P. 1 

# OAR Box 

# 1865 Prepped by Charmelle Mathews



### Document

Number: 

# 95 ) IV-J-3 8 Docket Number: 

# A-83-2 7

Printed 12/3/20089:15:32 AM

Sheet 95of 105-E-2- . 

# DOR R OLIUE R A-'83-2 7 IV-J-3 8 

# Cas e Histor

y # 

# 3 

# Quake r Stat e Oi l Switche s t o Coa

l for Stea m Generation Conversio n i s Firs tLarge Privatel y Funde d Coa

l Burnin g Flui d Be d Boile r Projec ti n U.S.A . Quake r State' s Cong

o Refinery i n Newell

, Wes tVirginia ha s converted t o coal-fire

d boiler s designed an

d fabricate

d by Keeler

/ Dorr-Oliver

. Cong o wa s th e onl y on e o f three Quake

r State refin erie s i n th e Per

m Grad e Crud e Regio n t o no tutiliz e coa

l a s it s primar y fue l fo r steam generation . Constructe d i n 1972 , Cong o use d No. 6 residua

l fue l oi l a s it s primar y fue l fo r proces s heater s and steam generation . Lowe r capita l equipmen tinvestmen to f packag e boilers an d fue

l handlin g system s o

f residua l fue l mad e coal-fire d unit s unattractive fo

r th e refiner

y a tthattime . Envi ronmenta l regulation s wer

e als o inexpensivel y an d easil y satisfie d b y restrictin g residua

l fue l t o a maximu m o f 2.0% sulfur . Quaker State decided t o researc h coal-fire d steam gener ator s fo r it s Cong

o Plan tafter analyzin g th e escalatio n o f resid ua l fue l costs . Prices increase d sharpl y du e to OPE

C crude oil price increase s and stric tenvi ronmenta l regulation s o n new and modifie

d emissio n source s impose d by th e 1977 Amendmen t t o th e Clea n Ai r Ac tFro m 197 2 to 1982 , th e cos to

f residua l fue l increase d 600 % - fro

m $4.0 0 pe r barre l ($.5 6 per M

M BTU ) t o $26.5 0 pe r barre

l ($3.6 1 pe r M

M BTU). Durin g th e sam e period , coa l cost s a tth e othe r two Quake r State refineries increase d only 270 % - fro m $10.0 0 pe r to n ($.4 2 per M M BTU ) t o $27.0 0 per to n ($1.1 5 pe r M

M BTU) . Based o n Tw o Quldlzed be d coal-fired boiler s a tQuake r State' s Cong o Refinery .

fue l cost s alone , a potential $4. 5 millio n per yea

r coul d b e saved b y convertin g t

o coal-fire d boilers . Wit h thi s i n mind , an d with th e expectatio n tha tsupply-limited oil would continu e t

o escalate i n pric e faste r tha n demand-limite d coal . Quake

r State began researchin g coal-fire

d boilers fo

r it s Cong o Refinery . I n 1982 , a tth e recommen datio n o f Stanley Jone s Mechan ica l Contractors , Inc , Keeler/DorrOlive r wa s selecte d t

o design , fabricat e an d erecttwo fluidized be d coal-fire d boilers . Eac

h ofth e two Keeler/Dorr-Olive

r boiler s have th e capacit

y to generat

e 120,00 0 pound s of

superheate d steam per hou r (54.48 0 kg/hr) at 26 5 psi g (12 0 kg

) pressure wit

h 100° F (56°C) superhea tTh e schedule d completio n dat e i s May . 1985 .

### Economic s Environmenta l Consideration s Quake r Stat e decide dt o in
stal l fluidizedbe dboiler s rathe r tha n conventiona l boiler s afte r analyzin g man y economi c an d environmenta l factors . Th e eco nomi c revie w analyze dth e pay bac k o f aconventiona l boile r

plan t an dwe t scrubber s o r

complianc e coa l vs . afluidizedbe dboile r installation . Th e conventiona l boile r

plan t an dbaghous e installatio n cos t wa s $ 9 million . Fo r

environmenta l reasons , th e plan t

woul drequir e low sulfu r complianc e grad e coa

l a t acos t o f $5 5 pe r ton . Annua l fue l saving s wa s estimate da t $3,568,500 . Additiona l as h dis
posa l cost s adjuste dth e fuel saving s t o $3,472,000 . Thi s in
stallatio n provide dasimpl e pay bac k o f 2.5 9 years . Th e fluidizedbe dboile r installatio n cos t

$13,500,000 . Suitabl e coal cos t

$35.0 0 aton . Annua l fue

l saving s wa s projecte d t o b e $5,121,000 . Thi s wa s ad
juste dt o $4,164,00 0 afte r in
cludin g annua l limeston e cos t o f $482,00 0 an das h disposa l cos t a t aconservativ e $10.0 0 aton . Th e simpl e paybac k

i s 3.2 4 year s an dcoul db e les s i

f alower sulfu r conten t coa l i s burned . Bot

h installation s wer e eligibl e for a 10 % energ y ta x credi t

an da n investmen t

ta x credi t Furthe r analysi s of

th e tw o installation s showe dtha t avail
abilit y an dpricin g wa s no t assure dfor

low-sulfur

compli
anc e grad e coal , neede dfo r a conventiona l boile r

plan t There
fore , flue ga s desulfurizatio n equipmen t

woul dmos t

likel y nee dt o b e installe di f

aconven tiona l boile r

plan t wa s buil t Thi s equipmen t

alon e woul drequir e abou t th e sam e capita l investmen t a s th e fluidbe dgenerators . Wit h thes e an dsevera l environmenta l consideration s i n mind , Quake r Stat e decide dt o instal l fluidbe d stea mgenerators . Conventiona l vs . Fluidize d Be d Boile r Installatio n Equipmen t Sulfu r Conten t Cos t Annua l Fue l Saving s Annua l As h Disposa l Cost s Annua l Limeston e Cost s Adjuste dSavings/Yea r Simpl e Pa

y Bac k Conventiona l Boile r Plan t

(•1 ) withou tFin e Ga s DesnUnrimatio n 120.00 0 PPH Stoke r

boiler s wit h baghouse , et c 1.33 % $9,000,00 0 (S75/pph ) $3,568,50 0 $ 96.50 0 $3,472,00 0 2.5 9 Year s Flui d Be d Boile r Plan t(*3 ) 120.00 0 PP H AFB boiler s wit h baghouse , et c 4 % $13,500,00 0 ($110/pph ) $ 5,121.00 0 $ 475.00 0 $ 482,00 0 $ 4.164.00 0 3.2 4 Year s (1 ) Conventiona l stea mgenerato r plan t base do n annua l coa l usag e o f 77.62 5 ton s a t $55.0 0 pe r

to n plu s $ 10.0 0 pe r to n as h disposa l fo r

12 % ash . (2 ) Flui dbe dstea mgenerato r base do n annua l coa l usag e o f

77.62 5 ton s a t $35.0 0 pe r

ton . 4 % S coa l requirin g 0. 5 poun dlimeston e pe r

poun dcoa l an d $10.0 0 pe r

to n for 12 % as h plu s limeston e disposal . Annua l fue l saving s o f th e fluidize

dbe d boiler s was projecte

da t S4.164.000 . Th e Cong o Plan t I s locate di n a n are adesignate db y th e Wes t Virgini aAi r

Pollutio n Contro l Commissio n (WVAPCC

) a s 1 ) Priorit y Classificatio n I an d2 ) a non-attainmen t

are afo r meetin g th e Nationa l Ambien t

Ai r Quality Standard s fo

r suspende dparticu
late s an dsulfur

dioxide . Du e t o this , th e Cong o Refiner y ha s stric t emissio n limitation s fo r constructio n o

f coal-fire dboilers . Quake r Stat e applie dt o th e WVAPC C i n lat e 198 1 for

apermi t t o construc t

thre e 120.00 0 pp h stoke r boiler s wit h abaghous e an darelate dcoa l an das h handlin g system . Th e WVAPC C Indicate d th e permi t

applicatio n coul db e approve dwit h Quake r State' s commitmen t

tha t th e sulfur conten t of coal purchase d woul dno t

excee d1.33 % an dth e annua l coal usag e woul dno t excee d77.62 5 tons . Coa l sup plier s however , expresse dthat l th e coa l require dt o mee t th e emissio n limitation s was to o restrictiv e t o provid e aviabl e supply . Thi s concern , combine d wit h th e hig h cos t

o f th e complianc e coal , motivate dQuak
e r Stat e i n 198 2 t o explor e th e us e of fluidbe dstea mgenerator s t o achiev e SO

acompliance . Afte r discussion s with Keeler

/ Dorr-Oliver , Quake r

Stat e de
cide dt o ru n pilo t

plan t studie s t o determin e limeston e suit
abilit y t o achiev e emissio n limit
ations . Thes e studie s showe d tha t th e limeston e Quake r

Stat e propose dt o us e maintaine dth e SO 2 emission s belo w th e max imu mallowabl e 1. 2 pound s SO 2 pe r M M BT U fo r coal s containin g u p t o 4 % sulfur . I n October , 1983 , th e Wes t Virgini aAi r

Pollutio n Contro l Commissio n grante daconstruc tio n permi t

reflectin g th e follow
in g conditions :P. 4


### Th e Contractor s (1 ) Th e concentratio n o

f particu
lat e matte r

admitte dfro

mth e boiler s wil l no t

excee d0.0 3 grain s pe r dr y standar dcubi c foot . SO 2 emissio n rate s from th e boiler s will no t

excee d1.2 pounds/M M BTU . (2 ) Steamplan t

emissio n limit
ation s (tons/yea r

fromstack) : Particulat e Matte r

85. 6 (Boile r stac k emissions ) Sulfur Dioxide 1680. 0 Nitroge n Oxide s 582. 0 Carbo n Monoxide 116. 4 Hydrocarbon s 38. 8 (3 ) Maximu msulfu r conten t of coa l use dwil l no t excee d4% . (4 ) Th e sulfu r

dioxid e contro l syste mwill hav e aminimu m contro l efficiency o

f 82% . (5 ) N o mor e tha n tw o o

f th e coa l an doil-fire dboiler s will oper at e a t an y give n tim e excep t durin g uni t

changeover s (start
ups) . (6 ) Annua l coa

l usag e will b e n o mor e tha n 77.62 5 tons .

Revie w of Pas tVs . Allowabl e Emissio n Limits Prio r BmJaalon s (Tons/Year

) Particulate s 143.07 Sulfu r Dioxid e 1.953.3 0 Nitroge n Oxide s 575.7 7 Carbo n Monoxid e 31.1 0 Hydrocarbons 6.2 2 Allowable Futur e Emission s (Tons/Year

) 85.5 8 1.944.5 0 582.2 0 116.4 3 38.8 0 Ne

tEmissio n Chang e (Tons/Tear

) -57. 5

- 8. 8 + 6.4 3 +85. 3 +32. 6 EP

A Significant Increas e (Tons/Tear

) 2 5 4 0 4 0 10 0 4 0

• • ther

e i s no t asignifican t

emis
sion increas e fo

r an y o f th e abov e emissions . Emissio n factor s ar e base do n AP-4 2 fo r 2 % sulfu r No . 6 fue l oi l an dstoker-fire dstea m generators . Prio r emission s ar e base do n a1980-8 1 averag e o

f 12,441.11 4 gallon s o f No . 6 residua l fue

l wit h hea t inpu t o f 1.901 8 x IO 1 2 BT

U pe r year . Equivalent

hea t inpu t fro m12.25 0 BT

U pe r poun dcoa

l require d77.62 5 ton s o

f coa l annually , an drequire da67 % conversio n o f SO 2 to CaS0 4 wit h 4 % sulfu r coa l o r amaximu mo

f 133 % sulfu

r coa l with n o con version . Actua

l SO 2 emissio n o

f 82 % capture wil

l b e abou t 1,12 0 tons/year . Quake r Stat e will achiev e SO j complianc e wit h it s ne w coal-fire d boilers . Desig n an dConstructio n Contract
- Stanle y Jone s Mech
anica l Contractors , Inc. , Sout h Fulton , Tennessee . Design , Fabricatio n an dErec
tio n Contract : Keeler/Dorr-Olive r Boile r Company , Williamsport, Pennsylvania . Engineerin g Contract : I.C . Thomasso n Associates . Nash
ville . Tennessee . Powerhous e Constructio n Contract : H . & M . Construction , Milan , Tennessee . 

# ^fp ^

Boile r tube s were shippe d for field erection .

Th e field-erecte d CPFS desig n wa s utilize d by Quake r Stat e to produc e 120.00 0 pph .

A view o f th e firs t larg e privatel y funde dcoa l burnin g fluidize dbe dboile r i n th e U.S .

### Th e K/D- O Mode l CPF S

Stea mGenerato r P. 5

Quake r State' s tw o coal-fire d fluidize dbe dboiler s ar e Keeler / Dorr-Oliver' s mode l CPF S stea m generators . Th e CPF S mode l ca n b e sho p fabricate dan dshippe d i n tw o module s t o generat e a maximu mo

f 80.00 0 pound s o

f stea mpe r hou r (pph) . Th e Cong o Refiner y require dth e capacit y t o produc e 120.00 0 pph ; therefore , th e field-erectedCPF S desig n was utilized . Thi s CPF S desig n use s a sparg e pip e ai r

distributo r

syste m whic h eliminate s th e nee dfo r be do r windbo x segmentation . I t i s use dt o achiev e rapi dloa d respons e an dhig h turndow n capabilit y of

7:1 . I t als o ha s th e following advantages : 1 ) Permit s acompletel y seal
welded , watercoole dfloo

r with
ou t numerou s penetration s fro mth e admissio n o

f fluid
izin g air . 2 ) Permit s multipl e zone s with
ou t acumbersom e windbo x desig n wit h multipl e ai r

sup plie s an ddampers . 3 ) Reduce s hea droo mb y elimi
natin g th e windbo x unde r th e bed . 4 ) Eliminate s sealin g require
men t betwee n th e windbo x an dflui dbed . 5 ) Provide s fo

r eas e o f inspectio n o r maintenanc e (sparg e pip e ca n b e withdrawn) . 6 ) Eliminate s segregatio n o f larg e as h particle s b y withdrawin g botto mas h betwee n sparg e pipes . Individua l allo y sparg e pipe s ar e inserte dthroug h th e water coole dfrontwal l an dar e bolte d int o place . Thi s allow s th e pip e t o Thi s CPF S desig n ha s di e turndow n capability o f

7:1 . b e remove ddurin g aboile r out age . Eac h sparg e pip e i s equippe d wit h aquic k

actin g dampe r

for contro l an damanuall y operate d balancin g damper . Al

l sparg e pipe s ar e connecte dt o acommo n ai r heade r whic h receive s com bustio n ai r

fromth e force ddraf

t fan . I n additio n t o multipl e sparg e pipes , turndow n capabilit y i s complemente db y th e placemen t o f th e in-be dsurfac e alon g eac h sid e ofth e furnace . A s individua l sparg e pipe s ar e turne dof f from th e side s towar dth e center , a disproportionat e amoun t o f in
be dsurfac e i s remove dfro mth e activ e be dare awhic h permit s a furthe r reductio n i n th e fue

l fee d an dstea mgeneratio n pe r uni t of plan t area . Thi s placemen t

of th e in-be dsurfac e als o provide s a cente r firing isl e fo

r overbe d feedin g o f coa l an dlimestone . T o preven t

erosio n problem s cause db y impingemen t

in-bed . waterwal l an dconvectio n tube s wer e place dvertically . Vertical tube s wer e als o use d becaus e horizonta l an dslope dtube s hav e th e tendanc y t o affect

th e hori
zonta l be dmotio n an dit s in
fluence o n functiona

l performanc e i s no t alway s predictable . Th e boiler s ar e ofth e natura l circulatio n typ e whic h ar e know n fo r thei r simplifie doperatio n an d maintenanc e an dthei r lowe r capita l an doperatin g costs . Keeler/Dorr-Olive

r als o supplie d asuperheate r

an deconomize r fo r th e bubblin g be dcombustio n system . Th e syste mdeliver s 120,00 0 pp h (54,48 0 kg/hr ) o f 26 5 psi g (12 0 kg ) superheate d stea mwit h 100° F (56°C ) super hea t An alrheate r

wa s no t necessar y fo

r thi s installation . Th e specifie dcoa l siz e i s 1 l A" x 0 . Fue l i s injecte dint o th e furnac e ove r

th e be db y a spreade r stoker . Stea mproduc
tion i s the n controlle db y adjust
in g th e fluidizlng-ai r

velocit y an d adjustin g th e fue

l flow. Th e spreade r

stoke r als o inject s sorben t

int o th e combus
tio n zon e a t

on e poin t

fro move r th e bed . Th e sorben t

particulat e siz e specifie di s W

x 0 fo

r optimu mSO

2 control . A fabri c filter control s particulat e emis
sion , an da n interna l recycl e loo p i s use dt o improv e carbo n burnou t an dreduc e sorben t consumption .

Stea m generation Stea m condition s Turndow n Pu d SO a Captur e 2 x 120.00 0 pp

h MC R 26 5 psi g wit

h 100° F superhea to r 510° F 7: 1 Bituminou s coa

L 4 % S.H V 1250 0 BTU/lb. as h 12 % 82 % 

# t DORROLIUE R P.O . Bo x 54 8 • WUliamsport. P A 1770 3 • (717 ) 326-336 1 Bulleti n No . K/D-O 44C18 5