# OAR Box 1865

Prepped byCharmelle Mathews



# Document

Number: 

# 98 ) IV-J-41 Docket Number: 

# A-83-27

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11%SPRAYDRYE RABSORPTIO NAPPLICATION S FO RHIG H SULFU RCOA L J . R . DONNELLY , Wester nPrecipitatio nDivision , Jo yManufacturin g Compan y Lo s Angeles , Californi a 9003 9 K . S . FELSVANG , A/ S Nir o Atomizer , Soeborg , Denmar k Abstrac t Spra yDrye r Absorptio n(SDA ) i s a relativel yne wtechnolog yfo r th e desulfurizatio no f flu e gase s fro m coal-fire d boilers . Th e firs t appli

cation s o f SDAstarte d up i n198 0 fo r th e desulfurizatio no f utilit ylo w sulfur , coal-fire d boile r flu e gases . Sinc e tha t time , th e SDAproces s ha s bee napplie d t o industria l boiler s firin g hig hsulfu r coal s (3-3.5 % sulfur ) wher e hig hremova l efficiencie s (greate r tha n90% ) an d hig h availabilitie s hav e bee ndemonstrated . Jo yManufacturin g Compan yan d A/ S Nir o Atomize r hav e bee nleader s i n developin g and supplyin g SD Asystem s fo r utilit yan d industria l boiler s i nth e Unite d States . Sinc e 1977 , th e tw o companie s hav e worke d togethe r t o improv e th e proces s fo r treatin g highe r sulfu r coal s an d t o develo p a n SDAproces s fo r simultaneou s remova l o f sulfu r oxide s an d nitroge nox ides . Today , seve nutilit yan d fou r industria l coal-fire d system s ar e i n operatio ntreatin g a wid e variet yo f coa l type s an d sulfu r contents . Thi s pape r present s a descriptio no f th e SDAproces s an d a discussio no f th e developmen t o f th e proces s fo r achievin g hig hremova l efficiencie s fo r hig hsulfu r coals . Result s o f pilo t plan t testin g fo r inle t SO 2 concentration s u p t o 5,00 0 pp mar e presented . Operatin g result s fro m commercia l system s treatin g 3-3.5 % sulfu r coa l ar e give nan d tes t result s fro m4.2 % sulfu r coa l ar e presented . Desig nparameter s fo r system s unde r constructio ntreatin g greate r tha n2,00 0 pp minle t SO 2 an d requirin g greate r tha n90 % remova l ar e given . Introductio n Th e concep t o f dr yflu e ga s desulfurizatio nbyspra ydrye r absorptio n (SDA ) wa s firs t teste d o nutilit ycoal-fire d boiler s durin g th e mid-1970 s an d th e firs t ful l scal e syste mstarte d u p i n1980 . Th e acceptanc e by th e utilit yindustr yha s grow nquit e rapidl yan d toda ymor e tha n8,00 0 MW o f coal-fire d generatin g capacit yar e committe d t o SD Aflu e ga s desulfur

ization . Sinc e 1980 , seve nutilit yan d fou r industria l unit s hav e start
e d up whic hemplo yth e SDAproces s a s develope d byJo yManufacturin g Compan yan d A/ S Nir o Atomizer . Initially , th e SDAproces s wa s selecte d fo r utilit yboiler s firin g lo w sulfu r coal . A s additiona l tes t result s becam e availabl e an d knowledg e o f th e proces s grew , th e proces s wa s selecte d fo r hig hsulfu r applica

tion s o nindustria l boilers . Today , system s ar e i noperatio ntreatin g flu e gase s fro mth e firin g o f up t o 3.5 % sulfu r coal . Th e proces s ha s bee nteste d commerciallyo n4.2 % sulfu r coa l a t greate r tha n95 % SO 2 removal . I naddition , test s hav e bee nperforme d o na Joy/Nir o develope d SDAsimultaneou s S0 Xand N0 Xremova l process . System s ar e currentl y unde r constructio nfo r treatin g greate r tha n2,00 0 pp minle t SO 2 concen tration s a t greate r tha n90 % remova l efficiency . Thi s pape r review s th e developmen t an d applicatio no f th e SDAproces s fo r hig hsulfu r coal-fire d boilers . Result s o f pilo t an d ful l scal e test s ar e give na s wel l a s desig nparameter s fo r hig hsulfur , hig hremova l applications . Developmen t Spra ydrye r absorptio nfo r flu e ga s desulfurizatio nwa s firs t tested , a s a par t o f a sulfu r recover yprocess , o na coal-fire d powe r plan t i n1972 . I n197 6 test s wer e conducte d o na throw-away , sodium-base d proces s util

izin g a spra ydrye r followe d b ya ba g filte r fo r dus t collection . I n 197 7 Jo yManufacturin g Compan yan d A/ S Nir o Atomize r signe d a nagreemen t t o jointl ydevelo p and marke t th e SDAproces s i nth e Unite d States . Sinc e then , Joy/Nir o hav e bee nver yactiv e i ntestin g th e SDAproces s an d developin g way s t o improv e th e proces s especiall yfo r highe r coa l sulfu r

DONNELL Y

### P. 4

applications . Tabl e I list s som e ke ydevelopmen t milestone s i napplica

tio no f th e SDAt o utilit yan d industria l coal-fire d boilers . TABL E I HIG H SULFU RSPRAYDRYE RABSORPTIO N DEVELOPMEN T MILESTONE S 1977-7 8 Pilo t Testin g - Fergu s Falls , Minnesot a (+2,00 0 pp mSO2 ) 1979-8 6 Copenhage nPilo t Plan t Test s (+2,50 0 pp mSO2 ) 198 0 Riversid e Start-Up (1.6 % Sulfur ) 198 1 Argonn e Start-Up (3.5 % Sulfur ) 1982-8 3 Riversid e Hig hSulfu r Testin g (3.2 % Sulfur ) 198 3 Argonn e Hig hSulfu r Testin g (4.2 % Sulfur ) 1983-8 5 Copenhage nHig hSulfu r Test s (+5,00 0 pp mSO2 ) 198 5 Buic k Moto r Divisio nPerformanc e Test s (1 % an d 3 % Sulfur ) I nOctobe r o f 197 7 Joy/Nir o joine d force s t o construc t an d operat e a 20,00 0 acf mpilo t plan t a t th e Hoo t Lak e Generatin g Statio ni nFergu s Falls , Minnesota . Thi s pilo t plan t wa s require d t o qualif yfo r biddin g o nBasi nElectri c Powe r Cooperative' s Antelop e Valle yStation . Th e pilo t plan t consiste d o f a spra ydryer , a revers e ai r ba g filter , a nelectro

stati c precipitator , a reagen t preparatio nsyste man d equipmen t fo r test
in g th e effect s o f partia l produc t recycle . Durin g 197 7 an d 1978 , a ser ie s o f parametri c test s wer e performe d t o quantif yth e effect s o f th e followin g variables : Singl e Pas s Versu s Recycl e Operatin g Mode s Lim e Versu s Sod a As ha s th e Adsorben t Influenc e o f Fl yAs hGrai nLoadin g an d Alkalinit y Ba g Filte r Versu s Electrostati c Precipitato r Influenc e o f Spra yDrye r Outle t Temperatur e Influenc e o f Inle t SO 2 Concentratio n Stoichiometr yVersu s SO 2 Remova l Inle t SO 2 concentration s a s hig ha s 2,00 0 pp m wer e teste d a t remova l efficiencie s aroun d 90% . Spra ydrye r outle t temperature s a s lo wa s 18 ° F . abov e th e adiabati c saturatio ntemperatur e wer e successfull y tested . Partia l produc t recycl e t o increas e th e fee d solid s t o nearl y -50 % wa s teste d an d confirme d th e positiv e effect s o f recycle . Th e pilo t plan t progra mwa s ver ysuccessful . Muc hvaluabl e desig ndat a wa s obtaine d t o sho wth e capabilitie s o f th e SDAprocess . Result s o f th e tes t progra mle d t o th e Antelop e Valle yStatio ncontrac t t o Joy/Nir o an d t o th e grantin g o f th e Felsvang , e t al , paten t (U.S . No . 4279873 ) i nJul y 198 1 coverin g th e produc t recycl e concept . Th e succes s o f th e Fergu s Fall s pilo t plan t le d t o a decisio nt o instal l a 5,00 0 acf mpilo t plan t a t Nir o Atomizer' s researc hfacilitie s i n Copenhagen , Denmark . Th e pilo t plan t consist s o f tw o spra ydryers , a pulse-je t ba g filter , a revers e ai r ba g filter , a rigi d fram e electrostat

i c precipitator , a reagen t preparatio nsyste man d a naci d ga s (SO2 , SO3 , HCl , HF , etc. ) injectio nsystem . Th e syste mstarte d up i n1979 , an d i n it s seve nyear s o f operatio nmor e tha n3,00 0 parametri c an d longe r term test s hav e bee nperforme d t o quantif yth e influenc e o f majo r an d mino r proces s variables . Th e pilo t plan t ha s bee nuse d fo r parametri c testing , projec t specifi c testin g an d proces s developmen t testing . Method s o f increasin g SO 2 removal , especiall yfo r highe r sulfu r coals , hav e bee n develope d usin g thi s pilo t plant . Tabl e I I present s th e result s o f som e hig hsulfu r test s conducte d o nth e Copenhage npilo t plant .

DONNELL YTABL E I I PILO T PLAN T RESULT S HIG H SULFU RAPPLICATION S 

### P. 5

Tes t No . 272 6 272 7 436 4 614 5 614 7 438 5 Temperatures , F . SDAInle t SDAOutle t Delt a T Saturatio n SO 2 Concentrations , Syste mInle t Syste mOutle t SO 2 Removal , % Dus t Collecto r Additiv e 

### 35 2 14 8 2 3 pp mDr y 340 6 

### 43 0 8 7 PJF -chlo r 

### 35 0 14 7 2 3

354 2 

### 50 7 8 6 PJF •ide

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520 0 

### 93 1 8 2 ES P non e 

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### 14 9 9 6 ES P 40 2 15 8 1 8 . 449 0 

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### 37 0

16 3 1 8

665 0 

### 5 1 9 9 PJF othe r PJ F - Pulse-Je t Ba g Filte r ES P - Electrostati c PRecipitato r
A s ca nb e seen , remova l efficiencie s i nth e 8 0 an d 90 % range s ca nb e achieve d a t typica l boile r inle t ga s condition s wit hinle t SO 2 concen tration s up t o 6,65 0 ppm . Th e beneficia l influenc e o f smal l amount s o f chlorid e (eithe r a s HC l i nth e flu e ga s o r calciu mchlorid e i nth e feed ) o noveral l remova l ar e evident . Greate r tha n90 % remova l ca nb e achieve d whe neithe r a nelectrostati c precipitato r o r pulse-je t filte r i s use d a s th e dus t collector . Fo r ver yhig hinle t SO 2 concentration s (greate r tha n 5,00 0 ppm) , wher e hig hremova l efficiencie s (greate r tha n90% ) ar e required , a ba g filte r i s use d a s th e dus t collecto r an d anothe r additiv e i s use d t o enhanc e removal . Joy/Nir o committe d i n197 9 t o demonstrat e th e SDAproces s o na ful l scal e syste ma t th e Riversid e Generatin g Station . Thi s 11 0 M Wsyste mconsist s o f a 45-foo t diamete r spra ydrye r absorber , a twelve-compartmen t revers e ai r ba g filte r an d a reagen t preparatio nsystem . I naddition , th e exist

ing electrostati c precipitator s ca nb e use d fo r dus t collection . Th e Riversid e syste mwa s operate d a s a demonstration/tes t uni t fo r th e firs t thre e year s an d the nturne d ove r t o Norther nState s Powe r fo r continue d operatio na s a commercia l unit . Durin g th e demonstratio nphas e o f th e project , si xcombination s o f coa l wer e fire d havin g sulfu r content s vary ing betwee n0. 8 an d 3.5% . Ove r 90 % SO 2 remova l ha s bee ndemonstrate d fo r bot hlo wan d hig hsulfu r coal . Tes t result s hav e bee nverifie d byinde

penden t testwor k performe d fo r EPR I an d EPA . Sinc e 1980 , severa l othe r ful l scal e system s hav e starte d up an d passe d performanc e testing . Eac hha s adde d mor e knowledg e t o developmen t and applicatio ndat a bas e fo r th e SDAproces s an d ha s resulte d i nth e incorporatio no f manyrefinement s i nth e syste mdesign . Syste mDescriptio n Spra yDrye r Absorptio nsystem s var ywidel yi nsiz e an d numbe r o f compo nents ; however , the yconsis t basicall yo f th e followin g subsystems : Spra yDrye r Absorbe r Module(s ) Dus t Collector(s ) Reagen t Preparatio nSyste m Recycl e Syste m Spra yDryin g Absorptio ni s a specia l cas e o f spra ydrying . Flu e ga s replace s othe r dryin g medi a t o giv e th e 'driving forc e fo r evaporatio n wate r fromth e atomize d fee d material . Lim e slurr yreplace s th e produc t fee d slurr ybecaus e o f it s reactivit yfo r aci d gase s (SO2 / SO3 , HCl , etc.) . Ke yparameter s i nspra ydryin g (atomization , ga s mixing , outle t

R . DONNELL Y

### P. 6

temperature ) ar e als o ke yparameter s fo r achievin g th e simultaneou s reac tio no f SO 2 wit hlim e an d dryin g o f th e fee d an d reactio nproducts . Figur e 1 show s th e ga s flo wpat hfo r a typica l multimodul e SD Aapplication . FIGUR E 1

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Flu e ga s passe s throug hth e ai r preheater s wher e i t cool s t o betwee n 300-400 ° F . an d i s ducte d t o th e inle t o f th e flu e ga s cleanin g system . Fro mher e th e ga s flo wi s spli t betwee nth e operatin g spra ydryer s an d enter s th e spra ydrye r throug heithe r a roo f o r compoun d ga s disperse r (compound shownhere) . Fo r a compoun d ga s disperse r th e flu e ga s flo w i s agai nspli t suc htha t approximatel y60 % o f th e flu e ga s enter s vi a th e roo f ga s disperse r an d th e remainin g 40 % vi a th e centra l ga s disperser . Th e selectio no f a roo f o r compoun d ga s disperse r i s a functio no f turn
dow nrequirement s an d chambe r size . Eac hdisperse r i s equippe d wit h adjustabl e vane s whic har e se t durin g start-u p t o ensur e prope r ga s rotatio nan d mixin g wit hth e atomize d clou d o f droplets . Th e fee d slurry , whe ncontacte d wit hth e ho t flu e gas , simultaneousl y dry s an d react s wit hSO2 . Asmal l portio no f th e dr yproduc t fall s t o th e botto mo f th e spra ydryer , whil e th e remainde r i s carrie d ove r t o th e dus t collecto r wher e additiona l SO 2 remova l take s place . Th e two-poin t dis

charg e desig nensure s a clea r ga s passag e eve ni f upse t occur s tha t result s i ndeposi t formation . Aportio no f th e dus t enterin g th e ba g filte r wil l dro p ou t i nth e hopper s and th e remainde r wil l stic k t o ba g surface s causin g a nincreas e i nbag

hous e pressur e drop . Periodically , on e baghous e compartmen t i s brough t of f lin e an d blownbac k wit hrevers e ai r t o remov e residua l dus t cake . Thi s i s sufficien t t o contro l operatin g pressur e dro p an d SO 2 remova l i n th e ba g filter . Th e dus t collecte d i s eithe r transporte d bac k t o th e recycl e bi no r t o th e disposa l silo . Th e spra ydrye r outle t temperatur e i s typicall ymaintaine d betwee n1 8 an d 35 ° F . abov e th e adiabati c saturation . Thi s temperatur e i s selecte d t o maintai nth e lowes t saf e outle t temperatur e t o improv e reagen t usag e ye t maintai na dr yproduct . Figur e 2 i s a simplifie d proces s flo wdiagra m fo r th e SDAsyste mshowin g th e fee d preparatio nsystem .

J . R . DONNELL Y

### P. 7

FIGUR E 2 PROCES S FLO WDIAGRAM

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Th e fee d preparatio nsyste m typicall yconsist s o f a lim e silo , feede r an d slaker , a recycl e bin , feede r an d agitate d tank , a n agitate d fee d tan k an d screen , an d a hea d tan k a s wel l a s th e associate d pumps , pipin g an d valves . Pebbl e quic k lim e i s fe d fromth e storag e sil o o r bi nint o a slake r wher e i t react s wit hwate r t o forma fin e suspensio ncontainin g 2 0 t o 30 % hydrate d lime . Th e slake r ma yb e eithe r a detention , attrition , past e o r bal l mil l type , th e choic e dependin g upo nth e capacity , lim e qualit yan d custome r preference . Fro m th e slake r th e lim e flow s eithe r t o a storag e tan k o r directl yt o th e fee d tan k vi a a screen . Dryproduc t collecte d fro m th e spra ydryer , baghous e o r electrostati c precipitato r i s conveye d t o a recycl e fee d bin . Fro mher e i t i s fe d vi a a rotar yfeede r t o a n agitate d recycl e tan k wher e a nomina l 50 % solid s slurr yi s prepared . Th e recycl e slurr yi s the ntransferre d vi a a scree n t o th e fee d tank t o produc e a fee d slurr ycontainin g fro m3 0 t o 45 % solids . Th e rati o o f lim e t o recycl e slurr yfe d t o th e fee d tan k i s controlle d b

ya n SO 2 signal . Fro mth e fee d tan k th e slurr yi s pumpe d t o a hea d tan k wher e approximatel y hal f o f th e slurr yflow s b ygravit yt o th e atomizer . Slurr yflo wcontro l i s base d o n boile r loa d an d spra ydrye r outle t temperature . Th e atomize r convert s th e fee d slurr yint o a clou d o f discree t droplet s du e t o th e shearin g actio no f th e slurr yleavin g th e hig hspee d atomizin g wheel . Figur e 3 show s a Nir o rotar yatomize r and th e patente d KNabrasio n resistan t wheel .

DONNELL Y

### P. 8

FIGUR E 3 ATOMIZE RAN D WEA RRESISTAN T ATOMIZE RWHEE L 

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AbrasionResistan tAtomize rWhee l

F-60 0Centriiuga lAtomize r

Th e atomize r whee l consist s o f a whee l body , mad e o f stainles s stee l o r mor e corrosio nresistan t alloy , an d insert s protrudin g int o th e whee l bodyt o forma laye r o f slurr yfo r protectio no f th e insid e o f th e whee l bodywhe nth e whee l i s rotating . Th e botto m plat e an d th e insert s ar e mad e o f abrasion-resistan t material , e.g . silico ncarbide . Operatin g result s Thre e system s treatin g flu e gase s fro mth e firin g o f 3 % o r highe r sulfu r coa l hav e starte d up an d undergon e performanc e testing . Thes e system s ar e locate d a t th e followin g sites : Argonn e Nationa l Laboratory , Argonne , Illinoi s Riversid e Generatin g Station , Minneapolis , Minnesot a GM-Buic k Stea mPlant , Flint , Michiga n Th e SDAsyste ma t Argonn e wa s th e firs t syste mapplie d t o hig hsulfu r coa l an d starte d u p i n1981 . Th e syste m wa s retrofitte d o na nexistin g stoker-fire d boiler . Th e SDAsyste m consist s o f a 25-foo t diamete r spra y drye r equippe d wit hcompoun d ga s disperser , a four-compartmen t pulse-je t baghous e usin g wove nfiberglas s bags , a past e typ e slake r an d a recycl e system . Tabl e II I present s result s o f testin g conducte d whil e th e uni t wa s firin g •3. 0 and 4.2 % sulfu r coal .

R . DONNELLY .P. 9

TABL E II I OPERATIN GRESULT S ARGONN E NATIONA L LABORATOR Y Typ e Coa l Sulfur , % Inle t Temperature , _F . SO 2 Removal , % Approac hTemperature , F . Stoichiometri c Rati o 

### 11 1 3. 0 35 0 9 0 2 2 

### 1. 3 m o i s 

### 3. 0 34 6 8 0 2 2 

### 1. 0 Wes t Virgini a

4. 2 4. 2 35 0 35 0 9 0 9 6 2 0 2 0 1.3 3 1.6 0 Th e result s fo r th e 3.0 % sulfu r coa l ar e fro mperformanc e test s conducte d durin g 1982 . A s i s shown , remova l efficiencie s betwee n8 0 an d 90 % ca nb e achieve d a t stoichiometri c ratio s betwee n1. 0 an d 1.3 . Thes e result s ar e fo r test s withou t chlorid e additio nt o enhanc e performance . I nadditio nt o th e performanc e test s an d norma l operatio nwit h3.0 % sul

fu r coal , Argonn e ha s conducte d severa l serie s o f specia l test s t o eval

uat e SDAproces s fo r highe r sulfu r coals , effect s o f performanc e enhance

men t additiv e an d demonstrat e Joy/Niro' s simultaneou s dr ySO x /NO xprocess . Th e result s showni nTabl e II I fo r th e 4.2 % sulfu r coa l ar e fro mtest s performe d b

yArgonn e i nconjunctio nwit hConoc o Coa l Company . Th e pro gra mgoa l wa s t o demonstrat e tha t SDAi s a cost-effectiv e strateg yfo r controllin g SO 2 emission s fro m hig hsulfu r coa l combustio nunde r 197 7 NSP S requirements . Th e tes t demonstrate d tha t 90 % SO 2 remova l coul d b e achieve d a t a cos t competitiv e wit ha we t limeston e FG D process , an d tha t up t o 96 % SO 2 remova l coul d b e achieve d a t norma l boile r outle t condi

tions . Thes e test s include d th e additio no f calciumchlorid e t o th e fee d slurr yt o enhanc e performance . A s i s shown , th e stoichiometr y require d t o achiev e 90 % remova l fo r th e 4.2 % sulfu r coa l i s nearl yth e sam e a s fo r th e 3 % sulfur . Thi s i s du e t o th e chlorid e addition . Tabl e I V

present s result s o f hig hsulfu r coa l test s performe d i n198 2 an d 198 3 a t th e Riversid e demonstratio nunit . Fo r th e hig hsulfu r tes t ser ies , on e mont hburn s o f 3.2 % Illinoi s bituminou s coa l wer e performed . Numerou s parametri c a s wel l a s longe r termtest s wer e performed . TABL E I V OPERATIN GRESULT S - 3.2 % SULFU RCOA L RIVERSID E GENERATIN GSTATIO N Seven-Da yChlorid e Tes t 1 2 3 Dem o Ru nAdditio n Jl ^ a-r r Ga s Flow , acf m531,00 0 510,00 0 470,00 0 500,00 0 500,00 0 Inle t Temperature , F . 33 1 31 6 35 1 34 0 33 5 Approac hTemperature , F . 3 2 3 5 1 8 1 8 1 8 S0 2 Removal , % 93. 8 90. 6 93. 5 93. 6 9 0 Fee d Slurr ySolids , I 3 4 3 4 3 2 3 5 3 5 Stoichiometri c Rati o 1. 6 1.4 6 1.3 4 1.3 7 1. 1 A s showni nth e table , bette r tha n90 % SO 2 remova l wa s demonstrate d a t stoichiometric s betwee n1. 3 an d 1. 6 dependin g o nth e spra ydrye r outle t temperature . Fo r th e seven-da ydemonstratio nrun , 93 % remova l wa s ..achieve

d a t a stoichiometri c rati o o f 1.37 . Fo r test s usin g chlorid e addition , 90 % remova l wa s achieve d a t a stoichiometri c rati o o f 1. 1 • , Th e SDAsyste minstalle d o nboile r numbe r thre e a t Genera l Motor s Buic k stea mplan t consist s o f a 32-foo t diamete r spra ydrye r equippe d wit ha

J . R . DONNELL YP.1 0

compoun d ga s disperser , a neight-compartmen t revers e ai r ba g filte r an d a nattritio ntyp e slaker . Th e boiler s ar e C E pulverize d coal , tangentia l fire d proces s stea mboiler s rate d a t 450,00 0 pound s pe r hour . Th e SDA syste mi s designe d t o handl e a wid e rang e o f coal s an d a combinatio no f coa l an d oil ywast e sludg e firing . Tabl e vpresent s result s o f perfor

manc e test s conducte d i nJanuar y1985 . TABL E V PERFORMANC E TES T RESULT S GENERA L MOTOR S - BUIC K STEAMPLAN T

Fue l Sulfur , % Ga s Flow , dcf m(dry ) Inle t Temperature , F . Approac hTemperature , F SO 2 Removal , % Measure d Guarantee d Stoichiometri c Rati o Measure d Guarantee d Lo wSulfu r 

### 0. 8 105,33 0 

### 32 7 3 6 7 3 7 0 0.6 9 0.7 0 Hig hSulfu r 

### 2. 7 103,18 0 

### 30 3 2 0 9 1 9 0 1.4 0 1.5 0 Th e performanc e test s wer e conducte d i ntw o series . Durin g th e firs t series , a blen d o f lo wsulfu r coa l an d oil ywast e sludg e wa s fired , whil e a nomina l 3 % sulfu r coa l wa s fire d durin g th e secon d series . A s i s show n i nth e table , bette r tha nrequire d remova l efficiencie s wer e achieve d a t lowe r tha nguarantee d stoichiometri c ratios . Futur e Application s Th e applicatio no f SDAt o highe r sulfu r coal s a t hig hremova l efficien

cie s continue s becaus e o f operatin g advantage s ove r competin g technolo

gies . Limitin g factor s affectin g th e maximu msulfu r coa l whic hth e SD A proces s ca ntrea t effectivel yare : th e remova l efficienc yrequired , th e spra ydow ntemperatur e (SD Ainle t temperatur e minu s SDAoutle t tempera
ture ) availabl e an d th e typ e o f dus t collecto r employed . Ver yhig h remova l require s hig hstoichiometric s whic hma yrequir e mor e lim e tha n ca nb e fe d int o th e system . Th e spra ydow ntemperatur e determine s th e maximu mwate r evaporatio nan d th e maximu mlim e whic hca nb e fe d int o th e system . Th e typ e o f dus t collecto r (electrostati c precipitato r versu s ba g filter ) affect s overal l remova l sinc e a portio no f th e SO 2 remova l take s plac e i nth e dus t collector . Aba g filte r i s mor e efficien t tha n a nelectrostati c precipitator . Th e us e o f performanc e enhancemen t additives , suc ha s chlorid e an d others , ca nincreas e thi s maximu msulfu r leve l significantly . Tabl e V I present s desig nparameter s fo r thre e hig h sulfu r system s unde r constructio nwhic hrequir e hig hremova l efficien

cies . TABL E V I DESIGNPARAMETER S HIG H SULFU R- HIG H REMOVA L Uni t Ga s Flow , acf m Inle t Temperature , F . Inle t SO 2 Concentration , SO 2 Removal , % Dus t Collecto r Start-Up Shenyang/Liaon i Chin a 170,00 0 

### 32 0 pp m2,10 0



### 9 0 

### PJF 7/8 7 

### n

g Bresci a Ital y 490,00 0 

### 30 0 2,00 0 

### 9 0 

### PJF 8/ 8 7 Salzbur g

Austri a 350,00 0 

### 36 0 2,50 0 

### )9 7 PJF 10/8 7

J . R . DONNELL YP.1 1

A s i s shown , th e inle t flu e ga s temperature s ar e al l lo w(300-360 ° F. ) whic hlimit s th e spra ydow navailabl e an d al l system s includ e a pulse-je t ba g filte r a s th e dus t collector . Al l thre e system s ar e bein g retro
fitte d o nboiler s firin g lo wrank , hig hsulfur , hig hchlorin e coals . Start-u p an d performanc e testin g o f thes e unit s i s schedule d fo r 1987 . Conclusion s Spra ydrye r absorptio ni s a relativel yne wtechnolog ywhic hha s gaine d rapi d acceptanc e b yth e utilit yan d industria l sector s a s a neffective , reliabl e mean s o f achievin g flu e ga s desulfurization . Th e proces s i s a specia l applicatio no f spra ydryin g an d ha s bee nextensivel yteste d a t th e pilo t an d full-scal e levels . Commercia l system s ar e in . operatio n whic hhav e demonstrate d th e abilit yt o achiev e 90 % remova l fro m3 % sulfu r coa l applications . Performanc e enhancemen t additives , suc ha s chloride , ca nsignificantl y exten d th e maximu msulfu r leve l tha t ca nb e treated, wit hchlorid e enhancement , up t o 96 % remova l ha s bee ndemonstrate d o na commercia l applicatio nfirin g 4.2 % sulfu r coal . Futur e application s no wunde r constructio nwil l requir e eve nhig hSO 2 remova l efficiencies . On e syste m i s designe d t o achiev e greate r tha n97 % SO 2 remova l whe nth e inle t concentratio ni s 2,50 0 ppm . A s tim e pro gresses , i t i s expecte d tha t th e SDAproces s wil l b e applie d t o cove r eve nmor e rigorou s applications . REFERENCE S Felsvang , K . s . "Desulfurizatio no f Lo wRank , Hig hSulfu r Coa l b yDr y Flu e Ga s Desulfurization, " 8t hInternationa l Congres s o f Chemica l Engineering , Chemica l Equipmen t Desig nan d Automation , Proha , Czechoslovakia , Septembe r 1984 . Donnelly , J . R. , e t al , "Spra yDrye r FG D Expereience , Joy/Nir o Installa

tions, " EPA/EPR I 9t hFG D Symposium , Cincinnati , Ohio , Jun e 1985 . Blythe , G . M. , e t al , "Fiel d Evaluatio no f Utilit yDr yScrubbin g System, " EPA/EPR I 8t hFG D Symposium , Ne wOrleans , Louisiana , Novembe r 1983 . Donnelly , J . R. , e t al , "Industria l Spra yDrye r FG D Experience, " ASM E Industria l Powe r Conference , Pittsburgh , Pennsylvania , Octobe r 1986 . Farber , P . S. , "Spra yDrye r an d Fabri c Filte r Installatio n- A nIndustri

a l Boile r Conversion, " 74t hAnnua l Meeting , APCA , Philadelphia , Penn
sylvania , Jun e 1981 . Farber , P . S . e t al , "Evaluatio no f a Spra yDrye r Flu e Ga s Cleanin g Syste mo nHig hSulfu r Coal , " Coa l Technolog y'83 , Houston , Texas , Novembe r 1983 . McLeod , D . N. , "Th e Start-Up an d Debu g o f th e Larges t Industria l Flu e Ga s Desulfurizatio nSyste mi nth e Unite d States, " Coa l Technolog y'84 , Houston , Texas , Novembe r 1984 .

DONNELL Y