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FGD
QUARTERLY
REPORT
INDUSTRIAL
ENVIRONMENTAL
RESEARCH
LABORATORY
VOL. 2 NO. 3
Summer 1978
RESEARCH TRIANGLE PARK, NC 27711
IN THIS ISSUE
This issue of the "FGD Quarterly Report" features an article
on flue gas desulfurization (FGD) technology in Japan. The
article is based on a study conducted by an interagency task
force at the request of Senator Henry M. Jackson. Unique
features of the Japanese approach to SOi control are em-
phasized, along with process applications observed by the task
force at several FGD plant sites in Japan.
Also highlighted in this issue are recent studies completed as
part of EPA's review of New Source Performance Standards
(NSPS). Additional topics include an update on lERL-RTP's
pilot plant and FGD studies to support NSPS for utility boilers.
This is the sixth issue of the "FGD Quarterly Report." The
report summarizes recent developments in EPA sponsored and
conducted RD&D activities in FGD, and is designed to respond
to reader requirements for FGD information. Input from our
readers is essential in meeting this objective. The Fall issue
will contain a return mailer survey/subscription renewal notice.
This survey will give you an opportunity to express your
criticisms and suggestions for future issues. In this way we can
continue to provide you with the most relevant information on
FGD. In the meantime you may express your comments to the
EPA Project Officer or the Radian Project Director for the
"FGD Quarterly Report" as identified on Page 11 of this issue.
US TASK FORCE STUDIES
JAPANESE FGD
At the request of the Honorable Henry M. Jackson,
Chairman, Senate Committee on Energy and Natural
Resources, EPA organized an interagency task force to evaluate
the current status of FGD technology in Japan. The basic
goals of the task force study were:
to evaluate the recent advances in Japanese scrubber
technology,
to determine the basic factors contributing to the ex-
tremely successful Japanese scrubber experience to date,
and
to ascertain to what extent this experience can be ap-
plied to US coal-fired power generating facilities.
The task force included Chairman Michael A. Maxwell of
EPA/1ERL-RTP, H. William Elder of the Tennessee Valley
Authority (TVA}, and Thomas M. Morasky of the Electric
Power Research Institute (EPRI). Dr. Jumpei Ando of Chuo
University in Tokyo acted as consultant, interpreter, and guide
during the study.
From January 30 to February 10, 1978, the task force visited
11 FGD plant sites and held discussions with most of the
major FGD system suppliers, the Japan Environment Agency, the
Electric Power Development Co., Ltd. (EPDC), the Ministry of
Internal Trade and Industry (MITI), and the Aichi Prefecture
Environmental Research Center.
FGD technology is working well in Japan. Each of the 11
scrubber installations visited was designed for and routinely
attains SO, removal efficiencies in excess of 90 percent while
achieving availability greater than 96 percent. The performance
of the coal-fired units was not appreciably different from that of
their oil-fired or industrial counterparts with respect to SO,
removal efficiency and system reliability.
Energy Trends and
the Development of FGD
Japanese energy production, heavily dependent on imported
oil, has increased rapidly during recent years. The oil crisis of
late 1973 and the resulting serious inflation have substantially
affected Japan's energy and environmental policies. Current
efforts aim to reduce dependence on imported oil which now
supplies more than 70 percent of Japan's total energy.
Use of domestic coal in the utility industry has been
promoted by MITI through its "Sunshine" project and im-
plemented by EPDC. EPDC is a government /industry funded
corporation founded in 1952 to mitigate the serious power
shortage in the post-war period of economic reconstruction.
EPDC has constructed and is now operating .1 number of coal-
fired power plants equipped with FGD systems, each of which
was visited by the task force. Although Japan imports over 54
Tg (60 million tons) of coal annually, all has thus far been
used for the production of coke for the steel industry. Im-
porting coal for fuel has only recently started, but coal imports
are expected to increase as more coal-fired power plants are
built.
Emissions of sulfur oxides (SOX) associated with the com-
bustion of fossil fuels increased rapidly in Japan during the
1950's and early 1960's. Since 1967, however, with the im-
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FGD QUARTERLY REPORT/SUMMER 1978
plementation of SOX emission regulations, this situation has
steadily improved. Between 1970 and 1975, SOX emission
regulations became more restrictive, and the volume of SOX
pollutants was reduced by 50 percent. This reduction was
achieved despite a 120 percent increase in energy consumption
during that period. In May 1973, the ambient SO, standard
was tightened from 0.05 pprn (yearly average basis) to 0.04
ppm (daily average basis), with a target date of achievement
by May 1978. This regulation limits the hourly average to 0.1
ppm and the yearly average to 0.016 ppm. This regulation is
much more stringent than those in effect in the US (0.03 ppm
yearly average basis) and Germany (0.05 ppm yearly average
basis). A plot of the yearly ambient SO, concentration in
Japan from 1965 to 1977 is given in the figure below.
0.016pp*i» standard
0.06r
0.05
0.04
0.03
0.02
0.01
0.0
The use of FGD systems in Japan has increased rapidly
since 1972 in response to the increasingly stringent SO,
emissions regulations. Recently, however, several factors have
effected a decline in construction of new FGD systems. Am-
bient SO, concentrations in large cities and industrial districts
have been reduced to 0.019 pprn, quite close to the yearly
ambient standard of 0.016 pprn. Also, the recent slowdown in
the Japanese economy has deterred industry from building new
FGD plants, the majority of which were constructed between
1970 and 1975 when the Japanese economy was growing
rapidly. The use of low sulfur fuels has increased in the past
few years, due in part to a smaller price differential between
high and low sulfur oils. Finally, the FGD byproduct market is
becoming saturated, and Japan has little area available for
waste product disposal.
Nevertheless, the present government policy of increased coal
usage for power production will necessitate additional FGD
systems in the future. Three new coal-fired utility units totaling
1175 MW equivalent are presently under construction. These
new FGD systems will employ limestone-gypsum processes and
are scheduled for startup in 1979/1980.
Currently, over 500 major FGD plants, having a combined
capacity of 28,000 MW equivalent, are operational in Japan.
Approximately half represent utility boiler applications
(predominantly oil-fired), 98 percent of which produce usable
gypsum from lime/limestone or dual alkali FGD processes.
Comparable figures for US coal-Tired utility installations show
11,508 MW equivalent of FGD capacity in service.
Lime/limestone processes producing a disposable sludge com-
prise 94 percent of the US utility systems.
EPDC Discusses Operating Experience
Since its establishment in 1952, EPDC has completed 7000
MW of generating capacity at 50 sites located throughout Japan.
These include coal-fired power plants built in accordance with the
national energy policy of reducing the nation's dependence on
foreign oil.
EPDC owns and operates five coal-fired units: Isogo (2),
Takehara (1), and Takasago (2). These units have a total
capacity of 1280 MW and are all equipped with limestone
scrubbers producing a salable gypsum product. EPDC has thus
acquired considerable in-house expertise on limestone FGD.
On January 31, the task force met with representatives of
EPDC at the firm's Tokyo headquarters. EPDC officials shared
their philosophy on the design and operation of limestone
scrubbing systems, as related below. Scrubber reliability was the
central topic of discussion.
Japanese suppliers and users of FGD systems regard scrubbing
as a chemical process, with scrubber operation requiring con-
stant supervision by trained personnel. Raw materials flowing into
scrubbing systems are controlled carefully to minimize chemistry
upsets and to approximate design conditions as closely as
possible. To maintain a relatively constant SOi inlet level, the
utility owners of operating scrubbers usually blend their coal prior
to firing. In addition, all scrubbers operating on coal-fired units
have electrostatic precipitators to minimize dust loading thereby
minimizing erosion problems. Excessive amounts of fly ash in a
scrubbing system can also result in increased solubilities of
unknown compounds that may affect scrubber chemistry.
EPDC personnel expressed their belief that certain design
variables have a significant effect on scrubber reliability. They
considered flue gas velocity most important to reliable scrubber
operation. Velocities should be minimized to protect reheater
sections by reducing mist carryover from scrubber vessels.
System redundancy is felt to be necessary only for pumps; EPDC
usually specifies one extra pump for every four pumps in a
system. Scaling problems are partially dependent on process type
and are not significant when firing coal containing 0.7 percent
sulfur or less. When firing coal with a higher sulfur content,
scaling is controllable to the extent that scrubber outages are not
required between annual boiler maintenance shutdowns.
EPDC users of limestone scrubbers buy dry pulverized
limestone according to strict quality control specifications for size
distributions and chemical composition. This control assures a
constant and reliable reagent feed into the scrubbing process.
Discussions with EPDC thus revealed important features of the
Japanese approach to FGD. Following these talks, the task force
visited many of the actual plant sites. These installations
demonstrated the application of several operating principles
described by EPDC.
Task Force Studies FGD Plant Sites
Each of the FGD plant sites visited by the task force (see map)
was selected because of its significance in Japan and its per-
tinence to the US utility FGD situation. The EPDC and Mitsui
Aluminum plants are coal-fired, use limestone scrubbing along
with US developed scrubbers, and are thus similar to many US
systems. Chuba Electrtc's Nishinagoya plant and Idemitsu
Kosan's Chiba plant are important because they use FGD
processes which have been applied at US utility sites (e.g., the
Wellman-Lord system operated by Northern Indiana Public
Service Company and the magnesium oxide systems demon-
strated by Boston Edison Company and Potomac Electric Power
Company). The Mitsubishi Heavy Industries (MHI) process ap-
plications at Owase and Shimoncski are of interest because MHI
has provided about half of the lime/limestone scrubbing systems
currently in operation in Japan. Finally, the Tatnano, Okayama,
and Saidaiji plant sites were Included because they demonstrate
the dual alkali process, a promising alternative to lime/limestone
scrubbing.
Takehara FGD Plant Demonstrates Success
On February 7, the task force visited the Takehara Power
Station of EPDC. The plant operates two boilers. Unit No. 1 has
a capacity of 250 MW and is fired by domestic Kyushu coals (2.0
percent sulfur content) blended on-site. This unit was constructed
in 1967 and was subsequently retrofitted with a Babcock-Hitachi
limestone/gypsum FGD system which began operation in
February 1977. Unit No. 2, an oil-fired boiler with a 350 MW
capacity, has no FGD system at present although this option is
under consideration.
The Takehara FGD system, installed on Unit No. 1, had been
in operation about 1 year at the time of the visit. Although this
operating time may be insufficient to assess long-term main-
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FGD QUARTERLY REPORT/SUMMER 1978
Key
Japanese FGD Plant Sites Visited by Task Force
tenance requirements, the performance has been outstanding.
Both SOj removal efficiency (over 93 percent) and availability
(98.6 percent) have been excellent, and are typical of other units
visited.
Experience at the Takehara plant is especially relevant to the
US situation because the system uses design features similar to
those offered by a US supplier of limestone scrubbing systems.
The water balance is relatively tight, comparable to closed-loop
sulfite sludge pond processes in the US, and the coal sulfur
content {2.0 percent) is within the range encountered at many US
installations.
An important process difference compared to US experience is
the use of forced oxidation of the limestone slurry to produce
gypsum. (This approach has been investigated in the US at the
pilot plant level and is described in the "FGD Quarterly Report,"
Volume 2, Number 1.)
Other notable features of the Takehara plant include the
recirculation of gypsum feed crystals to reduce scaling in the
scrubber, and relatively stable inlet SO, concentrations as a
result of coal blending. In addition, limestone is purchased as a
high quality, finely ground absorbent. Finally, qualified personnel
are permanently assigned to operate and maintain the FGD
system. These factors combined are undoubtedly largely
responsible for the success of the Takehara FGD system.
Unique Features of Japanese FGD
The task force noted several differences in comparing Japanese
FGD technology with that of the US. These include aspects of
scrubber design and operation, range of sulfur content in the
coal, monitoring and enforcement programs, and the relationship
between Japanese industry and regulatory agencies.
Scrubber system design and operation are characterized by a
conservative approach. EPDC required the scrubber system
supplier to correct, at his expense, any process or equipment
problems occurring within a year of acceptance. This approach
has generally resulted in FGD systems which are initially more
expensive than their US counterparts. However, because of
reduced operating problems, these Japanese installations have
required fewer subsequent changes.
Scrubber systems are operated by personnel specifically trained
for this purpose. Many utilities including EPDC contract with
subsidiary companies to supply operation and maintenance
services. These specially trained personnel are not rotated into
the power plant for other duties as is generally the case with US
utilities.
The range of sulfur content of the coal burned in Japanese
utility and industrial boilers is significantly lower than that used
in many US power generating systems. Japanese FGD systems
usually receive flue gases with SO, inlet values of 400-2300 ppm,
the range of inlet sulfur values experienced by many scrubber
systems applied to US coal-fired utility boilers. However, there is
no experience in Japan with the higher sulfur coals currently used
in conjunction with many US utility FGD systems. These higher
SO, content flue gases are generally more difficult to scrub due to
mass transfer limitations.
Japan uses a stringent monitoring and enforcement program.
This insures that utility and industrial sources are in continuous
compliance with environmental regulations. Each prefectural
government operates an environmental research center (sub-
sidized by the central government). Most research centers are
directly linked via telemetry systems to automatic monitoring
stations located at major emission sources and key ambient sites.
The existence of these monitoring systems has likely been in-
strumental in assuring that emission sources remain in constant
compliance, as violations would result in fines or forced shutdown
of the source.
In heavily industrialized areas, where the ambient con-
centration of sulfur oxides is considered sufficiently high to cause
health problems, an SO, emission tax has been levied. This tax
system has been in effect since 1974, and provides funds that are
used to treat patients with pollution-related illnesses such as
chronic bronchitis.
Another difference can best be expressed as the cooperative
spirit which appears to exist in Japanese industry (both users and
suppliers) and the regulatory agencies. Initially, most pollution
control equipment was installed during a period of strong
economic growth when capital expenditures were easily ab-
sorbed. The national goal of a cleaner environment has prompted
the central government to assist industry in many cases by
providing low interest loans and allowing a 7 year depreciation of
the pollution control facilities. In response, the utility industry has
made a positive effort to comply with environmental regulations
by employing the best scrubbers available and by operating them
according to design specifications. Other factors, such as the
Japanese culture/work ethic and the complex govern-
ment/industry relationship, are important but difficult to define.
Despite the differences noted in comparing Japanese and US
FGD systems, the task force felt that the highly successful
Japanese FGD experience is relevant to US power plants.
Scrubber technology applied in Japan (developed in many cases
by US firms) could be transferred to US plants with a reasonable
degree of confidence.
For further information on the task force findings, contact
EPA/lERL-RTP's M.A. Maxwell, (919) 541-2578 or (FTS) 629-
2578. For further information on pollution control in Japan, refer
to Dr. Jumpei Ando's report, "SO2 Abatement for Stationary
Sources in Japan," EPA-600/7-77-103a, NTIS No. PB 272 986,
September 1977 (available from NTIS see FGD Reports and
Abstracts section for ordering information).
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FGD QUARTERLY REPORT/SUMMER 1978
EPA ASSESSES NSPS
EPA's proposed revision of the New Source Performance
Standards (NSPS) for controlling SO, emissions from utility
boilers is scheduled for publication in September 1978.
As reported previously in the "FGD Quarterly Report" (Volume
I, Number 3), EPA's Office of Air Quality Planning and Standards
(OAQPS) has been reviewing the NSPS for SO, emissions from
fossil-fuel fired steam generators. In support of this effort, the
EPA Industrial Environmental Research Laboratory (1ERL) has
completed several studies on available FGD control technology.
Brief descriptions of some of these studies are given below.
Current NSPS limit SO, emissions to 520 ng/J (1.2 lb/10*
Btu) of heat input for coal and 340 ng/J (0.8 lb/10' Btu) of heat
input for other fuels. Revisions presently under consideration
would retain the current maximum emissions level, but would
also contain:
(a) a requirement for an 85 percent removal of SO, from
stack gases over each 24-hour period, regardless of the
original sulfur content of the fuel, or
(b) a reduction of SO, emissions to 86 ng/J (0.2 lb/10* Btu)
or less, with no specified requirement for a percentage
reduction in SO,.
Thus users of both high and low sulfur fuels would be required
to achieve at least the 85 percent reduction standard (with
maximum SO, emissions limits of 520 or 340 ng/J for coal or
other fuels respectively). Users of low sulfur fuels having
emissions no greater than 86 ng/J would not be required to
achieve a percentage reduction in SO, output.
Credit would be given toward attainment of the 85 percent
reduction standard for elimination of SO, by other processes such
as coal cleaning. When no fuel credit is given, compliance with
the 85 percent/24 hour standard may require an FGD system or
equivalent technology attaining over 90 percent mean efficiency
for 30 days.
FGD Processes Demonstrate Capabilities
A recent study conducted by PEDCo Environmental, Inc.,
"Flue Gas Desulfurization System Capabilities for Coal-Fired
Steam Generators," examines maximum SO, emission control
levels attainable with demonstrated techniques. Several
techniques were examined, including FGD, physical and
chemical coal cleaning, coal conversion processes, and the use
of low sulfur coals. FGD systems received special attention,
since the other approaches are being studied elsewhere by
EPA.
The emphasis of this study was the objective appraisal of
FGD systems with respect to both SO, removal potential and
system operability. This appraisal was accomplished by
reviewing the performance of operating systems and the
features of new systems designed to alleviate previous
problems.
The sulfur removal technologies examined were
lime/limestone wet scrubbing, Wellman-Lord sulfite scrubbing,
magnesium oxide slurry absorption, and dual alkali wet
scrubbing. The impact of key design parameters on SO,
removal efficiency and process operability was investigated for
each FGD process. In addition to process design and
operation, the operating experience of major FGD installations
was reviewed. This assessment included major systems in both
the US and Japan. Finally, the data from selected research
studies were used to evaluate the status of process development
and the potential for sustained system operation and high
removal efficiencies.
The investigation concluded that all FGD processes examined
are capable of removing SO, with mean efficiencies in excess
of 90 percent when applied to both high and low sulfur coal
combustion facilities. Such capabilities have been demonstrated
by pilot, prototype, and full-scale systems. Although sustained
operation at high SO, removal efficiencies has not been widely
achieved, a basis has been developed for the design of such
systems.
For more information on this study, contact J. E. Williams,
EPA/IERL-RTP, (919) 541-2483 or (FTS) 629-2483. (See also
the FGD Reports and Abstracts section in this issue.)
Operating Parameters
for FGD Processes
Affected by Stricter NSPS
Bechtel Corporation has completed a report on the design
and operating parameters that are monitored to ensure proper
operation of FGD systems. The study, "Flue Gas
Desulfurization Systems: Design and Operating Considerations,"
describes critical operating parameters for the following FGD
processes: lime/limestone, sodium carbonate, dual alkali,
magnesium oxide, and Wellman-Lord. Emphasis is given to the
implications of requiring 90 percent or greater SO, removal for
these various FGD systems.
The report concludes that SO, removal efficiencies of 90
percent or greater are obtainable for the FGD processes
examined if certain operating conditions are suitably altered.
These design changes could involve:
increased absorbent circulation rates,
more stringent requirements for uniform flow distribution,
increased scrubbing (contacting) stages or greater
contacting intensity,
elimination of gas by-pass if used for reheat, and
higher absorbent concentrations, which may in turn
require other changes (such as an altered residence
time) to control enhanced scaling tendencies.
If the increased SO, removal requirements are accompanied by
a higher sulfur content of the coal burned, the above design
changes will be intensified. Other fuel-related factors such as
coal heating value and composition must also be ac-
commodated (with increasing difficulty) as removal
requirements become more stringent.
Further information on this study is available from
J. E. Williams, EPA/IERL-RTP, (919) 541-2483 or (FTS) 629-
2483. (See also the FGD Reports and Abstracts section in this
issue.)
Impact of FGD on Utilities
A substantial commitment on the part of a utility to the
operation and maintenance of an FGD unit is essential in order
to maintain high levels of FGD unit availability.
A report prepared by Radian Corporation, "The Effect of Flue
Gas Desulfurization Availability on Electric Utilities" (se»> FGD
Reports and Abstracts section), assesses the impact of FGD
system availability on the ability of individual coal-tired
generating stations and generating systems to meet consumer
demands. The study concentrates on the operating experience
and data for the lime/limestone FGD processes because they
represent most commercial FGD applications on coal-fired
utility boilers.
FGD unit availability is a function of the modular
availability, the total number of modules in a given FGD unit,
and the number of spare modules. The FGD unit availability is
associated with a specific operating load (percent of capacity)
for the generating unit. The number of effective spare modules
varies with the operating load since all modules are not
necessarily required for loads of less than 100 percent capacity.
The use of spare FGD modules dramatically enhances total
unit availability.
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FGD QUARTERLY REPORT/SUMMER 1978
The availability of FGD units has a significant impact on the
ability of an individual generating station and on that of a
generating system to meet consumer demand. A reduction in
generating capability for a single station will vary depending on
the FGD unit availability. For a system, the effect of FGD
largely depends on the relative number of coat plants in that
system. These reductions in capability must be offset by adding
generating units or by improving the availability of the FGD
units.
The report goes on to conclude that in the last few years
significant progress has been made in solving the problems
experienced by existing FGD units. Areas presenting the
greatest challenge to FGD availability are corrosion, erosion,
deposits, unstable chemistry, and instrumentation.
Additional information on this report is available from
J. E. Williams, EPA/IERL-RTP (919) 541-2483 or (FTS) 629-
2483.
TWO PILOT PLANTS INITIATED
EPA/IERL-RTP recently awarded two contracts for pilot scale
(approximately 0.5 MW) investigation of two flue gas cleaning
processes.
A contract was awarded to UOP Process Division to evaluate
the Shell Flue Gas Treating process for simultaneous
NOX/SOX removal. In this process, a bed of copper oxide
reacts with SO, to form copper sulfate. The copper sulfate and,
to a lesser extent, the copper oxide act as catalysts in the
reduction of NOX with ammonia. When the bed is saturated
with copper sulfate, flue gas is switched to a fresh bed for
pollutant removal, and the spent bed is regenerated. In the
regenerating cycle, hydrogen is used to reduce the copper
sulfate to copper, yielding a concentrated SO, stream which
can be used to generate a salable by-product. The copper in
the bed is oxidized, and the unit is ready for acceptance of flue
gas again.
UOP will operate the test unit which will be connected to
coal-fired boilers at Tampa Electric Company's Big Bend
Station in North Ruskin, Florida. The Shell process is expected
to remove 90 percent of both NOX and SOX from the flue gas.
The project will be the first test of this technology on a coal-
fired source anywhere in the world.
The other contract, for an NOX removal project, was
awarded to Hitachi Zosen of Tokyo, Japan, to evaluate their
ammonia-based selective catalytic reduction process. The
process is based on the preference of ammonia (NH,) for NOX
over other flue gas constituents. Oxygen enhances the
reduction reactions which can best be expressed as:
6H.O
6H.O
4NH, + 4NO + O, cal2!yf 4N,
4NH, + 2NO, « O, catalyt 3N,
The first reaction predominates since approximately 90 to 95
percent of the NOX in combustion flue gas Is in the form of
NO. The process operates with an NHj/NO mole ratio of
about 1.0 and with a reaction temperature of 350 to 420°C.
Hitachi Zosen will subcontract to Chemico Air Pollution
Corporation to build and operate the unit, which will be
connected to Georgia Power Company's Unit No. 3 at Plant
Mitchell near Albany, Georgia. Application of the process,
which is expected to remove 90 percent of the NOX from th«
flue gas, will be the first test of the technology on a coal-fired
boiler in the U. S.
Both the NOX/SOX and the NOX projects will encompass
four phases: 1) design; 2) procurement and erection; 3) startup,
debugging, and optimization; and 4} long-term operation and
assessment. The projects should be completed by mid-1980 and
will permit an assessment of the applicability of NOX/SOX and
NOX flue gas treatment technology to US coal-fired boilers.
Further information is available from the EPA/IERL-RTP
project officer, J. D. Mobley, (919) 541-2915 or (FTS) 629-
2915.
CCEA PROGRAM UNDERWAY
EPA is currently developing and implementing a unified
conventional combustion environmental assessment (CCEA)
program. The environmental, economic, and energy impacts
resulting from a variety of emissions are being evaluated by
this major new program, which is examining a number of
current and ongoing studies and demonstration projects.
Emissions resulting from industrial, utility, residential, and
commercial stationary conventional combustion processes will
be considered. An assessment of pollutant control systems will
be made by analysis of pollutant emissions from these systems.
Specific pollutants of interest will include particulates, nitrogen
oxides (NOX), sulfur oxides (SOX), inorganics, organics, trace
elements, and ions.
The primary objective of the CCEA program is to identify
and evaluate information from all relevant data sources. This
information will be used as a basis for the following:
To determine how available information can be used to
assess the impacts of combustion processes.
To identify and acquire needed additional data.
* To define the requirements for modifications or ad-
ditional development of control technology.
To identify the requirements for modified or new stan-
dards to regulate pollutant emissions.
The CCEA program will coordinate and integrate ongoing
and future studies into a comprehensive environmental
assessment structure. It will thus serve as a centralized source
of information on the impacts of a variety of combustion
processes. Coordination and information exchange among
CCEA-related studies should minimize duplication and
maximize the return from available resources.
The planning stage of the CCEA program is essentially
complete. Presently, the identification and evaluation of related
ongoing and proposed studies have resulted in the choice of
approximately a dozen R&D studies with many more studies
anticipated. These studies will be integrated to form the
unified, core CCEA program.
Currently, potential program gaps, overlaps, and recom-
mendations for their resolution are being identified. Refinement
of the major CCEA objectives is underway. Recommendations
for implementing the program are also being developed.
For further information on the CCEA program, contact
W. H. Ponder or W. D. Peters, (919) 541-2915 or (FTS) 629-
2915. (See also "New IERL-RTP Periodicals Announced" in this
issue.)
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FGD QUARTERLY REPORT/SUMMER 1978
MODEL PREDICTS SIZE DISTRIBUTION OF SLUDGE PARTICLES
Sludge disposal represents a significant operating cost in
most applications of lime/limestone and dual alkali scrubbing
processes. Where calcium sulfite is the major product, the
waste sludge generally settles slowly and has a low settled
density,
A recent study, "Development of a Mathematical Basis for
Relating Sludge Properties to FGD-Scrubber Operating
Variables" (see FGD Reports and Abstracts section), examines
prospects for increasing the average particle size, of calcium
sulfite generated by these FGD systems. The objective of the
work, which was completed by Radian Corporation, was to
improve settling rate and settled density, and to correlate
sludge quality with design and operating conditions.
The report describes a mathematical model which was
developed to predict the crystal size distribution of calcium
sulfite produced in limestone FGD systems. The model com-
putes size distributions comparable to those observed in
operating scrubbers. The present model may not apply as well
to lime systems, but the approach used here can be adapted
as necessary data are obtained.
The model has been used to examine the sensitivity of the
product crystal size distribution to changes in process variables.
Prospects for improving the size distribution depend on further
investigation of nucleation kinetics in the system. Changes in
hold tank size or slurry solids content may lead to an increase
or decrease in crystal size, depending on the specific form of
the nucleation and growth rate expressions. The present growth
rate expression is based on experimental data for limestone
systems. However, no definite correlations relating nucleation
phenomena to design and operating conditions were found in
the present data.
Several methods for measuring the siie distribution of sludge
were compared. Two instrumental methods indicated much
finer size distributions than observed with the optical
microscope or micromesh sieves. Additional work is required to
resolve these discrepancies.
The report recommends further research at the bench and
pilot scale. Data thus obtained should be correlated with the
model developed in this study. For additional information,
contact the EPA/IERL-RTP project officer, R. H, Borgwardt,
(919) 541-2234 or (FTS) 629-2234.
DUAL ALKALI PROCESS DEMONSTRATED AT LG&E
EPA has selected Louisville Gas and Electric Company's
(LG&E's) Cane Run No. 6 Station for demonstration of a dual
alkali FGD system. LG&E and EPA are participating in the
design, operation, testing, and reporting of the demonstration
project. The purpose of the installation and operation is to
establish:
Overall performance SO, removal, lime utilization,
sodium makeup, regeneration of spent liquor, water
balance, scale potential, materials of construction, waste
cake properties, system reliability, and availability.
Economics capital investment and operating cost.
The work under the demonstration program is divided into
four phases. Phase I, preliminary design and cost estimate, is
summarized in a recently completed report, "Executive Sum-
mary for Full-Scale Dual Alkali Demonstration at Louisville
Gas and Electric Company-Preliminary Design and Cost
Estimate" (see FGD Reports and Abstracts section). Phase H
(engineering, design, and construction) is underway. A 3-month
period has been allotted for Phase III (start-up and acceptance
testing). Phase IV, a 1-year test program, is scheduled to start
in early 1979.
Further information is available from the EPA/IERL-RTP
project officer, N. Kaplan, (919) 541-2556 or (FTS) 629-2556.
(For abstracts of selected dual alkali test programs, and of the
project manual for this dual alkali system, see the FGD
Reports and Abstracts section in "FGD Quarterly Report,"
Volume 2, Number 1.)
FILM DISCUSSES FGD TECHNOLOGY IN US AND JAPAN
A film describing the history and current status of FGD
technology in the United States and Japan has been released
by EPA/IERL-RTP. "FGD: One Way to Cleaner Air" presents
detailed process descriptions and operating histories of FGD
systems installed at the following utilities:
* Chubu Electric Company's Nishinagoya Station,
Northern Indiana Public Service Company's (NIPSCO's)
Dean H. Mitchell Station,
* Kansas City Power and Light Company's La Cygne
Station,
Electric Power Development Corporation's (EPDC's)
Takasago Station,
* Chubu Electric Company's Owase Station,
Pennsylvania Power Company's Bruce Mansfield Stations
Nos. 1 and 2,
Montana Power Company's Colstrip Stations Nos. 1 and
2, and
Louisville Gas and Electric Company's (LG&E's) Cane
Run No. 4 and Paddy's Run No. 6 Stations.
The Nishinagoya and Dean H. Mitchell Stations are both
equipped with the Weltman-Lord FGD Process, a regenerable
system which produces marketable byproducts and regenerates
the absorbing solution for reuse. Various lime/limestone FGD
processes, including alkaline ash, carbide lime, and other
nonregenerable scrubber systems, are employed at the other six
installations featured in the film.
Several of EPA's completed and ongoing FGD test programs
are also discussed. The film describes in detail experiments at
LG&E's Paddy's Run Station and the Tennessee Valley
Authority's Shawnee Power Plant.
The 28-minute, 16-rnm film, in color and sound, will soon be
available on free loan, from:
HHR Fit media
Distribution Section
1212 Avenue of the Americas
New York, NY 10036
Requests for copies should specify film title and EPA number
(TF-127). (For information on other available films concerning
FGD, see the "FGD Quarterly Report," Volume 2, Number 2.)
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FGD QUARTERLY REPORT/SUMMER 1978
NEW lERL-RTP PERIODICALS ANNOUNCED
Process Measurements
Coal Technology Assessment
The first issue of a quarterly report, "Process Measurements
Review," has recently been released. The report focuses on the
development, assessment, and application of measurement
techniques for the energy and industrial process R&D programs
conducted by lERL-RTP's Process Measurements Branch. To
obtain a free subscription of this report, send a written request
to J. A. Dorsey (MD-62), EPA/IERL-RTP, Research Triangle
Park, NC 27711.
"The Future of Coal: Issues and Impacts" is a new periodical
scheduled for release by EPA/IERL-RTP. This report will
present information on EPA's Coal Technology Assessment
(CTA) program. The CTA program is designed to study the
impacts and questions resulting from increased US reliance on
coal for energy. Free subscriptions to this report series are
available on written request to: R. P. Hansen (MD-63),
EPA/IERL-RTP, Research Triangle Park, NC 27711.
Conventional Combustion
Environmental Assessment
A new periodical, "CCEA Quarterly Report," will soon be
released. The report will discuss EPA/lERL-RTP*s major new
conventional combustion environmental assessment (CCEA)
program, including overall scope and status, and related R&D
activities. The first two issues of the "CCEA Quarterly Report"
will be distributed, free of charge, to recipients of the "FGD
Quarterly Report." Both issues will contain return mailer cards
which may be used to indicate continued interest, change
addresses, or initiate new subscriptions. All others desiring a
free subscription to the "CCEA Quarterly Report" should send
a written request to: W. D. Peters (MD-61), EPA/IERL-RTP,
Research Triangle Park, NC 27711.
This brings to eight the total number of such publications
offered (including the "FGD Quarterly Report"). A brief
description of the others already in circulation appears in "FGD
Quarterly Report," Volume 2, Number 1. Information on these
reports may be obtained by contacting the respective project
officers indicated, at EPA/IERL-RTP, Research Triangle Park,
NC 27711:
Title
"Coal Cleaning Environmental
Review"
"Environmental Review of
Synthetic Fuels"
"FBC Environmental
Review"
Project Officer
J. D, Kilgroe (MD-61)
D. G. Lachapellc (MD-6S)
W. J. Rhodes (MD-61)
D. B. Henschel (MD-61)
MODELS CAN IDENTIFY
WATER RECYCLE/REUSE OPTIONS
Computer models are effective in identifying water
recycle/reuse options in coal-fired power plants. The models
are described in a report prepared recently by Radian Cor-
poration for EPA. The report, "Water Recycle/Reuse Alter-
natives in Coal-Fired Steam-Electric Power Plants," examines
three major water systems: cooling towers, ash sluicing, and
SOj/particulate scrubbing.
Models used were verified using the results of spot samples
taken at five plants. The verified models were then applied to
various water systems being evaluated at the five plants. The
computer simulations showed that improvements over existing
operations are both economically and technically feasible. Such
improvements would reduce water use and discharge.
Recirculation of the cooling water can .be increased in
cooling tower systems where calcium carbonate (CaCO3) or
calcium sulfate (CaSO,-2H,O) is the limiting scale-forming
species. All of the cooling tower blowdown liquid can then be
used as makeup to other major water consuming systems at
the plant, such as the ash sluicing system on FGD in-
stallations. Several factors are identified which can limit
recirculation in tower systems, such as chlorides and suspended
solids. Sulfuric acid addition or lime softening may be required
to achieve a high degree of recirculation, depending on the
plant makeup water quality.
Most fly ash sluicing operations are once-through with
discharge of the ash pond overflow. This study revealed that
recirculating fly ash sluice systems may be used. However,
since gypsum scaling and ash reactivity present can be
significant problems in such systems, treatment of blowdown
may be necessary prior to recycle or reuse elsewhere in the
plant.
Since lime-based SO,/particulate scrubbing systems may be
operated in a closed-loop fashion, water recycle/reuse is an
inherent part of the scrubbing system. However, cooling tower
blowdown or ash pond overflow can be used as scrubber
makeup water (excluding demister wash). Such practice would
result in zero water discharge from the water plant. Fresh
makeup water could be combined with cooling tower blowdown
or ash pond overflow and used as demister wash. This ap-
proach, however, is dependent on the respective water com-
positions and the amount of SO, removed in the demister. A
careful process analysis and pilot studies are suggested to
determine the quality of water required for demister wash in a
given FGD system.
The report describes the model assumptions and input data.
These factors restrict the use of the model in design of actual
modifications. However, generalized plans for developing water
recycle/reuse designs (including data analysis and pilot studies)
are given in the report. Further information is available from
J. W. Jones, EPA/IERL-RTP, (919) 541-2489 or (FTS) 629-
2489. (See also the FGD Reports and Abstracts section In this
issue.)
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FGD QUARTERLY REPORT/SUMMER 1978
MEETINGS HELD
FGD Waste Disposal
J. W. Jones of EPA/IERL-RTP's Emissions/Effluent
Technology Branch made a presentation on FGD-waste chemical
and physical properties, and served as a "wrap-up panel
member at a recent symposium on Waste Disposal from Coal
Power Plants. The symposium, sponsored by 1U Conversion
Systems, Inc., was held in Pittsburgh, Pennsylvania on June 20-
21, 1978. About 200 representatives from electric utilities, ar-
chitectural and engineering firms, FGD system suppliers, and
other private industries, as well as Federal and State regulatory
agencies attended the meetings. Major topics presented included
regulations, FGD waste properties, disposal methods, and
handling, dewatering, landfill techniques, and hydrogeology. In
addition, attendees visited an operational FGD waste treatment
and landfill disposal site at Duquesne Light's Phillips Station.
Jones started the technical session with an overview of the
problems associated with waste produced by coal-fired power
plants, including ash and FGD waste. Current regulations per-
taining to coal ash and FGD waste disposal were presented.
Jones discussed results of EPA-sponsored research on the
physical and chemical properties of treated and untreated FGD
wastes, and how these properties relate to waste handling,
disposal methods, and the potential for environmental impact of
disposal. In addition, plans for future work in this area were
described briefly.
For more information, contact J. W. Jones, EPA/IERL-RTP,
(919) 541-2489 or (FTS) 629-2489.
Third National
Energy/Environment Conference
N. Kaplan, M. A. Maxwell and J. W. Jones of EPA/IERL-RTP
presented papers on SOX control technology and waste disposal
technology at the Third National Conference of the Interagency
Energy/Environment R&D Program, held in June in Washington,
D. C. The conference, sponsored by EPA's Office of Energy,
Minerals, and Industry, provided the opportunity for in-depth
technical discussions of specific energy/environment problems.
Kaplan's and Maxwell's paper entitled, "Flue Gas
Desulfurization of Combustion Exhaust Gases," cited various SOX
control technologies, with emphasis on FGD. Process descrip-
tions were given for currently operating full-scale FGD systems.
The FGD systems were quantified by system type and plant
capacity, and were also categorized according to salable or
throwaway product.
The current status of FGD systems applied to utility and in-
dustrial boilers was described, with emphasis on utility systems.
Major problems incident to the application of FGD systems were
discussed with respect to their impact on system dependability.
The paper presented capital and operating costs for operating
FGD systems and for generalized designs, given certain basic
conditions. Control technology costs were compared with the
cost of electric power production.
Federal energy/environment R&D programs were discussed
briefly. The discussion emphasized large scale demonstration test
programs.
Projected growth of FGD use was given, based on currently
planned utility units facing more stringent regulations. Projected
growth rates were then compared with a projected need for FGD.
Jones' paper, entitled "Disposal of Power Plant Wastes,"
described an ongoing study that addresses potential en-
vironmental problems associated with wastes from modern coal-
fired electric generating plants, and the continuing effort to better
define, and solve the various disposal problems. Costs, potential
environmental problems, and alternative disposal options are
being examined. The study will provide a technical base for the
establishment of regulations (under the Clean Water Act and the
Resource Conservation and Recovery Act), and also will provide
a source of information for the utility industry.
The power plant waste disposal projects have produced
significant results. Among these are;
The chemical characteristics of FGD waste essentially
have been quantified; however, more study is needed to
control certain physical properties (e, g., particle size) of
the FGD waste solids.
Chemical treatment can improve the physical stability, as
well as lower the permeability and solubility of the major
constituents of FGD wastes.
* Coal ash needs further study, particularly as to the
potential toxicity of trace metals contained in the ash.
Ponding of FGD wastes does not appear to be a suitable
ultimate disposal method.
* A well-managed landfill of stabilized waste can avoid many
potential environmental problems.
» Waste disposal costs, a sizeable percentage of FGD system
costs, can be reduced with more efficient and economical
dewatering equipment.
In addition, costs can possibly be lowered by disposal of power
plant wastes in coat mines, a practice that already occurs
commercially. At-sea disposal of these wastes remains under
study.
Copies of both papers will be available in the "Proceedings of
the Third National Conference on the Interagency Energy/En-
vironment R&D Program." The Proceedings will be available,
free of charge, from:
Automation Industries, Inc.
Attention: Kathleen E. Dixon
14000 Georgia Avenue
Silver Spring, MD 20910
APCA Abstracts and Papers Available
Over 350 papers covering a broad range of air pollution topics
were presented at the 71st annual Air Pollution Control
Association (APCA) meeting and exhibition. The meeting, held in
Houston on June 25-30, also featured continuing education
courses, refresher courses, exhibits, and technical tours.
During the technical sessions, several FGD topics were ad-
dressed, including the EPA sponsored Shawnee FGD waste
disposal project (Aerospace Corp.), at-sea disposal of FGD waste
(A. D. Little), and dewatering of FGD waste (Auburn University).
Effects of NSPS, scrubber operation histories, and health effects
of SOX emissions were discussed in several papers.
Among the eight refresher courses offered was "Flue Gas
Desulfurization Waste Disposal Techniques," presented by M. C.
Osborne of the Emissions/Effluent Technology Branch of
EPA/IERL-RTP. Other topics included air pollution modeling,
emission monitoring methods, and energy/environment in-
teractions.
Over 100 industry and government agencies were represented
at the APCA exhibit. Exhibits featured the newest equipment and
related techniques for controlling and analyzing air pollution.
Pertinent EPA publications, including the "FGD Quarterly
Report" were also displayed.
The collected abstracts of technical papers delivered at the
conference are available, at $3.00 per copy, from APCA.
Payment must accompany order. The address is:
Air Pollution Control Association
P. O. Box 1861
Pittsburgh, PA 15230
Individual reprints of the technical papers may also be obtained
from the same address. The price per copy is $2.00 for members
and $3.00 for non-members.
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FGD QUARTERLY REPORT/SUMMER 1978
FGD REPORTS AND ABSTRACTS
Each report with an NTIS number can be ordered from
NTIS. The cost of paper copies varies by page count ($4.00
minimum); microfiche copies are $3. Payment must accompany
order. The address is:
National Technical Information Service
U. S. Department of Commerce
Springfield, Virginia 22161
(703) 557-4650
(FTS) 557-4650
EPA/IERL-RTP reports which do not have an NTIS number
are available free, as supplies permit, through IERl.-RTP's
Technical Information Service. The address is:
Technical Information Service (MD-64)
Industrial Environmental Research Laboratory
U. S. Environmental Protection Agency
Research Triangle Park, NC 27711
(919) 541-2216
(FTS) 629-2216
Flue Gas Desulfurization System Capabilities for
Coal-Fired Steam Generators. Volume I. Executive
Summary. Volume II. Technical Report.
T. Devitt, R. Gerstlc, L. Gibbs, S. Hartman, and R. Klier,
PEDCo Environmental, Inc., Cincinnati, Ohio, March 1978.
EPA-600/7-78-032 a & b. NTIS No. not available for Volume I.
NTIS No. for Volume I! is PB 279 417. EPA Project Officers:
J. E. Williams, IERL-RTP; and K. R. Durkee, OAQPS.
The report discusses the availability of technology for reducing
SO, emissions from coal-fired steam generators using flue gas
desulfurization (FGD) systems. Foreign and domestic lime,
limestone, double alkali, magnesium slurry, and Weliman-Lord
FGD systems are described, and the design parameters and
operating experiences are discussed. Steps that have been
taken to achieve high system operability are discussed. Also,
disposal of FGD system wastes is discussed briefly.
The Effect of Flue Gas Desulfurization Availability
on Electric Utilities. Volume I. Executive Sum-
mary. Volume II. Technical Report.
R. D. Delleney, Radian Corporation, Austin, Texas, March
1978. EPA-600/7-78-031a & b, (NTIS No. PB 281 366 & 7).
EPA Project Officers: J. E. Williams, IERL-RTP: and K. R.
Durkee, OAQPS.
The report gives results of an analysis of the effect of the
availability of a flue gas desulfurization system on the ability of
an individual power plant to generate electricity at its rated
capacity. (The availability of anything is the fraction of time it
is capable of service, whether or not it is actually in service.)
Also analyzed are its effects on a power generating system (a
group of several coal-, oil-, and gas-fired power plants plus
nuclear and hydroelectric plants).
Flue Gas Desulfurization Systems: Design and
Operating Considerations. Volume I. Executive
Summary. Volume II. Technical Report.
C. C. Leivo, Bechtel Corporation, San Francisco, California,
March 1978. EPA-600/7-78-030a & b. (NTIS No. PB 280 253
& 4). EPA Project Officers: J. E. Williams, IERL-RTP, and
K. R. Durkee, OAQPS.
The report describes flue gas desulfurization (FGD) systems and
the design and operating parameters that are monitored to
ensure proper operation. It explains how these parameters are
varied to accommodate changing boiler loads and fuel
characteristics, and describes the control of parameters to
prevent such problems as scale buildup. It describes effects of
designing and operating FGD systems for 90% or greater SOj
removal efficiencies, based on current testing program data. It
describes effects of coal characteristics on FGD performance,
along with operating and design techniques used to compensate
for coal property variations. It describes the purpose, need, and
methods for exhaust gas reheat, downstream of FGD systems.
It discusses alternatives to exhaust gas reheat.
EPA Utility FGD Survey: December 1977-January
1978
B, A. Laseke, Jr., PEDCo Environmental, Inc., Cincinnati,
Ohio, March 1978. EPA-600/7-78-051a. (NTIS No. PB 279
Oil). EPA Project Officers: N. Kaplan, IERL-RTP; and J. C.
Hertihy, DSSE.
The report presents a survey of utility flue gas desulfurization
(FGD) systems in the US. It summarizes information con-
tributed by the utility industry, process suppliers, regulatory
agencies, and consulting engineering firms. Systems are
tabulated alphabetically, by development status (operational,
under construction, in planning stages, or terminated
operations), by utility company, by process supplier, by
process, by waste disposal practice, and by regulatory class. It
presents data on system design, fuel sulfur content, operating
history, and actual performance. It discusses problems and
solutions associated with the boilers and FGD systems. Process
flow diagrams and FGD system economic data are appended to
the report.
Note: An updated supplement (EPA-600/7-78-051b) has been
issued and should be used in conjunction with this report.
EPA Industrial Boiler FGD Survey: Second
Quarter 1978
J. Tuttle, A. Patkar, N. Gregory, and M. Eckstein, PEDCo
Environmental, Inc., 11499 Chester Road, Cincinnati, Ohio,
July 1978. EPA-600/7-78-052b. EPA Project Officer: R. M.
McAdams. IERL-RTP.
The report presents detailed technical information concerning
application of flue gas desuifurization (FGD) systems to in-
dustrial boilers. Design and operation data have been obtained
from over 45 FGD control systems, with a capacity of over 7.5
million acfm ( 2200 MW equivalent). More than six FGD units
per year, on the average, have come on line since 1972, in-
dicating FGD to be a viable method of controlling SO,
emissions. The information was obtained by a survey of plant
personnel, control system vendors, regulatory agencies, and
consulting engineering firms. The data are given in two types
of tables: one gives summary information; the other, detailed
information. Summary tables present information as a function
of control process, control system vendor, disposal techniques,
operation status, start-up date, and flue gas capacity. Detailed
information includes: control system design, economics,
operating experience, problems and solutions, waste disposal
techniques, and maintenance practices.
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FGD QUARTERLY REPORT/SUMMER 1978
Executive Summary for Full-Scale Dual-Alkali
Demonstration at Louisville Gas and
Electric Co. Preliminary Design and Cost
Estimate
R. P. VanNess, R. C. Somers, T. Frank, J. M. Lysaght, I. L.
Jashnani, R. R. Lunt, and C. R. LaMantia, Louisville Gas and
Electric Company, Louisville, Kentucky, January 1978. EPA-
600/7-78-010a. (NTIS No, PB 281 530). EPA Project Officer:
N. Kaplan, IERL-RTP.
The report is the executive summary for the preliminary design
of the dual-alkali system, designed by Combustion Equipment
Associates, Inc./Arthur D. Little, Inc. and being installed to
control SO, emissions from Louisville Gas and Electric
Company's Cane Run Unit No. 6 boiler. The project consists of
four phases: I preliminary design and cost estimates; II
engineering design, construction, and mechanical testing; 111
startup and performance testing; and IV 1 year operation
and testing. Developed as part of Phase I, the executive
summary presents salient facts and conclusions from the Phase
I report for use by upper management and the general public.
Effects of Alternative New Source Performance
Standards on Flue Gas Desulfurization System
Supply and Demand
V. P. Patel and L. Gibbs, PEDCo Environmental, Inc., Cincinnati,
Ohio, March 1978. EPA-600/7-78-033. (NTIS No. PB 279 080.)
EPA Project Officers: J. E. Williams, IERL-RTP; and K. R.
Durkee, OAQPS.
The report discusses the capabilities of equipment vendors to
supply and install the quantity of flue gas desulfurization systems
required to meet alternative standards for coal-fired steam
generators. It analyzes limiting factors affecting supply
capabilities (such as the availability of components, equipment,
and skilled labor). It discusses guarantees that equipment ven-
dors have made and are witling to make, and the penalties that
they are willing to be assessed.
Potential Abatement Production and Marketing of
Byproduct Sulfuric Acid in the U. S.
J. 1. Bucy, R. L. Torstrick, W. L. Anders, J. L. Nevins, and P. A.
Corrigan, Tennessee Valley Authority, Muscle Shoals, Alabama,
April 1978. EPA-600/7-78-070. EPA Project Officer: C. J.
Chatlynne, IERL-RTP.
The report gives results of an evaluation of the market potential
for sulfur and sulfuric acid byproducts of combustion in power
plant boilers. (Air quality regulations require control of SOX
emissions from power plant boilers. Recovery of sulfur in useful
form would avoid waste disposal and conserve natural sulfur and
natural gas used to mine sulfur.) A cost model was developed to
estimate the least-cost compliance method from three alter-
natives: selecting a clean fuel strategy, selecting a limestone-
throwaway scrubbing technology, or selecting a sulfuric acid or
sulfur-producing scrubbing technology. For plants where
production of byproduct was the economic choice, a market
simulation model was used to evaluate distribution of byproducts
in competition with existing markets. Significant amounts of
sulfuric acid could be produced from SOX in power plant flue gas
and sold in competitive markets.
Water Recycle/Reuse Alternatives in Coal-Fired
Steam-Electric Power Plants. Volume I. Plant
Studies and General Implementation Plans.
Volume II. Appendices.
J. G. Nobletl and P. G. Christman, Radian Corporation,
Austin, Texas, March 1978. EPA-600/7-78-055a & b. (NTIS
No. for Volume 1 PB 282 211, NTIS No. for Volume II not
available.) EPA Project Officer: J. W. Jones, IERL-RTP.
The report gives results of an investigation of water
recycle/treatment/reuse alternatives in coal-fired power plants.
Five power plants from representative U. S. regions were
studied. The major systems encountered were cooling, ash
sluicing, and SOi/particulate scrubbers. Results were used to
provide general Implementation plans for the various options
identified. Computer models were used to identify the degree of
recirculation achievable in each water system without forming
scale. The effects of makeup water quality and various
operating parameters were determined for each water system.
Several alternatives for minimizing water requirements and
discharges were studied for each plant, and rough cost
estimates were made for comparison. An implementation plan
is presented for each water system and is divided into phases,
including system characterization, alternative evaluation, pilot
studies, and full-scale implementation. Volume I discusses the
recycle/treatment/reuse opportunities for cooling, ash sluicing,
and SOt paniculate scrubbing systems as well as combined
systems. It also includes the implementation plans. Volume II
presents detailed studies for each plant, plant selection
methodology, laboratory ash sluicing studies, kinetics for
CaCO, and Mg(OH), precipitation, and model descriptions.
Development of a Mathematical Basis for Relating
Sludge Properties to FGD-Scrubber Operating
Variables
J. L. Philips, J. C. Terry, K. A. Wilde, G. P. Behrens, P. S.
Lowell, J. L. Skloss, and K. W. Luke, Radian Corporation,
Austin, Texas, April 1978. EPA-600/7-78-072 (NTIS No. PB 281
582). EPA Project Officer: R. H. Borgwardt, IERL-RTP.
The report gives results of research to investigate prospects for
increasing the size of calcium sulfite sludge particles in flue gas
desulfurization systems. The approach included four work
packages: a literature survey and development of a mathematical
basis for predicting calcium sulfite sludge distribution; a com-
puter solution of the size distribution model to determine
parameter sensitivity; a literature survey and screening of
analytical methods for measuring settling rate, settled density,
and particle size distribution; and planning a test program to
investigate parameters not available from previous work to verify
the size distribution model. The crystal population balance
concept was introduced into the mathematical basis for
predicting particle size distribution of calcium sulfite sludge.
Relationships were derived that required nucleation and crystal
growth rate expressions which must be obtained from ex-
perimental data. Available pilot and full-scale scrubber data w<»«»
used to increase the usefulness of the theoretical model. The
relationship derived was solved for a specific process con-
figuration. An approximate solution was obtained assuming that
crystal size distribution does not change in the scrubber. A
computer routine was written to permit convenient parameter
sensitivity studies using the size distribution model.
10
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FGD QUARTERLY REPORT/SUMMER 1978
Controlling SO, Emissions from Coal-Fired Steam-
Electric Generators: Solid Waste Impact. Volume I.
Executive Summary. Volume II. Technical
Discussion.
P. P. Leo and J. Rossoff, The Aerospace Corporation. Los
Angeles, California, March 1978. EPA-600/7-78-044a & b.
(NTIS No. PB 281 099 & 100.) EPA Project Officer: J. W. Jones,
IERL-RTP.
The study assesses the technological, economic, and en-
vironmental impacts, projected to 1998, of the increased solid FGD
wastes resulting from the application of various more stringent
controls as well as of the current New Source Performance
Standards (NSPS) for SO, emissions from coal-fired steam-
electric generators. The study supports a review of the NSPS, by
EPA's Office of Air Quality Planning and Standards, that defines
a number of control strategies (e. g., increased scrubbing ef-
ficiency and coal washing) for achieviiig several levels of SO*
emission control, with emphasis on levels more stringent than
the current NSPS. The study considers three alternative
strategies (1.2 and 0.5 Ib SO./million Btu, and 90% SO,
removal), three plant sizes (1000, 500, and 25 MW). and five flue
gas desulfurization (FGD) systems (lime, limestone, double alkali,
magnesium oxide, and Wellman-Lord). Typical eastern and
western coals, as well as coal washing, are included. The study
ground rules include: (1) the nationwide survey to be 1978-1998;
(2) new-plant-instal!ed capacities during that interval (FPC
projection); (3) 1980 as the effective date for the more stringent
standards; and (4) western coal burned during the 1980-1998
period to be 45% of the total burned nationwide (variations in the
western coal percentage were also evaluated).
EPA PROJECT OFFICERS FOR CURRENT FGD RD&D PROJECTS
Robert H. Borgwardt, MD-65
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2234
(FTS)629-2234
Ted G. Brna, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2683
(FTS)629-2683
C. J. Chatlynne, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2915
(FTS>629-2915
Julian W. Jones, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2489
(FTS)629-2489
Norman Kaplan, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2556
(FTS1629-2556
Robert E. Landreth
USEPA, MERL-Cinn
26 West St. Claire St.
Cincinnati, OH 45268
Phone: (513)684-7871
(FTS)684-7871
R. Michael McAdams, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2915
(FTS)629-2915
J. David Mobley, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2915
(FTS)629-2915
Michael C. Osborne, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2898
(FTS)629-2898
Warren D. Peters, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2915
(FTS)629-2915
Wade H. Ponder, MD-61
USEPA, IERL-RTP
Research Triangle Park, NC 27711
Phone: (919)541-2915
(FTS)629-2915
Michael H. Rouller
USEPA, MERL-Cinn
26 West St. Claire St.
Cincinnati, OH 45268
Phone: (513)684-7871
(FTSJ684-7871
Donald E. Sannlng
USEPA, MERL-Cinn
26 West St. Claire Si.
Cincinnati, OH 45268
Phone: (513)684-7871
(FTS)684-7871
John E.Williams, MD-61
USEPA, IERL-RTP
Research Triangle Park. NC 27711
Phone: (919)541-2483
(FTS)629-2483
The "FGD Quarterly Report" is part of a comprehensive EPA Engineering Application/Information Transfer (EA/IT) Program on flue gas
desulfurization (FGD). The report is designed to meet four objectives: (1) To disseminate information concerning EPA sponsored and conducted
research, development, and demonstration (RDStD) activities in FGD; (2) to provide progress updates on selected ongoing contracts; (3) to
report final results of various FGD studies; (4) to provide interested persons with sources of more detailed information of FGD. The EA/IT
program is sponsored by EPA's Industrial Environmental Research Laboratory, Research Triangle Park, North Carolina (IERL-RTP).
The "FGD Quarterly Report" is prepared by Radian Corporation under EPA Contract No. 68-02-2608. The EPA Project Officer is R. Michael
McAdams (address above). The Radian Project Director is Elizabeth D. Gibson, P. O. Box 9948, Austin, Texas 78766 (512) 454-4797.
The report is distributed, without charge, to recipients interested in FGD. Persons wishing to report address changes, or initiate or cancel
their free subscriptions to the "FGD Quarterly Report" may do so by contacting the EPA Project Officer or Radian Project Director named
above.
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 an endorsement or recommendation for use by EPA.
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ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, N. C. 27711
Attention: R.M. McAdams (MD-61)
OFFICIAL BUSINESS
Penalty For Private Use $300
An Equal Opportunity Employer
Postage And Fees Paid
Environmental Protection Agency
EPA - 335
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