United States
Environmental Protection
Agency
EPA-600/7-84-065
June 1984
Research and
Development
RESULTS OF THE FIRST 2 YEARS
OF COMMERCIAL OPERATION OF
AN ORGANIC-ACID-ENHANCED
FGD SYSTEM
Prepared for
Office of Environmental Engineering and Technology
Prepared by
Industrial Environmental Research
Laboratory
Research Triangle Park NC 27711
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EPA-600/7-84-065
June 1984
RESULTS OF THE FIRST TWO YEARS OF
COMMERCIAL OPERATION OF AN ORGANIC-
ACID-ENHANCED FGD SYSTEM
Prepared by:
R. L. Glover
G. E. Brown
J. C. Dickerman
0. W. Hargrove
Radian Corporation
8-501 Mo-Pac Boulevard
Austin, Texas 78*759
EPA Contract No, 68-02-3171
Work Assignment No. S3
Project Officer:
J. David Mobley
Emissions Effluent Technology Branch
Industrial Environmental Research Laboratory
Office of Environmental Engineering and Technology
Research Triangle Park, NC 27711
Prepared for:
U. S. Environmental Protection Agency
Office of Research and Development
Washington, DC 20460
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ABSTRACT
The U. S. Environmental Protection Agency (EPA) has sponsored research
to develop organic-acid-enhanced flue gas desulfurization (FGD) technology
for existing and new coal burning facilities. A 1981 EPA-sponsored demon-
stration program at Springfield City Utilities Southwest Power Plant (SWPP),
located near Springfield, Missouri, showed that adipic acid and dibasic acid
(DBA) greatly enhanced FGD performance. SWPP has continued to use DBA to
achieve compliance with the 1971 SO* emissions standard under which they are
regulated. Thus, SWPP became the first commercial-scale system to use an
organic additive to enhance S02 removal.
This report documents the first two years (1982 and L983) of commer-
cial operation of the DBA system at SWPP. During 1982 and 1983, SWPP aver-
aged an SO2 emission rate of less than 1.0 lbs SO2/MM Btu. Conversely, in
1980 (prior to DBA addition), SWPP averaged approximately 5 lbs SOj/MM Btu.
FGD system reliability was also greatly improved averaging 97.9 percent in
1982 and 98.7 percent in 1983. These reliability figures compare to 45 per-
cent reliability in 1980. The SOj/Oj continuous emissions monitoring sys-
tem also exhibited excellent reliability exceeding 97 percent. Overall,
DBA has increased the flexibility of the SWPP system and, most importantly,
allowed SWPP to operate in compliance.
ii
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CONTENTS
Page
ABSTRACT ii
TABLES iV
FIGURES iV
1.0 SUMMARY 1-1
1.1 Background 1-1
1.2 Program Objectives 1-2
1.3 FGD System Description 1-3
1.4 Program Results 1-5
1.5 Conclusions 1-6
2.0 INTRODUCTION 2-1
2.1 Background 2-1
2.2 Program Objectives 2-2
3.0 FGD SYSTEM DESCRIPTION 3-1
3.1 Limestone Preparation Facility 3-1
3.2 Scrubber Modules 3-4
3.3 Solids Dewatering 3-5
3.4 Dibasic Feed System 3-6
4.0 ANALYSIS OF PROCESS CONDITIONS 4-1
4.1 Background 4-1
4.2 Scrubber Performance 4-1
4.3 DBA Consumption 4-5
4.4 Equipment Inspection and Reliability 4-6
5.0 DATA ACQUISITION 5-1
5.1 Continuous Emissions Monitoring System .. 5-1
5.2 CEMS Reliability 5-2
5.3 Quality Assurance 5-5
5.4 Ability of CEMS to Meet NSPS Requirements 5-7
6.0 REFERENCES 6-1
APPENDIX A - SWPP WEEKLY COAL ANALYSES A-l
APPENDIX B - SUMMARY OF FGD SYSTEM PERFORMANCE IN 1982 A-2
APPENDIX C - CONTINUOUS S02 EMISSIONS MONITORING RESULTS A-3
ill
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TABLES
Number Page
3-1 SWPP Average Monthly Coal Analyses for 1982 3-2 .
3-2 SWPP Average Monthly Coal Analyses for 1983 3-3
3-3 Typical Composition of Monsanto AGS Dibasic Acid
(Dry Basis) 3-7
3-4 Typical Composition of DuPont Dibasic Acid
(Dry Basis) 3-7
4-1 Summary of 1982 DBA Consumption Rates at SWPP 4-6
4-2 SWPP FGD System Reliability in 1982 and 1983 4-9
5-1 Summary of 1982 CEMS Reliability 5-4
5-2 Results of Method 6 Testing at SWPP on 19 August 1982 5-6
FIGURES
Number Page
1-1 SWPP FGD Flow Schema. 1-4 '
3-1 SWPP FGD Flow Scheme 3-1
3-2 DBA Flow Schematic Temporary System 3-8
3-3 Solubility of DBA in Water 3-10
3-4 DBA Flow Schematic Permanent System. 3-11
4-1 Comparison of SWPP Monthly Average SO2 Emission Rates;
1980 vs. 1982 and 1983 4-3
4-2 Comparison of SO2 Removal Efficiencies; 1980 vs. 1982 and 1983 4-4
5-1 Location of Continuous Monitors and Sample Ports at
SWPP 5-2
iv
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SECTION 1
SUMMARY
The U. S. Environmental Protection Agency (EPA) has sponsored a series
of research activities focused on developing organic-acid-enhanced flue gas
desulfurlzation (FGD) technology for existing and new coal burning facili-
ties. In 1982 and 1983. EPA conducted a continuous emissions monitoring
program at Springfield City Utilities Southwest Power Plant (SWPP) near
Springfield, Missouri, which had installed the first commercial-scale organic-
acid-enhanced FGD system. This report presents the results of that investi-
gation.
1.1 BACKGROUND
EPA's Industrial Environmental Research Laboratory at Research Triangle
Park (IERL-RTP) has an ongoing research and development program to improve
the performance of lime/limestone systems. One of the most promising aspects
of that effort has been the use of organic acids as buffering agents to in-
crease soluble alkalinity in limestone FGD systems. Adipic acid was identi-
fied as a suitable additive because of physical properties, availability,
and cost. After extensive laboratory-, pilot-, and prototype-scale studies
on adipic acid-enhanced limestone systems, EPA, in 1981, sponsored a full-
scale demonstration at SWPP with Radian Corporation employed as the test
contractor.^
A total of nine months of testing was conducted at SWPP. Four months
were spent at the beginning of the program investigating adipic acid addi-
tion in a forced oxidation system. Better than 90 percent S02 removal was
achieved in a 49-day duration run which was the longest continuous operating
period at SWPP to that date. Next, adipic acid addition achieved 85 to 95
percent S02 removal in a natural oxidation system over a period of three and
one-half months.
1-1
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Finally, a mixture of organic dibasic acids (DBA) was tested over a
3ix-week period following the adipic acid testing. DBA, a by-product of
adipic acid manufacturing, contains adipic, glutaric, and succinic acids,
and is less expensive than adipic acid. Testing at SWPP showed DBA to be
very effective in enhancing FGD system performance, resulting in a signifi-
cant decrease in SO2 emissions.
A cost analysis was then performed to determine the most cost effective
option which would enable SWPP to comply with the 1971 SOj> emissions stan-
dard. ^ Options considered included increasing the slurry rate to the
scrubbers, converting the scrubbers to spray towers, adipic acid enhance-
ment, and DBA addition. Lower costs associated with the DBA option as well
as its demonstrated effectiveness led SWPP to select DBA for long-term use.
In doing so, City Utilities' SWPP became the first commercial-scale facility
to utilize DBA in an FGD system application. This report documents commer-
cial operation of SWPP's DBA system covering the period from January 1982
to December 1983.
1.2 PROGRAM OBJECTIVES
Since operation at SWPP represents the first commercial scale use of
an organic acid-enhanced FGD sytem, IERL-RTP personnel decided it would be
useful to the Industry to document system performance following the demon-
stration program. Consequently, in May 1982, Radian Corporation was
contracted to monitor SO2 emissions and the overall process conditions at
SWPP. The primary objectives of'this program were to evaluate the perfor-
mance of the DBA-enhanced system and to note any long-term effects on the
process. A secondary objective was to document the performance of the
continuous emissions monitoring equipment in 1982 to determine the ability
of that equipment to collect data as required in the 1979 revisions to the
utility USPS. A brief description of the SWPP system and a summary of the
monitoring program results are presented in the following sections.
1-2
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1.3 FGD SYSTEM DESCRIPTION
The SWPP FGD system consists of two parallel tray tower modules, each
sized to handle 60 percent of the design flow. The coal typically contains
from 3.5 to 4.0 percent sulfur, corresponding to inlet flue gas concentra-
tions of 2000 to 2600 ppm S02. Limestone preparation, sludge dewaterlng,
and sludge disposal systems are common to the two modules.
Figure 1-1 shows the overall flow scheme for the FGD system. The flue
gas enters the presaturator area where it is cooled by clarified liquor
(supernatant) from the thickener. The gas then passes through three levels
of gas-liquid contact trays, the mist eliminator, and out of the stack. No
flue gas reheat is used.
Slurry is circulated from the reaction tank below the scrubber through
spray nozzles above the top level of trays. Makeup limestone is added from
the limestone storage tank to the reaction tank to maintain the pH setpoint.
Solids are first settled in the thickener, and the thickener underflow slurry
is dewatered on a vacuum filter belt. The resulting sludge is mixed with fly
ash in the pug mill and trucked to an on-site landfill. Supernatant (thick-
ener overflow) from the dewaterlng operation is returned to the FGD modules
as presaturator and mist eliminator wash water. Additional supernatant water
is utilized in the limestone preparation area.
A temporary DBA feed system was installed to add DBA solution on a con-
tinuous basis. DBA is delivered on site in 6000 gallon (22,710 liter) tank
trucks. Hot water (M.40°F, 60°C) was circulated through a stream" jacket
surrounding the tank to inhibit any DBA crystallization.
Initially, DBA was pumped from the tank truck to the ball mill sump.
The feed rate was set manually. After the DBA was mixed with the freshly
ground limestone slurry from the ball mills, the mixture was pumped to the
limestone storage tank. Since the limestone handling equipment was common
1-3
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TO
STACK
THICK (MIA -
OVUFIOW Cr~"
Dibasic
Acid
MCVCI.I
Trays
•(ACTIO* TAJIK
MU1
SUMftNATAMT
rr>HCxiNtn ovinnowi-
MTUNNTOMOCIU
VACUUM
ra.T(n
Figure 1-1. SWPP FGD Flow Schema.
1-4
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to boch scrubber modules, both scrubbers operated at essentially the same
DBA concentration. Later in September 1982, the DBA feed system was modified
to allow DBA to be fed separately into the reaction tank of either scrubber.
As of May 1983, SWPP began operation with a permanent DBA feed system.
This system includes an 18,000 gallon (68,000 liter) stainless steel storage
tank, immersion heater, two 30-gpm (114 liters/min) DBA circulation pumps,
feed line to the Individual modules, and a source of heated flush water.
SWPP estimates the cost of the permanent system at approximately $300,000.
To date, SWPP has reported no problems with the permanent feed system.
1.4 PROGRAM RESULTS
Analysis of the SWPP FGD system operation in 1982 and 1983 shows that
the DBA-enhanced system is continuing to perform well. SO2 emissions averaged
less than 1.0 lb S02/MM Btu (430 ng/J) in 1982 and 1983 compared to approx-
imately 5 lb SO2/MM Btu (2170 ng/J) in 1980 (before DBA use). FGD system
reliability averaged nearly 98 percent in 1982 and almost 99 percent in 1983.
In 1980, before the adipic acid demonstation program, the FGD system relia-
bility was only 45 percent.
The flexibility of the DBA-enhanced system was well demonstrated in
1982 as SWPP personnel adjusted conditions to minimize scaling in the mist
eliminators prior to installation of limestone classifiers. The pH setpoint
was reduced from the 5.4 pH setpoint used during the DBA demonstration to
5.0. The reduced pH resulted in increased limestone utilization which helped
maintain mist eliminator reliability; Higher DBA concentrations were required
with the lower pH setting, which resulted in a higher DBA consumption rate
(30 lbs DBA/ton SOj (15 g/kg SO2) removed compared to 15 lbs/ton (25 g/kg)
in the demonstration program.) However, the system reliability was main-
tained at a very high level in spite of a poor limestone grind. The instal-
lation of limestone classifiers in late 1982 permits operation at higher
pH's with good limestone utilization. 1983 results reported by SWPP show
the DBA consumption was reduced to about 25 lbs per ton S02 (5 g/kg SOj)
1-5
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using the new classifier system. Further reduction in DBA consumption may
be possible.
Finally* the continuous emissions monitoring system performed very well.
Although called upon to operate nearly all of 1982 (except for boiler outages
in April and December), the system average reliability was 97 percent. Only
minor problems were experienced, most of which involved power interruptions
to the DART® microprocessor. During 1983, very few problems were noted with
the CEM system.
1.5 CONCLUSIONS
SWPP's FGD system continues to perform very well with respect to both
reliability and SO2 reductions. DBA has increased the versatility of the
FGD system as shown by the successful operation at pH 5.0. SO2 emissions
were well within the 1.2 lb SO2/MM Btu (520 ng/J) limit, and the reliability
of both the FGD system and continuous monitoring system throughout 1982 and
1983 were excellent. In summary, the following conclusions can be drawn from
this program:
• Use of DBA allows SWPP to remain in compliance with the
SO2 regulation. An average SO2 emission of less than 1.0
lb SO2/MM Btu (430 ng/J) was measured in 1982 and 1983
with DBA addition compared to an emission rate of 5 lb S02/
MM Btu (2170 ng/J) in 1980 prior to the adipic acid demon-
stration program.
• DBA greatly increase's the flexibility of the FGD system,
allowing successful operation over a wide pH range.
Operation at a reduced pH in conjunction with better
utilization of fresh water to the FGD system allowed SWPP
to achieve an overall reliability of 97.9 percent in 1982.
An FGD system reliability of 98.7 percent was achieved in
1983.
• Limestone classification and grinding circuit performance
is important to overall system performance. In 1982, DBA
consumption at SWPP was about 30 lbs/ton SO2 (15 g/Vcg SO2)
1-6
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due primarily to operation at a lower pH and a decrese In
recycle pump performance. A limestone classification sys-
tem was installed in late 1982, enabling the system to
operate at a pH of 5.6-5.8 with good limestone utilization.
Higher pH operation reduced the DBA consumption rate to ap-
proximately 25 lb/ton SO2 (5 g/kg SOj) during 1983. Further
reductions in DBA consumption may be possible.
• Finally, continuous monitoring systems can be reliable in
commercial operation. The continuous monitoring system
at SWPP proved to be 97 percent reliable during 1982. The
relative accuracy remained well within tolerance limits
set by EPA. Based upon these results, the continuous
monitoring system can reliably and accurately supply
the data necessary to compute 30-day rolling average
emission rates over a long duration.
1-7
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SECTION 2
INTRODUCTION
The U. S. Environmental Protection Agency (EPA) has sponsored research
efforts to develop organic-acid-enhanced flue gas desulfurization (FGD) tech-
nology for coal-fired utilities. A demonstration program sponsored by EPA in
1981 at Springfield City Utilities Southwest Power Plant (SWPP) near Spring-
field, Missouri, showed dibasic acid (DBA), a mixture of organic acids, to
be very effective in enhancing FGD performance.^ After the conclusion of
this program, SWPP made a decision to use DBA on a permanent basis. Thus,
SWPP became the first commercial-scale facility to use an organic acid addi-
tive to enhance S02 removal. This report presents the results of an EPA
sponsored monitoring program at SWPP to document the first two years of
commercial operation.
2.1 BACKGROUND
The majority of FGD systems currently operated by the electric utility
industry use lime or limestone as the slurry reagent. Lime/limestone FGD
systems are anticipated to be the most widely used technologies in the
future because of lower capital and operating costs compared to other FGD
technologies. Limestone systems are generally the more cost-effective of
the two because of the lower cost of limestone. Limestone systems, however,
are limited by the reduced reactivity of the reagent which produces lower
soluble alkalinity in the scrubber slurry. This limitation is overcome by
operating at higher liquor-to-gas (L/G) ratios and employing larger reaction
tanks than other FGD processes.
EPA's Industrial Environmental Research Laboratory at Research Triangle
Park, North Carolina (IERL-RTP) has an ongoing research and development
program to improve the performance of lime/limestone systems. One of the
2-1
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most promising aspects of chac effort has been the use of organic acids as
buffering agents to increase soluble alkalinity in limestone FGD systems.
Adipic acid was identified as a suitable additive because of physical
properties, availability, and cost. After extensive laboratory-, pilot-and
prototype-scale studies on adipic acid-enhanced limestone systems, EPA, in
1981, sponsored a full-scale demonstration at SWPP with Radian Corporation
employed as the test contractor.
A total of nine months of testing was conducted at SWPP. About four
months were spent at the beginning of the program investigating adipic acid
addition in a forced oxidation system. After an initial shakedown period,
greater than 90 percent SO2 removal was achieved during a 49 day continuous
run. Next, adipic acid addition to a naturally oxidized system achieved 85
to 95 percent S02 removal over a period of approximately three and one-half
months. Finally, during a six week period, DBA (dibasic acid) was demon-
strated as a cost-effective alternative to pure adipic acid in a naturally
oxidized process. DBA, a by-product of adipic acid manufacturing, is pri-
marily a mixture of glutarlc, adipic and succinic acids.
The results of the DBA test phase of the demonstration program indi-
cated that DBA addition enhances FGD system performance and increases system
flexibility. Following the demonstration program, SWPP selected DBA for
long-term use as the most cost-effective option to insure compliance with
the 1971 S02 emission standard. Thus, SWPP became the first commercial-
scale facility to use an organic acid additive to enhance FGD system per-
formance. Since SWPP was the first commercial DBA system, IERL-RTP decided
to continue to monitor system performance for a period of two years.
2.2 PROGRAM OBJECTIVES
The primary objectives of this program were to: 1) document the first
year of cotmnercial operation of the DBA-enhanced system, and 2) demonstrate
that DBA would continue to effectively enhance performance over a long dura-
tion with the utility in sole control of process operating conditions. Most
2-2
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of Che effort was directed at the continuous monitoring results as a measure
of system performance with some effort devoted to analyzing changes in process
chemistry.
A secondary objective of the program was to assess the reliability of
the continuous emissions monitoring system. The 1979 NSPS for utility boilers
places rigorous demands on data acquisition systems. Therefore, EPA was in-
terested in measuring the reliability of the continuous emissions monitoring
system at SWPP during 1982.
2-3
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SECTION 3
FGD SYSTEM DESCRIPTION
The FGD system consists of tvo parallel tray tower nodules, each sized
to handle 60 percent of the design flow. The coal typically contains from
3.5 to 4.0 percent sulfur, corresponding to Inlet flue gas concentrations of
2000 to 2600 pprn S02. A monthly summary of SWPP coal analyses are presented
in Tables 3-1 and 3-2.
Figure 3-1 shows the overall flow scheme for the FGD system. The flue
gas enters the presaturator area where it is cooled by clarified liquor
(supernatant) from the thickener. The gas then passes through three levels
of trays where S02 removal is accomplished, through the mist eliminator, and
out the stack. No flue gas reheat is used.
Slurry is circulated from the reaction tank below the scrubber through
spray nozzles above the top level of trays. Makeup limestone is added from
the limestone storage tank to the reaction tank to maintain the pH setpoint.
The solids content of the recirculating slurry is controlled by pumping
slurry to the thickener. Solids are first settled in the thickener, and the
thickener underflow slurry is dewatered on a vacuum filter belt. The result-
ing sludge is mixed with fly ash In the pug mill and trucked to an on-site
landfill. Supernatant (thickener overflow) from the dewatering operation is
•
returned to the FGD modules as presaturator and mist eliminator wash water.
Additional supernatant water is utilized in the limestone preparation area.
3.1 LIMESTONE PREPARATION FACILITY
The limestone used in the FGD system is obtained from several quarries
around Springfield, and trucked to SWPP, where it is stored in "ready" piles.
Limestone is conveyed from the storage piles td one of two 1500 cubic feet
3-1
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TABLE 3-1. SWPP AVERAGE MONTHLY COAL ANALYSES FOR 1982*
X by Weight (as received) Heating Value
Month
Moisture
Ash
Volatlles
Fixed Carbon
Sulfur
(Btu/lb)
January
9.8
13.5
35.5
41.1
3.9
11,440
February
9.8
13.2
35.1
41.9
3.7
11,670
March
7.8
12.8
35.5
44.0
4.3
11,830
April
UNIT OUTAGE
May
7.1
12.9
33.2
46.9
2.9
12,000
June
8.3
12.0
35.4
44.2
3.1
11,970
July
7.2
12.A
37.0
43.5
3.7
11,940
August
8.1
13.8
37.4
40.7
3.1
11,550
Septeaber
6.1
13.6
39.6
40.7
3.8
11,780
October
5.2
10.5
38.4
46.0
3.7
12,500
Novenber
6.6
10.1
38.7
44.7
3.7
12,540
December
UNIT OUTAGE
Weekly coal analyses used to calculate nonthly averages are presented in Appendix A.
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TABLE 3-2 £WPP AVERAGE MONTHLY COAL ANALYSIS FOR 1983
naBaESaBBSSSSSS=SSS=SS3=SSSSSS3SS3BS3SSSSBC=S3=SSSSSE&SSa3SS5aSSSSS=S=SSSSSS3BS=S=BSSSSSSB=
X by Weight (as received) Heating Value
Month
Moisture
Ash
Volatiles
Fixed Carbon
Sulfur
(Btu/lb)
May*
9.4
9.8
36.5
44.2
3.6
11,923
June
8.9
12.2
36.7
42.2
3.8
11,896
July
8.9
12.4
36.6
42.1
3.9
11,864
August
6.7
10.9
37.2
45.2
3.8
12,444
September
7.0
11.7
36.7
44.6
3.9
12,212
October
10.4
12.0
37.2
40.3
3.9
10,915
November
8.0
12.1
36.6
43.3
3.9
11,979
December
8.0
12.1
36.3
43.3
3.9
11,979
*Unit outage from December 1982 through May 1983
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TO
STACX
Dibasic
Acid
MCVCU
nuicua
rnoMaoiuii
MiMruturoN
MATH
SUMRNATANf
(THICK INCH 0 VMW-OWh
MTumroraocfu
SUFUMATANT
TANK
SUJOOITO
UNonu
VACUUM
NITM
Figure 3-1. SWPP FGD flow scheme.
3-4
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(45 m3) storage silos prior to being fed to the wet ball mills. Each ball
mill is designed to process 9 tons (8160 kg) of limestone per hour. The re-
sulting slurry is 65 percent solids by weight and 50 to 60 percent through
200 mesh. Limestone classifiers have been installed recently to further re-
duce the size of the feed solids. The slurry from each ball mill is dis-
charged into a 1700 gallon (6440 liter) slurry sump. Here, the 65 percent
limestone slurry is diluted to a 30 percent solid slurry and pumped to the
limestone storage tank. The limestone is supplied to the scrubbers through
a recycle-type piping arrangement which allows higher slurry velocities and
reduces chances of plugging. Limestone transfer pumps (1 operating/1 standby
per scrubber module) feed the limestone slurry to each of the scrubber modules
based on an automatic pH control system. Control valves at each of the mod-
ules control the amount of limestone makeup fed to the reaction tanks to
maintain the pH setpoint. The remainder of the limestone slurry is recycled
back to the limestone storage tank.
3.2 SCRUBBER MODULES
The flue gas stream is divided downstream of the electrostatic precipi-
tator and passed through one of.two scrubber modules. Supernatant from the
thickener cools the gas entering the presaturation sections of the scrubber
modules from 300 to 120°F (149 to 52°C). The gas then passes through three
slurry-contacting stages. Each stage originally consisted of ten 6 ft. x
6.5 ft. x 3 ft. cages (1.8 x 1.95 x 0.9 m) which contained approximately four
inches (10.6 cm) of plastic TCA spheres (1.25 inches [3.18 cm] diameter). In
May 1981, the TCA cages in one of the 'modules were removed and three levels
of perforated trays were installed. The other module was likewise modified
In October 1981. The gas flow rate through each module is approximately
300,000 acfm (9000 m3/min) saturated at 125°F (52°C) at full load conditions.
The scrubber feed slurry is recycled from the 165,000 gal (627 m3) con-
crete reaction tank through a 36 inch (91 cm) pipe at a nominal rate of
13,500 gpm (51.3 m3/min). At full load conditions, the L/G ratio is 45 to 50
3-5
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gal/1000 acf (7 to 8 A/Nm3) and the gas phase pressure drop is 10 to 12 inches
U2O (25 to 30 cm). Eighteen spray nozzles are positioned above the top stage
of trays to distribute the slurry. The spent slurry and excess supernatant
from the presaturator section drain to the reaction tank. A constant level is
maintained in the reaction tanks by gravity overflow to a common sump tank be-
tween the two reaction tanks. Slurry is then pumped from the sump to the
thickener to control the reaction tank slurry solid concentration at about 10
weight percent.
Before the gas stream leaves the scrubber, it passes through two levels
of fiberglass chevron mist eliminators to remove entrained slurry. The lower
mist eliminator is continuously rinsed with supernatant water (top and bottom)
to prevent solids buildup. Spent wash water is collected in trap-out trays be-
low the lower chevrons and drains into the sump between the reaction tanks.
The upper mist eliminator is not washed.
The scrubbers are constructed of carbon steel and lined with natural
rubber. Reaction tanks are concrete. Duct work connecting both modules to
the stack is 1/4 inch (0.64 cm) thick carbon steel lined with fiberglass re-
inforced polyester.
3.3 SOLIDS DEWATERING
Thickener underflow slurry containing 25 to 40 weight percent solids is
pumped from below the center of the 860,000 gal (3.260 m3) thickener to the
vacuum filter belt. The flow rate is controlled by monitoring the torque on
the thickener rake. If the torque drops below a preset value, low solids
content in the thickener underflow is indicated. The underflow stream is
then recycled to the thickener mix well to build thickener solids inventory
while maintaining slurry velocities through the underflow piping, which mini-
mizes chances for plugging.
3-6
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Onca che underflow slurry reaches the filter belt, excess water is re-
moved from the sludge through the cloth belt by a 15 Inch (38.1 cm) H2O
vacuum produced by 300 HP (224 kilowatt) pump. The filtrate is collected in
tanks below the belt and then pumped back to the thickener. Overflow from
the thickener drains to the supernatant tank where it is pumped to the
scrubber modules and used to maintain tank levels, for quench purposes, for
limestone grinding, etc.
The cake produced from the filtering process contains between 50 and 70
weight percent solids. Filter cake solids content is dependent upon the
oxidation of the sulfite in the reaction tank and the crystal morphology of
the solids. As a final step in the disposal process, the filter cake is
mixed with fly ash in a pug mill and trucked to the landfill.
In emergency conditions, such as during filter equipment malfunctions,
the thickener underflow slurry can be pumped to either the ash pond or the
emergency pond to keep the FGD system in operation without overfilling the
thickener with solids. In this situation, additional makeup water and DBA
are required by the FGD system to replace that lost with the underflow slurry.
If the emergency pond is used, then clear liquor laden with DBA can be re-
turned to the FGD system to recover some of the DBA which was lost.
3.4 DIBASIC FEED SYSTEM
DBA is a mixture of glutaric, succinic, adipic and nitric acids and
other organic nitrogen compounds. It is obtained as a by-product in Che
production of adipic acid. SWPP used a 20 percent DBA solution supplied by
Monsanto Corporation during most of 1982. In mid-August, however, SWPP changed
to a 50 percent solution supplied by DuPont, which they used for the remainder
of the year. Typical composition (dry basis) for both the Monsanto and DuPont
products are shown in Tables 3—3 and 3—4, respectively.
3-7
-------
TABLE 3-3. TYPICAL COMPOSITION OF MONSANTO
AGS DIBASIC ACID (DRY BASIS)*
Component
Weight Percent
Glutaric Acid
56
Succinic Acid
19
Adipic Acid
14
Nitric Acid
11
*DBA is a by-product and its composition may vary.
Source: Reference 2
Table 3-4. TYPICAL COMPOSITION OF DUPONT
DIBASIC ACID (DRY BASIS)*
Component Weight Percent
Glutaric Acid
Succinic Acid
Adipic Acid
Organic Nitrogen Compounds
Nitric Acid
Copper
Vanadium
*DBA is a by-product and its composition may vary.
Source: E. I. DuPont DeNemours and Company, Inc.
A temporary DBA feed system was also used during 1982. The entire
temporary system was assembled on-site in a matter of a few days at a cost of
(3)
approximately $1000 . A flow schematic for the temporary feed system is
shown in Figure 3-2. Aa shown, a 6000 gal. stainless steel tanker trailer
served as the DBA storage tank. Hot water (140°F) supplied via two resi-
dential hot water heaters was recirculated through the thermal jacket of the
storage tanker to prevent crystallization of the DBA. Crystallization can
56
23
20
1
0.2
0.1
0.008
3-8
-------
REGULATING
VALVE
D. B. A. SUPPLY
METER
COLD WATER RETURN
MAKEUP WATER SUPPLY
HOT WATER SUPPLY
ELECTRIC HOT WATER HEATERS
H3"
PUMP
LIMESTONE
MAKEUP SUMP
2nd STAGE
HEATER
1st STAGE
HEATER
D. B. A. STORAGE
TANK TRAILER
TO F. G. D. MODULES
WITH LIMESTONE MAKEUP
Figure 3—2. DBA Flow Schematic Temporary System.
Source: Reference 4
-------
be a problem if the solution is allowed to cool. For example, a 20 percent
DBA solution oust be maintained above 75°F to prevent crystallization. As
shown in Figure 3—3» higher DBA concentrations will require higher tempera—
tures.
Initially» DBA was added to the limestone sump from the tanker. After
mixing with the freshly ground limestone from the ball mills, the mixture was
pumped to the limestone storage tank. Since the limestone handling system is
common to both scrubber modules, both scrubbers operated at essentially the
same DBA concentration. Late in September, however, the DBA system was up-
graded to allow DBA to be fed directly to the individual scrubber reaction
tanks. This modification allowed the system to be more responsive to sudden
process changes such as unit load swings.
Minor problems were encountered with the temporary system due to DBA
crystallization and subsequent feed system pluggage. For the most part,
these incidents were restricted to times when a new shipment of DBA had
cooled in transit and was being transferred to the storage tanker. The size
of the storage tanker (approximately the same size as the transport vessel)
also necessitated careful scheduling of DBA shipments. Overall, however,
operation of the temporary system proved to be very effective in 1982, with
SWPP achieving an overall S02 removal efficiency of 84.3 percent for the
year, which included bypass, startup and shutdown periods (4).
A permanent DBA feed system (see Figure 3-4) is now operational at SWPP.
The permanent system, estimated to cost approximately $300,000, includes an
18,000 gallon stainless steel storage tank equipped with an immersion heater,
two 30 gpm DBA circulation pumps, feed lines to the individual scrubbers, and
a source of heated flush water. Deliveries of DBA are transferred to the
storage tank via a closed pneumatic transfer system to avoid exposure to re-
duced ambient temperatures. Since becoming operational in May 1983, SWPP has
reported no problems with Che permanent system.<3,4) SWPP achieved an average
S02 removal efficiency of 85.1 percent during 1983 including startup, shutdown,
and upset conditions.
3-10
-------
200 —
180 _
160
t*
o
2 140-
3
u
4
U
4J
I*
| 120¦
100-
80 -
60-
, r
AO 60
Weight X DBA In Water
T"
20
~T
80
Figure 3-3. Solubility of DBA in Water.
Source: E. I. DuFont De Nemours and Company, Inc.
(Petrochemical Department Intermediate Division
publication E - 55901 Rev. 3/83)
3-11
-------
DIBASIC ACID
STORAGE
TANK
ELECTRIC
HEATER
)
t
HOT
WATER
heaters
FLUSH WATER SUPPLY
FLUSH WATER SUPPLIED
TO ALL REQUIRED POINTS
RECIRCULATION FLOW
BACKPRESSURE
REGULATION
PUMP
SUPPLY
FLOW
—{x|—0 CxJ_"
-tx}—
CIRCULATING PUMPS
FLUSH WATER SYSTEM
D.B.A. FEED TO INDIVIDUAL
F. G. D. MODULE REACTION TANKS
O
O
REGULATING
VALVES
METERS
Source: Reference 4
Figure 3—4. DBA Flow Schematic Permanent System.
-------
SECTION 4
ANALYSIS OF PROCESS CONDITIONS
One of the objectives of the program was to identify any long-term
effects of DBA addition to a lime/limestone FGD system. Along with the SO2
emissions data, SWPP personnel supplied copies of the scrubber operator's
log sheets, the plant chemist's DBA concentration log sheet, and the results
of the weekly proximate coal analyses during 1982. In 1983, data was obtained
from City Utilities quarterly report submitted to the EPA. This section
summarizes the results of the analysis of that data.
4.1 BACKGROUND
Data from January to June 1982 were obtained from SWPP records. In
June, Radian personnel upgraded the data acquisition system and arranged for
all data to be recorded on computer diskettes using the DART® microprocessor.
The diskettes were sent to Radian by SWPP personnel on a regular basis, where
they were analyzed and stored on tape using an IBM 3033 computer. An analysis
of this data as well as the data supplied by SWPP prior to June is presented
in the following sections. In 1983, the data was obtained from daily emission
summaries which were submitted to the Region VII enforcement division of the
EPA.
4.2 SCRUBBER PERFORMANCE
An inlet SO2 monitor was used du-ring the demonstration program to
measure the scrubber inlet SO2 concentrations. This monitor was provided
only for the duration of the demonstration program and was not available
during the 1982 SWPP monitoring program. Therefore, the S02 concentration
in the scrubber inlet flue gas was estimated from weekly SWPP proximate coal
analyses (see Appendix A). Inlet concentrations between analyses were
estimated by linear extrapolation.
4-1
-------
S02 emission races for each scrubber module were calculaced based upon
continuous monitor data. SO2 removals were estimated using the continuous
monitor results and an estimate of the inlet SO2 concentration from the
proximate coal analyses as described above. A summary of the SO2 removal
data for both modules during 1982 is provided in Appendix B. Overall SO2
emissions data for 1983 are included in Appendix D. Only overall emissions
are reported in Appendix D; no individual module data were obtained.
Perhaps the best indication of the performance of the SWPP scrubbers
is reflected in the 1982 and 1983 average monthly emission rates plotted in
Figure 4-1. For comparison, 1980 emission rates (prior to DBA use) are also
shown. As shown, DBA has allowed SWPP to reduce emissions from an average
of about 5 lb SOa/MM Btu in 1980 to less than 1.0 lb SO2/MM Btu in 1982 and
1983. Over the same periods, overall SO2 removal has likewise increased from
an average of 26 percent in 1980 to 84 percent in 1982 and 85 percent in 1983.
SWPP has also remained in compliance, even during periods when the coal sulfur
level increased to 4.7 percent (normal is 3.5 to 4.0 percent S). The emission
rate increased at the end of 1982 because of installation of classifiers in
each limestone circuit. The module under service was by-passed in order to
maintain generation under terms of the consent decree.
In addition, during most of 1982, the scrubbers were operated at a pH
of 5.0 to increase limestone utilization and reduce mist eliminator pluggage.
This is significantly less than the 5.4 pH at which the absorbers were
operated during the 1981 DBA demonstration testing. Despite the low pH
operation, DBA allowed SWPP to remain in compliance throughout the year.
Thus, SWPP utilized the versatility provided by DBA to avoid a potentially
severe and costly maintenance problem.
Finally, the daily average SO2 emission exceeded 1.2 lb S02/MM Btu only
four times when the scrubber modules were in operation for 18 or more hours
per day (three times on Module S-l and once for Module S-2. Two of these
times, the other scrubber's S02 emission was sufficiently low such that the
4-2
-------
overall emission rate (average of S-l and S-2 emissions) was less than 1.2
lb S02/MM Btu. In the other two cases, only one scrubber was in use due to
low boiler loads. There is also some evidence indicating that sulfite blind-
ing of the limestone may have been a problem during these two periods.
Sulfite blinding is thought to involve the precipitation of calcium sulfite
on the surface of limestone particles. Decreases in pH and/or sluggish pH
control with an associated drop in S02 removal characterize this phenomena.
The FGD system continued to perform well during 1983. As in 1982, the
average S02 emission rate was less than 1.0 lb S02/MM Btu. The 24-hour
average emission rate exceeded 1.2 lbs S02/MM Btu seven times in the 135
days of reporting. All but one of the seven days had high values because
of boiler startups without the scrubbers on-line. Most of the outages were
due to leaking condensor tubes and boiler water wall tube leaks. The system
still averaged above 85 percent S02 removal for the year in spite of several
incidences of start up and shutdown experienced during the last quarter.
(An outage encompassing the first 4 months of 1983 was required for system
maintenance including relining the stack.)
4.3 DBA CONSUMPTION
Throughout the program, SWPP supplied Radian with copies of log sheets
taken at SWPP so that process conditions at the plant could be tracked. One
parameter of particular interest was the consumption of DBA. At the end of
the demonstration program ( September and October 1981), approximately one
and a half months of testing were conducted to evaluate the performance of
DBA.^ At that time it was determined that a DBA feed rate of about 60 lb/hr
(27 kg/hr) was required to attain 85 percent S02 removal efficiency at a pH
of 5.4. That translates to a buffer capacity of about 500 pptn (adipic acid
equivalent) and a consumption rate of approximately 15 lb DBA/ton S02
(7.5 DBA/kg S02) absorbed.
4-3
-------
B- -
4- -
. 19 B Q
19 BS
I9B3
+
+
+
-I-
+
+
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Figure 4-1. Comparison of SWPP Monthly Average S02 Emission Rates,
1980 vs. 1982 and 1983.
Source: Reference 4
-------
I
Ui
s
1
OJ
o
CO
M
a!
M
(y>
w
o
2
w
5
I DO
90
BQ
ID
ED
SO
HO
30
20
ID
I9B2
I9B3
I960
Source: Reference 4
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Figure 4-2. Comparison of SO2 Removal Efficiencies:
1980 vs 1982 and 1983.
-------
The data for calculating the DBA consumption for 1982 are presented in
Table 4-1. The average inlet S02 concentration for each period was calculated
from the coal analyses performed by SWPP personnel (see Appendix A). The I.D.
fan amps for each module were averaged (see Appendix B) and converted to a
flue gas flow rate in dry standard cubic feet per minute. Then, an average
S02 absorption rate in lbs SO2 absorbed per minute could be calculated.
Finally, the total tons of SO2 absorbed for the period was determined.
As shown in Table 4-1, the DBA consumption rate at SWPP during the cur-
rent program was nearly twice that measured during the demonstration program.
Also, the average buffer capacity, expressed as equivalent adipic acid parts
per million, was about twice as high. Two reasons have been identified as
contributing to the increased DBA consumption rates. The first is a decrease
in the slurry recycle pH setpoint. Second, SWPP seems to have experienced a
reduction in the slurry recycle flow rate. Both of these conditions will
cause the required DBA concentration and consumption rate to increase.
The major difference in operating philosophy between the DBA test phase
in the demonstration program and 1982 operation was related to the recycle
slurry pH setpoint. During the demonstration program, the pH was controlled
at 5.4. However, SWPP reduced this pH to 5.0 during 1982 to improve limestone
utilization in an attempt to improve mist eliminator reliability. (Mist
eliminator reliability has been greatly improved by this technique and by
revising the system water balance and washing with greater amounts of fresh
water.) While the lower pH does improve limestone utilization, a higher
concentration of DBA is required to' achieve the desired S02 removal. Since
the system is operating at a higher concentration, the DBA lost in the water
associated with the waste sludge will also increase. Furthermore, degradation
of DBA will increase at lower pH operation. Thus, DBA use would be expected
to increase significantly as reflected in the DBA consumption data.
During the October 28 through December 1, 1982 period, the water balance
had been changed and operating conditions were returned to more closely match
4-6
-------
TABLE 4-1. SUMMARY OF 1982 DBA CONSUMPTION RATES AT SWPP
S^l S-2
Average S02 Average S02
Lbs DBA Hours Removed Hours Removed Total Tons lbs DBA Consumed
Period Used Operated (lbs S02/mln) Operated (lbs S02/mln) S02 ReMoved Ton S02 Removed
Jan 1-Feb 4
57,665
752.4
67.9
673.5
60.9
2,763
20.9
Feb 5-March 4
38,043
283.3
73.2
443.0
72.0
1,579
24.1
March 5-March 22
40,618
397.4
69.2
0
0
825
49.2
May 10-June 15
48,342
614.6
44.4
332.6
38.9
1,207
40.1
June 16-July 2
17,022
103.0
59.8
311.8
53.5
685
24.8
July 3-July 30
40,310
443.8
63.7
528.9
55.2
1,724
23.4
July 31-Aug 28
64,689
565.4
52.9
540.3
45.9
1,641
39.4
Aug 29-Oct 1
64,190
596.3
65.0
633.5
58.7
2,278
28.2
Oct 2-0ct 27
62,391
533.6
59.5
547.8
51.3
1,796
34.7
Oct 28-Dec 1
65.860
772.6
58.1
755.4
53.1
2,550
25.8
TOTAL -
499,130
5062.4
4766.8
17,048
29.3
-------
Chose observed in Che demonscration program. In November, Che average recycle
stream pH was 5.35, the S02 removal efficiency averaged 87.5 percent, and the
average load was 141 Mw. These conditions are very similar to the DBA portion
of the demonstration program. However, the required DBA concentration was
880 ppm with an associated DBA consumption rate of 25.8 pounds of DBA per ton
of S02 (13 g DBA/kg S02) removed (versus 15 lb DBA/ton S02 [7.5 g DBA/kg S02]
during the demonstration program) .
In examining reasons for the increased consumption, there does appear to
have been a drop—off in recycle pump performance between the demonstration
program and the latter part of 1982. Recycle slurry rates are not routinely
measured by SWPP. The electrical current consumption (amperage) for recycle
is recorded, though, and should reflect a trend in pump performance. During
DBA testing in 1981, the recycle pumps on Module S-l operated at an average
of 52 amps. In November 1982, Module S—1 recycle pumps averaged only 47 amps.
Similarly, the Module S-2 pump amps dropped from an average of 50 amps in 1981
to 45 amps in November 1982. Thus, decreased pump performance and therefore
a lower slurry flow rate was probably a major contributor to the increased
DBA comsumption requirements in the latter part of 1982.
In summary, DBA consumptions were up during 1982, averaging about 30
lbs DBA/ton of S02 removed. To a large extent, this was due to a decision
by SWPP to operate at a lower pH to achieve better limestone utilization and
improve mist eliminator reliability. Certainly this decision increased DBA
costs. However, it does serve to illustrate the versatility in operation
which DBA has allowed SWPP. Lower pH operation to improve reliability and
limestone utilization did not result in non-compliance with the S02 emission
standard.
In late 1982, SWPP installed a limestone classification system which
produces a finer limestone grind. The pH setpoint for the scrubber recycle
stream is now about 5.6. In 1983, the DBA usage dropped to approximately
4-8
-------
25 lb DBA/ton SOj removed while maintaining good limestone utilization and
mist eliminator reliability.^ This indicates that further optimization of
DBA addition may be possible since this is still greater than that achieved
during the demonstration program.
4.4 EQUIPMENT INSPECTION AND RELIABILITY
An inspection of SWPP's scrubber internals was made in December 1982 by
Radian personnel. Very little scale buildup was found anywheTe in the system.
There was no pluggage of the trays or of the mist eliminators. Mist elimina-
tor pluggage had historically been a problem at SWPP. Since the end of the
demonstration program, SWPP has increased the proportion of raw water in the
mist eliminator wash water and, as noted earlier, operated at a recycle slurry
pH near 5.0 for much of the time. These measures seem to have shown positive
results in the reduction of mist eliminator pluggage.
The FGD system reliability was also excellent during 1982 and 1983. As
shown in Table 4-2, the SWPP FGD system average reliability for 1982 and 1983
was 97.9 and 98.7 percent, respectively. This compares to an FGD system re-
liability during 1980 of only 45 percent.DBA is certainly not the sole
reason for this improvement. SWPP has made major equipment improvements
since 1980. However, the versatility offered by DBA, which allowed SWPP to
operate successfully at a lower pH (5.0) in 1982 to reduce mist eliminator
pluggage, was certainly a major factor.
4-9
-------
TABLE 4-2.
SWPP FGD SYSTEM RELIABILITY IN 1982 and
1983
Month
Reliability1
1982
1983
January
98.6
-outage-
February
99.8
-outage-
March
98.5
-outage-
April
- outage -
-outage-
May
96.4
96.1
June
97.8
99.9
July
98.0
99.1
August
96.7
98.5
September
99.9
99.8
October
96.0
99.7
November
97.6
99.6
December2
92.8
96.7
Average
97.9
98.7
Reliability « Hours FGD system operated
Hours called upon to operate*
2Scheduled outage started 12/3/82. Down a short time due to lightning.
Source: SWPP Quarterly Status Repqrts submitted to U.S. EPA Region VII.
4-10
-------
SECTION 5
DATA ACQUISITION
5.1 CONTINUOUS EMISSIONS MONITORING SYSTEM
The continuous emissions monitoring system (CEMS) data were used for two
purposes in this program. The first was to monitor FGD system performance
with DBA addition over an extended duration of operation. The S02 emissions
limit at SWPP is 1.2 lb/MM Btu, and the results of the CEMS were used as the
primary means of evaluating the ability of the DBA-enhanced system to meet
the 1.2 lb/MM Btu standard. A second purpose was to demonstrate the ability
of the CEMS to gather the type of data required by the 1979 revision to the
utility NSPS.^ To meet EPA requirements for data capture, at least two
data points must be taken each hour for a minimum of 18 hours each day and
22 days per 30 day period. The goal of the CEMS is to collect at least 4
data points per hour for 24 hours.
The monitoring system operates by periodic extraction of a sample of flue
gas from the plant duct work and analysis of the gas for its SOj and O2
concentrations. At SWPP, the flue gas exiting each scrubber is analyzed
using a DuPont Model 460, modified for two point sampling, and a Thermox WDG
III analyzer arrangement. Spectrophotmetric measurements were made at 302 nM
rather than the standard 280 nM because of difficulties encountered certifying
the new monitors. It has not been determined if DBA addition was responsible
for this problem.
Figure 5-1 shows the location of the instruments and sample ports with
respect to the scrubber. The locations of the sample ports were limited to
those installed during construction of the plant. They represent the best
locations for determining the individual performance of the two modules.
5-1
-------
(Effective process monitoring requires that emissions from each module be
measured rather than measuring emissions at the stack as would normally be
required for compliance purposes.)
Each of the sample acquisition systems consist of:
• a 30 micron stainless steel mesh filter and shield,
• a 1/2 inch (1.27 cm) stainless steel probe fixed in the
center sample port,
• 50 feet of 400°F (204°C) self-limiting, heat traced, in-
sulated, 1/4 inch (0.6 cm), double tube, Teflon, sample
line, and
• a moisture trap located in the DuPont analyzer.
The filter is positioned in the centroid of the duct at each sample location.
This location was selected as being representative during the demonstration
(1)
program.
To monitor the performance of both modules, the analyzer cycles from one
scrubber to the other every six minutes. The outlet for one module is
sampled for three minutes of the six minute period. For the other three
minutes, regulated instrument air purges the instruments and sample acquisi-
tion lines to reduce problems with corrosion and pluggage. The gas samples
are kept above the moisture dewpoint by heat tracing to prevent water con-
densation in the sample acquisition system lines.
The signal outputs from the analyzers are recorded using a Radian DART®
microprocessor which generates an hourly S02 emission report. At the end of
each 3-hour period, a 3-hour average is also calculated and displayed. At
the end of every day, a daily report is printed which includes all hourly
averages and a 24—hour average.
5-2
-------
Outlet
Ports
Gas to
Stack
Outlet Gas
Analyzers
Perforated
Tray
Contactors
Rue Gas Prom
Electrostatic
Precipitators
Figure 5-1. Location of Continuous Monitors and Sample Ports at SWPP.
5-3
-------
5.2 CEMS RELIABILITY
The continuous emissions monitoring system (CEMS) proved to be very re-
liable, capturing approximately 97 percent of the available data for each
scrubber throughout 1982. Table 5-1 gives the number of hours of operation,
the number of hours for which data were collected, and the percentage data
capture for each module by month. As expected, the lowest data capture was
achieved in January. It was during this period that SWPP personnel were
first called upon to maintain and troubleshoot the CEMS system. (During the
demonstration program, Radian Corporation engineers performed all system
maintenance.) As SWPP personnel gained more experience with the CEMS system,
the reliability increased even further. During the remainder of 1982, the
CEMS system proved to be 98 percent reliable.
The high reliability of the CEMS system is even more impressive when one
considers that the SWPP FGD system was 97.9 percent reliable during 1982.
Thus, the CEMS system was called upon to operate essentially all of 1982 with
the exception of scheduled outages in April and December. Most of the minor
problems encountered were, in fact, caused by power interruptions.
5.3 QUALITY ASSURANCE
In order to verify the accuracy of the CEMS system, a shortened relative
accuracy test was performed on August 19, 1982. Six EPA Method 6 tests were
run by drawing a sample through the same probe used by the continuous moni-
tors. Table 5-2 shows the results of the abbreviated relative accuracy test.
The relative accuracy as defined by EPA was about 18 percent, which is within
the 20 percent allowable. Note that the EPA procedure for relative accuracy
calls for a minimum of 9 tests, while 6 tests were performed in this abbrevi-
ated quality assurance test. One trend noted from the test results was that
the reference method for oxygen yielded consistently higher 02 concentrations
than did the Thermox monitor. It is very possible that the Thermox monitor
5-4
-------
TABLE 5-1. SUMMARY OF 1982 CEMS RELIABILITY
Scrubber Module S-l
Month
Hours of
FGD
Operation
Hours o£
CEMS
Operation
CEM
Reliability
«)
Scrubber Module S-2
Hours of
FGD
Operation
Hours of
CEMS
Operation
CEM
Reliability
(X)
January
728
661
90.8
656
594
90.5
February
283
283
100.0
539
533
98.9
March
493
490
99.4
S-2 not
in service due to
low loads.
April
Plant Outage
Plant Outage
May
415
411
99.0
265
255
96.2
June*
94
93
98.9
256
256
100.0
July
477
448
94.0
537
520
96.8
August
61*3
588
95.9
583
560
96.1
September
500
495
99.0
569
560
98.4
October
654
654
100.0
668
667
99.9
November
670
653
97.4
684
667
97.6
December
49
47
96.2
54
55
100.0
TOTALS
4976
4823
96.9
4811
4667
97.0
*Starting 0000 on 17 June.
-------
may have been slightly ouc of calibration during the quality assurance test-
ing, contributing, at least in part, to the lower readings. Lower 02 values,
as reported by the Thennox, will tend to lower the calculated SO* emission
rate. However, the difference in the emission rate calculated using the
Thermox and reference method O2 values is less than 5 percent under these
conditions.
Finally, to ensure the accuracy of the SO2 and O2 monitors, SWPP per-
sonnel periodically checked both the zero and span of the instruments using
cylinder gas at known concentrations. SWPP data show that the standard de-
viation during these checks was only ±14 ppm SO2, or less than 2 percent of
the span gas concentration (735 ppm S02). In face, the maximum S02 drift
reported was only 29 ppm. Similarly, the 02 standard deviation was ±0.17% 02
or 2.8 percent of the O2 span gas value (6.07% O2). The maximum O2 drift re-
ported was 0.37% 02.
5.4 ABILITY OF CEMS TO MEET 1979 NSPS REQUIREMENTS
The 1979 revision to the utility boiler NSPS specified S02 emission limits
and percentage emission reductions based on a 30-day rolling average. A sec-
ondary objective of the SWPP monitoring program was to evaluate the ability of
the CEMS to fulfill the data acquisition requirements of the 1979 standard.
Since an inlet SO2 monitor was not present at SWPP, S02 removal efficiencies
could only be estimated. S02 emissions could be tracked, however, using the
outlet S02 and 02 monitors.
Thirty day averages were not calculated prior to June, when the CEMS was
upgraded. SWPP operates under a 1971 standard which does not require a
thirty day rolling average. Results from June to December 1982 (see Appendix
C), however, indicate that the CEMS can reliably collect data to enable cal-
culation of the thirty day average. During this period, only one day of data
was invalid due to failure to capture the 18 hours of valid data required.
This "lose" day was, in fact, caused by a power failure at the SWPP facility.
5-6
-------
TABLE 5-2. RESULTS OF METHOD 6 TESTING AT SWPP ON 19 AUGUST 1982
SO2 Concentration 02 Concentration
ppra wet
Z wet
Emission Rate, lb
SO2/IO6 Btu
Run
No.
Time
Reference
Method1
CEM
Reference
Method2
CEM
Hz0 z
Reference
Method
CEM
Dlff.
1
10:00-10:30
279
306
6.4
5.9
1.8
0.685
0.726
-0.041
2
11:54-12:24
251
270
6.4
5.8
3.6
0.633
0.653
-0.020
3
12:57-13:27
264
250
6.3
6.0
3.6
0.661
0.613
0.048
4
13:43-14:13
277
245
6.3
5.7
7.8
0.741
0.626
0.115
5
14:30-15:00
304
287
6.6
5.8
6.5
0.815
0.725
0.090
6
15:25-15:55
' 298
258
6.3
5.6
5.6
0.770
0.663
0.137
average
0.718
0.663
0.055
Confidence Interval
CI
t 975
o.
2,571
" n/1^1 /n
-------
SECTION 6
REFERENCES
1. Hargrove, 0. W., Jr., et al, Results of the Full-Scale FGD System
Adipic Acid Demonstration Program, Final Report EPA-600/7-83-0356
U. S. Environmental Protection Agency, Industrial Environmental
Research Laboratory, Research Triangle Park, N.C. June 1983.
2. Phone conversation between David Colley, Radian Corporation, and Ken
Craig, SWPP, on September 15, 1982.
3. Phone conversation between Rob Glover, Radian Corporation, and Ken
Craig, SWPP, on September 15, 1983
4. Hicks, N. D., and D. M, Fraley, "Addition of Adipic and Dibasic
Acids to a Conventional Flue Gas Scrubber: Costs, Operating and
Design Experiences," presented at the 27th Annual American Public
Power Association Engineering & Operations Workshop, San Antonio,
TX, 14-17 February 1983.
5. Phone conversation between Rob Glover, Radian Corporation, and
0. C. Smith, SWPP, on September 21, 1983.
6. Federal Register, 1979, New Stationary Sources Performance Standards;
Electric Utility Steam Generating Units, Vol. 44, No. 113, June 11,
pp. 33580-33624.
7. Federal Register, EPA Continuous Monitoring Certification Testing,
Vol. 44, No. 197, p. 56281.
6-1
-------
Appendix A. SWPP Weekly Coal Analyses
SWPP 1982 COAL ANALYSIS
WEEKLY SAMPLES FROM #4 BELT
Wt. Z as Received Estimated
Fixed
Uncontrolled
Date
Moisture
Ash
Volatiles
i Carbon
Sulfur
Btu/Lb
Emission
01-05-82
10.5
14.0
35.0
40.4
4,5
11,263
8.0
01-12-82
9.8
15.2
34.9
40.0
3.6
11,224
6.4
01-19-82
10.0
13.0
35.6
41.4
3.5
11,463
6.1
01-26-82
9.0
11.8
36.5
42.7
3.8
11,816
6.4
Avg 1-82
9.8
13.5
35.5
41.1
3.9
11,442
6.8
02-01-82
10.3
13.6
35.6
40.5
3.7
11,293
6.6
02-09-82
-
-
-
No Sample
41*
-
-
02-16-82
8.0
11.4
37.2
43.4
3.6
11,975
6.0
02-23-82
11.2
14.7
32.4
41.8
3.8
11,753
6.5
Avg 2-82
9.8
13.2
35.1
41.9
3.7
11,674
6.4
03-02-82
8.2
14.2
35.9
41.6
4.7
11,573
8.1
03-09-82
-
-
-
No Sample
-
-
-
03-16-82
7.3
11.3
35.1
46.3
3.9
12,087
6.5
03-23-82
-
-
-
No Sample
-
-
-
03-30-82
—
—
-
No Sample
-
-
-
Avg 3-82
7.8
12.8
35.5
44.0
4.3
11,830
7.3
4-82
No Samples - Unit
Outage
05-04-82
—
•*»
No Sample
05-11-82
6.0
12.7
34.0
47.2
3.7
12,208
6.1
05-18-82
9.4
15.0
31.8
43.8
2.3
11,193
4.1
05-25-82
5.8
10.9
33.7
49.6
2.6
12,612
4.1.
Avg 5-82
7.1
12.9
33.2
46.9
2.9
12,004
4.8
06-01-82
8.7
10.4
34.7
45.3
2.6
12,136
4.3
06-08-82
8.1
10.6
36.5
44.8
2.7
12,240
4.4
06-15-82
8.9
13.3
35.2
42.6
3.9
11,576
6.7
06-22-82
7.1
12.8
34.0
46.2
3.0
12,047
5.0
06-29-82
8.6
12.8
36.5
42.2
3.4
11,845
5.7
Avg 6-82
8.3
12.0
35.4
44.2
3.1
11,969
5.2
07-08-82
7.9
11.8
36.3
43.9
3.5
12,015
5.8
07-13-82
8.0
12.2
36.1
43.7
3.6
11,858
6.0
07-20-82
5.9
14.0
17.6
42.6
3.8
11,708
6.5
07-27-82
7.0
11.5
38.0
43.6
3.7
12,188
6.5
Avg 7-82
7.2
12.4
37.0
43.5
3.7
11,942
6.1
Continued...
A-l
-------
SWPP 1982 Coal Analysis, continued.
Weekly samples from #4 belt
r*
•
Z as Received
Estimated
Fixed
Uncontrolled
Dace
Moisture
Ash
Volatiles
Carbon
Sulfur
BCu/Lb
Emission
08-03-82
7.5
13.7
36.7
42.1
3.4
11,715
5.8
08-10-82 .
8.9
12.9
37.4
40.8
3.1
11,604
5.3
08-17-82
8.3
12.8
36.2
42.7
3.4
11,690
5.8
08-24-82
7.6
13.2
38.6
40.6
2.9
11,823
4.9
08-31-83
8.2
16.3
38.1
37.3
2.5
10,931
4.6
Avg 8-82
8.1
13.8
37.4
40.7
3.1
11,553
5.4
09-07-82
8.6
13.7
37.5
40.2
3.3
11,468
5.8
09-14-82
3.9
17.3
40.6
38.2
4.3
11,396
7.5
09-21-82
4.5
10.5
41.5
43.5
3.6
12,514
5.8
09-28-82
7.4
13.0
38.8
40.8
3.8
11,745
6.5
Avg 9-82
6.1
13.6
39.6
40.7
3.8
11,781
6.4
10-05-82
5.2
11.6
41.4
41.8
3.8
12,009
6.3
10-12-82
4.9
6.5
33.6
55.0
3.7
13,292
5.6
10-19-82
6.6
12.4
37.3
43.7
3.2
11,934
5.4
10-26-82
4.0
11.4
41.1
43.5
3.9
12,779
6.1
Avg 10-82
5.2
10.5
38.4
46.0
3.7
12,504
5.8
11-02-82
5.0
9.2
38.1
47.7
3.6
12,962
5.6
11-10-82
4.1
11.3
42.0
42.6
3.6
12,949
5.6
11-16-82
6.7
10.2
39.4
43.8
3.6
12,425
5.8
11-23-82
7.6
9.8
37.3
45.3
4.0
12,461
6.4
11-30-82
9.4
9.8
36.5
44.2
3.6
11,923
6.0
Avg 11-82
6.6
10.1
38.7
44.7
3.7
12,544
5.9
A-2
-------
Appendix B. Summary of FGD System Performance in 1982
Flue Gas Inlet S02 Outlet SO2
Date
Tlae
Module
DBA
PH
Fan
Aaapa
Flow (1000
acfa)
L/C
approx pp»
dry 0Z S0z
ppa, dry
0Z 0,
REM
1/4
16:00
S-l
645
5.4
500
238
56.6
4800
753
84.3
S-2
583
5.3
500
233
57.8
1029
78.6
1/7
10:45
S-l
560
5.5
460
65.5
4535
464
89.8
S-2
565
5.4
430
82.4
544
88.0
1/12
12:30
S-l
688
5.55
560
287
47.0
3860
611
84.2
S-2
613
5.43
510
243
55.5
694
82.0
1/15
18:00
S-l
988
5.3
545
275
49.1
3780
561
85.2
S-2
945
5.3
510
243
55.5
644
83.0
1/19
10:45
S-l
673
5.43
540
271
49.8
3675
495
86.5
S-2
628
5.39
510
243
55.5
543
85.2
1/22
16:00
S-l
828
5.3
530
262
51.4
3760
486
87.1
S-2
790
5.3
480
214
63.2
568
84.9
1/28
10:45
S-l
935
5.3
.540
271
49.8
3900
619
84.1
2/2
11:00
S-l
720
5.2
430
181
74.4
3920
391
90.0
S-2
745
5.45
480
214
63.2
354
91.0
2/12
10:45
S-2
870
5.2
545
278
48.5
3690
608
83.5
2/17
18:00
S-l
880
No Fan All Day
S-2
718
5.2
510
55.5
3660
353
90.4
3/2
10:15
S-l
619
5.2
500
239
56.5
4890
450
90.0
3/12
16:00-
S-l
1820
5.1
517
252
53.5
4170
385
90.8
17:00
3/19
19:00
S-l
1650
5.0
500
238
56.6
3800
362
90.5
5/13
12:00
S-l
649
No DART for Hay 12
3310
362
89.1
5/19
10:30
S-l
973
5.0
530
263
51.4
2475
381
84.6
S-2
1105
5.0
510
243
55.5
122
95.1
5/25
11:00
S-l
1195
5.0
500
238
56.6
2480
268
89.2
S-2
1280
5.0
450
184
73.5
119
95.2
6/3
10:30
S-l
480
4.99
437
187
72.2
4.32*
0.70*
83.8
S-2
540
5.0
410
144
93.8
0.56
87.0
6/9
12:30
S-l
785
5.05
550
279
48.4
4.75*
0.94*
80.2
S-2
763
5.0
480
214
63.2
0.39
91.8
*S0, concentrations In lb SOg/Wt Btu.
(Continued)
-------
Dace
Tlae
Module
DBA
PH
Fan
Asps
Flue Can
Flow (1000
acfa)
L/C
Inlet SOj
approx ppa
dry 0Z S02
Outlet SO,
ppa, dry
02 0,
KEN
6/22
08:30
S-2
1245
5.1
560
293
46.1
3000
620
79.3
6/24
12:30
S-2
1095
5.0
550
283
47.7
3130
175
94.4
7/8
11:00
S-l
960
5.0
440
190
71.2
3510
355
89.9
S-2
1370
5.0
445
179
75.5
380
89.2
7/13
10:45
S-l
1160
5.05
465
210
64.3
6.07*
.30*
95.1
S-2
1395
5.05
440
174
77.7
.57*
90.6
7/15
10:45
S-l
918
5.2
520
255
53.0
3725
680
81.7
S-2
968
5.0
410
144
93.8
455
67.8
7/20
I0:4S
S-l
1128
5.0
525
259
52.2
3906
295
92.4
S-2
1310
5.0
477
211
64.1
166
95.8
7/22
10:45
S-l
920
5.0
530
263
51.4
3835
625
83.7
S-2
1047
5.0
490
224
60.4
262
93.2
7/27
17:00
S-l
1195
5.0
520
255
53.0
3654
435
88.1
S-2
1482
5.0
415
20.6
228
93.8
7/29
10:45
S-l
1190
4.93
510
247
54.8
3610
448
87.6
a/2
11:00
S-l
1370
5.0
560
287
47.0
3515
390
88.9
S-2
*1520
5.1
470
204
66.3
420
88.1
8/5
10:45
S-l
1100
5.1
540
49.8
3415
315
90.8
S-2
1178
5.2
520
214
53.3
400
88.3
8/10
11:00
S-l
1020
5.1
480
222
60.8
3215
365
88.6
S-2
1178
5.1
490
224
60.4
308
90.4
8/12
11:00
S-l
803
5.8
420
173
77.9
3295
455
86.2
S-2
849
5.0
395
129
105.0
340
89.7
8/17
09:45
S-l
1805
5.1
510
246
54.8
3500
555
841
S-2
1463
5.0
525
258
52.3
283
91.9
8/18
10:00
S-l
1088
5.05
510
246
54.8
5.69
560
83.6
S-2
1027
5.1
520
253
53.3
1.00
86.9
8/24
11:00
S-l
1985
5.0
430
181
74.4
2950
175
94.1
S-2
2060
5.0
517
250
53.9
500
83.1
8/26
14:30
S-l
1180
5.0
400
157
86.0
2896
260
91.0
S-2
1370
5.0
410
144
93.8
310
89.3
8/11
13:00
S-l
985
540
550
279
48.4
2753
377
86.3
S-2
95S
5.0
410
144
93.8
210
92.4
9/2
11:15
S-l
1364
5.0
560
287
47.0
2956
235
92.1
S-2
1660
5.0
510
243
55.5
182
93.8
9/1
14:00
S-l
Start Up
S-2
1325
5.0
490
224
60.4
249
92.8
(Continued)
*S0, concentrations In lb SOj/Wt Btu.
-------
Date
Tlae
Module
USA
PH
Fan
Ampa
Flue Caa
Flow (1000
acta)
L/C
Inlet SOj
approx ppa
dry OZ SO,
Outlet SO|
ppm, dry
OZ 02
REM
9/9
10:45
S-l
922
5.0
550
279
48.4
3771
700
81.4
S-2
1098
5.0
500
233
57.8
488
87.1
9/14
11:00
S-l
inoo
4.92
520
255
53.0
4541
489
89.2
S-2
1023
5.0
500
233
57.8
591
87.0
9/16
12:30
S-2
1265
5.14
510
243
55.5
4233
600
85.8
9/21
10:45
S-l
608
5.3
485
226
59.7
3462
559
83.9
9/23
10:50
S-2
970
5.0
460
194
69.7
3585
254
92.9
9/29
11:00
S-l
1100
5.18
560
287
47.0
3882
521
86.6
S-2 .
1240
5.0
510
243
55.5
395
89.8
10/ 5
13:00
S-l
1900
5.0
530
263
51.4
3809
432
88.7
S-2
1910
5.0
510
243
55.5
314
91.8
10/7
11 <00
S-l
630
5.45
520
255
53.0
3679
751
79.6
S-2
728
S.l
470
204
66.3
641
82.6
10/13
11:00
S-l
1285
5.4
510
246
54.8
3332
440
86.8
S-2
1505
5.05
490
223
60.4
500
85.0
10/14
14i00
S-l
Start Up
S-2
3225
5.0
490
223
60.4
210
93.7
10/19
12:15
S-l
1055
5.4
560
287
47.0
3227
605
81.3
S-2
823
5.0
480
214
63.2
410
87.3
10/21
13:00
S-l
1460
5.2
540
271
49.8
3100
400
87.1
S-2
740
5.05
500
234
57.8
540
82.6
10/26
15:30
S-l
880
5.4
500
239
56.6
3673
580
84.2
S-2
1140
5.3
480
214
63.2
560
84.8
10/29
13:00
S-l
1995
5.4
428
180
75.1
3532
410
88.4
S-2
1680
5.0
430
164
82.4
560
84.1
11/2
11:00
S-l
403
5.3
420
173
77.9
3343
505
84.9
S-2
458
5.4
500
233
57.8
310
90.7
11/4
13:00
S-l
558
5.3
520
255
53.0
3344
295
91.2
S-2
1885
5.42
510
243
55.5
350
89.5
11/9
11:15
S-l
795
5.4
480
222
60.8
3346
645
80.7
S-2
820
5.4
440
174
77.7
430
87.1
11/10
12:45
S-l
730
S.4
540
271
49.8
3346
480
85.7
*
S-2
575
5.4
480
214
63.2
485
85.5
11/12
14:30
S-l
478
5.4
560
287
47.0
5.65**
0.92**
83.7
S-2
693
5.4
490
224
60.4
0.435**
92.3
(Continued)
-------
Date
Tlae
Nodule
DBA
PH
Fan
Aaps
Flue Cos
Flow (1000
acfa)
L/C
Inlet SOi
approx ppa
dry OZ SOj
Outlet SOt
ppa, dry
OZ Oi
REM
11/15
11:00
S-l
918
5.28
555
283
47.7
3467
360
89.6
S-2
607
5.18
510
243
55.5
183
94.7
11/17
13:00
S-l
665
5.4
560
287
47.0
3541
570
83.9
S-2
652
5.4
495
228
59.1
299
91.6
11/19
13:00
S-l
782
5.4
540
271
49.8
3649
620
83.0
S-2
721
5.4
480
213
63.2
256
93.0
11/24
12:4$
S-l
1235
5.4
560
287
47.0
3831
728
81.0
S-2
820
5.3
500
234
57.8
500
86.9
11/27
11:30
S-l
960
5.4
435
185
72.8
3733
576
84.6
S-2 .
760
5.3
405
139
97.1
230
93.8
-------
Appendix C. Continuous SO2 Emissions Monitoring Results
RESULTS OF CONTINUOUS S02 EMISSIONS MONITORING
AT CITY UTILITIES OF SPRINGFIELD. MISSOURI FGD SYSTEM
SCRUBBER MODULE S-l-
SCRUBBER MODULE S-2-
0
1
24-HOUR
NO. 30
-DAY AVERAGE NO.
NO.
24-HOUR
NO.
30-
DAY AVERAGE NO.
DATE
EMISSION OF
EMISSION
OF
OF
EMISSION
OF
EMISSION
OF
RATE
HOURS
RATE
HOURS
DAYS
RATE
HOURS
RATE
HOURS
16JUN82
MODULE
S-l DOWN
0.65
9
17JUNA2
MODULE
5-1 DOWN
0.47
24
18JUN32
MODULE
S-l DOUN
0.37
24
19JUM82
1.10
23
MODULE
S-2
DOUN
20JUN82
o.ta
24
MODULE
S-2
DOUN
21JUN82
0.57
A
1.32
16
22JUH82
MODULE
S-l DOUN
0.96
24
23JUNS2
HODULE
S-l DOUN
0.30
24
24JUH82
MODULE
S-l DOUN
0.32
24
25JUN82
HODULE
S-l DOUN
0.56
22
26JUHA2
0
BOILER
DOUN
0.46
ft
BOILER
DOUN
27JUH32
MODULE
S-l DOWN
0.40
19
23JUH32
MODULE
S-l DOWN
0.46
24
29JUH52
0.56
14
0.31
24
30JUN52
0.63
24
0.37
24
01JULS2
0.33
9
BOILER
DOUN
0.2ft
9
BOILER
DOUN
02JUL&2
0
BOILER
DOUH
0
BOILER
DOUN
03JULS2
0*
30ILER
DOUN
0
BOILER
DOUN
04JUL82
0
BOILER
DOUN
0
BOILER
DOUN
0SJUL&2
0
BOILER
DOUN
0
BOILER
DOUN
06JUL&2
0.7ft
12
BOILER
DOUN
0
BOILER
DOUN
C7JUL82
0.70
23
0.73
13
P3JUL32
0.47
14
0.95
24
u9JUL32
0.5ft
11
0.59
24
10JUL32
MODULE
S-l DOUN
0.85
24
11JUL82
MODULE
S-l DOUN
1.09
24
12JUL32
0.60
14
1.00
24
13JUL32
0.43
IS
0.59
22
14JUL82
0.45
20
0.79
20
15JULS2
0.77
24
0.91
24
I0JUL&2
0.73
22
1.05
23
17JULS2
0.£2
24
0.73
3
1&JULS2
0.72
23
0.47
13
19JUL32
0.6ft
24
0.2ft
23
20JULfc2
0.43
24
0.24
24
21JUL82
0.60
24
0.27
24
22JJL42
0.73
24
0.65
382
14
0.3ft
24
0.63
591
NO.
OF
23
-------
24
24
24
25
26
27
27
27
26
25
25
25
25
25
26
26
25
25
25
25
25
25
25
24
24
25
24
23
23
23
23
23
22
RESULTS OF CONTINUOUS S02 EMISSIONS MONITORING
AT CITY UTILITIES OF SPRINGFIELD. MISSOURI FGD SYSTEM
SCRUBBER MODULE 5-1 --SCRUBBER MODULE S-2
4-HOUR
NO. 50-
DAY AVERAGE NO.
NO.
24-HOUR
NO. 30-
DAY AVERAGE NO.
MISSION
OF
EMISSION
OF
OF
EMISSION
OF
EMISSION
OF
RATE
HOURS
RATE
HOURS
DAYS
RATE
HOURS
RATE
HOURS
0.43
21
0.64
403
15
0.37
23
0.62
605
MODULE
S-l DOWN
0.64
403
15
1.04
24
0.64
605
MODULE
S-l DOWN
0.64
403
15
0.84
23
0.66
604
> 0.60
15
0.61
395
14
0.60
23
0.66
627
0.67
21
0.61
392
14
0.69
22
0.66
649
o.51
23
0.61
407
15
0.68
22
0.64
655
G.
-------
21
20
20
20
20
21
22
22
22
22
22
22
22
22
21
20
20
20
20
20
20
20
19
19
19
19
19
19
19
20
21
22
22
22
22
22
22
RESULTS OF CONTINUOUS S02 EMISSIONS MONITORING
AT CITY UTILITIES OF SPRINGFIELD, MISSOURI FGD SYSTEM
—
—SCRUBBER
MODULE S-l-
24-HOUR
NO. 31-
DAY AVERAGE
NO.
EMISSION
OF
EMISSION
OF
RATE
HOURS
RATE
HOURS
C.52
24
0.73
612
o.aa
24
0.73
615
a.?i
24
0.74
616
0.71
23
0.74
622
O.oi)
22
0.75
625
0.56
22
0.75
625
MODULE
S-l DOWN
0.75
602
MODULE
5-1 DGIriH
0.75
533
MODULE
S-l DOWN
0.76
560
0.75
17
0.76
553
O.oo
19
0.75
54 £
0 .30
23
0.75
547
0.94
20
0.77
563
0.99
24
0. 7ft
574
0.67
24
0.77
574
0.7fl
24
0.77
575
0.65
24
0.77
575
0.53
•e
0.75
559
MODULE
S-l DOWN
0.72
551
MODULE
S-l DOIJN
0.71
523
0.96
S
0.71
520
0.94
24
0.71
521
¦ 0.96
24
0.72
521
o.vu
24
0.74
537
a.t?
10
0.74
532
MODULE
S-l DOUN
0.75
5oa
0.65
11
0.76
455
0.31
24
0.76
495
0.73
24
0.77
495
0.66
24
0.77
455
O.fc?
24
0.77
495
C.70
24
0.77
495
0.79
24
0.77
495
0.75
24
0.77
496
0.79
24
0.78
4S£
o.6a
24
0.78
500
0.90
24
0.79
524
24-HOUR
NO.
30-
DAY AVERAGE
LHISSION
OF
EMISSION
RATE
HOURS
RATE
MODULE
S-2
DOMN
0.77
0.64
17
0.77
0.50
23
0.76
0.20
24
0.74
0.24
22
0.72
0.3ft
24
0.71
0.93
24
0.71
0.73
24
0.71
0.44
24
0.69
0.45
24
0.6ft
0.35
19
0.65
0.46
22
0.64
0.36
19
0.60
0.42
1
0.61
MODULE
S-2
DOUN
0.61
0.4ft
15
0.60
0.62
24
0.61
0.77
24
0.60
1.14
24
0.62
0.93
23
0.64
1.23
16
0.66
MODULE
S-2
DOWN
0.65
MODULE
S-2
DOUN
0.65
NODULE
S-2
DOUN
0.64
0.31
15
0.63
0.43
24
0.60
0.60
24
0.59
0.57
24
0.5ft
0.50
24
0.57
0.49
24
0.57
0.51
24
0.56
0.56
24
0.56
0.56
24
0.56
0.70
24
0.5ft
0.72
24
0.60
0.84
24
0.62
0.72
24
0.61
NO.
OF
DAYS
23
23
23
24
24
24
23
22
21
£0
2(1
10
21
22
22
22
22
21
21
20
20
23
20
21
21
20
19
19
19
19
1*
19
19
19
19
19
20
-------
RESULTS OF CONTINUOUS S02 EMISSIONS MONITORING
AT CITY UTILITIES OF SPRINGFIELD* MISSOURI F6D SYSTEM
SCRUBBER MODULE S-l SCRUBBER MODULE S~2
24-HOUR
NO. 30
-DAY AVERAGE
NO.
HO.
24-HOUR
NO. 30-
DAY AVERAGE
NO.
NO.
DATE
EMISSION
OF
EMISSION
OF
OF
EMISSION
OF
EMISSION
OF
OF
RATE
HOUgS
RATE
HOURS
Df.YS
RATE
HOURS
RATE
HOURS
DAYS
S50CTB2
8.53
24
0.7fi
548
21
0.52
24
0.60
562
22
060CT82
0.42
24
0.77
572
22
0.62
24
0.61
562
22
A70CT&2
0.70
24
0.76
579
23
0.71
24
0.62
562
22
08OCT82
0.50
24
0.76
534
23
0.76
24
0.64
567
22
090CT82
0. bl
24
0.75
585
23
0.86
24
0.65
569
22
100CT82
0.75
23
0.74
5 £.3
23
0.81
24
0.67
574
22
110CT42
0.57
24
0.73
5 L&
23
0.89
24
0.69
597
23
120CT82
0.52
24
0.72
5£8
23
0.74
24
0.69
621
24
130CTS2
8.73
21
0.72
585
23
0.78
24
0.70
630
25
14GCT82
0.61
18
0.73
579
23
0.56
24
0.70
630
25
15QCT82
0.54
21
0.72
592
24
0.59
24
0.69
630
25
160CT82
MODULE
S-l DOWN
0.72
592
24
0.75
11
0.68
617
24
170CT82
MODULE
S-l DOUN
0.72
552
24
0.85
8
0.67
602
23
180CT82
0.36
16
0.72
600
24
0.93
22
0.66
608
24
19QCTE2
0.61
24
0.70
600
24
0.82
24
0.67
632
25
200CTE2
0.71
24
0.70
600
24
0.86
24
0.67
656
26
210CT82
0.59
24
0.68
600
24
0.82
24
0.68
680
27
220CI32
•).D&
21
0.67
611
25
0.80
24
0.70
689
28
23QCT32
0.63
24
0.67
635
26
0.93
24
0.71
689
28
240CT82
fl.?l
24
0.66
643
27
0.68
24
0.71
689
2a
250CT32
1.22
24
0.6B
648
27
1.04
24
0.73
689
28
260CT82
0.90
24
0.6B
648
27
0.83
24
0.74
689
28
270CT32
0.93
24
0.69
64S
27
0.88
24
0.76
689
28
2SDCT32
0.92
24
0.70
648
27
0.86
24
0.77
639
23
290CT32
1.14
23
0.72
647
27
0.77
24
0.77
689
28
30CCT52
1.66
a
0.73
631
26
1.67
2
0.81
667
27
31GCT&2
l.fc?
24
0.77
631
26
MODULE
5-2 DOUN
0.81
643
26
01KOV£.2
1.59
20
o.ao
627
26
0.60
18
0.81
637
26
02HQV£2
1.06
24
o.ai
627
26
0.56
24
0.80
637
26
03NQV32
0.S1
24
o.ai
627
26
0.78
24
0.80
637
26
04NOV82
0.27
24
o.a2
627
26
0.81
24
0.81
637
26
05HOV&2
0.91
23
o.a4
626
26
0.68
23
0.81
636
26
06HOV32
0.77
22
0.84
624
26
0.43
22
0.81
634
26
C7i{OVa2
0.67
~9
0.85
609
25
1.05
19
0.82
629
26
08HOV82
0.53
13
0.85
598
24
0.95
23
0.82
628
26
09HGV82
1.20
22
0.86
597
24
0.76
24
0.82
628
26
10HOV32
0.31
24
0.87
597
24
0.73
24
0.81
628
26
-------
RESULTS OF CONTINUOUS S02 EMISSIONS MONITORING
AT CITY UTILITIES DfF SPRINGFIELD, HISSOURI FGD SYSTEM
SCRUBBER MODULE S-l SCRUBBER MODULE S-2
24-HOUR
NO.
30-DAY AVERAGE NO.
NO.
24-HOUR
NO.
30-DAY AVERAGE NO.
NO.
DATE
EMISSION
OF
EMISSION
OF
OF
EMISSION
OF
EMISSION
OF
OF
RATE
HOURS
SATE
HOURS
DAYS
RATE
HOURS
RATE
HOURS
DAYS
11N0V82
0.S1
21
o.8a
594
24
0.73
24
0.61
626
26
12N0V62
0.93
15
0 .39
563
23
0.60
24
0.60
626
26
13N0V62
< 0.71
24
0.89
594
23
0.46
24
0.60
626
26
14H0V32
0.6&
24
0.90
597
23
0.52
24
0.60
626
26
15.IOV52
0.67
19
0.69
616
24
0.42
19
0.79
636
27
1&H0V&2
0.61
24
o.aa
640
25
0.36
24
0.77
652
26
1/H0VA2
0.&6
24
o.aa
6': 5
26
0.51
24
0.76
654
26
1SN0V32
0.72
22
o.aa
646
26
0.39
24
0.74
654
26
i9iiova2
1.01
16
0.69
63S
25
0.43
24
0.73
654
26
20HGV82
0.53
24
0.90
6 5£
25
0.32
24
0.71
654
26
2ii-:ova2
0.60
24
0.90
641
25
0.41
24
0.70
654
26
22H0VS2
0.32
24
0.91
641
25
0.53
24
0.66
654
26
22NQV82
1.00
24
0.92
641
25
0.55
24
0.66
654
26
24N0V&2
1.06
24
0.91
641
25
0.52
24
0.66
654
26
25H0V62
0.96
24
0.91
641
25
0.57
24
0.65
654
26
2sllGVfi2
1.42
24
0.93
641
25
0.71
24
0.64
654
26
27HOV32
0.87
22
0.93
639
25
0.43
17
0.63
647
27
2ori0V82
o.aa
16
0.92
632
24
1.02
7
0.64
630
26
29.10VS2
0.9o
24
0.92
646
25
0.67
16
0.60
646
27
3GH0V62
0.62
24
0.67
646
25
0.72
24
0.61
670
26
01DEC32
0.61
24
0.65
652
25
0.90
24
0.62
676
26
02DEC32
0.41
16
BOILER
DOUN
1.06
17
BOILER
DOUN
0iDEC32
0.37
7
BOILER
DOWN
1.00
14
BOILER
DOUN
-------
Appendix D. Emission Monitoring Results for 1983
24 HOUR BOILER
DATE AVERAGE HOURS
5/19 1.5 10
5/20 2.0 24
5/21 1.0 24
5/22 1.0 24
5/23 0.9 24
5/24 1.0 24
5/25 1.1 24
5/26 0.9 24
5/27 1.2 24
5/28 1.6 24
5/29 0.3 7
5/30 0.0 0
5/31 1.2 16
6/1 0.8 24
6/2 1.0 24
6/3 0.8 24
6/4 0.8 24
6/5 0.9 24
6/6 1.0 24
6/7 1.0 24
6/8 1.0 24
6/9 1.0 24
6/10 1.3 24
6/11 0.8 24
6/12 0.6 24
6/13 0.8 24
6/14 0.5 24
6/15 0.7 24
6/16 0.7 24
6/17 0.8 12
6/18 0.0 0
6/19 0-.0 0
6/20 0.0 0
6/21 2.4 23
6/22 1-2 24
6/23 1-2 24
6/24 1.0 24
6/25 0.8 24
6/26 0.6 24
6/27 0.8 24
6/28 0.9 24
6/29 1.6 23
6/30 1.0 24
D-l
-------
EMISSION MONITORING RESULTS FOR 1983
24 HOUR
BOILER
DATE
AVERAGE
HOURS
7/1
1.1
24
7/2
0.8
24
7/3
1.0
24
7/4
1.0
24
7/5
0.7
14
7/6
0.0
0
7/7
1.2
15
7/8
0.9
24
7/9
0.9
24
7/10
0.9
24
7/11
1.0
24
7/12
0.9
24
7/13
1.0
24
7/14
0.8
24
7/15
0.8
24
7/16
0.8
24
7/17
0.8
24
7/18
1.0
24
7/19
0.8
24
7/20
1.0
24
7/21
0.7
24
7/22
0.6
24
7/23
0.6
24
7/24
0.5
24
7/25
0.6
24
7/26
0.7
24
7/27
0.7
24
7/28
1.0
24
7/29
0.9
24
7/30
0.7
24
7/31
0.5
24
8/1
0.8
24
8/2
0.7
24
8/3
1.2'
24
8/4
0.9
24
8/5
0.8
24
8/6
0.5
24
8/7
0.7
24
8/8
0.8
24
8/9
1.1
24
8/10
1.2
24
8/11
0.8
24
8/12
0.7
24
8/13
0.7
24
-------
EMISSION MONITORING RESULTS FOR 1983
24 HOUR BOILER
DATE AVERAGE HOURS
8/14 0.6 24
8/15 0.9 24
8/16 0.1 3
8/17 0.0 0
8/18 1.0 10
8/19 0.8 24
8/20 0.7 24
8/21 0.6 24
8/22 0.7 24
8/23 0.9 24
8/24 0.9 24
8/25 0.3 13
8/26 0.0 0
8/27 0.0 0
8/28 0.0 0
8/29 0.1 1
8/30 1.7 24
8/31 0.9 24
9/1 1.0 24
9/2 0.9 24
9/3 1.0 24
9/4 0.9 24
9/5 0.9 24
9/6 • 0.6 24
9/7 0.6 24
9/8 0.6 24
9/9 0.6 24
9/10 0.9 24
9/11 0.7 24
9/12 0.9 24
9/13 1.0 24
9/14 0.8 24
9/15 1.0 24
9/16 0.7 24
9/17 0.3 24
9/18 0.5 24
9/19 0.6 24
9/20 0.8 24
9/21 0.8 24
9/22 0*9 24
9/23 0.8 24
9/24 0.8 24
9/25 0.8 24
9/26 0.8 24
D-3
-------
EMISSION MONITORING RESULTS FOR 1983
24 HOUR
BOILER
DATE
AVERAGE
HOURS
9/27
0.8
24
9/28
0.8
24
9/29
0.8
24
9/30
0.8
24
10/1
0.8
24
10/2
0.8
24
10/3
0.9
24
10/4
0.8
24
10/5
0.8
24
10/6
0.8
24
10/7
1.3
19
10/8
0.0
0
10/9
0.0
0
10/10
0.0
0
10/11
0.0
0
10/12
0.0
0
10/13
0.0
0
10/14
0.0
0
10/15
0.0
0
10/16
0.0
0
10/17
0.0
0
10/18
0.0
0
10/19
0.0
0
10/20
. 0.0
0
10/21
0.0
0
10/22
0.0
0
10/23
0.0
0
10/24
0.0
0
10/25
0.0
0
10/26
0.0
0
10/27
0.0
0
10/28
0.0
0
10/29
O.Q
0
10/30
0.0
0
10/31
0.0
0
11/1
1.4
14
11/2
0.9
19
11/3
0.0
0
11/4
0.0
0
11/5
0.0
0
11/6
0.0
0
11/7
0.0
0
11/8
0.0
0
D-4
-------
EMISSION MONITORING RESULTS FOR 1983
24 HOUR
BOILER
DATE
AVERAGE
HOURS
11/9
0.0
0
11/10
0.0
0
11/11
0.0
0
11/12
0.0
0
11/13
0.0
0
11/14
1.5
14
11/15
0.9
24
11/16
0.9
11
11/17
0.0
0
11/18
0.0
0
11/19
0.0
0
11/20
0.0
0
11/21
1.1
11
11/22
1.0
7
11/23
0.0
0
11/24
0.0
0
11/25
0.0
0
11/26
0.0
0
11/27
0.0
0
11/28
0.0
0
11/29
0.0
0
11/30
0.0
0
12/1
0.0
0
12/2
0.0
0
12/3
0.0
0
12/4
0.0
0
12/5
0.0
0
12/6
0.0
0
12/7
0.0
0
12/8
0.0
0
12/9
0.0
0
12/10
0.0
0
12/11
0.0
0
12/12
0.0
0
12/13
0.0
0
12/14
0.0
0
12/15
0.0
0
12/16
0.0
0
12/17
1.7
6
12/18
3.5
24
12/19
1.3
24
12/20
1.2
24
12/21
1.9
24
12/22
0.9
24
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EMISSION MONITORING RESULTS FOR 1983
24 HOUR BOILER
DATE AVERAGE HOURS
12/23
12/24 0.9 24
12/25 1.0 24
12/26 0.9 24
12/27 0.8 24
12/28 0.9 24
12/29 1.2 24
12/30 1.1 24
12/31 0.6 24
D—6
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TECHNICAL REPORT DATA
(Please read Inunctions on the reverse before completing)
1. REPORT NO. a.
EPA-600/7-84-065
3. RECIPIENT'S ACCESS!OM NO.
4. TITLS ANOSUSTITL*
Results of the First 2 Years of Commercial Operation
of an Organic-Acid-Enhanced FGD System
8. REPORT OATE
June 1984
S. PERFORMING ORGANIZATION COOE
7. AUTHORISE
R. L. Glover, G. E. Brown, J. C. Dickerman, and
0. W. Hargrove
S. PERFORMING ORGANIZATION REPORT NO.
DCN- 83- 203-001- 53-19
9. PtH^OBMtNO OROANIZATIQN NAM! ANO ADDRESS
Radian Corporation
8501 Mo-Pac Boulevard
Austin* Texas 78759
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-3171, Task 53
12. SPONSORING AGENCY NAME ANO AOORSSS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OP REPORT ANO PERIOO COVEREO
Task Final; 4/82-4/84
14. SPONSORING AGENCY COOE
EPA/600/13
is. supplementary notes IERL-RTP proj ect officer is J. David Mobley, Mail Drop 61.
919/541-2612.
16. abstract rep0rt documents the first 2 years (1982 and 1983) of commercial oper-
ation of the dibasic acid (DBA) system at Springfield's Southwest Power Plant . . _
(SWPP), during which SWPP averaged an S02 emission rate of less than 1.0 lb S02 /
million Btu. (NOTE: EPA has sponsored research to develop organic-acid-enhanced
flue gas desulfurization (FGD) technology for existing and new coal burning facilities.
A 1981 EPA-sponsored demonstration program at SWPP, near Springfield, MO,
showed that adipic acid and DBA greatly enhanced FGD performance. SWPP has con-
tinued to use DBA to comply with the 1971 S02 emissions standard under which they
are regulated. Thus, SWPP became the first commercial-scale system to use an
organic additive to enhance S02 removal.) At SWPP in 1980 (before DBA addition),
SWPP averaged about 5 lb S02/million Btu. FGD system reliability was also greatly
improved, averaging 97.9% in 1982 and 98.7% in 1983, compared to 45% in 1980. The
S02/02 continuous emissions monitoring system also showed excellent reliability,
exceeding 97%. Overall, DBA has increased the flexibility of the SWPP system and,
most importantly, allowed SWPP to operate in compliance.
17. < KEY WOROS ANO OOCUMENT ANALYSIS
i. descriptor*
b.lOENTIFI ERS/OPEN ENOED TERMS
c. COS ATI Field/Croup
Pollution
Dibasic Organic Adds
Flue Gases
Desulfurization
Sulfur Oxides
Coal
Pollution Control
Stationary Sources
l3B
07C
21B
07A,07D
07B
21D
19. DISTRIBUTION STATEMENT
Release to Public
1». SECURITY CLASS fVtis At port)
Unclassified
21. NO. OF PAGES
62
30. SECURITY CLASS (thispage)
Unclassified
22. PRICS
CPA Form JJJO-I (t-79) J)-7
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