on another unit at this station.
Scrubber outages resulted from plugging in the
scrubber bed, which resulted from converting the bed
spray system from under-bed to over-bed.
78
PEDCo- ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE: DESCRIPTION FOR OPERATIONAL FGO SYSTEMS os/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
38
KANSAS CITY POWER & LIGHT
HAWTHORN NO 4
KANSAS CITY MISSOURI
100 MW
COAL 0.6- 3.0 PERCENT SULFUR
COMbUSTION ENGINEERING
LIMESTONE INJECTION ftWET SCRUB
RETROFIT
OPERATIONAL
99 PERCENT
802
70 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
S19/KW CAPITAL*2.2 MILS/KWH OP
OPERATIONAL
EXPERIENCE
KEFLK TU brtCKGKUuHU INFORMATION SECTION IN TABLE 3 OF THIS REPORT. FGD
SYSTLM HAS bEEN IN OPERATION SINCE AUGUST 1972. BOTH MODULES WERE DOWN
THE LNTIKE MONTH OF JANUARY BECAUSE OF FROZEN EQUIPMENT AND LINES, AND A
MANPOWER SHORTAGE. OPERA8ILITY FOR MODULES A AND b WAS U AND 78 PERCENT
RESPECTIVELY. MOuULE A WAS INOPERATIVE ALL OF FEBRUARY 3ECAUSE OF THE
CONTINUTATION OF A PROBLEM WITH LOSS OF DRAFT THROUGH THE
CONNECTING DUCTWORK.
PEDCo- ENVIRONMENT^
79
-------
BACKGROUND INFORMATION
ON
THE HAWTHORN POWER STATION: UNIT #4
THE HAWTHORN POWER STATION IS LOCATED ON THE NORTH BANK OF THE MISSOURI RIVER IN EAST KANSAS CITY,__
MISSOURI. THE PLANT HAS FIVE ELECTRIC GENERATING UNITS WITH A TOTAL RATED CAPACITY OF 980 MW. ONLY UNITS..
*3 AND #4 ARE RETROFITTED WITH FGD SYSTEMS.
BOILER #4 IS A BOTTOM PULVERIZED-COAL-FIRED UNIT MANUFACTURED BY COMBUSTION ENGINEERING AND INSTALLED..
IN EARLY 1950. THE PLANT BURNS TWO GRADES OF COAL: THE COAL WITH HIGHER ASH CONTENT TYPICALLY CONTAINS
14 PERCENT ASH AND 3 PERCENT SULFUR, WITH A HEAT CONTENT OF 11,400 BTU/LB: THE LOWER ASH COAL HAS.11 PERCENT.
ASH, 0.6 PERCENT SULFUR, AND A HEAT CONTENT OF 9800 BTU/LB.
ORIGINALLY THE FGD SYSTEM OPERATED ON FURNACE INJECTION OF LIMESTONE FOLLOWED BY FLUE GAS WET-SCRUBBJNG_.
SYSTEM IN WHICH BOTH THE SOg AND THE FURNACE CALCINED LIMESTONE ARE SCRUBBED AND ALLOWED TO REACT IN A
JEACTION TANK. BECAUSE.OF FURNACE TUBES PLUGGING^WHICH WAS ATTRIBUTED TO. LIMESTONE.INJECTION^THE SYSTEM
WAS CONVERTED IN 1972 TO TAILEND INJECTION, IN WHICH LIMESTONE IS INJECTED INTO THE GAS DUCT BETWEEN THE
AIR HEATER AND THE SCRUBBER VESSEL. .— .
THE FGD SYSTEM CONSISTS OF UO IDENTICAL MODULES, EACH CAPABLE OF TREATING 500,000 ACFM OF FLUE GAS
AT 300°F. BYPASSING OF THE MODULES IS POSSIBLE THROUGH A SYSTEM OF DUCTWORK AND DAMPERS AROUND EACH MODULE.__. ...
EACH MODULE CONSISTS OF A GLASS MARBLE BED, A CHEVRON TYPE FIBER GLASS DEMISTER AND A FINNED TUBE REHEATER.. _..
THE DEMISTER WASH SYSTEM USES A SET OF EIGHT WATER LANCES.THAT TURN ON AUTOMATICALLY..!?.WASH MUD
FROM THE DEMISTERS WHENEVER THE DAMPERS CLOSE. .
THE SPENT LIMESTONE SLURRY FROM ALL MODULES IS DISCHARGED INTO A CLARIFIER TANK, AND THE UNDERFLOW
IS PUMPED. UNSTABILJZED,, J[0_A_liqr.ACROM>II[Ep_PpHp,JIHICH_IjL*LSQ .USEp_F_pR_DJlPOSAL_JF.^l.y_.ASH. F_R_OM_THE.
OTHER BOILERS.
l^ jrH|..AVAI.LABJLJIY_FAnLO.R_F.OR_J.HE JiYSTEMS
PEDCo--ENVIRONMENTAL
80~ ~
-------
HAWTHORN UNIT #4 (Continued)
HAS BEEN LOW (IN THE RANGE OF 30X TO 40*). AVAILABILITY OF THE F6D SYSTEM HAS LAGGED BECAUSE OF THE MANY PROBLEMS ATTRIBUTED
TO DRY LIMESTONE INJECTION.
OPERATING HISTORY
APART FROM THOSE ENTAILED IN SWITCHING OF UNIT #4 FROM FURNACE INJECTION TO TAIL GAS INJECTION, THE MAJOR PROBLEMS EN-
COUNTERED WITH THE FGD SYSTEM ON BOILERS #3 AND #4 AT THE HAWTHORN POWER STATION HAVE BEEN IDENTICAL.
MAINTENANCE OF SOLIDS IN THE REACTION TANKS IN SUSPENSION WAS DIFFICULT AND CREATED BUILD UP OF MUD IN THE CORNERS OF
THE REACTION TANK. THE PROBLEM WAS SOLVED BY ROUNDING OF THE BOTTOM CORNERS, INSTALLATION OF FRESH WATER FLUSHING NOZZLES
ON EACH WALL, AND INCREASING THE HORSEPOWER OF THE TANK MIXERS.
IN LATE 1972, BECAUSE OF BOILER TUBE PLUGGING, WHICH WAS ATTRIBUTED TO FURNACE-LIMESTONE INJECTION, THE UNIT WAS CONVERTED
TO A TAILEND LIMESTONE INJECTION SYSTEM. SEDIMENT BUILD UP WAS EXPERIENCED IN THE DRAIN POTS HORIZONTAL HEADERS. ALSO,
DISLOCATION OF THE MARBLE BED DRAIN POT COVERS AND THE LOSS OF MARBLES WAS A FREQUENT PROBLEM WHICH WAS SOLVED BY INSTALLATION
OF NEW STAINLESS STEEL DRAINPOTS WITH EXPANDED METAL COVERS, AND MODIFYING THE POTS DRAIN PIPING. OTHER MODIFICATIONS INCLUDED
THE INSTALLATION OF A NEW DEMISTER WASH SYSTEM TO CONTROL DEMISTER PLUGGAGE, CHANGING THE FLUSHING SEQUENCE WITHIN THE WATER
SEAL TO ELIMINATE BYPASS SEAL PLUGGING. AND REPLACEMENT OF SPRAY NOZZLES. THESE MODIFICATIONS WERE COMPLETED BY APRIL 1974.
81 pEDCo- ENVIRONMENTAL
-------
Hawthorn 04
Month
Jul. 75
Aug. 75
Boiler
518
Operating hours
Module 1A
41
168
Module 4B
128
212
FGD
Roffu
8
? Derating (%)
e A ModuTe B
25
Sep. 75
395
206
210
52
53
Oct. 75
721
429
656
60
91
Comments
Marble bed plugging and strainer problems
S me for 4B
Last half of boiler due to No. 4B I.D. fan
outage. Shutdown both FGD module to Insure
not losing the whole unit.
New chemistry - attempting to run at 100Z
blowdown and near 0 percent solids. Emphasis
on participate control. Maintaining pH at 5
without limestone Injection.
Scrubber modules were returned to service on
Sept. 21 after replacement of the original I.D.
fan on the module 4B side.
New process design - marbles removed from
scrubber bed of Module A and replaced with a
stainless steel perforated bed. The marbles
were removed due to Increased operational
difficulties caused by their presence. Per-
furmance was very good resulting in Increased
availability and continuation of high particu-
late removal efficiency (97 percent).
Minor problem encountered in a boiler restric-
tion on the module 4A side somewhere between the
economizer and the inlet draft ductwork.resulting
PEDCo-ENVIRONMENTAL
82
-------
Hawthorn #4
Operating hours FGD Qperabllltv IZ)
Month Boiler Module 1A Module 4B Module A Module B Comments
1n decrease of gas velocity. New chemistry process
modification of running @ 1002 blowdown and 0.055
solids Is still 1n progress (Initiated late
August). S02 removal efficiency In the 50 to 60
percent range. KCPSL Is presently concentrating
heavily on participate emission control.
Nov> 75 720 0 713 0 ' 99 Module 4A was Inoperative during the report period
due to a loss of draft through the ductwork from
the economizer to the air preheater. This resulted
In frequent reheater plugging, extensive outage
time, and finally resulting in the utility bringing
the system down for the entire report period.
Dec. 75 640 0 103 0 16 A boiler outage of approximately 5 days duration
occurred In December due to a scheduled overhaul.
Jan- 76 0 0 0 00 The system was down all month because of frozen
equipment and lines and lack of manpower due to a
boiler and turbine overhaul on another unit at this
station.
Feb. 76 579 0 450 0 78 Module 4A was inoperative the entire month due to
continuation of problems concering the loss of draft
through the ductwork from the economizer to the air
preheater. Module 4B experienced problems 1n the
of marble bed plugging and the loss of a recycle
pump. PEDCo-ENVIRONMENTAL
83
-------
TABLE 3
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT HAME
UNIT LOCATION
UNIT RATING
39
KANSAS CITY POWER & LIGHT
LA CY&NE NO 1
LA CYGNE KANSAS
620 MW
FUEL CHARACTERISTICS COAL 5.2 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP UATE
FGD STATUS
EFFICIENCY,
PARTICIPATES
BABCOCK & UILCOX
LIMESTONE SCRUBBING
NEW
2/73
OPERATIONAL
98 PERCENT
S02
72 PERCENT
WATEK MAKE UP
SLUUGE DISPOSAL
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
$H3/KW CAPITAL
OPERATIONAL
EXPERIENCE
KEFEN TO BACKGKOUNO INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE FEB. 1973. THE ANNUAL AVERAGE
AVAILABILITY FOR ALL 7 MODULES DURING 1975 WAS IN EXCESS OF 63 PERCENT
(INCLUDING GENEKATOR REPAIR OUTAGE TIME). THE UTILITY IS CURRENTLY PLAN-
NING THE INSTALLATION OF AN ElbHTH MODULE, SCHEDULED TO BE PLACED IN
SERVICE SOMETIME DURING THE SUMMER OF 1977.
84
PEDCO- ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
LA CYGNE UNIT NO. 1
THE LA CYGNE POWER STATION OF KANSAS CITY POWER AND LIGHT COMPANY IS A NEW STATION. THE UNIT BEGAN COMMERCIAL OPERATION
ON JUNE 1. 1973, AS A JOINT PROJECT OF KANSAS GAS AND ELECTRIC COMPANY AND KANSAS CITY POWER ft LIGHT COMPANY. THE STATION IS
LOCATED ABOUT 55 MILES SOUTH OF KANSAS CITY, IN LINN COUNTY, KANSAS.
THE ELECTRIC POWER GENERATING FACILITIES CONSIST OF ONE 820-MW COAL-FIRED BASE-LOAD BOILER WITH ASSOCIATED STEAM TURBINES
AND ELECTRIC GENERATORS. THE PLANT ALSO HAS THREE OIL-FIRED BOILERS, UScD PRIMARILY FOR STARTUP OF THE LARGE UNIT. THEIR
COMBINED CAPACITY IS EQUIVALENT TO 28 MW.
THE BOILER AT LA CYGNE, WHICH WAS DESIGNED BY BABCOCK AND WILCOX, IS A DRY-BOTTOM. PULVERIZED COAL-FIRED CYCLONE UNIT. THE
COAL BURNED IS LOW GRADE, SUB-BITUMINOUS WITH AN AS-FIRED HEATING VALUE OF 9000 to 9700 BTU/LB AND ASH AND SULFUR CONTENTS OF
25 PERCENT AND 5 PERCENT, RESPECTIVELY. THE POLLUTION CONTROL EQUIPMENT ON THIS BOILER, WHICH CONSISTS OF SEVEN FLUE GAS
DESULFURIZATION MODULES, WAS ALSO BUILT BY BABCOCK AND WILCOX AS AN INTEGRAL PART OF THE POWER GENERATING FACILITIES.
BYPASSING OF THE BOILER'S FLUE GAS AROUND THE FGD SYSTEM IS NOT POSSIBLE.
PROBLEMS AND SOLUTIONS j
THE FGD INSTALLATION OF THE LA CYGNE BOILER NO. 1 HAS BEEN PLAGUED WITH NUMEROUS PROBLEMS SINCE THE FIRST TRIAL OPERATION
OF THE BOILER ON DECEMBER 26, 1972. SOME OF THESE PROBLEMS, SUCH AS THE VIBRATIONS OF THE INDUCED-DRAFT FANS AND THEIR
SENSITIVITY TO IMBALANCE. APPEARED EVEN BEFORE THE BOILER WAS FIRED.
AS THESE FABRICATION PROBLEMS WERE CORRECTED AND THE FGD SYSTEM WAS IN OPERATION. TWO OTHER TYPES OF PROBLEMS BEGAN TO
APPEAR. THE FIRST CATEGORY OF PROBLEMS IS ASSOCIATED WITH THE WET LIMESTONE PROCESS AND IT INCLUDES PLUGGING OF THE DEMISTER
AND STRAINERS. WEARING OF SPRAY NOZZLES. AND CORROSION OF REHEATER TUBES. THE SECOND CATEGORY OF PROBLEMS MAY BE UNIQUE TO THE
LACYGNE INSTALLATION; IT INCLUDES THE EFFECT OF THE SCRUBBED FLY ASH ON THE VISCOSITY AND FLOW CHARACTERISTICS OF THE RECIR-
CULATED SLURRY. WHICH RESTRICTED MOBILITY OF THE BALLS IN THE TCA TOWER.
PEDCo-ENVIRONMENTAL
85
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LA CYGNE UNIT NO. 1
IN ATTEMPTING TO SOLVE THESE PROBLEMS, IT WAS RECOGNIZED THAT THE FLY ASH CONTENT OF THE FLUE GAS (DUE TO LACK OF
PRIMARY PARTICULATE CONTROLS) IS IN LARGE PART RESPONSIBLE FOR THE PROBLEMS IN BOTH CATEGORIES. SEVERAL MODIFICATIONS HAVE
BEEN MADE TO ALLEVIATE THESE MOUNTING MECHANICAL PROBLEMS. ONE MAJOR CHANGE IS THE REPLACEMENT OF THE ORIGINAL TURBULENT
CONTACT ABSORBER'S FLOATING BED WITH SIEVE TRAYS. ALSO IN ORDER TO REDUCE THE EROSIVE EFFECT OF THE FLY ASH AND THE LARGE
SCALE PARTICLES. AND TO EXTEND THE LIFE OF THE LIMESTONE SLURRY SPRAY NOZ'LES ON THE VENTURI SCRUBBERS, A HYDROCLONE WAS
INSTALLED IN THE SLURRY RECIRCULATION LINE OF EACH MODULE TO CENTRIFUGALS SEPARATE AND REMOVE THESE PARTICLES FROM THE
SYSTEM.
THE CORROSION PROBLEMS ASSOCIATED WITH THE CONDENSATION OF ACID VAPORS FROM THE GAS ON THE REHEATER TUBE BUNDLES WERE
BROUGHT UNDER CONTROL BY THE INJECTION OF SLIP STREAMS OF HOT AIR P\OH THE BOILER'S COMBUSTION AIR HEATER IN THE PATH OF THE
SCRUBBED FLUE GASES AT THE INLET TO THE REHEATER UNITS. THIS PRACTICE HAS CAUSED A REDUCTION IN THE MAXIMUM GENERATING
CAPACITY OF THE BOILER DUE TO THE LIMITED AVAILABLE AIR FOR COAL COMBUSTION.
BECAUSE THE FGD SYSTEM INCLUDES NO SPARE MODULES AND IT CANNOT BE BYPASSED, OUTPUT OF THE BOILER IS TOTALLY CONTROLLED
BY THE PERFORMANCE AND AVAILABILITY OF THE FGD MODULES. PRESENT PROCEDURES CALL FOR CLEANING ONE MODULE EACH NIGHT ON A
ROTATIONAL SCHEDULE AND KEEPING ALL MODULES AVAILABLE DURING THE DAYTIME PEAK PERIODS. CLEANOUTS REQUIRE 3 MEN FOR A PERIOD OF
10 to 12 HOURS. RECENT JMODIFICATIONS BY THE UTILITY ON THE SCRUBBER INSTALLATION HAVE RESULTED IN PLANS FOR PROLONGED OP-
ERATIONAL PERIODS, WITH MODULES STAYING ON-LINE CONTINUOUSLY FOR PERIODS UP TO 3 WEEKS.
PEDCo- ENVIRONMENTAL
86
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FGD SYSTEM AVAILABILITY
LA CYGNE UNIT NO. 1
Month Boiler
Jan.
Feb.
Mar.
Apr.
May.
June
Jul.
Aug.
Sep.
Oct.
Nov.
Dec.
Jan.
Feb.
Mar.
Apr.
May.
Jun.
Jul.
Aug.
Sepjt
74
74
74
74
74
. 74
74
74
74
74
74
74
75
75
75
75
75
75
75 614
75 630
-.75.
Percent AvallabllIty-by module
A
49
66
67
69
92
75
90
69
90
90
;
•
82
95
88
78
75
78
B
32
68
70
83
84
80
90
88
71
71
96
85
85
90
88
84
C
44
59
75
78
83
80
73
73
60
60
90
94
84
90
87
84
D E F
87 23 37
76 52 100
Boiler Shutdown
88 74 100
85 78 84
90 82 83
81 85 79
81 81 78
76 83 89
61 84 85
61 84 85
Boiler Shutdown
Boiler Shutdown
Boiler Shutdown
76 93 92
5 Days of Operation
90 90 89
85 84 86
84 85 87
78 92 85
G
81
65
88
80
87
77
99
86
84
84
96
83
89
85
83
85 79. 78 74
Average
50
69
80
80
86
80
85
81
76
76
90
89
86
86
84
80
Comments
M. dule A and D are used for research tests.
One module is shut down each evening for cleaning.
System shutdown Oct. 16, 1975 due to
generator and I.D. air fan problems.
System remained Inoperative throughout the
duration of the month.
PEOCo-ENVIRONMENTAL
87
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FGD SYSTEM AVAILABILITY
LA CYGNE UNIT NO. 1
Percent Availability by module
Month Boiler hrs. A B C D E F G Average Comments
Oct. 75 ' 66 77 46 74 72 73 65 68 The availability figures given for the months of
Nov. 75 93 90 80 93 96 89 94 91 October and November do not Include the outage
Dec. 75 91 87 81 85 87 89 8/4 86 time accumulated from October 16 to November 13.
Boiler outages of 80. 50 and 11 hrs., totaling
141 hrs., occurred during the month of December.
Note: The 1974 figures are based on actual operating hours of each module over boiler hours. During reduced boiler load opera-
tion, some of these modules were not needed and were shut down, although they were available. Actual availability was therefore
somewhat higher than some of these figures Indicate. The 1975 figures are based on the hours the module was in service or
available for service divided by the total hours In the month.
PEDCo-ENVIRONMENTAL
88
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TABLE 3
PERFORMANCE DESCRIPTION FOK OPERATIONAL F6D SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY!
PARTICIPATES
H2
KANSAS POWER £ LIGHT
LAWRENCE NO 4
LAURENCE KANSAS
125 MW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION ftWCT SCRUB
RETROFIT
12/68
OPERATIONAL
99 PERCENT
S02
75 PERCENT
WATEK MAKE UP
SLUUGE DISPOSAL
UNSTABILIZED SLUUGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE DECEMbER 1968. THIS UNIT Ii> CUR-
RENTLY BURNING LOW SULFUR WYOMING COAL. THE OPERATION OF THE SCRUBBER HAS
bEEN MORE EFFICIENT AND ECONOMICAL FOR THIS COAL TYPE BECAUSE A LESSER
DEGREE OF S02 REMOVAL IS REQUIRED FOR COMPLIANCE. THE UTILITY PLANS TO
KEPLACE THIS SCRUBBING SYSTEM WITH A VENTRI-ROU AND SPRAY TOWER SCRUBBING
SYSTEM.
89
PEDCo-ENVIRONMtNTAL
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BACKGROUND INFORMATION
ON
THE LAURENCE POWER STATION: UNIT #4
LAURENCE POUER STATION'S UNIT #4 IS A CYCLIC LOAD STEAM BOILER EQUIPPED TO BURN COAL. NATURAL GAS SUPPLEMENTED WITH OIL
OR COMBINATION OF THESE THREE FUELS. THE BOILER UAS BUILT BY COMBUSTION ENGINEERING AND PLACED IN SERVICE IN 1959. THE
GENERATING CAPACITY VARIES FROM 125 MU TO 143 MU UITH THE TYPE OF FUEL BEING BURNED. RETROFITTING WITH AN FGD SYSTEM IN
NOVEMBER 1968 HAS INTRODUCED ADDITIONAL PRESSURE DROP IN THE FLUE GAS SYSTEM AND FURTHER REDUCED THE BOILER CAPACITY TO 115 MU.
PRESENTLY THE COAL AT THE LAURENCE POUER PLANT HAS A HEATING VALUE OF 12,000 BTU/LB AND AN ASH AND SULFUR CONTENT
OF 12.0 PERCENT AND 3.8 PERCENT. THE COMPANY IS IN THE PROCESS OF SWITCHING TO WYOMING COAL WHICH CONTAINS FROM 0.4 TO 0.8
PERCENT. THE COMPANY IS IN THE PROCESS OF SWITCHING TO WYOMING COAL WHICH CONTAINS FROM 0.4 TO 0.8 PERCENT SULFUR AND 10 PER-
CENT SULFUR ASH AND HAS A GROSS HEATING VALUE OF 10,000 BTU/LB.
THE BOILER HAS TWO MODULES, EACH DESIGNED TO HANDLE ROUGHLY 150,000 SCFM OF FLUE GAS AND CONSISTS OF A SINGLE STAGE MARBLE
BED SCRUBBER FOLLOWED BY A CHEVRON TYPE DEMISTER AND AN INDIRECT C.S. REHEATER. ORIGINALLY, BOTH MODULES WERE FITTED UITH
BY-PASS DUCTS AND HYDRAULIC SEAL DAMPERS, BUT LATER THEY WERE REMOVED BECAUSE OF EXTENSIVE CORROSION AND PLUGGING.
THE PLANT HAS LIMESTONE.STORING AND MILLING FACILITIES. THE LIMESTONE USED CONTAINS 93 PERCENT CALCIUM CARBONATE,
6 PERCENT SILICA AND 1 PERCENT MAGNESIUM CARBONATE.
THE SPENT SLURRY FROM THE UNIT, ALONG UITH THE SLURRY FROM UNIT #5, IS SENT TO THREE INTERCONNECTED UNLINED SLUDGE DISPOSAL
PONDS OF 16, 28, AND 4 ACRES. KANSAS RIVER WATER IS ADDED TO THE 4 ACRE POND. THE CLARIFIED WATER FROM THIS POND IS RECYCLED.
THE SLUDGE IS NOT TREATED FURTHER AND IS REPORTED TO SET AND SOLIDIFY IN THE PONDS.
PROBLEMS AND SOLUTIONS
THE FGD SYSTEM ON BOILER #4 HAD MANY PROBLEMS, SOME OF WHICH WERE: THE BUILD UP AND PLUGGING OF THE INLET DUCT WHERE
HOT GASES ENTERED THE SCRUBBERS. ERROSION OF SCRUBBERS UALLS, CORROSION OF SCRUBBERS INTERNALS, BUILD UP ON ID FANS ROTORS AND
PLUGGING OF DRAIN LINES. MARBLE BEDS AND DEMISTERS. THE S02 REMOVAL WAS QUITE LOW DUE TO OVERBURNING OF THE LIMESTONE AND THE
PEDCo-ENVIRONMENTAL
90
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LAURENCE UNIT #4 (continued)
DROPOUT OF THE LIME WITH THE ASH IN THE BOTTOM OF THE SCRUBBER.
THE SCRUBBERS WERE MODIFIED IN 1969 BY RAISING THE DEMISTER AND ADDING SOOT BLOWERS IN THE INLET DUCT AND REHEATER
TO ALLEVIATE PLUGGING PROBLEMS. NEW SPRAY NOZZLES WERE ALSO INSTALLED. REHEATER PLUGGING WAS ELIMINATED BY REPLACING
COPPER REHEAT COILS WITH A CARBON STEEL UNIT HAVING WIDELY SPACED FINS.
THE MAJOR MODIFICATIONS IN 1970 WERE SANDBLASTING AND COATING OF THE INTE'.IOR OF THE SCRUBBERS, REPLACEMENT OF
ALL INTERNAL STEEL PIPES WITH PLASTIC AND FIBER GLASS, AND REPLACEMENT OF STAINLESS STEEL DEMISTERS WITH ONE MADE OF FIBER-
GLASS. SINCE THE DEMISTER PLUGGING WAS NOT COMPLETELY REDUCED, MANUAL WASHI !G BECAME NECESSARY EVERY NIGHT TO MAINTAIN
THE OUTPUT REQUIRED OF THE UNIT.
THE MODIFICATIONS IN THE SUMMER OF 1972 ON THE BOILER'S TWO FGD MOPOLES INCLUDED ENLARGEMENT OF THE CRYSTALLIZATION
TANK, INSTALLATION OF NEW PLASTIC SPRAY NOZZLES, AND NEW SLURRY PUMPS AND STRAINERS AND NEW MULTIPLE MIXERS IN THE TANK.
THE OUTSTANDING PROBLEMS REMAINING ARE CORROSION, UNSATISFACTORY DAMPER OPERATION, EXAPNSION JOINT FAILURE, DEMISTER
FOULING, RAPID SLURRY PUMP WEAR, AND VALVE FAILURE. THE OPERATION OF THE FGD SYSTEM SINCE THE FALL OF 1973 HAS BEEN
THE MOST SUCCESSFUL TO DATE.
THE OPERATION OF THE SCRUBBER SYSTEM ON THE WYOMING COAL HAS PROVED TO BE MORE EFFICIENT AND ECONOMICAL DUE TO THE LESSER
DEGREE OF S02 REMOVAL REQUIRED FOR COMPLIANCE. THE SCRUBBER SYSTEM IS STILL OPERATING IN THE HIGH SOLIDS MODE AS AN S02 AND
PARTICULATE REMOVAL SYSTEM. NORMAL MANUAL CLEANING REQUIREMENTS HAVE BEEN REDUCED TO 2-4 HOUR SHIFTS PER SCRUBBER PER WEEK.
IN 1974 THIS UNIT WAS AVAILABLE FOR OPERATION 343 DAYS. FIFTY PERCENT OF THE FUEL CONSUMED WAS COAL, 2 PERCENT FUEL OIL
AND 48 PERCENT NATURAL GAS. DURING 1975 THIS UNIT WAS AVAILABLE FOR OPERATING 333 DAYS. SIXTY-FOUR PERCENT OF THE FUEL CON-
SUMED WAS COAL, 3 PERCENT FUEL OIL AND 33 PERCENT NATURAL GAS.
BY 1977, THE TWO FGD MODULES WILL BE REPLACED BY TWO NEW C.E. UNITS EACH CONSISTING OF A VENTRI-ROD UNIT AND A
SPRAY CHAMBER. A NEW ELECTROSTATIC PRECIPITATOR IS ALSO TO BE INSTALLED.
PEDCo- ENVIRONMENTAL
91
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Month
Jul. 75
Aug. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Jan. 76
Feb. 76
Operating hours
Boiler Module A HoWle B
Lawrence 04
Availability
Module A Module B
Not logged
Not logged
Not logged
Not logged
Not logged
Not logged
Not logged
Not logged
Comments
The FGD system has operated satisfactorily for over one
year. Availability 1s reported to be adequate for the
operation of this particular station. Station load is
reduced to 50 percent every night. Therefore, one of
the modules can be taken off-line for nightly cleaning
or repair. Wyoming coal (0.5 percent sulfur) Is being
burned 1n this boiler. Some natural gas has been
burned since June 20.
Burned coal 100 percent of time. Need to shut each
module down once per week for Inspection and cleanup. No
boiler outages In July and Aug.
Present projections by the utility call for this unit to
be available 330 days during 1976. The fuel consumption
split will be 80 percent coal, 12 percent natural gas
and 8 percent fuel oil. This scrubber system is being
replace^ by the utility with a venturl rod-section fol-
lowed by a spray tower.
PEDCo-ENVlRONMENTAL
92
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
«f3
KANSAS POWER * LIGHT
LAWRENCE NO 5
LAURENCE KANSAS
tOO MW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION MET SCRUB
NEW
11/71
OPERATIONAL
99 PERCENT
S02
65 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNSTABILIZE.D SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFEK TO BACKGROUND INFORMATION SECTION IN TABLE 6 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 1971. THIS UNIT IS CUR-
RENTLY BURNING LOW SULFUR WYOMING COAL. THE OPERATION OF THE SCRUBBER HAS
BEEN MORE EFFICIENT AND ECONOMICAL FOR THIS COAL TYPE BECAUSE A LESSER
DEGREE OF S02 REMOVAL IS REQUIRED FOR COMPLIANCE. THE UTILITY PLANS TO
REPLACE THIS SCRUBBING SYSTEM WITH A VENTRI-ROU AND SPRAY TOWER SCRUBBING
SYSTEM.
93
PEDCo-ENVIRONMENT
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BACKGROUND INFORMATION
ON
THE ..LAWRENCE .POWER_STA.TIJ)N_ UNIT_£5_
THE UNIT #5 AT LAWRENCE POWER STATION IS A CYCLIC LOAD STEAM BOILER AND..IS EQUIPPED TO..BURN .COAL, NATURAL_.GAS_
.SUPPLEMENTED WITH OIL OR COMBINATION OF THESE THREE FUELS. THE BOILER WHICH WAS PLACED IN SERVICE IN 1971 HAS A RA.TED.
.CAPACITY OF 400 MW WHEN BURNING COAL AND NATURAL GAS.
PRESENTLY THE COAL AT THE LAWRENCE POWER PLANT HAS A HEATING VALUE OF 12.000 BTU/LB AND AN. ASH AND SULFUR CONTENJ_
OF 12.0 PERCENT AND 3.8 PERCENT. THE COMPANY IS IN THE PROCESS OF SWITCHING TO WYOMING COAL WHICH CONTAINS FROM O.4..
TO 0.8 PERCENT SULFUR AND 10 PERCENT ASH AND HAS A GROSS HEATING VALUE OF 10,000 BTU/LB.
THE BOILER'S FGD SYSTEM WAS BUILT BY COMBUSTION ENGINEERING AND PLACED IN SERVICE IN 1971. THE BOILER HAS EIGHT
IDENTICAL MODULES, EACH DESIGNED TO HANDLE ROUGHLY 150,000 SCFM OF FLUE GAS AND CONSISTS OF A SINGLE STAGE MARBLE BED.
SCRUBBER FOLLOWED BY A CHEVRON TYPE DEMISTER AND AN INDIRECT C.S. REHEATER. ALL THE MODULES ARE FITTED WITH BY-PASS
DUCTS AND HYDRAULIC SEAL DAMPERS. THE PLANT HAS LIMESTONE STORING AND MILLING FACILITIES. THE LIMESTONE USED_CONTA1NJS
93 PERCENT CALCIUM CARBONATE, 6 PERCENT SILICA AND 1 PERCENT MAGNESIUM CARBONATE.
THE SPENT SLURRY FROM THE UNIT ALONG WITH THE SLURRY FROM UNIT #4 IS SENT TO THREE INTERCONNECTED UNLINED SLUDGE.
DISPOSAL PONDS OF 16, 28, AND 4 ACRES. COOLING TOWER SLOWDOWN SUPPLIES MAKE-UP WATER TO THE POND. SYSTEM.... CL.ARIFIE.Q
POND WATER IS RECYCLED. THE SLUDGE IS NOT TREATED FURTHER AND IS REPORTED TO SET AND SOLIDIFY IN THE PONDS.
PROBLEMS AND SOLUTIONS . .
THE FGD SYSTEM ON BOILER #5 HAD SIMILAR PROBLEMS TO THOSE OF THE FGD SYSTEM ON BOILER #4. AMONG THOSE PROBLEMS.
WERE: LOCALIZED CORROSION IN SOME EQUIPMENT, UNSATISFACTORY DAMPER OPERATION, DEMISTER FOULING, EXPANSION JOINTS FAILURE
AND RAPID WEAR OF SLURRY RECIRCULATING PUMPS. IN ADDITION TO THE ABOVE, BOILER #5 IS STILL PLAGUED WITH POOR FLUE
6AA. DISTRIBUTION TO JHE EI_GHT FGD. MJ)DULE_S._ WHICH , UNLIKE. THE _MOD_ULES. .ON_ BOILER_#4_,_ ALL_ARE_J_NJ.E_RC.ONNECTED TJL.O.NE..C.OMMQM
J5TACK. .... .
THE FGD SYSTEM_AyAILABILITY_IS_REPORTEp TO. .BE..AD.EQUATE FOR THE..OP.ERAT.ION. OF..THIS..PARI.ICULAR. STATION, STATION-
PEDCo-ENVIRONMENTAL
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LAWRENCE UNIT #5 (continued)
.OAO IS REDUCED TO 50 PERCENT EVERY NIGHT. THEREFORE AS MANY AS FOUR MODULES CAN BE SHUT DOWN FOR CLEANING AND REPAIR EACH
EVENING.
THE OPERATION OF THE SCRUBBER SYSTEM ON WYOMING COAL HAS PROVED TO BE MORE EFFICIENT AND ECONOMICAL BECAUSE OF THE LESSER
1EGREE OF S02 REMOVAL REQUIRED.
IN 1974 THE UNIT WAS AVAILABLE FOR OPERATION 338 DAYS, 66 PERCENT OF THE FUEL CONSUMED WAS NATURAL GAS, 27 PERCENT COAL
*ND 6 PERCENT FUEL OIL. DURING 1975 THE UNIT WAS AVAILABLE FOR OPERATION 352 DAYS WITH THE FUEL CONSUMPTION SPLIT BEING 45
'ERCENT NATURAL GAS. 42 PERCENT COAL AND 13 PERCENT FUEL OIL.
PEDCo-ENVIRONMENTAL
95
-------
Lawrence *5
Months
Boiler
Operating hours
FGD modul'es
Comments
Jul. 75
Aug. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Jan. 76
Feb. 76
Not logged
Not logged
Not logged
Not logged
Wyoming coal 1s being burned In this unit. The FGD system availability 1s
reported to be adequate for the operation of this station. Station load
Is reduced to SOX every night so that as many as four modules can be shut
down for cleaning and repair each evening.
FGO units were off-line for most of June for major rebuilding of spray system
In all modules. Some oil was burned 1n order to bypass FGD modules during
repair.
Burning oil and gas 1n July and August. No FGO operation.
Employed gas and oil on a part-time basis during September and October.
Boiler outage occurred due to Inspection and turbine repair. Slurry tank screen
also required replacement.
Present projections by the utility for this unit calls for 330 days of operation
in 1976 with the fuel consumption split being 60 percent coal, 25 percent fuel
oil and 15 percent natural gas. This unit will be converted to a venturl-rod and
spray tower system, like Unit 4.
96
PEDCo-ENVIRONMENTAL
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TABLE 9
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCAUON
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KENTUCKY UTILITIES
GREEN RIVER UNITS 1 AND 2
CENTRAL CITY KENTUCKY
6t MW
COAL 3.8 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
RETROFIT
9/75
OPERATIONAL
99.7 PERCENT
S02
60 PERCENT GUARANTEE
WATER MAKE UP
SLUUbE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGNOUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
SYSTEM BECAME OPERATIONAL SEPTEMBER 13il975. OPERATION IS CURRENTLY
BEING CONDUCTED ON A HALF-LOAD BASIS BECAUSE OF A TURBINE REPAIR.
OPERATIONAL DATA AVAILABLE FOR THE PAST THREE MONTHS SHOWS THAT SYSTEM
AVAILABILITY. OPCRABILITY AND UTILIZATION HAVE AVERAGED 62, 39, AND 25
PERCENT RESPECTIVELY. SYSTEM OUTAGES HAVE RESULTED FROM MINOR MECHANICAL
STARTUP PROBLEMS AND COMPONENT CLEANOUTS. THE SYSTEM IS NOW BEING PRE-
PARED FOR AN EXTENDED RELIABILITY TEST PROGRAM.
97
PEDCo-ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
GREEN RIVER POWER STATION
THE GREEN RIVER POWER STATION OF THE KENTUCKY UTILITIES COMPANY IS SITUATED ON GREEN RIVER. NEAR CENTRAL CITY, IN
MUHLENBERG COUNTY. KENTUCKY.
THE STATION CONSISTS OF TWO POWER GENERATING UNITS AND FOUR BOILERS. THE POWER GENERATORS AT THIS STATION ARE PEAK LOAD
UNITS. THE BOILERS PROVIDING STEAM TO THE GENERATORS ARE NORMALLY OPERATIONAL 5 DAYS PER WEEK. WITH ONE OR MORE OF THE BOILERS
OFTEN OPERATING AT REDUCED CAPACITY.
THE S02 AND PARTICULATE CONTROL SYSTEM FOR BOILERS 1. 2 and 3 CONSISTS OF MECHANICAL COLLECTORS AND A TAIL END LIME
SCRUBBING SYSTEM.
THE LIME SCRUBBING SYSTEM CONTRACT WAS AWARDED TO AMERICAN AIR FILTER IN JUNE 1973." CONSTRUCTION WAS COMPLETED AND THE
SYSTEM STARTED UP SEPTEMBER 13, 1975. THE SYSTEM WAS DESIGNED TO TREAT THE FLUE GAS FROM BOILERS 1. 2, AND 3, WHICH HAS A
COMBINED RATED CAPACITY OF 64 MW. WITH THE FUEL BURNED BEING PRIMARILY HIGH SULFUR (3.5 TO 4.0 PERCENT) WESTERN KENTUCKY COAL.
THE FGD SYSTEM CONSISTS OFIONE SCRUBBER MODULE TO HANDLE A MAXIMUM OF 360,000 ACFM AT 300°F. THE FLUE GAS IS DRAWN FROM
THE EXISTING BREECHING THROUGH A GUILLOTINE TYPE ISOLATION DAMPER AND DUCT SYSTEM TO THE SCRUBBER FAN. THE GASES THEN FLOW TH
THROUGH AN ADJUSTABLE THROAT VENTURI SCRUBBER AND FLOODED ELBOW, WHICH WAS PROVIDED PRIMARILY FOR PARTICULATE REMOVAL. SOg
REMOVAL OCCURS BY REACTION WITH THE LIME SLURRY IN THE MOBILE BED CONTACTOR WHICH CONSISTS OF TEN DIFFERENT COMPARTMENTALIZED
SECTIONS WITH OVERHEAD SLURRY SPRAYS AND UNDER-BED DAMPERS TO ACCOMODATE GAS VOLUME TURNDOWN REQUIREMENTS.
THE SLURRY/RECYCLE SYSTEM CONSISTS OF A PARTITIONED REACTANT TANK WITH RECYCLE PUMPS FOR SUPPLYING THE CONTACTOR AND
VENTURI. A LIME SLURRY SLAKING AND FEED SYSTEM, AND A BLEED SYSTEM DISCHARGING TO A SETTLING POND WITH RETURN WATER FROM THE
POND TO BE USED AS PRIMARY MAKE-UP.
PEDCo-ENVIRONMENTAL
98
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FGD SYSTEM AVAILABILITY
GREEN RIVER NOS. 1 AND 2
Total , Boiler Module
Period period (hrs.) operation (hrs.) availability (hrs.)
Dec. 75
744
Availability = 74%
Reliability » 78%
Operabllity = 65%
Utilization • 35%
Jan. 76 744
Availability « 42%
Reliability « 14%
Operability = 11%
Utilization = 9%
Feb. 26 696
Availability = 70%
Reliability = 42%
Operabllity - 42%
Utilization = 30%
398
550
f Hrs. module
called upon
to operate
331
572
312
456
499
486
499
Hrs. module
operated Comments
257 System became operational September
13, 1975, on a half-load basis due
to a turbine overhaul. The half-load
mode throughout of operation con-
tinued the report period. The utility
began logging operating data as of
December 1975.
64 System was down a total of 432 hours
In January. Major problems were
failure of the recycle pumps and feed
tank agitator, thaw out and repairs to
numerous frozen lines, and shutdown
of sump pumps.
211 The system was inoperative a total of
210 hours during the month of Feb-
ruary. Mechanical problems included
repairs to tank agitators, recycle
pumps, reactant pumps. Clean out of
reactant pumps, slurry pumps, slake
tanks and mix-hold tank contributed
accounted for the remaining outage
lime.
PEDCO-ENVIRONMENTAL
99
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OK RETROFIT
START UP UATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER HAKE UP
SLUDGE: DISPOSAL
H5
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
KLY WEST FLORIDA
37 MW
OIL 2.4 PERCENT SULFUR
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
NEW
10/72
OPERATIONAL
90 PERCENT
85 PERCENT-ESTIMATED
MAKE. UP RATE ESTIMATED 100 GPM
UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
S 21.b/KW CAPITAL COST
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE OCTOBER 1972. THE FGD SYSTEM HAS
BEEN OUT OF SEKVICE SINCE JANUARY 26,1975. MODIFICATIONS AND REPAIRS ARE
CURRENTLY IN PROGRESS. SYSTEM RESTART IS AT LEAST A MONTH AWAY. CHECKOUT
OF ALL SYSTEM MOTORS AND PUMPS MUST BE COMPLETED BEFORE STARTUP CAN
COMMENCE.
100
PEDCo-ENVlHONMtrtlftt
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BACKGROUND INFORMATION
ON
STOCK ISLAND PLANT
THE UTILITY BOARD OF THE CITY OF KEY WEST OPERATES AN OIL-FIRED 37 MW POWER PLANT ON STOCK ISLAND, ADJACENT TO THE ISLAND
CITY OF KEY WEST. THIS STEAM GENERATOR BURNS A HIGH SULFUR FUEL OIL (2.4 - 2.75X SULFUR) GENERATING 210,000 CFM OF FLUE
GAS AT 390»F. TO REMOVE THE SULFUR DIOXIDE FROM THE FLUE GAS A SCRUBBING SYSTEM, CONSISTING OF TWO MODULES, HAS BEEN
DESIGNED BY ZURN AIR SYSTEMS AND EMPLOYS PULVERIZED CORAL AND SEAWATER. THE CORAL IS INITIALLY GROUND TO A FINE POWDER IN A
HAMMER-MILL CRUSHER AND THEN MIXED WITH SEAWATER TO FORM A DILUTE SLURRY AND TRANSFERRED TO THE SCRUBBING SYSTEM WHERE SULFUR .
DIOXIDE IS ABSORBED. THE CLEANED GAS IS DISCHARGED TO ATMOSPHERE AND THE SPENT SLURRY IS PUMPED TO A SETTLING POND WHERE
THE SOLIDS SETTLE OUT. THE CLARIFIED SEAWATER IS DISCHARGED INTO THE GULF.
THE TWO SCRUBBER MODULES ARE DESIGNED TO HANDLE A COMBINED TOTAL OF 126,950 CFM AT 150'F. THE FLUE GASES FROM THE BOILER
ARE DRAWN THROUGH THE INDUCED DRAFT FAN AND FORCED EITHER THROUGH THE BYPASS DUCT OR THROUGH ONE OR BOTH SCRUBBERS VIA THREE
SETS OF DAMPERS BETWEEN THE INDUCED DRAFT FAN AND THE STACK. PRIOR TO ENTERING THE SCRUBBING SYSTEM THE GAS IS COOLED FROM
360-F TO 160-F BY SEAWATER SPRAYS. THIS INSURES PROTECTION OF THE FIBERGLASS COMPONENTS OF THE SCRUBBER MODULES. A PRESSURE
DROP OF 12 TO 14" WATER GAUGE IS THE NORMAL OPERATING RANGE FOR THE SCRUBBERS.
THE FGD SYSTEM WAS PLACED IN OPERATION DURING OCTOBER, 1972. THE SYSTEM WAS SHUT DOWN ON JAN. 28, 1975 FOR REPAIR OF
THE BOILER FOUNDATION AND DUCTWORK BAFFLES. SOME OTHER IMPORTANT MODIFICATIONS TO BE COMPLETED ARE: REPLACING SPRAY TREES
AND OTHER STAINLESS STEEL PARTS WITH MONEL; MODIFICATION AND SEALING OF INLET DAMPERS; INDUCED DRAFT FAN REPAIRS; REPAIR OF
HOLES IN HOPPER WALL AND DUCT FLOOR.
101
-------
Stock Island
Operating hours FGD system rnmnf»nt<
Month Boner FfiD system Availability _ Conintents
FGD system was shut down on Jan. 28, 1975 due to ductwork baffle
damage. Spray trees and other stainless steel parts have been
replaced with Monel.
J(jl ?5 00 FGO system Is still out of service, but reportedly will be
Au 75 00 restarted In early October. Boiler has been down since August
30 for I.D. fan repairs.
s 75 00 FGD system 1s still out of service. Date of system restart 1s
Qct> 75 00 Indefinite at the present time.
Moy ?5 00 FGD system is still out of service. The utility Is in the process
Dec 75 0 0 of replacing the dampers and various system parts. Date of system
restart is still Indefinite.
Jan 76 00 Repairs to outlet damper have been completed. All the holes in the
Feb ?6 00 hopper wall and ductwork have been patched. New spray trees have
been installed. The utility 1s still in the process of repairing
the inlet damper. The system will not restart for at least another
month pending checkout of all pumps and motors.
PEOCo-ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
53
LOUISVILLE GAS & ELECTRIC
PADDYS RUN NO 6
LOUISVILLE KENTUCKY
65 MW
COAL 3.5-4.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
RETROFIT
t/73
OPERATIONAL
99.6 PERCENT
90 PERCENT RANGE
33 JGAL/LB MOLE S02 REMOVED
UNSTABILIZEO SLUDGE DISPOSED IN UNLINED POND
S57/KW CAPITAL
&53/KM - 2.5 MILLS/KWH
REFEK TO BACKGROUND INFORMATION SECTION IN TAbLfc. 3 OF THIS REPORT. THIS
FGU SYSTEM HAS BEEN OPERATIONAL SINCE APRIL 1973. OPERABlLlTY WAS 100
PERCENT IN JANUARY. S02 REMOVAL EFFICIENCY WAS 99 PERCENT DURING THIS
OPt-KATING PERIOD. THL SYSTEM WAS SHUTDOWN IN EARLY FEBRUARY IN PREPARA-
TION FOR THE EPA SCKUbBEH AND SLUDGE STUDY WHICH MAY COMMENCE IN JUNE OR
JULY OF 1976. THE SCRUBBER WILL NOT BE OPERATED UNTIL THIS TIME UNLESS
THE NEED ARISESIPEAK LOAD DEMAND).
103
PEDCO- ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
THE PADDY'S RUN POWER STATION
PADDY'S RUN ..POWERI STATION IS LOCATED IN LOUISVILLE, KENTUCKY. THE PLANT HAS SIX ELECTRIC POWER
.GENERATING UNITS WITH A TOTAL RATED CAPACITY OF 320 MW. UNIT NO. 6 IS RETROFITTED WITH A CARBIDE LIME_
BASE FGD SYSTEM.
UNIT N0._6 IS A PEAK LOAD COAL-FIRED BOILER. THE BOILER WAS MANUFACTURED BY FOSTER WHEELER .AND.
WAS INSTALLED IN 1950. IN 1973, THE BOILER BURNED COAL WITH A GROSS HEATING VALUE OF 11,500 BFU/LB
AND AN AVERAGE SULFUR AND ASH CONTENT OF 3.7 PERCENT AND 13 PERCENT, RESPECTIVELY.
THE FGD SYSTEM CONSISTS OF TWO MODULES. EACH HANDLES 175,000 ACFM OF 350»F FLUE GAS...EACH MODULE
IS MADE UP OF TWO STAGES OF 3 INCH MARBLE BEDS FOLLOWED BY TWO STAGE CHEVRON TYPE DEMISTER. THE GAS
IS REHEATED BY DIRECT COMBUSTION OF NATURAL GAS. SOg REMOVAL EFFICIENCY IS REPORTED TO BE 80 PERCENT.
THE LIME USED CONTAINS 90 TO 92.0 PERCENT CALCIUM HYDROXIDE, 2.0 TO 2.5 PERCENT SILICA, 3.0 JO
i
8.0 PERCENT CALCIUM CARBONATE, AND 0.1 PERCENT MAGNESIUM OXIDE.
THE UNIT OPERATES ON A CLOSED LOOP MODE: THE SOg IS ABSORBED IN THE TOWER'S MARBLE BED BY A SLURRY
OF CALCIUM SULFITE TO FORM A MIXTURE OF CALCIUM SULFITE/BISULFITE . THE TOWER'S EFFLUENT IS CONVERTED
IN THE REACTION TANK TO CALCIUM SULFITE BY THE ADDITION OF CALCIUM HYDROXIDE. ONE-HALF OF THE REACTION
TANK EFFLUENT IS RETURNED TO THE SOg TOWERS WHILE THE OTHER HALF IS FED TO A CLARIFIER TANK. THE CALCIUM.
_SULFITE CRYSTALS PRECIPITATE WITH THE AID OF A FLOCCULANT WHICH IS ADDED AT THE RATE OF 4-7 PPM. THE
OVERFLOW IS RETURNED TO THE REACTION TANK WHILE THE UNDERFLOW CONTAINING 22 TO 24 PERCENT SOLIDS IS
STABILIZED BY MIXING IT WITHJ.IME. ABOUT 60 TO 100 POUNDS OF LIME ARE USED PER TON OF DRY SOLIDS_OF
SLUDGE. THE FIXED SLUDGE IS TRANSPORTED BY TRUCKS TO A 10-ACRE OFF-SITE DUMP FOR USE AS LANDFILL.
PEDCo-ENVJKONMtNTAL
MM-
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PADDY'S RUN (continued)
PROBLEMS AND SOLUTIONS
DURING THE INITIAL 45 DAYS OF OPERATION ONLY ONE ABSORBER WAS PLACED IN SERVICE TO OBSERVE THE EQUIPMENT AND TO
DETERMINE THE MODIFICATIONS NEEDED FOR THE SYSTEM. BEGINNING MAY 19, 1974. THE SYSTEM WAS SHUT DOWN FOR A MONTH TO
MAKE A NUMBER OF MODIFICATIONS. THE MOST SIGNIFICANT BEING THE INSTALLATION OF EQUIPMENT FOR INJECTING A FLOCCULATING
AGENT INTO THE CLARIFIER TANK. DURING THE PERIOD FROM JUNE 19 TO JULY 11. THE INCONSISTENT SIZING OF RECEIVED SLURRY
ADDITIVE MATERIAL CAUSED AN UPSET IN THE ADDITIVE CONTROL VALVES AND UNDUE PLUGGING OF SLURRY LINE STRAINERS. THIS
PROBLEM WAS CORRECTED WITH THE INSTALLATION OF A DISINTEGRATOR IN THE SLURRY ADDITIVE SYSTEM. DURING AUGUST 19 TO
SEPTEMBER 5. THE UNIT WAS SHUT DOWN TO ENLARGE THE CLARIFIER'S OVERFLOW SYSTEM. OTHER OPERATIONAL-MODIFICATIONS-MADE WERE
LOWERING OF THE SLURRY. pH TO REMOVE SULFITE SCALING FORMED ON THE UPPER BED PERFORATED SUPPORT PLATE AND ON THE MARBLES.
THE OPERABILITY FACTORS FOR. EACH MODULE ARE PRESENTED IN THE FOLLOWING TABLE.
PEDCo-ENVIRONMENTAL
105
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Month
April 73
May 73
June 73
July 73
Aug. 73
Sept. 73
OPERABILITY (%)
Nodule A Module B
18
11
0.1
21
53
85
65
21
64
72
FGD SYSTEM AVAILABILITY
PADDY'S RUN UNIT NO. 6
COMMENTS
During this month, only one module was operated at a time with frequent
shutdowns for Inspection of equipment and minor repairs.
Mode of operation In April continued through May 19th., when the unit was
shutdown to carryout a number of modifications. The most significant
modification was the installation of equipment for Injection of a
"~ s
flocculating agent Into the clarifier tank.
From June 19th to July llth, the operation was Intermittent due to
mechanical problems with the slurry pumps.
During a scheduled outage from July 12th through August 1st, several
repairs were made to the lime slurry makeup system and disintegrator unit
was Installed in order to alleviate plugging problems in the strainers and
the slurry control valves.
Between August 2nd and August 18th, the operation was continuous except
for brief shutdown due to boiler related problem. During the period
between August 19th and September 5th, the system was shut down to replace
the clarifler's underflow line with one of larger diameter and to Install
additional pump capacity in the clarlfier's overflow system.
The unit operated continuou-ly between September 6th and September 20th
except for 7 hr. shutdown to repair a marble bed support plate. The unit
was shutdown during the remaining days of the month due to trouble in the
boiler's turbine generator.
PEDCo- ENVIRONMENTAL
106
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PADDY'S RUN UNIT NO. 6 (continued)
OPERABILITY (%)
Month Module A Module B
Oct. 73
Nov. 73
Dec. 73
Jan. 74
through
Jun. 74
Jul. 74
Aug. 74
Sep. 74
Oct. 74
Nov. 74
through
Aug. 75
Sep. 75
Oct. 75
49
35
44
0
51
50
0
100
0
100
100
94
100
78
0
81
77
0
100
0
100
100
Nov. 75 100 100
Dec. 75 90 90
COMMENTS
The F6D system was In service through December 20th. 1973 after which the
boiler (and the scrubbers) were shutdown due to "no demand" from this
peaking load boiler.
Boiler 1s down because of "no demand"
Boiler and FGD system resumed operation on July 10. 1974.
Unit has been on and off frequently due to fluctuation In power demand.
Boiler Is down because of "no demand".
Boiler turned on specifically to perform limestone test runs on FGD system.
Boiler 1s down because of "no demand"
Boiler and FGD system operational all of September and first two weeks 1n
October. System outage during the last two weeks of October due primarily
to breeching 1n the boiler section. Operability for both modules during
the operational period was 100% (Based upon LG&E's Peak Load Determination).
SOg removal was reported to be in excess of 98%.
Boiler and scrubber system ran most of the report period on a Monday through
Friday basis. Two minor outages occurred In December due to the malfunction and
repair of the dual strainer switch shaft In the bottom of the scrubber module.
PEDCo-ENVlRONMtNlrtl
107
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PADDY'S RUN UNIT NO. 6 (continued)
OPERABILITY (X)
Nodule A Module B
Month
Jan. 76 100 100
Feb. 76 0 0
COMMENTS
S02 removal efficiency was reported to be 99% during the month of January. The
system was shutdown In early February In preparation for the EPA scrubber/sludge
study which should commence 1n June or July of this year. The scrubber will
not be operated until the Initiation of the study program unless the peaking load
boiler Is required for power demands. Some general highlights of the scrubber/
sludge study program are:
0 6 month duration.
0 1 scheduled shutdown for test modlf1ca1tons.
0 Scrubber will run on carbide lime and commercial lime.
0 Determination of minimum retention times.
• Deliberate high chloride concentration operation.
0 MgO Innoculatlon.
8 Extensive sludge study: Fixation, leachates, seasonal variations.
Note: Since Paddy's Run No. 6 Is a peak load boiler, there were several
occasions 1n July and August 1974 when the boiler operated for
less than a day. During these short boiler runs, the FGD
system was not turned on and was bypassed although 1t was avail-
able.
PEDCo-ENVIRONMENTAL
108
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TABLE 3
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICULATES
S02
WATER HAKE UP
SLUDGE DISPOSAL
55
MONTANA POWER CO.
COLSTRIP NO 1
COLSTRIP MONTANA
360 MW
COAL 0.8 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
LIME SCRUBBING
NEW
10/75
OPERATIONAL
UNIT COST
OPERATIONAL
EXPERIENCE
CAPITAL S50/KW
CONSTRUCTION MAS COMPLETED BEHIND SCHEDULE. THE F6D SYSTEM STARTED UP AND
PROCEEliLD THROUGH A SHAKEDOWN AND DEBUGGING OPERATION PHASE. THIS UNIT
HAS COMMENCED FULL COMMERCIAL OPERATION AND IS CURRENTLY OPERATING AT
FULL LOAD CAPACITY. OPERATING DATA ACCUMULATED TO DATE IS IN THE PROCESS
OF BEING EVALUATED BY THE UTILITY FOR PRESENTATION TO STATE REGULATORY
AGENCIES.
109
PEDCo-ENVIRONMENTAL
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY*
PARTICULATES
63
NEVADA POWER
REID GAHDNER NO 1
HOftPA NEVADA
125 MW
COAL 0.5- 1.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
RETROFIT
<*/7<*
OPERATIONAL
99 PERCENT
S02
85 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
190 jGPM
SHt/KU CAPITAL (197H DOLLARS) $600.000 ANNUAL COST
REFER TO BACKGROUND INFORMATION SECTION IN TABLL 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BcEN OPERATIONAL SINCE APRIL 1971. THIS SYSTEM WAS ON-LINE
Ittb hRS. IN JANUARY. WHICH EQUATES INTO A 29 PERCENT OPERABILITY FACTOR.
THREE FORCED SCRUBBER OUTAGES OCCURRED DURING THIS PERIOD DUE TO REHEATER
STEAM LEAKSt A VENTURI STRAINER COLLAPSE AND A FROZEN CARBONATE LINE.
TOTAL OPERATING TIME LOGGED BY THIS SCRUBBING SYSTEM TO DATE IS
HRS.
no
PEDCo-ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
REID GARDNER UNIT NO. 1
THE REID GARDNER POWER STATION IS LOCATED NEAR MOAPA, NEVADA, ABOUT 50 MILES NORTH OF LAS VEGAS. AT
PRESENT THE STATION HAS TWO ELECTRIC POWER GENERATING UNITS, (REID GARDNER 1 AND 2) EACH RATED AT 125 MW.
BOTH UNITS ARE RETROFITTED WITH SODIUM CARBONATE BASED FLUE GAS DESULFURIZATION SYSTEMS. THE COAL BURNED
AT THE PLANT HAS AN AVERAGE GROSS HEATING VALUE OF 12,450 BTU/LB, AND ASH AND SULFUR CONTENTS OF 8 AND
0.5 PERCENT RESPECTIVELY.
THE FGD SYSTEM ON REID GARDNER 1 WAS MANUFACTURED BY COMBUSTION EQUIPMENT ASSOCIATES AND PLACED
IN OPERATION DURING APRIL, 1974. THE DESIGN OF THIS SYSTEM WAS BASED ON DATA GATHERED FROM THE OPERATION
OF AN 8000 ACFM PILOT PLANT WHICH OPERATED AT THE REID GARDNER POWER STATION DURING 1971 AND 1972.
THE FGD SYSTEM CONSISTS OF A SINGLE MODULE, DESIGNED TO HANDLE 473,000 ACFM OF GAS AT 350'F. EACH
MODULE IS MADE UP OF A TWIN VARIABLE THROAT VENTURI SCRUBBER FOLLOWED BY A SINGLE STAGE WASH TRAY.
BYPASSING OF EACH MODULE IS POSSIBLE THROUGH A GUILLOTINE TYPE BYPASS VALVE. THE PLANT HAS A COMMON
TRONA (SODIUM CARBONATE ORE) STORAGE AND SAND REMOVAL PLANT WHICH SERVES BOTH FGD MODULES ON REID GARDNER
1 AND 2. S02 REMOVAL EFFICIENCY IS REPORTED TO BE 85 PERCENT.
IN THIS SODIUM CARBONATE PROCESS, THE HOT FLUE GAS FROM THE BOILER PASSES FIRST THROUGH AN EXISTING
MECHANICAL COLLECTOR (MULTICYCLONE) WHERE ABOUT 75 PERCENT OF THE FLY ASH IS REMOVED. ITS PRESSURE IS
THEN BOOSTED BY AN I.D. FAN BEFORE IT SPLITS INTO TWO STREAMS AS IT ENTERS THE TWIN THROAT VENTURI
SCRUBBER. HERE THE HOT FLUE GAS IS QUENCHED BY A SHOWER OF CIRCULATED SODIUM BASE LIQUOR. THE GAS THEN
ENTERS THE WASH TRAY AND BUBBLES THROUGH THE WATER ON THE SIEVE TRAY. THE SCRUBBER GAS WHICH IS ESSENTIALLY
FREE OF FLY ASH AND SULFUR DIOXIDE, PASSES THROUGH THE RADIAL VANE MIST ELIMINATOR WHERE THE REMAINING
LIQUID DROPLETS CARRIED OVER WITH THE GAS ARE TRAPPED AND REMOVED.
THE EFFLUENT FROM THE FGD SYSTEM IS MADE UP OF TWO SOURCES: THE SLIP STREAM OF SPENT LIQUOR DISCHARGED
FROM THE RECIRCULATION TANK, AND THE ALKALINE CLARIFIER UNDERFLOW WHICH SERVES TO NEUTRALIZE THE pH OF
THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE SLUDGE SETTLING PONDS. THERE ARE TWO SLUDGE SETTLING
PEDCo-ENVIRONMENTAL
111
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REID GARDNER UNIT 1 (CONTINUED)
PONDS. THE SPENT LIQUOR IS PUMPED ONE OF THEM AT A TIME. THE OVERFLOW FROM THIS POND IS PUMPED TO A
LARGER 45 ACRE POND WHERE THE BRINE IS EVAPORATED. THE FGD SYSTEM OPERATES ON AN OPEN WATER LOOP WITH NO
LIQUOR RECYCLED TO THE MODULES FROM THE PONDS.
'PROBLEMS AND SOLUTIONS
THE MAJOR PROBLEM IN THE OPERATION OF THE FGD MODULES, HAS BEEN AND STILL IS THE LACK OF AN ADEQUATE
SUPPLY OF TRONA (SODIUM CARBONATE ORE). IN ORDER TO SOLVE THIS PROBLEM, SODIUM CARBONATE BRINE HAS BEEN
USED TO SUPPLEMENT TRONA. THE SYSTEM HAD THE USUAL START-UP PROBLEMS SUCH AS RUBBER LINERS ON RECIRCULATION
LINES GETTING LOOSE DUE TO POOR FABRICATION. FREEZE UP OF INSTRUMENTS AND ASH PLUGGING IN_CONTROL VALVE
BYPASS LINES. OTHER MINOR PROBLEMS WERE LEAKAGE IN THE MECHANICAL SEALS OF THE RECIRCULATIOK PUMPS.
ALSO MECHANICAL FAILURE PROBLEMS WERE EXPERIENC£D WITH THE GUILLOTINE TYPE BYPASS DAMPERS, WHICH WERE
LATER CORRECTED WITH UPGRADED REPLACEMENT PARTS.
AS EXPECTED, THIS SODIUM BASED FGD SYSTEM HAS NOT EXPERIENCED SUCH PROBLEMS AS EQUIPMENT SCALING.
DEMISTER PLUGGING, CORROSION OR EROSION WHICH ARE USUALLY ASSOCIATED WITH LIME/LIMESTONE FGD SYSTEMS.
PEDCo-ENVIRONMENTAL
112
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Reid Gardner 1
Month
Operating Hours
BoilerFGD system
QperabiHtv (%}
Jul. 75
Aug. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Jan. 76
716
303
654
646
85X
559
106
394
186
77
35
60
29
COMMENTS
During February the FGD system operated with 95 percent availability
on trona supplemented with soda ash. January availability was only
about 65 percent because of frozen sodium carbonate feed lines.
Problems In February Included a two-day lack of chemicals. No
significant problems occurred In March. The unit ran April 1
through April 12 with 100Z availability. The boiler was then shutdown
for routine maintenance. The system was placed back on line May 12.
Second performance test was passed. Problems Included rubber-lined
pipe abrasion and routine mechanical problems. Minor Instrumentation
problems. High ash content, up to 20%, had no effect on emissions.
Four forced unit outages occurred, 3 of which were caused by scrubber
malfunctions.
Low operating time due to a scheduled boiler maintenance. An outage
also occurred due to the malfunction of a soda ash blower.
The utility reports system performance In terms of the operablHty Index.
Unit No. 1 operablllty was low for the month of November because of
delays 1n repair material delivery.
Three forced scrubber outages occurred during the month due to reheater
steam leaks, collapse of a venturl strainer, and a frozen carbonate line-
The system was shutdown for a 16 day period for completion of piping con-
version. This outage was not due to a scrubber malfunction.
PEDCo-ENVlRCiWcUTAL
113
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NANC
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICIPATES
S02
WATER WAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
61
NEVADA POWER
REIO GARDNER NO 2
HOAPA NEVADA
125 MM
COAL 0.5- 1.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
SODlun CARBONATE SCRUBBING
RETROFIT
12/7S
OPERATIONAL
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTEM HAS BEEN OPERATIONAL SINCE FEB. 1973. SYSTEM OPtRAQILlTY FOR
THE MONTH OF JANUARY EXCEEDED 66 PERCENT. DURING THE REPORT MONTH THE
BOILER WAS OUT OF SERVICE 3 DAYS. SCKUBOER OUTAGES WERE CAUSED BY FROZEN
CARBONATE LINESi PLUGGED PRESSURE SENSING LINES AND AN WERHAUL OF A TRAY
RECYCLE PUMP. TOTAL OPERATING TIME LOGGED BY THIS SCRUBBING SYSTEM TO
DATE IS 7369 HRS.
114
PEDCo-ENVIRONWitttiftl.
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BACKGROUND INFORMATION
ON
REID GARDNER UNIT NO. 2
THE REID GARDNtR POWER STATION IS LOCATED NEAR MOAPA, NEVADA, ABOUT 50 MILES NORTH OF LAS VEGAS. AT
PRESENT THE STATION HAS TWO ELECTRIC POWER GENERATING UNITS, (REID GARDNER 1 AND 2) EACH RATED AT 125 MW.
BOTH UNITS ARE RETROFITTED WITH SODIUM CARBONATE BASED FLUE GAS DESULFURIZATION SYSTEMS. THE COAL BURNED
AT THE PLANT HAS AN AVERAGE GROSS HEATING VALUE OF 12,450 BTU/LB, AND ASH AND SULFUR CONTENTS OF 8 AND
0.5 PERCENT RESPECTIVELY.
THE FGD SYSTEM ON REID GARDNER 1 WAS MANUFACTURED BY COMBUSTION EQUIPMENT ASSOCIATES AND PLACED
IN OPERATION DURING APRIL, 1974. THE DESIGN OF THIS SYSTEM WAS BASED ON DATA GATHERED FROM THE OPERATION
OF AN 8000 ACFM PILOT PLANT WHICH OPERATED AT THE REID GARDNER POWER STATION DURING 1971 AND 1972.
THE FGD SYSTEM CONSISTS OF A SINGLE MODULE, DESIGNED TO HANDLE 473,000 ACFM OF GAS AT 350°F. EACH
MODULE IS MADE UP OF A TWIN VARIABLE THROAT VENTURI SCRUBBER FOLLOWED BY A SINGLE STAGE WASH TRAY.
BYPASSING OF EACH MODULE IS POSSIBLE THROUGH A GUILLOTINE TYPE BYPASS VALVE. THE PLANT HAS A COMMON
TRONA (SODIUM CARBONATE ORE) STORAGE AND SAND REMOVAL PLANT WHICH SERVES BOTH FGD MODULES ON REID GARDNER
1 AND 2. S02 REMOVAL EFFICIENCY IS REPORTED TO BE 85 PERCENT.
IN THIS SODIUM CARBONATE PROCESS, THE HOT FLUE GAS FROM THE BOILER PASSES FIRST THROUGH AN EXISTING
MECHANICAL COLLECTOR (MULTICYCLONE) WHERE ABOUT 75 PERCENT OF THE FLY ASH IS REMOVED. ITS PRESSURE IS
THEN BOOSTED BY AN I.D. FAN BEFORE IT SPLITS INTO TWO STREAMS AS IT ENTERS THE TWIN THROAT VENTURI
SCRUBBER. HERE THE HOT FLUE GAS IS QUENCHED BY A SHOWER OF CIRCULATED SODIUM BASE LIQUOR. THE GAS THEN
ENTERS THE WASH TRAY AND BUBBLES THROUGH THE WATER ON THE SIEVE TRAY. THE SCRUBBER GAS WHICH IS ESSENTIALLY
FREE OF FLY ASH AND SULFUR DIOXIDE, PASSES THROUGH THE RADIAL VANE MIST ELIMINATOR WHERE THE REMAINING
LIQUID DROPLETS CARRIED OVER WITH THE GAS ARE TRAPPED AND REMOVED.
THE EFFLUENT FROM THE FGD SYSTEM IS MADE UP OF TWO SOURCES: THE SLIP STREAM OF SPENT LIQUOR DISCHARGED
FROM THE RECIRCULATION TANK, AND THE ALKALINE CLARIFIER UNDERFLOW WHICH SERVES TO NEUTRALIZE THE pH OF
THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE SLUDGE SETTLING PONDS. THERE ARE TWO SLUDGE SETTLING
PEDCo- ENVIRONMENTAL
115
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REID GARDNER UNIT NO. 2 (continued)
PONDS, THE SPENT LIQUOR IS PUMPED ONE OF THEM AT A TIME. THE OVERFLOW FROM THIS POND IS PUMPED TO A
LARGER 45 ACRE POND WHERE THE BRINE IS EVAPORATED. THE FGD SYSTEM OPERATES ON AN OPEN WATER LOOP WITH NO
LIQUOR RECYCLED TO THE MODULES FROM THE PONDS.
PROBLEMS AND SOLUTIONS
THE MAJOR PROBLEM IN THE OPERATION OF THE FGD MODULES, HAS BEEN AND STILL IS THE LACK OF AN ADEQUATE
SUPPLY OF TRONA (SODIUM CARBONATE ORE). IN ORDER TO SOLVE THIS PROBLEM, SODIUM CARBONATE BRINE HAS BEEN
USED TO SUPPLEMENT TRONA. THE SYSTEM HAD THE USUAL START-UP PROBLEMS SUCH AS RUBBER LINERS ON RECIRCULATION
LINES GETTING LOOSE DUE TO POOR FABRICATION, FREEZE UP OF INSTRUMENTS AND ASH PLUGGING IN CONTROL VALVE
BYPASS LINES. OTHER MINOR PROBLEMS WERE LEAKAGE IN THE MECHANICAL SEALS OF THE .RECIRCULATION PUMPS.
ALSO MECHANICAL FAILURE PROBLEMS WERE EXPERIENCED WITH THE GUILLOTINE TYPE BYPASS DAMPERS, WHICH WERE
LATER CORRECTED WITH UPGRADED REPLACEMENT PARTS.
AS EXPECTED, THIS SODIUM BASED FGD SYSTEM HAS NOT EXPERIENCED SUCH PROBLEMS AS EQUIPMENT SCALING.
DEMISTER PLUGGING, CORROSION OR EROSION WHICH ARE USUALLY ASSOCIATED WITH LIME/LIMESTONE FGD SYSTEMS.
PEDCo-ENVIRONMENTAL
116
-------
Reid Gardner 2
Month
Jul. 75
Operating Hours
Bo Her FGD system
FGO System
Operability (X)
85X
COMMENTS
During February the FGD system operated with 90 percent availability on
trona supplemented with soda ash. Problems Included a plugged recycle
line strainer, seal water filters and boiler controls. Unit has now
restarted after shutdown for a five year turbine overhaul.
Second performance test was passed. Problems Included rubber-lined
pipe abrasion and routine mechanical problems. Miner Instrumentation
problems. High ash content, up to 20%, had no effect on emissions.
Aug. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Jan. 76
645
531
603
691
496
464
596
458
77
87
99
66
Three forced outages occurred due to strainer plugging, broken bucket
elevator, and worn out redrculatlon piping and rubber liner leakage.
Three forced outages occurred during the month of October due to pump
repair, Instrument plugging, and repair of piping leakage.
The utility reports system performance in terms of the operabllity Index.
Boiler was out of service a total of 3 days during the month. Scrubber
outages were caused by frozen carbonate lines, plugged pressure sensing
lines, and overhaul of a tray recycle pump.
PEDCo-ENVIRONMENT
117
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 03/76
IDENTIFICATION NO. 79
UTILITY NAME PHILADELPHIA ELECTRIC CO.
UNIT NAME EDDYSTUNE NO 1A
UNIT LOCATION EDDYSTONE PENNSYLVANIA
UNIT RATING 120 MM
FUEL CHARACTERISTICS COAL 2.5 PERCENT SULFUR
FGD VENDOR UNITED ENGINEERS
PROCESS MAGNESIUM OXIDE SCRUBBING
NEW OR RETROFIT RETROFIT
START UP OATE 9/75
FGD STATUS OPERATIONAL
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST $17 MILLION CAPITAL
OPERATIONAL THE S02 SCRUBBER HAS BEEN TEMPORARILY SHUTDOWN BECAUSE THE ACIO PLANT RE-
EXPERIENCE GENERATION FACILITY AT THE OLIN CHEMICAL SULFUKIC ACID PLANT IN PAULSBORO
NEW JERSEY HAS PERMANENTLY CEASED OPERATIONS. CONSIDERATIONS ARE NOW
BEING GIVEN TO THE RELOCATION OF THE REGENERATION FACILITY. ONCE THIS DE-
CISION IS MADE A MINIMUM PERIOD OF SIX MONTHS WILL BE REQUIRED TO RELO-
CATE THE REGENERATION FACILITY. THE PARTICULATE SCRUBBERS ARE CONTINUING
TO OPERATE. THL UTILITY IS STILL EXPERIENCING PROBLEMS WITH THE FANS, RE-
HEAT BURNERS, DAMPERS. AND EXPANSION JOINTS.
118
PEDCo- ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OK RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
66
PUBLIC SERVICE CO. OF COLORADO
VALMONT NO. 5
VALMONT COLORADO
50 MW
COAL 0.72 PERCENT SULFUR
UOP / PUb SERVICE OF COLORADO
LIMESTONE SCRUBBING
RETROFIT
10/7*
OPERATIONAL
95 PERCENT
8S PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
CLOSED LOOP
UNSTABILIZED SLUDGE DISPOSED IN LINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
SYSTLM HAS BEEI4 OPERATIONAL SINCE NOVEMBER 1971. THE FGO SYSTEM CURRENTLY
OPERATIONAL AT THIS STATION IS AN EXPERIMENTAL UNIT, ORIGINALLY DESIGNED
BY UNIVERSAL OIL PRODUCTS FOR PAKTICULATE REMOVAL ONLY. ONE OF THE TWO
PARALLEL SCRUBBING MODULES WAS CONVERTED TO LIMESTONL SCRUBBING FOR
EXPERIMENTAL PURPOSES ONLY.
119
PEDCo-ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
VALNONT NO. 5
THE VALMONT POWER STATION OF THE PUBLIC SERVICE COMPANY OF COLORADO IS LOCATED IN VALMONT. COLORADO, APPROXIMATELY 20
MILES NORTH OF DENVER. COLORADO. VALMONT NO. 5 IS A COAL-FIRED UNIT WHICH OCCASIONALLY FIRES GAS A FEW MONTHS DURING THE
YEAR. THE COAL GENERALLY EMPLOYED IS WYOMING ROSEBUD WHICH HAS AN AVERAGE GROSS HEATING VALUE OF 10,780 BTU/LB WITH ASH CONTENT
IN THE 6 TO 7 PERCENT RANGE AND SULFUR CONTENT LESS THAN 1 PERCENT.
THE FGD SYSTEM CURRENTLY BEING TESTED AT THIS STATION IS AN EXPERIMENTAL UNIT ORIGINALLY DESIGNED BY UNIVERSAL OIL
PRODUCTS FOR PARTICULATE REMOVAL ONLY. THIS TCA UNIT CONSISTS OF 2 PARALLEL MODULES WITH A COMBINED CAPABILITY OF TREATING
APPROXIMATELY 50 PERCENT OF THE TOTAL FLUE GAS LOAD OR THE EQUIVALENT OF APPROXIMATELY 100 MW GENERATING CAPACITY (50 MM PER
MODULE). THIS SYSTEM WAS COMPLETED AND OPERATIONAL IN 1971 AND RAN THROUGH TO OCTOBER 1974. PARTICULATE REMOVAL EFFICIENCY
WAS MEASURED TO BE 95 PERCENT. SOg REMOVAL EFFICIENCY WAS 45 PERCENT AND AVAILABILITY WAS APPROXIMATELY 70 PERCENT. FREQUENT
SCRUBBER OUTAGES WERE CAUSED PRIMARILY BY A SUPERSATURATED CALCIUM SULFATE CONDITION IN THE SCRUBBING LIQUOR. IN ORDER TO
MINIMIZE THE NUMBER OF CLEAN OUTS AND TO RECTIFY THE SCALING PROBLEM A pH CONTROL PROGRAM WAS IMPLEMENTED FOR ONE OF THE
SCRUBBING MODULES EMPLOYING LIMESTONE ADDITION TO THE SCRUBBING LIQUOR. THIS MODIFICATION WAS EXPECTED TO MINIMIZE
SCALING, DECREASE SCRUBBER OUTAGES FOR CLEAN OUTS, AND INCREASE AVAILABILITY. THE EXPECTED RESULTS DID NOT MATERIALIZE.
SCALE BUILD-UP CONTINUED AND AVAILABILITY DECREASED. RESULTS OBTAINED DURING THE pH CONTROL PROGRAM SHOWED PARTICULATE
REMOVAL EFFICIENCY AT THE 95% LEVEL. S02 REMOVAL EFFICIENCY INCREASED TO 85X AND AVAILABILITY DROPPED TO 70 PERCENT. THE
UNSTABILIZED SLUDGE GENERATED DURING THIS OPERATION PHASE WAS PUMPED TO A LINED POND. THE OPERATIONAL DATA GENERATED FROM
.THE LIMESTONE MODIFICATION PROGRAM IS OF A PRELIMINARY NATURE BASED UPON RESULTS OBTAINED FROM THE FOUR AND A HALF MONTH
TESTING PROGRAM.
120
-------
Valmont No. 5
Operating hours FGD System
Month Boiler FGD System Operablllty (%) Comments
Sep. 75 0 0 0 This facility has been Inactive since September 1. 1975
Oct. 75 0 0 0 due to a turbine generator failure. The unit Is scheduled
to go on line again sometime in December 1975.
Nov. 75 0 0 0 This unit is still Inactive due to a boiler overhaul. The
Dec. 75 0 0 0 scrubber/absorber train is available and will be coupled Into
the system when the boiler goes back on-line.
Jan. 76 0 0 0 The boiler overhaul has been completed. The unit is available
Feb. 76 0 0 0 In the particulate removal mode only. The limestone
modification program Implemented for one of the two scrubbing
modules has been delayed by the utility for an Indefinite
period.
121
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VLNDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICIPATES
802
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
100
TENNESSEE. VALLLY AUTHORITY
SHAUNEE N0.10A
PADUCAH KENTUCKY
10 MW
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
RETROFIT
V72
OPERATIONAL
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
TUKBULENT CONTACT ABSOKtiER(TCA) LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN
OPERATIONAL SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA.
TVA IS THE CONSTRUCTOR AND FACILITY OPERATOR. THE BECH1EL CORP. OF SAN
FRANCISCO IS THE MAJOR CONTRACTOR, TEST DIRECTOR. AND KIPORT WRITER.
122
PEDCo-ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 03/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
HATER MAKE UP
SLUDGE DISPOSAL
101
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10B
PADUCAH KENTUCKY
10 MU
COAL 2.9 PERCENT SULFUR
CHEMICO
LIME/LIMESTONE SCRUBBING
RETROFIT
V72
OPERATIONAL
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
VENTURI/SPRAY TOWER LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN OPERATIONAL
SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA. TVA IS THE
CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN FRANCISCO IS
THE MAJOR CONTRACTOR*TEST DIRECTOR, AND REPORT WRITER.
123
PEDCo-ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
SHAUNEE NOS. 10A, 10B, AND IOC
IN JUNE, 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE LIME AND LIMESTONE WET SCRUBBING SYSTEMS FOR THE REMOVAL
OF SULFUR DIOXIDE AND PARTICULATES FROM COAL-FIRED BOILER FLUE GASES. THE PROGRAM WAS INITIATED AND CARRIED OUT IN A TEST
FACILITY WHICH WAS INCORPORATED INTO THE FLUE GAS DUCT WORK OF UNIT NO. 10, A COAL-FIRED BOILER AT THE TVA SHAWNEE POWER
STATION, PADUCAH, KENTUCKY. TVA IS THE CONSTRUCTOR AND FACILITY OPERATOR AND THE BECHTEL CORP. IS THE MAJOR CONTRACTOR. TEST
DIRECTOR, AND REPORT WRITER.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE TREATING PART OF THE FLUE GAS FROM THE
BOILER. EACH SCRUBBER TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30,000 ACFM OR THE EQUIVALENT OF APPROXIMATELY 10 MW OF
POWER PLANT GENERATING CAPACITY.
THE THREE PARALLEL WET SCRUBBER SYSTEMS SELECTED FOR THE TEST PROJECT WERE: 1) A VENTURI WITH A SPRAY TOWER AFTER
ABSORBER; 2) A TURBULENT CONTACT ABSORBER (TCA) AND 3) A MARBLE-BED ABSORBER. THE VENTURI SYSTEM, MANUFACTURED BY CHEMICAL
CONSTRUCTION CO., CONTAINS AN ADJUSTABLE THROAT THAT PERMITS CONTROL AND VARIATION OF PRESSURE DROP UNDER A WIDE RANGE OF FLOW
CONDITIONS. THE TCA UNIT MANUFACTURED BY UNIVERSAL OIL PRODUCTS, EMPLOYS A FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT
ARE FREE TO MOVE BETWEEN RETURNING GRIDS. THE MARBLE-BED ABSORBER, SUPPLIED BY COMBUSTION ENGINEERING CO., USES A PACKING
OF 3/4 INCH GLASS MARBLE SPHERES AND A TURBULENT LAYER OF LIQUID AND GAS ABOVE THE MARBLE LAYER TO ENHANCE MASS TRANSFER.
IN JUNE 1974, THE EPA, THROUGH ITS OFFICE OF RESEARCH AND DEVELOPMENT AND INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
INITIATED A THREE-YEAR ADVANCED TEST PROGRAM AT THE SHAWNEE FACILITY. THE MAJOR GOALS ESTABLISHED FOR THE ADVANCED PROGRAM
ARE: (1) CONTINUATION OF LONG-TERM TESTING, EMPHASIZING RELIABLE OPERATION OF MIST ELIMINATION SYSTEMS AT INCREASED GAS
VELOCITY. (2) INVESTIGATION OF ADVANCED PROCESS AND EQUIPMENT DESIGN VARIATIONS FOR IMPROVING SYSTEM RELIABILITY AND PROCESS
ECONOMICS, AND (3) TO PERFORM LONG-TERM RELIABILITY TESTING ON PROMISING PROCESS AND EQUIPMENT DESIGN VARIATIONS.
THE TWO PARALLEL SCRUBBING SYSTESM OPERATING DURING THE ADVANCED PROGRAM ARE THE VENTURI/SPRAY TOWER SYSTEM AND THE
TCA UNIT. OPERATION OF THE MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
PEDCO-ENV1RONMENTAL
124
-------
SHAWNEE NOS. 10A, 10B, and IOC (continued)
EACH OF THE ABOVE TWO SYSTEMS CONTAINS ITS OWN SLURRY HANDLING FACILITIES AND IS CAPABLE OF TREATING APPROXIMATELY 30,000
ACFM OF GAS AT 300°F CONTAINING 1800 TO 4000 PPM OF S02 AND 2 TO 4 GRAINS/SCF OF PARTICULATES. BOILER NO. 1 NORMALLY BURNS
A HIGH-SULFUR BITUMINOUS COAL.
FROM JUNE 1974 TO JANUARY 1976. THE MIST ELIMINATION AND LIMESTONE UTILIZATION TESTS WERE CONDUCTED AT THE SHAWNEE
FACILITY. DURING THIS TEST PERIOD THE VENTURI/SPRAY TOWER SYSTEM WAS OPERATED ON BOTH LIME AND LIMESTONE AND THE TCA SYSTEM
WITH LIMESTONE. TESTING WAS PERFORMED UNDER A CLOSED LIQUOR LOOP OPERATION MODE. DURING THIS PERIOD THE SLURRY SOLIDS CON-
TAINED APPROXIMATELY 40.TO 50 WEIGHT PERCENT FLY ASH BECAUSE OF RELATIVELY HIGH GAS INLET PARTICULATE LOADING. THIS TESTING
PROGRAM IS SCHEDULED TO RUN THROUGH TO JUNE 1977.
PEDCo-ENVIRONMENTAL
125
-------
Shawnee Nos. 10A and 10B
FGD System Operating Hours
Test Run Period FGD System
Month 10A 10B operability (X) Comments.
Sep. 75 This 1s an experimental EPA-funded system. Currently proceeding
Oct. 75' with the test program. Tow absorber modules are currently opera-
tional (10 MW each) with the marble-bed absorber still Inoperative
(since July, 1973). Currently, experiments are related to mist
eliminator section.
Nov. 75 Recent testing at Shawnee has shown that the chevron mist elim-
Oec. 75 Inators 1n both the spray tower ari'd the TCA can be kept free of
solids build-up at high alkali utilization (greater than 90 percent)
using only Intermittent washing with available raw water. This high
Utilization 1s normally achieved with lime and has been achieved
with limestone at (1) reduced scrubber Inlet slurry pH (about 5.2)
and (2) with the use of three effluent tanks in series to simulate a
plug-flow reactor.
Presently, testing Is continuing to determine the effects of process
variables on mist eliminator performance and on limestone utiliza-
tion. Future plans Include: (1) factorial 'testing with lime and
limestone to determine the effects of process variables on SO- re-
moval for the scrubber systems, and (2) testing the oxidation of
sludge to gypsum in the venturi/spray tower system using air
sparging of an acidified slurry bleed stream.
Jan 76 Presently, the utility and the contractor are continuing with the
Feb. 76 advanced test program being conducted at this facility. The high-
lights of this program are:
PEDCo-ENVIRONMENTAL
126
-------
Shawnee Nos. 10A and 10B (continued)
Evaluate scrubber operablllty during variable load
operation
Continuation of long-term reliability testing
Investigation of methods for Improving waste solids
separation
Continuation of sludge oxidation and sludge fixation
study programs
Evaluation of system performance at reduced fly ash
loadings
Determination of the practical upper limits of S02 removal
efficiency
Magnesium ion addition to the scrubbing slurry
Characterization of all stack gas emission components
Evaluation of materials of construction of all scrubber
and plant related components.
Development of a design and cost analysis computer
program for full scale lime/limestone systems.
127
PEDCo- ENVIRONMENTAL
-------
Table 4
NUMBER AND TOTAL MW OF FGD SYSTEMS
129
-------
TABLE 4
NUMBER AND TOTAL MW OF FGO SYSTEMS
STATUS NO.OF MW
UNITS
OPCKATIONAL 23 3««»8.
UNDER CONSTRUCTION 20 7256.
PLANNING
CONTRACT AWARDED It 5861.
LETTER OF INTENT " 9 3771.
REQUESTING/EVALUATING BIDS 6 3102.
CONSIDERING ONLY FGD SYSTEMS 37 19253.
TOTAL 109 13091.
PEDCO-ENVIRONMENTAL
I O I
-------
Table 5
SUMMARY OF FGD SYSTEMS BY COMPANY
133
-------
TABLE 5
SUMMARY OF FGD SYSTEMS BY COMPANY
UTILITY
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTLM
ARIZONA ELECTRIC POWER COOP
ARIZONA PUBLIC SERVICE
BASIN ELECTRIC POWEK COOP
CENTRAL ILLINOIS LIGHT CO.
CENTRAL ILLINOIS PUBLIC SERV
CINCINNATI GAS 8 ELECTRIC CO.
COLUMBUS 8 SOUTHERN OHIO ELEC.
COMMONWEALTH EDISUN
DETROIT EDISON
DUQUESNE LIGHT
GENERAL MOTOKS
GULF POWER CO.
INDIANAPOLIS POWEK £ LIGHT CO.
KANSAS CITY POWER & LIGHT
KANSAS POWEK & LIGHT
KENTUCKY UTILITIES
KEY WEST UTILITY BOARD
LOUISVILLE GAS 8 ELECTRIC
MINNKOTA POWER COOPERATIVE
MONTANA POWER CO,
NEVADA POWEK
NEW ENGLAND ELEC SYSTEM
NORTHERN INDIANA PUt3 SERVICE
NORTHERN STATES POWER CO.
PENNSYLVANIA POWLH CO.
PHILADELPHIA ELECTRIC CO.
PUBLIC SERVICE co OF NEW P.EX.
PUBLIC SERVICE CO. OF COLORADO
PUBLIC SERVICE INDIANA
RICKENBACKER AFB
S. CAROLINA PUR SERV AUTHORITY
S. MISSISSIPPI ELEC PWR ASSOC
SOUTHERN CALIFORNIA EDISON
SPRINGFIELD CITY UTILITIES
TENNESSEE VALLEY AUTHORITY
TEXAS UTILITIES CO.
UNITED POWER ASSOCIATION
UTAH POWER & LIGHT CO.
TOTAL
NO.
2
2
2
5
5
3
1
2
4
2
1
2
1
3
1
3
4
1
1
8
1
4
10
1
3
2
3
4
4
1
2
1
1
2
6
1
3
4
2
1
OPERATIONAL
. STATUS
i*wi«0 i n%/«* I • w*«
CONTRACT
AWARDED
MW
45U.
1250.
405.
1875.
2550.
857.
600.
900.
1550.
542.
180.
920.
32.
63.
530.
1060.
1885.
64.
37.
2213.
450.
2120.
3000.
650.
705.
1360.
2505.
846.
1715.
50.
1300.
20.
140.
360.
4410.
200.
570.
3172.
1090.
415.
NO.
0
0
0
1
0
0
0
0
0
1
0
2
1
3
0
3
2
1
1
1
0
1
2
0
0
0
0
1
0
1
0
0
0
0
0
0
2
0
0
0
MW
0.
0.
0.
115.
0.
0.
0.
0.
0.
167.
0.
920.
32.
63.
0.
1060.
525.
64.
37.
65.
0.
360.
250.
0.
0.
0.
0.
120.
0.
SO.
0.
0.
0.
0.
0.
0.
20.
0.
0.
0.
NO.
• o
0
0
2
0
1
0
0
1
0
1
0
0
0
1
0
0
0
0
3
1
1
1
0
1
2
2
0
0
0
0
1
0
0
0
1
1
0
0
0
MW
0.
0.
0.
410.
0.
100.
0.
0.
400.
leo".
u.
0.
0.
530.
0.
0.
0.
0.
786.
450.
360.
125.
0.
115.
1360.
1670.
0.
0.
0.
0.
20.
0.
0.
0.
200.
550.
0.
0.
0.
NO.
2
0
0
0
0
0
0
0
1
0
0
0
0
0
0
2
0
0
1
0
0
0
0
0
0
0
0
2
0
0
0
1
2
0
0
0
2
0
0
Mb
450.
0.
0.
0.
0.
0.
0.
0.
400.
425.
0.
0.
0.
0.
0.
0.
1360.
0.
0.
425.
0.
0.
0.
0.
0.
0.
0.
' U.
715.
0.
0.
0.
140.
360.
0.
0.
0.
1586.
0.
0.
LETTER OF REQUESTING/
INTENT
NO.
0
0
2
0
0
0
0
0
0
. °
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
1
2
0
0
0
0
0
0
0
0
2
0
1
MW
0.
0.
405.
0.
0.
0.
0.
0.
°?
o!
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
125.
0.
0.
' 0.
0.
240.
1000.
0.
0.
0.
0.
0.
0.
0.
0.
1586.
0.
415.
CVAL. BIDS
NO.
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
2
0
MW
0.
0.
0.
0.
0.
0.
600.
300.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
277.
0.
0.
0.
0.
0.
0.
835.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
1090.
0.
CONSIDERING
FGD
NO.
0
2
0
2
5
2
0
1
2
0
0
0
o
0
0
o
0
0
0
2
o
2
6
1
2
0
0
2
0
0
2
0
0
0
6
0
o
0
0
0
SYSTEMS
MW
0.
1250.
0.
1350.
2550.
757.
0.
600.
750.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
660.
0.
1400.
2500.
650.
590.
0.
0.
486.
0.
0.
1300.
0.
0.
0.
4410.
0.
0.
0.
0.
0.
TOTALS
109 43091. 23 3848. 20 7256. 14 5861.
3771.
3102. 37 19253.
PEOCo-ENVIRONMENTAL
135
-------
Table 6
SUMMARY OF FGD SYSTEMS BY VENDOR
137
-------
TAULE 6
SUMKARY OF FGO SYSTEMS DY VLNUOR
TOTAL OPERATK
MANUFACTURER/PROCESS NO.
ADL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI J
TOTAL. ADL/COKBUSTION EQUIP ASS 1
AMERICAN AIK FILTER
LIME SCRUBBING 3
TOTAL, AMERICAN AIR FILTER 3
BABCOCK 8 WILCOX
LIMESTONE SCRUBBING 2
TOTAL, BABCOCK & WILCOX 2
CHEMICO
LIME SCRUBBING 7
LIME/LIMESTONE SCRUBBING 1
TOTAL, CHEMICO 5
CHIYODA INTERNATIONAL
THOROUGHBRED 101 *
TOTAL, CHIYODA INTERNATIONAL 1
COMBUSTION ENGINEERING
LIME SCRUBBING ;:
LIMESTONE INJECTION XwET SCRUB '*
LIMESTONE SCRUBBING 2
TOTAL, COMBUSTION ENGINEERING a
COMBUSTION EQUIP. ASSOCIATES
LIME SCRUBBING *
SODIUM CARBONATE SCRUBBING 3
TOTAL, COMBUSTION EQUIP. ASSOCI 6
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL 1
TOTAL, DAVY POWERGAS/ALLIED CHE 1
FOSTER WHEELER
ACTIVATED CARBON 1
TOTAL, FOSTER WHEELER 1
KOCH
DOUBLE ALKALI *
TAT 111 . KOCH l
MW
20.
20.
667.
667.
967.
967.
2590.
10.
2600.
23.
23.
2<*8.
765.
1360.
2373.
1170.
375.
1515.
115.
115.
20.
20.
32.
32.
NO.
1
1
1
1
2
2
2
1
3
1
1
1
0
5
1
2
3
0
0
1
1
1
1
•STATUS
)NAL C
MW
20.
20.
6H.
6 ENVIRONMENTAL
-------
TABLE 6
SUMMARY OF FGU SYSTEMS BY VENDOR
TOTAL OPERATI
MANUFACTURER/PROCESS
PEABODY ENGINEERING
LIMESTONE SCRUBBING
TOTALt PEABODY ENGINEERING
RESEARCH COTTKELL
LIME SCRUBBING
LIMESTONE SCRUBBING
TOTAL. RESEARCH COTTRELL
RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
TOTALt RILEY STOKER/ENVIRONEERI
SCE
LIME SCRUBBING
TOTALt SCE
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
TOTAL. TENNESSEE VALLEY AUTHOR!
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUUBING
TOTAL. UNITED ENGINEERS
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
LIME/LIMESTONE SCRUBBING
LIMESTONE SCRUBBING
TOTAL. UNIVERSAL OIL PRODUCTS
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
TOTALt UOP / PUB SERVICE OF COL
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
TOTALt ZURN AIR SYSTEMS
NO.
1
1
1
2
3
1
1
1
1
1
1
1
1
1
1
2
4
1
1
1
1
MU
160.
160.
20.
365.
365.
100.
100.
160.
160.
550.
550.
120.
120.
too.
10.
730.
11HO.
50.
50.
37.
37.
NO.
0
0
0
1
1
0
0
0
0
0
0
1
1
0
1
0
1
1
1
1
1
-STATU!
ONAL <
nw
0.
0.
0.
115.
115.
0.
0.
0.
0.
0.
0..
120.
120.
0.
10.
0.
10.
50.
50.
37.
37.
CONSTRUCTION
NO.
1
1
1
1
2
1
1
1
1
1
1
0
0
1
0
2
3
0
0
0
0
MU
180.
160.
20.
250.
270.
100.
100.
160.
160.
550.
550.
0.
0.
too.
0.
730.
1130.
0.
0.
0.
0.
11104.
23 3646.
20 7256.
140
PEDCb- ENVIRONMENTAL
-------
Table 7
SUMMARY OF NEW AND RETROFIT FGD SYSTEMS BY PROCESS
141
-------
TABLE 7
SUMMARY OF NEW AND RETROFIT FGD SYSTEMS BY PROCESS
MM CAPACITY(NO. OF PLANTS)
PROCESS
LIME SCRUBBING
LIME/LIMESTONE SCRUBBING
(PROCESS NOT SELECTED)
LIMESTONE SCRUBBING
SUBTOTAL - LIME/LIMESTONE
ACTIVATED CARBON
DOUBLE ALKALI
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
REGENERABLE NOT SELECTED
SODIUM CARBONATE SCRUBBING
THOROUGHBRED 101
WELLMAN LORD
UELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/LIMESTONE * OF TOTAL MW
NEW OR OPERATIONAL
RETROFIT
NO. MW
N 1 360
R 4 1049
N
R
N
R
N
R
N
R
N
R
N
R
R
N
R
N
R
R
N
R
N
R
N
R
W N
R
U
2
3
6
4.
12.
0
1
0
2
0
1
0
0
0
0
0
2
o
1
o
0
0
0
4
19
0
20
1257
697
1617.
1766.
0
20
0
52
0
120
0
0
0
0
0
250
0
23
0
0
0
0
. 1617.
. 2231.
100
79
CONSTRUCTION
NO. MW
6 3305
4 b41
0
0
6
2
12.
6.
0
0
o
0
0
0
0
0
0
0
1
0
o
0
0
0
0
1
13.
7.
0
0
2440
730
5745.
1271.
0
0
0
0
0
0
0
0
0
0
125
0
0
0
0
0
0
115
5670.
1366.
96
92
CONTRACT
AWARDED
NO. MW
2 625
0 0
0
0
9
1
11.
1.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
12.
2.
0
0
3696
<*25
4721.
425.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
375
340
5096.
765.
93
56
LETTER OF
INTENT
NO. MW
1 415 ....
0 0
0
0
4
0
5.
0.
0
0
0
0
0
1
0
0
0
0
1
0
0
0
2
0
0
0
6.
1.
0
0
1991
0
2406.
0.
0
0
0
0
0
240
0
0
0
0
125
0
0
0
1000
0
0
0
3531.
240.
66
o"
LANNEO-
REOUE
EVAL.
NO.
0
1
3
0
0
0
3.
1.
0
0
0
0
0
0
2
0
0
0
0
0
0
0
0
0
0
0
5.
1.
.STING/
BIDS
nw
0
277
1190 -
0
0
0
1390.
277.
0
0
0
0
0
0
1435
0
0
0
0
0
0
0 '
0
0
0
0
2625.
277.
49
100
CONSIDERING
FGD SYSTEM
NO. MW
6 4250
2 660
0
2
1
0
7.
4.
0
0
0
0
0
2
16
5
0
1
0
0
0
0
0
0
0
0
25.
12.
0
1410
400
0
4650.
2070.
0
.0
0
0
0
466
9100
2297
0
650
0
0
0
0
0
0
0
0
13750.
5503.
34
38
• TOTAL NO.
OF PLANTS
NO. MW
16 9155
11 2b27
3
4
23
9
42.
24.
0
1
0
2
0
4
20
5
0
1
2
2
0
1
2
0
1
2
67.
42.
PEDCo-
1190
1430
9984
1652
20529.
5609.
0
20
0
52
0
846
10535
2297
0
650
250
250
0
23
1000
0
375
32669.
10402.
ENVlftONMtl
63
56
143
-------
Table 8
SUMMARY OF OPERATING FGD SYSTEMS BY PROCESS AND GENERATING UNITS
145
-------
TADLE 8
SUMMARY OF OPERATING FGD SYSTEMS BY
PROCESS AND GENERATING UNITS AS OF 03/76
PROCESS/GENERATING UNITS
FGU/MU STARTUP EXPERIENCED.)
ACTIVATED CARBON
SCHOLZ NO. 2A
20
20.
2-76
DOUBLE ALKALI
CHEVROLET PARMA 1 2 3 ft
SCHOLZ NO. 1A
32
20
52,
3-7*
2-75
2
-------
TABLE: a
SUMMARY OF OPERATING FGD SYSTEMS BY
PROCESS AND GENERATING UNI IS AS OF 03/76
PROCESS/GENERATING UNITS FGD/MU STARTUP EXPERIENCE(MO.)
WILL COUNTY NO 1 167 2-72 H9
1954, . 395
MAGNESIUM OXIDE SCRUBBING
EDOYSTONE NO 1A 120 9-75 6
120. 6
SODIUM CARBONATE SCRUBBING
REID GARDNER NO 1 125 *-7* 23
REID GARDNER NO 2 125 12-73 27
250. v 50
THOROUGHBRED 101
SCHOLZ NOS. IB ft 2B 23 3-75 12
•••••• ' »•••
23. 12
148 PEDCO-ENVIRONMENIAL
-------
Table 9
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS
149
-------
TADLE 9
SUMMAKY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS AS OF 03/76
PROCESS/GENEKATING UNIT
.-SLUDGE-
STABILIZED
—SLUDGE—
UNSTABILIZED
—POND—
LINED
POND
UNLINED
LIME SCRUBBING
PADDYS RUN NO 6
PHILLIPS
TOTAL
410
410.
65
65,
65
410
475.
LIMESTONE SCRUBBING
HAWTHORN NO 3
HAWTHORN NO 4
LAWRENCE NO 4
LAWKENCE NO 5
CHOLLA NO 1
LA CYGNE NO 1
STOCK ISLAND PLANT
VALMONT NO. 5
WILL COUNTY NO 1
TOTAL
167
167.
140
100
125
400
115
620
50
1750.
50
167
217.
140
100
125
400
115
820
37
1737.
151
PEDCo-ENVIRONMENTAL
-------
Table 10
SUMMARY OF F6D SYSTEMS BY PROCESS AND REGULATORY CLASS
153
-------
TABLE 10
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
MW CAPACZTYiNO. OF PLANTS)
PROCESS
LIME SCRUBBING
LIME/LIMESTONE SCRUBBING
(PROCESS NOT SELECTED)
LIMESTONE SCRUBBING
SUBTOTAL - LIME/LIMESTONE
REGULATORY OPERATIONAL
CLASS
NO.
A 0
B 2
C 9
0 0
E 0
A ' 0
B 0
C 2
0 0
E 0
A U
B 3
C 3
D 3
E 0
A 0.
B 5.
c a.
D 3.
E 0.
CONSTRUCTION
CONTRACT
AWARDED
MW
0
920
469
0
0
0
0
20
0
0
0
355
1021
575
0
0.
1275.
1533.
575.
0.
NO.
2
5
2
0
1
0
0
• 0
0
0
3
3
1
0
1
5.
6.
3.
0.
2.
MW
765
2660
361
0
20
0
0
0
0
0
630
1610
5t>0
0
160
1615.
4290.
911.
0.
200.
NU.
1
1
0
0
0
0
0
0
0
0
7
2
1
0
0
6.
3.
1.
0.
0.
MW
425
400
0
0
0
0
0
0
0
0
2536
136Q
425
0
0
2561.
1760.
425.
0.
0.
LETTER OF REQUESTING/
INTENT
NO.
0
0
0
0
1
. 0
0
0
0
0
2
2
"0
0
0
2.
2.
0.
0.
1.
MW
0
0
0
0
415
0
0
0
0
0
1566
405
0
0
0
1566.
405.
0.
0.
415.
EVAL.
NO.
0
0
1
0
0
2
0
0
1
0
0
0
0
0
0
2.
0.
1.
1.
0.
i BIDS
MW
0
0
277
0
0
1D90
0
0
300
0
0
0
0
0
0
1090.
0.
277.
300.
0.
CONSIDERING
IUTAL NU.
OF PLANTS
FGD SYSTEM
NO.
6
0
2
0
0
0
0
0
0
2
1
0
0
0
0
7.
0.
2.
0.
2.
MW
4250
0
660
0
0
0
0
0
0
1410
400
0
0
0
0
4650.
0.
660.
0.
1410.
NO.
9
8
6
0
2
2
0
2
1
2
13
10
5
3
1
24.
16.
15.
4.
5.
MW
5460
4000
1767
0
435
1090
0
20
300
1410
5352
3730
1999
575
160
11902.
7730.
3606.
675.
2025.
A. BOILER CONSfKUCTEO SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STAT£ STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT ZS EQUAL TO OR LESS STRINGENT THAN NSPS
0. OTHER
E. REGULATORY CLASS UNKNOWN
PEDCo-ENVIRONMENTAL
155
-------
SUMMARY OF FGO SYSTEMS BY PROCESS AND REGULATORY CLASS
MM CAPACITYJNO. OF PLANTS)
PROCESS
ACTIVATED CARBON
DOUBLE ALKALI
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
REGENERABLE NOT SELECTED
Bi Aikkirn .-------.-•
REGULATORY OPERATIONAL
CLASS
NO. MM
A 0 0
BOO
C 1 20
D 0 0
EDO
A 0
B 1
C 1
D(i
V
E 0
A 0
B 1
CM
V
D 0
E 0
A U
B 0
C 0
D 0
E 0
An
w
B 0
C 0
D G
E 0
0
32
20
o
0
0
120
o
0
0
0
0
o
0
0
o
0
0
0
0
CONSTRUCTION
NO. MW
0 0
0 0
0 0
0 0
0 0
0
0
0
o
0
0
0
o
0
0
0
0
0
0
0
o
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
CONTRACT
AWARDED
NO. MW
0 0
0 0
0 0
0 0
0 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
LETTER OF REQUESTING/
INTENT EVAL. BIDS
NO. MW NO. MM
00 00
00 00
00 00
00 00
00 00
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2
-------
TABLE 10
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
MU CAPACITY(NO. OF PLANTS)
PROCESS
SODIUM CARBONATE SCRUBBING
THOROUGHBRED 101
UELLMAN LORD
UELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/STONE » OF TOTAL MW
REGULATORY OPERATIONAL CONSTRUCTION
CLASS
NO. MW NO. MU
A U 0 00
B 2 250 1 125.
COO 00
Dn o 0 0
E
B
c
E
A
B
o
E
A •
B
c
Q
E
A
B
C
D
E
A
B
C
D
E
0
0
1
Q
0
0
o
o
o
0
0
0
o
o
0
0
9
11
3
0
0
o
0
23
o
0
0
o
o
o
0
0
0
0
o
0 .
0.
. 1677.
. 1596.
575.
0.
0
76
V6
100
0
0
0
0
0
o
0
0
0
o
0
0
0
0
1
0
0
5
9
4
0
2
0
0
0
0
0
0
0
0
0
0
0
0
0
115
0
0
. 1615.
. 4415.
. 1026.
0.
. 200.
100
97
89
0
100
CONTRACT
AWARDED
NO. MW
0 0
0 0
0 0
0 0
0
0
0
0
0
0
0
0
0
0
0
0
2
0
0
0
8.
5.
1.
0.
0.
0
0
0
0
0
0
0
0
0
0
0
0
715
0
0
0
2961.
2475.
425.
0.
0.
100
71
100
0
0
LETTER OF REQUESTING/
INTENT EVAL. BADS
NO. MW NO. MW
00 00
1 125 00
00 00
00 00
0
0
0
0
0
0
0
2
0
0
0
0
0
0
0
0
2.
6.
0.
0.
1.
0
0
0
0
0
0
0
1000
0
0
0
0
0
0
0
0
1586.
1770.
0.
0.
HIS.
100
23
0
0
100
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3.
1.
1.
1.
0.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1690.
835.
277.
300.
0.
64
0
100
100
0
CONSIDERING
FGD SYSTEM
NO. MW
0 0
0 0
0 0
0 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
12.
15.
8.
0.
. 2.
0
0
0
0
0
0
0
0
0
0
0
0
o •
0
0
0
7950.
7150.
2743.
0.
1410.
56
0
21
0
100
TOTAL NO.
OF PLANTS
NO. MW
0 0
4 500
0 0
0 0
0
0
0
1
0
0
0
2
0
0
0
0
2
1
0
0
30.
45.
25.
4.
5.
D
0
0
23
0
0
0
1000
0
0
0
0
715
115
0
0
15802.
18322.
6067.
675.
2025.
75
42
63
100
100
i: s;g SS^T?. w«aj2°ss sru •™»««^«'«jSi -B
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
0. OTHER
C. REGULATORY CLASS UNKNOWN
PEDCo-ENVIRONMENTAL
157
-------
Table 11
SUMMARY OF OPERATIONAL FGD SYSTEMS
159
-------
TABLE 11
SUMMARY OF OPERATIONAL F6D SYSTEMS AS OF 03/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF F60 PROCESS/VENDOR
RETROFIT UNIT
FUEL CHARACTERISTICS
HO/YR
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
COMMONWEALTH EDISON
WILL COUNTY NO 1
DUQUESNE LIGHT
PHILLIPS
OUOUESr'E LIGHT
ELKAMA
GENERAL MOTORS
CHEVROLET PARMA 12341
GULF POWER CO.
SCHOLZ NO. 1A
GULF POWER CO.
SCHOLZ NO. 2A
GULF POWER CO.
SCHOLZ NOS. IB & 28
KANSAS CITY POWER & LIGHT
HAWTHORN NO 3
KANSAS CITY POWER ft LIGHT
HAWTHORN NO 4
KANSAS CITY POWER & LIGHT
LA CYGNE NO 1
KANSAS POWER & LIGHT
LAWRENCE NO 4
KANSAS POWER & LIGHT
LAWRENCE NO 5
KENTUCKY UTILITIES
GREEN RIVER UNITS 1 AND 2
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
R
R
R
R
R
R
R
R
R
R
N
R
N
R
N
115
167
mo
510
32
20
20
23
140
100
620
125
too
64
37
RESEARCH COTTRELL
LIMESTONE SCRUBBING
BABCOCK & WILCOX
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
CHEMICO
LIME SCRUBBING
KOCH
DOUBLE. ALKALI
ADL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI
FOSTER WHEELER
ACTIVATED CARBON
CHIYODA INTERNATIONAL
THOROUGHBRED 101
COMBUSTION ENGINEERING
LIMESTONE INJECTION SWET SCRUB
COMBUSTION ENGINEERING
LIMESTONE INJECTION &WET SCRUB
BABCOCK & WILCOX
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE INJECTION 4WET SCRUB
COMBUSTION ENGINEERING
LIMESTONE INJECTION 4WET SCRUB
AMERICAN AIR FILTER
LIME SCRUBBING
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
COAL 0.44-1 PERCENT SULFUR 10/73
COAL - 9463 BTUt 2.1% SULFUR 2/72
COAL • i.o- 2.6 PERCENT SULFUR 7/73
COAL i.o - 2.8 PERCENT SULFUR 10/75
COAL 2.5 PERCENT SULFUR
COAL 3.0 PERCENT SULFUR
COAL 3.0 PERCENT SULFUR
COAL 3.0 PERCENT SULFUR
3/74
2/75
2/76
3/75
COAL o.b- 3.0 PERCENT SULFUR 11/72
COAL 0.6- 3.0 PERCENT SULFUR 8/72
COAL 5.2 PERCENT SULFUR
COAL 0.5 PERCENT SULFUR
COAL 0*5 PERCENT SULFUR
COAL 3.6 PERCENT SULFUR
OIL 2.4 PERCENT SULFUR
2/73
12/68
11/71
9/75
10/72
161
PEDCo- ENVIRONMENTAL
-------
TABLE 11
SUMMARY OF OPERATIONAL FGD SYSTEMS AS OF 03/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD PROCESS/VENDOR
RETROFIT UNIT
FUEL CHARACTERISTICS
MO/YR
LOUISVILLE GAS ft ELECTRIC R
PADDYS RUN NO 6
MONTANA POWER CO. N
COLSTRIP NO 1
NEVADA POWER R
REID GAKDNER NO 2
NEVADA POWER R
REID GAKDNER NO 1
PHILADELPHIA ELECTRIC CO. R
EDDYSTONE NO 1A
PUDLIC SERVICE CO. OF COLORADO R
VALMONT NO. s
TENNESSEE VALLEY AUTHORITY R
SHAWNEE N0.10A
TENNESSEE VALLEY AUTHORITY R
SHAWNEE N0.10B
65 COMBUSTION ENGINEERING
LIME SCRUBBING
360 COMBUSTION EQUIP. ASSOCIATES
LIME SCRUBBING
125 COMBUSTION EQUIP. ASSOCIATES
SODIUM CAKBONATE SCRUBBING
125 COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
120 UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
50 UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
10 UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
10 CHEMICO
LIME/LIMESTONE SCRUBBING
COAL 3.5-4.0 PERCENT SULFUR 4/73
COAL 0.8 PERCENT SULFUR
10/75
COAL o.s- i.o PERCENT SULFUR 12/73
COAL o.s- itO PERCENT SULFUR 4/74
COAL 2.5 PERCENT SULFUR 9/75
COAL 0.72 PERCENT SULFUR 10/74
COAL 2.9 PERCENT SULFUR 4/72
COAL 2.9 PERCENT SULFUR 4/72
PEDCo-ENVIRONMENTAL
162
-------
Table 12
SUMMARY OF FGD SYSTEMS UNDER CONSTRUCTION
163
-------
TABLE 12
SUMMARY OF FGO SYSTEMS UNDER CONSTRUCTION AS OF 03/76
UTILITY COMPANY
POWEH STATION
NEW OR SIZE OF FGO PROCESS/VENDOR
RETROFIT UNIT
FULL CHARACTERISTICS
MO/YR
ARIZONA PUBLIC SERVICE
FOUR COKNEKS NO. 5A
ARIZONA PUBLIC SERVICE
CHOLLA NO 2
CENTRAL ILLINOIS LIGHT CO.
OUCK CREEK NO.l
COLUMBUS ft SOUTHERN OHIO ELEC.
CONESVILLE NO 5
DETROIT EDISON
ST.CLAIR NO 6
INDIANAPOLIS POWER fc LIGHT CO.
-PETERSBURG NO 3
LOUISVILLE GAS S ELECTRIC
CANE RUN NO 4
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 5
LOUISVILLE GAS ft ELECTRIC
MILL CREEK NO 3
MIMNKOTA POWER COOPERATIVE
MILTON R. YOUNG NO. 2
MONTANA POWER CO.
COLSTKIP NO 2
NEVADA POWER
REID GARDNER NO 3
NORTHERN INDIANA PUB SERVICE
MITCHELL NO 11
NORTHERN STATES POWER CO.
SHERBURfcE NO 1
NORTHERN STATES POWER CO.
SHERBURNE NO 2
R
N
N
N
R
N
R
R
N
N
N
N
R
N
N
160
250
100
HOD
180
S30
176
183
425
450
360
125
115
600
680
SCE
LIME SCKUBUING
RESEARCH COTTRELL
L1MLS10NE SCRUBBING
RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
PEABODY ENGINEERING
LIMESTONE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
COMBUSTION EQUIP. ASSOCIATES
LIME SCRUBBING
COMBUSTION EQUIP. ASSOCIATES
LIME SCRUBBING
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
DAVY POWERGAS/ALLIEO CHEMICAL
WELLMAN LORD/ALLILD CHEMICAL
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
COALf 0.7 - 0.75. SULFUR (AVG) 2/76
COAL 0.44-1 PERCENT SULFUR 6/77
COAL 2.5-3.0 PERCENT SULFUR
6/76
COAL 4.5 - 4.9 PERCENT SULFUR 6/76
COAL 3.7 PERCENT SULFUR
3/76
COAL 3.0-3.5 PERCENT SULFUR 4/77
COAL 3.5-4.05 PERCENT SULFUR 6/76
COAL 3.5-4.05 PERCENT SULFUR 12/77
COAL 3.5- 4.0 PERCENT SULFUR 7/77
LIGNITE - 6.500 8TU. 0.78 S 8/77
COAL 0.8 PERCENT SULFUR 7/76
COAL 0.5- 1.0 PERCENT SULFUR 6/76
COAL 3.2- 3.5 PERCENT SULFUR 4/76
COAL 0*8 PERCENT SULFUR
COAL 0.6 PERCENT SULFUR
5/76
5/77
PEDCo-ENVIRONMENTAL
165
-------
TABLE 12
SUMWARY OF FGD SYSTEMS UNDER CONSTRUCTION AS OF 03/76
UTILITY COMPANY NEW OR SIZE OF F60
POWER STATION RETROFIT UNIT (MM)
PKOCtSS/VENDOR
FUEL CHARACTERISTICS MO/YR
PENNSYLVANIA POWEK CO. N 835
BRUCE MANSFIELD NO. 1
PENNSYLVANIA POWER CO. N 835
BRUCE MANSFIELD NO. 2
RICKENBACKER AFB R 20
RICKENBACKER
SPRINGFIELD CITY UTILITIES N 200
SOUTHWEST NO. 1
TENNESSEE VALLEY AUTHORITY R 550
WIDOWS CREEK NO 8
CHEMICO
LIME SCRUBBING
CHEMICO
LIME SCRUBBING
RESEARCH COTTRELL
LIME SCRUBBING
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
COAL t.3 PERCENT SULFUR 4/76
COAL H.3 PERCENT SULFUR 4/77
COAL 5.0 PERCENT SULFUR 3/76
COAL 3.5 PERCENT SULFUR 7/76
COAL 3*7 PERCENT SULFUR 2/77
PEDCo-ENVIRONMENlAl
166
-------
Table 13
SUMMARY OF PLANNED FGD SYSTEMS
167
-------
TABLE: is
SUMMARY OF PLANNED FGO SYSTEMS AS OF 03/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGO VENDOR/PROCESS
RETROFIT UNIT
-------
TABLE 13
SUMMARY OF PLANNED FGD SYSTEMS AS OF 03/7fe
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD VENDOR/PROCESS
RETROFIT UNIT
FUEL CHARACTERISTICS
MO/YR
NEVADA POWER
REID GARDNER NO 4
PHILADELPHIA ELECTRIC CO.
CDDYSTONE NO IB
ARIZONA ELECTRIC POWER COOP
APACHE NO 3
ARIZONA ELECTRIC POWER COOP
APACHE NO 2
TEXAS UTILITIES CO.
MARTIN LAKE NO. 3
TEXAS UTILITIES CO.
MARTIN LAKE NO. 4
UTAH POWER £ LIGHT CO.
HUNTINGTUN NO.l
PUBLIC SERVICE co OF NEW MEX.
SAN JUAN NO. 4
REQUESTING/EVALUATING BIDS
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 3
LOUISVILLE GAS & ELECTRIC
CANE RUN MO 6
CINCINNATI GAS & ELECTRIC CO.
MIAMI FORT NO 6
CENTRAL ILLINOIS PUBLIC SERV
NEWTON NO.l
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
UNITED POWER ASSOCIATION
COAL CREEK NO. 2
N
R
N
N
N
N
N
N
:os
N
R
N
N
N
N
125
240
205
200
793
793
415
500
835
277
300
600
545
545
COMBUSTION EQUIP. ASSOCI/
SODIUM CARBONATE SCRUBBIK
UNITED ENGINEERS
MAGNESIUM OXIDE STUBBING
RESEARCH COTTRELL
LIMES10NE SCRUBBING
RESEARCH COTTRELL
LIMLSTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
DAVY POWERGAS
WELLMAN LORD
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME SCRUBblNG
NOT SELECTED
LIME/LIMESTONE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME/LIMESTONE
NOT SELECTED
COAL o-b- i.o PERCENT SULFUR o/ o
COAL 2.5 PERCENT SULFUR
10/78
COAL o.s- o.a PERCENT SULFUR 6/79
COAL 0.5- 0*8 PERCENT SULFUR 6/79
COAL 1.0 PERCENT SULFUR 12/78
COAL 1.0 PERCENT SULFUR 12/79
COAL 0.5 PERCENT SULFUR 6/77
COAL 0.8 PERCENT SULFUR 5/81
COAL 4.3 PERCENT SULFUR 4/79
COAL 3.5- 4.0 PERCENT SULFUR 9/78
COAL 1.3 PERCENT SULFUR
1/78
COAL 2.8-3.2 PERCENT SULFUR 12/77
LIGNITE - 0.63 PERCENT SULFUR 11/78
LIGNITE - 0.64 PERCENT SULFUR 11/79
LIME/LIMESTONE
CONSIDERING FGD SYSTEM
LOUISVILLE GAS g ELECTRIC
MILL CREEK NO 1
330 NOT SELECTED
LIME SCRUBBING
COAL 3.5- 4.0 PERCENT SULFUR 1/82
170
PEDGo-ENVIRONMENTAL
-------
TABLE 13
SUMMARY OF PLANNED FGO SYSTEMS AS OF 03/76
UTILITY COMPANY
POWER STATION
NEW OK SIZE OF FGD VENDOR/PROCESS
RETROFIT UNIT CMW>
FUEL CHARACTERISTICS
MO/YR
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 2
CINCINNATI GAS & ELECTRIC CO*
EAST BEND NO 2
CENTRAL ILLINOIS LIGHT CO.
E.D.EDWARDS NO.3
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO.2
BASIN ELECTRIC POWER COOP
BCULAH NO. 1
NEVADA POWER
HARRY ALLEN STATION NO.
-------
SUMHAKY OF PLANNED FGD SYSTEMS AS OF 03/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD VENDOR/PROCESS
RETROFIT UNIT (MW)
FUEL CHARACTERISTICS
MO/YR
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 1
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 8
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 1
PHILADELPHIA ELECTRIC CO.
CROMBY
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 7
NEW ENGLAND ELEC SYSTEM
BRAYTON POINT NO.3
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 2
BASIN ELECTRIC POWER COOP
MISSOURI BASIN NO 1
BASIN ELECTRIC POwER COOP
MISSOURI BASIN NO 3
NEVADA POWER
WARNER VALLEY STATION NO. 2
NEVADA POWER
WARNER VALLEY STATION NO. 1
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO 2
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 5B
SOUTHERN CALIFORNIA EDISON
KAIPAROWITZ NO. 3
PUBLIC SERVICE INDIANA
GXBSON NO. H
R
R
N
R
R
R
N
N
N
N
N
R
R
N
N
755
«fOO
625
150
190
650
625
550
550
250
250
336
595
750
650
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME SCRUUUING
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
REGENEKABLE NOT SELECTED
NOT SELECTED
LIME SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME SCRUBBING
NOT SELECTED
NOT SELECTED
COALt 0.7 - 0.73* &ULFUN (AVbl
COAL 3 PERCENT SULFUR
COAL 2.0- 5.0 PERCENT SULFUR
COAL 2-H PERCENT SULFUR
COAL 3 PERCENT SULFUR
COAL 3.0 PERCENT SULFUR
COAL 2.0- 5.0 PERCENT SULFUR
COAL
COAL
COAL
COAL
COAL 2.4 PERCENT SULFUR
COAL, 0.7 - 0.75. SULFUR (AVG)
COAL 10,600, BTU, 0.5X S
COAL
u/ u
O/ 0
3/79
10/78
O/ 0
O/ 0
3/80
1/60
6/83
6/62
6/81
10/78
O/ 0
0/84
0/79
172
PEDCo- ENVIRONMENTAL
-------
SUMMARY OF PLANNED FGD SYSTEMS AS OF 03/76
UTILITY COMPANY
POWER STATION
PUBLIC SERVICE INDIANA
GIBSON NO. 3
SOUTHERN CALIFORNIA EDISON
KAIPAROWITZ NO. 2
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2
SOUTHERN CALIFORNIA EDISON
MOHAVE NO IB
SOUTHERN CALIFORNIA EDISON
KAIPAROWITZ NO. •*
SOUTHERN CALIFORNIA EDISON
KAIPAROWITZ NO. 1
NEW OR SIZE OF FGD VENDOR/PROCESS
RETROFIT UNIT
N 650 NOT SELECTED
NOT SELECTED
N 750 NOT SELECTED
LIME SCKUbBING
R 790 NOT SELECTED
LIME/LIMESTONE SCRUBBING
R 620 NOT SELECTED
LIME/LIMESTONE SCRUBBING
N 750 NOT SELECTED
LIME SCRUBBING
N 750 NOT SELECTED
LIME SCRUBBING
FUEL CHARACTERISTICS MO/YR
COAL. 3.3» SULFUR 0/78
COAL 10.800.BTU. 0.58 S 0/63
COAL 0.5 TO 0.8 X SULFUR 6/77
COAL 0.5- 0.8 PERCENT SULFUR 6/77
COAL 10.800.BTUi 0.58 S
COAL 10.800.BTU. 0.5* S
0/85
0/82
173
PEDCo-ENVIRONMENTAL
-------
Table 14
SUMMARY LIST OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
175
-------
TABLE 11*
SUMMARY LIST OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
FGD STATUS REPORT 03/76
I.D. NUMBER AND COMPANY NAME UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
1 UAYTOlM POM£R AND LIGHT CO.
2 DAYTON POWEK AND LIGHT CO.
3 GENERAL PUBLIC UTILITIES
if GENERAL PUBLIC UTILITIES
5 UULF POWEH CO.
6 GULF POWER CO.
7 GULF POWEK CU.
6 KENTUCKY UTILITIES
9 POTOHftC ELECTRIC & POWER
10 POTOMAC ELECTRIC & POWER
11 POTOMAC ELECTK1C & POWER
12 POTOMAC ELECTRIC & POWER
13 POWER AUTHORITY OF NEW YORK
lit SALT RIVE« PROJECT
is SALT RIVER PROJECT
16 SALT RIVEK PROJECT
17 SPRINGFIELD WATER LIGHT POWER
16 TEXAS POWER AND LIGHT CO.
19 TEXAS POWER AND LIGHT CO.
20 VIRGINIA ELECTRIC AND POWER CO
KILLEN NO 1
K1LLEN NO 2
CUHO NO.l
SEWAKD NO.7
CKIST NO. t AND NO.
CRIST NO. 6 AND NO.
LANDING SMITH NO. 1
GHENT
CHALK POINT NO. H
DICKERSON NO H
HUKtoANTOWN NO.l
MOR&ANTOWN NO.2
ARTHUR KILL
NAVAJO NO 1
NAVAJO NO 2
NAVAJO NO 3
DALLMAN NO 3
TWIN OAKS NO. 1
TWIN OAKS NO. 2
MT. STORM
WRIGHTSVILLE OHIO 1-83 7
WRIbHTSVILLE OHIO 1-61 7
ERIE PENNSYLVANIA ' 5-67 7
SEWAKD PENNSYLVANIA 5-64 7
5 PEMSACOLA FLORIDA 0-78 7
7 PEIVSACOLA FLORIDA 0-60 7
AND NO. 2 PANAMA CITY FLORIDA 0-80 7
GHEitfT KENTUCKY 1-77 7
PKINCC GEORGE COUNTY MARYLAND 6-76 7
DICKEKSON MARYLAND 5-82 7
NEWUUKG MARYLAND 6-79 7
NEWUUKG hARYLAUD 6-79 7
STATEN ISLAND NEW YORK 7-60 7
PAGE ARUONA 0-0 7
PAGE ARIZONA .0-0 7
PAGE ARIZONA ' 0-07
SPRINGFIELD ILLINOIS 6-79 7
ROBERTSON COUNTY TEXAS 6-60 7
ROBERTSON COUNTY TEXAS 9-81 7
«T. STORM WEST VIRGINIA 0-0 7
D
D
A
A
B
6
B
E
D
D
C
C
B
D
D
D
A
A
A
C
7. CONSIDERING FGO SYSTEM AS WELL AS ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT is MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
C. REGULATORY CLASS UNKNOWN
177
PEDCO-ENVIRONMENTAL
-------
Table 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
179
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING
CUKKENT MONTH
03/76
I.D. NUMBER 1
DAYTON POWER AND LIGHT CO.
KILLEN NO 1
600 MM - NEW
COAL
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP' 1/83
SITE PREPARATION IS UNDERWAY. COMPANY IS INVESTIGATING LONG TEKM SUPPLY
OF LOW SULFUR COAL FOK COMPLIANCE WITH REGULATIONS WITHOUT INSTALLING FGD
SYSTtM. UECISION OH THIS MATTER IS DUE MID 1976. SPACE HAS BEEN RESERVED
IN THE PLANT LAYOUT FOR FGD SYSTEM IF NEEDED. KILLEN NO.l NOW SCHEDULED
FOR STARTUP AFTER KILLEN NO.2.
I.D. NUMBER 2
DAYTON POWER AND LIGHT CO.
KILLEN NO 2
600 MW - NEW
COAL
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 1/61
SITE PREPARATION IS UNDERWAY. COMPANY IS INVESTIGATING LONG TERM SUPPLY
OF LOW SULFUR COAL FOR COMPLIANCE WITH REGULATIONS WITHOUT INSTALLING FGD
SYSTEM. DECISION ON THIS MATTER IS DUE MID 1976. SPACE HAS BEEN RESERVED
IN THE PLANT LAYOUT FOR FGD SYSTEM IF NEEDED.
I.D. NUMBER 3
GENERAL PUBLIC UTILITIES
COHO NO.l
600 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 5/67
STARTUP DATE CHANGED TO 5/67 FOR BOTH BOILER AND FGD SYSTEM. LIME, LIME-
STONE SCRUBBINGt AND COAL DESULFuRI^ATION ARC THE PRIMARY PROCESSES BEING
CONSIDERED. NO DECISION HAS BEEN MADE YET.
I.D. NUMBER
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF fGO SYSTEMS IN THE EARLY PLANNING STAGES DURING 03/76
CURRENT MONTH
I.D. NUMBER £
GULF POWEK CO.
CRIST NO. 6 AND NO. 7
820 Mk - RETROFIT
NOT SELECTED
NOT SELECTED
STARTUP 0/flO
UNIT (, IS 320 HW. UNIT 7 IS 500 Mb.
1.0. NUMBER 7
GULF POUER CO.
LANSING SMITH NO. 1 AND NO.
305 MW - RETROFIT
COAL
NOT SELECTED
MOT SELECTED
STARTUP 0/80
UNIT NO. 1 IS 125 nw. UNIT NO. 2 IS 180 MU. IF SCRUBBERS ARC SELECTED*
THEY WILL BE REQUIRED IN 1979 AND 1980 ON THE RESPECTIVE UNITS.
I.D. NUMBER a
KENTUCKY UTILITIES
GHENT
510 MW - NEW
COAL 3-K PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 1/77
IN THE EARLY PLANNING STAGE. COMPANY ALSO HAS-AN EXISTING 510 MW UNIT
AND UNDECIDED ON WHICH UNIT TO INSTALL THE FGO SYSTEM.
1.0. NUMBER 9
POTOMAC EUECTKIC & POWER
CHALK POINT NO. H
630 HW - NEW
OIL
NOT SELECTED
NOT SELECTED
STARTUP b/76
AWAITING PERFORMANCE RESULTS FROM MGO UNIT ON OICKERSON NO. 3 (MONTGOMERY
COUNTY). UNIT WILL HAVE PEABODY-LURGI 2-STAGE VENTURI SCRUBBERS FOR PAR-
TICULATE CONTROL. COMPANY MAY ELECT NOT TO INSTALL FGO SYSTEM IF USE OF
LOU SULFUR OIL IS CONTINUED. BOILER START-UP SCHEDULED FOR LATE 1976.
I.D. NUMBER 10
POTOMAC ELECTRIC & POWER
DICKERSON NO t
600 nw - NEW
COAL 2.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 5/82
THLRE ARE NO FIRM PLANS FOR INSTALLATION OF FGO SYSTEM.
BOILER IS PLANNED FOR 1982.
STARTUP DATE OF
182
PEOCo-ENVJRONMENTAL
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING 03/76
CURRENT MONTH
I.D. NUMBER 11
POTOMAC LLECTRIC & POWER
MORGANTOhN NO.l
56B MW - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/79
THLRE ARE NO FIRM PLANS FOR INSTALLATION OF FGD SYSTEM.
COMPANY PLANS TO EVALUATE ALL COMMERCIALLY AVAILABLE SOg CONTROL METHODS
INCLUDING COAL GASIFICATION AND USE. OF LOW SULFUR COAL. COMPANY IS ALSO
AWAITING RESULTS OF MGO SYSTEM OPERATION AT THE OICKERSON PLANT. DECISION
EXPECTED WITHIN A YEAR.
I.D. NUMBER 12
POTOMAC ELECTRIC £ POWER
MORGANTOWN NO.2
558 MW - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/79
THERE ARE NO FIRM PLANS FOR INSTALLATION OF FGD SYSTEM.
COMPANY PLANS TO EVALUATE ALL COMMERCIALLY AVAILABLE S02 CONTROL METHODS
INCLUDING COAL GASIFICATION AND USE OF LOW SULFUR COAL. COMPANY IS ALSO
AWAITING RESULTS OF MGO SYSTEM OPERATION AT THE DICKERSON PLANT. DECISION
EXPECTED WITHIN A YEAR.
I.D, NUMBER 13
POWER AUTHORITY OF NEW YORK
ARTHUR KILL
700 MM - NEW
COAL - 3% SULFUR - REFUSE
NOT SELECTED
NOT SELECTED
STARTUP 7/80
THt UTILITY IS CONSIDERING BOTH REGENERABLC AND LIMESTONE SCRUBBING
PROCESSES. FGD IS BEING CONSIDERED FOR A FOSSIL FUEL BURNING UNIT WHICH
MAY EMPLOY REFUSE OR COAL. THE PREFERRED INSTALLATION SITE IS THE ARTHUR
KILL FACILITY LOCATED ON STATEN ISLAND. THE PROJECT DESIGN ENGINEERS ARC
SARGENT AND LUNDY.
I.D. NUMtiER m
SALT RIVLR PROJECT
NAVAJO NO 1
750 I"!U - RETROFIT
COAL 0.45 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP O/ 0
THE UTILITY IS PRESENTLY INVESTIGATING THE USE OF LOW SULFUR COAL AND
DESULFURIZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THL SRP/EPA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPECIFIED.
I.D. NUMBER 15
SALT RIVER PROJECT
NAVAJO NO 2
750 MW - RETROFIT
COAL 0.45 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP O/ 0
THE UTILITY IS PRESENTLY INVESTIGATING THE USE OF LOW SULFUR COAL AND
DESULFURIZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THE SRP/tPA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPECIFIED.
183
PEDCo- ENVIRONMENTAL
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COMPANY
POWER STATION
TABLE 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING
03/76
CURRENT MONTH
I.D. NUMBER 16
SALT RIVER PROJECT
NAVAJO NO 3
750 MW - RETROFIT
COAL 0.«»J> PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP O/ 0
I.D. NUMUER 17
SPRINGFIELD WATER LIGHT POWER
DALLMAN NO 3
190 MW - NEW
COAL 3.0- 4.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 6/79
I.D. DUMBER 16
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 1
750 MW - NEW
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 6/60
I.D. NUMBER 19
TEXAS POUER AND LIGHT CO.
TWIN OAKS NO. 2
750 MW - NEW
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 9/61
I.D. NUM6ER ' 20
VIRGINIA ELECTRIC AND POWER CO
MT. STORM
11H7 MW - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THE. UTILITY IS PRESENTLY INVESTIGATING THE USE OF LOW SULFUR COAL AND
DESULFUH1ZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THE SRP/EPA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPECIFIED.
FGO SYSTEM IS UNUER CONSIDERATION WITH BOTH REGENERABLE AND LIMESTONE
SCRUBBING BEING CONSIDERED. BECAUSE OF SPACE LIMITATIONS A REGENERABLE
SYSTEM IS THE LIKELY CHOICE. THE COMPANY IS ALSO CONSIDERING COMPLIANCE
THROUGH BURNING OF LOW SULFUR WESTERN COAL.
"THIS UNIT WILL BE JOINTLY OWNED-BY .TP«L AND ALCOA.
NOT BEEN MADE WHETHER TO INSTALL FGO FACILITIES.
A FIRM DECISION HAS
"THIS'UNIT WILL BE JOINTLY OWNED BY TP»L AND ALCOA.
NOT BEEN MADE WHETHER TO INSTALL FGD FACILITIES.
A FIRM DECISION HAS
THE UTILITY IS PRESENTLY CONSIUERENG BOTH DESULFURIZATION AND THE USE OF
LOW SULFUR COAL. A DESULFURIZATION SYSTEM WOULD TREAT 69 PERCENT OF THE
FLUE GAS FROM THREE BOILERS. CONSTRUCTION AND STARTUP DATES ARE CON-
SIDERED INDEFINITE AT THIS TIME.
184
PEDCo-ENVIRONMENTAL
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Table 16
F6D SYSTEM OPERATIONS THAT HAVE BEEN TERMINATED OR SHUT DOWN INDEFINITELY
185
-------
Table 16
TERMINATED OPERATIONAL F6D SYSTEMS 2/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY.
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
1
BOSTON EDISON
MYSTIC NO 6
EVERETT MASSACHUSETTS
150 MW
OIL 2.5 PERCENT SULFUR
CHEMICO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
4/72
OPERATIONAL
50 PERCENT
90 PERCENT
S32/KW CAPITAL + CALCINATION
AVERAGE FGD SYSTEM AVAILABILITY FACTORS - APRIL 72 TO MAY 73. 17*.
JUNE 73 TO DEC. 73. *6X. JAN. 7* TO JUNE 7H. 60%. JUNE 7*. 60K.
THE FGD SYSTEM HAS .BEEN SHUT DOWN INDEFINITELY SINCE JUNE 7*.
PEDCo-ENVlfcONMENTAL
187
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BACKGROUND INFORMATION
ON
THE MYSTIC POWER STATION. UNIT NO. 6
THE MAGNESIUM OXIDE FGD SYSTEM AT BOSTON EDISON CONSISTS OF A CHENICO SINGLE-STAGE. VENTURI SCRUBBER. THE SCRUBBER UNIT
IS CONSTRUCTED OF CARBON STEEL WITH A SPRAY APPLIED POLYESTER LINING. THE SCRUBBER TREATS 440,000 ACFM OF 300°F FLUE GAS CON-
TAINING S02 CONCENTRATION OF 1410 PPM. S02 REMOVAL EFFICIENCY IS REPORTED TO BE 90 PERCENT.
THE MgO PROCESS IS A REGENERABLE PROCESS. THE SCRUBBER CAPTURES S02 BY FORMATION OF MAGNESIUM SULFITE. THIS PRODUCT
SLURRY IS THEN FILTERED AND DRIED. THE DRY MATERIAL IS THEN CALCINED AT HIGH TEMPERATURES TO DRIVE OFF THE S02 AND REGENERATE
MgO. THE S02 STREAM IS THEN PROCESSED IN A SULFURIC ACID PLANT OT MAKE 98 PERCENT ACID.
PROBLEMS AND SOLUTIONS
FROM THE INITIAL START-UP IN APRIL 1972 TO MAY 1973, THE SCRUBBER OPERATED INTERMITTENTLY DUE TO MECHANICAL DIFFICULTIES.
THE MAJOR PROBLEM BEING THE DESIGN AND OPERATION OF MgSOj CRYSTAL DRYER. REDEISGN AND FUEL CHANGE APPEAR TO HAVE SOLVED THESE
PROBLEMS. STACK AND PUMP PROBLEMS OCCURRED DURING THE USE OF REGENERATED MgO. SCALE WAS FORMED IN THE MgO SLURRY PIPING DUE
TO OVERHEATING OF THE SLURRY DURING ACTIVATION OF THE STEAM FREEZE PROTECTION SYSTEM. IN 1974, THE SYSTEM OPERATION WAS
LIMITED BY BOILER UNAVILABILITY. SINCE FEBRUARY 1974, AVAILABILITY TO THE BOILER HAS BEEN INCREASED. THE SYSTEM HAS BEEN
SHUTDOWN INDEFINITELY SINCE JUNE 1974 WHEN EPA FUNDS EXPIRED FOR THE CALCINING PORTION OF'THIS OPERATION.
THE AVAILABILITY FACTORS FOR THE SYSTEM SINCE START-UP. ARE PRESENTED IN THE FOLLOWING TABLE.
PEDCo-ENVIRONMENTAL
188
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Month Availability (X)
Apr.
May
June
Jul.
Aug.
Sep.
Oct.
Nov.
Dec.
Jan.
Feb.
Mar.
Apr.
Nay.
Jun.
72 to
73
. 73
73
73
73
73
73
73
74
74
74
74
74
74
17
68
61
38
60
26
13
28
25
87
81
57
80
FGD SYSTEM AVAILABILITY
MYSTIC UNIT NO. 6
Comments
The module operate Intermittently due to mechanical difficulties. One major problem
being the design and operation of the magnesium sulflte crystals dryer.
The boiler was down for the.annual overhaul outage. System availability decreased
during the last quarter of the year due to heavy erosion/corrosion attach which was
experienced 1n the liquor redrculatlon pumps and centrifuge.
Systems availability was limited by boiler related problems which caused frequent
shutdowns' In January and February.
572 availability due to 2 weeks acid plant outage. Not due to FGD system failure.
Demonstration program was completed and FGD system was shut down. EPA funding of
MgSOj calcination has expired.- There are no definite plans for restarting of this unit.
Average Availability (Jan - June, 1974) • 59.7 Percent.
PEDCo-ENVIRONMENTAL
189
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Table 16
T-ERMINATED OPERATIONAL FGD SYSTEMS .2/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
OAIRYLAND POWER COOP
ALMA STATION
AI."A WISCONSIN
80 «**
FUEL CHARACTERISTICS COAL 3.0- 3.5 PERCENT SULFUR
F60 VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY.
PARTICIPATES
S02
FOSTER WHEELER
LIME INJECTION
RETROFIT
6/71
OPERATIONAL
83 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
•SS5SS
EXPERIENCE
ORU
SINCE 1971 t UESTERN LOU SULFUR COAL. THE TEST SHOWED ABOUT SOI
S02 REMOVAL EFFICIENCY. BUT PRECIPITATOR PERFORMANCE WAS ADVERSELY
AFFECTED. THE FGD PROJECT HAS BEEN SHUT DOWN INDEFINITELY SINCE
AUGUST 1974, AND THERE ARE NO PLANS FOR FUTURE OPERATION.
PEDCo-ENVIRONMENTAL
190
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Table 16
TERMINATED OPERATIONAL FGO SYSTEMS 2/76
IDENTIFICATION NO,
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
ILLINOIS POWER
WOOD RIVER NO EXCHANGER LEAKS HAVE BEEN ENCOUNTERED, AND AN
EVALUATION IS NOW BEING MADE TO DETERMINE WHETHER TO REPLACE THE HEAT
Ett^cE? OR TO REPAIR IT. THE SYSTEM is SHUT DOWN INDEFINITELY AT
PRESENT.
PEDCo-ENVIRONMENTAL
191
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BACKGROUND INFORMATION
ON
WOOD RIVER NO. 4
THE WOOD RIVER NO. 4 BOILER IS LOCATED NEAR EAST ALTON, ILLINOIS. NORTH OF ST. LOUIS. THE BOILER HAS A RATED
CAPACITY OF 110 MW. IT IS RETROFITTED WITH CATALYTIC OXIDATION FGD SYSTEM WHICH IS DESIGNED BY MONSANTO ENVIRO-
CHEM SYSTEMS. THE SYSTEM TREATS THE FLUE GAS FROM THE HIGH EFFICIENCY ELECTROSTATIC PRECIPITATOR.
IN THIS SYSTEM. THE FLUE GAS IS HEATED TO A TEMPERATURE OF 850»F AND IS PASSED THROUGH A VANADIUM PENTOXIDE
FIXED BED CATALYTIC CONVERTER WHERE SOg IS OXIDIZED TO S03. THE GAS THEN FLOWS THROUGH AN ACID ABSORPTION TOWER
WHERE THE SULFUR TRIOXIDE IN THE GAS CONVERTS TO SULFURIC ACID. AN ACID MIST ELIMINATOR ENSURES THE REMOVAL OF ENTRAINED
ACID MIST FROM THE GAS STREAM. THE CLEANED GAS IS DISCHARGED TO THE STACK AND THE PRODUCT ACID IS COOLED AND STORED
IN TANKS.
PROBLEMS AND SOLUTIONS
SINCE COMPLETION OF THE SYSTEM IN JULY OF 1972. A SERIES OF MECHANICAL DIFFICULTIES HAS OCCURRED AND MODIFICATIONS
HAVE BEEN EFFECTED. DURING JULY OF 1973. AN ACCEPTANCE TEST WAS CONDUCTED TO ESTABLISH THE SPECIFIED 85 PERCENT
SULFUR DIOXIDE REMOVAL, WHILE PRODUCING AN ACID PRODUCT OF REQUIRED CONCENTRATION OF 77.7 PERCENT. BOTH OF THESE
SPECIFICATIONS WERE MET DURING THAT TEST.
LONG TERM OPERATION OF THE SYSTEM HAS BEEN DELAYED DUE TO DELAYED DELIVERY OF EQUIPMENT FOR A PLANNED SYSTEM
MODIFICATION OF CONVERTING THE REHEATER BURNERS FROM NATURAL GAS TO FUEL OIL. SEVERAL MAJOR PROBLEMS INCLUDE FROZEN
DAMPERS ON REHEAT BURNERS. CRACKS IN THE TEFLON LINER ON THE ACID PUMP'S DISCHARGE HEADER. CRACKS IN THE REHEAT DUCTING.
FALL OF REFRACTORY BRICKS FROM THE REHEATER BURNER DOME AND THE NEED FOR REINFORCEMENT OF THE STRUCTURE SUPPORTING
THE HIGH TEMPERATURE FLUE GAS DUST TO THE CATALYTIC CONVERTER. MOST OF THESE PROBLEMS HAVE BEEN CORRECTED. AT THE
PRESENT TIME ILLINOIS POWER AND EPA ARE DETERMINING HOW TO CORRECT LEAKING ACID COOLERS. PATCHING ATTEMPTS HAVE
BEEN UNSUCCESSFUL. REPAIR OR REPLACEMENT OF THE COOLERS IS EXPECTED TO TAKE SEVERAL MONTHS.
PEDCo- ENVIRONMENTAL
192
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OPERATING LOG
CATALYTIC OXIDATION SYSTEM
WOOD RIVER NO. 4 - ILLINOIS POWER CO.
SYSTEM OPERATING
DATE HOURS
9-4-72 12
9-5-72 24
9-6-72 24
9-7-72 2
9-10-72 6
9-11-72 2
9-12-72 16
9-13-72 24
9-14-72 24
9-15-72 24
9-16-72 24
9-17-72 24
9-18-72 24
9-19-72 3 ,
9-24-72 17
10-6-72 12
10-7-72 24
10-8-72 24
10-9-72 24
10-10-72 18
10-12-72 16
10-13-72 20
PEDCo-ENVIRONMENTAL
I ,7
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OPERATING LOG (continued)
DATE
10-14-72
10-30-72
10-31-72
7-21-73
7-22-73
7-23-73
7-24-73
7-25-73
7-26-73
7-27-73
7-28-73
7-29-73
TOTAL
SYSTEM OPERATING
HOURS
16
24
16
18
24
18
24
14
13
19
19
_£
602 HOURS
194
PEDCo-ENVIRONMENTAL
-------
Table 16
TERMINATED OPERATIONAL FGD SYSTEMS 2/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
POTOMAC ELECTRIC ft POWER'
DICKERSON NO 3
OICKERSON MARYLAND
93 MW
FUEL CHARACTERISTICS COAL 2.0 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY!
PARTICULATES
CHEMICO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/73
OPERATIONAL
502
90 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
S70/KW CAPITAL
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 16 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE SEPTEMBER 1973. THE UNIT HAS BEEN
TERMINATED AS AN S02 SCRUBBER. HOWEVERtIT WILL CONTINUE TO OPERATE AS A
PARTICULATE SCRUBBER.
PEDCo-tftvmONMENTAL
195
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BACKGROUND INFORMATION
ON
DICKERSON NO. 3
THE DICKERSON STATION OF POTOMAC ELECTRIC POWER CO. (PEPCO) IS LOCATED ON THE POTOMAC RIVER OUTSIDE THE TOWN OF DICKERSON. MARYLAND,
ABOUT 30 MILES NORTHWEST OF WASHINGTON, D.C. THE STATION CURRENTLY HAS THREE ELECTRIC GENERATORS EACH RATED AT 190 MW. UNIT NO. 3 IS A
DRY BOTTOM COAL-FIRED BOILER THAT WAS DESIGNED BY COMBUSTION ENGINEERING AND INSTALLED IN 1962. THE COAL PRESENTLY BURNED HAS AN AVERAGE
GROSS HEATING VALUE OF 11,700 BTU/LB, AVERAGE ASH AND SULFUR CONTENTS ARE 14 AND 2 PERCENT, RESPECTIVELY. THE BOILER IS FITTED WITH AN
ELECTROSTATIC PRECIPITATOR DESIGNED AND INSTALLED BY RESEARCH - COTTRELL IN 1962. THE FGD SYSTEM INSTALLED EMPLOYS THE CHEMICO-BASIC
MAGNESIUM OXIDE SCRUBBING PROCESS. THE RETROFIT SYSTEM HANDLES APPROXIMATELY 5W OF THE EXHAUST GAS FROM THE 190 MW NO. 3 UNIT.
THE FGD SYSTEM CONSISTS OF A SINGLE, TWO-STAGE SCRUBBER/ABSORBER WHICH INCORPORATES AN ADJUSTABLE THROAT VENTURI SCURBBER FOR PARTICU-
LATE REMOVAL AND A SECOND STAGE ABSORBER USING A FIXED VENTURI CONFIGURATION TO REMOVE SULFUR DIOXIDE. THE LIQUOR STREAMS FOR BOTH STAGES
ARE SEPARATE AND OPERATE IN A CLOSED LOOP MODE. UNTIL MID-1975 MAGNESIUM SULFITE GENERATED WAS TRANSFERRED TO AN EPA FINANCED FACILITY AT
THE ESSEX CHEMICAL COMPANY SULFURIC ACID MANUFACTURING PLANT IN RUMFORD, RHODE ISLAND, WHERE MAGNESIUM OXIDE WAS REGENERATED AND SOg FROM
THE REGENERATION PROCESS WAS CONVERTED TO SULFURIC ACID. THE RUMFORD FACILITY HAS SINCE BEEN CLOSED DOWN.
SYSTEM CONSTRUCTION WAS COMPLETED IN AUGUST AND STARTED UP IN SEPTEMBER 1973. INTERMITTENT OPERATIONS FOR SHAKEDOWN PURPOSES PROCEEDED
THROUGH JANUARY,1974 , WITH THE LONGEST CONTINUOUS RUN DURING THIS OPERATION PHASE BEING 271 HOURS. THE SYSTEM WAS AGAIN RESTARTED FROM
JULY 1974 THROUGH DECEMBER 1974, AND AGAIN AUGUST 11, 1975 FOR APPROXIMATELY 87 HRS.
FGD UNIT OUTAGES WERE PRIMARILY CAUSED BY PIPE AND PUMP CORROSION PROBLEMS AND MAJOR TURBINE OVERHAUL OF THE BOILER. HOWEVER. PARTICULATE
AND S02 REMOVAL EFFICIENCY GUARANTEES HAVE BEEN COORROBERATED DURING OPERATIONAL PHASES.
THE REMAINING SUPPLY OF MAGNESIUM OXIDE, ABOUT 100 TONS (10 DAYS). HAS BEEN DEPLETED AND THE DICKERSON UNIT HAS BEEN TERMINATED AS AN S02
SCRUBBER.
PEDCo-ENVIRONMENTAL
196
-------
Table 16
TERMINATED OPERATIONAL FGD SYSTEMS 2/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
SOUTHERN CALIFORNIA EDISON
MOHAVE NO 1A
LAUGHLIN NEVADA
170 MW
FUEL CHARACTERISTICS COAL 0.5- 0.8 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
RETROFIT
OPERATIONAL
UNIT COST
OPERATIONAL
EXPERIENCE
THIS EXPERIMENTAL MODULE STARTED UP OCT. 31. 197* AND OPERATED WITH AN
AVAILABILITY OF 60.4» THROUGH FOUR MONTHS OF TESTING. TESTS HAVE BEEN
COMPLETED, AND THE FGD SYSTEM WAS SHUT DOWN INDEFINITELY ON JULY 2. 1975.
NEVADA ASSEMBLY BILL NO. 708 HAS PLACED A 2-YEAR MORATORIUM ON THE
ENFORCEMENT OF THE COMPLIANCE SCHEDULE FOR THIS STATION. FURTHER FGO
ACTIVITIES WILL BE DEPENDENT ON FUTURE LEGISLATION.
PEOCo-
197
-------
Mohave No. 1A - Vertical Module
Operating hours F6D System
B system availability Comments
F6E
234 46 FGD outages - station request, 36 hours; Inspection, 55 hrs. fix
sphere migration problem, 333 hrs; other outages, 31 hrs.
Dec. 74 606 237 39 FGD OUTAGES - station request, 140 hrs; fix sphere migration problem,
197 hrs; Inspection and sphere redistribution, 45 hrs/repa1r trap -
out try leakage, 120 hrs; booster fan false trip, 5 hrs.
Jan. 75 514 402 78 FGD OUTAGES - station request, 38 hrs - generator down. 158 hrs;
Inspection and nozzle cleaning. 35 hrs; booster fan trips. 30 hrs; Install
slurry piping strains, 9 hrs; Inspection and presaturatlon repair, 72 hrs.
Feb. 75 480 401 84 FGD OUTAGES - Modify and repair presaturator slurry nozzles, 37 hrs;
unplug thickener underflow piping, 46 hrs; generator down, 188 hrs.
PEOCo- ENVIRONMENTAL
198
-------
Table 16
TERMINATED OPERATIONAL FGD SYSTEMS 12/75
IDENTIFICATION NO. 6
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
so2
MATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2A
LAUGHLIN NEVADA
160 MW
COAL 0.5- 0.8 PERCENT SULFUR
SCE/ STEARNS ROGER
LIME SCRUBBING
RETROFIT
11/73
OPERATIONAL
90 PERCENT
370 GAL/LB MOLE S02 REMOVED
STABILIZED SLUDGE DISPOSED IN UNLINED POND
SINCE STARTUP OF FORMAL TEST PROGRAM ON JANUARY 16, W74,AND UP TO DECEMBER 20, W74, THIS EXPERIMENTAL
HORIZONTAL MODULE OPERATED 5280 HRS. WITH AN OVERALL AVAILABILITY OF 77.4 PERCENT. S02 REMOVAL
EFFICIENCY WAS 90 IN FLUE GAS TO SIMULATE CONDITIONS FROM COMBUSTION OF HIGH SULFUR COAL. THIS FGD
IVSTFM OPERATED FROM NOVEMBER 1973 UNTIL FEBRUARY 1975. FGD PLANS AT THIS STATION WILL BE BASED
oJ INFORMATION THAT INCLUDES OPERATIONAL DATA THAT HAVE BEEN OBTAINED DURING THE FGD TEST PROGRAMS
AT THE HOHAVE STATION? THE PHOTOTYPE SYSTEM AT MOHAVE IS NOW BEING DISMANTLED AND IS BEING SHIPPED
TO THE FOUR CORNERS PLANT. OPERATED BY ARIZONA PUBLIC.SERVICE. FOR INSTALLATION.
PEDCO-ENV1RONMENTAL
199
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BACKGROUND INFORMATION
ON
MOHAVE POWER STATION UNIT NO. 2A
THE MOHAVE POWER STATION IS LOCATED ABOUT TWO MILES FROM LAUGHLIN, IN CLARK COUNTY. NEVADA. AT
PRESENT, MOHAVE HAS TWO 790 MW RATED CAPACITY COAL FIRED BOILERS. THE-COAL BEING BURNED HAS AN AVERAGE
HEATING VALUE OF 9250 BTU PER POUND AND ASH AND SULFUR CONTENTS OF 10 AND 0.40 PERCENT RESPECTIVELY.
UNIT 2 AT MOHAVE IS RETROFITTED WITH A 160 MW CAPACITY LIME BASE FGD SYSTEM.
THE SCRUBBER WHICH IS A HORIZONTAL MODULE, WAS DESIGNED BY SOUTHERN CALIFORNIA EDISON. ITS INITIAL
START-UP WAS IN NOVEMBER 1973. THE SYSTEM TREATS ABOUT 420,000 ACFM, WHICH IS 20 PERCENT OF THE TOTAL
FLUE GAS FROM THE BOILER. THE SYSTEM WHICH IS A CLOSED-LOOP SYSTEM; HAS A SCRUBBER WITH FOUR COUNTER-
CURRENT STAGES. THIS SCRUBBER IS MADE UP OF A DEMISTER AND AN INDIRECT HEAT EXCHANGER.
PARI OF JHE SLURRY__FROM_TH_E_SYSTEM IS THICKENED IN A CLARIFIER AND PUMPED TO A LINED DISPOSAL P.ON_D_,
WHERE IT IS ALLOWED TO SETTLE. SUPERNATANT WATER FROM THE POND IS RECIRCULATED TO THE SCRUBBERS.
PROBLEMS AND SOLUTIONS
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING THE OPERATION. THE MINOR ONES MENTIONED ARE PLUGGAGE IN
" THE LIME SLAKER, A SLIGHT SCALE BUILD UP ON THE DEMISTERS AND FAN VIBRATIONS. IN ORDER TO SOLVE THE
ABOVE PROBLEMS, THE MAKE UP WATER SOURCE WAS CHANGED, THE CONTINUOUS SPRAY WASH WAS CHANGED TO DELUGE
_ INTE_RMITTE_NT_ SPRAY,_TH_E DE_MISTER WAS REINFORCED AND REALIGNMENT OF FAN WAS CORRECTED. OTHER PROBLEMS
"WERE DAMAGE TO ONE OF'THE"SHUT OFF VALVES, PLUGGAGE OF THE CLARIFIER OUTLET DUE TO ACCIDENTAL DROP OF A
HARD HAT AND EROSION DAMAGE OF PIPES.
THE OVERALL AVAILABILITY OF THE SYSTEM FROM JANUARY 16, 1974 TO DECEMBER 20, 1974 HAS BEEN 77.4 PERCENT.
PEDCo-ENVIRONMENTAL
200
-------
Table 16
TERMINATED OPERATIONAL FGD SYSTEMS 2/76
7
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
TENNESSEE VALLEY AUTHORITY
SHAMNEE NO. 10.C
PAOUCAH KENTUCKY
10 MW
FUEL CHARACTERISTICS COAL 2.9 PERCENT'.SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
TENNESSEE VALLEY AUTHORITY
LIME/LIMESTONE SCRUBBING
RETROFIT
H/72
OPERATIONAL
OPERATIONAL
EXPERIENCE
REFER TO BACKGKOUND INFORMATION SECTION IN TABLE 16 OF THIS KEPOKT. THIS
FGU SYSTEM HAS litlEN OPERATIONAL SINCE APRIL. 1972. THIS MARBLE-BED AB-
SORBER, MANUFACTURED BY COMBUSTION ENGINEERING CO., WAS DISCONTINUED
EARLY IN THE TEST PROGRAM BECAUSE OF CONTINUED OPERATING PROBLEMS WITH
NOZZLE FAILURE AND SUBSEQUENT PLUGGING OF THE MARBLE BED. THIS SYSTEM
BECAME OPERATIONAL IN APRIL 1972 AND WAS PERMANENTLY TERMINATED IN
JULY 1973.
PEDCo- ENVIRONMENTAL
201
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BACKGROUND INFORMATION
ON
SHAWNEE NOS. IDA, 10B. AND IOC
IN JUNE. 1968. THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE WET LIME AND LIMESTONE SCRUBBING SYSTEMS FOR THE REMOVAL
OF SULFUR DIOXIDE AND PARTICULATES FROM FLUE GAS. THE PROGRAM WAS INITIATED AND CARRIED OUT IN A TEST FACILITY WHICH WAS
INCORPORATED INTO THE FLUE GAS DUCT WORK OF UNIT NO. 10. A COAL-FIRED BOILER AT THE TVA SHAWNEE POWER STATION. PADUCAH.
KENTUCKY. TVA IS THE CONSTRUCTOR AND FACILITY OPERATOR AND THE BECHTEL CORP. IS THE MAJOR CONTRACTOR AND TEST DIRECTOR.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE TREATING PART OF THE FLUE GAS FROM THE
BOILER. EACH SCRUBBER TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30.000 ACFM OR THE EQUIVALENT OF APPROXIMATELY 10 MW OF
POWER PLANT GENERATING CAPACITY.
THE THREE PARALLEL WET SCRUBBER SYSTEMS SELECTED FOR THE TEST PROJECT WERE: 1) A VENTURI WITH A SPRAY TOWER AFTER
ABSORBER; 2) A TURBULENT CONTACT ABSORBER (TCA) AND 3) A MARBLE-BED ABSORBER. THE VENTURI SYSTEM. MANUFACTURED BY CHEMICAL
CONSTRUCTION CO., CONTAINS AN ADJUSTABLE THROAT THAT PERMITS CONTROL AND VARIATION OF PRESSURE DROP UNDER A WIDE RANGE OF FLOW
CONDITIONS. THE TCA UNIT MANUFACTURED BY UNIVERSAL OIL PRODUCTS. EMPLOYS A FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT
ARE FREE TO MOVE BETWEEN RETURNING GRIDS. THE MARBLE-BED ABSORBER. SUPPLIED BY COMBUSTION ENGINEERING CO.. USES A PACKING ,
OF 3/4 INCH GLASS MARBLE SPHERES AND A TURBULENT LAYER OF LIQUID AND GAS ABOVE THE MARBLE LAYER TO ENHANCE MASS TRANSFER.
THE TEST FACILITY WAS DESIGNED SO THAT MODIFICATIONS AND VARIATIONS OF SCRUBBER INTERNALS AND PIPING CONFIGURATIONS COULD
BE READILY EMPLOYED FOR EACH SCRUBBER SYSTEM. EACH SYSTEM IS CAPABLE OF TREATING APPROXIMATELY 30.000 ACFM OF FLUE GAS AT
300'F CONTAINING 1800 TO 4000 PPM OF S02 AND 2 TO 5 GRAINS/SCF OF PARTICULATES. TESTING OF THE TCA AND THE VENTURI SPRAY
TOWER IS CURRENTLY IN PROGRESS; OPERATION OF THE MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
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DEFINITIONS
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DEFINITIONS
Boiler Capacity Factor
Boiler Utilization Parameter
Efficiency,
Particulates
(kWh generation in year)/(maximum continuous generating
capacity in kW x 8760 hr/yr).
SO,
FGD Availability Factor
FGD Reliability Factor
FGD Operability Factor
FGD Utilization Factor
FGD Status
Category 1
Category 2
Category 3
Hours boiler operated/hours in period,
percentage.
expressed as a
Operational - The actual percentage of particulates re-
moved by the FGD system and the particulate control de-
vices from the untreated flue gas. All others - The
design efficiency (percentage) of particulate removed by
the FGD system and the particulate control devices.
Operational - The actual percentage of S02 removed from
the flue gas. All others - The design efficiency.
Hours the FGD system was available for operation (whether
operated or not)/hours in period, expressed as a percentage,
Hours the FGD system operated/hours FGD system was called
upon to operate, expressed as a percentage.
Hours the FGD system was operated/boiler operating hours
in period, expressed as a percentage.
Hours FGD system operated/hours in period, expressed as
a percentage.
Operational - Unit has been or is in service removing SO2.
Under Construction - Ground has been broken for installa-
tion of FGD system, but FGD system has not become opera-
tional .
Planned, Contract Awarded - Contract has been signed for
purchase of FGD system but ground has not been broken
for installation.
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Category 4
Category 5
Category 6
Category 7
FGD Vendor
Fuel Characteristics
Identification Number
New
Operational Experience
Process
DEFINITIONS
Planned, Letter of Intent Signed - Letter of intent has
been signed, but legal contract for purchase has not been
awarded.
Planned, Requesting/Evaluating Bids - Bid requests have
been released but no letter of intent or contract has
been issued.
Considering only FGD Systems - An FGD system is proposed
"as a means to meet an SO2 regulation.
Considering an FGD system as well as alternative methods
(Tables 14, 15).
Vendor with a signed contract, letter of intent or strong
commitment because of test unit or past purchases.
Type of fuel, average gross heating value in Btu/lb,
average percent ash and average percent sulfur content
for fuel as fired.
Number of unit in the alphabetical listing in Tables 1,
2, 3 or Tables 14, 15.
FGD unit and boiler were designed at the same time or
space for addition of an FGD unit was reserved when
boiler was constructed.
Operational - Brief summary of FGD system operation
since start-up and description of current month's per-
formance. All others - Comments regarding stage of con-
struction, etc.
Company name if process is patented. Generic name if
several companies have similar processes.
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Regulatory Class
Retrofit
Sludge Disposal
Start-up Date
Unit Cost
DEFINITIONS
A. New boiler constructed subject to Federal New Source
Performance Standards.
B. Existing boiler subject to State Standard that is
more stringent than the Federal New Source Perform-
ance Standard (NSPS).
C. Existing boiler subject to State Standard that is
equal to or less stringent than NSPS.
D. Other.
E. Unknown.
FGD unit must be added to an existing boiler not
specifically designed to accommodate FGD unit.
Comments on disposal method for those units generating
sludge including: lined or unlined ponds, stabilized or
unstabilized sludge, and on- or off-site disposal.
Operational - Date when S02 removal began. All others -
Date when S02 removal is scheduled to begin. Generally
this will be the start-up date of the boiler.
Capital Cost in $/kW including: SC<2 absorption and regen-
eration system, SO2 recovery system, solids disposal,
site improvements, land, roads, tracks, substation, engi-
neering costs, contractors fee and interest on capital
during construction.
Annualized Cost in mills/kWh including fixed and variable
costs. Fixed costs include: interest on capital, deprecia-
tion, insurance, taxes, and labor costs including overhead.
Variable costs include: raw materials, utilities, and
maintenance.
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DEFINITIONS
Unit Location City and State listed in mailing address.
Unit Name Unit identification as it appears in Electrical World -
Direction of Electrical Utilities, McGraw-Hill - Current
Edition - or as indicated by utility representative for
installations in planning stages.
Unit Rating Operational - Maximum continuous gross generation capacity
in MW? Preoperational - maximum continuous design genera-
tion capacity in MW
Utility Name Name of corporation as it appears in Electrical World -
Directory of Electrical Utilities, McGraw-Hill - Current
Edition - as space permits.
Water Make-Up Gallons per minute of make-up water required per MW of
capacity.
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