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# OAR Box 1828 Prepped by Ollie Stewart



### Document

Number: 

# 314 ) IV-B-1 8 Docket Number: 

# A-83-2 7

Printed 11/12/2008 11:12:59 AM Sheet 314 of 325P. 2 

# RADIA N 

# A-83-2 7
CORPORATIO N IV-B-1 8 MEMORANDU

M
DATE : Apri l 23 , 198 7 TO : Ji m

Eddinger , EPA/IS B FROM : J . Thoma s Waddell , Radia nCorporatio n SUBJECT : Demonstratio nStatu s o f Industria l Fluidize dBed CombustionUnit s

1. 0 INTRODUCTIO N Thi s memorandum

present s th e result s o f a recen t surve y conducte dt o reexamin e th e demonstratio nstatu s o f fluidize dbe d combustion(FBC ) unit s inth e industria l secto r (define dherei nt o includ e institutiona l an d commercia l uses) . Recen t literatur e discussin g FB C technolog y wa s surveyed , an dtelephon e contact s wer e mad e wit hFB C uni t vendor s an d Stat e environmenta l agencies . Th e informatio ngathere dwa s use dt o addres s th e tw o followin g questions : 1 ) I s FB C a demonstrate dsulfu r dioxid e (SO- ) contro l technolog y fo r industria l purposes ? 2 ) Ca n FB C unit s achiev e 9 0 percen t remova l o f SO - on a sustaine d basis ? 2. 0 DEMONSTRATIO N

STATU S O F FB C UNIT S I N TH E UNITE D STATE S Tabl e 1 present s dat a o n existin g industria l coal-fire dFB C unit s in th e Unite dState s o f greate r tha no r equa l t o 7 5 millio nBtu/hou r hea t inpu t capacity ; on e 5 0 millio nBtu/hou r Canadia nFB C uni t i s als o included . O f th e 2 5 boiler s listed , 9 ar e designe dwit hbubblin g beds , 1 4 hav e circulatin g beds , an d 2 hav e a 2-stag e be d design . Th e SO - remova l efficiencie s fo r thes e unit s rang e fro m 7 1 t o 9 2 percen t an d averag e

Progres s Center/320 0 E
. Chape l Hil l Rd./Nelso n Hwy./P.O
. Bo x13000/Researc h Triangl e Park , N.C
. 27709/(919)541-910 0T ABL E 1 . EJISTIN G INDUSTRIA L COAL-FIRE D FB C UNIT S I N TH E U.S . 0 7 5 MMBtu/h r Hea t Inout )

r o Conoan v Georgetow i Univ . Ia

l Kentuck y Agri cultura l Energ

y Corporation Idah o Nationa l Enoineerino Lab.la ) Midwes t Grai n Product s Ion a Bee f Processor s AndersonClavton Californi a Portlan dCeten t B.F . Goodric h 6enera l Motor s Centra l Sov

a Sohi o 11 ) Quake r Stat e Archer-Daniels Midlan d Stea l Hea t Authorit y 111 Scot t Paoer lon e Enero v Nuaber o f LocationManufacture r Unit s Nashinpton . D

C Franklin . K

Y

Idah o Falls . I D Pekin . I L Aiarillo . T

> Jacksonville , I

L Cotton , C

A

Henrv , IL Pontiac . N I Chattanooga , T

N Lua , O H Ne.ell . N

V Decatur . I

L
Nilles-Firre . P

A
Chester . P

A lone . C A F N

1 F N 2

F N 2

F N 1 Norise r 1 Norise r 1 Pvrooowe r 1 Pyropone r 1 Pvrooo«e r I Pvropone r 1 CD O 1 ro o . 2 I'D O 5

CO O 1

C E 1 C E 1 Hea t

Inou t (MMBtu/hr ) 12 0 7 5

e i 17 1
B B 10 6 22 ? 14 9 44 3 U 3 10 2 15 0 53 0
7 5 81 5 18 2 Be d Tvoe Bub . Bub .

Bub . Bub . 2-staae 2-stap e Cir . Cir . Cir . Cir . Bub . Bub . Ctr . Cir . Cir . Cir . Coa l S 50

2 Conten t Regulation (xt.Z ) (Ibs/miBt u 3. 3 3.1

0.6 8 2. 7
4.1 6
3-3. 5 0.55-0.7 5 3. 5 2. 5 2. 8 2. 8 2.5-4. 0 4. 1
0. 7 (n ) (o l 1. 2 N.A . 1. 2

0. 6 an d 70 1 Red . 1. 2
0.6 5 1. 2 0.1 3 1. 2 1. 2 0.4 4 1. 2 1. 2 1. 2

N.A .
N.A . 0.2 6 IS0 2 Reaova l 9 1 861b )

86(d.e l 82(d.e l 84(d,g ) 78(h ) 84-88(h l 85(d ) 9 0 (k. ) 90. 7 (k l B7(d.e ) 7|-82(h l 90-92(i 1

N.A . 90(i ) 92(h ) Ca: S Rati o 3. 0 3. 0

10. 3 2. 2 2. 8

N.A . 3.5(i )
2.5U ) N.A . N.A . N.A . N.A . 2.0-2.5( 1

N.A .
N.A . 1.5 Start-U

p Dat e 7/7 9 10/8 2

5/8 4 5/8 4 9/8 2 9/B 6 5/8 5 10/8 5 11/8 6 198 5 10/8 4 9/8 5 ) 12/8 6
198 4
198 4 1/8 7 Reliabilit y

(I I N.A . 99(c )

92(f )
96. 1
N.A .
N.A .

. N.A . I00(j ) N.A . N.A . 9 0 43U ) N.A .
N.A .
N.A . N.A . Referenc e

1 2. 3

4 5 6 7 8, 9 1 0 1 1 1 1 12,1 3 1 4 I S 1 6 1 7 1 8

Genera l Motor s Ft . Navne , I N Canadia n Forces . Princ e Edna' d Bas e Island . Canad a R S F H 19 0

5 0 Bub . N.A . N.A . N.A . N.A . 12/8 6 N.A . 1 9

5. 5 N.A . 93.5!n l 4.0(a ) 12/8 2 91(o ) 2 1P. 4

.9.

. jxSYMBOL S AND FOOTNOTE S

F W = Foste r Wheele r KD O = Keele r Oorr-Olive r C E = Coabustio nEngineerin g R S = Rile y

Stoke r Bub . - Bubblin g Bed Cir . = Circulatin g Bed (a ) Deaonstratio nunit , ib ) Coaglianc e tes t data . (c ) Estiaat e sinc e earl y

1986 , (d ) Actua l operatin g data . (e ) Long-te n(i.e. , 2 5 day s o r longer ) CEM

data . (f ) Reliabilit y

calculate dfo r 1 o f th e 2 units . (g ) Two-da y

test . (h ) Percen t reaova l reguire dt o aee t eaission s liait . (i ) Desig ninforaation . ij ) Reliabilit y

for fir t quarte r o f 1986 . (k ) Base do

nStat e perai t estiaate . (1 ) No longe r i noperation . Caapany snitche dfuel s fo r econoai c reasons . (a ) Reliabilit y

for firs t 3 aonth s o f operation . (n ) Anthracit e eula . (o ) Designe dfo r 7 fue l types ; aai nfue l i s anthracit e eula . (p ) 30-da y eaission s tes t conducte db y U.S . EPA .



# JP. 5

8 7 percent . Th e fuel s burne drang e insulfu r conten t fro m 0.5 5 t o 4.1 6 weigh t percent . Sulfu r dioxid e emissio nrate s rang e fro m 0.1 3 t o 1. 2 lbs/millio nBtu . Th e bubblin g be dFB C unit s rang e i nsiz e fro m 7 5 t o 17 1 millio n Btu/hour . Thes e unit s hav e SOpremova l efficiencie s rangin g fro m 7 1 t o 9 1 percen t an

daveragin g abou t 8 4 percent . Th e two 2-stag e boiler s hav e hea t input s o f 8 8 an

d10 6 millio nBtu/hour , an dSO- remova l efficiencie s o f 8 4 an d7 8 percent , respectively . Th e circulatin g be dFBC' s rang e inhea t inpu t fro m 7 5 t o 81 5 millio nBtu/hour . Sulfu r dioxid e remova l efficiencie s fo r thes e boiler s rang e fro m 8 4 t o 9 2 percen t an daverag e 9 0 percent . Tabl e 2 list s industria l FB C unit s tha t ar e currentl y bein g planne do r ar e unde r constructio ninth e U.S. , an dwhic hbur nsulfur-bearin g fuels . Twenty-si xboiler s ar e liste drepresentin g 1 5 differen t sites . O f th e 2 6 FB C units , 2 2 ar e designe dwit hcirculatin g beds ; th e remainin g boiler s hav e a 2-stag e design . Th e circulatin g be dunit s rang e insiz e fro m 19 0 t o 62 5 millio nBtu/hou r wit ha naverag e o f 30 4 millio nBtu/hour . Thes e FB C unit s ar e designe dt o bur nfuel s wit hsulfu r content s rangin g fro m 0.2 5 t o 6. 0 weigh t percent . Desig nSOpremova l efficiencie s wer e obtaine dfro m th e boile r vendor s fo r 1 7 units . Thes e efficiencie s rang e fro m 8 3 t o 9 7 percen t an daverag e 9 3 percent . Sulfu r dioxid e emissio nrate s rang e fro m 0.0 4 t o 1. 2 lb/millio nBtu . 3. 0 ACHIEVABILIT YO F 9 0 PERCEN T S0 2 REMOVAL Emissio ntes t dat a fo r fiv e FB C units , includin g fou r short-term an d two long-term

tests , ar e presente dinth e Summar y o f Regulator y

Analysis . Althoug hth e boiler s liste dwer e no t generall y operate dt o maintai n9 0 percen t SOpremova l ona long-term basis , fou r o f th e fiv e boiler s attaine d greate r tha n9 0 percen t SO premova l (u pt o 9 9 percent ) fo r shor t period s durin g th e tests . Thes e tes t dat a demonstrat e tha t greate r tha n9 0 percen t 2 0 SOpremova l ca nb e achieve dwhe nburnin g low - o r high-sulfu r coal . A s liste dinTabl e 1 , a 30-da y emissio ntes t wa s conducte dona bubblin g be dFB C uni t a t th e Canadia nForce s Bas e inSummerside , Princ eTABLE 2 . INDUSTRIAL-COMMERCIAL-INSTITUTIONA L FB C UNIT S PLANNE D O R UNDE R CONSTRUCTIO N

Sulfu r SO . Desig n Desig n No . o f Hea t Inpu t Be d Desig n Fue l Conten t Regulatio n SO . Remova l Ca: S Estimate d Manufacture r Unit s (MWtu/hr ) Typ e Type (wt . X ) (l b SO,/MMBtu ) IS ) Rati o Start-u p Referenc e Company/Locatio n

U i McPherso n Oi l Pyropowe r

Ker n Co. , C

A Cogeneratio n Nationa l CP C Corp . Stockton , C

A Bloge n Powe r CP C Ivanpah , C

A Archer-Daniels-Midlan d KD O Ceda r Rapids , I A Universit y o f Missour i R S Columbia , M

O Universit y o f Nort h N.A . Carolin a Chape l Hill , N

C A . E . Stale y Mfg . R S Decatur , I L Iow a Stat e Universit y Pyropowe r Ames , I A Lauhof f Grai n B.M . Danville , I L GW F Powe r System s CP C Fresno . C

A GMF Powe r System s CP C Contr a Cost a County , C A Archer-Daniels-Mldlan d Hormse r De s Moines , I A Archer-Oanlels-Mtdlan d Mormse r Mankato . M N Archer-Daniels-Mldlan d Wormse r Kansa s City . M

O S.E . Missour i Universit y Mormse r Cap e Girardeau , M

O 62 5 Cir . Wester n Coa l 0.5-0. 6 25 5
19 0 60 0 25 0 31 5

20 0 42 5 28 8 26 5 Cir . Canadia n Coa l 0.2 5

Cir . Coa l Fine s 0.5 8 Cir . Bit . Coa l 3.5-4. 0 Cir . Bit . Coa l Cir . Bit . Coa l

Cir . Bit . Coa l

19 0 19 0 15 0 10 0 7 5 Cir .

2 - Stag e 2 - Stag e 2 - Stag e 2 - Stag e Petroleu

m Cok e N.A . N.A . N.A . N.A . 4. 0

2. 5

Cir . Bit . Coa l 4.0-6. 0 3. 0 Cir . Bit . Coa l 2.0-3. 0 Cir . Wester n Coa l 0. 4 2. 1 N.A . N.A . N.A . N.A . 0.1 °

0.0 5

0.0 5 N.A . 1. 2

1.2 " 0.6 b 1. 2 0.0 4 0.0 8 N.A . N.A . N.A . N.A . 93-9 4

8 8
97 90-9 2 8 3

N.A . 9 0 N.A . 9 5 97 N.A . N.A . N.A . N.A . 1.5-2. 0 9/8 9

1. 8 12/8 7

1. 8 10/8 7
2.0-2. 5 198 7
1.5-2. 0 9/8 7

N.A . 8/9 0

2. 2 12/8 8
1.5-2. 0 198 8

N.A . 12/8 8
1. 8 199 0
2. 5 199 0

N.A . N.A .
N.A . N.A .
N.A . N.A .
N.A . N.A . 2 3 2 4

2 4 1 5 2 5 2 6

2 7 2 3 2 8 2 4 2 4 2 9 2 9 2 9 2 9

^ D O = Keele r Dorr-Oliver , CP C = Combustio n Powe r Co. , R S = Rile y Stoker , B

W = Babcoc k 4 Wilcox . Base d on a Stat e requiremen t fo r 90 S SO - reductio n an d th e sulfu r conten t o f th e desig n coal .
c Stll l I

n plannin g stages . Wil l b e designe d t o mee t NSPS . "Als o subjec t t o 80 S S0 2 reduction .P. 7

2 1 Edwar dIsland , Canada . Th e boiler , designe db y Foste r Wheeler , ha s a hea t inpu t capacit y

o f abou t 5 0 millio nBtu/hour . Th e FB C uni t wa s teste dfo r 2 3 day s an dwa s operate da t abou t 7 0 percen t o f ful l load. Coa l wit ha n averag e sulfu r conten t o f 5. 5 percen t wa s burne ddurin g th e test . Th e SOp remova l efficienc y

average d93. 5 percent . Thi s demonstrate s tha t greate r tha n9 0 percen t SOpreductio nca nb e achieve dwit hhigh-sulfu r coal s o na sustaine dbasis . Durin g short-term

test s a t th e Canadia nForce s Base , th e FB C uni t attaine dver y

highSO premova l efficiencie s (>9 9 percent ) an dver y low outle t SO pemission s (approachin g 0 ppm) . Thi s indicate s tha t SO premova l i s no t mas s transfe r limite da t highCa: S ratio s an dtha t 9 0 percen t SO ,

2 1 remova l o r greate r shoul db e achieve dwhe nburnin g low-sulfu r coal . Thi s conclusio ni s supporte db y pilot-scale , bubblin g bedtest s conducte db y th e Universit y

o f Nort hDakot a Energy Researc hCente r whic hha s show n9 0 percen t 2 2 an dgreate r SOpremova l o nlow-sulfu r wester ncoals . Althoug hth e abov e dat a ar e base do nbubblin g beddesigns , equa l o r bette r performanc e i s expecte dfro m circulatin g an

d2-stag e system s becaus e o f mor e rapi dcarbo nburnout , highe r limeston e particl e densitie s inth e freeboar darea , an

dmor e uniform

gas-soli dcontac t betwee nSO pan d limestone . 4. 0 CONCLUSION S Give nth e numbers o f FB C unit s bot hcurrentl y operatin g an

di nth e planning/constructio nstages , a s wel l a s th e performanc e level s o f thos e i n operation , FB C i s considere da demonstrate dtechnolog y fo r th e contro l o f SOp emissions . Th e availabl e dat a demonstrat e tha t FB C unit s ca nb e designed , constructed , an doperate dt o achiev e 9 0 percen t SOpremova l o na sustaine dbasis . Thi s findin g i s supporte db y comment s fro

m FB C engineer s an duser s a t a recen t technica l conferenc e statin g tha t FB C coul d"mee t an d beat " th e propose dnew sourc e performanc e standard s (NSPS ) o f 9 0 percen t SO , 3 0 reductio nfrom

al l coal - an

d oil-fire dindustria l boilers .P. 8

REFERENCE S

1 . Power . 12 9 (2) : S l - S1 6 (85) . 2 . Tri pRepor t fro

m May , P . A. , Radia nCorporation , t o Neuffer , W . J. , EPA/ISB , Novembe r 27 , 1985 . Kentucky Agricultura l Energy Corporatio n Fluidize dBedCombustio nBoiler . 3 . Telecon . Waddell , J . T. , Radia nCorporation , wit hBraden , J. , Kentuck y Agricultura l Energy

Corporation , Novembe r 4 , 1986 . FB C Reliabilit y Information . 4 . Tri pRepor t fro

m Waddell , J . T. , Radia nCorporation , t o Eddinger , J . A. , EPA/ISB , Jun e 11 , 1986 . Idaho Nationa l Engineerin g Laborator y Fluidjize d Be dCombustio nBoilers . 5 . Tri pRepor t fro

m Waddell , J . T. , Radia nCorporation , t o Eddinger , J . A. , EPA/ISB , Jun e 11 , 1986 . Midwes t Grai nProduct s o f Illinoi s Fluidize dBedCombustio nBoiler . 6 . Peduto , E . F. , e t al . (GC A Corporation) , Continuou s Monitorin g o f Wormse r Fluidize dBedCombustor , prepare dfo r U.S . Environmenta l Protectio nAgency , Researc hTriangl e Park , N.C , Jun e 1984 . 7 . Telecon . Waddell , J . T. , Radia nCorporation , wit hHarper , B. , Wormser , Octobe r 31 , 1986 . Informatio no nWormse r FB C Units . 8 . Sout hCoas t Ai r Qualit y Managemen t District , Permi t t o Construc t - Californi a PortlandCemen t Co. , Applicatio nNo . 104231 , E l Monte , Ca. , Apri l 28 , 1983 . 9 . Power . 13 0 (10) : 4 3 (86) . 10 . Glueck , N . S . (B . F . Goodrich) , Circulatin g Fluidize dBedCombustio n Boile r Cas e History , fro m Proceeding s o f th e 4t hNationa l Conferenc e o n Evaluatin g th e Fluidize dBedCombustio nOption , Governmen t Institute , Inc. , Rockville , Maryland . Jun e 1986 . 11 . Telecon . Waddell , J . T. , Radia nCorporation , wit hTesfai , M. , Pyropowe r Corporation , Octobe r 29 , 1986 . Informatio no nPyropowe r FB C Units . 12 . Tri pRepor t fro

m May , P . A. , Radia nCorporation , t o Neuffer , W . J. , EPA/ISB , August 1 , 1985 . Keeler/Dorr-Olive r Fluidize dBedCombustio n Boiler . 13 . Lette r fro

m Shah , J . S. , Keeler/Dorr-Oliver , t o Farmer , J. , U.S . EPA , Februar y 18 , 1986 . Respons e t o reques t fo r FB C data .P. 9

14 . Ussia , A . P . (Quake r Stat e Oi l Refiner y Corporation) , Cas e History : Quake r State' s Tw o FB C Boiler s a t th e Newell , Wes t Virgini a Refinery , fro m Proceeding s o f th e 4t hNationa l Conferenc e onEvaluatin g th e Fluidize dBedCombustio nOption , Governmen t Institute , Inc. , Rockville , Maryland . Jun e 1986 . 15 . Telecon . Elliot , J . A. , Radia nCorporation , wit hLinch , B. , Keeler/Dorr-Oliver , Apri l 8 , 1987 . Informatio nonKeeler/Dorr-Olive r FB C Units . 16 . Telecon . Waddell , J . T. , Radia nCorporation , wit hHintz , D. , Keeler/Dorr-Oliver , Octobe r 31 , 1986 . Informatio no nKeeler/Dor r Olive r FB C Units . 17 . Telecon . Waddell , J . T. , Radia nCorporation , wit hWolfe , B. , Combustio nEngineering, Novembe r 4 , 1986 . Informatio no nCombustio n Engineerin g FB C Uni t a t Scot t Paper . 18 . Telecon . Waddell , J . T. , Radia nCorporation , wit hBuzzuto , C , Combustio nEngineering , Apri l 9 , 1987 . Informatio no nCombustio n Engineerin g FB C Units . 19 . Telecon . Waddell , J . T. , Radia nCorporation , wit hCoulthard , J. , Rile y Stoke r Corporation , Novembe r 4 , 1986 . Informatio no nRile y Stoke r FB C Uni t a t Genera l Motors . 20 . U.S . Environmenta l Protectio nAgency , Summar y o f Regulator y

Analysi s fo r New Sourc e Performanc e Standards : Industrial-Commercial Institutiona l Steam

Generatin g Unit s o f Greate r tha n10 0 millio nBtu/h r Hea t Input , EPA-450/3-86-005 , Jun e 1986 . 21 . Radia nCorporation , Statistica l Analysi s o f Emissio nTes t Dat a fro m th e Fluidize dBe dBoile r a t Princ e Edwar dIsland , Canad a (Draf t Report) , prepare dfo r EPA/OAQPS , Researc hTriangl e Park , NC , Septembe r 1986 . 22 . Mann , M . D. , e t al . (Universit y o f Nort hDakot a Energ y Researc h Center) , Fluidize dBed Combustio no f Low-Rank Coals , Prepare dfo r U.S . Departmen t o f Energy , Septembe r 1986 . 23 . Telecon . Elliot , J . A. , Radia nCorporation , wit hTesfai , M. , Pyropowe r Corporation , Apri l 8 , 1987 . Informatio no nPyropowe r FB C Units . 24 . Telecon . White , D . M. , Radia nCorporation , wit hVande r Molen , B. , Combustio nPowe r Co. , Apri l 14 , 1987 . Informatio no nCombustio nPowe r FB C Units . 25 . Telecon . Elliot , J . A. , Radia nCorporation , wit hCoulthard , J. , Rile y Stoke r Corporation , Apri l 7 , 1987 . Informatio nFB C Uni t a t th e Universit y

o f Missouri .P.1 0



# 'V

26 . Telecon . Waddell , J . T. , Radia nCorporation , wit hDuBose , R. ,

Universit y

o f Nort hCarolin a - Chape l Hill , Apri l 13 , 1987 . Informatio no nPlanne dFB C Unit s a t UNC-Chape l Hill . 27 . Telecon . Waddell , J . T. , Radia nCorporation , wit hDavidson , M. , A . E . Stale y Manufacturin g Co. , Apri l 13 , 1987 . Informatio nonFB C unit s bein g buil t a t A . E . Staley . 28 . Telecon . Elliot , J . A. , Radia nCorporation , wit hArkett , A. , Babcoc k & Wilcox , Apri l 7 , 1987 . Informatio nonFB C Uni t a t Lanhof f Grain . 29 . Governmen t Institutes , Inc. , Proceeding s o f th e 4t hNationa l Conferenc e o nEvaluatin g th e Fluidize dBedCombustio nOption , Rockville , Maryland , Jun e 1986 . p . XIII-159 . 30 . Coa l & Svnfuel s Technology . 7(22):1(86) .