SUMMARY REPORT • FLUE GAS DESULFURIZATION SYSTEMS • MARCH - APRIL 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 of 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
Page
3
9
33
131
135
139
143
147
151
155
161
165
169
177
181
187
207
Prepared by
PEDCo-Environmental Specialists, Inc.
Suite 13, Atkinson Square
Cincinnati, Ohio 45246
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
-------
Table 1
SUMMARY LIST OF FGD SYSTEMS
-------
TABLE 1
SUMMARY LIST OF FGO SYSTEMS
FGD STATUS REPORT 05/76
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
1 ALABAMA ELECTRIC COOP
2 ALABAMA ELECTRIC COOP
3 ALLEGHENY POWER SYSTEM
4 ALLEGHENY POWER SYSTEM
5 ARIZONA ELECTRIC POWER COOP
6 ARIZONA ELECTRIC POWER COOP
7 ARIZONA PUBLIC SERVICE
6 ARIZONA PUBLIC SERVICE
9 ARIZONA PUBLIC SERVICE
10 ARIZONA PUBLIC SERVICE
11 ARIZONA PUBLIC SERVICE
12 BASIN ELECTRIC POWER COOP
13 BASIN ELECTRIC POWER COOP
14 BASIN ELECTRIC POWER COOP
15 BASIN ELECTRIC POWER COOP
16 BASIN ELECTRIC POWER COOP '
17 BRAZOS ELECTKIC POwER COOP
IB CENTRAL ILLINOIS LIGHT CO.
19 CENTRAL ILLINOIS LIGHT CO.
20 CENTRAL ILLINOIS LIGHT CO.
21 CENTRAL ILLINOIS PUBLIC SERV
22 CINCINNATI GAS & ELECTRIC CO.
23 CINCINNATI TAS 8 ELECTRIC CO.
24 COLUMBUS A SOUTHERN OHIO ELEC
25 COLUMBUS & SOUTHERN OHIO ELEC
26 COLl'MHUS * SOUTHERN OHIO ELEC
27 COLUMOUS g, SOUTHERN OHIO ELEC
26 COMMONWEALTH EOISON
29 COMMONWEALTH EDISON
30 DETROIT EDISON
31 DUOUESNE LIGHT
32 DUOUESNE LIGHT
33 GENERAL MOTORS
34 GULF POWER CO.
35 GULF POWER CO.
TOMBIGBEE NO. 2
TOMUIGBEE NO. 3
PLEASANTS NO. 1
PLEASANTS NO. 2
APACHE NO 2
APACHE NO 3
CHOLLA NO 1
CHOLLA NO 2
FOUR CORNERS NO. 4
FOUR CORNERS NO. 5A
FOUR CORNERS NO. SB'
BLULAH NO. 1
BEULAH NO. 2
MISSOURI BASIN NO 1
MISSOURI BASIN NO 2
^.MISSOURI BASIN NO 3
.GAT COOPERATIVE PROJECT NO.
DUCK CRCEK NO.l
DUCK CREEK NO.2
E.D.EDWAROS NO.3
NLWTON NO.l
EAST BEND NO 2
MIAMI FORT NO 6
. CONESVILLE NO 5
. CONLSVILLE NO 6
. POSTON NO. 5
. POSTON MO. 6
POWE.RTON NO. 51
WILL COUNTY NO 1
ST.CLAIR NO 6
ELHAMA
PHILLIPS
CHEVROLET PARMA 1 2 3 & 4
SCHOLZ NO. 1A
SCHOLZ NO. 2A
JACKSON ALABAMA
JACKSON ALABAMA
BELLMONT W VIRGINIA
BELLMONT W VIRGINIA
COCHISE ARIZONA
COCHISE ARIZONA
JOSEPH CITY ARIZONA
JOSEPH CITY ARIZONA
FARMINGTON NEW MEXICO
FARMINGTON NEW MEXICO
FARMINGTON NEW MEXICO
BEULAH NORTH DAKOTA
BEULAH NORTH DAKOTA
WHEATLAND WYOMING
WHEATLAND WYOMING
WHEATLAND WYOMING
SAN MIGUEL TEXAS
CANTON ILLINOIS
CANTON ILLINOIS
BAKTONVILLE ILLINOIS
NEWTON ILLINOIS
RABBIT HASH KENTUCKY
NORTH BEND OHIO
CONESVILLE OHIO
CONESVILLE OHIO
ATHENS OHIO
ATHENS OHIO
PEKlN ILLINOIS
ROMEOVILLC ILLINOIS .
BELLE RIVER MICHIGAN
ELRAMA PENNSYLVANIA
SOUTH HEIGHT PENNSYLVANIA
PARMA OHIO
CHATTAHOOCHEE FLORIDA
CHATTAHOOCHEE FLORIDA
1. OPERATIONAL UNITS H.
2. UNITS UNDER CONSTRUCTION 5.
3. PLANNED - CONTRACT AWARDED 6.
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIOS
CONSIDERING ONLY FGD SYSTEMS
A.
!'
C.
D*
E.
BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
S2IJ-52 !U-JrCT 1° SIAIE STANDARD ™AT I* MORE STRINGENT THAN THE FEDERAL NSPS
BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
OTHER
REGULATORY CLASS UNKNOWN
3-78
3-79
3-79
3-60
6-76
6-79
10-73
6-77
0- 0
2-76
0- 0
0-81
0-81
1-80
6-60
6-63
12-79
6-76
1-82
7-79
12-77
1-80
1-78
6-76
1-78
0-81
0-63
12-79
2-72
S-76
10-75
7-73
3-74
2-75
2-76
3
3
3
3
4
4
1
2
6
1
6
6
6
6
6
6
3
2
6
6
5
6
5
2
3
6
6
3
1
2
1
1
1
1
1
A
A
A
A
B
B
B
B
B
B
B
B
B
B
B
B
E
A
A
C
A
A
D
B
B
B
B
C
C
E
B
B
B
C
C
PEOCo-ENVIRONMENTAL
-------
TABLE 1
SUMMARY LIST OF FGO SYSTEMS
FGD STATUS REPORT 05/76
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
36 GULF POWER CO.
37 INDIANAPOLIS POWER ft LIGHT
36 KANSAS CITY POWER A LIGHT
39 KANSAS CITY POWER ft LIGHT
40 KANSAS CITY POWER ft LIGHT
41 KANSAS POWER ft LIGHT
42 KANSAS POWER ft LIGHT
43 KANSAS POWER ft LIGHT
44 KANSAS POWER ft LIGHT
45 KENTUCKY UTILITIES
46 KEY WEST UTILITY BOARD
47 LOUISVILLE GAS ELECTRIC
48 LOUISVILLE GAS ELECTRIC
49 LOUISVILLE GAS ELECTRIC
50 LOUISVILLE GAS ELECTKIC
51 LOUISVILLE GAS ELECTRIC
52 LOUISVILLE GAS ELECTRIC
53 LOUISVILLE GAS ELECTRIC
54 LOUISVILLE GAS ELECTRIC
55 MINNKOTA POWER COOPERATIVE
56 MONTANA POWER CO.
57 MONTANA POkER CO.
56 MONTANA POwER CO.
59 MONTANA POuER CO.
60 NEVADA POWER
61 NEVADA POWER
62 NEVADn POWER
63 NEVADA POWER
64 NEVADA POWER
65 NEVADA POWER
66 NEVADA POWER
67 NEVADA POWER
66 NEVADA POWER
69 NEVADA POWER
70 NEW ENGLAND ELEC SYSTEM
1.
2.
3.
A.
B.
C.
0.
E.
UNITS 1 AND 2
SCHOLZ NOS. IB ft 2B
CO. PETERSBURG NO 3
HAWTHORN NO 3
HAWTHORN NO 4
LA CYGNE NO 1
JEFFERY NO. 1
JLFFERY NO. 2
LAWRENCE MO 4
LAMKENCE NO 5
GREEN RIVER
STOCK ISLAND PLANT
CANE RUN NO 4
CANE RUN NO 5
CANE RUN NO 6
MILL CREEK NO 1
:. HILL CREEK NO 2
""MILL CREEK NO 3
'MILL CREEK NO 4
PAOOYS hUN NO 6
MILTON R. YOUNG NO.
COLSTRIP NO 1
CULSTRIP NO 2
COLSTRIP NO.3
COLSTRIP NO.4
HAKKY ALLEN STATION NO.
HARRY ALLEN STATION NO.
HAKKY ALLEN STATION NO. 3
HARHY ALLEN STATION NO. 4
REIO GARDNER NO 1
REID GARDNER NO 2
REID GARDNER NO 3
REID GARDNER NO 4
WARNER VALLEY STATION NO. 1
WARNER VALLEY STATION NO. 2
BRAYTON POINT NO.3
1
2
CHATTAHOOCHEE FLORIDA
PETERSBURG INDIANA
KANSAS CITY MISSOURI
KANSAS CITY MISSOURI
LA CYGNE KANSAS
ST MARY 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
COLSTRIP MONTANA
COLSTRIP MONTANA
COLSTRIP MONTANA
N. E. LAS VEGAS
N. E. LAS VEGAS
N. E. LAS VEGAS
N. E. LAS VEGAS
MOAPA NEVADA
MOAPA NEVADA
MOAPA NEVADA
MOAPA NEVADA
ST. GEORGE UTAH
ST. GEORGE UTAH
SOMERSET MASSACHUSETTS
OPERATIONAL UNITS 4.
UNITS UNDER CONSTRUCTION &.
PLANNED - CONTRACT AWARDED 6.
PLANNED - LETTER OF INTENT SIGNED
PLANNED • REQUESTING/EVALUATING BIDS
CONSIDERING ONLY FGD SYSTEMS
3-75
9-77
11-72
6-72
2-73
6-78
6-79
12-66
11-71
9-75
10-72
6-76
12-77
9-78
1-82
1-61
7-77
7-79
4-73
6-77
10-75
7-76
7-80
7-61
6-83
6-64
6-85
6-66
4-74
4-74
6-76
0- 0
6-82
6-63
0- 0
1
2
1
1
1
9
3
1
1
1
1
2
2
5
6
6
2
3
1
2
1
2
C
A
B
B
C
B
B
D
D
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
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 FGD SYSTEMS
FGO STATUS REPORT 05/76
1,0. NUMBER AND COMPANY NAME
71 NORTHERN INDIANA PUB SERVICE
72 NORTHERN INDIANA PUB SERVICE
73 NORTHERN INDIANA PUB SERVICE
71 NORTHERN STATES POWER CO.
75 NORTHERN STATES POWER CO.
76 PENNSYLVANIA POWLR CO.
77 PENNSYLVANIA POWER CO.
78 PENNSYLVANIA POWER CO.
79 PHILADELPHIA ELECTRIC CO.
60 PHILADELPHIA ELECTRIC CO.
81 PHILADELPHIA ELECTRIC CO.
«2 PHILADELPHIA ELECTRIC CO.
63 PUBLIC SERVICE CO OF COLORADO
64 PUBLIC SERVICE CO OF NEW HEX.
85 PUBLIC SERVICE CO OF NEW HEX.
86 PUBLIC SERVICE CO OF NEW HEX.
87 PUBLIC SERVICE CO OF NEW HEX.
86 PUBLIC SERVICE INDIANA
89 PUBLIC SERVICE INDIANA
90 RICKENBACKCR AFO
91 S. CAROLINA PUB SERV AUTHORITY
92 S. MISSISSIPPI ELEC PWH ASSOC
93 S. MISSISSIPPI ELEC PUR ASSOC
9«t SOUTHERN CALIFORNIA EDISON
95 SOUTHERN CALIFORNIA EDISON
96 SOUTHERN ILLINOIS POwEK COOP
97 SPRIMGFIELO CITY UTILITIES
96 TENNESSEE VALLEY AUTHORITY
99 TENNESSEE VALLEY AUTHORITY
100 TENNESSEE VALLEY AUTHORITY
101 TEXAS UTILITIES CO.
10? TEXAS UTILITIES CO.
103 TEXAS UTILITIES CO.
10* TEXAS UTILITIES CO.
105 UNITED POWER ASSOCIATION
UNIT NAME
BAILLY NO. 7
BAILLY NO. 6
MITCHELL NO 11
SHEKDURNE NO 1
SHERBURNE NO 2
BRUCE MANSFIELD NO. 1
BRUCE MANSFIELD NO. 2
BRUCE MANSFIELD NO. 3
CROMBY
EDUYSTONE NO 1A
EUDYSTONE NO IB
EDDYSTONE NO 2
VALMONT NO. 5
SAN JUAN NO. 1
SAN JUAN NO. 2
SAN JUAN NO. 3
SAN JUAN NO.
-------
TABLE 1
SUMMARY LIST OF FGD SYSTEMS
F60 STATUS REPORT 05/76
1.0. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
RE6
CLASS
106 UNITED POWER ASSOCIATION
107 UTAH POWER & LIGHT CO.
108 UTAH POWER & LIGHT CO.
COAL CREEK NO. 2
EMERY NO.l
HUNTIN6TON N0.1--
UNDERWOOD NORTH DAKOTA
EMERY COUNTY UTAH
PRICE UTAH
11-79
6-76
*-7T
5
3
2
A
A
A
1. OPERATIONAL UNITS <*.
2. UNITS UNDER CONSTRUCTION 5.
3. PLANNED - CONTRACT AWARDED 6.
A.
B.
C.
0.
E.
PLANNED - LETTER OF INTENT SIGNED
PLANNED • REQUESTING/EVALUATING BIOS
CONSIDERING ONLY FGD SYSTEMS
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
8
-------
Table 2
STATUS OF FGD SYSTEMS
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
05/76
CURRENT MONTH
1.0. NUMBER 1
ALABAMA ELECTRIC COOP
TOMBIGREE NO. 2
225 MM - NEW
COAL 0.8- 1.5 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/76
PEABODY ENGINEERING WAS AWARDED CONTRACT TO INSTALL FGD SYSTEM ON
TOMBIGBEE NO. 2. AT THE PRESENT TIME. WORK IS PROCEEDING ON THE FOUNDA-
TION OF THIS LIMESTONE SCRUBBING SYSTEM.
I.D. NUMBER 2
ALABAMA ELECTRIC COOP
TOMBIGBEE. NO. 3
225 MM - NEW
COAL 0.8- 1.5 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/79
PEABODY ENGINEERING WAS AWARDED CONTRACT TO INSTALL FGD SYSTEM ON
TOMBIGBEE NO. 3. AT THE PRESENT TIME, WORK IS PROCEEDING ON THE FOUNDA-
TION OF THIS LIMESTONE SCRUBBING SYSTEM.
I.D. NUMBER 3
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 1
625 MW - NEW
COAL 2.0- 5.0 PERCENT SULFUR
BABCOCK AND WILCOX
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 LIME CO. TO
SUPPLY THIOSORBIC LIME FOR THE PLANNED S02 SCRUBBERS AT PLEASANTS NOS. 1
ANij 2. THE CONTRACT FOR THIS LIME SCRUBBING PROCESS HAS BEEN AWARDED TO
BABCOCK AND WILCOX. GUARANTEED S02 AND PARTICULATE REMOVAL EFFICIENCIES
FOR THIS EMISSION CONTROL SYSTEM ARE 90 AND 99.55 PERCENT RESPECTIVELY.
I.D. NUMBER <»
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 2
625 MW - NEW
COAL 2.0- 5.0 PERCENT SULFuR
BABCOCK AND WILCOX
LIME SCRUBBING
STARTUP 3/80
THE THREE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM HAVE CONCLUDED A LONG-TERM AGREEMENT WITH THE DRAVO LIME CO. TO
SUPPLY THIOSORBIC LIME FOR THE PLANNED S02 SCRUBBERS AT PLEASANTS NOS. 1
AND 2. THE CONTRACT FOR THIS LIME SCRUBBING PROCESS HAS BEEN - AWARDED TO
BABCOCK AND WILCOX. GUARANTEED S02 AND PARTICIPATE REMOVAL EFFICIENCIES
FOR THIS EMISSION CONTROL SYSTEM ARE 90 AND 99.55 PERCENT RESPECTIVELY.
I.D. NUMBER 5
ARIZONA ELECTRIC POWER COOP
APACHE NO 2
200 MW - NEW
COAL 0.5- 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/78
LETTER OF INTENT TO INSTALL AN FGD SYSTEM WAS ISSUED TO RESEARCH COTTRELL.
ENGINEERING DESIGN WORK IS PROCEEDING. THE INITIAL SITE PREPARATION
FOUNDATION WORK IS ALREADY UNDERWAY. THE CONCRETE FOR THE SCRUBBER TOWER
HAS ALREADY BEEN POURED. GUARANTEED S02 AND PARTICULATE REMOVAL EFFI-
CIENCIES ARE 50 AND 99.<» PERCENT RESPECTIVELY.
PEDCo- ENVIRONMENTAL
11
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
05/76
CURRENT MONTH
1.0. NUMBER 6
ARIZONA ELECTRIC POWER COOP
APACHE. MO 3
205 MW - NEW
COAL 0.5- 0.6 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/79
LETTER OF INTENT TO INSTALL AN FGD SYSTEM WAS ISSUED TO RESEARCH COTTRELLt
THE ENGINEERING DESIGN WORK IS PROCEEDING. THE INITIAL SITE PREPARATION
WORK IS ALREADY UNDERWAY. THE CONCRETE FOR THE SCRUBBER TOWER FOUNDATION
HAS ALREADY BEEN POURED. GUARANTEED S02 AND PARTICULATE REMOVAL EFFI-
CIENCIES ARE SO AND 99.4 PERCENT RESPECTIVELY.
I.D. NUMBER 7
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
115 MW - RETROFIT
COAL 0.44-1 PERCENT SULFUR
RESEARCH COTTRCLL
LIMESTONE SCRUBBING
STARTUP 10/73
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 1973. RELIABILITY FOR
MODULES A AND B DURING THE MONTH OF APRIL WAS 99 AND 97.4 PERCENT RE-
SPECTIVELY. RELIABILITY FOR BOTH MODULES HAS AVERAGED IN EXCESS OF 90 AND
63 PERCENT RESPECTIVELY DURING THE PERIOD OF APRIL 1979 TO JANUARY 1976.
I.D. NUMBER B
ARIZONA PUBLIC SERVICE
CHOLLA NO 2
250 MW - NEW
COAL 0.44-1 PERCENT SULFUR
RESEARCH COTTRELL
LIKE.STONE SCRUBBING
STARTUP 6/77
RESEARCH COTTRELL WAS AWARDED A CONTRACT TO INSTALL FGO SYSTEM ON
CHOLLA NO. 2. AND IS PRESENTLY WORKING ON THE DESIGN PHASE OF THIS
PROJECT. ENGINEERING IS SUBSTANTIALLY COMPLETE. CONSTRUCTION IS
UNDERWAY.
I.D. NUMBER 9
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 4
755 MW - RETROFIT
COALi 0.7 - 0.75S SULFUR (AVG)
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THIS 755 HW UNIT WILL BE CONTROLLED PENDING THE OUTCOME OF TESTS TO BE
MADE ON THE PROTOTYPE 160 MW FGO MODULE NOW BEING INSTALLED ON UNIT s.
I.D. NUMBER 10
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 5A
160 MW - RETROFIT
COAL. 0.7 PERCENT SULFUR
SCE
LIME SCRUBBING
STARTUP 2/76
THIS 160 MW SYSTEM HAS BEEN MOVED FROM THE MOHAVE STATION OF SOUTHERN
CALIFORNIA EDISON WHERE THE SYSTEM WAS PREVIOUSLY TESTED. THE SYSTEM
WILL TREAT APPROXIMATELY 20 PERCENT OF THE FLUE GAS FROM UNIT NO. 5,
RATED AT 755 MW(NET). THE ENGINEERING AND CONSTRUCTION WORK HAS BEEN
COMPLETED. THE SYSTEM BECAME OPERATIONAL ON FEBRUARY 17. 1976. THE EXPER-
IMENTAL SCRUBBER WAS TAKEN OUT OF SERVICE IN MID-APRIL FOR A SCHEDULED
BOILER OVERHAUL.
PEDCo- ENVIRONMENTAL
12
-------
COMPANY
TABLE 2
STATUS OF FGO SYSTEMS DURING
OS/76
POWER STATION CURRENT MONTH '
1.0. NUMBER 11
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. SB
595 MW - RETROFIT
COALt 0.7 - 0.75i SULFUR (AVG)
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THE BALANCE OF THIS 755 HW UNIT WILL BE CONTROLLED PENDING THE OUTCOME
OF TESTS TO BE MADE ON THE PROTOTYPE 160 HW FGO MODULE NOW BEING INSTALLED
NO START-UP DATE HAS BEEN SCHEDULED.
I.D. NUMBER 12
BASIN ELECTRIC POWER COOP
BEULAH NO. 1
i»50 MW • NEW
COAL 1.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
THE UTILITY IS NOW INVESTIGATING VARIOUS FGD PROCESSES. THIS NEW STATIONt
CURRENTLY KNOWN AS THE BEULAH PROJECTt WILL INCLUDE TWO NEW COAL-FIRED
BOILERS WHICH WILL BE REQUIRED TO COMPLY WITH WITH AIR EMISSION STANDARDS
VIA THE BEST AVAILABLE TECHNOLOGY.
I.D. NUMBER 19
BASIN ELECTRIC POWER COOP
BEULAH NO. 2
450 MW - NEW
COAL 1.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/61
THE UTILITY IS NOW INVESTIGATING VARIOUS FGD PROCESSES. THIS NEW STATION,
CURRENTLY KNOWN AS THE BEULAH PROJECT, WILL INCLUDE TWO NEW COAL-FIRED
B04LERS WHICH WILL BE REQUIRED TO COMPLY WITH WITH AIR EMISSION STANDARDS
VIA THE BEST AVAILABLE TECHNOLOGY.
I.D. NUMBER l«t
BASIN ELECTRIC 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
BTU.LOW SULFUR COAL ALONE WILL NOT MEET STANDARDS. BASIN ELECTRIC IS NOW
INVESTIGATING VARIOUS FGO PROCESSES.
I.D. NUMBER 15
BASIN FLECTRIC POWER COOP
MISSOURI BASIN NO 2
550 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/60
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.
PEDCo-ENVIRONMENTAL
13
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 05/76
CURRENT MONTH
I.D. NUMHLR 16
BASIN ELECTRIC POWER COOP
MISSOURI BASIN NO 3
550 MU - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/83
BECAUSE OF THE STRICT WYOMING EMISSION STANDARDS OF 0.2LBS PER MILLION
BTUtLOW SULFUR COAL ALONE WILL NOT MEET STANDARDS. BASIN ELECTRIC IS NOW
INVESTIGATING VARIOUS FGO PROCESSES.
I.D. NUMBER 17
BRAZOS ELECTRIC POWER COOP
G X T COOPEHATIVE PROJECT NO.l
i»00 MW - NEW
COAL 1.67 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 12/79
BABCOCK AND WILCOX HAS BEEN AWARDED THE CONTRACT FOR THE INSTALLATION OF
THIS ENTIRE NEW SYSTEM. THE EMISSION CONTROL EQUIPMENT FOR THE COAL-FIRED
RAUIANT BOILER WILL CONSIST OF ELECTROSTATIC PKECIPITATORS UPSTREAM OF
THE LIMESTONE SCRUBBING MODULES. THE SCRUBBER FLUE GAS CAPACITY IS
NOMINALLY DESIGNED TO EXCEED 1.5 MILLION ACFM. THE DESIGN SOg REMOVAL
EFFICIENCY IS 66 PERCENT FOR m»00 PPM S02 INLET. LIGNITE COAL WILL BE
FIRED IN THE BOILER. THE CONSULTING ENGINEERING FIRM IS TIPPETT AND GEE.
1.0. NUMBER 18
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO.l
100 MU - NEW
COAL 2.5-3.0 PERCENT SULFUR
RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
STARTUP 6/76
THE UNIT IS NOW UNDER CONSTRUCTION AND IS SCHEDULED FOR COMPLETION IN
JUNE 1976. STATION CAPACITY IS HOOMW, BUT FLUE GAS FROM ONLY 100 MW
WU.L BE TREATED INITIALLY.
I.D. NUMBER 19
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO.2
100 MW - NEW
COAL 2.5-3.0 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 1/82
THIS PROPOSED LIMESTONE UNIT IS SCHEDULED TO COMMENCE OPERATION IN
JANUARY 1962. A SYSTEM SUPPLIER HAS NOT YET BEEN SELECTED.
I.D. NUMBER 20
CENTRAL ILLINOIS LIGHT CO.
E.D.EDWARDS NO.3
357 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 7/79
THE UTILITY PLANS TO USE LOW SULFUR COAL FROM 6/76 UNTIL SYSTEM STARTUP.
TH£ PROCESS AND SYSTEM SUPPLIER HAVE NOT YET BEEN SELECTED.
PEDCo-ENVIRONMENTAL
14
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F&D SYSTEMS DURING
OS/76
CURRENT MONTH
I.D. NUMBER 21
CENTRAL ILLINOIS PUBLIC SERV
NEWTON NO.l
600 MK - NEW
COAL 2.8-3.2 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 12/77
THE UTILITY IS NOW IN THE PROCESS OF EVALUATING BIOS FOR LIME/LIMESTONE
AND DOUBLE ALKALI SCRUUBING. A DECISION CONCERNING THE PARTICULAR PROCESS
AND SYSTEM SUPPLIER WILL BE ANNOUNCED SHORTLY. THE DESIGN BASIS OF THE
SCRUBBING SYSTEM CALLS FOR S02 REMOVAL EFFICIENCY TO MEET AIR QUALITY
STANDARDS FOR 4 PERCENT SULFUR COAL.
I.D. NUMBER 22
CINCINNATI GAS ft ELECTRIC CO.
EAST BEND NO 2
600 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 1/80
UTILITY WILL GO OUT FOR BIOS IN LATE 1976. THE COMPANY IS PRESENTLY OB-
TAINING CONSTRUCTION AND OPERATING PERMITS. STARTUP DATE HAS BEEN MOVED
BACK TO JANUARY 1980. THE COAL SOURCE FOR THIS UNIT HAS NOT VET BEEN SE-
LECTED.
I.D. NUMBER 23
CINCINNATI GAS A ELECTRIC CO.
MIAMI FORT NO 8
500 MW - NEW
COAL 1.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 1/76
THE UTILITY HAS SIGNED A CONTRACT FOR THE PURCHASE OF LOW SULFUR COAL
(1.3 PERCENT SULFURI. THE COAL BED FOR UNIT NO.8 IS NOW IN THE PROCESS OP
BEING REDESIGNED TO ACCEPT THE LOW SULFUR COAL. IN ADDITION TO LIME/
LIMESTONE SCRUBBING! THE UTILITY IS ALSO INVESTIGATING THE POSSIBILITY
OF'BURNING LOW SULFUR COAL 10.7 PERCENT SULFUR) IN ORDER TO MEET NSPS.
NO COMMITMENTS HAVE BEEN MADE.
1.0. NUMBER 24
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE NO 5
<«00 MM - NEW
COAL 4.5 - 4.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
STARTUP 6/76
THE UTILITY SIGNED LONG-TERM CONTRACTS WITH DRAVO FOR THE PURCHASE OF
THIOSORRIC LIME AND WITH IUCS FOR THE PURCHASE OF SLUDGE FIXATIVES. THE
BOILER AND FGD SYSTEM ARE STILL UNDER 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 PRECIPITATOR WILL BE INSTALLED UPSTREAM
OF THE FGO SYSTEM. PRESENT PLANS CALL FUR ONE MODULE OF THIS DUAL.MODULAR
SYSTEM TO GO ON-LINE JUNE 23t 1976.
I.D. NUMBER 25
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE NO 6
400 MW • NEW
COAL 4.5 - 4.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
STARTUP 1/78
THE UTILITY SIGNED LONG-TERM CONTRACTS WITH ORAVO FOR THE PURCHASE OF
THIOSORBIC 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 CONCSVILLE 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.
PEDCo-ENVIRONMENTAL
15
-------
COMPANY
POWER STATION
I.D. NUMBER 26
COLUMBUS g SOUTHERN OHIO ELEC,
POSTON NO. 5
375 MW - NEW
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
TABLE 2
STATUS OF FGD SYSTEMS DURING 05/76
CURRENT MONTH.
UNIT WILL BURN 2.5 PERCENT SULFUR OHIO COAL,
I.D. NUMBER 27
COLUMBUS S SOUTHERN OHIO ELEC*
POSTON NO. 6
375 MW - NEW
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/83
I.D. NUMBER 20
COMMONWEALTH EDISON
POWERTON NO. 51
•425 MW - RETROFIT
COAL 3.6 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 12/79
I.D. NUMBER 29
COMMONWEALTH EUISON
WILL COUNTY NO 1
167 MW - RETROFIT
COAL - 9463 BTU, 2.IS SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 2/72
I.D. NUMBER 30
DETROIT EDISON
ST.CLAIR NO f,
180 MW - RETROFIT
COAL 3.7 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
UNIT WILL BURN 2.5 PERCENT SULFUR OHIO COAL.
"FOR"THIS"FGD"SYSTEM"HAS BEEN AWARDED TO UNIVERSAL OIL
PoDUE ?RO«SI IS°A CLOSED-LOOP WET LIMESTONE SCRUBBING SYSTEM
imirn WILL BE BACKFITTED TO BOILER 5li ONE OF TWO IDENTICAL BOILERS
§uJpLY?NG STEAM TO AN 850 MW TURBINE-GENERATOR. THE FGD SYSTEM IS DE-
!l6NED TO TREAT FLUE GAS RESULTING FROM THE COMBUSTION OF HIGH SULFUR
III" ?s.6 PE"ENT SULFUR* 8.3 PERCENT ASH* 17.3 PERCENT MOISTURE* 10,500
BTU/LB.) AND MEET S02 EMISSION STANDARDS OF 1.6 LB. S02/MM BTU.
CKGROUNriNFORMATION'sECTION'lN'TABLE 3 OF THIS REPORT. THIS
HAS BEEN OPERATIONAL SINCE FEBRUARY 1972. THE UNIT HAS RE-
sS!!l?E W SSJlFOttoSlllG A MAJOR BOILER. TURBINE, AND SCRUB-
nuiRhAUL SYSTEM OPERABILITY FOR BOTH MODULES DURING THE REPORT
iS! KS ts AND 2! PERCENT IN MARCH AND 20 AND «9 PERCENT IN APRIL FOR
NOUULES A AND B KESPECT IVELY. MODULES A AND B WERE IN SERVICE A TOTAL OF
Sw So a£! HOURS HOURS RESPECTIVELY, IN "«, WHICH TRJNWTES INTO
ANNUAL OPEKABILITY FACTORS OF 52 AND H2 PERCENT RESPECTIVELY. ............
» sf u OF »»«KE "«. TK
i ri«
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS OUR ING
05/76
CURRENT MONTH
I.D. NUMBER 31
DUQUESNE LIGHT
ELRAMA
510 MW - RETROFIT
COAL 1.0 • 2. B PERCENT SULFUR
CHEMICO.
LIME SCRUBBING
STARTUP 10/75
THC FGD SYSTEM MAS PLACED IN SERVICE ON OCTOBER 26, 1975. INITIAL
OPERATION PROCEEDED WITH FLUE GAS FROM ONE BOILER BEING TREATED BY THE
SCKUBOING SYSTEM, P SECOND BOILER WAS TIED INTO THE SYSTEM ON FEBRUARY *t
1976. DURING THE REPORT PERIOD MODIFICATIONS TO THE FIFTH SCRUBBING VES-
SEL WERE COMPLETED AND THE VESSEL IS NOW OPERATING WITH TWO RUBBER-LINED
1.0. NUMBER 32
DUQUESNE LIGHT
PHILLIPS
110 MW - RETROFIT
COAL 1*0- 2.8 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 7/73
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTEM HAS BELN OPERATIONAL SINCE JULY 1973. THE UTILITY REPORTS THAT
A TOTAL OF <» BOILERS (NOS. 3t4«5,A 6) WERE COUPLED INTO THE SCRUBBING
SYSTEM DURING THE REPORT PERIOD. THE SYSTEM IS NOW OPERATING ON HIGH
CALCIUM LIME FOLLOWING THE COMPLETION OF THE THIOSORBIC LIME TEST PRO-
GRAM. THE SCRUBBING SYSTEM AVAILABILITY DURING THE FIRST QUARTER Op 1976
WAS 72 PERCENT. THE SLUDGE STABILIZATION PRACTICES ARE STILL CONTINUING
AT THIS FACILITY.
I.D. NUMBER 33
GENERAL MOTORS
CHEVROLET PARMA 1 2 3 « f
32 MW . RETROFIT
COAL 2.5 PERCENT SULFUR
KOCH
DOUBLE ALKALI
STARTUP
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE MARCH 197*. SYSTtM OPERABILlTY
•DURING THE MONTHS OF MARCH AND APRIL WAS 17 AND 76 PERCENT RESPECTIVELY.
SYSTEM OPERABILITY AVERAGED IN EXCESS OF sa PERCENT DURING THE LAST EIGHT
MONTHS. CURRENTLY, A SCRUBBING SYSTEM CHARACTERIZATION STUDY, SPONSORED
BY THE EPA, IS BEING CONDUCTED BY A.D. LITTLE.
I.D. NUMBER 3t
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 s OF THIS REPORT. THIS
FGD SYSTEM HAS BELN OPERATIONAL SINCE FEB. 1975. THE PROTOTYPE SYSTEM
OPERATED A TOTAL OF H7HH HRS. DURING 1975i TRANSLATING INTO AN ANNUAL
AVERAGE OPERABILITY OF 89 PERCENT. THE SYSTEM WAS PUT BACK IN SERVICE
MARCH 12, 1976, FOLLOWING A SCHEDULED BOILER OVERHAUL. SYSTEM OPERABILITY
WAS 9«t PERCENT FOR THE DURATION OF THE MONTH.
I.D. NUMBER 35
GULF POWER CO.
SCHOLZ NO. 2A
20 MW - RETROFIT
COAL 3.0 PERCENT SULFUR
FOSTER WHEELER
ACTIVATED CARBON
STARTUP 2/76
KEFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THE
SYSTEM SUPPLIER AND TEST DIRECTOR {SOUTHERN SERVICES) REPORTED THREE
OPERATIONAL RUNS DURING THE REPORT PERIOD. PERFORMANCE OF THE FRONT-END
OF THE SYSTEM (ADSORPTION AND REGENERATION) WAS CONSIDERED ADEQUATE. THE
RESOX SECTION OPERATED INTERMITTENTLY DURING THE REPORT PERIOD BECAUSE OF
PLUGGING PROBLEMS IN THE SULFUR CONDENSER. TO DATE. THE SYSTEM S02
REMOVAL EFFICIENCY HAS EXCEEDED THE NOMINAL DESIGN VALUE (96 PERCENT).
PEDCo-ENVIRONMENTAL
17
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING 05/76
CURRENT MONTH'
1.0. NUMBER 36
GULF POWLR CO.
SCHOLZ NOS. in X 2B
23 MW - RETROFIT
COAL 5.0 PERCENT SULFUR (MAX)
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 OPERABILI-
TY. INCLUDING SYSTEM COMMISSIONING, EXTENDING FROM FEB. 11,1975, TO
DECEMBER 31,1975, WAS 60 PERC'ENT. SYSTEM OPERABILITY FOR THE MONTHS OF
MARCH AND APRIL WAS 100 AND m PERCENT RESPECTIVELY. THE SYSTEM WAS TAKEN
OUT OF SERVICE ON APRIL 5 FOR A SCHEDULED SYSTEM'S DESIGN MODIFICATION.
I.D. NUMBER 37
INDIANAPOLIS POWER X LIGHT CO.
PETERSBURG NO 3
530 MW - NEW
COAL 3.0-3.5 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 9/77
UNIVERSAL OIL PRODUCTS HAS BEEN SELECTED TO BUILD THE LIMESTONE SCRUBBING
SYSrLM. THE FLUE GAS FROM THE 530 MW UNIT WILL BE TREATED BY FOUR
SCRUBBING MODULES. CONSTRUCTION ON THI-S SYSTEM IS NOW IN PROGRESS.
WORK IS PROCEEDING ACCORDING TO SCHEDULE. CURRENTLY, WORK ON THE
FOUNDATION AND INSTALLATION OF THE RECYCLE TANKS IS BEING COMPLETED.
THE SCRUBBING MODULES ARE NOW BEING FABRICATED. THE STARTUP DATE HAS
BEEN MOVED BACK TO SEPTEMBER 1977.
1.0. NUMBER 38
KANSAS CITY POWER X LIGHT
HAWTHORN NO 3
140 MW . RETROFIT
COAL 0.6- 3.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION XWET SCRUB
STARTUP 11/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 1972. BOTH MODULES WERE
DOWN THROUGHOUT THE REPORT PERIOD. THE UTILITY IS CURRENTLY ELIMINATING
THi BY-PASS SEALS AND INSTALLING SLIDE-GATE DAMPERS. IN ADDITION, THE
B-MOUULE WAS RECONVERTED TO AN UNDERBED SPRAY ARRANGEMENT BECAUSE OF
CONTINUING PLUGGING PROBLEMS.
I.D. NUMBER 39
KANSAS CITY POWER X LIGHT
HAWTHORN NO
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
05/76
CURRENT MONTH
I.D. NUMBER 41
KANSAS POiJER « LIGHT
JEFFERY NO. 1
680 MM - NEW
COAL 0.32 PERCENT SULFUR
COMBUSTigi! ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/76
THE UTILITY HAS PURCHASED AN AIR QUALITY CONTROL SYSTEM FROM COMBUSTION
ENGINEERING FOR PARTICULATE AND S02 REMOVAL. THE SYSTEM WILL CONSIST OF
AN ESP DOWNSTREAM OF THE AIR HEATER PLUS ID FANS AND SPRAY TOWERS. AN
OVERFIRE AIR SYSTEM AT THE TANGENTIAL FIRED PULVERIZED BURNERS WILL CON-
TROL THE NOX EMISSIONS. THE CLEANED GASES WILL BE VENTED TO A 600 FOOT
STACK.
I.D. NUMBER 42
KANSAS POWER « LIGHT
JEFFERY NO. 2
680 MM - NEW
COAL 0.32 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/79
THE UTILITY HAS PURCHASED AN AIR QUALITY CONTROL SYSTEM FROM COMBUSTION
ENGINEERING FOR PARTICULATE AND S02 REMOVAL. THE SYSTEM WILL CONSIST OF
AN ESP DOWNSTREAM OF THE AIR HEATER PLUS ID FANS AND SPRAY TOWERS. AN
OVtRFIRE AIR SYSTEM AT THE TANGENTIAL FIRED PULVERIZED BURNERS WILL CON-
TRUL THE NOX EMISSIONS. THE CLEANED GASES WILL BE VENTED TO A 600 FOOT
STACK.
I.D. NUMBER 43
KANSAS POWER 8 LIGHT
LAWRENCE NO 4
125 MW - RETROFIT
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION 4WET SCRUB
STARTUP 12/68
REFEK TO BACKGROUND INFORMATION SECTION IN TABLE 3 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
DEGREE 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
KANSAS POWER ft LIGHT
LAWRENCE NO 5
400 MW - NEW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION &WET SCRUB
STARTUP 11/71
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. 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-ROD AND SPRAY TOWER SCRUBBING
SYSTEM.
I.D. NUMBER 45
KENTUCKY UTILITIES
GREEN RIVER UNITS 1 AND
64 MW - RETROFIT
COAL 3.6 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 9/7S
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
SYSTEM BECAME OPERATIONAL SEPTEMBER 13, 1975. THE OPERATIONAL DATA
SUPPLIED BY THE UTILITY FOR THE REPORT PERIOD SHOWS THAT SYSTEM
AVAILABILITYi RELIABILITY. OPERABILITY. ANU UTILIZATION WAS 97« 95t 65*
AND 52 PERCENT RESPECTIVELY FOR THE MONTH OF MARCH AND 90. 100. 100. AND
77 PERCENT RESPECTIVELY FOR THE MONTH OF APRIL.
PEDCo- ENVIRONMENTAL
19
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COMPANY
POULR STATION
I.D. NUMBER 46
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
37 riW - NEW
OIL 2.4 PERCENT SULFUR
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
STARTUP 10/72
I.D. NUMBER 47
LOUISVILLE GAS 8 ELECTRIC
CANE RUN NO if
176 MW - RETROFIT
COAL 3.5-i».05 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 6/76
I.D. NUMBER i»8
LOUISVILLE GAS g ELECTRIC
CANE RUN NO 5
183 MW - RETROFIT
COAL 3.5-i*.05 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 12/77
1.0. NUMBER 49
LOUISVILLE GAS g, ELECTRIC
CANE RUN NO 6
277 MW - RETROFIT
COAL 3.5- 4.0 PERCENT SULFUR
NOT SELECTTED
NOT SELECTED
STARTUP 9/7fl
I.D. NUMBER 50
LOUISVILLE GAS g ELECTRIC
MILL CREEK NO 1
330 MW - RETROFIT
COAL 3.5- 4.0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 1/62
TABLE 2
STATUS OF FGD SYSTEMS DURING
05/76
CURRENT MONTH
REFEH TO BACKGROUND INFORMATION SECTION IN TABLE 3~OF~THIS~REPORTl"THIS~'
FGO SYSTEM HAS BEEN OPERATIONAL SINCE OCTOBER 1972. THF FGD SYSTEM HAS
?F™ ^,Tv°F SLRVICE SINCE JANUARY 28,1975. MODIFICATIONS AND REPAIRS ARE
CURRENTLY IN PROGRESS. SYSTEM RESTART IS STILL INDEFINITE. A CHECKOUT
OF ALL SYSTEM MOTORS AND PUMPS MUST BE COMPLETED BEFORE STARTUP CAN
COMMENCE.
THE UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGD EQUIPMENT ON THIS UNIT BY JUNE 1,1976. THE
CONTRACT HAS BEEN AWARDED TO AMERICAN AIR FILTER. THE SYSTEM WILL OPERATE
ON A CLOSED WATER LOOP AND THE SLUDGE WILL BE STABILIZED. THIS SYSTEH IS
PRESENTLY UNDER CONSTRUCTION. .
THE UTILITY HAS SIGNEJ A CONSENT AGREEMENT WITH THE EPA"FOR~THE~INSTALT
LATION AND OPERATION OF FGO EQUIPMENT ON THIS UNIT BY DECEMBER 1,1977.
THL,,CONTRACT FOR THIS LIME SCRUBBING SYSTEM HAS BEEN AWARDED TO
COMBUSTION ENGINEERING. THE UNIT IS PRESENTLY UNDER CONSTRUCTION.
THL UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL
LATION AND OPERATION OF FGO EQUIPMENT ON THIS UNIT BY SEPTEMBER 1,1978
DURING THE REPORT PERIOD THE UTILITY ANNOUNCED THAT THEY HAVE SEEN
SELECTED BY THE EPA TO NEGOTIATE A CONTRACT FOR THE INSTALLATION OF A
DOUBLE ALKALI SYSTEM ON THIS UNIT. THE PROCESS BEING GIVEN PRIME
CONSIDERATION IS THE CEA/AOL DUAL ALKALI FGD SYSTEM.
A COMPLIANCE SCHEDULE HAS BEEN SUBMITTED TO THE JEFFERSON~COUNTY"AIR~
DISTRICT WITH »/M ESTABLISHED AS THE IlSlS OATC F0«
PEDCo-ENVIRONMENTAL
20
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS DURING
05/76
CURRENT MONTH'
I.D. NUMBER 51
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 2
330 MM • 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 1/61 ESTABLISHED AS THE STARTUP DATE FOR AN
FGU SYSTEM.
I.D. NUMBER 52
LOUISVILLE GAS 8 ELECTRIC
MILL CREEK NO 3
425 MW - NEW
COAL 3.5- 4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 7/77
THL UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGU EQUIPMENT ON THIS POWER GENERATING UNIT BY
JULY 1,1977. THIS NEW FACILITY WILL BE REQUIRED TO MEET FEDERAL NSPS FOR
THE LIMITATION OF S02 EMISSIONS. CONTRACT HAS BEEN AWARDED TO AMERICAN
AIR FILTER. THE SYSTEM WILL OPERATE ON A CLOSED WATER LOOP AND THE SLUDGE
WILL BE STABILIZED. CONSTRUCTION HAS BEGUN ON THE FGD SYSTEM.
I.D. NUMBER 53
LOUISVILLE GAS 8 ELECTRIC
MILL CREEK NO 4
425 MW - NEW
COAL 3.5- 4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 7/79
THE UTILITY HAS SIGNED A CONSENT AGREEMENT WITH THE EPA FOR THE INSTAL-
LATION AND OPERATION OF FGD EQUIPMENT ON THIS POWER GENERATING UNIT BY
JULY 1.1979. THIS NEW FACILITY WILL BE REQUIRED TO MEET FEDERAL NSPS FOR
THE LIMITATION OF S02 EMISSIONS. THE CONTRACT HAS BEEN AWARDED TO
AMERICAN AIR FILTER FOR A LIME SCRUBBING SYSTEM.
I.D. NUMBER 54
LOUISVILLE GAS 8 ELECTRIC
PADDYS RUN NO 6
65 MW - RETROFIT
COAL 3.5-4.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 4/73
REFEK TO BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT. THIS
FGD SYSTEM MAS BEEN OPERATIONAL SINCE APRIL 1973. OPERABILITY WAS 100
PERCENT IN JANUARY. S02 REMOVAL EFFICIENCY WAS 99 PERCENT DURING THIS
OPERATING PERIOD. THE SYSTEM WAS SHUTDOWN IN EARLY FEBRUARY IN PREPARA-
TION FOR THE EPA SCRUBBER AND SLUDGE STUDY WHICH MAY COMMENCE IN JUNE. OR
JULY OF 1976. THE SCHUBbEH WILL NOT BE OPERATED UNTIL THIS TIME UNLESS
THE NEED ARISES (PEAK LOAD DEMAND). CURRENTLY, THE UTILITY IS COMPLETING
MODIFICATIONS ON THIS UNIT IN ANTICIPATION OF THE STUDY PROGRAM.
I.D. NUMBER 55
MINNKOTA POWER COOPERATIVE
MILTON R. YOUNG NO. 2
450 MW - NEW
LIGNITE - 6.500 BTu, 0.7K S
COMBUSTION EQUIP. ASSOCIATES
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 6/77
THL CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO COMBUSTION EQUIPMENT
ASSOCIATES. THE A/c. FIRM IS SANDERSON AND PORTER. THE BOILER IS NOw UNDER
CONSTRUCTION. THE TANKS FOR THE FGU SYSTEM HAVE BEEN FABRICATED AND ARE
SCHEDULED FOR INSTALLATION IN JULY 1976. A PILOT PLANT (5000 ACFM) WAS
PUT IN SERVICE ON OCTOBER 13,1975. THE PILOT PLANT KUNS ARE BEING CON-
DUCTED TO DETERMINE THE MAJOR CRITERIA FOR A FULL-SUE INSTALLATION.
SPECIFICALLY.THIS INCLUDES RELIABILITY TESTING. EVALUATION OFF VARIOUS PH
CONTROL SYSTEMS AND ANALYSES OF VARIOUS TYPES OF FLYASH ABSORBENTS.
PEOCo-ENVIRONMENTAL
21
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COMPANY
POWER STATION
1.0. NUMBER 56
MONTANA POWER CO.
COLSTRIP NO 1
360 MW - NEW
COAL 0.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 10/75
TABLE 2
STATUS OF FGD SYSTEMS DURING 05/76
CURRENT MONTH
THE COLSTRIP PLANT IS A MINE MOUTH INSTALLATION. CONSTRUCTION ON~THls"""~'
UNIT WAS COMPLETED BEHIND SCHEDULE. THE FGD SYSTEM STARTED UP IN LATE
1975 AND PROCEEDED THROUGH A SHAKLDOWN AND DEBUGGING OPERATION PHASE. THE
UNIT IS NOW OPERATING AT FULL COMMERCIAL CAPACITY. OPERATING DATA AC-
CUMULATED TO-DATE IS IN THE PROCESS OF BEING EVALUATED BY THE UTILITY FOR
PRESENTATION TO STATE REGULATORY AGENCIES.
I.D. NUMBER 57
MONTANA POWER CO.
COLSTRIP NO 2
360 MW - RETROFIT
COAL 0.8 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/76
I.D. NUMBER 58
MONTANA POWER CO.
COLSTRIP NO.3
700 MW - NEW
COAL 0.7 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 7/80
I.D. NUMBER 59
MONTANA POWER CO.
COLSTRIP N0.it
700 MW - NEW
COAL 0.7 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 7/81
I.D. NUMBER 60
NEVADA POWER
HARRY ALLEN STATION NO. 1
500 MW • NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/63
THE COLSTRIP PLANT IS A MINE MOUTH INSTALLATION. THIS FGD SYSTEM IS NOW
UNDER CONSTRUCTION. TURBINE ROLL AND SYSTEM CHECKOUT IS SCHEDULED FOR
MID-JUNE 1976. NO DELAYS FOR THE JULY STARTUP ARE ANTICIPATED. THE
CONSULTING ENGINEERING FIRM IS BECHTEL.
THE UTILITY IS CURRENTLY WAITING FOR APPROVAL OF A CERTIFICATE TO
CONSTRUCT BOILERS 3 AND * BEFORE PROCEEDING WITH ORDERS TO INSTALL FGD
SYSTEMS. THE FGD PROCESS BEING GIVEN PRIME CONSIDERATION FOR UNITS 3 AND
«f IS THE LIME/ALKALINE FLYASH SCRUBBING SYSTEM CURRENTLY OPERATING AND
BEING INSTALLED ON COLSTRIP UNITS 1 AND 2 RESPECTIVELY
THE UTILITY IS CURRENTLY WAITING FOR 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 LIME/ALKALINE FLYASH SCRUBBING SYSTEM CURRENTLY OPERATING AND
BEING INSTALLED ON COLSTRIP UNITS 1 AND 2 RESPECTIVELY
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD
TIONS HAVE NOT YET BEEN PREPARED.
PEDCo-ENVIRONMti^AL
22
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COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING 05/76
POWER STATION
CURRENT MONTH
1.0. NUMBER 61
NEVADA POWER
HARRY ALLEN STATION NO. 2
500 NW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/Bf
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGO SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
I.D. NUMBER 62
NEVADA POWER
HARRY ALLEN STATION NO.
500 MM - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/65
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGO SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
I.D. NUMBER 63
NEVADA POWER
HARRY ALLEN STATION NO.
500 MW • NEW
COAL
NOT SELECTED
NOT SELLLTED
STARTUP 6/66
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM.
TIONS HAVE NOT YET BEEN PREPARED.
•'-4. *
SPECIFICA-
I.D. NUMBER 61
NEVADA POWER
REID GARDNER NO 1
125 MW • RETROFIT
COAL 0.5- 1.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
STARTUP
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE APRIL 1974. SYSTEM OPERAblLlTY FOR
THE MONTHS OF MAKCH AND APRIL WAS 72 AND 91 PERCENT RESPECTIVELY. ONE
FOKCED SCRUBBER OUTAGE OCCURRED DURING THE REPORT PERIOD BECAUSE OF A
VENTURI LEAK. THE BOILER WAS SHUTDOWN APRIL 5 FOR A VALVE AND COAL CON-
DUIT INSPECTION.
I.D. NUMBER 65
NEVADA POWER
REIO GARDNER NO 2
125 MW - RETROFIT
COAL 0.5- 1.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
STARTUP t/7H
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE APR. 197t. SYSTEM OPERABILITV FOR
THE MONTHS OF MARCH AND APRIL WAS 60 AND 77 PERCENT RESPECTIVELY. DURING
THE REPORT PERIOD SEVERAL FORCED SCRUBBER OUTAGES WERE REPORTEDi
PRIMARILY CAUSED BY PLUGGED SENSING LINES. REHEATER REPAIRS,
AND MALFUNCTIONS IN THE TRAY SYSTEM.
PEOCo-ENVIRONMENTAL
23
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COMPANY
TABLE 2
STATUS OF FGO SYSTEMS DURING
05/76
POWER STATION
CURRENT MONTH
I.D. NUMBER 66
NEVADA POWER
REID GARDNER NO 3
125 MM - NEW
COAL 0.5- 1.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
STARTUP 6/76
FOK SPECIFIC INFORMATION ON THE TYPE OF SCRUBBING SYSTEM CURRENTLY UNDER
CONSTRUCTION FOR THIS UNIT REFER TO THE BACKGROUND INFORMATION SECTIONS
FOH REID GARDNER NOS 1 AND 2 IN TABLE 3 OF THIS REPORT. THE PRELIMINARY
CHECKOUT AND OPERATION OF THE BOILER HAS ALREADY STARTED. THE FGD SYSTEM
IS NOW SCHEDULED TO COMMENCE OPERATION ON JUNE 7t 1976. CONSTRUCTION IS
STILL PROCEEDING.
I.D. NUMBER 67
NEVADA POWER
REID GARDNER NO
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F6D SYSTEMS DURING 05/76
CURRENT NONT*1
ItO. NUMUCR 71
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 7
190 MW - RETROFIT
COAL 3 PERCENT SULPUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
CONSIDERING A LIME OR LIMESTONE SCRUBBING UNIT. ALSO WAITING FOR PER-
FORMANCE OF WELLMAN LORD/ALLIED CHEMICAL UNIT UNDER CONSTRUCTION AT THEIR
O.N.MITCHELL NO.11 UNIT. LOU SULFUR COAL MAY BE EMPLOYED TO COMPLY WITH
S02 EMISSION REGULATIONS. •
I.D. NUMBER 72
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 8
400 MW - RETROFIT
COAL 3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
CONSIDERING A LIME OR LIMESTONE SCRUBBING UNIT. ALSO WAITING FOR PERFOR-
MANCE OF WELLMAN LORD/ALLIED CHEMICAL UNIT UNDER CONSTRUCTION AT THEIR
D. H. MITCHELL NO. 11 UNIT. LOW SULFUR COAL MAY BE BURNED TO COMPLY WITH
S02 EMISSION REGULATIONS.
I.D. NUMBER 73
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 5/76
THIS FGD SYSTEM IS AN INTEGRATION OF THE WELLMAN-LORD S02 RECOVERY PRO-
CESS OF DAVY POWEKGAS AND ALLIED CHEMICAL'S S02 TO SULFUR REDUCTION
-PROCESS. DAVY POWEKGAS IS THE ENGINEER AND CONSTRUCTOR OF THE FGD
'FACILITY AND ALLIEU CHEMICAL is THE SYSTEM OPERATOR AND PRODUCT MARKETER.
THE STARTUP DATE FOR THE OPERATION OF THIS SYSTEM HAS BEEN DELAYED ONE
MONTH BECAUSE OF A FIRE WHICH OCCURRED IN THE ABSORBER SECTION OF THE FGD
SYSTEM. PRESENTLY. THE SYSTEM OPERATORS ARE CHECKING OUT THE VARIOUS SUB-
SYSTEMS BY PASSING WATER AND GAS THROUGH THE EQUIPMENT.
I.D. NUMBER 7t
NORTHERN STATES POWER CO,
SHERBURNE NO 1
680 MW - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 5/76
A PRELIMINARY SYSTEM CHECKOUT BY PASSING WATER AND AIR THROUGH THE EQUIP-
MENT WAS SUCCESSFULLY COMPLETED BY THE UTILITY. THE SYSTEM WAS PUT IN
SERVICE ON MARCH U, 1976. TREATING FLUE GAS FROM BOILER NO.l. WHICH
FIRES A LOW SULFUR WESTERN COAL. FOLLOWING THE 3/16 STARTUP THE SYSTEM
WAS TESTED ON VARIOUS LOAD CAPACITIES AND IS CURRENTLY OPERATING AT FULL
COMMERCIAL LOAD. A 30-DAY VENDOR RELIABILITY TEST PROGRAM IS SCHEDULED
TO COMMENCE IN MID-SUMMER 1976.
1.0. NUMBER 75
NORTHERN STATES POwER CO.
SHERBURNE NO 2
680 MW - NEW
COAL 0.6 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 5/77
THE FGD SYSTEM IS CURRENTLY UNDER CONSTRUCTION. RECENT SCRUBBER DESIGN
CHANGES HAVE CAUSED EQUIPMENT DELIVERY DELAYS. IN ADDITION. SOME PROBLEMS
HAVE ARISEN IN OBTAINING SOME ELECTRICAL CONTROLS. HOWEVER. THE OVERALL
SCHEDULE HAS NOT BEEN UPSET AND CONSTRUCTION OF THE SYSTEM IS CONTINUING
ON SCHEDULE.
PEDCo-ENVIRONMENTAL
25
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COMPANY
POWER STATION
I.D. NUMBER 76
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. I
835 Mw - NEW
COAL 1.3 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 1/76
I.D. NUMBER 77
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 2
835 MW - NEW
COAL 1.3 PERCENT SULFUR
CMEMICO
LIME SCRUBBING
STARTUP 1/77
I.D. NUMBER 78
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 3
635 MW - NEW
COAL 1.3 PEKCENT SULFUR
PULLMAN KELLOGG
LIMESTONE SCRUBBING
STARTUP 1/79
I.D. NUMBER 79
PHILADELPHIA ELECTRIC CO.
CROMBY
150 MW - RETROFIT
COAL 2-1 PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXIUF SCRUBBING
STARTUP 10/78
TABLE 2
STATUS OF FGD SYSTEMS DURING
05/76
CURRENT MONTH
"REFER'TO'THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS EMISSION CONTKOL SYSTEM IS CAPABLE OF REMOVING FLYASH AND S02 FROM
3.35 MM ACFM OF FLUE GAS VIA WET LIME SCRUBDING. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASL OF OPERATION BEGAN FOR PART OF THE SYSTEM IN DECEMBER
1975. FULL COMMERCIAL OPERATION COMMENCED IN APRIL 1976. TO OATEt ALL 6
OF THE SCRUBBER/ABSORBER TRAINS HAVE BEEN PUT INTO OPERATION.
THE FGD SYSTEM FOR THIS INSTALLATION WILL BE A CHEMICO WET LIME SCRUBBING
SYSTEM CAPABLE OF REMOVING PARTICULATE MATTER AND S02 FROM THE FLUE GAS.
THIS SYSTEM IS CURRENTLY UNDER CONSTRUCTION. LONG DELAYS HAVE BEEN EN-
COUNTERED IN MATERIAL DELIVERIES. THE FGD SYSTEM STARTUP DATE IS NOW
SCHEDULED FOR APRIL 1977.
PULLMAN INC., ANNOUNCED DURING THE REPORT PERIOD THAT ITS PULLMAN KELLOGG
DIVISION HAS BEEN AWARDED A CONTRACT IN EXCESS OF $50 MILLION FOR AN FGD
SYSTEM TO BE INSTALLED ON THIS COAL-FIRED 835 MW UNIT. THE EMISSION CON-
TRQL SYSTEM WILL CONSIST OF 5 WEIR HORIZONTAL CROSS-FLOW WET ABSORBER
MOUULES OPERATED IN CONJUNCTION WITH A PATENTED CATALYTIC CHEMISTRY PRO-
CESS DEVELOPED BY KELLOGG. ESP'S WILL BE INSTALLED UPSTREAM OF THE
SCRUBBING SYSTEM.
"THE'UTILITY PLANS TO RETROFIT ONE OF THE TWO BOILERS AT CROMBY WITH AN
FGU SYSTEM. HOWEVER, A FINAL DECISION HAS NOT BEEN MADE. THE PROCESS
BEING GIVEN PRIME CONSIDERATION IS MAGNESIUM OXIDE SCRUBBING DESIGNED
JOINTLY BY UNITED ENGINEERS AND PHILADELPHIA ELECTRIC. ENGINEERING
DESIGN WORK IS SCHEDULED FOR 1976. FGD SYSTEM STARTUP IS NOW SCHEDULED
FOR OCTOBER 1978.
1.0. NUMBER BO
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO 1A
120 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXIDE 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 PAULS80RO
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. THE UTILITY IS STILL EXPERIENCING PROBLEMS WITH THE FANS. RE-
HEAT BURNERS. OAMPERSt AND EXPANSION JOINTS.
PEDCo-INYIRONWItrtlAL
26
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING 05/76
CURRENT MONTH
I.D. NUMBER 81
PHILADELPHIA ELECTRIC CO.
EODYSTONE NO IB
2i*0 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
STARTUP 10/76
THE RETROFITTING OF SECOND STAGE SCRUBBERS ON THE BALANCE OF THE FLUE GAS
FROM EODYSTONE 1 IS AWAITING PERFORMANCE OF THE EXISTING 2-STAGE UNIT
WHICH IS TREATING ONE THIRD OF THE BOILER FLUE GAS. THIS UNIT CONSISTS
OF A AND B PARTICULATE SCRUBBING TRAINSi EACH ARE 120 MW. CHECK VALVE
FAILURE ON A TRAIN HAS BEEN CORRECTED. FAN ON B TRAIN IS STILL AT THE
FACTORY FOR REPAIR.
I.D. NUMBER 62
PHILADELPHIA ELECTRIC CO.
EODYSTONE NO 2
336 MU - RETROFIT
COAL 2."» PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
STARTUP 10/76
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 76. AT WHICH TIME EVALUATION OF
DATA FROM UNIT 1 SHOULD BE COMPLETE.
1.0. NUMBER 63
PUBLIC SERVICE CO OF COLORADO
VALMONT NO. 5
50 MW - RETROFIT
COAL 0.72 PERCENT SULFUR
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
STARTUP 10/74
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 9 OF THIS REPORT. THIS
SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 197
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING 05/76
POWER STATION
CURRENT MONTH
I.D. NUMBER 86
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 3
500 MW - NEW
COAL 0.6 PERCENT SULFUR
DAVY POWERGAS
WELLNAN 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 67
PUBLIC SERVICE CO OF NEW HEX,
SAN JUAN NO. H
500 MW - NEW
COAL 0.6 PERCENT SULFUR
DAVY POWERGAS
WELLMAN LORD
STARTUP 5/61
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 1981.
I.D. NUMBER 88
PUBLIC SERVICE INDIANA
GIBSON NO. 3
650 MW - NEW
COAL 3.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/78
BID EVALUATION IS UNDERWAY.
I.D. NUMBER 89
PUBLIC SERVICE INDIANA
GIBSON NO. i»
650 MW • NEW
COAL 3.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/79
BID SPECIFICATIONS ARE BEING PREPARED.
I.D. NUMBER 90
RICKENBACKER AFB
RICKENBACKER
20 MW • RETROFIT
COAL 3.6 PERCENT SyLFUR
RESEARCH COTTRELL
LIME SCRUBBING
STARTUP 3/76
THL SYSTEM SUPPLIER REPORTED THAT THE FGD SYSTEM BECAME OPERATIONAL ON
MARCH 11, 1976. SYSTEM OPERABILITV WAS REPORTED TO BE 97 PERCENT FOR THE
DURATION OF THE MONTH. THE SYSTEM WAS BROUGHT DOWN ON APRIL H» BECAUSE
OF PUMP PROBLEMS. A 1.5 WEEK OUTAGE RESULTED BECAUSE OF A SPARE PART
SHIPMENT. S02 INLET CONCENTRATIONS HAVE BEEN AT THE 1800 PPM LEVEL, LIHE
UTILIZATION HAS BEEN GOOD. THE S02 REMOVAL EFFICIENCY WAS REPORTED TO BE
AS HIGH AS 96 PERCENT.
PEOCo-ENVIRONMENTAL
28
-------
COMPANY
TABLE 2
STATUS OF FGD SYSTEMS DURING
05/76
POWER STATION
CURRENT MONTH
I.D. NUMBER 91
S. CAROLINA PUB SERV AUTHORITY
WINYAH NO. 2
mo 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 260 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.
I.D. NUMBER 92
S. MISSISSIPPI ELEC PWR ASSOC
R.O. MORHOW NO.l
160 MW - NEW
COAL 1 PERCENT SULFUR
RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
STARTUP 11/77
THE CONTRACT FOR THIS LIMESTONE SYSTEM HAS BEEN AWARDED TO RILEY
STOKER/ENVIRONEERING. GUARANTEED S02 REMOVAL EFFICIENCY IS 65 PERCENT.
FABRICATION OF EQUIPMENT IS NOW IN PROGRESS. SYSTEM STARTUP IS SCHEDULED
FOR NOVEMBER 1977.
1.0. NUMBER 93
S. MISSISSIPPI ELEC PWR ASSOC
R.D. MORROW NO.2
160 MW . NEW
COAL 1 PERCENT SULFUR
RILEY STOKEK/ENVIRONEERING
LIMESTONE SCRUBBING
STARTUP 6/76
THE CONTRACT FOR THIS LIMESTONE SYSTEM HAS BEEN AWARDED TO RILEY
STOKER/ENVIRONEERING. GUARANTEED S02 REMOVAL EFFICIENCY IS 65 PERCENT.
FABRICATION OF EQUIPMENT IS NOW IN PROGRESS. SYSTEM STARTUP IS SCHEDULED
FOR JUNE 1976.
I.D. NUMBER 91
SOUTHERN CALIFORNIA EDISON
MOHAVE NO IB
620 Mw - RETROFIT
COAL 0.5- 0.6 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP 6/77
THE TOTAL CAPACITY OF BOILER IS 790 MW. EXISTING EXPERIMENTAL FGD NODULE
WILL TREAT ONLY 170 MW. FINAL SELECTION OF THE PROCESS HAS BEEN POST-
PONED. SEE MOHAVE 1A.
I.D. NUMBER 95
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2
790 MW . RETROFIT
COAL 0.5 TO 0.6 X SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP 6/77
A PROTOTYPE 170 MW LIME SCRUBBING SYSTEM (HORIZONTAL MODULE) ON THIS UNIT
WAS OPERATED FROM NOVEMBER 1973 UNTIL FEBRUARY 1975. AVAILABILITY FOR THE
PERIOD 1/16/70 TO 2/9/75 AVERAGED 73.58. THIS SYSTEM IS TO BE REINSTALL-
ED AT THE FOUR CORNERS PLANT. OPERATED BY AhlZONA PUBLIC SERVICE.
PEDCo-ENVIRONMENTAL
29
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS DURING
05/76
CURRENT MONTH
I.D. NUMBER 96
SOUTHERN ILLINOIS POWER COOP
SOUTHERN ILLINOIS POWER PT. 4
184 MW - NEW
COAL
BABCOCK ft WILCOX
LIMESTONE' SCRUBBING
STARTUP 1/7B
THE CONTRACT FOR THIS LIMESTONE SCRUBBING SYSTEM HAS BEEN AWARDED TO
BABCOCK AND WILCOX. THE FGD SYSTEM WILL CONSIST OF 2 SCRUBBING MODULESi
TREATING THE FLUE GAS FROM A COAL-FIRED BOILERt HAVING A NOMINAL DESIGN
CAPACITY OF 691.500 ACFM AT 290F. THE DESIGN S02 REMOVAL EFFICIENCY IS
89.4 PERCENT* BASED UPON AN INLET OF 3.326 PPM OF $02. THE CONSULTING
ENGINEERING FIRM FOR THE PROJECT IS BURNS-MCDONALD.
1.0. NUMBER 97
SPRINGFIELD CITY UTILITIES
SOUTHWEST NO. 1
200 MW - NEW
COAL 3.5 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 8/76
THE CONSTRUCTION OF THE BOILER AND FGD SYSTEM AT THIS INSTALLATION IS
STILL PROCEEDING BEHIND SCHEDULE. THE SCRUBBER, ESP, AND I.D.FANS ARE NOW
BEING INSTALLED. COMPLETION IS SCHEDULED FOR MID-SUMMER 1976. SYSTEM
STARTUP HAS BEEN DELAYED TO AUGUST 1,1976.
I.D. NUMBER 96
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10A
10 MW - RETROFIT
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
STARTUP 4/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
TURBULENT CONTACT ABSORBER ITCA) 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.
I.D. NUMBER 99
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10B
10 MW - RETROFIT
COAL 2.9 PERCENT SuLFUR
CHEMICO
LIME/LIMESTONE SCRUBBING
STARTUP 4/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
VEMTURI/SPRAY TOkCR 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.
I.D. NUMBER 100
TENNESSEE VALLEY AUTHORITY
WIUOWS CREEK 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 PROCESS EQUIPMENT INCLUDING THE
SCRUBBER, MIST ELIMINATOR, PIPING, INSTRUMENTATION, HOT AIR INJECTION
SYSTEM AND AIR HEATER FANS. THE ID FANS ARE NOW BEING INSTALLED AS IS THE
LIMESTONE CRUSHER. ALL EQUIPMENT REQUISITIONS HAVE BEEN COMPLETED* THE
SCHEDULED STARTUP DATE IS FEBRUARY 1977. *
PEDCo-ENVIRONMENTAL
30
-------
COMPANY
POWER STATIO.M
TABLE 2
STATUS OF FGD SYSTEMS DURING 05/76
CURRENT MONTH
I.D. NUMBER 101
TEXAS UTILITIES CO.
MARTIN LAKE NO. 1
793 Mki - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 1/77
THE CONTRACT FOR THIS FGO SYSTEM WAS AWARDED TO RESEARCH-COTTRELL. THIS
NEW FACILITY IS NOW UNDER CONSTRUCTION. THE FGD SYSTEM STARTUP DATE IS
NOW SCHEDULED FOR JANUARY 1977.
I.D. NUMBER 102
TEXAS UTILITIES CO.
MARTIN LAKE NO. 2
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STAKTUP 10/77
THE CONTRACT FOR THIS FGD SYSTEM WAS AWARDED TO RESEARCH-COTTRELL. THIS
NEW FACILITY IS NOW UNDER CONSTRUCTION. THE FGD SYSTEM STARTUP DATE IS
NOW SCHEDULED FOR OCTOBER 1977.
I.D. NUMBER 103
TEXAS UTILITIES CO.
MARTIN LAKE NO. 3
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 12/78
UTILITY HAS SIGNED A LETTER OF INTENT WITH RESEARCH COTTRELL. THE BOILER
IS CURRENTLY BEING ERECTED AT THIS NEW FACILITY.
I.D. NUMBER 104
TEXAS UTILITIES CO.
MARTIN LAKE NO. H
793 Mb - NEW
COAL i.o PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 12/79
UTILITY HAS SIGNED A LETTER OF INTENT WITH RESEARCH COTTRELL. THE BOILER
IS CURRENTLY BEING ERECTED AT THIS NEW FACILITY.
I.D. NUMBER 105
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
545 Mb - NEW
LIGNITE - 0.63 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE
STARTUP 11/76
THE UTILITY IS CURRENTLY IN THE PROCESS OF REQUESTING/EVALUATING BIDS FOR
A NON-REGENERABLE LIME OR LIMESTONE SCRUBBING SYSTEM FOR S02 REMOVAL. IN
ADDITION. THE BIDDER CAN ALSO SPECIFY ALKALINE FLYASH SCRUBBING AS AN
ALTERNATIVE S02 REMOVAL PROCESS. INITIAL STARTUP OF THE INSTALLATION IS
NOW PROJECTED FOR 6/78 WITH FULL COMMERCIAL OPERATION BY 11/76.
PEDCo-ENVIRONMENTAL
31
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F6D SYSTEMS DURING
05/76
CURRENT MONTH
I.D. NUMBER 106
UNITED POWER ASSOCIATION
COAL CREEK NO. 2
545 MW - NEW
LIGNITE - 0.63 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE
STARTUP 11/79
THE UTILITY IS CURRENTLY IN THE PROCESS OF REQUESTING/EVALUATING BIDS FOR
A NON-REGENERABLE LIME OR LIMESTONE SCRUBBING SYSTEM FOR S02 REMOVAL. IN
ADDITION, THE BIDDER CAN ALSO SPECIFY ALKALINE FLYASH SCRUBBING AS AN
ALTERNATIVE S02 REMOVAL PROCESS. INITIAL STARTUP OF THE INSTALLATION IS
NOW PROJECTED FOR 8/79 WITH FULL COMMERCIAL OPERATION BY 11/79.
I.D. NUMBER 107
UTAH POWER & LIGHT CO.
EMERY NO.l
i»00 MW . NEW
COAL 0.5 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 6/76
THE CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO CHEMICO. THE PEBBLE
LIME WET SCRUBBING SYSTEM IS DESIGNED TO OPERATE IN AN OPEN-LOOP MODE
WITH AN S02 REMOVAL EFFICIENCY OF 80 PERCENT FOR LOW SULFUR UTAH COAL.
PARTICULATE EMISSIONS WILL BE CONTROLLED BY AN UPSTREAM ESP, THE SLUDGE
WILL BE STABILIZED WITH FLYASH AND DISPOSED ON THE PLANT SITE.
I.D. NUMBER 108
UTAH POWER * LIGHT CO.
HUNTINGTON NO.l
<»15 MW • RETROFIT
COAL 0.5 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 6/77
A LETTER OF INTENT HAS BEEN SIGNED WITH CHEMICO FOR THE INSTALLATION OF
A LIME SCRUBBING SYSTEM ON THIS NEW UNIT. MATERIALS ARE NOW ARRIVING AT
THE. PLANT SITE. SITE PREPARATION AND CONSTRUCTION IS NOW UNDERWAY. THE
STAJE OF UTAH REGULATIONS REQUIRE THE BEST AVAILABLE AND MOST COST
EFFECTIVE TECHNOLOGY FOR S02 REMOVAL.
PEDCo-ENVIRONMENTAL
32
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Table 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
33
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 09/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F60 VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICIPATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
JOSEPH CITY ARIZONA
115 MW
COAL 0.
-------
BACKGROUND INFORMATION
ON
THE CHOLLA POWER PLANT
THE CHOLLA POWER STATION, LOCATED NEAR JOSEPH CITY, ARIZONA, HAS ONE 115-NW 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 NOW BEING-BURNED HAS AN AVERAGE HEATING VALUE (DRY BAS^S)
OF 12,146 BTU/LB AND ASH AND SULFUR CONTENTS OF 12.3 PERCENT AND 0.44 PERCENT, RESPECTIVELY. | . , , ,i,
THE FGD SYSTEM AT THE CHOLLA PLANT WAS MANUFACTURED BY RESEARCH-COTTRELL AND INSTALLATION WAS COMPLETED ON DECEMBER 3, 1973. THE COMBINED S02
REMOVAL EFFICIENCY (FOR BOTH MODULES A AND B) IS REPORTED TO BE 58.5 PERCENT. THE 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. MODULF 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 4.5 PERCENT 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 CONSISTING OF THREE TUBE BUNDLES.
LIMESTONE FOR THE FGD SYSTEM IS PURCHASED IN GROUND FORM SUITABLE FOR SLURRYING. THE MAIN SOURCE OF SUPPLY IS THE SUPERIOR CO., LOCATED NEAR
PHOENIX, ARIZONA.
THE PLANT HAS NO SLUDGE TREATMENT OR FIXATION SYSTEMS. THE SLUDGE IS PUMPED TO THE FLY ASH POND ON AN INTERMITTENT BASIS THROUGH A COMMON PIPING
SYSTEM WITH THE FLY ASH. NO POND WATER IS RECYCLED TO THE FGD SYSTEM.
PROBLEMS AND SOLUTIONS
DECEMBER. 1973 TO APRIL 2. 1974 - BECAUSE OF A DIFFERENCE IN SIZE OF THE MAIN DUCT AND THE REHEATER TRANSITION DUCT, THE-GAS FLOW PRODUCED HARMONIC
VIBRATIONS IN THE REHEATER. THE VIBRATIONS WERE PARTIALLY DAMPED BY INSTALLATION OF BAFFLES. ONE OF THE REHEATER TUBE BUNDLES WAS BADLY CORRODED
BY ACID THAT CONDENSED IN THE UNINSULATED DUCT UPSTREAM OF THE REHEATERS. THE TUBE BUNDLE WAS REPLACED, AND A BAFFLE WAS INSTALLED TO DIVERT CONDENSED
ACID FROM REHEATER TUBES. ALSO. THE DUCT UPSTREAM OF THE REHEATER WAS INSULATED. THE ACID CONDENSATION OCCURRED ONLY IN THE MODULE WITH NO TOWER
PACKING AND HENCE LOW S02 REMOVAL EFFICIENCY.
PEDCo-ENVIRONMENTAL
36
-------
CHOLLA POWER PLANT (Continued)
ANOTHER PROBLEM WAS DUE TO SOLIDS BUILDUP IN THE FDS STUFFING GLAND BOX AND ON TOP OF THE SPRAY DOME. ALSO, SOME LINES PLUGGED, PARTICULARLY
WHEN THE SYSTEM OPERATED AT LOW FLOW RATES. SOLIDS SETTLED OUT IN STANDBY PUMPS, AND EXCESSIVE FAN VIBRATIONS OCCURRED BECAUSE OF ACCUMULATION OF SCALE
BUILDUP WHEN THE UNIT WAS IDLE. TO SOLVE THESE PROBLEMS, PACKING GLAND POSITION WAS REVERSED (INSTALLED UPSIDE DOWN). THE FAN WAS SANDBLASTED, THE
PIPING WAS MODIFIED TO ELIMINATE STAGNANT POCKETS, AND PUMPS WERE FLUSHED IMMEDIATELY AFTER REMOVAL FROM SERVICE.
MORE RECENT PROBLEMS INCLUDE: SIGNIFICANT CORROSION ATTACH IN THE VESSEL WALLS OF THE FLOODED-DISC PARTICUALTE SCRUBBER OR MODULE; ACID CORROSION
IN THE REHEATER HOUSING OF MODULE B; SCALE BUILDUP IN THE PIPE OUTLET AT THE SLUDGE/FLY ASH EVAPORATION POND; PLUGGING IN THE SCRUBBER TOWER PACKING
AND MIST ELIMINATOR; EROSION IN THE PUMPS; CORROSION IN THE BOILER EXHAUST ELBOW OF THE DUCTWORK LEADING FROM THE SCRUBBERS TO THE STACK.
PEDCo-ENVIRONMENTAL
37
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FGD SYSTEM RELIABILITY
CHOLLA UNIT NO. 1
Month
Jan. 74
Feb. 74
Mar. 74
Apr. 74
May 74
Jun. 74
Jul. 74
Aug. 74
Sep. 74
Oct. 74
Nov. 74
Dec. 74
Jan. 75
Feb. 75
Mar. 75
Apr. 75
May 75
Jun. 75
Jul. 75
Aug. 75
RELIABILITY
(*)
Module A Module B
97
100
100
66
98
100
97
97
95
83
100
100
98
96
88
48
100
97
95
90
94
66
57
99
100
92
97
99
68
98
100
99
99
65
40
100
98
100
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 shut down to clean flow restrictions 1n flooded-dlsc reclrculatlon lines.
Module A was down for Inspection one time.
PEDCo-ENVIRONMENTAL
38
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FGD SYSTEM RELIABILITY
CHOLLA UNIT NO. 1 (continued)
Month
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Jan. 76
Feb. 76
Mar. 76
Apr. 76
99
99
99
98
Comments
Minor outage due to flooded-dlsc lines.
Outages resulted from scheduled equipment overhauls and recoatlng of vessels.
No major outages or problems occurred during the report period. Minor problems
during December Included the rebuilding of a recycle pump and malfunctioning of
the B-side reheater coll.
Module A operated 715 hours during the report month, and Module B operated 654 hours.
Module A experienced some minor valve and line plugging. Module B operating hours were
lower because of reduced system requirements.
The unit 1s currently experiencing coating failures 1n the elbow of the scrubber exhaust duct.
Also, the utility performed some minor repairs to the housing of the B-s1de reheater.
PEDCo-ENVlRUNirtt.mL
39
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 05/76
IDENTIFICATION NO. 10
UTILITY NAME ARIZONA PUBLIC SERVICE
UNIT NAME FOUR CORNERS NO. 5A
UNIT LOCATION FARMINGTON NEW MEXICO
UNIT RATING 160 MW
FUEL CHARACTERISTICS COALi 0.7 PERCENT SULFUR
FGD VENDOR SCE
PROCESS LIME SCRUBBING
NEW OR RETROFIT RETROFIT
START UP DATE 2/76
FGD STATUS OPERATIONAL
EFFICIENCY.
- PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
rr ™IS 16° MW SYSTE" H«S BEEN MOVED FROM THE MOHAVE STATION OF SOUTHERN
EXPERIENCE CALIFORNIA EDISON WHERE THE SYSTEM WAS PREVIOUSLY TESTED. THE SYSTEM
WILL TREAT APPROXIMATELY 20 PERCENT OF THE FLUE GAS FROM UNIT NO. 5,
RATED AT 755 MW(NET). THE ENGINEERING AND CONSTRUCTION WORK HAS BEEN
COMPLETED. THE SYSTEM BECAME OPERATIONAL ON FEBRUARY 17i 1976. THE EXPER.
IMENTAL SCRUBBER HAS TAKEN OUT OF SERVICE IN MID-APRIL FOR A SCHEDULED
BOILER OVERHAUL*
40
PEDCo-ENVIRONMENTAJ.
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 05/76
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
29
COMMONWEALTH EOISON
WILL COUNTY NO 1
RONCOVILLE ILLINOIS
167 MW
COAL - 9<»63 BTUt 2.IX SULFUR
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
RETROFIT
2/72
OPERATIONAL
98 PERCENT
S02
82 PERCENT
WATER MAKE UP
106 GAL/LB MOLE S02 REMOVED
SLUDGE DISPOSAL
STABILIZED SLUDGE DISPOSED IN CLAY LINED POND
UNIT COST
S96/KW CAP. W/NO SLUDGE TREAT.6.9 MILLS/KWH AT 653 BLR. CAP.
OPERATIONAL
EXPERIENCE
REFEK TO BACKGKOUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE FEBRUARY 1972. THE UNIT WAS RE-
TURNED TO SERVICE IN MAKCH FOLLOWING A MAJOR BOILER, TU.iBINE, AND SCRUB-
BER OVERHAUL. SYSTEM OPERABILITY FOR BOTH MODULES DURINu THE REPORT
PERIOD WAS <*5 AND 20 PERCENT IN MARCH AND 20 AND H9 PERCENT IN APRIL FOR
MODULES A AND U RESPECTIVELY. MODULES A AND B WERE IN SERVICE A TOTAL OF
3213 AND 2580 HOURS HOURS RESPECTIVELY* IN 1975, WHICH TRANLATES INTO
ANNUAL OPERABILITY FACTORS OF 52 AND <»2 PERCENT RESPECTIVELY.
41
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 LARGE-SCALE INSTALLATION ON WILL COUNTY STATION'S UNIT NO. 1. AFTER DECIDING ON A WET SCRUBBER SYSTEM USING LIME OR
LIMESTONE, BECHTEL PREPARED A SPECIFICATION AND RELEASED IT FOR BID. FROM NINE BIDDERS THAT WERE SOLICITED, SEVEN PROPOSALS WERE RECEIVED. AFTER
DETAILED STUDY AND BID EVALUATION WITH SPECIAL CONSIDERATION OF THE PROJECT SCHEDULE, BABCOCK AND WILCOX WAS AUTHORIZED IN SEPTEMBER 1970 TO BEGIN
DETAILED ENGINEERING FOR A LIMESTONE SLURRY SYSTEM. COMPLETION DEADLINE FOR THE PROJECT WAS DECEMBER 31, 1971, A DEADLINE ESTABLISHED BY THE
ILLINOIS COMMERCE COMMISSION AS PART OF A RATE CASE.
THE BABCOCK AND WILCOX PROCESS WAS GUARANTEED TO REMOVE .98 PERCENT OF THE FLY ASH AND 76 PERCENT OF THE SULFUR DIOXIDE. THESE EFFICIENCIES
WERE BASED ON A DUST INLET LOADING OF 1.355 GRAINS PER STANDARD CUBIC FOOT AT 70°F AND ON BURNING OF ILLINOIS COAL CONTAINING 4 PERCENT SULFUR.
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 NO. 1 IS RETROFITTED WITH AN FGD SYSTEM.
UNIT NO. 1 IS A WET-BOTTOM COAL-FIRED BOILER PRODUCING 167 MW OF ELECTRICITY. THE BOILER WAS MANUFACTURED BY BABCOCK AND WILCOX AND WAS INSTALLED
IN 1955. THE PLANT NOW BURNS A LOW-SULFUR (K3 PERCENT) WESTERN COAL AND A HIGH-SULFUR ILLINOIS COAL.
THE WET LIMESTONE FGD 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 A SLUDGE TREATEMENT AND STABILIZATION UNIT. S02 REMOVAL EFFICIENCY IS REPORTED TO BE
82 PERCENT. SHORTLY AFTER STARTUP AND DURING INITIAL SHAKEDOWN, NUMEROUS PROBLEMS WERE ENCOUNTERED. COMMONWEALTH EDISON SHUT DOWN MODULE B IN
MAY 1973 TO CONCENTRATE ON SOLVING THE PROBLEMS OF MODULE A. MODULE B WAS NOT RESTARTED UNTIL MAY 1975.
THE LIMESTONE GRINDING FACILITIES CONSIST 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.
PEDCo-ENVIRONMENTAL
42
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MILL COUNTY (Continued)
SLUDGE FROM THE SYSTEM IS SENT TO A CLARIFIER. THE OVERFLOW IS RETURNED TO THE PROCESS; THE UNDERFLOW IS STABILIZED BY MIXING IT WITH LIME AND
FLY ASH. ABOUT 200 POUNDS OF LIME AND 400 POUNDS OF FLY ASH ARE USED PER TON OF DRY SOLIDS OF SLUDGE. THE FIXED SLUDGE IS TRANSPORTED BY CONCRETE
MIXING TRUCKS TO AN ON-SITE HOLDING BASIN FOR SOLIDIFICATION. THE STABILIZED MATERIAL IS THEN HAULED AWAY APPROXIMATELY A WEEK LATER TO AN OFF-SITE
DISPOSAL AREA.
PROBLEMS AND SOLUTIONS
1972 - DEMISTER PLUGGING WAS A CONSTANT PROBLEM, MAINLY BECAUSE OF HEAVY LIMESTONE ACCUMULATIONS ON THE BOTTOM OF THE DEMISTER AND PARTLY BECAUSE
OF LOW WASHWATER PRESSURE CAUSED BY LEAKS IN THE POND RETURN BYPASS. BECAUSE OF THESE PROBLEMS MODULES A AND B WERE OUT OF SERVICE FOR SEVERAL DAYS
EACH MONTH DURING MARCK, APRIL, JUNE, AND JULY 1972. THE MODULES WERE ALSO OUT OF SERVICE FROM SEPTEMBER 26 TO NOVEMBER 21, 1972, BECAUSE THE BOILER
WAS DOWN.
IN ORDER TO SOLVE THE DEMISTER PROBLEM, THE SLURRY NOZZLES WERE LOWERED AND THE SLURRY CIRCULATION SYSTEM WAS LEFT OUT OF SERVICE TO KEEP THE
DEMISTER CLEAN. SINCE THE SITUATION DID NOT IMPROVE, THE DEMISTER ELEMENTS WERE HAND-WASHED. THIS SOLVED THE PROBLEM PARTIALLY, BUT CAUSED DIFFICULTY
WITH THE VENTURI NOZZLES BECAUSE BROKEN ELEMENTS FROM THE DEMISTER GOT INTO THE SLURRY SYSTEM.
AT HIGH GAS FLOW RATES, THE REHEATER OF MODULE B VIBRATED EXCESSIVELY. THEREFORE, MODULE B WAS TAKEN OUT OF SERVICE IN APRIL TO ALLOW REHEATER
MODIFICATIONS, WHICH INCLUDED REBRACING OF THE REHEATER TUBES AND INSTALLATION OF A BAFFLE PLATE TO REDUCE THE VIBRATIONS.
OTHER REASONS FOR OUTAGES WERE EROSION AND PLUGGING OF SPRAY NOZZLES, INTERNAL AND EXTERNAL BUILDUP OF DEPOSITS ON VENTURI NOZZLES, CORROSION,
SULFITE BLINDING PROBLEMS, AND FAN VIBRATIONS.
1973 - DEMISTER PLUGGING CONTINUED. FURTHERMORE, THE DEMISTER ON MODULE B BROKE LOOSE FROM ITS MOUNTINGS AND THE RESULTANT CARRYOVER OF WASH-
WATER PLUGGED THE REHEATER. THIS REHEATER ALSO LEAKED BECAUSE OF CHLORIDE PITTING CORROSION. MODULE A WAS DOWN FROM APRIL 24 TO MAY 24, 1973, AND
MODULE B WAS DOWN FROM APRIL TO DATE. THERE WAS NO SCRUBBER OPERATION FROM AUGUST 27 to SEPTEMBER 26, 1973.
IN EFFORTS TO SOLVE THE DEMISTER AND REHEATER PROBLEMS, A CONSTANT UNDERSPRAY AND INTERMITTENT OVERSPRAY WERE USED TO WASH ALL THE DEMISTER
COMPARTMENTS OF MODULE A. EXTRA NOZZLES WERE ADDED AND A CLEAN WATER SUPPLY WAS MAINTAINED. THE REHEATER UNIT WAS ALSO RETUBED.
1974 - ONLY MODULE A OPERATED DURING 1974. THE MAIN PROBLEMS WERE FREEZING OF THE VENTURI THROAT DRIVE MECHANISM, TANK SCREEN BLINDING, DUCT
CORROSION, AND VIBRATIONS. LOSS OF BUILDING HEAT CAUSED EXTENSIVE DAMAGE AND KEPT THE SYSTEM DOWN FOR THE ENTIRE MONTH OF JANURY 1974.
1975 - ENTERING 1975 MODULE A WAS OPERATIONAL AND MODULE B WAS STILL UNDERGOING MODIFICATION. IN THE FIRST QUARTER OF 1975 THERE WERE EIGHT
A-MODULE OUTAGES; ONLY ONE HAS A FORCED OUTAGE. DUE TO THE SPLITTING OF A SLURRY VENTURI SUPPLY HOSE. MOBULE B WAS RETURNED TO SERVICE ON MAY 20, 1975.
PEDCo-ENVIRONMEMlAL
43
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WILL COUNTY (continued)
THE UTILITY DECIDED TO OPERATE THE SCRUBBER ON ILLINOIS HIGH-SULFUR COAL. WHEN THIS OPERATION BEGAN, A MULTITUDE OF PROBLEMS OCCURRED: LOWER
PARTICULATE REMOVAL EFFICIENCIES, HIGH SLURRY CARRYOVERS. DEMISTER PLUGGING, REHEATER COIL FOULING AND LEAKS. MODULE A WAS TAKEN OUT OF SERVICE
IN MID-JUNE FOR THE REMAINDER OF 1975. BY MID-SEPTEMBER 1975 MODULE B WAS TAKEN OUT OF SERVICE OWING TO MASSIVE SCALING IN THE ABSORBER SYSTEM.
FINALLY. UNIT NO. 1 WAS SHUT DOWN FOR OVERHAUL OF THE BOILER. TURBINE. AND SCRUBBER IN MID-OCTOBER; THIS OUTAGE LASTED MORE THAN 4 rtONTHS.
OPERABILITY FACTORS FOR EACH MODULE AND THE CORRESPONDING COMMENTS FOR THE REPORT PERIOD ARE PRESENTED IN THE FOLLOWING TABLE.
PEDCo- ENVIRONMENTAL
44
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FGD SYSTEM OPERABILITY
WILL COUNTY UNIT NO. 1 *
PERIOD OPERABILITY (X)
Month/Year Module A Module B
Mar. 72 0 35
Apr. 72
May 72
Jun. 72
Jul. 72
Aug. 72
34
70
14
32
31
79
21
Comments
Module A down for repair and modification of demister wash piping assembly.
Module B was removed from service every 2 or 3 days to hand-wash the demister.
Other problems were vibration of reheater tube bundle, rapid erosion of scrubber
spray nozzles, plugging of venturl nozzles.
Module A out of service for 6 days because of near-rupture of a venturl pipe
expansion joint. Heavy buildup of sol Ids on demister. Module B out of service most
of the time for similar repair of venturl pipe expansion joint, and for modification
of reheater unit and demister wash system.
A two week outage of Module B to rebrace the reheater unit, to Install underspray
nozzles on demister, and to Install heavier screens In the sump. Reheater plugging
caused additional outages.
Both Modules were out of service owing to high differential pressure across the
demlsters. Leakage of pond return bypass valve caused demister plugging. Also during this
period, the rubber lining of scrubber A was repaired.
Plugging of venturl nozzles and demister caused shutdown of Module A for 2 days for
repairs. Module B was out of service for 22 days for cleaning of the demister and
reheater unit, Installation of overhead spray nozzles, and replacement of sections
of the demister. The boiler was down for 2 days for repair of the generator.
PEDCo-ENVIRONMENTAl
45
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HILL COUNTY UNIT NO. 1 (continued)
PERIOD
Month/Year
Sep. 72
Oct. 72
Mar. 73
Apr. 73
May 73
Jun. 73
Jul. 73
OPERABILITY (X)
Module A Module B
0 30.
Nov. 72
Dec. 72
Jan. 73
Feb. 73
0
22
0
22
0
30
0
24
65
0
16
51
11
13
0
0
Comments
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 modification of reheater unit and repair of
redrculatlon tank screens.
Boiler and scrubbers were down. Principal modifications Included Installation of
reheater baffle plates to dampen vibrations and Installation of an experimental demlster
wash system.
Boiler problems causing unstable operation kept both modules down during this month.
Modules operated Intermittently because of electrostatic preclpltator testing and mis-
cellaneous Instrument problems.
Both modules were down for repairs and modifications.
Modules were out of service because of cracks In the Inlet ductwork of the booster fan.
Improper Installation of demlster caused plugging of Module B reheater unit.
Module A was out of service for 5 days because of demlster plugging. Boiler was down
for 4 days of Inspection. Module B was down because of leaks from reheater tubes.
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 to allow concentration on the problems with Module A. Boiler-
related problems were responsible for most of the outages of Module A.
Module A problems: reheater tubes leaks and high fan vibrations.
PEDCo-ENVIRONMEFITAL
46
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WILL COUNTY UNIT NO. 1 (continued)
PERIOD
Month/Year
Jul. 73
Sep. 73
Oct. 73
Nov. 73
Dec. 73
Jan. 74
Feb. 74
Mar. 74
Apr. 74
May 74
OPERABILITY (X)
Module A Module B
19 0
0 0
32 0
51 0
21
72
93
• Comments
More reheater tube leaks on Module A attributed to chloride corrosion attack.
Modules were down. During this month. Chicago Fly Ash Co. finished cleaning and treating
the northeast half of the sludge pond.
Module A tripped several times because of bad limit switches In the bypass and block dampers.
Unit was also taken down to balance the booster I.D. fan.
Routine Inspection of Module A revealed some plugging. Module was kept down for cleaning
and some modification. Poor gas distribution In module suspected to contribute to demlster
problems.
Modules were down. The month was devoted to modification and maintenance, mostly of demlster,
ventuM throats, pumps, and Isolation valves.
Modules were down owing to freezing In the 10-Inch-diameter, 4400-ft. line between modules"
and pond. Some damage to sump pumps. Freezing also damaged some Instruments.
The frozen pipeline was thawed, reanchored, and returned to service. The Instruments
damaged by freezing were repaired. Module A kept down until arrival of second-stage
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. Operation was on low-sulfur coal. Sump screen from Module B was
substituted for damaged screen In Module A.
Module. A operated for entire month except for short outages for Inspection. Much of this
operation was on high-sulfur coal.
PEDCo-ENVIRONMENTAL
47
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HILL COUNTY UNIT NO. 1 (continued)
PERIOD
Month/Year
Jun. 74
Jul. 74
Aug. 74
Sep. 74
Oct. 74
Nov. 74
Dec. 74
Jan. 75
Feb. 75
OPERABILITY (X)
Module A Module B
55 0
96 0
91 0
85 0
94 0
97
99
99
99
0
0
Comments
Module A operated for about 300 hours. The system was off for 2 weeks for repair of venturl
throat drive.
Module A operated for the whole month except for one Inspection outage and two boiler
shutdowns. Module B remains down until satisfactory operation of Module A Is achieved.
Module A was down six times this month: three times because of no boiler demand, twice
for repair of leaks In steam piping, and once for balancing of a fan.
Module A was off three times; once for cleaning of deposits from the venturl throat, once
for repair of a desuperheater leak, and once because boiler was down.
Module A was down four times: once because of boiler outages, once for Inspection, and
twice for repair of 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: once for Inspection and once for no demand. One small
reheater leak 1n a stainless steel bundle was blanked-off on-line. During the Inspection,
demlster underwash nozzles were cleaned and a small section of demlster was replaced.
Inspection showed that conditions Inside the scrubber were about the same as before. Coal
burned this month averaged less than IX sulfur. Modification of Module B Is continuing.
Chicago Fly Ash Is treating material from the scrubber with portland cement and fly ash and
PEDCp-ENYIRONMENTAL
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HILL COUNTY UNIT NO. 1 (continued)
PERIOD
Month/Year
Mar. 75
Apr. 75
Nay 75
Jun. 75
Jul. 75
Aug. 75
OPERABILITY (*)
Module A Module B
40 0
40 0
84
61
37
85
79
0 .100
Comments
dumping the treated material Into the north half of the holding basin.
Module A was down four times: twice for no demand, once for a venturl hose leak, once for an
accidental 50-mlnute trip.
Sludge pond was overburdened by near-continuous operation of Module A. The FGD system was
shut down to allow evaporation of water from the pond. During shut down, the following
modifications were made. Pump gland water flows were reduced from 10 to 5 gpm. Filter
backwash was routed out of sys'tem. Continuous demlster underspray was changed to Intermittent.
Module A reminded out of service until May 5, when It was determined that there was enough
freeboard In the pond to start operating. There were two more outages: one for 45 minutes,
the result of a damper trip; the other for cleaning of underspray nozzles.
Module B was placed In service 10:20.A.M., May 20, for the first time since noon on April
13, 1973. After brief start-up, which was routine, operation was delayed until the 20th
because of two broken oil pumps on the reclrculatlon tank mixers. Since the start-up, Module B
has been out of service twice: once for a venturl pump trip, and once for a reclrculatlon
tank level trip. The total outage time was only 1 hour. 40 minutes.
Module A sustained five outages during the month. Module Is presently out of service to allow
Installation of new demlsters and reheater. Module B was out of service 8 times. Longest
outage was for 95 hours for cleaning of booster fan and demlster. Booster fan vibrations
caused a shutdown on June 30.
Module A cannot be returned to service until the new reheater, ordered In April, Is received
and Installed. Module B sustained four outages. Reheater failures at 1000 hours seem to be
caused by vibration fatigue. One minor steam header leak also occurred.
PEDCo-ENVIRONMENTAL
49
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WILL COUNTY UNIT NO. 1 (continued)
PERIOD OPERABILITY (%)
Month/Year Module A Module B
Sep. 75 0 63
Oct. 75
Nov. 75
Dec. 75
Jan. 76
Feb. 76
Mar. 76
Apr. 76
0 100
0 0
45 20
20
49
Comnents
Nodule A remained out of service all month because of delay on the new reheater order.
Module B was down three times because of massive absorber scale, demlster and I.D. booster
fan cleaning, balancing I.D. booster fan, and plugging of absorber pump screen. Total outage
time was 238 hours, 40 minutes.
On October 11, overhaul began on the Will County Unit No. 1 boiler, turbine, and scrubber.
Module B experienced two minor outages during the 11-day period prior to the overhaul.
Module A was down for delivery of the new reheater.
The scheduled overhaul of the boiler, turbine, and scrubber modules continued. Major
maintenance areas included module reheaters, pond return pump, venturl spray nozzles,
venturl and absorber modules, pump valves, and sumps.
Module B reheater was returned from manufacturer after repairs and revisions. Scrubber re-
heaters could be Installed and operating by the end of January.
The unit remained out of service for completion of the boiler, turbine, and scrubber over-
haul that began on October 11, 1975. System restart Is now scheduled for mid-March 1976.
Unit No. 1 returned to service 1n March following an extended major boiler, turbine and
scrubber overhaul. Module A was put into the gas path on March 22 and remained 1n service
until March 29 because of delays 1n the Installation of a repaired reheater.
During the month of April Module A Incurred pump liner failures when an Isolation valve broke
and fell into the venturl recycle pump. Module B outages during the month resulted from reheater
tube bundle leaks; plugged absorber tank screens; and venturl pump liner failure. High
sulfur coal (3.5 percent sulfur) was burned in the boiler throughout the month. In addition, the
utility initiated a testing and evaluation program during the month. This program 1s designed
to provide data and Information concerning chemistry and related operating characteristics.
50
PEDCo- ENVIRONMENTAL
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
31
DUOUESNE LIGHT
ELRAHA
ELRAMA PENNSYLVANIA
510 nw
FUEL CHARACTERISTICS COAL 1.0 - 2.6 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICIPATES
S02
WATER HAKE UP
CHEniCO
LINE SCRUBBING
RETROFIT
10/75
OPERATIONAL
63 PERCENT FOR 2» SULFUR COAL
SLUDGE DISPOSAL
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
S93/KW CAPITAL
OPERATIONAL
EXPERIENCE
THE FGD SYSTEM WAS PLACED IN SERVICE ON OCTOBER 26t 1975. INITIAL
OPERATION PROCEEDED WITH FLUE GAS FROM ONE BOILER BEING TREATED BY THE
SCRUBBING SYSTEM. A SECOND BOILER WAS TIED INTO THE SYSTEM ON FEBRUARY <*.
1976. DURING THE REPORT PERIOD MODIFICATIONS TO THE FIFTH SCRUBBING VES-
SEL WERE COMPLETED AND THE VESSEL IS NOW OPERATING WITH TWO RUBBER-LINED
PEDCo-ENVIRONMENIAL
51
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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 SYSTEM AT THE PHILLIPS STATION. GIBBS & HILL IS THE ARCHITECT-
ENGINEER, AND CHEMICO SCRUBBERS HAVE BEEN INSTALLED WITHIN THE SAME DESIGNATED BATTERY AS AT PHILLIPS. MECHANICAL AND ELECTRICAL DUST-REMOVAL EQUIPMENT
REMOVES MOST PARTICULATES FROM THE BOILER EMISSIONS, AND THE GAS TO AND FROM THE SCRUBBERS IS HEADERED IN THE SAME WAY. UNLIKE THE PHILLIPS SYSTEM.
HOWEVER. THERE ARE FOUR BOILERS. EACH WITH ITS OWN TURBINE GENERATOR. FIVE SINGLE-STAGE SCRUBBERS WERE INSTALLED. WITH THE INTENTION THAT KNOWLEDGE
GAINED FROM THE TEST PROGRAM AT PHILLIPS WOULfr BE APPLIED TO ELRAMA TO ENABLE COMPLIANCE WITH EMISSION REGULATIONS.
*
THE FIRST ELRAMA SCRUBBER WAS PLACED IN SERVICE ON OCTOBER 26, 1975. IT HAD BEEN SCHEDULED FOR AN EARLIER STARTUP DATE, BUT BECAUSE OF THE
SEVERITY AND NUMBER OF PROBLEMS ENCOUNTERED AT PHILLIPS. STARTUP WAS DELAYED UNTIL MANY OF THE PROBLEMS AT PHILLIPS WERE RESOLVED AND THE MODIFICATIONS
COULD BE INCORPORATED AT BOTH STATIONS.
BOILER NO. 2 WAS INITIALLY CONNECTED TO THE FGD SYSTEM ON OCTOBER 26. 1975. THIS BOILER HAS AN EQUIVALENT CAPACITY OF APPROXIMATELY 100 MW, AND
THE EMISSIONS ARE HANDLED BY ONE SCRUBBER. TO ENSURE RELIABILITY IN THE CASE OF A SCRUBBER MALFUNCTION, TWO SCRUBBERS ARE OPERATED AT PARTIAL LOAD
TO PROTECT THE BOILER AND TURBINE GENERATOR AGAINST A TRIP-OFF.
THE BOILER OPERATED CONTINUOUSLY ON THE SCRUBBER SYSTEM THROUGH JANURY 1976. TWO MINOR OUTAGES OCCURRED DURING THIS PERIOD. ONE CAUSED BY
INOPERATIVE THROAT DAMPERS AND THE OTHER INVOLVING FAILURE OF A LIME FEEDER BELT.
UNTIL ADDITIONAL CONSTRUCTION IS COMPLETED. TWO BOILERS ARE THE MAXIMUM THAT CAN BE TIED INTO THE SCRUBBING SYSTEM. TO DATE THE UTILITY
HAS ENCOUNTERED THE USUAL MINOR STARTUP PROBLEMS AND SOME MAJOR PROBLEMS AS WELL. THE MAJOR PROBLEMS HAVE ENTAILED FROZEN PIPES AND THICKENERS. THE
LATTER INVOLVING HARDWARE AND DESIGN ASSOCIATED WITH RECIRCULATION OF THE SLUDGE WITHIN THE THICKENERS TO ATTAIN 30 TO 40 PERCENT SOLIDS CONCENTRATION.
THE SLUDGE BEING GENERATED AT THIS STATION IS TREATED BY THE IUCS METHOD, WHICH EMPLOYS A VACUUM FILTER THAT INCREASES THE SOLIDS IN THE UNDER-
FLOW TO 50 TO 60 PERCENT. SO THAT LESSER AMOUNTS OF DRY FLY ASH ARE REQUIRED FOR MIXING WITH THE SLUDGE.
PEDCo- ENVIRONMENTAL
52
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ELRAMA POWER STATION
Operating Hours
Period Boiler Scrubber Vessels
12 1234
Garments
Oct. 75
To
Jan. 76
Feb. 76
Mar. 76
Apr. 76
1169 1508 976 838
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
1n various combinations. The service hours to January 31, 1974 are posted 1n the
accompanying table. The fifth vessel has not been In service because 1t Is being re-
vised for trial Installation of rubber-lined recycle pumps.
The system operated during the report period with 2 boilers coupled Into the scrubbing
system. Revisions to the fifth scrubbing vessel have been completed and operations
are proceeding with two rubber-lined recycle pumps.
53
PEDCo-ENVIRONMENIAL
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
32
DUQUESNE LIGHT
PHILLIPS
SOUTH HEIGHT PENNSYLVANIA
410 MW
FUEL CHARACTERISTICS COAL 1.0- 2.6 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
CHEMICO
LIME SCRUBBING
RETROFIT
7/73
OPERATIONAL
S02
83 PERCENT FOR 2» SULFUR COAL
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
STABILIZED SLUDGE DISPOSED IN UNLINED POND
S103/KW CAPITAL * 5 MILLS/KWHRANNUALIZED COSTS
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTLM HAS OEEN OPERATIONAL SINCE JULY 1973. THE UTILITY REPORTS THAT
A TOTAL OF H BOILERS (NOS. 3t<*.5,& 6) WERE COUPLED INTO THE SCRUBBING
SYSTEM DURING THE REPORT PERIOD. THE SYSTEM IS NOW OPERATING ON HIGH
CALCIUM LIME FOLLOWING THE COMPLETION OF THE THIOSORBIC LIME TEST PRO-
GRAM. THE SCRUBBING SYSTEM AVAILABILITY DURING THE FIRST QUARTER OF 1976
WAS 72 PERCENT. THE SLUDGE STABILIZATION PRACTICES ARE STILL CONTINUING
AT THIS rACICZTY•
PEOCo- ENVIRONMENTAL
54
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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 RESULATANT FLUE GASES ARE DISCHARGED TO A COMMON HEADER, TO WHICH THE FGD MODULES ARE
CONNECTED THROUGH ISOLATION VALVES. THE BOILERS ARE CURRENTLY BURNING COAL WITH A HEATING VALUE OF 11,350 BTU PER POUND AND SULFUR AND ASH CONTENTS
OF 2.2 AND 18.2 PERCENT, RESPECTIVELY.
THE FGD SYSTEM, WHICH SUPPLEMENTS THE EXISTING MECHANICAL AND ELECTROSTATIC DUST COLLECTORS, CONSISTS OF FOUR TRAINS OF WET VENTURI-TYPE SCRUBBERS,
INSTALLED AT A COST OF APPROXIMATELY $103/kW. GIBBS & HILL, INC., WAS ENGAGED AS THE A-E FIRM FOR THE ENTIRE PROJECT; BATTERY LIMITS OF THE CHEMICO
CORPORATION ARE CONFINED TO THE SCRUBBERS AND ASSOCIATED PUMPS AND CONTROLS BETWEEN THE INLET HOT GAS DUCT MANIFOLD AND THE EXIT WET GAS HEADER (IN-
CLUDING THE REHEATER, EXCLUDING THE NEW ID FANS).
THE FOUR TRAINS ARE LOCATED DOWNSTREAM Of EXISTING MECHANICAL COLLECTORS AND ESP'S INSTALLED IN SERIES ON EACH OF THE SIX PULVERIZED-COAL-FIRED
BOILERS. THREE OF THE TRAINS 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 GAS STREAMS FROM AIR BOILERS TO THE SCRUBBER SYSTEM, WHERE THEY CAN
BE SENT TO ANY OR ALL OF THE TRAINS. THE SCRUBBED GAS IS EXHAUSTED THROUGH A COMMON DUCT AND AN OIL-FIRED REHEATER TO A NEW GROUND-SUPPORTED STACK,
WHICH CONTAINS AN INNER ACID-RESISTANT BRICK STACK.
SLAKED QUICKLIME IS ADDED TO THE LOWER CONE OF EACH OF THE SCRUBBER VESSELS TO NEUTRALIZE THE RECIRCULATING LIQUOR, WHICH, IN SINGLE-STAGE SCRUB-
BING WITH HIGH-CALCIUM LIME, REACTS WITH APPROXIMATELY 50 PERCENT OF THE SOg IN THE FLUE GAS. A LIQUOR BLEED FLOW OF APPROXIMATELY 4 PERCENT IS SENT
TO ONE OR BOTH OF THE THICKENERS FOR REMOVAL OF SOLIDS. THE OVERFLOW IS RETURNED TO THE SYSTEM, AND THE UNDERFLOW IS PIPED TO THE SLUDGE TREATMENT
SYSTEM. THE UNDERFLOW IS STABILIZED 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 LOCATED ABOUT ONE MILE FROM THE STATION, WHERE THE MATERIAL SOLIDIFIES.
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 ADN FLOWS UP THROUGH THE MIST ELIMINATOR. WHERE FINE DROPLETS ARE REMOVED BEFORE THE GAS LEAVES THE
SCRUBBER.
PEDCo-ENVIRONMENTAL
55
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PHILLIPS POWER STATION (continued)
STARTUP OF A PORTION OF THE PHILLIPS SCRUBBER SYSTEM BEGAN JULY 1973. SEVERAL PROBLEMS THEN DEVELOPED IN THE FORM OF EROSION OF FANS AND THE LIME
FEED SYSTEM. CAUSING OUTAGES OF THE SCRUBBER SYSTEM. AFTER AN EXTENDED OUTAGE, THE SCRUBBER SYSTEM WAS RETURNED TO SERVICE IN MARCH 1974. THE SYSTEM
HAS BEEN OPERATING CONTINUOUSLY SINCE THAT TIME WITH VARIOUS NUMBERS OF BOILERS CONNECTED TO THE SCRUBBER SYSTEM AND SCRUBBER TRAINS IN SERVICE.
DETERMINATION OF THE AVAILABILITY OF THE PHILLIPS SYSTEM HAS BEEN DIFFICULT. UNTIL ALL BOILERS WERE CONNECTED TO THE SCRUBBERS, THERE WAS AT
LEAST ONE SPARE TRAIN AND AS MUCH AS 100 PERCENT SPARE SCRUBBER CAPACITY. THEREFORE. HAVING A TRAIN OUT OF SERVICE FOR MAINTENANCE DID NOT REDUCE THE
CAPABILITY OF THE SCRUBBER SYSTEM. UNTIL ALL SIX BOILERS WERE CONNECTED, MEANINGFUL AVAILABILITY FACTORS COULD NOT BE COMPUTED. ON MARCH 17. 1975, THE
SIXTH BOILER WAS CONNECTED, AND ALL FOUR SCRUBBER TRAINS WERE REQUIRED TO BE IN SERVICE. OPERATION IN THAT MODE CONTINUED UNTIL AUGUST 4, 1975. WHEN
THE NO. 6 BOILER WAS REMOVED FROM THE SCRUBBER SYSTEM BECAUSE THE pH LEVEL COULD NOT BE MAINTAINED AND DEPOSITS BECAME UNMANAGEABLE TO THE POINT THAT
SCRUBBER OUTAGES WERE REDUCING GENERATING CAPABILITY OF THE STATION.
PEDCo-ENVIRONMENTAL
56
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PHILLIPS POWER STATION
Operating Hours
Boiler Scrubber-Absorber
Month 1234 5 6 101 201 301 401 Comments
Fourth FGD train and sixth boiler were tied In on March 17. 1975. Par-
tlculate tests In May showed outlet loadings of 0.04 Ib/mllllon Btu.
Jul. 75 83 644 703 349 605 643 400 180 537 723 The two-stage train has been out of service from June 19 for general
cleaning and repair of a leak In the first-stage scrubber.
Aug. 75 354 701 454 457 517 445 478 682 323 319 Scrubber unavailability forced returning Boiler No. 6 to the scrubber
bypass gas path to prevent loss of boiler capacity. Plugging and
maintenance problems have been encountered. Evaluation of various
recycle pumps 1s continuing.
Sep. 75 463 287 669 503 672 525 57 561 685 536 In October 1975, Phillips Initiated thlosorblc lime scrubbing In their
Oct. 75 547 575 620 604 681 687 607 207 505 487 single-stage modules on an experimental basis. The purpose Is to study
compliance feasibility. S02 removal efficiency, and quality of the •
sludge generated by the single-stage modules.
Nov. 75 16 720 688 70 720 593 626 720 0 75 The utility concluded the thlosorblc lime testing program In mid-
Dec. 75 172 660 709 0 689 547 360 661 182 386 December. Four boilers were coupled to the scrubbing system during the
run. The utility 1s now analyzing the data generated during the test
program. The scrubbers have been put back on regular lime. No unusual
problems were encountered during the test run.
Jan. 76 222 722 639 0 662 661 277 536 101 707 The 2.5-month test program with thlosorblc lime Included 1612 service
hours on one train and 1309 hours on another train. Results Indicate
that the required degree of S02 removal (83 percent) can be obtained
with an MgO content of 8-10 percent In the lime with single-stage
scrubbing.
PEOCo-ENVIRONMENTAL
57
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PHILLIPS POWER STATION (Continued)
Month
1
Operating Hours
Boiler
2345 6
Scrubber-Absorber
101 201 301 401
Feb. 76 445
Mar. 76
588 672
633 571
657
695
662
353
166
659
406
461
Comments
Plant operation 1s proceeding with a total of 4 boilers coupled Into the
scrubbing system (equaling 336 MM, which 1s 87 percent of the total
plant capacity). The FGO system operated on high calcium lime during
the report period. The general operation mode at this facility has one
of the four scrubbing trains out continually for repairs, cleaning, and
preventatlve maintenance. The utility 1s still experiencing problems
with solids deposition In the venturl throat of the scrubbing module,
causing movement Inhibition and greater pressure drops. The FGD
system availability for the first quarter of 1976 was 72 percent. The
sludge stabilization practices are still continuing at this facility.
58
PEDCo-ENVIRONMcrtfAL
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PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
33
GENERAL MOTORS
CHEVROLET PARMA 1 2 3 * »
PARMA OHIO
32 MW
COAL 2.5 PERCENT SULFUR
KOCH
DOUBLE ALKALI
RETROFIT
3/7H
OPERATIONAL
80 PERCENT
90 PERCENT
CLOSED LOOP
UNSTABILIZED SLUUGE DISPOSED IN UNLINEO POND
S3.2 MILLION CAPITAL * ftll.70 PER TON OF COAL ANNUALIZEO
REFER TO BACKGROUND INFORMATION SECTION IN TA?LE 3 OF THIS REPORT. THIS
FGO SYSTEM HAS BEEN OPERATIONAL SINCE MARCH 1971. SYSTEM OPERABILITY
DURING THE MONTHS OF MARCH AND APRIL WAS 17 AND 76 PERCENT RESPECTIVELY.
SYSTEM OPERABILITY AVERAGED IN EXCESS OF 56 PERCENT DURING THE LAST EIGHT
MONTHS. CURRENTLY! A SCRUBBING SYSTEM CHARACTERIZATION STUDY. SPONSORED
BY THE EPA* IS BCING CONDUCTED BY A.D. LITTLE.
59
PEDCO-ENVIRONMENTAL
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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 SULFUR.
THE FGD SYSTEM SCRUBBING MODULES WERE SUPPLIED BY KOCK ENGINEERING. INSTALLATION WAS COMPLETED ON FEBRUARY 28, 1974. THE SYSTEM CONSISTS OF FOUR
SCRUBBERS OPERATING IN PARALLEL. EACH SCRUBBER IS MADE OF THREE BUBBLE-CAP ABSORPTION TRAYS AND A MESH MIST ELIMINATOR.
THE S02 CONTAINED IN THE FLUE GAS IS ABSORBED BY A REGENERATED CAUSTIC SOLUTION (0.1 MOLAR NAOH), FORMING SOLUBLE SODIUM SALTS. THE SPENT CAUSTIC
IS THEN REGENERATED BY REACTING THE SOLUTION WITH SLAKED LIME, RESULTING IN THE FORMATION OF CALCIUM SULFITE AND SULFATE SOLIDS, WHICH ARE SEPARATED
OUT OF THE SOLUTION. NEXT, SODA ASH IS ADDED TO THE SOLUTION IN ORDER TO MAKE UP FOR SODIUM LOSSES AND MINIMIZE THE SCALE POTENTIAL FROM THE CALCIUM
WHICH REMAINS IN SOLUTION. THE REGENERATED CAUSTIC FORMED IS THEN RECYCLED BACK TO THE SCRUBBER FOR ADDITIONAL S0? REMOVAL, THE SLUDGE WHICH RESULTS
IS DEWATERED AND HAULED AWAY BY TRUCK TO AN OFF-SITE LANDFILL.
PROBLEMS AND SOLUTIONS
THE SYSTEM WAS STARTED UP ON FEBRUARY 28, 1974 AND BY APRIL 31 IT HAD 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 PERFORMANCE BUT
NOT COMPLETELY ELIMINATED THE PROBLEM. PREMATURE CAKE CRACKING IN THE VACUUM FILTERS REQUIRED THE PRESENCE OF AN OPERATOR DURING OPERATION. G.M.
ANTICIPATES THAT THE CHANGE TO NYLON FROM POLYPROPYLENE WILL SOLVE THIS PROBLEM.
CAKE WASHING TO REDUCE SODIUM LOSSES WAS NOT INITIALLY SUCCESSFUL BECAUSE THE SPRAY WATER TENDED TO KNOCK THE CAKE OFF THE DRUM. ALTERATIONS
IN SPRAY PATTERN AND OTHER MEASURES HAVE APPARENTLY SOLVED THIS PROBLEM. THERE HAS BEEN NO EVIDENCE OF CORROSION OR ABRASION IN THE PUMPS OR PIPING.
THE SYSTEM WAS SHUT DOWN FROM MAY 1 TO MAY 28, 1974, BECAUSE OF UNEXPECTED BUILDUP 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
PEDCo-ENVIRONMENTAL
60
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CHEVROLET PARMA (continued)
AT MORE FREQUENT INTERVALS. SYSTEM AVAILABILITY TO THE BOILER WAS 87 PERCENT IN APRIL 1974. LESS THAN 10 PERCENT IN MAY. AND 100 PERCENT IN JUNE.
JULY, AND AUGUST AFTER THE SYSTEM VMS RESTARTED. PLUGGING BY CaC03 DEPOSITS IN THE OVERFLOW LINE BETWEEN THE CLARIFIERS AND IN THE LINE FROM
CLARIFIER NO. 2 TO THE NIX TANKS WAS CORRECTED BY RELOCATING A CHEMICAL FEED LINE AND REPLACING SOME PIPING. THE SYSTEM WAS DOWN THROUGHOUT JULY AND
AUGUST FOR REPLACEMENT OF GRAVITY FLOW LINES WITH AN OPEN FLUME THAT CAN BE EASILY CLEANED.
PEDCo-ENVIRONNtwTAl
61
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CHEVROLET PARMA
Operating Hours
Boiler
Month. 12341
Jun. 75
Jul. 75
Aug. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
2331*
2135
FGD system
2 3
0 ** 0
0
0
1848*
1250
0
0
Qperabmty (X)
1234
0
0
59
0
0
79
0
0
0
0
Comments
Recent operation has been Intermittent. Tests have been
conducted for analysis of partlculate loading at the boiler
outlet. The system was restarted In May but was shut down
because of a plugged chemical feed line to clarlfler. After
restart about June 10, the system was shut down because of
similar plugging In another part of the line. Unit ran for
about 2 weeks 1n June.
FGD system was down 1n July and August for replacement of
gravity flow lines with an open flume.
FGD system restarted September 8, and operated during this
period at an availability factor of 80 percent.
The FGD system operated during the report period except
for a scheduled holiday shutdown from December 23 to
January 4, 1976. Because of problems with solids and solids
carryover, G.M. conducted stream tests during December to
determine whether the sol Ids carryover is due to a high
solids reclrculation rate. The FGD system was down most of
December because of these tests, which caused the low
operabillty factor.
* Note: The figures given for September and October represent
the operation hours from September 8 to November 9 Inclusive.
PEDCo- ENVIRONMENTAL
62
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CHEVROLET PARMA (continued)
Operation hours
Boiler FD6 system
Month 1234123
Jan. 76
Feb. 76 2997 1196
Mar. 76
1379
240
Qperab1l1ty (X)
41234
40
17
Apr.
1084
847
78
Conments
G.M. has found solids concentration 1n the clarlfler too high
for efficient system operation. A.D. Little 1s scheduled to
conduct tests on the system 1n April as part of an EPA evaluation.
The low system operabillty during the month of March resulted from
extensive modifications performed on the system by G.M. During this
period the scrubber blowdown and scrubber flow Indication system was
revised.
From April 19 to the end of the month the system was operable 100X.
During this period all system modifications were completed and all
major problem areas corrected.
63
PEOCo- ENVIRONMENTAL
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT.LOCATION
UNIT RATING
GULF POWER CO.
SCHOLZ NO. 1A
CHATTAHOOCHEE FLORIDA
20 MW
FUEL CHARACTERISTICS COAL 3.0 PERCENT SULFUR
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
ADL/COHBUSTXON EQUIP ASSOCIATE
DOUBLE ALKALI
RETROFIT
2/75
OPERATIONAL
99.7 PERCENT
S02
WATER HAKE UP
95 PERCENT
CLOSED LOOP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
UNSTABILIZED SLUDGE DISPOSED IN LINED POND
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE FEB. 1975. THE PROTOTYPE SYSTEM
OPERATED A TOTAL OF H7HH HRS. DURING 1975. TRANSLATING INTO AN ANNUAL
AVERAGE OPEHABILITY OF 39 PERCENT. THE SYSTEM WAS PUT BACK IN SERVICE
MARCH 12, 1976, FOLLOWING A SCHEDULED BOILER OVERHAUL. SYSTEM OPERABILITY
WAS 9<» PERCENT FOR THE DURATION OF THE MONTH.
64
PEOCo- ENVIRONMENTAL
-------
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 WITH AN AVERAGE HEATING VALUE OF
12,400 BTU/LB, 14 PERCENT ASH, AND SULFUR CONTENTS RANGING AS HIGH AS 5 PERCENT.
A 20 MW PROTOTYPE DUAL ALKALI SYSTEM WAS JOINTLY DEVELOPED, DESIGNED, AND INSTALLED. BY COMBUSTION EQUIPMENT ASSOCIATES AND ARUTHRU D. LITTLE. THE
PROTOTYPE SYSTEM AT THE SCHOLZ STEAM PLANT IS INSTALLED ON BOILER NO. 1, A BABCOCK ft UILCOX PULVERIZED-COAL-FIRED BOILER. THE SYSTEM IS DESIGNED TO
HANDLE 50 PERCENT OF THE FLUE GAS FROM THE BOILER. THE BOILER HAS BEEN RETROFITTED WITH A SECTIONALIZED, HIGH-EFFICIENCY ESP CAPABLE OF 99.7 PERCENT
PARTICULATE REMOVAL. THE ESP CAN BE SELECTIVELY DE-ENERGIZED FOR STUDY OF PARTICULATE IMPACT ON THE FGD OPERATION.
THE PROTOTYPE UNIT INCORPORATES A HIGH DEGREE OF FLEXIBILITY FOR GENERATION OF DESIGN AND OPERATING INFORMATION FOR A WIDE VARIETY OF APPLICATIONS.
ALTHOUGH THE BASIC MODE OF SYSTEM OPERATION IS DUAL ALKALI WITH LIME REGENERATION, THE SYSTEM WAS DESIGNED TO ACCOMMODATE LIMESTONE REGENERATION
AND LIME/LIMESTONE REGENERATION.
THE SYSTEM CONSISTS OF A VENTURI SCRUBBER AND AN ABSORPTION TOWER, WITH AN ADDITIONAL STORAGE SILO FOR LIMESTONE. A MIX TANK. AND OTHER ASSORTED
TANKS. PUMPS. CONTROLLERS, AND PIPING.
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 BACK IN SERVICE IN EARLY MARCH 1976.
PEDCo-ENVIRONMENTAL
65
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SCHOLZ 1A - DOUBLE ALKALI
Period
Feb. 75
to
Jul. 75
Jul. 75
to
Sep. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Operating hours
BoilerFGD system
2,600
FGD system
OperablHty (X)
83
44
100
620
732
560
732
90
100
Comments
Unit was placed 1n operation Feburary 8, 1975, and operated until July 18
when It was shut down for 2 months modifications, repairs, and replacement
of parts. The system was unavailable to the boiler for a 491-hour period
because of adjustments and modifications required for the formal EPA test
program In mid-May.
The system was shut down from mid-July to mid-September for mechanical
overhaul Involving replacement parts for valves that had failed.
The system was put back 1n operation on September 16, 1975. From mid-
September to mid-October the air preheater was repaired and boiler op-
eration adjusted to reduce oxygen levels 1n the flue gas to the 5 to 6
percent range. The system operated approximately 800 hours during this
period.
The system ran continuously for the remainder of the test period through
January 2, 1976. S02 levels during this period ranged from 800 to 1700
ppm. The system operated in the concentrated mode throughout the
remainder of the test period. In the period from mid-September to
January 2, 1976, the system operated about 2100 hours, with an
operability factor of 97 percent.
PEDCo-ENVIRONMENTAL
66
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SCHOLZ 1A - DOUBLE ALKALI (continued)
Period
Jan. 76
Feb. 76
Operating hours
Boiler F6D system
FGD system
Qperabmty (I)
Mar. 76
445
Comments
The FGD system and boiler underwent a scheduled overhaul during the
report period. System restart Is scheduled for mid-March 1976, to con-
tinue till June. During this operating period high-sulfur coal (3.5-4.0
percent) will be burned to allow evaluation of system performance on
high-sulfur coal.
The system was put back 1n service on March 12, 1976. The total number
of operating hours for the month of March was 445 hours. This
translates Into a 94* operablllty factor since the March 12 restart.
67
PEDCo- ENVIRONMENTAL
-------
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS OS/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
35
GULF POWER CO.
SCHOLZ NO. 2A
CHATTAHOOCHEE FLORIDA
20 MW
COAL 3.0 PERCENT SULFUR
FOSTER WHEELER
ACTIVATED CARBON
RETROFIT
2/76
OPERATIONAL
99.7 PERCENT
71.5 PERCENT (DESIGN)
N/A DRY ADSORPTION SYSTEM
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THE
SYSUM SUPPLIFR AND TEST DIRECTOR (SOUTHERN SERVICES) REPORTED THREE
OPERATIONAL RUNS DURING THE REPORT PERIOD. PERFORMANCE OF THE FRONT-END
OF THE SYSTEM (ADSORPTION AND REGENERATION) WAS CONSIDERED ADEQUATE. THE
RESOX SECTION OPERATED INTERMITTENTLY DURING THE REPORT PERIOD BECAUSE OF
PLUGGING PROBLEMS IN THE SULFUR CONDENSER. TO DATE. THE SYSTEM S02
REMOVAL EFFICIENCY HAS EXCEEDED THE NOMINAL DESIGN VALUE (96 PERCENT).
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 FEBRUARY 15, 1974, AT THE SCHOLZ STEAM POWER
PLANT IN CHATTACHOOCHEE, FLA. CONSTRUCTION WAS COMPLETED AND A TESTING PROGRAM WAS INITIATED IN MAY 1975.
THE SYSTEM AT THE SCHOLZ PLANT CONSISTS OF A 20-MW ADSORBER SECTION AND A 47.5-MW REGENERATION AND REDUCTION SECTION. THE 20 MW ADSORBER IS
DEISGNED TO ACCEPT HALF OF THE MAXiMUM FLUE GAS FLOW FROM UNIT NO. 2. THE COAL-FIRED BOILER IS RATED AT 40 MW (NOMINAL); IT FIRES COAL WITH A HEATING
VALUE OF 12,400 BTU/LB, ASH CONTENT IS 14 PERCENT, AND SULFUR CONTENT RANGING AS HIGH AS 5 PERCENT.
THE PURPOSE OF THE ADSORPTION SECTION IS TO REMOVE SOg, NOX> AND PARTICULATE FROM THE FLUE GAS WITH ACTIVATED CHAR, CONVERTING THE CAPTURED
POLLUTANTS TO SULFURIC ACID. THE REGENERATION SECTION PROVIDES CONTINUOUS ON-SITE REGENERATION OF THE CHAR, WHICH HAS BEEN LOADED WITH SOg IN THE FORM
OF H2S04. THE CHAR IS REGENERATED AND A LOW-VOLUME, 50,,-RICH OFF-GAS STREAM IS FED FORWARD TO THE RESOX REACTOR, WHICH REDUCES THE SO., STREAM TO GASEOUS
ELEMENTAL- SULFUR THAT IS COLLECTED AND STORED IN AN INSULATED TANK.
THE DEMONSTRATION UNIT HAS TWO ROWS OF MODULES, EACH ROW CONSISTING OF SIX MODULES. THE ADSORPTION SECTION IS A TWO-STAGE DESIGN CONSISTING
OF VERTICAL COLUMNS OF PARALLEL LOUVER BEDS, WHICH SUPPORT AND CONTAIN THE ACTIVATED CHARCOAL. S02 DIOXIDE, OXYGEN, WATER VAPOR, AND NOX ARE AD-
SORBED BY THE CHAR PELLETS FROM THE CROSS-FLOWING FLUE GAS AT 250 TO 300°F. THE S02 THEN REACTS WTIH 02 AND H20 TO FORM 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 SO.,. THE 50.,-RICH GAS IS THEN PASSED THROUGH A VESSEL CONTAINING CRUSHED COAL, RESULTING IN
REDUCTION TO GASEOUS ELEMENTAL SULFUR AND CARBON DIOXIDE. THIS LATTER PROCESS IS CARRIED OUT AT 1200° TO 1500°F.
THE INITIAL SHAKEDOWN ON FLUE GAS BEGAN AUGUST 11, 1975. AND PROCEEDED CONTINUOUSLY FOR 10 DAYS. THE REGENERATION SECTION WAS OPERATIONAL ABOUT
60 PERCENT OF THE TIME. HOWEVER, THE. REDUCTION SECTION HAS NOT YET BEEN INTEGRATED INTO SYSTEM OPERATION. S02 REMOVAL WAS WELL ABOVE EXPECTATIONS
AND PRESSURE DROP ACROSS THE ADSORBER WAS WELL BELOW DESIGN LEVELS. THE SYSTEM WAS SHUT DOWN FOR CORRECTION OF SEVERAL OPERATING PROBLEMS, EQUIPMENT
MODIFICATIONS, AND EVALUATION OF THE INTIAL OPERATING DATA. OPERATION WAS RESUMED IN OCTOBER 1975, WHEN TWO CONSECUTIVE RUNS WERE CONDUCTED WITH THE
REDUCTION PORTION OF THE SYSTEM PROCESSING FRONT-END OFF-GAS AT FULL OPERATING TEMPERATURES. A PROGRAM OF MODIFICATION WAS COMPLETED ON THIS SYSTEM
IN EARLY JANUARY 1976. REPRODUCTION OF FLUE GAS INTO THE INTEGRATED SYSTEM COMMENCED IN FEBRUARY 1976. THE SYSTEM IS CURRENTLY OPERATING THROUGH
4-MONTH TEST PROGRAM SPONSORED BY SOUTHERN SERVICES AND FOSTER WHEELER.
PEDCo-ENVIRONMhNTAL
69
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FKBF SYSTEM OPERATING HISTORY
t
Period . Comments
May 75 Completion of .construction was followed by a 3-month commissioning period which
Jun. 75 various pieces of equipment were operated Individually and then 1n combinations to
Jul. 75 simulate subsystem operation. Subsystem operations were Integrated Into section
Aug. 75 operations and flue gas was passed through the adsorber and regenerator for a 10-day
Sep. 75 period beginning August.11. RESOX construction was Incomplete at this time.
Oct. 75 Two consecutive runs were conducted on the RESOX portion of the system on front-end
process off-gas at full operating temperatures. This operational period lasted 5
days.
Nov. 5 A program of modifications on the system began in late August 1975 and continued
Dec. 75 through January 1976, with the exception of the 5-day RESOX operation In October.
Jan. 76 Modifications were completed and pre-startup testing was conducted in late January
and early February. A 3-day continuous dry run was successfully completed.
Feb. 76 All materials-handling loops and RESOX loops were operated at full operating
temperatures and pressures. Reproduction of flue gas Into the system commenced,
and a 4-month formal test program conducted by Southern Services and Foster Wheeler
Is now In progress.
Nar. 76 Three operational periods were logged by the prototype system during the report
Apr. 76 months. During these runs the adsorption and regeneration sections performed
adequately. The RESOX section operated Intermittently because of plugging problems
In the sulfur condenser. Also, the front end of the system was taken down at one
point due to frequent high temperature excursions. This problem was corrected by
modifying system operating procedures. Currently, work 1s proceeding on the
solution of the sulfur condenser problem.
PEDCo-ENVIRONMENTAL
70
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 05/76
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
36
GULF POWER CO.
SCHOLZ NOS. IB « 2B
CHATTAHOOCHEE FLORIDA
23 MW
COAL 5.0 PERCENT SULFUR (HAX)
CHIYODA INTERNATIONAL
THOROUGHBRED 101
RETROFIT
3/75
OPERATIONAL
•»«
99.7 PERCENT
90 PERCENT
WATER HAKE UP
SLUDGE DISPOSAL
UNSTABILIZED SLUUGE DISPOSED IN DRY GYPSUM POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF REPORT. THIS FGD
SYSTEM HAS BEEN OPERATIONAL SINCE MARCH 1975. THE TOTAL SYSTEM OPERABILI-
TY. INCLUDING SYSTEM COMMISSIONlNGi EXTENDING FROM FEB. ll,1975i TO
DECEMBER 31«1975. WAS 60 PERCENT. SYSTEM OPERA8ILITY FOR THE MONTHS OF
MARCH AND APRIL WAS 100 AND 1* PERCENT RESPECTIVELY. THE SYSTEM WAS TAKEN
OUT OF SERVICE ON APRIL 5 FOR A SCHEDULED SYSTEM'S DESIGN MODIFICATION.
PEDCO- ENVIRONMENTAL
71
-------
BACKGROUND INFORMATION
ON
SCHOLZ UNITS 1 AND 2 - CHIYODA
. THE SCHOLZ POWER PLANT IS LOCATED IN CHATTAHOOCHEE, FLORIDA, ABOUT 50 MILES WEST OF TALLAHASSEE. THE FGD SYSTEM WAS DESIGNED BY CHIYODA
INTERNATIONAL CORP. FOR TESTING AND PROCESS DEMONSTRATION ON A COAL-FIRED BOILER. THE PROCESS IS USED IN JAPAN ONLY ON OIL-FIRED AND GAS-FIRED BOILERS.
AND TAIL GAS FROM CLAUS UNITS.
THE SYSTEM AT SCHOLZ CAN HANDLE ONE-HALF THE LOAD (53,000 SCFM) FROM EITHER OF THE 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 PRE-
CIPITATORS 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. THE FIRST FEW MONTHS SHAKEDOWN PERIOD WAS CHARACTERIZED BY MANY SMALL PROBLEMS RESULTING IN A
LOW OPERABILITY (3W FEBRUARY-MAY). MANY OF THESE PROBLEMS WERE RESOLVED BY JUNE, AND OPERABILITY DURING JUNE AND JULY WAS SOMEWHAT IMPROVED (84X).
A SIX-WEEK OUTAGE STARTING IN AUGUST WAS THE RESULT OF UNBALANCING OF THE GYPSUM CENTRIFUGES. AFTER REPAIR OF THE CENTRIFUGES AND INSTALLATION ON
SEPTEMBER 15, THE OPERABILITY THROUGH DECEMBER. 1975 AVERAGED ABOVE 97X.
PEDCo-ENVIRONMENTAL
72
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SCHLOZ IB AND 2B - CHIYOOA
Boiler
Operating hours
ing
FG
D system
FGD system
OperaHlitv
75
Jul. 75
Aug. 75
Sep* 75
Oct> 75
N°V' 75
De°' 75
Ja"' 76
Feb' ?6
Mar. 76
Apr< 76
45°
741
10°
0
45
100
10°
98
66
n
100
14
Comments
This Is a pilot plant size demonstration unit. Engineering design began
September 1973. Startup occurred In March 1975. After Initial operation for
break-In tests, unit will be shut down for Internal Inspection. Reliability. tests
will then follow, starting July 1975. Chemical performance was satisfactory.
Emission tests have not been performed. Some pump and Instrument failures have
occurred.
Unit has been out of service for minor repairs throughout July.
operated at a 95 percent S02 removal efficiency during this period.
Gulf Power is attempting to upgrade this value to a higher efficiency level.
Waste water discharge from this unit still a problem area.
Outage time was less than one hour during November operation due to a broken
flue gas blower Inlet vane and repair of a pinhole In the prescrubber FRP
lining.
Scrubber outages during December resulted from continuing repairs to a pinhole
in the prescrubber FRP lining.
Outage time 1n January-February was primarily for repair and modification of
the suction and discharge piping on the absorbent circulation pumps. These FRP
lines broke in January at some weak field Joints. S02 removal efficiency has been
as high as 95%.
""it was stopped April 5 for a scheduled shut down to allow installation and
PEDCo- ENVIRONMENTAL
73
-------
SCHOLZ IB AND 2B - CHIYODA (Continued)
„ u Operating hours FGD system
Honth Boiler FGP system OperabfHty (X)
Comments
modifications for reducing the quantity of liquid waste from the system. Start-up
and testing of this modification was planned for the first week In May. A fire
at the plant, however, necessitated a delay In system restart for an additional
3 to 4 week period.
PEDCo-ENVIRONMENTAL
74
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
38
KANSAS CITY POWER ft LIGHT
HAWTHORN NO 3
KANSAS CITY MISSOURI
1HO MW
FUEL CHARACTERISTICS COAL 0.6- 3.0 PERCENT SULFUR
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
COMBUSTION ENGINEERING
LIMESTONE INJECTION «UET SCRUB
RETROFIT
11/72
OPERATIONAL
99 PERCENT
S02
70 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
UNSTABILIZLD SLUDGE DISPOSED IN UNLINED POND
S19/KW CAPITAL*2.5 MILS/KWH OP
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPEHATIONAL SINCE NOVEMBER 1972. BOTH MODULES WERE
DOWN THROUGHOUT THE REPORT PERIOD. THE UTILITY IS CURRENTLY ELIMINATING
THE BY-PASS SEALS AND INSTALLING SLIDE-GATE DAMPERS. IN ADDITION, THE
B-MODULE WAS RECONVERTED TO AN UNDERBED SPRAY ARRANGEMENT BECAUSE OF
CONTINUING PLUGGING PROBLEMS.
75
PEOCo-ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE HAWTHORN POWER STATION: UNIT NO. 3
THE.HAWTHORN POWER STATION IS LOCATED ON THE NORTH BANK OF THE MISSOURI RIVER IN EAST KANSAS CITY, MISSOURI. THE PLANT HAS FIVE ELECTRIC
GENERATING UNITS WITH A TOTAL RATED CAPACITY OF 980 MW. ONLY UNITS 3 AND 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 BUT/LB. •
THE FGD SYSTEM OPERATES ON LIMESTONE FURNACE INJECTION FOLLOWED BY A FLUE GAS WET-SCRUBBING SYSTEM IN WHICH BOTH THE S02 AND THE FURNACE CALCINED
LIMESTONE ARE SCRUBBED AND ALLOWED TO REACT IN A REACTION TANK.
THE FGD SYSTEM CONSISTS OF TWO IDENTICAL MODULES, EACH CAPABLE OF TREATING 500,000 ACFM OF FLUE GAS AT 300°F. BYPASSING OF THE MODULES IS
POSSIBLE THROUGH A SYSTEM OF DUCTWORK AND DAMPERS AROUND EACH MODULE. EACH MODULE CONSISTS OF A GLASS MARBLE BED, A CHEVRON TYPE FIBERGLASS DEMISTER,
AND A FINNED TUBE REHEATER. THE DEMISTER WASH SYSTEM USES A SET OF EIGHT WATER LANCES THAT TURN ON AUTOMATICALLY. TO WASH MUD FROM THE DEMISTERS
WHENEVER THE DAMPERS CLOSE.
THE SPENT LIMESTONE SLURRY FROM THE MODULES IS DISCHARGED INTO A CLARIFIER TANK, AND THE UNDERFLOW IS PUMPED. UNSTABILIZED, 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.
BECAUSE MAINTAINING THE SOLIDS IN THE REACTION TANKS IN SUSPENSION WAS DIFFICULT, BUILDUP OF MUD OCCURRED IN THE CORNERS OF THE TANK. THE
PROBLEM WAS SOLVED BY ROUNDING THE BOTTOM CORNERS, INSTALLING FRESH WATER FLUSHING NOZZLES ON EACH WALL, AND INCREASING THE HORSEPOWER OF THE TANK
MIXERS.
SEDIMENT BUILDUP OCCURRED IN THE DRAIN POTS HORIZONTAL HEADERS. ALSO, FREQUENT DISLOCATION OF THE MARBLE BED DRAIN POT COVERS AND CONSEQUENT
LOSS OF MARBLES WAS SOLVED BY INSTALLING NEW STAINLESS STEEL DRAIN POTS WITH EXPANDED METAL COVERS AND MODIFYING THE DRAIN PIPING. OTHER MODIFI-
CATIONS INCLUDED INSTALLING A NEW WASH SYSTEM TO CONTROL DEMISTER PLUGGING. CHANGING THE FLUSHING SEQUENCE WITHIN THE WATER SEAL TO ELIMINATE BYPASS
SEAL PLUGGING. AND REPLACING SPRAY NOZZLES. THESE MODIFICATIONS WERE COMPLETED BY FEBRUARY 1974. ADDITIONAL MODIFICATIONS AND SYSTEM DESIGN CHANGES
ARE CONTAINED IN THE COMMENTS SECTION OF THE OPERATING HISTORY SUMMARY FOR THIS INSTALLATION.
PEDCO-ENVIRONMENTAL
76
-------
HAWTHRON NO. 3
Operating Hours FGD Operablllty (X)
Month Boiler . Module 3A .Module 3B Module AModule B Comments
Jul. 75 584 0 0 Problems with Module 3A Included a leak In city water line, a plugged
duct to the I.D. fan, and a malfunctioning outlet damper from the
scrubber.
247 42 Marbles were lost from the bed and a spray header was broken.
Aug< 75 o 0 00 0 Lost I.D. fan for half of the boiler. Carryover of July problems.
Sep. 75 358 247 81 69 23 Outage due to cleaning and mechanical repairs. Pots, covers, and marbles
In the marble bed of module 3B were replaced.
Oct. 75 180 117 145 65 > 81 Module 3A outage was due largely to replacement of a recycle pump motor.
:JV A scheduled boiler overhaul reduced boiler operation hours.
Nov. 75 0 0 0 0 0 Boiler and scrubbers were shut down for a scheduled turbine overhaul.
Ogc. 75 • o 0 00 0 The system Is scheduled to go back on-Hne 1n January 1976.
Jan 76 0 0 00 0 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.
Feb. 76 503 148 7 37 1 Scrubber outages resulted from plugging 1n the scrubber bed. caused by
conversion from an under-bed to over-bed spray system.
Mar. 76 0 0 00 0 Reconversion of Module 3B's spray system arrangement has been completed.
Apr< 76 0 0 00 0 Also, the bypass system has been modified and changed to a slide-gate
damper arrangement.
PEDCo-ENVIRONMENTAL
77
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 05/76
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 HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
39
KANSAS CITY POWER 8 LI6HT
HAWTHORN NO 4
KAriSAS CITY MISSOURI
100 MW
COAL 0.6- 3.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION IWET SCRUB
RETROFIT
8/72
OPERATIONAL
99 PERCENT
70 PERCENT
UNSTABILIZED SLUDGE DISPOSED IN UNLINED POND
S19/KU CAPITAL*2.2 MILS/KWH OP
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTEM HAS BEEN OPERATIONAL SINCE AUGUST 1972. OPERABILITY FOR
MODULES A AND B WAS 0 AND 3 PERCENT RESPECTIVELY IN MARCH AND «2 AND
HO PERCENT RESPECTIVELY IN APRIL. DURING THE REPORT PERIOD THE UNIT'S
BY-PASS SEALS WERE REPLACED WITH SLIDE-GATE DAMPERS.
78
PEDCo- ENVIRONMENTAL
-------
BACKGROUND INFORMATION
ON
THE HAWTHORN POWER STATION: UNIT NO. 4
THE HAWTHORN POWER STATON 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 EALRY 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 LL PERCENT ASH, 0.6 PERCENT SULFUR, AND A HEAT CONTENT OF 9800 BUT/LB.
ORIGINALLY THE FGD SYSTEM OPERATED ON FURNACE INJECTION OF LIMESTONE FOLLOWED BY FLUE GAS WET-SCRUBBING SYSTEM IN WHICH BOTH THE S02 AND THE
FURNACE CALCINED LIMESTONE ARE SCRUBBED AND ALLOWED TO REACT IN A REACTION 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 CONSISTW OF TWO IDENTICAL^ODULES, EACH CAPABLE OF TREATING 500,000 ACFM OF FLUE GAS AT 300°F. BYPASSING OF THE MODULES IS
POSSIBLE THROUGH A SYSTEM OF DUCTWORK AND DAMPERS AROUND EACH MODULE. EACH MODULE CONSISTS OF A GLASS MARBLE BED, A CHEVRON TYPE FIBERGLASS DEMISTER,
AND A FINNED TUBE REHEATER.
THE DEMISTER WASH SYSTEM USES A SET OF EIGHT WATER LANCES THAT TURN ON AUTOMATICALLY TO WASH MUD FROM THE DEMISTERS WHENEVER THE DAMPERS CLOSE.
THE SPENT LIMESTONE SLURRY FROM ALL MODULES IS DISCHARGED INTO A CLARIFIER TANK, AND THE UNDERFLOW IS PUMPED. UNSTABILIZED. TO A 160-ACRE
UNLINED POND, WHICH IS ALSO USED FOR DISPOSAL OF FLY ASH FROM THE OTHER BOILERS.
BECAUSE OF CONTINUED OPERATIONAL PROBLEMS SINCE START-UP, THE AVAILABILITY FACTOR FOR THE SYSTEMS HAS BEEN LOW, (IN THE .RANGE OF 30 PERCENT TO
40 PERCENT). AVAILABILITY OF THE FGD SYSTEM HAS BEEN HAMPERED BY MANY PROBLEMS ATTRIBUTED TO DRY LIMESTONE INJECTION.
OPERATING HISTORY
APART FROM THOSE ENTAILED IN SWITCHING OF UNIT 4 FROM FURNACE INJECTION TO TIAL GAS INJECTION, THE MAJOR PROBLEMS ENCOUNTERED WITH THE FGD
SYSTEM ON BOILERS 3 AND 4 AT THE HAWTHORN POWER STATION HAVE BEEN IDENTICAL.
DIFFICULTY IN MAINTAINING SOLIDS IN THE REACTION TANKS IN SUSPENSION CAUSED BUILDUP OF MUD IN THE CORNERS OF THE REACTION TANK. THE PROBLEM WAS
SOLVED BY ROUNDING THE BOTTOM CORNERS, INSTALLING FRESH WATER FLUSING 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 BUILDUP OCCURRED IN THE DRAIN POTS HORIZONTAL HEADERS. ALSO, FREQUENT DISLOCATION OF THE MARBLE BED DRAIN POT
PEDCo-ENVIRONMENTAL
79
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HAWTHORN UNIT NO. 4 (Continued)
COVERS AND CONSEQUENT LOSS OF MARBLES WAS SOLVED BY INSTALLING NEW STAINLESS STEEL DRAIN POTS WITH EXPANDED METAL COVERS AND MODIFYING THE POTS
DRAIN PIPING. OTHER MODIFICATIONS INCLUDED INSTALLING A NEW DEMISTER WASH SYSTEM TO CONTROL DEMISTER PLUGGING, CHANGING THE FLUSHING SEQUENCE WITHIN
THE WATER SEAL TO ELIMINATE BYPASS SEAL PLUGGING. AND REPLACING SPRAY NOZZLES. THESE MODIFICATIONS WERE COMPLETED BY APRIL 1974. ADDITIONAL
MODIFICATIONS AND SYSTEM DESIGN CHANGES ARE CONTAINED IN THE COMMENTS SECTION OF THE OPERATING HISTORY SUMMARY FOR THIS INSTALLATION.
PEDCo-ENVIRONMENTAL
80
-------
HAWTHORN NO. 4
Operating Hours FGD OperablHty (%)
Month BoilerModule 4A Module 4B Module AModule B Comments
Jul. 75 518 41 128 8 25 Marble bed plugging and strainer problems on both modules.
Aug. 75 168 212 Lost half of boiler due to No. 48 I.D. fan outage. Both FGD modules were
shut down to ensure against the loss of the entire unit. New
chemistry - attempting to run at 100% blowdown and near 0 percent
solids. Emphasis on participate control. Maintaining pH at 5 without
limestone Injection.
Sep. 395 206 210 52 S3 Scrubber modules were returned to service on Sept. 21 after replacement
of the original I.D. fan on 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 because of continuing operational difficulties. Very good
performance resulted 1n Increased availability and continuation of
high participate removal efficiency (97 percent).
Oct. 75 721 429 656 60 91 Minor boiler restriction on the Module 4A side between the economizer
and the Inlet draft ductwork caused reduction of gas velocity. New
chemistry process modification of running at 100 percent blowdown and
zero percent solids 1s still 1n progress. SOg removal efficiency in the
50 to 60 percent range. KCP&L 1s concentrating heavily on particulate
emission control.
Nov. 75 720 0 713 0 99 Module 4A was shut down during the report period because of loss of
draft through the ductwork from the economizer to the air preheater.
01
81
-------
HAWTHORN NO. 4 (Continued)
Operating Hours FGD Operabllity (%)
Month BoilerModule 4A Module 4B Module AModule B Comments
The reheater plugged frequently until the system was shut down.
Dec. 75 640 0 103 0 16 Boiler outage of 5 days was due to a scheduled overhaul.
Jan. 76 0 0 0 0 0 The system was down all month because of frozen equipment and lines;
manpower was assigned to a boiler and turbine overhaul on another unit.
Feb- 76 579 0 450 0 78 Module 4A was shut down the entire month because of continuing loss
of draft through the ductwork from the economizer to the air preheater.
Marble bed plugging and loss of a recycle pump occurred on Module 4B.
Mar. 76 706 0 24 0 3.4 . During the report period the unit's bypass seals were replaced with
Apr. 76 550 231 2£0 42 40 slide-gate dampers.
PEDCo-ENVIRONMENTAL
82
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME'
UNIT LOCATION
UNIT RATING
HO
KANSAS CITY POWER ft LIGHT
LA CYGNE NO 1
LA CYGNE KANSAS
620 MW
FUEL CHARACTERISTICS COAL 5.0 PERCENT SULFUR
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULARS
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
NEW
2/73
OPERATIONAL
<*.
98 PERCENT
S02
76 PERCENT
WATER MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
UNSTABILIZED SiUDGE DISPOSED IN UNLINED POND
UNIT COST
S52/KH CAPITAL * 1.26 MILLS/ KWH
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE FEBRUARY 1973. DURING 1975 THE
TOTAL AVAILABILITY OF THE FGD SYSTEM AVERAGED IN EXCESS OF 04 PERCENT
(INCLUDING BOTH WORKING AND RESERVE HOURS). DURING THE FIRST QUARTER OP
1976 SYSTEM AVAILABILITY HAS AVERAGED 63i92, AND 91 PERCENT FOR THE
MONTHS OF JANUARY, FEBRUARY, AND MARCH RESPECTIVELY. THE SYSTEM WAS
BROUGHT DOWN ON APRIL 6 FOR A SCHEDULED BOILER AND AIR PREHEATER
OVERHAUL.
83
PEDCo-ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
LA CYGNE UNIT NO. 1
. THE LA CYGNE POWER STATION OF KANSAS CITY POWER AND LIGHT COMPANY BEGAN COMMERCIAL OPERATION ON JUNE 1M973, AS A JOINT PROJECT OF KANSAS"GAS"
AND ELECTRIC COMPANY AND KANSAS CITY POWER & LIGHT COMPANY. THE STATION IS LOCATED ABOUT 55 MILES SOUTH OF KANSAS CITY, IN LINN COUNTY. KANSAS.
ELECTRIC POWER GENERATING FACILITIES CONSIST OF ONE 820 MW COAL-FIRED BASE-LOAD BOILER WITH ASSOCIATED STEAM TURBINES AND ELECTRIC GENERATORS.
THE PLANT HAS THREE OIL-FIRED BOILERS, USED PRIMARILY FOR STARTUP OF THE LARGE UNIT. THEIR COMBINED CAPACITY IS EQUIVALENT TO 28 MW.
THE BOILER AT LA CYGNE, DESIGNED BY BABCOCK AND WILCOX, IS A DRY-BOTTOM, PULVERIZED-COAL-FIRED CYCLONE UNIT. THE COAL BURNED IS LOW-GRADE,
SUBBITUMINOUS, WITH AN AS-FIRED HEATING VALUE OF 9000 TO 9700 BTU/LB AND ASH AND SULFUR CONTENTS OF 25 PERCENT AND 5 PERCENT, RESPECTIVELY. POLLUTION
CONTROL EQUIPMENT ON THIS BOILER CONSISTS OF SEVEN FGD MODULES, 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
THE FGD INSTALLATION HAS BEEN PLAGUED WITH NUMEROUS PROBLEMS SINCE THE FIRST TRIAL OPERATION ON DECEMBER 26. 1972. SOME OF THESE PROBLEMS, SUCH AS
VIBRATIONS OF THE INDUCED-DRAFT FANS AND THEIR SENSITIVITY TO IMBALANCE, OCCURRED EVEN BEFORE THE BOILER WAS FIRED.
AS THESE FABRICATION PROBLEMS WERE CORRECTED AND THE FGD SYSTEM WENT INTO OPERATION, TWO OTHER TYPES OF PROBLEMS APPEARED. THE FIRST TYPE,
ASSOCIATED WITH THE WET LIMESTONE PROCESS, INCLUDES PLUGGING OF THE DEMISTER AND STRAINERS, WEARING OF SPRAY NOZZLES, AND CORROSION OF REHEATER TUBES.
PROBLEMS OF THE SECOND TYPE MAY BE UNIQUE TO THE LACYGNE INSTALLATION; THEY CONCERN THE EFFECT OF THE SCRUBBED FLY ASH ON VISCOSITY AND FLOW CHARACTER-
ISTICS OF THE RECIRCULATED SLURRY, WHICH RESTRICTS MOBILITY OF THE BALLS IN THE TCA TOWER.
FLY ASH CONTENT OF THE FLUE GAS (DUE TO LACK OF PRIMARY PARTICULATE CONTROLS) IS LARGELY RESPONSIBLE FOR BOTH TYPES OF PROBLEMS. SEVERAL MODIFICA-
TIONS HAVE BEEN MADE: THE ORIGINAL TURBULENT CONTACT ABSORBER'S FLOATING BED WAS REPLACED WITH SIEVE TRAYS; ALSO TO REDUCE THE EROSIVE EFFECT OF FLY
ASH AND LARGE-SCALE PARTICLES, AND TO EXTEND THE LIFE OF THE LIMESTONE SLURRY SPRAY NOZZLES ON THE VENTURI SCRUBBERS, A HYDROCLONE WAS INSTALLED IN THE
SLURRY RECIRCULATION LINE OF EACH MODULE TO CENTRIFUGALLY SEPARATE AND REMOVE THESE PARTICLES FROM THE SYSTEM.
THE CORROSION ASSOCIATED WITH CONDENSATION OF ACID VAPORS FROM THE GAS ON THE REHEATER TUBE BUNDLES WAS CONTROLLED BY INJECTION OF SLIP STREAMS OF
HOT AIR FROM THE BOILER'S COMBUSTION AIR HEATER INTO THE SCRUBBED FLUE GASES AT THE INLET TO THE REHEATER UNITS. THIS PRACTICE HAS REDUCED THE MAXIMUM
GENERATING CAPACITY OF THE BOILER BY LIMITING THE AIR AVAILABLE FOR COAL COMBUSTION.
PEDCO- ENVIRONMENTAL
84
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LA CYGNE UNIT NO. 1 (Continued)
BECAUSE THE FGD SYSTEM INCLUDES NO SPARE MODULES AND IT CANNOT BE BYPASSED, OUTPUT OF THE BOILER IS TOTALLY CONTROLLED BY PERFORMANCE AND
AVAILABILITY OF THE FGD MODULES. PRESENT PROCEDURES CALL FOR CLEANING ONE MODULE EACH NIGHT ON A ROTATIONAL SCHEDULE AND KEEPING ALL MODULES AVAILABLE
DURING THE DAYTIME PEAK PERIODS. CLEANOUTS REQUIRE THREE MEN FOR A PERIOD OF 10 TO 12 HOURS. RECENT MODIFICATIONS BY THE UTILITY ON THE SCRUBBER
INSTALLATION HAVE RESULTED IN PLANS FOR PROLONGED OPERATIONAL PERIODS. WITH MODULES STAYING ON-LINE CONTINUOUSLY FOR PERIODS UP TO 3 WEEKS.
PEDCo-ENVIRONMENTAL
85
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FGD SYSTEM AVAILABILITY
LA CYGNE UNIT NO. 1
Month Boiler Hours A
Jan.
Feb.
Mar.
Apr.
May
Jun.
Jul.
Aug.
Sep.
Oct.
Nov.
Dec.
Jan.
Feb.
Mar.
Apr.
74
74
74
74
74
74
74
74
74
74
74
75
75
75 694
75
May 75 683
Jun.
Jul.
Aug.
Sep.
75 667
75 590
75 630
75 610
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
87
76
Boiler
88
85
90
81
~81
76
61
61
Boiler
Boiler
Boiler
76
5 Days
90
85
84
78
85
™w
E
23
52
f
37
100
G
81
65
Average
50
69
Shutdown
74
78
82
85
81
83
84
84
100
84
83
79
78
89
85
85
88
80
87
77
99
86
84
84
80
80
86
80
85
81
76
76
Shutdown
Shutdown
Shutdown
93
of
90
84
85
92
79
92
Operation
89
86
87
85
78
96
83
89
85
83
74
90
89
86
86
84
80
Comnents
Modules A and D are used for research tests.
One module Is shut down each evening for cleaning.
System shutdown Oct. 16. 1975 owing to problems with
86
PEDCo- ENVIRONMENTAL.
-------
FGD SYSTEM AVAILABILITY (continued)
LA CYGNE UNIT NO. 1
Percent Avallablllty-by Module
- • Comments
nontn BOI ler nours
Oct. 75 231
Nov. 75 346
Dec. 75 597
Jan. 76
Feb. 76
Mar. 76
Apr. 76
inn \t U t i M n»«.i »a»
66 77 46 74 72 73 65 68
93 90 80 93 96 89 94 91
91 87 81 85 87 89 84 86
83
92
91
generator and I.D. air fan. System remained Inoperative
throughout the month.
Availability figures for October and November do not Include
the outage time from October 16 to November 13. Boiler outages
of 80. 50, and 11 hours, totaling 141 hours, occurred during
December.
The system was shot down on April 6 for a scheduled boiler and
air preheater overhaul. During this outage some maintenance
Is being performed on the scrubber ductwork because of
corrosion problems.
Note: The 1974 figures are based on actual operating hours of
each module divided by hours of boiler operation.
« During reduced boiler load operation, some of these
modules were not needed and were shut down, although
they were available. Availability was therefore
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
87
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT- LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP UATE
FGD STATUS
EFFICIENCYt
PARTICULATES
S02
WATER HAKE UP
SLUDGE DISPOSAL
43
KANSAS POWER ft LIGHT
LAWRENCE NO 4
LAWRENCE KANSAS
125 MW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION ftUET SCRUB
RETROFIT
12/68
OPERATIONAL
99 PERCENT
75 PERCENT
UNSTADILIZED SLUOGE DISPOSED IN UNLtNED POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTEM HAS BEEN OPERATIONAL SINCE DECEMBER 1966. THIS UNIT IS CUR-
RLNTLY 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 VCNTRI-ROD AND SPRAY TOWER SCRUBBING
SYSTEM.
PEDCo-ENVIRONMENTAL
88
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BACKGROUND INFORMATION
ON
THE LAWRENCE POWER STATION: UNIT NO. 4
LAWRENCE POWER STATION'S UNIT NO. 4 IS A CYCLIC LOAD STEAM BOILER EQUIPPED TO BURN COAL, NATURAL GAS SUPPLEMENTED WITH OIL. OR COMBINATIONS OF
THESE THREE FUELS. THE BOILER WAS BUILT BY COMBUSTION ENGINEERING AND PLACED IN SERVICE IN 1959. GENERATING CAPACITY VARIES FROM 125 MW TO 143 MM WITH
THE TYPE OF FUEL BEING BURNED. RETROFITTING WITH AN FGD SYSTEM IN NOVEMBER 1968 INTRODUCED ADDITIONAL PRESSURE DROP IN THE FLUE GAS SYSTEM AND
REDUCED BOILER CAPACITY TO 115 MW.
THE COAL NOW BURNED AT THE LAWRENCE POWER PLANT IS A LOW-SULFUR SOUTHEAST WYOMING COAL, HAVING AN AVERAGE HEATING VALUE OF 10,000 BTU/LB AND SULFUR
AND ASH CONTENTS OF 0.5 AND 11 PERCENT RESPECTIVELY.
THE BOILER HAS TWO MODULES, EACH DESIGNED TO HANDLE ROUGHLY 150,000 SCFM OF FLUE GAS. EACH MODULE 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 WITH BYPASS DUCTS AND HYDRAULIC SEAL DAMPERS. .
WHICH WERE LATER REMOVED BECAUSE OF EXTENSIVE' CORROSION AND PLUGGING.
THE PLANT HAS FACILITIES FOR STORING AND MILLING THE LIMESTONE. WHICH CONTAINS 93 PERCENT CALCIUM CARBONATf, 6 PERCENT SILICA. AND 1 PERCENT
MAGNESIUM CARBONATE.
SPENT SLURRY FROM THE UNIT, ALONG WITH THE SLURRY FROM UNIT NO. 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
PROBLEMS WITH THE FGD SYSTEM ON BOILER NO. 4 HAVE INCLUDED BUILDUP AND PLUGGING OF THE INLET DUCT WHERE HOT GASES ENTER THE SCRUBBERS. EROSION
OF SCRUBBERS WALLS. CORROSION OF SCRUBBERS INTERNALS, BUILDUP ON ID FAN ROTORS. AND PLUGGING OF DRAIN LINES, MARBLE BEDS. AND DEMISTERS. LOW SO REMOVAL
WAS CAUSED BY OVERBURNING OF THE LIMESTONE AND DROPOUT OF THE LIME WITH THE ASH IN THE BOTTOM OF THE SCRUBBER. *
THE SCRUBBERS WERE MODIFIED IN 1969 BY RAISING THE DEMISTER AND ADDING SOOT BLOWERS IN THE INLET DUCT AND REHEATER TO REDUCE PLUGGING. NEW SPRAY
NOZZLES WERE ALSO INSTALLED. REHEATER PLUGGING WAS ELIMINATED BY REPLACING COPPER REHEAT COILS WITH A CARBON STEEL UNIT HAVING WIDELY SPACED FINS.
89 PEDCo-ENVIRONMENTAL
-------
LAWRENCE UNIT NO. 4 (Continued)
MAJOR MODIFICATIONS IN 1970 WERE SANDBLASTING AND COATING OF THE INTERIOR OF THE SCRUBBERS, REPLACEMENT OF ALL INTERNAL STEEL PIPES WITH PLASTIC
AND FIBERGLASS, AND REPLACEMENT OF STAINLESS STEEL DEMISTERS WITH FIBERGLASS. *SINCE DEMISTER PLUGGING WAS NOT COMPLETELY ELIMINATED. THE UNIT WAS
WASHED MANUALLY EVERY NIGHT TO MAINTAIN THE REQUIRED OUTPUT.
THE MODIFICATIONS IN THE SUMMER OF 1972 ON THE TWO FGD MODULES INCLUDED ENLARGEMENT OF THE CRYSTALLIZATION TANK, AND INSTALLATION OF NEW
PLASTIC SPRAY NOZZLES, NEW SLURRY PUMPS AND STRAINERS, AND NEW MULTIPLE MIXERS IN THE TANK.
PROBLEMS REMAINING ARE CORROSION, UNSATISFACTORY DAMPER OPERATION. EXPANSION JOINT FAILURE, DEMISTER FOULING. RAPID WEARING OF THE SLURRY PUMP.
AND VALVE FAILURE. OPERATION OF THE FGD SYSTEM SINCE THE FALL OF 1973 HAS BEEN THE MOST SUCCESSFUL TO DATE.
OPERATION OF THE SCRUBBER SYSTEM ON THE WYOMING COAL HAS PROVED TO BE MORE EFFICIENT AND ECONOMICAL THAN EARLIER OPERATIONS BECAUSE A LESSER DEGREE
OF S02 REMOVAL IS REQUIRED FOR COMPLIANCE. THE SCRUBBER SYSTEM IS STILL OPERATING IN THE HIGH-SOLIDS MODE AS AN SOg AND PARTICULATE REMOVAL SYSTEM.
NORMAL MANUAL CLEANING REQUIREMENTS HAVE BEEN REDUCED TO TWO-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 CONSUMED 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 VENTURI ROD UNIT AND A SPRAY CHAMBER. A NEW ELECTRO-
STATIC PRECIPITATOR IS ALSO TO BE INSTALLED.
PEDCo-ENVIRONMENTM.
90
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LAURENCE NO. 4
Month
Jul. 75
Aug. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Jan. 76
Feb. 76
Mar. 76
Apr. 76
Boiler
HoduteA
erating hours
lule B
Operating h
ule A VfoS
Not logged
Not logged
Not logged
Not logged
Not Logged
Not logged
Not logged
Not logged
Availability
HoduTeTModule B
Comments
The FGD system has operated satisfactorily for over a year.
Availability is reported to be adequate for the operation of
this station. Station load is reduced to 50 percent every
night. Therefore, one of the modules can be taken off-line
nightly for cleaning or repair. Wyoming coal (0.5 percent
sulfur is being burned in this boiler/ Some natural gas has been
burned since June 20.
Burned coal 100 percent of time. Each module shut down once per
week for inspection and cleanup. No boiler outages In July and
August.
Present projections by the utility call for this unit to be
available 330 days-during 1976. The fuel comsumptlon will be 80
percent coal, 12 percent natural gas, and 8 percent fuel oil.
The utility is replacing this scrubber system with a venturi
rod-section followed by a spray tower.
91
PEDCO-ENVIRONMENTAL
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS OS/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
502
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
KANSAS POWER 8 LIGHT
LAWRENCE NO 5
LAWRENCE KANSAS
too MW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE INJECTION 4WET SCRUB
NEW
11/71
OPERATIONAL
99 PERCENT
65 PERCENT
UNSTABILIZED SLUDGE DISPOSED IN UNLINEO POND
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 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-ROO AND SPRAY TOWER SCRUBBING
SYSTEM.
92
PEDCo-ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
THE LAWRENCE POWER STATION: UNIT NO. 5
UNIT NO. 5 AT LAWRENCE POWER STATION IS A CYCLIC-LOAD STEAM BOILER EQUIPPED TO BURN COAL, NATURAL GAS SUPPLEMENTED WITH OIL. OR COMBINATIONS OF
THESE FUELS. THE BOILER, PLACED IN SERVICE IN 1971, HAS A RATED CAPACITY OF 400 MW WHEN BURNING COAL AND NATURAL GAS.
THE COAL NOW BURNED AT THE LAWRENCE POWER PLANT IS A LOW-SULFUR SOUTHEAST WYOMING COAL, HAVING AN AVERAGE HEATING VALUE OF 10.000 BTU/LB AND
SULFUR AND ASH CONTENTS OF 0.5 AND 11 PERCENT RESPECTIVELY.
THE BOILER'S 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. EACH MODULE 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 BYPASS DUCTS AND HYDRAULIC SEAL DAMPERS. THE PLANT FACILITIES FOR STORING AND MILLING THE
LIMESTONE, WHICH CONTAINS 93 PERCENT CALCIUM CARBONATE, 6 PERCENT SILICA, AND 1 PERCENT MAGNESIUM CARBONATE.
SPENT SLURRY FROM THE UNIT ALONG WITH THE SLURRY FROM UNIT NO. 4 IS SENT TO THREE INTERCONNECTED UNLINED SLUDGE DISPOSAL PONDS OF 16. 28, AND
4 ACRES. COOLING TOWER BLOWDOWN SUPPLIES MAKE-UP WATER TO THE POND SYSTEM. CLARIFIED POND WATER IS RECYCLED. THE SLUDGE IS NOT TREATED FURTHER
AND IS REPORTED TO SET AND SOLIDIFY IN THE PONDS.
PROBLEMS AND SOLUTIONS
PROBLEMS WITH THE FGD SYSTEM ON BOILER NO. 5 WERE SIMILAR PROBLEMS TO THOSE OF THE SYSTEM ON BOILER NO. 4: LOCALIZED CORROSION IN SOME EQUIPMENT.
UNSATISFACTORY DAMPER OPERATION, DEMISTER FOULING. EXPANSION JOINT FAILURE. AND RAPID WEAR OF SLURRY-RECIRCULATING PUMPS. IN ADDITION TO THESE
PROBLEMS. BOILER No. 5 IS PLAGUED WITH POOR FLUE GAS DISTRIBUTION TO THE EIGHT FGD MODULES WHICH. UNLIKE THE MODULES ON BOILER NO. 4 ARE ALL INTER-
CONNECTED TO A COMMON STACK.
FGD SYSTEM AVAILABILITY IS REPORTED TO BE ADEQUATE FOR OPERATION OF THIS STATION. BECAUSE STATION LOAD IS REDUCED TO 50 PERCENT EVERY NIGHT.
AS MANY AS FOUR MODULES CAN BE SHUT DOWN FOR CLEANING AND REPAIR EACH EVENING.
OPERATION OF THE SCRUBBER SYSTEM ON WYOMING COAL HAS PROVED TO BE MORE EFFICIENT AND ECONOMICAL BECAUSE OF THE LESSER DEGREE OF SO REMOVAL
REQUIRED.
PEDCo- ENVIRONMENTAL
93
-------
LAURENCE UNIT NO. 5 (Continued)
IN 1974 THE UNIT WAS AVAILABLE FOR OPERATION 338 DAYS: 66 PERCENT OF THE FUEL CONSUMED WAS NATURAL GAS. 27 PERCENT COAL. AND 6 PERCENT FUEL OIL.
DURING 1975 THE UNIT WAS AVAILABLE FOR OPERATION 352 DAYS. FUEL CONSUMPTION.WAS 45 PERCENT NATURAL GAS. 42 PERCENT COAL. AND 13 PERCENT FUEL OIL.
PEDCo- ENVIRONMENTAL
94
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LAURENCE NO. 5
Months
Operating hours
Open
BoTTer
FGD modules
Comments
Jul. 75
Aug. 75
Sep. 75
Oct. 75
Nov. 75
Dec. 75
Jan. 76
Feb. 76
Mar. 76
Apr. 76
Not logged
Not logged
Not logged
Not logged
Not logged
Wyoming coal Is being burned In this unit. FGD system availability Is reported to be
adequate for operation of this station. Since station load 1s reduced to 50 percent
every night, as many as four modules can be shut down for cleaning and repair each
evening.
FGD units were off-line'most of June for major rebuilding of the spray systems 1n all
modules. Some oil was burned to allow bypassing of the repair.
011 and gas were burned In July and August. No FGD operation.
Gas and oil burned on a part-time basis during September and October. Boiler outage
was due to Inspection, turbine repair, and replacement of the slurry tank screen.
Projections by the utility for this unit call for 330 days of operation 1n 1976 with
fuel consumption being 60 percent coal. 25 percent fuel oil. and 15 percent natural
gas. Like Unit 4, this unit will be converted to a venturl-rod and spray tower system.
PEDCo-ENVIRONMENTAL
95
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FRO STATUS
EFFICIENCY!
PARTICULATES
S02
KENTUCKY UTILITIES
GREEN RIVER UNITS 1 AND 2
CENTRAL CITY KENTUCKY
64 nw
COAL 3.8 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
RETROFIT
9/75
OPERATIONAL
*«
»M
99.7 PERCENT '
60 PERCENT GUARANTEE
WATER MAKE UP
SLUDGE DISPOSAL
CLOSED LOOP
STABILIZED SLUDGE DISPOSED IN UNLINED POND
UNIT COST
OPERATIONAL
EXPERIENCE
S64/KU CAPITAL
REFER TO BACKGROUND INFORMATION SECTION IN TABLE s OF THIS REPORT. THIS
SYSTEM BECAME OPERATIONAL SEPTEMBER 13. 1975. THE OPERATIONAL DATA
SUPPLIED BY THE UTILITY FOR THE REPORT PERIOD SHOWS THAT SYSTEM
AVAlLABILITYt KELIABILITYt OPERABILITY. AND UTILIZATION WAS 97. 95, 85,
AND 52 PERCENT RESPECTIVELY FOR THE MONTH OF MARCH AND 90. 100. lOOi AND
77 PERCENT RESPECTIVELY FOR THE MONTH OF APRIL.
PEDCo-ENVIRONMENTAL
96
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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 ARE PEAK LOAD UNITS. THE BOILERS PROVIDING STEAM
TO THE GENERATORS ARE NORMALLY OPERATIONAL 5 DAYS PER WEEK, WITH ONE OR MORE OFTEN OPERATING AT REDUCED CAPACITY.
THE S02 AND PARTICULATE CONTROL SYSTEMS FOR BOILERS 1, 2, AND 3 CONSIST OF MECHANICAL COLLECTORS AND A TAIL-END LIME SCRUBBING SYSTEM.
A CONTRACT FOR THE LIME SCRUBBING SYSTEM 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 FLUE GAS FROM BOILERS 1, 2, AND 3, WHICH HAVE A COMBINED RATED CAPACITY OF 64 MW. THE FUEL
IS PRIMARILY A HIGH-SULFUR (3.5 TO 4.0 PERCENT) WESTERN KENTUCKY COAL.
THE FGD SYSTEM CONSISTS OF ONE SCRUBBER MODULE DESIGNED TO HANDLE A MAXIMUM GAS CAPACITY 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 THROUGH AN ADJUSTABLE-THROAT
VENTURI SCRUBBER AND FLOODED ELBOW, WHICH WAS PROVIDED PRIMARILY FOR PARTICULATE REMOVAL. S02 IS REMOVED BY REACTION WITH THE LIME SLURRY IN THE MOBILE
BED CONTACTOR, WHICH CONSISTS OF TEN COMPARTMENT SECTIONS WITH OVERHEAD SLURRY SPRAYS AND UNDERBED DAMPERS TO ACCOMMODATE GAS VOLUME TURNDOWN.
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. RETURN WATER FROM THE POND IS USED AS PRIMARY MAKE-UP.
g?
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FGD SYSTEM AVAILABILTY
GREEN RIVER NOS. 1 AND 2
Period
Dec. 75
Total
period (hr)
744
Availability = 74X
Reliability « 78%
Operablllty « 65X
Utilization = 35%
Jan. 76 744
Availability = 42X
Reliability = 14X
Operablllty = 11X
Utilization = 9X
Feb. 76 696
Availability - 70X
Reliability » 42*
Operablllty = 42X
Utilization = 30X
Mar. 76 744
Availability - 97X
Reliability = 95X
Operablllty • 85X
Utilization - 52X
Boiler
operation (hr)
398
Module
availability (hr)
550
No. hr. module
called upon
to operate
331
Hr. module
operated
257
572
312
456
64
499
486
499
211
450
722
409
386
Comments
System became operational September 13, 1975, on a half-
load basis because of turbine overhaul. The half-load
mode continued throughout the report period. Logging of
operating data began December 1975.
System was down a total of 432 hours 1n January. Major
problems were failure of the recycle pumps and feed
tank agitator, thawing and repair of numerous frozen
lines, and shutdown of sump pumps.
The system was Inoperative a total of 210 hours in
February. Outage was due to repairs of tank agitators,
recycle pumps, and reactant pumps and to cleanout of
reactant pumps, slurry pumps, slake tanks, and mix-hold
tank.
During the report period all the rubber-lined Impellers
were replaced in the pumps.
PEOCo-ENVIRONMENTAL
98
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FGD SYSTEM AVAILABILITY (Continued)
GREEN RIVER NOS. 1 AND 2
No. hr. module
Total Boiler Module called upon • Hr. module
Period, period (hr) operation (hr) a vail ability (hr) to operate operated Comments
Apr. 76 720 552 648 552 552 The utility made a prior commitment to run at 100 percent
AvaiUblllty » 90S operablllty during the month of April.
Reliability - 100X
Operablllty - 100X
Utilization - 77%
PEDCo- ENVIRONMENTAL
99
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FGD VENDOR
PROCESS
NCW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
KLY WEST FLORIDA
37 MW
FUEL CHARACTERISTICS OIL
2.1 PERCENT SULFUR
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
NEW
10/72
OPERATIONAL
90 PERCENT
S02
WATER MAKE UP
65 PERCENT-ESTIMATED
MAKE UP RATE ESTIMATED 100 GPM
SLUDGE DISPOSAL
UNLINED POND
UNIT COST
S 21.6/KW CAPITAL COST
OPERATIONAL
EXPERIENCE
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 SERVICE SINCE JANUARY 2Btl975. MODIFICATIONS AND REPAIRS ARE
CURRENTLY IN PROGRESS. SYSTEM RESTART IS STILL INDEFINITE. A CHECKOUT
OF ALL SYSTEM MOTORS AND PUMPS MUST BE COMPLETED BEFORE STARTUP CAN
COMMENCE.
100
PEDCo-ENVIRONMtrtTAL
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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 - 2.75% 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. THE SYSTEM USES PULVERIZED CORAL AND SEAWATER. THE CORAL
IS INITIALLY GROUND TO A FINE POWDER IN A HAMMER-MILL CRUSHER. THEN MIXED WITH SEAWATER TO FORM A DILUTE SLURRY AND TRANSFERRED TO THE SCRUBBING SYSTEM
TO ABSORB SULFUR DIOXIDE. THE CLEANED GAS IS DISCHARGED TO ATMOSPHERE AND THE SPENT SLURRY IS PUMPED TO A SETTLING POND. 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. FLUE GASES FROM TEH BOILER ARE DRAWN THROUGH AN INDUCED
DRAFT FAN AND FORCED EITHER THROUGH THE BYPASS DUCT OR THROUGH ONE OR BOTH SCRUBBERS VIA THREE SETS OF DAMPERS BETWEEN THE INDUCED-DRAFT FAN AND THE
STACK. BEFORE ENTERING THE SCRUBBING SYSTEM THE GAS IS COOLED FROM 360°F TO 160°F BY SEAWATER SPRAYS. THIS COOLING PROTECTS THE FIBERGLASS COMPONENTS
OF THE SCRUBBER MODULES. A PRESSURE DROP OF 12 TO 14 INCHES WATER GAUGE IS THE NORMAL OEPRATING RANGE FOR THE SCRUBBERS.
THE FGD SYSTEM WAS PLACED IN OPERATION IN OCTOBER 1972. THE SYSTEM WAS SHUT DOWN ON JANUARY 28. 1975. FOR REPAIR OF THE BOILER FOUNDATION AND
DUCTWORK BAFFLES. OTHER IMPORTANT MODIFICATIONS TO BE COMPLETED ARE: REPLACING SPRAY TREES AND OTHER STAINLESS STEEL PARTS WITH MONEL; MODIFYING AND
SEALING INLET DAMPERS; REPAIRING THE INDUCED-DRAFT FAN; AND REPAIRING HOLE IN HOPPER WALL AND DUCT FLOOR.
PEDCo-ENVIRONMENTAL
101
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STOCK ISLAND
Operating hours
FGD system
Month Boiler FED system
Jul.
Aug.
Sep.
Oct.
Nov.
Dec.
Jan.
Feb.
Mar.
Apr.
75
75
75
75
75
75
76
76
76
76
0
0
0
0
0
0
0
0
0
0
Availability
0
0
0
0
0
0
0
0
0
0
Comments
FGD system was shut down on January 28, 1975, because of damaged ductwork baffles.
Spray trees and other stainless steel parts have been replaced with Monel.
FGD system Is still out of service but Is scheduled for restart In early October.
Boiler has been down since August 30 for repairs of the Induced-draft fan.
FGD system 1s still out of service. Date of system restart 1s Indefinite.
FGD system Is still out of service. The utility Is replacing dampers and various
system parts. Date of system restart Is still Indefinite.
Repairs to outlet damper are complete. All holes In the hopper wall and ductwork
have been patched. New spray trees have been Installed. The utility Is still
repairing the Inlet damper. The system will not restart for at least another
month pending checkout of all pumps and motors.
The FGD system restart has been delayed because of boiler-related problems. Date
of system restart Is still Indefinite.
PEDCo-ENVIRONMENTAL
102
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS OS/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
LOUISVILLE GAS ft ELECTRIC
PADDYS RUN NO 6
LOUISVILLE KENTUCKY
65 HW
COAL 3.5-t.O PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
RETROFIT
«»/73
OPERATIONAL
99 PERCENT DESIGN
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
80 PERCENT (DESIGN)
33 GAL/LB MOLE S02 REMOVED
UNSTABILIZEO SLUDGE DISPOSED IN UNLINEO POND
S57/KW CAPITAL
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE APRIL 1973. OPERABILITY WAS 100
PERCENT IN JANUARY. S02 REMOVAL EFFICIENCY WAS 99 PERCENT DURING THIS
OPERATING PERIOD. THE SYSTEM WAS SHUTDOWN IN EARLY FEBRUARY IN PREPARA-
TION FOR THE EPA SCRUBBER AND SLUDGE STUDY WHICH MAY COMMENCE IN JUNE OR
JULY OF 1976. THE SCRUBBER WILL NOT BE OPERATED UNTIL THIS TIME UNLESS
THE NEED ARISES (PEAK LOAD DEMAND). CURRENTLY* THE UTILITY IS COMPLETING
MODIFICATIONS ON THIS UNIT IN ANTICIPATION OF THE STUDY PROGRAM.
103
PEDCo-ENVIRONMENTAL
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BACKGROUND INFORMATION
ON
PADDY'S RUN POWER STATION
PADDY'S RUN POWER STATION IS LOCATED IN LOUISVILLE, KENTUCKY. THE PLANT HAS SIX ELECTRIC POWER GENERATING UNITS WITH A TOTAL RATED CAPACITY OF
320 MW. UNIT NO. 6 IS RETROFITTED WITH A CARBIDE LIME-BASE FGD SYSTEM.
UNIT NO. 6 IS A PEAK LOAD COAL-FIRED BOILER, MANUFACTURED BY FOSTER WHEELER AND INSTALLED IN 1950. IN 1973, THE BOILER BURNED COAL WITH A GROSS
HEATING VALUE OF 11,500 BTU/LB AND AVERAGE SULFUR AND ASH CONTENTS OF 3.7 PERCENT AND 13 PERCENT, RESPECTIVELY.
THE FGD SYSTEM CONSISTS OF TWO MODULES. EACH HANDLES 175,000 ACFM OF 350°F FLUE GAS. EACH MODULE IS MADE UP OF TWO STAGES OF 3-INCH MARBLE
BEDS, FOLLOWED BY A TWO-STAGE CHEVRON-TYPE DEMISTER. THE GAS IS REHEATED BY DIRECT COMBUSTION OF NATURAL GAS. S02 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 TO 8.0 PERCENT CALCIUM CARBONATE, AND 0.1 PERCENT
MAGNESIUM OXIDE.
THE UNIT OPERATES ON A CLOSED-LOOP MODE: THE S02 IS ABSORBED IN THE MARBLE BED BY A SLURRY OF CALCIUM SULFITE TO FORM A MIXTURE OF CALCIUM
SULFITE/BISULFITE. EFFLUENT FROM THE MARBLE-BED TOWER IS CONVERTED IN THE REACTION TANK TO CALCIUM SULFITE BY THE ADDITION OF CALCIUM HYDROXIDE. HALF
OF THE REACTION TANK EFFLUENT IS RETURNED TO THE S02 TOWERS, WHILE THE OTHER HALF IS FED TO A CLARIFIER TANK. THE CALCIUM SULFITE CRYSTALS PRE-
CIPITATE WITH THE AID OF A FLOCCULANT, WHICH IS ADDED AT THE RATE OF 4 TO 7 PPM. THE OVERFLOW IS RETURNED TO THE REACTION TANK; THE UNDERFLOW,
CONTAINING 22 TO 24 PERCENT SOLIDS, IS STABILIZED BY MIXING IT WITH LIME. 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 SUMP FOR USE AS LANDFILL.
DURING THE INITIAL 45 DAYS OF OPERATION ONLY ONE ABSORBER WAS PLACED IN SERVICE, ALLOWING OPERATORS TO OBSERVE THE EQUIPMENT AND TO DETERMINE ANY
NEEDED MODIFICATIONS. BEGINNING MAY 19, 1974, THE SYSTEM WAS SHUT DOWN FOR A MONTH FOR MODIFICATIONS, THE MOST SIGNIFICANT BEING INSTALLATION OF
EQUIPMENT FOR INJECTING A FLOCCULATING AGENT INTO THE CLARIFIER TANK. DURING THE PERIOD JUNE 19 TO JULY 11, INCONSISTENT SIZING OF SLURRY ADDITIVE
MATERIAL AS RECEIVED CAUSED MALFUNCTION OF THE ADDITIVE CONTROL VALVES AND UNDUE PLUGGING OF SLURRY LINE STRAINERS. THESE PROBLEMS WERE CORRECTED
BY INSTALLATION OF A DISINTEGRATOR IN THE SLURRY ADDITIVE SYSTEM. FROM AUGUST 19 TO SEPTEMBER 5, THE UNIT WAS SHUT DOWN TO ENLARGE THE CLARIFIER'S
OVERFLOW SYSTEM. ANOTHER MODIFICATION MADE WAS LOWERING OF THE SLURRY pH TO REMOVE SULFITE SCALING FORMED ON THE UPPER BED PERFORATED SUPPORT
PLATE AND ON THE MARBLES.
OPERATING DATA. DESIGN MODIFICATIONS, PROBLEMS AND SOLUTIONS SINCE THE SYSTEM START-UP ARE PRESENTED AND DISCUSSED IN THE FOLLOWING TABLE.
PEDCo-ENVIRONMENTAL
104
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FGD SYSTEM AVAILABILITY
PADDY'S RUN UNIT NO. 6
QperabHlty {*)
Month Module A Module B . Comments
Apr.'73 18 56 Modules were operated one at a time, with frequent shutdowns for Inspection of equipment and
minor repairs.
May 73 11 65 Single-module operation continued through May 19, when the unit was shut down for modifications.
The most significant modification was Installation of equipment for Injection of a flocculating
agent Into the clarifier tank.
jun. 73 0.1 6 Operation was Intermittent from June 19 to July 11 because of mechanical problems with the slurry
pumps.
jul. 73 21 21 During a scheduled outage from July 12 through August 1, several repairs were made to the lime
slurry makeup system. A disintegrator unit was Installed to reduce plugging of strainers .and
slurry control valves.
Aug. 73 53 64 The operation was continuous from August 2 to August 18 except for a brief shutdown due to a
boiler-related problem. From August 19 to September 5. the system was shut down to replace the
clarifier1s underflow line with one of larger diameter and to Install additional pump capacity In
the clarifier's overflow system.
Sep. 73 85 72 The unit operated continuously between September £ and September 20 except for a 7-hour shutdown
to repair a marble bed support plate. The unit was shut down the remainder of the month because
of trouble in the boiler's turbine generator.
Oct. 73 49 94 The FGD system was In service through December 20 after which the boiler (and the scrubbers) were
Nov. 73 35 100 shut down because of "no demand" (this 1s a peaking-load boiler).
Dec. 73 44 78
Jan. 74 00 Boiler shut down because of "no demand."
through
Jun. 74
PEDCo-ENVlRONMENTAt
105
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FGD SYSTEM AVAILABILITY
PADDY'S RUN UNIT NO. 6 (tontlnued)
Operablllty (%)
Month Module A Module B Comnents
Jul. 74 51 81 Boiler and FGD system resumed operation July 10. 1974.
Aug. 74 50 77 Unit has been on and off frequently due to fluctuation In power demand.
Sep. 74 0 0 Boiler Is down because of "no demand."
Oct. 74 100 100 Boiler turned on specifically to perform limestone tests on FGD system.
Nov. 74 0 0 Boiler Is down because of "no demand."
through
Aug. 75
SeP- 75 100 TOO Boiler and FGD system operational all of September and first two weeks 1n October. System outage
Oct- 75 100 100 during the last two weeks of October was due primarily to breeching In the boiler section. Opera-
blllty for both modules during the operational period was 100 percent (based upon LG&E's Peak Load
Determination). S02 removal was reported to be over 98 percent.
Nov- 75 10° TOO Boiler and scrubber system ran most of the report period on a Monday-through-Friday basis. Two
Dec- 75 90 90 minor outages 1n December were due to malfunction and repair of the dual strainer switch shaft Into
bottom of the scrubber module.
Jan- 76 100 100 S02 removal efficiency was reported to be 99 percent during January. The system was shut down In
Feb- 76 00 early February 1n preparation for an EPA scrubber/sludge study scheduled for June or July. The
scrubber will not be operated until the start of the study program unless the boiler 1s required
for peaking power demands. Highlights of the scrubber/sludge study program are as follows:
0 6 month duration.
0 One scheduled shutdown for test modifications.
0 Scrubber will run on carbide Hrne and commercial lime.
• Determination of minimum retention times.
PEDCo-ENVIRONMENTAL
106
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FGD SYSTEM AVAILABILITY
PADDY'S RUN UNIT NO. 6 (Continued)
QperabllUy (*) Comments
Month HoduleA HoSule B Con-nents
0 Deliberate high chloride concentration operation.
• MgO Innoculatlon.
• Extensive sludge study: Fixation, leachates, seasonal variations.
7fi 00 The unit did not operate during the report period in anticipation of the EPA scrubber/sludge
00 study. The utility 1s now completing system modifications for the operation of the test program.
• *o
Note: Since Paddy's Run No. 6 Is a peak load boiler, it operated for less than a day on several
occasions 1n July and August 1974. During these short boiler runs, the FGD system was
not turned on and was bypassed although it was available.
PEDCo-ENVIRONMENTAL
107
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TABLE 3
PERFORMANCE: DESCRIPTION FOR OPERATIONAL FGD SYSTEMS os/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
56
MONTANA POWER CO,
COLSTRIP NO 1
COLSTRIP MONTANA
360 MM
FUEL CHARACTERISTICS COAL 0.6 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
COMBUSTION EQUIP. ASSOCIATES
LIME/ALKALINE FLYASH SCRUBBING
NEW
10/75
OPERATIONAL
99 PERCENT
S02
60 PERCENT
WATER MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
UNSTABILIZED SLUUGE DISPOSED IN UNLINED POND
UNIT COST
S50/KW CAPITAL
OPERATIONAL
EXPERIENCE
THE COLSTRIP PLANT IS A MINE MOUTH INSTALLATION. CONSTRUCTION ON THIS
UNIT WAS COMPLETED BEHIND SCHEDULE. THE FGD SYSTEM STARTED UP IN LATE
197b AND PROCEEDED THROUGH A SHAKEDOWN AND DEBUGGING OPERATION PHASE. THE
UNIT IS NOW OPERATING AT FULL COMMERCIAL CAPACITY. OPERATING DATA AC-
CUMULATED TO-DATE IS IN THE PROCESS OF BEING EVALUATED BY- THE UTILITY FOR
PRESENTATION TO STATE REGULATORY AGENCIES.
108
PEDCo-ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICIPATES
S02
NEVADA POWER
REID GARDNER NO 1
MOAPA NEVADA
125 MW
COAL 0.5- 1.0 PERCENT SULFUR
COMBUSTION EBUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
RETROFIT
OPERATIONAL
99 PERCENT
65 PERCENT
WATER MAKE UP
SLUD6E DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
190 6PM
UNSTAHILIZED SLUDGE DISPOSED IN UNLINED POND
$«tt/KW CAPITAL (1974 DOLLARS) SfeOOtOOO ANNUALlZED
REFLK TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGD SYSTEM HAS BEEN OPERATIONAL SINCE APRIL 1974. SYSTEM OPERABlLlTY FOR
THE MONTHS OF MARCH AND APRIL WAS 72 AND 91 PERCENT RESPECTIVELY. ONE
FORCED SCRUBBEK OUTAGE OCCURRED DURING THE REPORT PERIOD BECAUSE OF A
VENTURI LEAK. THE BOILER WAS SHUTDOWN APRIL 5 FOR A VALVE AND COAL CON-
DUIT INSPECTION.
109
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. 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 FGD 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 IN APRIL 1974. SYSTEM DESIGN WAS BASED
ON DATA GATHERED FROM OPERATION OF AN 8000-ACFM PILOT PLANT AT THE REID GARDNER POWER STATION IN 1971 AND 1972.
THE FGD SYSTEM CONSISTS OF A SINGLE MODULE, DESIGNED TO HANDLE 473,000 ACFM OF GAS AT 350°F. THE MODULE IS MADE UP OF A TWIN VARIABLE-THROAT
VENTURI SCRUBBER, FOLLOWED BY A SINGLE-STAGE WASH TRAY. BYPASSING OF THE MODULE IS POSSIBLE THROUGH A GUILLOTINE-TYPE BYPASS VALVE. A COMMON FACILITY
FOR TRONA (SODIUM CARBONATE ORE) STORAGE AND SAND REMOVAL SERVES BOTH FGD MODULES ON REID GARDNER UNITS 1 AND 2. SO, REMOVAL EFFICIENCY IS REPORTED
TO BE 85 PERCENT.
IN THIS SODIUM CARBONATE PROCESS, HOT FLUE GAS FROM THE BOILER PASSES FIRST THROUGH MECHANICAL COLLECTOR (MULTICYCLONE), WHERE ABOUT 75 PERCENT
OF THE FLY ASH IS REMOVED. PRESSURE IS THEN BOOSTED BY AN INDUCED-DRAFT FAN BEFORE THE GAS STREAM SPLITS AS IT ENTERS THE TWIN-THROAT VENTURI
SCRUBBER. THE HOT FLUE GAS IS QUENCHED BY A SHOWER OF CIRCULATED SODIUM BASE LIQUOR. THE GAS THEN ENTERS THE WASH TRAY AND BUBBLES THROUGH THE RADIAL-
VANE MIST ELIMINATOR, WHERE THE REMAINING LIQUID DROPLETS CARRIED OVER WITH THE GAS ARE TRAPPED AND REMOVED.
EFFLUENT FROM THE FGD SYSTEM IS FROM TWO SOURCES: THE SLIP STREAM OF SPENT LIQUOR DISCHARGED FROM THE RECIRCULATION TANK, AND THE ALKALINE
CLARIFIER UNDERFLOW, WHICH SERVES TO NEUTRALIZE THE pH OF THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE SLUDGE SETTLING PONDS. THE SPENT LIQUOR
IS PUMPED INTO ONE OF TWO SETTLING PONDS. THE OVERFLOW FROM THIS POND IS PUMPED TO A LARGER 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. '
PEDCo-ENVIRONMENTAL
110
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REID GARDNER 1
Operating Hours
Month Boiler FGD system Operablllty (%} Comnents
During February the FGD system operated with 95 percent availability on trona
supplemented with soda ash. Availability 1n January was only about 65 percent because
of frozen sodium carbonate feed lines. Problems 1n February Included a 2-day lack of
chemicals. No significant problems occurred In March. The unit ran April 1 through
April 12 with 100 percent availability. The boiler was then shut down for routine
maintenance. The system was placed back on line May 12. .Second performance test was
Jul. 75 851 passed. Problems Included an abrasion of rubber-lined pipes and routine mechanical and
Instrumental problems. High ash content, up to 20 percent, had no effect on
emissions.
Aug. 75
Sep. 75 716 559 77 Of four forced outages, three were caused by scrubber malfunctions.
Oct. 75 303 106 35 Low operating time was due to scheduled boiler maintenance. One outage was due to the
malfunction of a soda ash blower.
Nov. 75 654 394 60 The utility reports system performance in terms of the operabillty Index. Unit No. 1
Dec. 75 operabillty was low for the month of November because of delays In delivery of repair
materials.
Jan. 76 646 186 29 Three forced outages during the month were due to reheater steam leaks, collapse
of a venturi strainer, and a frozen carbonate line. The system was shut down for 16
days for completion of piping conversion; this outage was not due to scrubber
Feb. 76 664 520 78 malfunction. The utility reported five scrubber inoperative periods during the month
of February, three of which were scrubber related outages. The forced scrubber
occurred because of guillotine damper unit switch problems, depletion of chemical,
chemical line plugging and seal water problems.
Mar. 76 398 287 72 Only one scrubber-related outage occurred during the month, because of a venturi leak.
PEDCo-ENVIRONMENT
Ill
-------
REID GARDNER 1 (Continued)
Operating Hours
Month Bo Her FGD system OperablHtv (%) Comments
Apr. 76 106 97 91 The boiler was taken out of service on April 5 for Inspection of valves and coal
conduits.
112 PEDCO-ENVIR0NMHWAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS OS/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICIPATES
S02
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
65
NEVADA POWER
REID GARDNER NO 2
MOAPA NEVADA
125 nw
COAL 0.5- 1.0 PERCENT SULFUR
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
RETROFIT
OPERATIONAL
99 PERCENT
65 PERCENT
190 6PM
UNSTABILIZEO SLUUGE DISPOSED IN UNLINED POND
S<»t/KW(1974 DOLLARS)* S600 t OOOANNUALIZEO
KEFEK TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
FGO SYSTEM HAS BEEN OPERATIONAL SINCE APR. 197<*. SYSTEM OPERABILXTY FOR
THE MONTHS OF MARCH AND APRIL WAS 60 AND 77 PERCENT RESPECTIVELY. DURING
THE REPORT PERIOD SEVERAL FORCED SCRUBBER OUTAGES WERE XEPORTEDt
PRIMARILY CAUSED BY PLUGGED SENSING LINES* REHEATER REPAIRS.
AND MALFUNCTIONS IN THE TRAY SYSTEM.
PEDCo-ENVIRONMENTAL
113
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BACKGROUND INFORMATION
ON
REID GARDNER UNIT NO. 2
THE REID GARDNER POWER STATION IS LOCATED NEAR HOAPA, NEVADA. ABOUT 50 MILES NORTH OF LAS VEGAS. THE STATIONS HAS TWO ELECTRIC POWER GENERATING
UNITS, (REID GARDNER 1 AND 2) EACH RATED AT 125 MW. BOTH UNITS ARE RETROFITTED WITH SODIUM CARBONATE BASED FGD 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 WAS MANUFACTURED BY COMBUSTION EQUIPMENT ASSOCIATES AND PLACES IN OPERATION IN APRIL 1974. SYSTEM DESIGN WAS
BASED ON DATA GATHERED FROM OPERATION OF AN 8000 ACFM PILOT PLANT AT THE REID GARDNER POWER STATION IN 1971 AND 1972.
THE FGD SYSTEM CONSISTS OF A SINGLE MODULE, DESIGNED TO HANDLE 473,000 ACFM OF GAS AT 350°F. THE MODULE IS MADE UP OF A TWIN VARIABLE-THROAT
VENTURI SCRUBBER, FOLLOWED BY A SINGLE-STAGE WASH TRAY. BYPASSING OF THE MODULE IS POSSIBLE THROUGH A GUILLOTINE-TYPE BAYPASS VALVE. A COMMON FACILITY
FOR TRONA (SODIUM CARBONATE ORE) STORAGE AND SAND REMOVAL SERVES BOTH FGD MODULE ON REID GARDNER UNITS 1 AND 2. S02 REMOVAL EFFICIENCY IS REPORTED TO
BE 85 PERCENT.
IN THIS SODIUM CARBONATE PROCESS, HOT FLUE GAS FROM THE BOILER PASSES FIRST THROUGH A MECHANICAL COLLECTOR (MULTICYCLONE), WHERE ABOUT 75 PERCENT
OF THE FLY ASH IS REMOVED. PRESSURE IS THEN BOOSTED BY AN INDUCED DRAFT FAN BEFORE THE GAS STREAM SPLITS AS IT ENTERS THE TWIN THROAT VENTURI SCRUBBER.
THE HOT FLUE GAS IS QUENCHED BY A SHOWER OF CIRCULATED SODIUM BASE LIQUOR. THE GAS THEN ENTERS THE WASH TRAY AND BUBBLES THROUGH THE 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.
EFFLUENT FROM THE FGD SYSTEM IS FROM TWO SOURCES: THE SLIP STREAM OF SPENT LIQUOR DISCHARGED FROM THE RECIRCULATION TANK, AND THE ALKALINE
CLARIFIER UNDERFLOW, WHICH SERVES TO NEUTRALIZE THE pH OF THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE SLUDGE SETTLING PONDS. THE SPENT LIQUOR
IS PUMPED INTO ONE OF TWO SETTLING PONDS. THE OVERFLOW FROM THIS POND IS PUMPED TO A LARGER 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.
PEDCo-ENVIRONMENTAL
114
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REID GARDNER 2
Operating Hours
FGD System
Month Boiler FGD system . OperabllUv (*) Comments
During February the FGD system operated with 90 percent operabillty on trona supplemented
with soda ash. Problems Included a plugged recycle line strainer, seal water filters,
and boiler controls. Unit has restarted after shutdown for 5-year turbine overhaul.
Ju1' 75 85X Second performance test was passed. Problems Included abrasion of rubber-lined pipes and
routine mechanical and instrumental problems. High ash content, up to 20%, had no effect
on emissions.
Aug. 75
Sep. 75 645 496 77^ Three forced outages were due to strainer plugging, broken bucket elevator, worn re-
circulation piping, and rubber liner leakage.
Oct. 75 531 464 87 Three forced outages during October were due to pump repair, Instrument plugging, and
repair of piping leakage.
Nov. 75 603 596 99 The utility reports system performance in terms of the operabllity Index.
Dec. 75
Jan. 76 691 458 66 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.
Feb. 76 675 578 86 The utility reported four scrubber Inoperative periods during the month, three of which were
scrubber-related outages. The forced scrubber outages occurred because of plugging in a
venturi pump, depletion of chemical, chemical line plugging, and seal water problems.
Mar. 76 660 395 60 The utility reported that the FGD system was operational over 395 hours during this period.
PEDCO-ENVIRONMENTAL
115
-------
REID GARDNER 2 (Continued)
Operating Hours
FGD System
Honth Boiler FGD system OperabHlty (X) Comments
One scrubber-related outage occurred during the month, because of plugging 1n the tray
system and subsequent overhaul of the tray recycle pumps.
Apr. 76 629 488 77 Four forced scrubber outages, totaling over 98 hours, were reported by the utility for the
month of April. The scrubber has been 1n operation 8711 hours since startup.
PEDCo- ENVIRONMENTAL
116
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS OS/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL .CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY.
PARTICULATES
NORTHERN STATES POWER CO.
SHEKBURNE NO 1
BECKER MINNESOTA
660 MU
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
NEW
3/76
OPERATIONAL
99 PERCENT GUARANTEE
502
50 PERCENT GUARANTEE
WATER MAKE UP
SLUDGE DISPOSAL
UNLINED POND
UNIT COST
S60/KW CAPITAL
OPERATIONAL
EXPERIENCE
A PRELIMINARY SYSTEM CHECKOUT BY PASSING WATER AND AIR THROUGH THE EQUIP-
MENT WAS SUCCESSFULLY COMPLETED BY THE UTILITY. THE SYSTEM WAS PUT IN
SERVICE ON MAKCH 16i 1976t TREATING FLUE GAS FROM BOILER N0.lt WHICH
FIRES A LOW SULFUR WESTERN COAL. FOLLOWING THE 3/16 STARTUP THE SYSTEM
WAS TESTED ON VARIOUS LOAD CAPACITIES AND IS CURRENTLY OPERATING AT FULL
COMMERCIAL LOAD. A SO-DAY VENDOR RELIABILITY TEST PROGRAM IS SCHEDULED
TO COMMENCE IN MID-SUMMER 1976.
PEDpo-ENVIRONNpUL
117
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT .LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYt
PARTICULATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
76
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 1
SHIPPINGPORT PENNSYLVANIA
635 MW
COAL
-------
BACKGROUND INFORMATION
ON
BRUCE MANSFIELD UNIT NO. 1
THE BRUCE MANSFIELD PLANT IS A 2700-HW. THREE-UNIT. COAL-FIRED FACILITY LOCATED ON THE OHIO RIVER IN THE BOROUGH OF SHIPPING PORT. PENNSYLVANIA.
THIS NEW FACILITY IS BEING BUILT BY PENNSYLVANIA POWER CO., WHICH IS ACTING ON ITS OWN BEHALF AND AS AGENT FOR THE OTHER PARTICIPATING COMPANIES -
CLEVELAND ELECTRIC ILLUMINATING CO.. DUQUESNE LIGHT CO.. OHIO EDISON CO.. AND TOLEDO EDISON CO.
BRUCE MANSFIELD NO. 1 IS A COAL-FIRED. ONCE-THROUGH. SUPERCRITICAL STEAM GENERATOR WHICH FIRES 333 TONS/HR. OF COAL, NEARLY 6.5 MM LB/HR.
OF STEAM AT 3.785 PSIG, 1005°F/1005°F. THE EMISSION CONTROL EQUIPMENT REQUIRED FOR THIS UNIT IS DESIGNED TO MEET STATE EMISSION REGULATIONS OF
0.6 LBS S02/106 BTU OF HEAT INPUT AND 0.0175 GR/SCF OF PARTICULATE WHEN BURNING 11,900 BTU/LB COAL HAVING AVERAGE ASH AND SULFUR CONTENTS OF 12.5
AND 4.3 PERCENT.
IN LATE 1970, AN INTENSIVE INVESTIGATION OF MORE THAN 30 POTENTIAL DESULFURIZATION SYSTEMS WAS INITIATED. THE SYSTEM ULTIMATELY CHOSEN FOR
THE REMOVAL OF FLY ASH AND SULFUR OXIDES WASTHE VENTURI WET-SCRUBBING SYSTEM, MANUFACTURED BY CHEMICO AIR POLLUTION CONTROL CO.. EMPLOYING DRAVO
CORPORATION'S THIOSORBIC LIME.
THE DESIGN FEATURES OF THE SCRUBBING SYSTEM CALLS FOR EACH SCRUBBING TRAIN TO CONSIST OF A SCRUBBING VESSEL, A 9000-HP I.D. FAN, AND
AN ABSORBER VESSEL. THERE ARE 6 SCRUBBER TRAINS PER UNIT, 5 OF WHICH ARE REQUIRED TO HANDLE THE FLUE GAS FLOW FROM THE BOILER AT FULL LOAD (3.35 MM
ACFM AT 285°F). THE SCRUBBER/ABSORBER TRAINS ARE ARRANGED IN TWO GROUPS OF THREE. THE TREATED FLUE GAS, WHICH HAS PASSED THROUGH THE SCRUBBING
SYSTEM. IS DUCTED THROUGH A COMMON REHEAT CHAMBER AND THEN EXHAUSTED UP THE 950-FT. STACK.
THE ADJUSTABLE VENTURI THROAT SCRUBBING MODULE REMOVES NEARLY ALL OF THE FLY ASH CONTAINED IN THE FLUE GAS. THE ABSORBER MODULE. WHICH IS A
FIXED-THROAT VENTURI, REMOVES THE REMAINING FLY ASH. SOg IS ABSORBED IN BOTH THE SCRUBBER AND ABSORBER BY DROPLETS OF LIME SLURRY. CONTAINING
2 TO 6 PERCENT MgO.
THE SCRUBBER-RECYCLE BLEED IS THEN COMBINED WITH A FLY ASH SLURRY FROM THE BOILER AND A FLOCCULANT AND PUMPED TO A 200 FT. DIAMETER THICKENER.
SLUDGE FROM THE THICKENER IS THEN PUMPED TO A WASTE DISPOSAL SYSTEM WHERE IT IS MIXED WITH A STABILIZING AGENT (CALCILOX) AND THEN PUMPED
APPROXIMATELY 7 MILES TO THE LITTLE BLUE RUN RAVINE FOR LAND FILL.
1]g PEOCo-ENVIRONMENTAL
-------
BRUCE MANSFIELD NO. 1
Operating Hours
Month Boiler FGD Modules"" Comnents
12 34 56
Dec- n Initial operation (shakedown and debugging) for part of the system commenced 1n
December 1975.
Jan. 76
Feb. 76
Mar. 76
Apr' 76 260° 290° 230° 110° 40° The Installation began full commercial operation In April. The scrubbing system
Is currently handling flue gas at a total equivalent capacity of 840 to 850-MW
(gross). The total module by module operation hours logged to-date are
posted 1n the accompanying table.
PEDCo-ENVIKUNMtNTAL
120
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 05/76
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
SLUDGE DISPOSAL
60
•
PHILADELPHIA ELECTRIC CO.
EDOYSTONE NO 1A
EODYSTONE PENNSYLVANIA
120 MW
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/75
OPERATIONAL
UNIT COST
$17 MILLION CAPITAL
OPERATIONAL
EXPERIENCE
THE SOS SCRUBBER HAS BEEN TEMPORARILY SHUTDOWN BECAUSE THE ACID PLANT RE-
GENERATION FACILITY AT THE OLIN CHEMICAL SULFURIC ACID PLANT IN PAULSBORO
NEW JERSEY HAS PERMANENTLY CEASED OPERATIONS. CONSIDERATIONS ARE NOW
BEING blVCN 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. THE UTILITY IS STILL EXPERIENCING PROBLEMS WITH THE FANS, RE-
HEAT BURNERS, DAMPERS, AND EXPANSION JOINTS.
PEDCo-ENVIRONMENTAL
121
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
83
PUBLIC SERVICE CO OF COLORADO
VALMONT NO. 5
VALMONT COLORADO
50 HW
FUEL CHARACTERISTICS COAL 0.72 PERCENT SULFUR
F60 VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
RETROFIT
OPERATIONAL
95 PERCENT
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
85 PERCENT
CLOSED LOOP
UNSTABILIZED SLUDGE DISPOSED IN LINED POND
OPERATIONAL
EXPERIENCE
KEFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
SYSTE.M HAS BEEN OPERATIONAL SINCE NOVEMBER l97«t. THE FGD SYSTEM CURRENTLY
OPERATIONAL AT THIS STATION IS AN EXPERIMENTAL UNIT, ORIGINALLY DESIGNED
BY UNIVERSAL OIL PRODUCTS FOR PARTICULATE REMOVAL ONLY. ONE OF THE TWO
PARALLEL SCRUBBING MODULES WAS CONVERTED TO LIMESTONE SCRUBBING FOR
EXPERIMENTAL PURPOSES ONLY.
PEDCo-ENVIRONMENTAL
122
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BACKGROUND INFORMATION
ON
VALMONT NO. 5
THE VALMONT POWER STATION OF THE PUBLIC SERVICE COMPANY OF COLORADO IS LOCATED IN VALMONT, COLORADO, APPROXIMATELY 20 MILES NORTH OF DENVER.
VALMONT'NO. s is A COAL-FIRED UNIT BURNS THAT FIRES GAS A FEW MONTHS DURING THE YEAR. THE COAL GENERALLY EMPLOYED FOR THIS UNIT is WYOMING ROSEBUD,
WHICH HAS AN AVERAGE GROSS HEATING VALUE OF 10,780 BUT/LB WITH ASH CONTENT IN THE 6 TO 7 PERCENT RANGE AND SULFUR CONTENT LESS THAN 1 PERCENT.
THE FGD SYSTEM BEING TESTED AT THIS STATION IS AN EXPERIMENTAL UNIT ORIGINALLY DESIGNED BY UNIVERSAL OIL PRODUCTS FOR PARTICULATE REMOVAL ONLY.
THIS TCA UNIT CONSISTS OF TWO PARALLEL MODULES WITH A COMBINED CAPABILITY OF TREATING APPROXIMATELY 50 PERCENT OF THE TOTAL FLUE GAS LOAD OR THE
EQUIVALENT OF APPROXIMATELY 100 MW GENERATING CAPACITY (50 MW PER MODULE). THIS SYSTEM WAS COMPLETED AND OPERATIONAL IN 1971 AND RAN UNTIL OCTOBER
1974. PARTICULATE REMOVAL EFFICIENCY WAS MEASURED AT 95 PERCENT, S02 REMOVAL EFFICIENCY WAS 45 PERCENT, AND AVAILABILITY WAS APPROXIMATELY 70 PERCENT.
FREQUENT SCRUBBER OUTAGES WERE CAUSED PRIMARILY BY SUPERSATURATED CALCIUM SULFATE IN THE SCRUBBING LIQUOR. TO MINIMIZE CLEANOUTS AND RECTIFY THE
SCALING PROBLEM, A pH CONTROL PROGRAM WAS IMPLEMENTED FOR ONE OF THE SCRUBBING MODULES WITH ADDITION OF LIMESTONE TO THE SCRUBBING LIQUOR. THIS
MODIFICATION WAS EXPECTED TO MINIMIZE SCALING. DECREASE SCRUBBER OUTAGES FOR CLEANOUTS, AND INCREASE AVAILABILITY. THE EXPECTED RESULTS DID NOT
MATERIALIZE. SCALE BUILDUP CONTINUED AND AVAILABILITY DECREASED. TESTS DURING THE pH CONTROL PROGRAM SHOWED PARTICULATE REMOVAL EFFICIENCY AT 95
PERCENT. S02 REMOVAL EFFICIENCY INCREASED TO 85 PERCENT, AND AVAILABILITY DROPPED TO 70 PERCENT. THE UNSTABILIZED SLUDGE GENERATED DURING THIS
OPERATION WAS PUMPED TO A LINED POND. THE OPERATIONAL DATA GENERATED FROM THE LIMESTONE MODIFICATION PROGRAM ARE PRELIMINARY, BASED ON A 4.5-MONTH
TESTING PROGRAM.
PEDCo- ENVIRONMENTAL
123
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VALMONT NO. 5
Month
Sep. 75
Oct. 7.5
Nov. 75
Dec. 75
Jan. 76
Feb. 76
Mar. 76
Apr. 76
Boiler
0
0
0
0
0
0
Operating Hours
FGD System
0
0
0
0
0
0
0
0
FGD System
Qperablllty (X)
0
0
0
0
0
0
0
0
Comments
This facility has been Inactive since September 1, 1976, because of a turbine gen-
erator failure. The unit 1s scheduled to go on line again In December 1975.
This unit Is still Inactive because of a boiler overhaul. The scrubber/absorber
train Is available and will be coupled Into the system when the boiler goes back
on-line.
The boiler overhaul has been completed. The unit Is available in the partlculate
removal mode only. The utility is suspending resumption of the limestone modification
operation for an Indefinite period.
The experimental limestone scrubbing program was Inactive during the report period.
Resumption of the program Is considered Indefinite at the present time.
PEDCo-ENVIRONMENTAL
124
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGU VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYi
PARTICULATES
S02
90
RICKENBACKER AFB
RICKENBACKER
COLMBUS OHIO
20 MW
COAL 3.6 PERCENT SULFUR
RESEARCH COTTRELL
LIME SCRUBBING
RETROFIT
3/76
OPERATIONAL
99 PERCENT
90 PERCENT
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
THE SYSTEM SUPPLIER REPORTED THAT THE FGO SYSTEM BECAME OPERATIONAL ON
MARCH 11. 1976. SYSTEM OPERABILITY MAS REPORTED TO BE 97 PERCENT FOR THE
DURATION OF THE MONTH. THE SYSTEM WAS BROUGHT DOWN ON APRIL It BECAUSE
OF PUMP PROBLEMS. A 1.5 WEEK OUTAGE RESULTED BECAUSE OF A SPARE PART
SHIPMENT. S02 INLET CONCENTRATIONS HAVE BEEN AT THE 1800 PPM LEVEL. LIME
UTILIZATION HAS BEEN GOOD. THE S02 REMOVAL EFFICIENCY WAS REPORTED TO BE
AS HIGH AS 96 PERCENT.
PEDCo-ENVIRONMENTAL
125
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS 05/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY!
PARTICIPATES
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
98
TENNESSEE VALLEY AUTHORITY
SHAWNEE NO.IDA
PADUCAH KENTUCKY
10 MM
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
RETROFIT
*/72
OPERATIONAL
KEFER 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.
126
PEDCo- ENVIRONMENTAL
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS 05/76
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
99
TENNESSEE VALLEY AUTHORITY
SHAUNEE N0.10B
PAOUCAH KENTUCKY
10 MW
COAL 2.9 PERCENT SULFUR
CHEMICO
LIME/LIMESTONE SCRUBBING
RETROFIT
«»/72
OPERATIONAL
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
REFEK TO BACKGKOUND 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 DIRECTORt AND REPORT WRITER.
PEDCo-ENVIRONMENTAL
127
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BACKGROUND INFORMATION
ON
SHAWNEE NOS. IDA, 10B. AND IOC
IN JUNE 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE LIME AND LIMESTONE SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND PARTICULATES FROM
COAL-FIRED BOILER FLUE GASES. THE PROGRAM WAS CARRIED OUT IN A TEST FACILITY INCORPORATED INTO THE FLUE GAS DUCTWORK OF UNIT NO. 10, A COAL-FIRED BOILER
AT THE TVA SHAWNEE POWER STATION. PAOUCAH, KENTUCKY. TVA IS THE CONSTRUCTOR AND FACILITY OPERATOR; BECHTEL CORP. IS THE MAJOR CONTRACTOR. TEST
DIRECTOR. AND REPORT WRITER.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE. TREATING PART OF THE FLUE GAS FROM THE BOILER. EACH SCRUBBER
TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30.000 ACFM OR THE EQUIVALENT OF APPROXIMATELY 10 MW OF POWER PLANT GENERATING CAPACITY.
THREE PARALLEL WET SCRUBBER SYSTEMS WERE SELECTED FOR THE TEST PROJECT: 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 UNDEUl.A WIDE RANGE OF FLOW CONDITIONS. THE TCA UNIT, MANUFACTURED BY UNIVERSAL OIL PRODUCTS, INCORPORATES
A FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT ARE FREE TO MOVE BETWEEN RETURNING GRIDS. THE MARBLE-BED ABSORBER. SUPPLIED BY COMBUSTION
ENGINEERING CO., 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 INITIATED A 3-YEAR ADVANCED TEST PROGRAM AT THE SHAWNEE FACILITY WITH THESE MAJOR GOALS: (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) LONG-TERM RELIABILITY TESTING ON PROMISING PROCESS AND EQUIPMENT DESIGN
VARIATIONS.
THE TWO PARALLEL SCRUBBING SYSTEMS OPERATING DURING THE ADVANCED PROGRAM ARE THE VENTURI/SPRAY TOWER SYSTEM AND THE TCA UNIT. OPERATION OF THE
MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
EACH OF THE SCRUBBING SYSTEMS CONTAINS ITS OWN SLURRY HANDLING FACILITIES AND CAN TREAT APPROXIMATELY 30.000 ACFM OF GAS AT 300°F CONTAINING
1800 TO 4000 PPM OF SOg AND 2 TO 4 GRAINS/SCF OF PARTICULATES. BOILER NO. 1 NORMALLY BURNS A HIGH-SULFUR BITUMINOUS COAL.
FROM JUNE 1974 TO JANUARY. 1976, 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 CONTAINED APPROXIMATELY 40 TO 50 WEIGHT PERCENT FLY ASH BECAUSE OF RELATIVELY HIGH GAS INLET
PARTICULATE LOADING. THIS TESTING PROGRAM IS SCHEDULED TO RUN TILL JUNE 1977.
PEDCo- ENVIRONMENTAL
•
128
-------
SHAHNEE NOS. 10A AND 10B
FGD.System Operating Hours
Test Run Period wK TW Comnents
Sep. 75 This experimental EPA-funded operation Is proceeding with the test program. Two absorber
Oct. 75 modules are currently operational (10 MW each); the marble-bed absorber Is still Inoperative
(since July 1973). Current experiments are related to mist eliminator section.
Nov. 75 Recent testing at Shawnee has shown that the chevron mist eliminators In both the spray
Dec. 75 tower and the TCA can be kept free of solids buildup at high alkali utilization (greater
than 90 percent) using only intermittent washing with available raw water. This high
utilization is normally achieved with lime; it has been achieved with limestone at reduced
scrubber Inlet slurry pH (about 5.2) and with three effluent tanks In series to simulate a
plug-flow reactor.
Testing Is continuing to determine the effects of process variables on mist eliminator per-
formance and on limestone utilization. Future plans include: (1) factorial testing
with lime and limestone to determine the effects of process variables on S02 removal and
(2) testing the oxidation of sludge to gypsum in the venturi/spray tower system using air
sparging of an acidified slurry bleed stream.
Jan. 75 The advanced test program is continuing. Highlights of this prgram are as follows:
0 Evaluate scrubber operabillty during variable load operation.
0 Continue long-term reliability testing.
0 Investigate methods for improving waste solids separation.
0 Continue sludge oxidation and sludge fixation study programs.
0 Evaluate system performance at reduced fly ash loadings.
• Determine the practical upper limits of S02 removal efficiency.
0 Evaluate addition of magnesium ion to the scrubbing slurry.
PEDCo- ENVIRONMENTAL
129
-------
SHAWNEE NOS. 10A AND 10B (Continued)
FGD System Operating Hours
Test Run Period ~K£ C-W' Consents
• Characterize all stack gas emission components.
• Evaluate materials of construction of all scrubber and plant-related components.
0 Develop a computer program for design and cost analysis of full-scale lime/limestone
systems.
Mar' 76 Bechtel reported that the factorial test program, evaluating the performance of the lime/
Apr< 76 limestone scrubbing systems with and without magnesium addition, has been completed. Cur-
rently, testing Is proceeding on the evaluation of system performance as a function of low
residence times (1.5 to 5.0 minutes) In the recycle tanks. In addition, a fly ash-free
duct Is being Installed at the test facility, thus enabling evaluation of system per-
formance In the absence of fly ash.
PEDCo-ENVIRONMENTAL
130
-------
Table 4
NUMBER AND TOTAL MW OF F6D SYSTEMS
131
-------
TABLE t
NUMBER AND TOTAL MU OF FGO SYSTEMS
STATUS
OPERATIONAL
UNDER CONSTRUCTION
PLANNING
CONTRACT AWARDED
NO. OF
UNITS
27
19
16
LETTER OF INTENT 6
REQUESTING/EVALUATING BIOS 5
CONSIDERING ONLY FGD SYSTEMS 31
TOTAL . 108
MU
7562.
73«H».
3356.
2467.
1S003.
41275.
133
PEDCo- ENVIRONMENTAL
-------
Table 5
SUMMARY OF FGD SYSTEMS BY COMPANY
135
-------
TABLE 5
SUMMARY OF FGD SYSTEMS BY COMPANY
UTILITY
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTEM
ARIZONA ELECTRIC POWER COOP
ARIZONA PUBLIC SERVICE
BASIN ELECTRIC POWER COOP
BRAZOS ELECTRIC POWER COOP
CENTRAL ILLINOIS LIGHT CO.
CENTRAL ILLINOIS PUBLIC SERV
CINCINNATI GAS & ELECTRIC CO.
COLUrBUS X SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
DETROIT EDISON
DUQUESNE LIGHT
GENERAL MOTORS
GULF POWER CO.
INDIANAPOLIS POWER & LIGHT CO.
KANSAS CITY POWER & LIGHT
KANSAS POWER & LIGHT
KENTUCKY UTILITIES
KEY WEST'UTILITY BOARD
LOUISVILLE GAS & ELECTRIC
MINNHOTA POWER COOPERATIVE ,
MONTANA POWER CO. j
NEVADA POWER
NEW ENGLAND ELEC SYSTEM
NORTHERN INDIANA PUB SERVICE
NORTHERN STATES POWER CO.
PENNSYLVANIA POWER CO.
PHILADELPHIA ELECTRIC CO.
PUBLIC SERVICE CO OF COLORADO
PUBLIC SERVICE CO OF NEW MEX.
PUBLIC SERVICE INDIANA
RICKENBACKLR AFB
S. CAROLINA PUR SERV AUTHORITY
S. MISSISSIPPI ELEC PWR ASSOC
SOUTHERN CALIFORNIA EDISON
SOUTHERN ILLINOIS POWER COOP
SPRINGFIELD CITY UTILITIES
TENNESSEE VALLEY AUTHORITY
TEXAS UTILITIES Co.
UNITED POWER ASSOCIATION
UTAH POWER ft LIGHT CO.
TOTAL
OPERATIONAL
CONSTRUCTION
CONTRACT
AWARDED
NO.
2
2
2
5
5
1
3
1
2
4
2
1
2
1
3
'-•I
a
4
1
1
a
i
4
10
i
3
2
3
4
1
4
2
1
1
2
2
1
1
3
4
2
2
MW
450.
1250.
405.
1675.
2550.
too.
857.
600.
1100.
1550.
592.
180.
920.
32.
63.
530.
1060.
1885.
64.
37.
2213.
450.
2120.
3000.
650.
705.
1360.
2505.
846.
50.
1715.
1300.
20.
140.
360.
1410.
184.
200.
570.
2379.
1090.
815.
NO.
0
0
0
2
0
0
0
0
0
0
1
0
2
1
3
0
3
2
1
1
1
0
1
2
0
0
1
1
1
1
0
0
1
0
0
0
0
0
2
0
0
0
MW
0.
' 0.
0.
275.
0.
0.
0.
0.
0.
0.
167.
0.
920.
• 32.
63.
0.
1060.
525.
64.
37.
65.
0.
360.
250.
0.
0.
680.
835.
120.
50.
0.
0.
20.
0.
0.
0.
0.
0.
20.
0.
0.
0.
NO.
0
0
0
1
0
0
1
0
0
1
0
1
0
0
0
1
0
0
0
0
3
1
1
1
0
1
1
1
0
0
0
0
0
0
0
0
0
1
1
2
0
1
MW
0.
0.
0.
250.
0.
0.
100.
0.
0.
400.
0.
180.
0.
0.
0.
530.
0.
0.
0.
0.
7R6.
450.
360.
125.
0.
115.
6AO.
835.
0.
0.
0.
0.
0.
0.
0.
0.
0.
200.
550.
1586.
0.
HIS.
NO.
2
2
0
0
0
1
0
0
0
1
1
0
0
0
0
0
0
2
0
0
1
0
0
0
0
0
0
1
0
0
2
0
0
1
2 :
0 *
1
0
0
0
0
1
MW
450,
1250.
0.
0.
0.
400.
0.
0.
0.
400.
425.
0.
0.
0.
0.
0.
0.
1360.
0.
0.
425.
0.
0.
0.
0.
0.
0.
835.
0.
0.
715.
0.
0.
140.
360.
0.
184.
0.
0.
0.
0.
400.
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
0
0
0
1
0
0
0
0
1
0
2
0
0
0
0
0
0
0
0
2
0
0
MW
0.
0.
405.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
125.
0.
0.
0.
0.
240.
0.
1000.
0.
0.
0.
0.
0.
0.
0.
0.
793.
0.
0.
EVAL.
NO.
0
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
0
0
0
0
0
0
0
0
0
0
0
0
0
2
0
BIOS
MW
0.
0.
0.
0.
0.
0.
0.
600.
500.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
277.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
1090.
0.
CONSIDERING
FGO
NO.
0
n
0
9
R
0
9
0
1
2
0
0
0
0
0
n
0
0
0
0
9
0
a
6
i
9
n
0
9
0
0
9
0
0
0
2
0
0
0
0
0
0
SYSTEMS
MW
0.
0.
0.
1350.
2550.
0.
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.
1410.
0.
0.
0.
0.
0.
0.
TOTALS
108 40482. 27 554S. 19 7562. 16 7344. 6 2563.
2467. 31 15003.
PEDCo-ENVIRONMENTAL
137
-------
Table 6
SUMMARY OF FGD SYSTEMS BY VENDOR
139
-------
TABLE 6
SUMMARY OF FGD SYSTEMS BY VENDOR
TOTAL
MANUFACTURER/PROCESS
AOL/COMBUSTION EQUIP ASSOCIAiE
DOUBLE ALKALI
TOTAL, ADL/COMBUSTION EQUIP ASS
AMERICAN AIR FILTER
LIME SCRUBBING
TOTAL, AMERICAN AlR FILTER
BABCOCK & WILCOX
LIMESTONE SCRUBBING
TOTAL* BABCOCK & WILCOX
CHEMICO
LIME SCRUBBING
LIME/LIMESTONE SCRUBBING
TOTAL, CHEMICO
CHIYOOA INTERNATIONAL
THOROUGHBRED 101
TOTAL, CHIYOOA INTERNATIONAL
COMBUSTION ENGINEERING
LIME SCRUBBING
LIMESTONE INJECTION 8MET SCRUB
LIMESTONE SCRUBBING
TOTAL, COMBUSTION ENGINEERING
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
TOTAL, COMBUSTION EQUIP. ASSOCI
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
TOTAL, DAVY POWERGAS/ALLIEO CHE
FOSTER WHEELER
ACTIVATED CARBON
TOTAL, FOSTER WHEELER
KOCH
DOUBLE ALKALI
TOTAL* KOCH
NO.
1
1
3
3
2
2
5
1
6
1
1
2
H
2
8
3
3
1
1
1
1
1
1
MU
20.
20.
667.
667.
987.
987.
3005.
10.
4fll5.
*
23.
23.
2>,8.
765.
1360.
2373.
375.
375.
115.
115.
20.
20.
32.
32.
OPERATIONAL CONSTRUCTION
NO.
1
1
1
1
2
2
3
1
t»
1
1
1
it
1
6
2
2
0
0
1
1
1
1
MU
20.
20.
61.
6H.
987.
987.
1755.
10.
1765.
23.
23.
65.
765.
680.
1510.
250.
250.
0.
0.
20.
20.
32.
92.
NO.
• o
0
2
2
0
0
2
0
2
0
0
1
0
1
2
1
1
1
1
0
0
0
0
MU
0.
0.
603.
603.
0.
0.
1250.
0.
1250.
0.
0.
183.
0.
680.
863.
125.
125.
115.
115.
0.
0.
0.
0.
141
PEDCo-ENVIRONMENTAL
-------
TABLE 6
SUMMARY OF FGO SYSTEMS BY VENDOR
TOTAL
MANUFACTURER/PROCESS
COMBUSTION EQUIP. ASSOCIATES
LIME/ALKALINE FLYASH SCRUBBING
TOTAL. COMBUSTION EQUIP. ASSOCZA
PEABODY ENGINEERING
LIMESTONE SCKUDBlNG
TOTAL, PEAPODY ENGINEERING
RESEARCH COTTRELL
LIME SCRUBBING
LIMESTONE SCRUBBING
TOTAL, RESEARCH COTTRELL
RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
TOTAL, RILEY STOKER/ENVIRONEERI
SCE
LIME SCRUBBING
TOTAL, SCE
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
TOTAL, TENNESSEE VALLEY AUTHOR!
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
TOTAL, UNITED ENGINEERS
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
LIME/LlhESTUUE SCRUBBING
LIMESTONE SCRUBBING
TOTAL, UNIVERSAL OIL PRODUCTS
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
TOTAL, UOP / PUB SERVICE OF COL
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
TOTALi ZURN AIR SYSTEMS
NO.
3
9
1
1
1
4
5
1
1
1
1
1
1
1
1
1
1
2
4
1
1
1
1
MW
1170.
1170.
180.
160.
20.
1951.
1971.
100.
1-4)0.
160.
160.
550.
550.
1*0.
120.
too.
10.
730.
1140.
50.
50.
37.
37.
OPERATIONAL CONSTRUCTION
NO.
1
1
0
0
1
1
2
0
0
1
1
0
0
1
1
0
1
0
1
1
1
1
1
MW
360.
360.
0.
0.
20.
115.
135.
0.
0.
160.
160.
0.
0.
120.
120.
0.
10.
0.
10.
50.
50.
37.
37.
NO.
'. 2
2
1
1
0
3
3
1
1
0
0
1
1
0
0
1
0
2
3
0
0
0
0
MW
•
810.
810.
180.
180.
0.
1836.
1636.
100.
100.
0.
0.
550.
550.
0.
0.
too.
0.
730.
1130.
0.
0.
0.
0.
46 13105.
27 5543.
19 7562.
PEDCo-ENVIRONMENTAL
142
-------
Table 7
SUMMARY OF NEW AND RETROFIT FGD SYSTEMS BY PROCESS
143
-------
TABLE 7
SUMMARY OF NEW AND RETROFIT FGD SYSTEMS BY PROCESS
MW CAPACITYCNO. OF PLANTS)
PROCESS
LIME SCRUBBING
LIME/ALKALINE FLYASH SCRUBBING
(PROCESS NOT SELECTED)
LIME/LIMESTONE
(PROCESS NOT SELECTED)
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
WELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/LIMESTONE X OF TOTAL MW
NEW OR OPERATIONAL
RETROFIT
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
NO.
1
6
1
0
0
0
0
2
4
6
'4*5:
0
1
0
'• 2
0
1
0
0
0
0
0
2
0
1
0
0
0
0
6.
21.
100
81
MW
635
1229
360
0
0
0
0
20
1937
697
3132.
1946.
0
20
0
52
0
120
0
0
0
0
0
250
0
23
0
0
0
0
3132.
CONSTRUCTION CONTRACT
AWARDED
NO.
3
3
1
1
0
0
0
0
7
2
11.
6.
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
1
12.
7.
MW
1660
776
450
360
0
0
0
0
3346
730
5456.
1866.
0
0
0
0
0
0
0
0
0
0
125
0
0
0
0
0
0
115
5561.
1981.
NO.
5
0
0
0
0
0
0
0
10
1
is.
1.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
16.
2.
98
94
1/IC
MW
2475
0
0
0
0
0
0
0
3729
425
6204.
425.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
375
340
6579.
769.
94
56
LETTER OF
INTENT
NO.
0
0
0
0
0
0
0
0
4
0
4.
0.
0
0
0
0
0
1
0
0
0
0
1
0
0
0
2
0
0
0
7.
1.
MW
0
0
0
0
0
0
0
0
1196
0
1198.
0.
0
0
0
0
0
240
0
0
0
0
125
0
0
0
1000
0
0
0
2323.
240.
52
0^
REQUESTING/ CONSIOERINfi
EVAL. BIDS FGO SYSTEM
NO.
0
0
0
0
2
0
0
0
0
0
2.
0.
.0
0
0
0
0
0
2
1
0
0
0
0
0
0
0
0
0
0
i!
MW
0
0
0
0
1090
0
0
0
0
0
1090.
0.
0
0
0
0
0
0
1100
277
0
0
0
0
0
0
0
0
0
0
2190.
277.
50
0
NO.
0
2
0
0
0
0
• 0
2
1
0
1.
4.
0
0
0
0
0
2
18
5
0
1
0
0
o
0
0
0
0
0
19.
12.
MW
0
660
0
0
0
0
o
1410
400
0
400.
2070.
0
0
0
0
o
486
9100
2297
0
650
0
0
0
0
0
0
0
0
9500.
5503.
4
38
• TOTAL NO.
OF PLANTS
NO. MW
9 4970
11 2665
2 610
1 360
2 1090
0 0
0 0
4 1430
26 10610
9 1852
39. 17460.
25. . 6307.
0 0
1 20
0 0
2 52
0 0
4 846
20 10200
6 2574
0 0
1 650
2 250
2 250
0 0
1 23
2 1000
0 0
1 375
2 455
64. 29305.
44. 11177.
60
56
-------
Table 8
SUMMARY OF OPERATING FGD SYSTEMS BY PROCESS AND GENERATING UNITS
147
-------
TABLE B
SUMMARY OF OPERATING FGD SYSTEMS BY
PROCESS AND GENERATING UNITS AS OF 05/76
PROCESS/GENERATING UNITS FGO/MW STARTUP EXPERIENCED.)
ACTIVATED CARBON
SCHOLZ NO. 2A 20 2-76 3
20. 3
DOUBLE ALKALI
CHEVROLET PARMA 123*4 32 3-7«f 26
SCHOLZ NO. 1A 20 2-75 15
52. " 41
LIME SCRUBBING '-}.
BRUCE MANSFIELD NO* 1 835 4-76 1
ELRAMA . 510 10-75 7
FOUR CORNERS NO. 5A -160 2-76 3
GREEN RIVER UNITS 1 AND 2 64 9-75 8
PADDYS RUN NO 6 65 4-73 37
PHILLIPS 410 7-73 34
RICKENBACKER 20 3-76 2
2064. 92
LIME/ALKALINE FLYASH SCRUBBING
COLSTRIP NO 1 . 360 10-75 7
360. 7
LIME/LIMESTONE SCRUBBING
SHAWNEE N0.10A 10 4-72 49
SHAWNEE N0.10B 10 4-72 49
20. 96
149
PEDCo-ENVIRONMENUl
-------
TABLE 6
SUMMARY OF OPERATING FGD SYSTEMS BY
PROCESS AND GENERATING UNITS AS OF 05/76
PROCESS/GENERATING UNITS FGO/MW STARTUP EXPERIENCED.)
LIMESTONE SCRUBBING
HAWTHORN NO 3 140 11-72 42
HAWTHORN NO 4 100 6-72 45
LAWRENCE NO 4 125 12-68 69
LAWRENCE NO- 5 400 11-71 54
CHOLLA NO 1 115 10-73 31
LA CYGNE NO 1 620 2-73 39
SHERBURNE NO 1 660 3-76 2
STOCK ISLAND PLANT 37 10-72 43
VALMONT NO. 5 50 10-74 19
WILL COUNTY NO 1 167 2-72 51
2634. 415
MAGNESIUM OXIDE SCRUBBING
EDOYSTONE NO 1A 120 9-75 6
120. 6
SODIUM CARBONATE SCRUBBING
REID GARDNER NO 1 125 4-74 25
REID GARDNER NO 2 125 4-74 25
250. 50
THOROUGHBRED 101
SCHOLZ NOS. IB I 2B 23 3-75 14
• ••»••• ••»»
23. 14
PEDCo- ENVIRONMENTAL'
150
-------
Table 9
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS
151
-------
TABLE 9
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS AS OF 05/76
PROCESS/GENERATING UNIT "SLUDGE" —SLUDGE— —POND— POND--
STABILIZED UNSTABILIZED LINED UNLZNEO
DOUBLE ALKALI
CHEVROLET PARMA 1234*
SCHOLZ NO. 1A
TOTAL
32 32
20 20
0. 52. 20. 32.
LIME SCRUBBING
BRUCE MANSFIELD NO. 1 835 635
ELRAMA 510 510
GREEN RIVER UNITS i AND 2 6* '*
PADDYS RUN NO 6 *5 65
PHILLIPS
TOTAL 1619. 65, 0. 188*.
' LIME/ALKALINE FLYASH SCRUBBING
COLSTRIP NO 1 360 360
TOTAL 0. 360. 0. 360.
LIMESTONE SCRUBBING
HAWTHORN NO 3 1"*0 1"»0
HAWTHORN NO "» 100 100
LAWRENCE NO t 125 125
LAWRENCE NO 5 *»00 "*00
CHOLLA NO 1 115 115
LA CYGNE NO 1 820 820
SHERBURNL NO 1 6°0
STOCK ISLAND PLANT 37
VALMONT NO. 5 50 50
WILL COUNTY NO 1 167 167
TOTAL 167. 1750. 217. 2*17.
SODIUM CARBONATE SCRUBBING
PEDCo-ENVIRONMENTAL
153
-------
TABLE 9
SUMMARY OF SLUDGE DISPOSAL PRACTICES FOR OPERATIONAL F60 SYSTEMS AS OF 05/76
PROCESS/GENERATING UNIT
—SLUDGE-
STABILIZED
—SLUDGE—
UNSTABILIZED
—POND-
LINED
—POND—
UNLINED
REID GARDNER NO 1
REID GARDNER NO 2
TOTAL
125
125
250.
129
125
250 e
THOROUGHBRED 101
SCHOLZ NOS. IB * 2B
TOTAL
23
29.
23
23.
0.
PEDCo- ENVIRONMENTAL
154
-------
Table 10
SUMMARY OF F6D SYSTEMS BY PROCESS AND REGULATORY CLASS
155
-------
TABLC 10
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
MM CAPACXTYtNO. OF PLANTS)
PROCESS
Lint SCRUBBING
LIME/ALKALINE FLYASH SCRUBBING
(PROCESS NOT SELECTED)
LIME/LIMESTONE
(PROCESS NOT SELECTED)
LIME/LIMESTONE SCRUBBING
(PROCESS NOT SELECTED)
LIMESTONE SCRUBBING
SUBTOTAL - LIME/LIMESTONE
REGULATORY OPERATIONAL CONSTRUCTION
CLASS
NO. MW NO. MU
A o o 2 640
B 4 1915 2 1235
C 2 129 2 361
E
:NG A
B
C
o
E
A
B
C
0
E
A
B
C
0
E
A
B
C
0
E
A
8
C
D
E
o
1
0
o
1
o
0
o
o
o
o
:,V.O
"o
o
2
0
0
0
1*
3
2
1
0.
a.
a.
2.
2.
0
20
0
0
360
0
0
0
0
0
0
0
o
0
20
0
0
0
1035
1024
525
50
0.
2950.
1533.
525.
70.
0
0
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
5
2
1
0
1
a.
5.
3.
0.
1.
0
0
360
450
0
0
0
0
0
0
0
0
0
0
0
0
0
2416
930
550
0
180
3616.
2615.
911.
0.
160.
CONTRACT
AWARDED
NO. MW
4 2075
1 400
0 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
6
3
1
0
1
10.
4.
1.
0.
1.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1134
2195
425
0
400
3209.
2595.
425.
0.
400.
LETTER OF REQUESTING/
INTENT EVAL. BIDS
NO. MW NO. MW
00 00
00 00
00 00
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2
2
0
0
0
2.
2.
0.
0.
Q.
0
0
0
0
0
0
0
0
0
0
0
0
C
0
0
0
0
793
405
0
0
0
793.
405.
0.
0.
0.
0
0
0
0
0
0
0
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2.
0.
0.
0.
0.
0
0
0
0
0
0
0
1090
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1090.
0.
0.
0.
0.
CONSIDERING
FGO SYSTEM
NO. MW
0 0
0 0
2 660
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2
1
0
0
0
0
1.
0.
2.
0.
2.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1410
400
0
0
0
0
400.
0.
660.
0.
1410.
TOTAL NO.
OF PLANTS
NO. MU
6 2915
7 3550
6 1150
0
1
1
1
1
0
0
2
0
0
0
0
0
0
2
0
2
14
11
5
2
3
23.
19.
14.
2.
6.
u
20
360
450
360
0
0
1090
0
0
0
0
0
0
20
0
1410
4743
4565
1999
525
630
9106.
8565.
3529.
525.
2060.
B* BOILER SUBJECTCTODSTATEESTANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
?! BOILER SUBJECT TO STATE STANDARD THAT IS E8UAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
PEDCo- ENVIRONMENTAL
157
-------
TABLE 10
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
HW CAPACITY(NO. OF PLANTSI
PROCESS
ACTIVATED CARBON
DOUBLE ALKALI
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
REGENERABLE NOT SELECTED
REGULATORY OPERATIONAL
CLASS
A
B
C
D
E
A
B
C
D
E
A
B
C
0
E
A
B
C
D
E
A
B
C
D
E
NOi
0
0
1
0
0
0
1
1
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
MU
0
0
20
0
0
0
32
20
0
0
0
120
0
0
0
0
0
0
0
0
0
0
0
0
0
NO.
0
0
0
0
0
0
0
0
0
0
0
0
c.
0
0
0
0
0
0
0
0
0
0
0
0
flON CONTRACT
AWARDED
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
NO.
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
MU
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
LETTER OF REQUESTING/
INTENT
NO.
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
MW
0
0
0
0
0
0
0
0
0
0
0
240
0
0
0
0
0
0
0
0
0
0
0
0
0
EVAL. BIOS
NO.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
1
1
0
0
0
0
0
0
MW
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
600
0
277
500
0
0
0
0
0
0
CONSIDERING
FGD SYSTEM
NO.
0
0
0
0
0
0
0
0
0
0
0
0
2
0
0
5
15
3
0
0
0
0
1
0
0
MW
0
0
0
0
0
0
0
0
0
0
0
0
486
0
0
3300
7150
9«f7
0
0
0
0
650
0
0
• TOTAL NO.
OF PLANTS
NO.
0
0
1
0
0
0
1
1
0
0
0
2
2
0
0
6
15
<*
1
0
0
0
1
0
0
MW
0
0
20
0
0
0
32
20
0
0
0
360
486
0
0
3900
7150
1224
500
0
0
0
650
0
0
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
158
PEDCo-ENVIRONMENTAL-
-------
TABLE 10
SUMMARY OF FGD SYSTEMS BY PROCESS AND REGULATORY CLASS
MU CAPACITYINO. OF PLANTS)
PROCESS
SODIUM CARBONATE SCRUBBING
THOROUGHBRED 101
WELLMAN LORD
WELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/STONE » OF TOTAL MW
REGULATORY OPERATIONAL
CLASS
NO. MU
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
0
2
0
0
0
0
0
1
0
0
0
0
0
0
:JV. °
'0
0
0
0
0
0
12
11
2
2
0
250
0
0
0
0
0
23
0
0
0
0
0
0
0
0
0
0
0
0
0.
. 3352.
. 1596.
525.
70.
0
68
96
100
100
CONSTRUCTION
NO. MU
0 0
1 125
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
1 115
0 0
0 0
8. 3616.
6. 2740.
4. 1026.
0. 0.
1. 180.
100
95
69
0
100
CONTRACT
AWARDED
NO.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2
0
0
0
10.
6.
1.
0.
1.
MU
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
715
0
0
0
3209.
3310.
425.
0.
400.
100
78
100
0
100
LETTER OF REQUESTING/
INTENT EVAL. BIDS
NO.
0
1
0
0
0
0
0
0
0
0
0
2
0
0
0
0
0
0
0
0
2.
6.
0.
0.
0.
e
MU
0
125
0
0
0
0
0
0
0
0
0
1000
0
0
0
0
0
0
0
0
793.
1770.
0.
0.
0.
100
23
0
0
0
NO.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3.
0.
1.
1.
0.
MW
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1690.
0.
277.
500.
0.
64
0
0
0
0
CONSIDERING
FGO SYSTEM
NO.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
6.
15.
6.
0.
2.
MU
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3700.
7150.
2743.
0.
1410.
11
0
24
0
100
TOTAL NO.
OF PLANTS
NO.
0
4
0
0
0
0
0
1
0
0
0
2
0
0
0
0
2
1
0
0
29.
45.
25.
3.
6.
MU
0
500
0
0
0
0
0
23
0
0
0
1000
0
0
0
0
715
115
0
0
13008,
18322,
6067,
1025,
2060,
70
47
56
51
100
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT To STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
lea
PEDCo-ENVIRONMENTAL
-------
Table 11
SUMMARY OF OPERATIONAL FGD SYSTEMS
161
-------
TABLE 11
SUMMARY OF OPERATIONAL FGD SYSTEMS AS OF 05/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD PROCESS/VENDOR
RETROFIT UNIT (MM)
FUEL CHARACTERISTICS
.HO/YR
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 5A
COMMONWEALTH EDISON
WILL COUNTY NO 1
DUQUESNE LIGHT
PHILLIPS
OUQUESNE LIGHT
ELRAMA
GENERAL MOTORS
CHEVROLET PARMA 1 2 3 * "»
GULF POWER CO.
SCHOLZ NO. 1A
GULF POWER CO.
SCHOLZ NO. 2A
GULF POWER CO.
SCHOLZ NOS. IB ft 28
KANSAS CITY POWER ft LIGHT
LA CYGNE NO 1
KANSAS CITY POWER ft LIGHT
HAWTHORN NO t
KANSAS CITY POWER ft LIGHT
HAWTHORN NO 3
KANSAS.POWER ft LIGHT
LAWRENCE NO t
KANSAS POWER ft LIGHT
LAWRENCE NO 5
KENTUCKY UTILITIES
GREEN RIVER UNITS 1 AND 2
R
R
R
R
R
R
*;
R
R
N
R
R
R
N
R
115
160
167
mo
510
32
20
20
23
820
100
110
125
400
6*
RESEARCH COTTRELL
LIMESTONE SCRUBBING
SCE
LIME SCRUBBING
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
CHEMICO
LIME SCRUBBING
KOCH
DOUBLE ALKALI
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI
FOSTER WHEELER
ACTIVATED CARBON
CHIYODA INTERNATIONAL
THOROUGHBRED 101
BABCOCK ft WILCOX
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE INJECTION «WET SCRUB
COMBUSTION ENGINEERING
LIMESTONE INJECTION &WET SCRUB
COMBUSTION ENGINEERING
LIMESTONE INJECTION ftUET«SCRUB
»
COMBUSTION ENGINEERING
LIMESTONE INJECTION ftWCT SCRUB
AMERICAN AIR FILTER
LIME SCRUBBING
COAL O.Ht-1 PERCENT SuLFuR 10/73
COALi 0.7 PERCENT SULFUR
2/76
COAL - 9463 BTUt 2.IK SULFUR 2/72
COAL 1.0- 2.8 PERCENT SULFUR 7/73
COAL i.o • 2.a PERCENT SULFUR 10/75
COAL 2.5 PERCENT SULFUR
COAL 3.0 PERCENT SULFUR
COAL 3.0 PERCENT SULFUR
3/74
2/75
2/76
COAL 5.0 PERCENT SULFUR (MAX) 3/75
COAL 5*0 PERCENT SULFUR
2/73
COAL 0.6- s.o PERCENT SULFUR 8/72
COAL 0.6- s.o PERCENT SULFUR 11/72
COAL 0.5 PERCENT SULFUR
COAL 0.5 PERCENT SULFUR
COAL 3.8 PERCENT SULFUR
12/68
11/71
9/75
PEDCo-ENVIRONMENTAL
163
-------
TABLE 11
SUMMARY OF OPERATIONAL FGO SYSTEMS AS OF 05/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGO PROCESS/VENDOR
RETROFIT UNIT (MW)
FUEL CHARACTERISTICS
MO/YR
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
LOUISVILLE GAS ft ELECTRIC
PADDYS RUN NO 6
MONTANA POWER CO.
COLSTRIP NO 1
NEVADA POWER
REID GARDNER NO 2
NEVADA POWER
REID GARDNER NO 1
NORTHERN STATES POWER CO.
SHERE3URNE NO 1
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NQ. 1
PHILADELPHIA ELECTRIC CO.
EODYSTONE NO 1A
PUOLIC SERVICE CO OF COLORADO
VALMONT NO. 5
RICKENBACKER AFB
RICKENBACKER
TENNESSEE VALLEY AUTHORITY
SHAWNEE NO.IDA
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10B
N
R
N
R
R
N
•"*
R
R
R
R
R
37
65
360
125
125
660
635
120
50
20
10
10
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
COMBUSTION EQUIP. ASSOCIATES
LIME/ALKALINE FLYASH SCRUBBING
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
UOP / PUB SERVICE OF COLORADO
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIME SCRUBBING
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
CHEMICO
LIME/LIMESTONE SCRUBBING
OIL 2.i» PERCENT SULFUR 10/72
COAL 3.5-
-------
Table 12
SUMMARY OF FGD SYSTEMS UNDER CONSTRUCTION
165
-------
TABLE 12
SUMMARY OF FGD SYSTEMS UNDER CONSTRUCTION AS OF 05/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGD PROCESS/VENDOR
RETROFIT UNIT (MW)
FUEL CHARACTERISTICS
•MO/YR
ARIZONA PUBLIC SERVICE
CHOLLA NO 2
CENTRAL ILLINOIS LIGHT CO.
OUCK CREEK NO.l
COLUMBUS ft SOUTHERN OHIO ELEC.
COMESVILLE NO 5
DETROIT EDISON
ST.CLAIR NO 6
INDIANAPOLIS POWER & LIGHT CO.
PETERSBURG NO 3
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 3
LOUISVILLE GAS 8 ELECTRIC
CANE RUN NO 5
LOUISVILLE GAS 8 ELECTRIC
CANE RUN NO H
MINNKOTA POWER COOPERATIVE
MILTON R. YOUNG NO. 2
MONTANA POWER CO.
COLSTRIP NO 2
NEVADA POWER
REID GARDNER NO 3
NORTHERN INDIANA PUB SERVICE
MITCHELL NO 11
NORTHERN STATES POWER CO.
SHERBURNE NO 2
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 2
SPRINGFIELD CITY UTILITIES
SOUTHWEST NOt 1
N
N
N
R
N
N
RJr.
1
R
N,
N
R
N
N
N
250
100
1*00
180
530
425
183
178
450
360
125
115
680
835
200
RESEARCH COTTRELL
LIMESTONE 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/ALKALINE FLYASH SCRUBBING
COMBUSTION EQUIP. ASSOCIATES
LIME/ALKALINE FLYASH SCRUBBING
COMBUSTION EQUIP. ASSOCIATES
SODIUM CARBONATE SCRUBBING
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
CHEMICO
LIME SCRUBBING
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
COAL 0.44-1 PERCENT SULFUR
COAL 2.5-3.0 PERCENT SULFUR
COAL 4.5 - 4.9 PERCENT SULFUR
COAL 3.7 PERCENT SULFUR
COAL 3.0-3.5 PERCENT SULFUR
COAL 3.5-
PERCENT SULFUR
COAL 3.5-4.05 PERCENT SULFUR
COAL s.5-4.05 PERCENT SULFUR
LIGNITE - 6.500 BTU. 0.7* S
COAL 0.8 PERCENT SULFUR
COAL o.s- i.o PERCENT SULFUR
COAL 3.2- 3.5 PERCENT SULFUR
COAL 0.8 PERCENT SULFUR
COAL 4.3 PERCENT SULFUR
COAL 3.5 PERCENT SULFUR
6/77
6/76
6/76
5/76
9/77
7/77
12/77
6/76
8/77
7/76
6/76
5/76
5/77
4/77
8/76
167
PEDCo-ENVIRONMENTAL
-------
TABLE 12
SUMMARY OF F60 SYSTEMS UNDER CONSTRUCTION AS OF 05/76
UTILITY COMPANY
POWER STATION
TENNESSLE VALLEY AUTHORITY
WIDOWS CREEK NO 8
TEXAS UTILITIES CO.
MARTIN LAKE NO. 1
TEXAS UTILITIES CO.
MARTIN LAKE NO. 2
UTAH POWER ft LIGHT CO.
HUNTIN6TON NO.l
NEW OR SIZE OF FGD PROCESS/VENDOR
RETROFIT UNIT (MW)
R
N
550 TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
795 RESEARCH COTTRELL
LIMESTONE SCRUBBING
799 RESEARCH COTTRELL
LIMESTONE SCRUBBING
415 CHEMICO
LIME SCRUBBING
FUEL CHARACTERISTICS MO/YR
COAL 3.7 PERCENT SULFUR 2/77
COAL 1.0 PERCENT SULFUR 1/77
COAL 1.0 PERCENT SULFUR 10/77
COAL 0.5 PERCENT SULFUR 6/77
168
PEDCo-ENVIRONMENJAl
-------
Table 13
SUMMARY OF PLANNED FGD SYSTEMS
169
-------
TABLE 13
SUMMARY OF PLANNED FGD SYSTEMS AS OF 05/76
UTILITY COMPANY
POWER STATION
NEW OR SIZE OF FGO VENDOR/PROCESS*
RETROFIT UNIT
-------
TABLE 13
SUMMARY OF PLANNED FGD SYSTEMS AS OF 05/76
UTILITY COMPANY
POWER STATION
NEW OR
RETROFIT
SIZE OF FGD
UNIT (MW)
VENDOR/PROCESS
FUEL CHARACTERISTICS
MO/YR
PUBLIC SERVICE CO OF NEW MEX. R
SAN JUAN NO. 2
SOUTHERN ILLINOIS POWER COOP N
SOUTHERN* ILLINOIS POWER PT. 4
S. MISSISSIPPI ELEC PWR ASSOC N
R.D. MORROW NO.l
340 DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
BABCOCK 1 WILCOX
LIMESTONE SCRUBBING
180 RILEY STOKER/ENVIRONEERING
LIMESTONE SCRUBBING
COAL O.A PERCENT SULFUR 7/77
COAL 1/76
COAL 1 PERCENT SULFUR 11/77
LETTER OF INTENT SIGNED
NEVADA POWER
REID GARDNER NO 4
ARIZONA ELECTRIC POWER COOP
APACHE NO 3
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO IB
ARIZONA ELECTRIC POWER COOP
APACHE NO 2
TEXAS UTILITIES Co.
MARTIN LAKE NO. 3
TEXAS UTILITIES co.
MARTIN LAKE NO. 4
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 3
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. ^
REQUESTING/EVALUATING BIDS
CINCINNATI GAS 8 ELECTRIC CO. N
MIAMI FORT NO 8
LOUISVILLE GAS ft ELECTRIC R
CANE RUN NO 6
CENTRAL ILLINOIS PUBLIC SERV N
NEWTON NO.l
UNITED POWER ASSOCIATION N
COAL CREEK NO. 2
125
205
240
200
793
0
500
500
500
277
600
545
COMBUSTION EQUIP. ASSOCIA
SODIUM CARBONATE SCRUBBINl
RESEARCH COTTRELL
LIMESTONE SCRUBBING
UNITED ENGINEERS
MAGNESIUM OXIDE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
DAVY POWERGAS
WELLMAN LORD
DAVY POWERGAS
WELLMAN LORD
NOT SELECTED
NOT SELECTED
NOT SELECTTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
COAL 0-5- 1.0 PERCENT SULFUR O/ 0
COAL 0.5- o.s PERCENT SULFUR 6/79
COAL 2.5 PERCENT SULFUR
COAL 1.0 PERCENT SULFUR
COAL 1.0 PERCENT SULFUR
COAL 0.8 PERCENT SULFUR
COAL 0.8 PERCENT SULFUR
COAL 1.3 PERCENT SULFUR
10/78
COAL 0.5- 0.6 PERCENT SULFUR 6/76
12/76
12/79
5/79
5/61
1/78
COAL 3.5- "».o PERCENT SULFUR 9/76
COAL 2.8-3.2 PERCENT SULFUR
12/77
LIME/LIMESTONE
LIGNITE - 0.63 PERCENT SULFUR 11/79
172
PEDCo-ENVIRONMENTAL
-------
TABLE 13
SUMMARY OF PLANNED FGD SYSTEMS AS OF 05/76
UTILITY COMPANY
POWER STATION
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
NEW OR SIZE OF F6D VENDOR/PROCESS
RETROFIT UNIT
-------
TABLE 13
SUMMARY OF PLANNED F60 SYSTEMS AS OF OS/76
UTILITY COMPANY
POWEH STATION
NEW OR SIZE OF F6D VENDOR/PROCESS
RETROFIT UNIT
-------
TABLE IS
SUMMARY OF PLANNED FGD SYSTEMS AS OF OS/76
UTILITY COMPANY
POUCH STATION
NEW OR . SIZE OF F60 VENDOR/PROCESS
RETROFIT UNIT (MU)
FUEL CHARACTERISTICS
MO/YR
PUBLIC SERVICE INDIANA
GIBSON NO. 3
PUBLIC SERVICE INDIANA
GIBSON NO. H
650 NOT SELECTED
NOT SELECTED
650 NOT SELECTED
NOT SELECTED
COAL 3.3 PERCENT SULFUR
COAL 3.3 PERCENT SULFUR
0/76
0/79
175
PEDCo-ENVIRONMENTAL
-------
Table 14
SUMMARY LIST OF F6D SYSTEMS IN THE EARLY PLANNING STAGES
177
-------
TABLE 1H
SUMMARY LIST or FGO SYSTEMS IN THE EARLY PLANNING STAGES
FGO STATUS REPORT 05/76
I.D. NUMBER AND COMPANY NAME
UNIT NAME
LOCATION
START UP DATE STATUS
REG
CLASS
1 DAYTON POWER AND LIGHT CO.
2 DAYTON POWER AND LIGHT CO.
3 GENERAL PUBLIC UTILITIES
-------
Table 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES
181
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF F6D SYSTEMS IN THE EARLY PLANNING STAGES DURING
05/76
CURRENT MONTH
1.0. NUMBER 1
DAYTON POWER AND LIGHT CO.
KILLEN NO 1
600 MW - NEW
COAL
NOT SELECTED
LIMESTONE'SCRUBBING
STARTUP 1/83
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. 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 FGO SYSTEM IF NEEDED.
I.D. NUMBER 3
GENERAL PUBLIC UTILITIES
COHO NO.l
800 Mb - NEW
COAL
NOT SELECTED
NOT SfLECTED
STARTUP 5/87
STARTUP DATE CHANGED TO 5/87 FOR BOTH BOILER AND FGD SYSTEM. LIME, LIME-
STONE SCRUBBING* AND COAL DESULFURIZATION ARE THE PRIMARY PROCESSES BEING
GQNS10ERED. NO DECISION HAS BEEN MADE YET.
I.D. NUMBER 4
GENERAL PUBLIC UTILITIES
SEWARO NO.7
800 Mb - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 5/81*
STARTUP DATE CHANGED TO 5/6«» FOR BOTH BOILER AND FGD SYSTEM. LIME.
LIMESTONE SCRUBBING, AND COAL DESULFURIZATION ARE THE PRIMARY PROCESSES
BEING CONSIDERED. NO DECISION HAS BEEN MADE YET. .,,
I.D. NUMBER 5
GULF POWER CO.
CRIST NO. H AND .NO. 5
150 MW • RETROFIT
NOT SELECTED
NOT SELECTED
STARTUP 0/76
EACH UNIT IS 75 NW.
1976.
IF SCRUBBERS ARE SELECTED THEY WILL BE REQUIRED IN
183
PEDCo-ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF FGO SYSTEMS IN THE EARLY PLANNING STAGES DURING 05/76
CURRENT MONTH
1.0. NUMBER 6
GULF POWER CO.
CRIST NO. 6 AND NO. 7
620 MW - RETROFIT
NOT SELECTED
NOT SELECTED
STARTUP 0/60
UNIT 6 IS 320 MW. UNIT 7 IS 500 MW.
I.D. NUMBER 7
GULF POWER CO.
LANSING SMITH NO. 1 AND NO.
305 MW - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP 0/80
UNIT NO. 1 IS 125 MW. UNIT NO. 2 IS 180 MW. IF SCRUBBERS ARE SELECTED*
THEY WILL BE REQUIRED IN 1979 AND 1980 ON THE RESPECTIVE UNITS.
I.D. NUMBER 8
KENTUCKY UTILITIES
GHENT
510 MW - NEW
COAL 3-R 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 F6D SYSTEM.
I.D. NUMBER 9
POTOMAC ELECTRIC & POWER
CHALK POINT NO. i>
630 MW - NEW
OIL
NOT SELECTED
NOT SELECTED
STARTUP 6/76
AWAITING PERFORMANCE RESULTS FROM MGO UNIT ON DICKERSON NO. 3 (MONTGOMERY
COUNTY). UNIT WILL HAVE PEABODY-LURGI 2-STAGE VENTURI SCRUBBERS FOR PAR*
TICULATE CONTROL. COMPANY MAY ELECT NOT TO INSTALL FGO SYSTEM IF USE OF
LOW SULFUR OIL IS CONTINUED. BOILER START-UP SCHEDULED FOR LATE 1976.
I.D. NUMBER 10
POTOMAC ELECTRIC ft POWER
DICKERSON NO •»
600 MM - NEW
COAL 2.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 5/62
THERE ARE NO FIRM PLANS FOR INSTALLATION OF FGD SYSTEM.
BOILER IS PLANNED FOR 1982.
STARTUP DATE OF
184
PEDCo- ENVIRONMENTAL
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING 05/76
CURRENT MONTH,
1.0. NUMBER 11
POTOMAC ELECTRIC ft POWER
MORGANTOWN NO.l
588 MU - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/79
THEME 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 OICKERSON PLANT. DECISION
EXPECTED WITHIN A YEAR.
I.D. NUMBER 12
POTOMAC ELECTRIC ft POWER
MORGANTOWN NO.2
556 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 MW • NEW
COAL - 3S SULFUR - REFUSE
NOT SELECTED
NOT SELECTED
STARTUP 9/82
THE UTILITY IS CONSIDERING BOTH REGENERABLE AND LIMESTONE SCRUBBING
PROCESSES. FGD TECHNOLOGY IS BEING CONSIDERED FOR A FOSSIL FUEL BURNING
UNIT WHICH WILL EMPLOY COAL AS THE PRIMARY FUEL. REFUSE AND OIL WILL BE
PROVIDED FOR SUPPLEMENTAL FUEL SUPPLIES. THE PREFERRED INSTALLATION SITE
IS THE ARTHUR KILL FACILITY LOCATED ON STATEN ISLAND. THE PROJECT DESIGN
ENGINEERS ARE SARGENT AND LUNDY.
I.D. NUMBER 14
SALT RIVER PROJECT
NAVAJO NO 1
750 MW - RETROFIT
COAL 0.45 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP O/ 0
THE UTILITY IS PRESENTLY INVESTIGATING THE USE OF LOW SULFUR COAL AND
DESULFURIZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THE SRP/EPA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPECIFIED.
I.D. NUMBER 15
SALT RIVER PROJECT
NAVAJO NO 2
700 MW - RETROFIT
COAL 0.45 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP O/ 0
THE UTILITY IS PRESENTLY INVESTIGATING THE USE OF LOW SULFUR COAL AND
DESULFURIZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THE SRP/EPA STUDY. NO SPECIFIC STARTUP DATE HAS YET BEEN
SPECIFIED.
185
PEDCo-ENVIRONMtrtTAl
-------
COMPANY
POWER STATION
TABLE 15
STATUS OF FGD SYSTEMS IN THE EARLY PLANNING STAGES DURING 05/76
CURRENT MONTH
I.D. NUMBER 16
SALT RIVER PROJECT
NAVAJO NO 3
750 MW - RETROFIT
COAL 0.45 PERCENT SULFUR
NOT SELECTED
LIME/LIMESTONE SCRUBBING
STARTUP O/ 0
THL UTILITY IS PRESENTLY INVESTIGATING THE USE OF LOW SULFUR COAL AND
DESULFURIZATION PROCESSES. A DEFINITIVE DECISION WILL BE MADE PENDING
COMPLETION OF THE SRP/EPA STUDY. NO SPECIFIC STARTUP DATE HAS VET BEEN
SPECIFIED.
1.0. NUMBER 17
SPRINGFIELD WATER LIGHT POWER
DALLMAN NO 3
190 MM • NEW
COAL 3.0- H.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 6/79
FGU SYSTEM IS UNDER CONSIDERATION WITH BOTH REGENERABLE AND LIMESTONE
SCKUBBING BEING CONSIDERED. BECAUSE OF SPACE LIMITATIONS A REGENERABLE
SYSTEM IS THE LIKELY CHOICE. THE COMPANY IS ALSO CONSIDERING COMPLIANCE
THROUGH BURNING OF LOW SULFUR WESTERN COAL.
I.D. NUMBER 16
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 1
750 MM - NEW
LIGNITE
NOT SFLECTED
NOT SELECTED
STARTUP B/60
THIS UNIT WILL BE JOINTLY OWNED BY TPSL AND ALCOA.
NOT BEEN MADE WHETHER TO INSTALL FGD FACILITIES.
A FIRM DECISION HAS
I.D. NUMBER 19
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 2
750 MW • NEW
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 9/61
THIS UNIT WILL BE JOINTLY OWNED BY TPSL AND ALCOA.
NOT BEEN MADE WHETHER TO INSTALL FGD FACILITIES.
A FIRM DECISION HAS
I.D. NUMBER 20
VIRGINIA ELECTRIC AND POWER CO
MT. STORM
11«»7 MW - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THE UTILITY IS PRESENTLY CONSIDERENG BOTH OESULFURIZATION 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.
186
PEDCo- ENVIRONMENTAL
-------
Table 16
FGD SYSTEM OPERATIONS THAT HAVE BEEN TERMINATED OR SHUT DOWN INDEFINITELY
187
-------
Table 16
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY.
PARTICULATES
S02
1
BOSTON EDISON
MYSTIC NO 6
EVEFSTT MASSACHUSETTS
150 MW
OIL 2.5 PERCENT SULFUR
CHEMICO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
<»/72
OPERATIONAL
50 PERCENT
90 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
S32/KW CAPITAL * CALCINATION
AVERAGE FGD SYSTEM AVAILABILITY FACTORS - APRIL 72 TO MAY 73. 17*.
JUNE 73 TO DEC. 73. H8X. JAN. 7H TO JUNE 7H. 60S. JUNE 74. 80*.
THE FGD SYSTEM HAS BEEN SHUT DOWN INDEFINITELY SINCE JUNE 7«*.
PEDCO-ENVIRONMENTAL
189
-------
BACKGROUND INFORMATION
ON
THE MYSTIC POWER STATION, UNIT NO. 6
THE MAGNESIUM OXIDE FGD SYSTEM «T BOSTON EDISON CONSISTS OF A CHEMICO 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 CONTAINING SOg AT A 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 CALCINED AT HIGH TEMPERATURES TO DRIVE OFF THE S02 AND REGENERATE MgO. THE S02 STREAM IS PROCESSED IN A SULFURIC ACID
PLANT TO MAKE 98 PERCENT GRADE OF SULFURIC ACID.
PROBLEMS AND SOLUTIONS
FROM THE INITIAL START-UP IN APRIL 1972 UNTIL MAY 1973 THE SCRUBBER OPERATED INTERMITTENTLY BECAUSE OF MECHANICAL DIFFICULTIES. THE MAJOR PROBLEM.
ENTAILING DESIGN AND OPERATION OF MgSOj CRYS'jAL DRYER, APPARENTLY HAS BEEN RESOLVED BY REDESIGN AND FUEL CHANGE. PROBLEMS WITH THE STACK AND PUMP
OCCURRED DURING USE OF REGENERATED MgO. OVERHEATING OF THE SLURRY DURING ACTIVATION OF THE STEAM FREEZE PROTECTION SYSTEM CAUSED FORMATION OF SCALE
IN THE MgO SLURRY PIPING. IN 1974,. SYSTEM OPERATION WAS LIMITED BY BOILER AVAILABILITY. SINCE FEBRUARY 1974 AVAILABILITY OF THE BOILER HAS BEEN
INCREASED. THE SYSTEM HAS BEEN SHUT DOWN INDEFINITELY SINCE JUNE 1974, WHEN EPA FUNDS FOR THE CALCINING PORTION OF THIS OPERATION WERE EXHAUSTED.
AVAILABILITY FACTORS AND COMMENTS CONCERNING THE OPERATION OF THIS SYSTEM SINCE STARTUP ARE PRESENTED IN THE FOLLOWING TABLE.
PEDCo- ENVIRONMENTAL
190
-------
FGD SYSTEM AVAILABILITY
MYSTIC UNIT NO. 6
Month Availability (1) Comments
Apr< 72 17 The module operated Intermittently because of mechanical difficulties. A major problem concerned
to design and operation of the magnesium sulflte crystals dryer.
May 73
Jun. 73 68
Jul. 73 61
Aug> 73 The boiler was down for the annual overhaul. System availability decreased'during the last quarter
Sep 73 38 of the year because of heavy erosion/corrosion 1n the liquor redrculatlon pumps and centrifuge.
Oct. 73 60
Nov. 73 26
Dec. 73 13
Jan 74 28 System availability was limited by boiler-related problems that caused frequent shutdowns In
Pet>. 74 25 January and February.
Mar. 74 87
Apr. 74 81
(ky 74 57 57 percent availability was due to 2 weeks outage of the acid plant rather than to FGD system
Jun 74 80 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 (January to June, 1974) - 59.7 Percent.
191 PEDCo-ENVIRONMENTAL
-------
Table 16
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYt
PARTICULATES
S02
DAIRYLAND POWER COOP
ALMA STATION
ALMA WISCONSIN
60 MW
COAL 3.0- 3.5 PERCENT SULFUR
FOSTER WHEELER
LIME INJECTION
RETROFIT
6/71
OPERATIONAL
25 PERCENT
WATER HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
"
THIS EXPERIMENTAL WET LIME FURNACE INJLCTION SYSTEM HAS BEEN OPEKATIONAL
SINCE 1971 FOR PERIODS UP TO 30 DAYS. IN AUGUST 1971 THE UNIT WAS TESTED
FOR TWO DAYS USING WESTERN LOW SULFUR COAL. THE TEST SHOWED ABOUT SOX
S02 REMOVAL EFFICIENCY, BUT PRECIPITATOR PERFORMANCE WAS ADVERSELY
AFFECTED. THE FGD PROJECT HAS BEEN SHUT DOWN INDEFINITELY SINCE
AUGUST 197* t AND THERE ARE NO PLANS FOR FUTURE OPERATION.
PEDCo- ENVIRONMENTAL,
192
-------
Table 16
TERMINATED OPERATIONAL FGO SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
ILLINOIS POWER
WOOD RIVER NO H
EAST ALTON ILLINOIS
no nw
FUEL CHARACTERISTICS COAL 2.9- 3.2 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY.
PARTICULATES
MONSANTO ENVIRO CHEM SYSTEMS
CATALYTIC OXIDATION
RETROFIT
10/72
OPERATIONAL
S02
85 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
S7S/Kh CAPITAL*** MILLS/KWH OP
OPERATIONAL
EXPERIENCE
THE FGO SYSTEM HAS HAD CONSIDERABLE AMOUNT OF PROBLEMS SINCE STARTUP IN
1972. TOTAL OPERATION WAS «f«m HOURS IN 1972. 158 HOURS IN 1973» AND 55
HOURS IN 1974. HEAT EXCHANGER LEAKS HAVE BEEN ENCOUNTERED. AND AN
EVALUATION IS NOW BEING MADE TO DETERMINE WHETHER TO REPLACE THE HEAT
EXCHANGER OR TO REPAIR IT. THE SYSTEM IS SHUT DOWN INDEFINITELY AT
PRESENT.
193
PEDCO-ENVIRONMENTAL
-------
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 RETRO-
FITTED WITH A CATALYTIC OXIDATION FGD SYSTEM DESIGNED BY MONSANTO ENVIRO-CHEM SYSTEMS. THE SYSTEM TREATS THE FLUE GAS FROM A HIGH EFFICIENCY ELECTRO-
STATIC PRECIPITATOR.
THE FLUE GAS IS HEATED TO A TEMPERATURE OF 850°F AND IS PASSED THROUGH A VANADIUM. PENTOXIDE FIXED-BED CATALYTIC CONVERTER, WHERE S02 IS OXIDIZED TO
SO . THE GAS THEN FLOWS THROUGH AN ACID ABSORPTION TOWER, WHERE THE SULFUR TRIOXIDE IN THE GAS IS CONVERTED TO SULFURIC ACID. AN ACID MIST ELIMINATOR
ENSURES REMOVAL OF ENTRAINED ACID MIST FROM THE GAS STREAM. THE CLEANED GAS IS DISCHARGED TO THE STACK AND THE PRODUCT ACID IS COOLED AND STORED IN
TANKS.
PROBLEMS AND SOLUTIONS
SINCE COMPLETION OF THE SYSTEM IN JULY 1972, A SERIES OF MECHANICAL DIFFICULTIES HAS OCCURRED AND MODIFICATIONS HAVE BEEN EFFECTED. DURING JULY
1973, AN ACCEPTANCE TEST WAS CONDUCTED TO ESTABLISH THE SPECIFIED 85 PERCENT SULFUR DIOXIDE REMOVAL, WHILE PRODUCING AN ACID PRODUCT OF RQUIRED CON-
CENTRATION OF 77.7 PERCENT. BOTH OF THESE SPECIFICATIONS WERE MET.
LONG TERM OPERATION OF THE SYSTEM HAS BEEN DELAYED BECAUSE OF DELAYED DELIVERY OF EQUIPMENT FOR A PLANNED SYSTEM MODIFICATION TO CONVERT 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 NEED FOR REINFORCEMENT OF THE
STRUCTURE SUPPORTING THE HIGH TEMPERATURE FLUE GAS DUCT TO THE CATALYTIC CONVERTER. MOST OF THESE PROBLEMS HAVE BEEN CORRECTED. ILLINOIS POWER AND EPA
ARE NOW DETERMINING HOW TO CORRECT LEAKING ACID COOLERS. PATCHING ATTEMPTS HAVE BEEN UNSUCCESSFUL. REPAIR OR REPLACEMENT OF THE COOLERS IS EXPECTED
TO TAKE SEVERAL MONTHS.
194
PEDCo-ENVIRONMENTAL
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OPERATING LOG
CATALYTIC OXIDATION SYSTEM
•
WOOD RIVER NO. 4 - ILLINOIS POWER CO.
System operating
Date
9-4-72
9-5-72
9-6-72
9-7-72
9-10-72
9-11-72
9-12-72
9-13-72
9-14-72
9-15-72
9-16-72
9-17-72
9-18-72
9-19-72
9-24-72
10-6-72
10-7-72
hours
12
24
24
2
6
2
16
24
24
24
24
24
24
3
17
12
24
Date
10-8-72
10-9-72
10-10-72
10-12-72
10-13-72
10-14-72
10-30-72
10-31-72
7-21-73
7-22-73
7-23-73
7-24-73
7-25-73
7-26-73
7-17-73
7-28-73
7-29-73
hours
24
24
18
16
20
16
24
16
18
24
18
24
14
13
19
19
9
TOTAL
602 HOURS
195
PEDCo-ENVIRONMENTAL
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Table 16
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
POTOMAC ELECTRIC & POWER
DICKERSON NO 3
OICKERSON MARYLAND
95 MW
FUEL CHARACTERISTICS COAL 2.0 PERCENT SULFUR
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY!
PARTICULATES
CHEMICO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/73
OPERATIONAL
S02
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. HOWEVER.IT WILL CONTINUE TO OPERATE AS A
PARTICULATE SCRUBBER.
PEDUo-tnvmONMENTAL
196
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BACKGROUND INFORMATION
ON
OICKERSON NO. 3
.THE DICKERSON STATION OF POTOMAC ELECTRIC POWER CO. (PEPCO) IS LOCATED ON THE POTOMAC RIVER NEAR DICKERSON, MARYLAND, ABOUT 30 MILES NORTHWEST OF
WASHINGTON. D.C. THE STATION HAS THREE ELECTRIC GENERATORS. EACH RATED AT 190 MW. UNIT NO. 3 IS A DRY BOTTOM COAL-FIRED BOILER DESIGNED BY COMBUSTION
ENGINEERING AND INSTALLED IN 1962. THE COAL NOW BURNED HAS AN AVERAGE GROSS HEATING VALUE OF 11.700 BTU/LB AND AVERAGE ASH AND SULFUR CONTENTS OF
14 AND 2 PERCENT. RESPECTIVELY. THE BOILER IS FITTED WITH AN ELECTROSTATIC PRECIPITATOR DESIGNED AND INSTALLED BY RESEARCH-COTTRELL IN 1962. THE FGD
SYSTEM EMPLOYS THE CHEMICO-BASIC MAGNESIUM OXIDE SCRUBBING PROCESS. THE RETROFIT -SYSTEM HANDLES APPROXIMATELY 50 PERCENT OF THE EXHAUST GAS FROM THE
NO. 3 UNIT.
THE FGD SYSTEM CONSISTS OF A SINGLE. TWO-STAGE SCRUBBER/ABSORBER, WHICH INCORPORATES AN ADJUSTABLE-THROAT VENTURI SCRUBBER FOR PARTICULATE
REMOVAL AND A SECOND STAGE ABSORBER WITH A FIXED VENTURI TO REMOVE SULFUR DIOXIDE. THE LIQUOR STREAMS FOR BOTH STAGES ARE SEPARATE AND OPERATE IN A
CLOSED LOOP MODE. UNTIL MID-1975 THE MAGNESIUM SULFITE GENERATED WAS TRANSFERRED TO AN EPA FINANCED FACILITY AT THE ESSEX CHEMICAL COMPANY SULFURIC
ACID MANUFACTURING PLANT IN RUMFORD. RHODE ISLAND, WHERE MAGNESIUM OXIDE WAS REGENERATED AND S02 FROM THE REGENERATION PROCESS WAS CONVERTED TO SULFURIC
ACID. THE RUMFORD FACILITY HAS SINCE BEEN CLOSED DOWN.
CONSTRUCTION WAS COMPLETED IN AUGUST AND THE SYSTEM STARTED UP IN SEPTEMBER 1973. IN INTERMITTENT OPERATIONS FOR SHAKEDOWN THROUGH JANUARY 1974,
THE LONGEST CONTINUOUS RUN WAS 271 HOURS. THE SYSTEM WAS RESTARTED FROM JULY THROUGH DECEMBER 1974, AND AGAIN ON AUGUST 11. 1975, FOR APPROXIMATELY
87 HOURS.
FGD UNIT OUTAGES WERE CAUSED PRIMARILY BY PIPE AND PUMP CORROSION AND MAJOR TURBINE OVERHAUL OF THE BOILER. PARTICULATE AND S02 REMOVAL EFFICIENCY
GUARANTEES WERE CORROBORATED DURING OPERATIONAL PHASES.
THE REMAINING SUPPLY OF MAGNESIUM OXIDE, ABOUT 100 TONS (10 DAYS). HAS BEEN DEPLETED. AND THE DICKERSON UNIT HAS BEEN TERMINATED AS AN FGD SYSTEM.
PEDCo-ENVIRONMtNiAL
197
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DICKERSON NO. 3
FGD SYSTEM OPERATING HISTORY
_ . . Comments
Operating Period
Sep 73 problems during this period ranged from corrosion leaks In expansion joints to problems In material
to handling equipment, feeding and slaking of MgO, plugging In the MgO mix tank and suction lines to
Jan. 74 the MgO make-up pumps.
Jan> 74 Maintenance and modifications were performed on the system. The major system revision made during
to this period was the addition of a pre-mlx tank In the MgO system.
Apr. 74
Apr 74 UnHteo" operation because the utility did not have access to the EPA calcining facility at the Essex
to chemical Company sulfurlc add plant. By the end of June 1974, all the MgO at Dlckerson had been used
Ju1< 74 and a silo plus three train cars were full of MgSOj.
Aug, 74 During this period the system generally operated at 75 percent of the design gas flow.
to
Dec. 74
Jan. 75
Problems developed In the bucket elevator transporting the MgS03 from the dryer to the storage silo.
Feb> 75 Unit No. 3 was taken out of service for an 8 to 12 week turbine overhaul. The scrubber was Inspected,
to maintenance and modifications were made.
Jul. 75
PEDCo-ENVIRONMENTAL
198
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DICKERSON NO. 3 (Continued)
FGD SYSTEM OPERATING HISTORY
Operating Period Comments
Aug. 75 The FGD system was restarted In August. Steam was lost to the MgO mix tank, resulting in a very moist
product from the centrifuge. Caking In the dryer occurred. At this point, the utility decided to test
only the first-stage of the scrubbing system, taking gas ahead- of the preclpltator. FGD operation at
Dlckerson terminated at this point.
PEDCo-ENVIRONMENTAL
199
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Table 16
TERMINATED OPERATIONAL FGD SYSTEMS
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
UNIT COST
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
RETROFIT
11/74
OPERATIONAL
OPERATIONAL
EXPERIENCE
THIS EXPERIMENTAL MODULE STARTED UP OCT. 31, 197* AND OPERATED WITH AN
AVAILABILITY OF 60.tS THROUGH FOUR MONTHS OF TESTING. TESTS HAVE BEEN
COMPLETED, AND THE F&D SYSTEM WAS SHUT DOWN INDEFINITELY ON JULY 2, 1975.
NEVADA ASSEMBLY bILL NO. 706 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.
200
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Table 16
TERMINATED OPERATIONAL FGD SYSTEMS
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
so2
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2A
LAUGHLIN NEVADA
160 MW
COAL 0.5- 0.8 PERCENT SULFUR
SCE/ STEARNS ROGER
LIME SCRUBBING
RETROFIT
11/73
OPERATIONAL
-«
90 PERCENT
370 GAL/LB MOLE SOg REMOVED
STABILIZED SLUDGE DISPOSED IN UNLINED POND
TO THE FOUR CORNERS PLANT. OPERATED BY ARIZONA PUBLIC SERVICE. FOR INSTALLATION.
PEDCo- ENVIRONMENTAL
201
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BACKGROUND INFORMATION
ON
THE MOHAVE TEST MODULES PROGRAM: NOS. 1A AND 2A
no PROTOTYPE SUL™ D,o,,M ABSORBER HONLES WERE .NSTALLEO „ ,„ ,T « WHWE 6EHEMIIBS sm,OH . w SOUTH£m
. A TO „«. MIED „ 170 „, M
ALSO RATEO AT ,„ „. MS ,BSTALLEO „ reEAT , SImLM FLU£ as „,„„„ FRW „ m 2 ^ imtM
«». »ET ™T»«,S CENEMTI)B CAPAC.TV 0, 790 W . EKH WO. . reSTEm, Lffl,.SULFU8 ^ „„„ A „„„„, ^ „
AND SULFUR CONTENTS OF 10 AND 0.4 PERCENT RESPECTIVELY. '
VERTICAL MODULE
m VERTICAL HOOUU, A UN..ERSA! 0,L PROOUCTS TURmBT COMTACT «SO«BE« (TCA). w TESTED „ T.O »DES: FIRST. AS A TCA UK,T PROH
.. .« TO APRK 30. ,„. „ S.COHO AS A *«. PACKE0 AeSORBE, ,«,. « «» THE «, „ ,„,. UERE REPL4CED
-------
MOHAVE NO. 1A - VERTICAL TEST MODULE
OUTAGE TIME HISTORY: NOVEMBER 2, 1974 TO JULY 2, 1975
Reason Time (hr)
1. Repair grids and redistribute TCA balls 710
2. Clean scale from scrubber internals 344
3. Repair/replace plugged nozzles 153
4. Repair leaks in trap-out tray 120
5. Repair/realign PPA packing 85
6. Correct booster fan trip problems 72
7. Conduct inspections for extended operations 46
8. Remove hardhat from thickener 46
9. Total outage time 1585
Total" outage time: 1585 hours
Total calendar time: 5813 hours
Total operational time: 4228 hours
Percent availability: 72.73
PEDCo-ENVIRONMENTAL
203
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MOHAVE NO. 2A - HORIZONTAL TEST MODULE
OUTAGE TIME HISTORY: JANUARY 16. 1974 TO FEBRUARY 9, 1975
Reason Time (hr)
1. Modify and repair plastic demlster blades 503
2. Correct booster fan balance problems 317
3. Pump repair 256
4. Spray nozzle replacement 238
5. Modify gas Inlet flow distribution 162
6. Repair hopper leaks 135
7. Remove hardhat from thickener 82
8. Modify slaking water for scale prevention 45
9. Conduct Inspections for extended operations 19_
10. Total outage time 1757
Total outage time: 1757 hours
Total calendar time: 9328 hours
Total operating time: 7571 hours
Percent availability: 81.161
PEDCo-ENVIRONMENTAL
204
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Table 16
TERMINATED OPERATIONAL FGD SYSTEMS 2/76
IDENTIFICATION NO.
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
TENNESSEE VALLEY AUTHORITY
SHAWNEE NO. IOC
PADUCAH 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 HAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
TENNESSEE VALLEY AUTHORITY
LIME/LIMESTONE SCRUBBING
RETROFIT
H/72
OPERATIONAL
REFEH TO BACKGROUND INFORMATION SECTION IN TABLE 16 OF THIS KEPOKT. THIS
FGD SYSTLM HAS KEEN OPERATIONAL SINCE APRIL.15.72. 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
205
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BACKGROUND INFORMATION
ON
SHAWNEE NOS. 10A, 10B, AND IOC
IN JUNE 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE WET LIME AND LIMESTONE SCRUBBING SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND PARTICULATES
FROM FLUE GAS. THE PROGRAM WAS CARRIED OUT IN A TEST FACILITY INCORPORATED INTO THE FLUE GAS DUCT WORK OF UNIT NO. 10, A COAL-IFRED BOILER AT THE
TVA SHAWNEE POWER STATION, PADUCAH, KENTUCKY. TVA IS THE CONSTUCTOR AND FACILITY OPERATOR AND THE BECHTEL CORP. IS THE MAJOR CONTRACTOR AND TEST
DIRECTOR.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE TREATING PART OF THE FLUE GAS FROM THE BOILER. EACH SCRUBBER •
TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30,000 ACFM, OR THE EQUIVALENT OF APPROXIMATELY 10 MW OF POWER PLANT GENERATING CAPACITY.
THREE PARALLEL WET SCRUBBER SYSTEMS WERE SELECTED FOR THE TEST PROJECT: 1) A VENTURI WITH A SPRAY TOWER AFTER ABSORBER; 2) A TURBULENT CONTACT
ABSORBER (TCA) AND 3) A MARBLE-BED ABSORBER. THE VENTURI SYSTEM; MANUFACTURED BY CHEMICAL CONSTRUCTION CO., CONTAINS AN ADJUSTABLE THROAT THAT PERMITS
CONTROL AND VARIATION OF PRESSURE DROP UNDER A WIDE RANGE OF FLOW CONDITIONS. THE TCA UNIT, MANUFACTURED BY UNIVERSAL OIL PRODUCTS, EMPLOYS A
FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT ARE FREE TO MOVE BETWEEN RETURNING GRIDS. THE MARBLE-BED ABSORBER, SUPPLIED BY COMBUSTION ENGINEERING
CO., USES A PACKING OF 3/4-INCH GLASS MARBLE SPHERES AND A TURBULENT LAYER OF LIQUID AND GAS ABOVE THE MARBLE LAYER TO ENHANCE MASS TRANSFER.
THE TEST FACILITY WAS DESIGNED SO THAT MODIFICATIONS AND VARIATIONS OF SCRUBBER INTERNALS AND PIPING COULD BE READILY EMPLOYED FOR EACH SCRUBBER
SYSTEM. EACH SYSTEM CAN TREAT APPROXIMATELY 30,000 ACFM OF FLUE GAS AT 300°F CONTAINING 1800 TO 4000 PPM OF S02 AND 2 TO 5 GRAINS/SCF OF PARTICULATES.
TESTING OF THE TCA AND THE VENTURI SPRAY TOWER IS IN PROGRESS; OPERATION OF THE MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
PEDCo-ENVIRONMENTAL
206
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DEFINITIONS
207
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DEFINITIONS
Boiler Capacity Factor
Boiler Utilization Parameter
Efficiency,
Particulates
SO,
FGD Availability Factor
FGD Reliability Factor
FGD Operability Factor
FGD Utilization Factor
FGD Status
Category 1
Category 2
Category 3
(kWh generation in year)/(maximum continuous generating
capacity in kW x 8760 hr/yr).
Hours boiler operated/hours in period, expressed as a
percentage.
Operational - The actual percentage of particulates re-
moved by the FGD system and the particulate control de-
vices from the untreated flue gas. All others - The
design efficiency (percentage) of particulate removed by
the FGD system and the particulate control devices.
Operational - The actual percentage of S02 removed from
the flue gas. All others - The design efficiency.
Hours the FGD system was available for operation (whether
operated or not)/hours in period, expressed as a percentage,
Hours the FGD system operated/hours FGD system was called
upon to operate, expressed as a percentage.
Hours the FGD system was operated/boiler operating hours
in period, expressed as a percentage.
Hours FGD system operated/hours in period, expressed as
a percentage.
Operational - Unit has been or is in service removing S02.
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.
209
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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.
210
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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 SO2 removal is scheduled to begin. Generally
this will be the start-up date of the boiler.
Capital Cost in $/kW including: S02 absorption and regen-
eration system, 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.
211
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Unit Location
Unit Name
Unit Rating
Utility Name
Water Make-Up
DEFINITIONS
City and State listed in mailing address.
Unit identification as it appears 'in Electrical World -
Direction of Electrical Utilities, McGraw-Hill - Current
Edition - or as indicated by utility representative for
installations in planning stages.
Operational - Maximum continuous gross generation capacity
in MW; Preoperational - maximum continuous design genera-
tion capacity in MW
Name of corporation as it appears in Electrical World -
Directory of Electrical Utilities, McGraw-Hill - Current
Edition - as space permits .
Gallons per minute of make-up water required per MW
capacity.
of
212
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