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FGD
QUARTERLY
REPORT
INDUSTRIAL
ENVIRONMENTAL
RESEARCH
LABORATORY
VOL. 1 NO. 2
AUGUST 1977
RESEARCH TRIANGLE PARK, NC 27711
INTRODUCTION TO THE
SECOND ISSUE
Comments and recommendations for improvement of the FGD
Quarterly Report series began to come in within days after the
first issue was distributed. In response to the recommendations,
the format for this second issue has been altered somewhat. A
more comprehensive Report Abstracts Section has been added
and the arrangement and style of presentation have been
changed slightly. A third report in this series, scheduled for
distribution in October, will contain a return mailer which must
be returned if you wish to continue receiving this report. Any
comments or suggestions which will improve the content or
format of this report series are welcomed. All such comments
should be directed to EPA or Radian Corporation personnel
named on page 11 of this report.
FOURTH FGD SYMPOSIUM SCHEDULED
The Fourth Symposium on Flue Gas Desulfurization will be
held on November 8-11, 1977 at the Diplomat Hotel, Hollywood,
Florida. The Symposium will be sponsored by the EPA/IERL-
RTP and is intended to provide a forum for the exchange of ideas
and information on recent developments in FGD systems and
processes. Sessions will be held on nonregenerable processes, by-
product disposal/utilization, regenerable processes and advanced
FGD processes. A special evening session will present a panel
discussion of operating experience and process improvements in
commercial FGD systems.
An announcement brochure has been mailed to interested
parties. Those desiring additional information on the Symposium
may contact Franklin A. Ayer, Symposium Coordinator,
Research Triangle Institute, P. O. Box 12194, Research Triangle
Park, North Carolina, 27709, telephone (919) 541-6260.
LIME/LIMESTONE SCRUBBING
ATTVA'S SHAWNEE PLANT
EPA's Industrial Environmental Research Laboratory-RTP and
its predecessors over approximately the past 15 years have
undertaken a program of research and development to establish
the technical and economic feasibility of promising processes for
removing sulfur dioxide and particulates from coal-fired boiler
flue gases. An important part of this effort involves the operation
and testing of a prototype wet lime and limestone scrubbing test
facility located at the Tennessee Valley Authority's (TVA)
Shawnee Power Plant near Paducah, Kentucky. This versatile
facility allows comprehensive testing of up to three scrubber types
under a variety of operating conditions. Bechtel Corporation of
San Francisco, as the major contractor, designed the test facility
and directs the tes; program. TVA constructed and operates the
facility.
The test facility consists of three parallel scrubber systems: a
venturi followed by a spray tower, a Turbulent Contact Absorber
(TCA), and a Marble-Bed Absorber. Each system is capable of
treating approximately 10 MW equivalent (30,000 acfrn @ 300°F)
of flue gas from Shawnee Unit 10 (nominally 150 MW total)
containing 1000 to 5000 ppm sulfur dioxide (SO,) and 0.2-11
g/m! of particulates (fly ash). Operation of the Marble-Bed
Absorber was discontinued in July 1973, and subsequent
operation has been limited to the two remaining scrubber
systems. Each of the systems can be operated in a variety of
configurations.
The Shawnee program has made major contributions toward
improvement of lime and limestone scrubbing technology in the
areas of reliability, variable load operation, system control,
sludge disposal techniques, and process economics. The most
significant results to date include the following:
• Demonstration has shown that conventional lime/limestone
systems can be operated reliably. Two separate reliability
problems have been identified — scaling and soft, mud-type
solids deposits — and methods to control each have been
demonstrated.
• Soft, mud-type solids deposition was shown to be a function of
alkali utilization. At high alkali utilization (greater than about
85%) these solids are much more easily removed, and very
infrequent intermittent fresh water wash is adequate for their
complete removal in restricted areas such as the mist eliminator
where accumulation can lead to plugging problems.
• Several equipment or process variations were demonstrated to
improve alkali utilization. This is particularly significant for
limestone where alkali utilization is typically about 60-70% and
can be increased to 85-95%. or comparable to that normally
obtained with lime. This not only improves reliability, but also
reduces costs by permitting the use of a much less expensive
alkali feed material and by substantially reducing the quantity of
by-product sludge produced.
• The ability to operate during widely varying boiler load and inlet
SO[ concentrations for extended periods was demonstrated on
the venturi spray tower system using lime with no reliability or
system control problems. This has long been a major concern of
utilities for lime/limestone FGD systems.
• Addition of MgO to either lime or limestone systems has shown
that a substantial increase in SO, removal efficiency can be
obtained, and also indicates a good potential for operating with
the scrubber solution unsaturated with respect to gypsum.
However, further work is needed to fully understand how to
design and control such a system for subsaturated operation to
avoid potential problems.
• The initial results of staged-scrubber forced oxidation studies at
Shawnee appear very promising. The ability to obtain
simultaneously both high alkali utilization (over 90%) and
essentially complete oxidation of sulfite to sulfate (gypsum)
opens up numerous possibilities for further reducing costs and
quantity of sludge produced while maintaining or even im-
proving operating reliability.
• Data generated during the factorial testing have been very
useful in developing and checking the accuracy of the design
models for scale-up to full-scale lime/limestone systems. The
models have also been useful in developing other valuable tools
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FGD QUARTERLY REPORT/AUGUST 1977
for industry such as the computerized Shawnee data base and
the design/economic study computer program. Furthermore, all
of these will have increased value as they are expanded to in-
clude additional data and other equipment and process
variations.
Substantial progress and significant improvement have been
made over the past several years in lime/limestone scrubbing. A
positive, applications-oriented program involving participation
and coordination by EPRI, the utility industry, and FGD system
vendors is being considered as a means of improving acceptance
and appreciation of pilot plant and prototype results to com-
mercial size units. The Shawnee prototype test facility is expected
to play an important role in this program continuation.
EPA Task Officer
JohnE. Williams
Industrial Environmental
Research Laboratory
Research Triangle Park,
North Carolina 27711
Phone: (919)541-2483
FTS 629-2483
Contractor
Tennessee Valley Authority
Dr. A. F, Little
Muscle Shoals, Alabama 35660
Phone: (205) 383-4631
FTS 872-8516
evaluation procedure will cover the various components of FGD
systems. Both products will be technically oriented and will
provide information useful for preliminary selection and
evaluation of FGD systems.
EPA Task Officer
James H. Black
Industrial Environmental
Research Laboratory
Research Triangle Park,
North Carolina 27711
Phone: (919)542-2915
FTS 629-2915
Contractor
PEDCo Environmental
Thomas C. Ponder
Suite 13, Atkinson Square
Cincinnati, Ohio 45246
Phone: (513)771-4330
Contractor
Radian Corporation
Charles E. Hudak
8500 Shoal Creek Blvd.
P. O. Box 9948
Austin, Texas 78766
Phone: (512)454-4797
Contractor
Bechtel Corporation
Dr. Harlan Head
P. O. Box 3965
San Francisco, California 94119
Phone: (415)768-3514
ENGINEERING APPLICATIONS/
INFORMATION TRANSFER PROGRAM
The Process Technology Branch of EPA's Industrial En-
vironmental Research Laboratory-RTP has developed an
Engineering Applications/Information Transfer (EA/IT) Program.
Preliminary studies in the program were conducted by Radian
Corporation, Austin, Texas, and PEDCo Environmental. Cin-
cinnati, Ohio.
During the preliminary studies. Radian and PEDCo conducted
a survey of the air pollution control technology information
requirements of F.PA regional personnel and utility 'industry
personnel. As a result of this survey, requirements have been
identified for a data book, a cost'reliability evaluation procedure.
Summary Reports, and a Quarterly Reports series.
The Quarterly Report series is a mechanism for the
dissemination of information on interim progress as reported to
1ERL-RTP by current contractors. This series provides in-
formation on FGD RD&D activities sponsored by EPA. The first
two issues of the series have been published and distributed.
Format and content of the report are subject to modification,
according to user response.
The Summary Reports are brief precise reports summarizing
important features of various FGD technologies. Reports have
been prepared summarizing the Wellman-Lord FGD process and
lime/limestone scrubbing. The Reports are undergoing final
review by IERL-RTP and should be available from EPA in 3 to 4
months. As with the Quarterly Reports, the format and content
of the Summary Report series are subject to modification based
on recommendations by users.
A data book and cost/evaluation procedure are now being
prepared, and constitute the main thrust of the Engineering
Applications portion of the EA/IT Program. The data book will
address lime slurry scrubbing systems while the cost/reliability
ATOMICS INTERNATIONAL
AQUEOUS CARBONATE PROCESS
A preliminary design and cost estimate has been completed for
a demonstration plant using Atomics International's (Al) Aqueous
Carbonate Process. The plant will process flue gas from a coal-
fired boiler to remove SO, and produce elemental sulfur. The
process will demonstrate a second generation, regenprable FGD
process and will be installed at Niagara Mohawk Power Cor-
poration's Charles R. Hunlley Station in Tonawanda. New York.
The preliminary design and cost estimate are currently being
reviewed by EPA and Empire State Electric Energy Research
Corporation (ESEERCO), the main contractor for this demon-
stration project.
In the Al Aqueous Carbonate Process, flue gas and an aqueous
solution of Na.COj are fed to a spray dryer which acts as a
scrubbing vessel. The exit stream consists of scrubbed flue gas
and a dry mixture of sodium carbonate, sulfite. and sulfatr. The
dry salt mixture is then reduced in a pool of molten salt to
regenerate Na,CO,, Elemental sulfur is a process by-product.
C
EPA Task Officer
J. Chatlynne
Industrial Environmental
Research Laboratory
Research Triangle Park,
North Carolina 27711
Phone: (919) 541-2915
FTS 629-2915
Subcontractor
Atomics International
R. D. Oldenkamp
8900 DeSoto Avenue
Canoga Park, California 91304
Phone: (213) 341-1000
Contractor
Empire State Electric Energy
Research Corporation
1271 Avenue of the Americas
New York, New York 10020
Phone: (212) 246-4300
Subcontractor
Niagara Mohawk Power Corp,
300 Erie Boulevard
West Syracuse, New York 13202
Phone: (315) 474-1511
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FED QUARTERLY REPORT/AUGUST 1977
BAHCO LIME SCRUBBER
EVALUATION
The Swedish-engineered Bahco Lime Scrubber has been
successfully used for FGD in 18 separate oil-fired applications
outside the United States. Research-Cottrell, the licensed United
States distributor of the scrubber, has installed a unit at
Rickenbacker Air Force Base near Columbus, Ohio. The unit is
designed to handle flue gas from up to eight stoker-fired boilers
(3MW equivalent each) burning high sulfur {3% to 4%) coal. The
installation at Rickenbacker AFB is the first application of the
Bahco Process Scrubber in the United States and also the first
application to coal-fired boilers.
Installation was completed and the unit was started up in mid-
March 1976. The first month of operation was devoted primarily
to assuring operability of the system and system components at
design conditions. At the same time, installation of the in-
strumentation required for automatic control and for conducting
the planned test program was completed. The original test
program has not yet been completed. The system has performed
very well using either lime or limestone as the alkali additive.
Both the SO, removal efficiency and the paniculate removal
have consistently exceeded the design specifications. No
operating or reliability problems {such as scaling and plugging)
were noted using either lime or limestone. As is the case with
most new installations, problems of a mechanical nature have
been encountered, none of which were process related. These
problems have now largely been resolved with the help of the
suppliers under the equipment warranties.
Consideration is being given to an extension of the test
program in order to evaluate an economical alternate alkali feed
material available locally. Sludge from municipal lime water
softening plants (primarily CaCO,) is reported to be available in
substantial quantities in that area (including Columbus, Ohio,
and even from the Rickenbacker AFB softening plant).
Use of this material appears promising for environmental as
well as economic reasons. In the softening process, 2 moles of
CaCOj are produced per mole of lime consumed. If the CaCO, is
then utilized in the FGD system, only a single waste sludge
stream will result from both operations.
EPA Task Officer
John E. Williams
Industrial Environmental
Research Laboratory
Research Triangle Park,
North Carolina 27711
Phone: (919) 541-2483
FTS 629-2483
Contractor
Research-Cottrell
Air Pollution Control Division
P.O. Box 750
Bound Brook. New Jersey 08805
Phone:(201)885-7000
CALCIUM SULFATE/SULFITE
COPRECIPITATION STUDY
The Calcium Sulfate Sulfite Coprecipitation Study conducted
by Radian Corporation under EPA Contract No. 68-02-1883 was
completed in October 1976. A final report of the study has been
published in two volumes. A full description of the report appears
in the Report Abstracts section of this report. Volume 1 (EPA-
600'2-76-273a) contains theoretical analyses, results, and
discussion: Volume II (EPA 600-'2-76-273b) contains appendices
of analytical methods and data. They are available from NTIS as
PB 264-953 AS and PB 264-954 AS at $4.50 and $11,
respectively.
MATHEMATICAL MODELING FOR
LIME/LIMESTONE SO2 ABSORPTION
A final report was published for Research Grant No. 800781, a
project concerned with mathematical modeling of SO* absorption
in the lime and limestone TCA scrubber. The work was con-
ducted at West Virginia University under the direction of
Professor C. V. Wen, Department of Chemical Engineering. The
report is described in the Abstracts section of this report and is
available from NTIS as PB 266-104 IAS (EPA 600'7-77-0261 at
S5.50 per copy.
ON-GOING FGD
DEMONSTRATION PROJECTS
The nature of a demonstration project is such that significant
results are not seen, nor are operating costs or reliability data
apparent, until the project has been operational for some time. A
number of demonstration projects currently underway under EPA
sponsorship are considered to be extremely important to FGD
technology. The projects are, however, in their early stages, and
significant results have not yet been received. For this reason.
and in the interest of maintaining an awareness of these projects,
the descriptions which appeared in Volume I, Number 1 of the
FGD Quarterly Report are reprinted here.
FORCED OXIDATION IN
SINGLE-LOOP LIMESTONE SCRUBBERS
IERL-RTP in-house pilot plant studies of forced oxidation in
single-loop limestone scrubbers are discussed in a report entitled
"Sludge Oxidation in Limestone FGD Scrubbers" (EPA 600/7-77-
061) by R. H. Borgwardt (see Report Abstracts section). The
results of the study indicale promise for improving sludge quality,
reducing waste production, and improving operating reliabilities
by forcing oxidation within the scrubbing loop. As side benefits,
the overall process is greatly simplified — both from the
chemical and operational standpoints.
WELLMAN-LORD/ALLIED
FGD SYSTEM START-UP
The Wellman-Lord 'Allied FGD System has been installed on
Northern Indiana Public Service Company's (NIPSCO) 115 MW
coal-fired Unit No, 11 at the D. H. Mitchell Station in Gary,
Indiana. This system incorporates the Wellrnan-Lord SO,
Recovery Process with the Allied Chemical SOS Reduction
Process. Costs of installation and operation of this demonstration
facility are being shared by the Environmental Protection Agency
and NIPSCO. Capital costs of the project are approximately
$129/kW and the annualized costs are expected to total about
8.1 mills/kWh. Although these figures represent the costs in-
curred by the NIPSCO demonstration installation, they do not
necessarily represent the costs of a commercial Wellman-
Lord/AIlied system.
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FGD QUARTERLY REPORT/AUGUST 1977
A recent report by the Stack Gas Emission Studies staff of the
Tennessee Valley Authority estimated the capital costs of the
Wellman-Lord system to be $120 'kW for a new 200 MW boiler
burning 3.5% sulfur coal. Annualized costs were estimated to be
6,6 mills
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FBD QUARTERLY REPORT/AUGUST 1977
facility are Morrison and Knudson, Inc. and Ralph M. Parsons
Company.
Present plans call for work on the demonstration of the Citrate
Process to be divided into the following four phases:
Phase 1 — Process Design and Definitive Cost Estimates
(completed in March 1977)
Phase II — Detailed Engineering Design, Construction, and
Mechanical Acceptance
Phase III — Start-Up and Performance Testing
Phase IV — Comprehensive Emission Testing
The entire period of demonstration (Phase I through Phase IV)
is scheduled for approximately 42 months. If the planned
schedule is adhered to, the year-long emission test program will
conclude early in 1980.
EPAJask Officer
C. J. Chatlynne
Industrial Environmental
Research Laboratory
Research Triangle Park,
North Carolina 27711
Phone: (919)541-2915
FTS 629-2915
Contractor_
Morrison-Knudson Co., Inc.
Dick Mandenburg
P. O. Box 7808
Boise, Idaho 83729
Phone: (208) 345-5000
Task Offlcejr_
William Nissen
U. S. Bureau of Mines
Metallurgy Research Center
Salt Lake City, Utah
Phone: (801S 524-5350
Contractor
St. Joe Minerals Corporation
Zinc Smelting Division
William H. Steele
P. O. Box A
Monaca, Pennsylvania 15061
Phone: (412)774-1020
Contractor
Ralph M. Parsons Company
Jack Brocoff
100 West Walnut Avenue
Pasadena, California 91124
Phone: (213)440-2000
completed. Performance, hardware, and process test data plus
economic data from the 2 years of operation have been collected.
Final reports have been completed by Chemico, the process
supplier, and will soon be completed by York Research, EPA's
independent testing contractor.
Significant results from the 2-year test include:
Performance — Test data show that particle removal ef-
ficiencies are very high. Inlet particle loading ranged from
0.14 g/m3 to 10.8 g/ms while the outlet particle loading from
the scrubber was continually below 0.05 g/m1, well within
new source performance standards. The SO, removal ef-
ficiency was consistently above 90% when the system was
operating at design gas flow and inlet SO, concentrations
above 1,000 pprn.
Hardware — Generally, the major equipment operated
satisfactorily throughout the test. Many problems did arise
with system operation, but the 2-year test program allowed
ample time to identify possible solutions. As a result of the
performance of various items of equipment, information was
obtained about the materials required for handling
magnesium oxide slurry.
Process — The magnesium oxide BO, scrubbing porcess has
demonstrated that it can achieve a 90% or better SO,
removal efficiency. It can produce commercially salable
sulfuric acid and MgO which can be recycled.
Economics — Annual operating costs over the 2-year period
of operation have been determined to be approximately 5.1
mills per kWh.
^ EPA Task Officer_
C. J. Chatlynne
Industrial Environmental
Research Laboratory
Research Triangle Park,
North Carolina 27711
Phone: (919) 541-2915
FTS 629-2915
Contractor
York Research Corporation
1 Research Drive
Stamford, Connecticut 06906
Phone: (203) 325-1371
MAG-OX TESTING
AT PEPCO COMPLETED
The test program of a 95 MW magnesium oxide (MgO)
scrubbing system installed at Potomac Electric Power Company's
(PEPCO) coal-fired Dickerson Generating Station has been
Contractor
Chemico Air Pollution
Control Company
1 Penn Plaza
New York, New York 10001
Phone: (212) 239-5300
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FGD QUARTERLY REPORT/AUGUST 1977
FLUE GAS DESULFURIZATION
REPORTS AND ABSTRACTS
This section of the Quarterly Report contains abstracts of
recently completed EPA reports relating to flue gas
desulfurization. Each listing includes date of the report, contract
(or grant) number. National Technical Information Service
(NTJS) accession number, arid EPA Office of Research and
Development number.
Each report wifh an NTJS number can be ordered from NTIS.
The cost of paper copies varies by page count ($3.50 minimum):
microfiche copies are S3. Payment must accompany order. The
address is: National Technical Information Service
U. S. Department of Commerce
Springfield, Virginia 22161
Reports which do not have an NTiS number are available, as
supplies permit, through lERL-RTP's Technical Information
Service (TISJ. If copies are limited, a reproduced copy of the
report may be purchased from TIS. The address is:
W. W. Whelan
Technical Information Service
Industrial Environmental Research Laboratory
Mail Drop 64
Environmental Protection Agency
Research Triangle Park, North Carolina 27711
Phone. (919) 541-2218
FTS 629-2218
EPA 340 l-76-008a
PB 260-549/1GA
Summary of Participate and Sulfur Oxide
Emission Reductions Achieved Nationwide for
Selected Industrial Source Categories 1970-1975.
Volume 1 — Summary.
Martin F. Massoglia, Research Triangle Institute, Research
Triangle Park, North Carolina, November 1976.
EPA340/l-76-008b
PB 260-550/9GA
Summary of Particulate and Sulfur Oxide
Emission Reductions Achieved Nationwide for
Selected Industrial Source Categories 1970-1975.
Volume 2 — Calculations.
Martin F Massoglia, Research Triangle Institute, Research
Triangle Park, North Carolina, November 1976.
EPA 600/2-76-093b
PB 254-166 AS
Field Test Sampling/Analytical Strategies and
Implementation Cost Estimates: Coal Gasification
and Flue Gas Desulfurization
J. W. Hamersma and S. L. Reynolds, TRW Systems Group,
Redondo Beach, California, April 1976.
EPA Contract No. 68-02-1412
The report gives results of a determination of sampling and
analysis implementation costs for two energy related process
technologies: wet limestone scrubbing of flue gas and a turgi
coal gasification system Two different sampling and analytical
approaches were costed which would yield the same information
output. The first approach, requiring two levels of sampling and
analytical effort, is called the phased sampling program. The
second approach was a direct single effort to achieve the same
level of information for decision-making as the phased approach.
In the test cases, costed from sample acquisition through
analysis, the phased sampling and analytical approach was the
most cost effective.
EPA 600/2-76-130
PB 254-168/AS
Reductant Gases for Flue Gas Desulfurization
Systems
D. W. Hissong, K. S. Murthy, and A. W. Lemmon, Jr., Battelle-
Columbus Laboratories, Columbus, Ohio, May 1976.
EPA Contract No. 68-02-1323
The report gives results of a study of the use of coal or residual
oil gasification to produce a hydrogen/carbon rnonoxide-rich gas
for use as a reductant for regenerable flue gas desulfurization
{FGD} processes. Two different reduction systems are considered:
one for the type of FGD process that produces a concentrated
SO, stream: the other, for the type that uses a liquid-phase
Clans reactor. Detailed data on the composition of the raw gas
from several gasifiers are analyzed. To supplement the data on
trace constituents in the gas, thermodynamic calculations were
made to determine the equilibrium gas-phase concentrations for
a typical coal and typical gasification conditions. Mass transfer
was calculated to determine the extent to which certain gaseous
species could be removed by water-washing of the gas. The ef-
fects of the remaining trace constituents on the components of
the reduction systems are analyzed. Additional research on trace
constituents and their effects are recommended. The capital and
operating costs for reductant systems based on gasification of
coal and residual oil are estimated and compared with those for
reduction systems based on natural gas.
EPA 600/2-76-135a
PB 258-303 7AS
Development of the Westvaco Activated Carbon
Process for SO, Recovery as Elemental Sulfur,
Volume 1
G. N. Brown, C. M. Reed, A. J. Repik, R. L. Stallings, and S, L
Torrence, Westvaco, North Charleston, South Carolina, May
1976
EPA Contract No. 68-02-0003
The report gives results of a demonstration (in a 20,000 cfh
integral pilot plant) of an all dry, fluidized bed process, using
activated carbon for recovering SO, as elemental sulfur. Granular
carbon was recycled continuously more than 20 times between
contact with flue gas from an oil-fired boiler and carbon
regeneration to recover sulfur. During the 315 hour run, carbon
performance remained high with essentially no chemical and low
mechanical losses. Over 90 percent of the 2000 ppni SO, was
removed from the flue gas as sulfuric acid by catalytic oxidation
and subsequent hydrolysis within the carbon granule. In the two-
step regeneration: (1) the acid was converted to elemental sulfur
at 300°F with internally produced H,S, and (2) an external
source of hydrogen at 1000°F was used to thermally strip the by-
product sulfur from the carbon and produce the required H,S by
reaction with the remaining sulfur on carbon. Sufficient process
and design information was developed from data obtained in the
integral run and prior stepwise pilot equipment operation to
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FGD QUARTERLY REPORT/AUGUST 1977
permit scale-up to a 15 MW prototype for a coal-fired boiler. In
the preliminary design, reducing gas is produced in a coal
gasifier. An economic assessment of a 1000 MW conceptual
design for the process indicates capital and operating costs
competitive with those of other regenerable systems.
EPA 600, 2-76-135b
PB 263-627, 2AS
Development of the Westvaco Activated Carbon
Process for SO, Recovery as Elemental Sulfur,
Volume II, Appendix
G. N. Brown. C. M. Reed, A. J. Repik, K. 1. Stalling*, and S. L.
Torrence, Westvaco, North Charleston, South Carolina, May
1976.
EPA Contract No. 68-02-0003
See EPA 600 '2-76-135a. PB 258-303/7AS, for abstract.
EPA 600,'2-76-136a
PB 255-317, AS
Proceedings: Symposium on Flue Gas
Desulfurization — New Orleans, March 1976,
Volume 1
R. D. Stern, W. H. Ponser, and R. C. Christman, Environmental
Protection Agency, Research Triangle Park, North Carolina, May
1976.
The proceedings document the presentations made during the
symposium, which dealt with the status of flue gas desulfurizatton
technology in the United States and abroad. Subjects considered
included: regenerable, non-regenerable. and advanced processes;
process costs; and by-product disposal, utilization, and
marketing. The purpose of the symposium was to provide
developers, vendors, users, and those concerned with regulatory
guidelines with a current review of progress made in applying
processes for the reduction of sulfur dioxide emissions at the full-
and semi-commercial scale.
EPA 600/2-76-136b
PB 262-722/2AS
Proceedings: Symposium on Flue Gas
Desulfurization — New Orleans, March 1976,
Volume II
R. I). Stern, W. H. Ponder, and R. C. Christman, Environmental
Protection Agency, Research Triangle Park, North Carolina, May
1976.
See EPA 600/2-76-136a, PB 255-317/AS, for abstract.
annualized operating costs for five flye gas desulfurization jf:GD)
systems: lime, wet limestone, magnesium oxide, Wellman-Lotd,
and double alkali. Two methods are given for calculating the
costs for the five systems: a detailed, flexible nomograph
procedure, and a rapid equation procedure. All items that affect
the capital and annualized operating costs of FGD systems in
these estimating procedures are compared with actual costs
incurred by FGD system operators. Any differences between the
estimated and actual costs are accounted for; the estimating
procedures are modified when necessary.
EPA 600 2-76-273a
PB 264-953, AS
Experimental and Theoretical Studies of Solid
Solution Formation in Lime and Limestone SO2
Scrubbers, Volume I. Final Report.
Benjamin F. Jones, Philip S. Lowell, Frank B. Meserole, Radian
Corporation. Austin, Texas. October 1976
EPA Contract No. 68-02-1883
The report gives results of a theoretical and experimental study to
characterize the coprecipitation of calcium sulfate with calcium
sulfite hemihydrate. A coprecipitation product had been
suggested to explain the mechanism by which sulfate could be
precipitated from a scrubber solution subsaturated with respect to
calcium sulfate. Lime and limestone SO, scrubbing systems with
oxidation rates below 20 percent had been operated long-term at
steady-state with liquors subsaturated with respect to all known
calcium sulfate solid forms and yet sulfate was measured in the
solids. The existence of a calcium sulfate'calcium sulfite solid
solution has been confirmed experimentally and a theoretical
formulation has been established. Calcium sulfite hemihydrate
was precipitated under controlled laboratory conditions from
solutions subsaturated in calcium sulfate. Specific chemical
analysis and infrared spectroscopic techniques were used to
identify sulfate in the solids. The precipitate's sulfate content was
studied as a function of the relative saturation of calcium sulfate
and the precipitation rate of calcium sulfite hemihydrate. Also,
the effects of high magnesium concentrations and limestone
dissolution on the sulfate content of the solids were measured.
EPA 600/2-76-273b
PB 264-954 AS
Experimental and Theoretical Studies of Solid
Solution Formation in Lime and Limestone SOZ
Scrubbers, Volume II, Appendices
Benjamin F. Jones, Philip S. Lowell, and Frank B. Meserole,
Radian Corporation, Austin, Texas, October 1976
EPA Contract No. 68-02-1883
See EPA 600/2-76-273a, PB 264-953/AS, for abstract.
EPA 600 2-76-150
PB 255-978; AS
Simplified Procedures for Estimating Flue Gas
Desulfurization System Costs
T. C. Ponder, Jr., L. V. Yerino, V. Katari, Y. Shah, and T. W.
Devitt, PEDCo-Environmental, Inc., Cincinnati, Ohio, June 1976.
EPA Contract No. 68-02-1321
The report gives procedures for estimating the capital costs and
EPA 600/2-76-279
PB 261-914/6AS
Equilibrium Partial Pressure of Sulfur Dioxide in
Alkaline Scrubbing Processes
David K. Oestreich, Environmental Protection Agency, Research
Triangle Park, North Carolina, October 1976
The report gives results of IERL-HTP in-house studies in which
equilibrium partial pressure of SO, was measured as a function of
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FGD QUARTERLY REPORT/AUGUST 1977
pH, temperature, and concentration of sulfur {IV) on various
scrubber liquors. These studies were done for potassium-,
sodium-, and citrate-based scrubbing systems. It is shown that
equations developed by earlier workers for predicting SO^ partial
pressures are incorrect- Theoretical expressions are developed to
relate the equilibrium partial pressure of SO, to the important
scrubber parameters. These expressions are experimentally
validated at the 90 percent confidence level.
EPA 600/2-76-281
PB 261-922 9AS
Desuifurization of Steel Mill Sinter Plant Gases
Gary D. Brown, Richard T. Coleman, James C. Dickerman, and
Philip S. Lowell, Radian Corporation, Austin, Texas, October
1976.
EPA Contract No. 68-02-1319
The report gives results of an evaluation of the technical and
economic feasibility of using limestone scrubbing technology to
control sinter plant emissions. Data from Soviet and Japanese
sinter plants employing limestone scrubbing technology were
used to develop a realistic design basis. A conceptual process
design was developed and used to prepare economic estimates.
Results of the process design indicate that control of sinter plant
emissions by limestone scrubbing is technically feasible.
Economic evaluations show that limestone scrubbing will in-
crease the cost of producing sinter by about SI.82 per metric ton
of product sinter for a standard sinter plant operation. For a
sinter plant with a windbox gas recirculation system, the cost
increase would be about $1.44 per metric ton of product sinter.
EPA 600/3-76-090
PB 260-910 /5GA
Sulfur Dioxide Photooxidation Rates and Aerosol
Formation Mechanisms. A Smog Chamber
Study.
W. C. Kocmond and J. Y. Yang, Calspan Corp., Buffalo, New
York, August 1976.
EPA 600/7-76-008
PB 258-783, AS
EPA Alkali Scrubbing Test Facility: Advanced
Program (Second Progress Report)
Harlan N. Head, Bechte! Corporation, San Francisco, California,
September 1976
EPA Contract No. 68-02-1814
The report gives results of advanced testing (from June 1975 to
February 1976) of 30,000 acfm (10 MW equivalent)
lime/limestone wet scrubbers for SO, and particulate removal at
TVA's Shawnee Power Station. No reliability problems were
experienced in 1143 hours of lime testing with cycling gas rate to
simulate variable load operation in the venturi/spray tower.
Clean operation of the mist eliminator (M.E.) system (3-pass,
open-vane chevron M.E. with intermittent top and bottom wash)
was achieved using lime in the venturi/spray tower system, but
plugging occurred with a similar M.E. system using limestone in
the Turbulent Contact Absorber. In tests to improve limestone
utilization, M.E. reliability was found to be a strong function of
alklai utilization. In both scrubber systems, intermittent top and
bottom wash kept the M.E. clean at alkali utilization greater than
85 percent. Below 85 percent alkali utilization, a continuous
bottom wash was required. Limestone utilization was correlated
with scrubber inlet pH, hold tank residence time, and hold tank
design.
EPA 600 7-76-018
PB 259-211 1GA
Control of Waste and Water Pollution from Power
Plant Flue Gas Cleaning Systems: First Annual R
and D Report
P. P. Leo and J. Rossoff, The Aerospace Corporation, Los
Angeles, California, October 1976
EPA Contract No. 68-02-1010
This report summarizes and assesses the state of research and
development in the fields of non-regenerable flue gas cleaning
(FGC) waste treatment, utilization, and disposal, as well as water
reuse technology, for coal-fired utility power plants. Significant
results cover: (1) chemical and physical characterization of
wastes from eastern and western United States plants using lime.
limestone, or double-alkali scrubbing systems; (2) chemical and
physical properties and leaching characteristics of treated and
untreated wastes: (3) field evaluations of treated and untreated
waste disposal; (4) disposal alternatives; (5) cost estimates for
ponding and for fixation disposal methods; (6) disposal standards;
(7) gypsum production and marketing; (8) potential use of wastes
in fertilizer production and Portland cement manufacture; (9j
beneficiation studies; and (10) total power plant water reuse.
Reports are to be issued annually to evaluate the progress of
FGC waste disposal and utilization technology. Results, not
available but to be included in subsequent reports, will cover:
coal-pile drainage, ash characterization and disposal, soil at-
tenuation effects, and conceptualized design cost analyses for
various methods of FGC waste disposal.
EPA 600/7-76-030
PB 262-857 6AS
Feasibility of Producing Elemental Sulfur from
Magnesium Sulfite
Philip S. Lowell, IV. E. Corbett, G. IX Brown, and K. A. Wilde,
Radian Corporation, Austin, Texas, October 1976.
EPA Contract No. 68-02-1319.
The report gives results of a study to extend potential applications
of MgO flue gas desulfurization processes by allowing the sulfur
to be recovered as elemental sulfur as well as sulfuric acid. The
study considered the feasibility of combining the exothermic SO.
reduction reaction with the endothermir MgSO, calcination.
Preliminary consideration of the reductants carbon monoxide,
hydrogen, methane, and hydrogen sulfide showed that the
reaction with SO? can supply part, or in some cases all, of the
heat of decomposition of MgSO,. Considered in detail were: (1)
low-temperature catalytic decomposition using a commercially
available low-Btu synthetic-gas reductanl mixture; and (2) high-
temperature noncatalytic decomposition using a medium-Btu
reducing gas from an oxygen-blown gaslfier. Complete heat and
material balances for conceptual process designs for the above
cases were developed to identify problems. Recommendations for
work required to continue process development are given.
Problems identified include catalyst physical stability,
catalyst/MgO separation, dust carry-over, and noncatalytic
reduction kinetics.
8
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FGO QUARTERLY REPORT/AUGUST 1977
EPA 600 7-77-005
PB 263-469. 9AS
Evaluation of the General Motors' Double Alkali
SO2 Control System
Edward Interess, Arthur D. Little, Inc., Cambridge,
Massachusetts, January 1977.
EPA Contract No. 68-02-1332
The report is an evaluation of the double alkali flue gas
desulfurization (FGD) system, installed to control SO, emissions
from the coal-fired industrial boiler complex at General Motors'
Chevrolet Plant in Parma, Ohio. It describes the boiler and FGD
systems, it addresses performance with respect to SO, removal,
filter cake properties, lime stoichoimetry, carbonate softening,
soda ash stoichiometry, scaling, oxidation, and reliability. The
evaluation is presented in terms of three 1-month long intensive
test periods and a longer term non-intensive test period. System
material balances are presented for some of these periods. A
general history of the operation is also presented.
EPA 600/7-77-026
PB 266-104/9GA
Analysis and Stimulation of Recycle SO2 — Lime
Slurry in TCA (Turbulent Contact Absorber)
Scrubber System
C. Y Wen and Fred K. Fong, West Virginia University,
Morgantown, .West Virginia, March 1977.
The report gives results of an analysis of flue gas desulfurization
by a turbulent contact absorber (TCA) employing time slurry,
including the development of performance equations for the
scrubber-hold tank recycle system. Performance characteristics
investigated include pressure drop of the scrubber, CO, and SO,
absorptions, and lime utilization. Experimental data obtained
from EPA/Research Triangle Park and TVA/Shawnee Power
Station are used for the analysis and correlation. The analysis of
CO, absorption indicates that the overall mass transfer coefficient
is a function of the pH of inlet and outlet scrubber liquor and is
very sensitive to the liquor flow rate. (The rate of SO, absorption
in a TCA has been developed previously by McMichael et al.,
1976). The correlations developed are used to formulate a
simulation procedure for predicting SO, scrubbing efficiency as a
function of pH of slurry and gas and liquor flow rates. The result
of simulation indicates that, for a given lime feed rate and a fixed
inlet and outlet SO, concentration, a maximum flue gas flow rate
exists which the scrubber can treat by the recycling slurry. An
example is shown for the design of a TCA capable of
desulfurizing flue gas from a 50-MW power station.
total waste production, (b) improved settling and dewatering
properties of the sludge, and (c) avoidance of chemical fixation of
the sludge. It is shown that appropriate oxidizer designs can
achieve complete conversion with reasonable air stoichiometries
at atmospheric pressure without catalysts. Gypsum filterable to
80% solids can be obtained in either two- or single-stage
scrubbers. In either case, efficiency is determined primarily by
the physical absorption of oxygen from the air injected into the
oxidizer, when the oxidation step is conducted within the
scrubbing loop. The study shows that the required oxygen
transfer efficiencies can be obtained either with an air-sparged
tower or with an air ejector, when used to aerate the slurry in the
scrubber effluent hold tank. Merits of the various approaches are
compared and discussed in terms of the quality of gypsum
produced, operability of the system, air-feed pressure
requirements, and predictability of performance when scaled-up
to larger systems.
EPA 625 2-74-004
PB 258-802 8GA
Limestone Wet Scrubbing Test Results at the
EPA Alkali Scrubbing Test Facility. Capsule
Report
Environmental Protection Agency, Cincinnati, Ohio, January
1974.
This Capsule Report discusses the highlights of the first detailed
engineering progress report. It describes the test facility and test
program and presents results to date of the limestone wet
scrubbing testing. In addition, the reliability and operability of the
test facility during long term (2 + weeks) closed liquor loop
operation is discussed. (Color illustrations in black and white.)
EPA 625/2-75-007
PB 258-817 6GA
Flue Gas Desulfurization and Sulfuric Acid
Production via Magnesia Scrubbing. Capsule
Report
Environmental Protection Agency, Cincinnati, Ohio, May 1975.
This Capsule Report explains the technology used m establishing
a large prototype sulfur dioxide recovery plant based upon
magnesia slurry scrubbing. The Cheinico-Basic magnesia process
was chosen. During this period, the system's ability to regenerate
and reuse magnesium oxide was demonstrated and over 5,000
tons of sulfuric acid were produced from magnesium sulfite and
sold in the commercial market.
EPA 625/2-75-008
PB 258-804 4GA
EPA-600/7-77-061
Sludge Oxidation in Limestone FGD Scrubbers
Robert H. Borgwardt, Emissions/Effluent Technology Branch,
Environmental Protection Agency, Research Triangle Park, North
Carolina, June 1977.
The report gives results of an experimental study of techniques
suitable for forcing the oxidation of calcium sulfite (a throwaway
product of flue gas desulfurization scrubbers now operating in the
U. S.) to gypsum, over a range of scrubber operating conditions
applicable to the use of high-sulfur coals. Potential advantages of
converting this product to gypsum include: (a) reduction of the
Lime/Limestone Wet Scrubbing Test Results at
the EPA Alkali Scrubbing Test Facility. Capsule
Report
Environmental Protection Agency, Cincinnati, Ohio, May 1975.
This Capsule Report describes a program conducted by EPA to
lest prototype lime and limestone wet scrubbing systems for
removing sulfur dioxide and particular.? matter from coal-fired
boiler flue gases. The program is being carried out in a test
facility which is integrated into the flue gas duct-work of a coat-
fired boiler at the Tennessee Valley Authority (TVA) Shawnee
Power Station, Paducah, Kentucky. This report describes a series
of lime and limestone reliability tests conducted from March 1973
to December 1974.
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FGO QUARTERLY REPORT/AUGUST 1977
FGD RD&D CONTRACTS
This section of the Quarterly Report contains a list of current EPA FGD projects, the EPA Task Officer responsible for project management,
and the project contractor. Also included are the mailing addresses arid phone numbers of the project Officers.
EPA Task Officer
R. H. Borgwardt
IERL-RTP
J. W. Jones
IERL-RTP
J. W. Jones
IERL-RTP
N. Kaplan
IERL-RTP
N. Kaplan
IERL-RTP
N. Kaplan
IERL-RTP
J. E. Williams
IERL-RTP
J.-C. Williams
IERL-RTP
J. E, Williams
IERL-RTP
J. H. Black
IERL-RTP
Contractor
Monsanto Corp.
St. Louis, MO
Louisville Gas & Electric
Louisville, KY
Radian Corp.
Austin. TX
Engr, Science, Inc.
Arcadia, CA
A. D. Little
Cambridge, MA
Not Awarded
Bechtel Corp.
San Francisco, CA
U. S. Air Force
Columbus, OH
TVA
Paducah. KY
TRW, Inc.
Vienna, VA
NON-REGENERABLE PROCESSES
Implemented Task Title
In-house Lime/Limestone Pilot Studies
LG&E Full-Scale Scrubber Testing and Waste Disposal Program
Engineering and Analytical Support for the LG&E Scrubber Test Program
Key West Limestone Scrubbing Test Program
GM Double Alkali Industrial Boiler Test Program
Test Program for the Full-Scale Double Alkali FGD Utility Demonstration
Prototype Study of Lime'Limestone Scrubbing — Advanced Testing and Data Evaluation
Test and Evaluation Program on the Bahco Lime Process
Operation of Shawnee Lime 'Limestone Scrubbing Test
Facility During Advanced Test Program Phase
Study to Evaluate the Use of Dry Sorbents and Fabric
Filtration for Flue Gas Desulfumation
EPA Task Officer
J. H. Black
1ERL-RTP
J. W. Jones
IERL-RTP
J. W. Jones
IERL-RTP
J. W. Jones
IERL-RTP
J. W. Jones
IERL-RTP
J. W. Jones
IERL-RTP
J. W. Jones
IERL-RTP
J. W. Jones
IERL-RTP
J. W. Jones
IERL-RTP
FGD
Contractor
TVA
Muscle Shoals, Al.
Not Awarded
Aerospace Corp.
Los Angeles, CA
Not Awarded
A. D. Little
Cambridge, MA
TRW, Inc.
Vienna, VA
TRW, Inc.
Vienna, VA
TVA
Paducah, KY
TVA
Muscle Shoals, AL
R. Landreth
MERL-Cincinnati
R. Landreth
MERL-Cincinnati
M. H. Roulier
MERL-Cincinnati
U. S. Army
Corps of Engineers
U, S. Army
Corps of Engineers
TVA
Muscle Shoals, AL
BY-PRODUCTS MARKETING AND DISPOSAL
Implemented Task Title
FGD By-Product Marketing Study
Lime/Limestone Scrubbing Sludge Conversion Pilot Studies
Study of Disposal of By-Products from Non-Regenerable FGD Systems
Disposal'Utilization of Flue Gas Cleaning By-Products — Technology Assessment and Transfer
Evaluation of Alternatives for Disposal of FGD Sludges
Preliminary Process Evaluation of Processes that Utilize FGD Waste
Preliminary Design and Evaluation-Extraction of Non-Bauxite Ores
with Lime-Limestone Waste as One Feed Material
Shawnee FGC Waste Disposal Field Evaluation
Lime Limestone Scrubbing and Fluidized Bed Combustion Waste
Characterization and Utilization (in Fertilizer) Studies
Lab and Field Evaluation of First and Second Generation FGC Waste Treatment Processes
FGC Waste Leachate-Liner Compatibility Studies
Studies of Attenuation of FGC Waste Leachate by Soils
10
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FGD QUARTERLY REPORT/AUGUST 1977
EPA Task Officer
Contractor
R. H, Borgwardt Radian Corp.
IERL-RTP Austin, TX
C. Chatlynne
IERL-RTP
C. Chatlynne
IERL-RTP
J H. Black
IERL-RTP
J. H. Black
IERL-RTP
J. H. Black
IERL-RTP
J. H. Black
IERL-RTP
Battelle Memorial
Columbus, OH
Radian Corp.
Austin, TX
Radian Corp.
Austin, TX
PEDCo
Cincinnati, OH
PEDCo
Cincinnati, OH
TVA
Muscle Shoals, AL
SUPPORT STUDIES
implemented Task Title
Experimental and Theoretical Studies of Solid Solution
Formation in Lime/Limestone SO? Scrubbers
Study of Alternatives in Reducing SO, from Non-Utility Combustion Sources
Kinetics of Producing Sulfur from MgSOs
Design, Develop, and Implement Engineering Applications'Information Transfer Program
Development and Implementation of a Flue Gas Cleaning Decision Model
Non-Utility Combustion Source Survey
FGD Energy Optimization Study
EPA TASK OFFICERS FOR CURRENT FGD RD&D STUDIES
James H. Black
Industrial Environmental Research Lab
Research Triangle Park, NC 27711
Phone: (919) 541-2915
FTS 629-2915
Robert Borgwardt
Industrial Environmental Research Lab
Research Triangle Park, NC 27711
Phone: (919) 541-2234
FTS 629-2234
Charles Chatlynne
Industrial Environmental Research Lab
Research Triangle Park, NC 27711
Phone: (919) 541-2915
FTS 629-2915
Julian Jones
Industrial Environmental Research Lab
Research Triangle Park, NC 27711
Phone: (919)541-2915
FTS 629-2915
Norman Kaplan
Industrial Environmental Research Lab
Research Triangle Park, NC 27711
Phone: (919) 541-2556
FTS 629-2556
Robert Landreth
Municipal Environmental Research Lab
26 West St. Claire St.
Cincinnati, OH 45268
Phone: (513) 684-7871
FTS 684-7871
Wade Ponder
Industrial Environmental Research Lab
Research Triangle Park, NC 27711
Phone: (919) 541-2915
FTS 629-2915
Michael Roulier
Municipal Environmental Research Lab
26 West St. Claire St.
Cincinnati, OH 45268
Phone: (513) 684-7871
FTS 584-787!
John Williams
Industrial Environmental Research Lab
Research Triangle Park, NC 27711
Phone: (919) 541-2483
FTS 629-2483
The FGD Quarterly Report is prepared by Radian Corporation under EPA Contract No. 68-02-2608. The EPA Project Officer is James H.
Black, (919) 541-2915. The Radian Project Director is Charles E. Hudak, (512) 454-4797. The Radian Program Manager is R. Murray Wells
Comments on this issue as well as topics for inclusion in and requests for issues should be communicated to them.
The views expressed in the FGD Quarterly Report do not necessarily reflect the views and policies of the Environmental Protection Agency.
Mention of trade names or commercial products does not constitute endorsement or recommendation for use by EPA.
11
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