Advanced Emissions Control Development Project

Transcription

1 ~~~ Advanced Emissions Control Development Project j$& Phase Final Report Appendices for the period: November, 993 to February 29, 994 Submitted: February 29,996 RDD:96: OO:Ol *- Babcock & Wilcox Alliance Research Center 562 Beeson Street Alliance, Ohio DSCLAMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. - -~ OCDO Grant Agreement: CDOD U.S. DOE - PETC Contract: DE-FC22-94PC9425 Babcock & Wilcox Contract: CRD-30 \ George A. Farthing Project Manager Phone: 2 6/

2 Babcock & Wilcox assumes no liability with respect to the use of, or for damages resulting from the use of, or makes any warranty or representation regarding any information, apparatus, method, or process disclosed in this report. Babcock & Wilcox expressly excludes any and all warranties either expressed or implied, which might arise under law or custom or trade, including without limitation, warranties of merchantability and of fitness for specified or intended purpose.

3 TABLE OF CONTENTS APPEND A Wet Scrubber Sampling and Analysis Schedules DBA/Lime Chemical Analysis Limestone Forced Oxidation Chemical Analysis APPEND B Air Toxic Benchmarking Baghouse Conditions Air Toxic Benchmarking ESP Conditions Air Toxic Benchmarking Wet Scrubber Conditions APPEND C Quality Assurance Results

4 APPEND A Wet Scrubber Sampling and Analysis Schedules DBA/Lime Chemical Analysis Limestone Forced Oxidation Chemical Analysis

5 DBA Makeup Lime 7 Recirculation Slurry Total Sulfate Total Sulfite Total Carbonate Total Calcium Total Magnesium Total Solids -+- lhatch lhatch lhatch Specific Gravity Dissolved Species DBA Ca, Mg llweek / 8 hours l/series / 8 hours Na, K, Fe, Mn, A l/series l/series c l/series / 8 hours SO3 Settling Bin MEW Tank CRW Tank il llday Solids Size Distribution Suspended Solids PH Hydroclone Underflow Uday Hydroclone Overflow / 8 hours - Sampling Matrix and Analysis Schedule DBA/Lime Tests llday llday llday llday

6 Lime Slurry Makeup Water z Recirculation Slurry Total Sulfate SS/daily Total Sulfite SS/daily Total Carbonate SS/daily Total Calcium lhatch SS/daily Total Magnesium lhatch SS/daily Total Solids lhatch SS/daily Suspended Solids SS/daily Specific Gravity SS/daily PH Reactivity Hydroclone Underflow Settling MEW Tank CRW SS/daily lhatch Solids Size Distribution / week Ca, Mg /series / 8 hours Na, K, Fe, Mn, A lheries l/series c /series / 8 hours SO3 Hydroclone Overflow / 8 hours

7 AECDP March DBA-Lime Tests ~~ [Date DBA [ /Time 3095 Makeu H20 Total 930 Ca Ca(OHjC03 S03 S04 MgO Total CdS mmolefi wt%,d (mmolefirnmolefi (mmole/l(%, dry molar loxid % % r-kzr-q Lyij Susp Spec % dg Solids Solids Grav MMu pprn Hydroclone Underflow (pprn lmn Al (pprn (pprn C (pprn S S03. lppm lpprn ' , _ Fe K (pprn Na lppm lmg pprn Hydroclone Overflow lpprn Re z Solids Dissolved Dist DBA Ca j 520' () Both total & suspended solids are biased low due to sample taken from top of 55 gal drum, not 6" down

8 - Limestone Slur Total Ca C03 (SO3 S04 lug0 mmole/i mmolej mmole/l mmole/i %. DW ~, Total Ca/S molar Susp Spec Oxid Solids Solids Grav % % %g/g Solids Dissolved Dist DBA Ca 20.5 Na K Fe Mn (A C S 503 lppm lppm.sampks tot "Solids' liq Mg MMU ppm lppm pprn ppm ppm ppm ppm lppm lppm

9 , Hydrocione Overflow , S ~ 0.0 ~ ~ x ~~

10 ~~ Other Limestone (2-95) n Reactivity CaO MgO c02 Si02 A Fe Ti02 6.

11 s i T 3 0 E d 3 APPEND B Air Toxic Benchmarking Baghouse Conditions Air Toxic Benchmarking ESP Conditions Air Toxic Benchmarking Wet Scrubber Conditions

12 Baghouse Operating Conditions During Air Toxic Benchmark Testing BH CEDF BH Average Air-to- Gas Sample Coal Convection Total BH nlet Module BH Outlet Pressure Cloth Convection BH nlet BH Outlet Date Test# Sample Time Flow PassTemp Load Temp Temp Temp Drop Ratio Pass bhr DegF MBTUhr DegF DegF DegF inh20 ftlmin %(Dry) %(Dry) % (Dry) 6/26/995 BENCH4 M26-la* , /26/995 BENCH5 M , BENCH 6 M29-2* , /27/995 BENCH 7 M26-2a* , O /27/995 BENCH 8 M29-3* , /28/995 BENCH9 M , /29/995 BENCH 6 M26-lb , /29/995 BENCH 6B M26-2b , BENCH 6C M , O Average 7, Standard Deviation % Standard Deviation 0.8%.9% 0.8% 4.3% 3.5% 7.5% 7.8% 2.7% 4. % 8.% 7.8% * - indicates baghouse particulate bypass AECDP BHOP.LS 0/25/995

13 ESP Operating Conditions During Air Toxic Benchmark Testing ESP nlet Temp DegF ESP Outlet Temp DegF ESP Outlet Opacity % Specific Collection Convection Area Pass (SCA) 02 Yo (Dry) ESP nlet 02 % (Dry) ESP Outlet 02 % (Dry) % % % % % % Tray Pressure Drop inh20 Total Tower Pressure Drop inh20 Gas Sample Sample Time Coal Flow 6/28/995 BENCH 2 M , /28/995 BENCH 3 M , BENCHl4 M , /29/995 BENCHl5 M , Average Standard Deviation % Standard Deviation 7, % % % % Date P h) Convectio CEDF n Pass Total Temp Load DegF MBTWhr Test# lblhr Wet Scrubber Operating Conditions During Air Toxic Benchmark Testing FGD Outlet 02 FGD nlet so2 ppm FGD Outlet SO2 ppm Gas Sample Sample Time 6/28/995 BENCH 2 M , /28/995 BENCH 3 M26-2" , /29/995 BENCH4 M , /29/995 BENCH5 M ,98 Average Standard Deviation % Standard Deviation % 2, % Date Test# - Yo (Dry) SO2 Tower Removal UG Ratio Velocity % gpmlkacfm fps Slurry ph Tray ph % % 9.o % % % % % % * water in the FGD outlet impingers contributed to high SO2 Removal AECDP BHOP.LS 0/25/995

14 APPEND C Quality Assurance Results a

15 AECDP Phase Final Report Appendix C: Quality Assurance A detailed summary of the analytical effort required of the configuration and configuration 2 benchmarking tests are presented in Tables and 2. - Table Air Toxics Analysis Summary Baghouse Configuration Sample Matrix M26A Solids M26A mpingers M29 Solids M29 mpingers BH Ash Coal # Samples Particulate Weight Trace Metals Analysis Acid Gases 6 l l Number of analyses include blanks, spikes, and duplicates #HGAAS Analyses # GFAAS Analyses # CVAAS Analyses 2 Hg Species 2 # C Analyses # SE Analyse

16 AECDP Phase Final Report - Table 2 Air Toxics Analysis Summary ESPNET Scrubber Configuration ~ Sample Matrix ulate Weight M26A 6 M26A 6 M29 Solids 6 M29 mpingers 42 ESP Ash 2 Trace Metals Limestone Slurry ~ 2 Gypsum WFGD 2 Acid Hg Species / ( ( Number of analyses include blanks, spikes, and duplicates ~ #HGAAS Analyses # GFAAS Analyses # CVAAS Analyses # SE Analyse # C Analyses l g i 6 l 4 2 4

17 E - Recalibration Rates GFAAS, CVAAS, HGAAS, CP Check standards prepared from a source independent of the calibration standards must fall between 90-0%of the true value. When outside of this range, the check standard was repeated. f still outside of the acceptable range, the standard was prepared again and reanalyzed. When values are still unacceptable, the instrument was recalibrated until acceptable check standard values were obtained. f necessary, new calibration standards were prepared. Spike Recoveries Summaries of the anaytical precision and accuracy results are provided in Tables 3 through Table 2. Analytical accuracies reflected by the percent recovery for spiked samples are well within the targeted range of 50-50%. 8 Table 3 Spike Recoveries for M26A Fluoride Table 4 Spike Recoveries for M26A Chloride Method Sample ppm Spike ppm Detection % Recovery pprn H,SO, mpinger Chloride, SE NaOH mpinger Chloride, SE The chloride spiked sample samples prepared for C analysis were found to be contaminated. c-3

18 AECDP Phase Final Report Table 5 Spike Recoveries for M26A Filter Solids Configuration Sample Spike Detection % Recovery ppm ppm ppm Baghouse ESP B aghouse ESP Table 6 Spike Recoveries for M29 H,O,-HNO, mpingers c-4

19 AECDP Phase Final Report Table 7 Mercury Spike Recoveries M29 mpinger Solution Analyte Sample PPb Spike PPb Detection PPb % Recovery o Sample ppb Spike ppb Detection ppb % Recovery Arsenic Barium Beryllium Cadmium Chromium mpingers 5 & 6: H,SO,-KMnO, Mercury Mercury 30.o mpinger 4 8 N HC mpinger Rinse Mercury. Table 8 Spike Recoveries for Coal Composite Analyte Antimony Cobalt Lead Nickel Manganese Mercury Selenium C

20 AECDP Phase Final Report Table 9 Spike Recoveries for Limestone Slurry Analyte ~ Antimony Arsenic Barium! Sample Spike Detection ppb ppb ppb !! 25 0 C-6 % Recovery

21 AECDP Phase Final Reporf Table 0 Spike Recoveries for Wet Scrubber Filtrate Analyte Sample Spike Detection % Recovery ppb ppb ppb Antimony Arsenic < Barium Beryllium < Cadmium Chromium Cobalt Lead Nickel Manganese Mercury < _- --- Selenium c-7

22 AECDP Phase Final Report Table Spike Recoveries for Wet Scrubber Gypsum Solids r Analyte Sample Spike Detection % Recovery ppb ppb ppb Antimony Arsenic Barium Beryllium < Cadmium Chromium Cobalt Lead Nickel Manganese Mercury Selenium c-8

23 Table 2 Spike Recoveries for Wet Scrubber Filtrate AECDP Phase Final Report Analyte Sample Spike Detection % Recovery ppb ppb ppb Antimony Arsenic < Barium Beryllium < Cadmium Chromium Cobalt Lead Nickel Manganese Mercury < _-- Selenium c-9

24 AECDP Phase Final Report Table 3 Spike Recoveries for Ash Analyte Sample Spike Detection ppb ppb ppb Arsenic Barium Beryllium Cadmium Chromium Cobalt Lead Nickel o 85 Manganese Mercury Selenium Antimony % Recovery i c-0

25 AECDP Phase Final Report Replicate Analysis Analytical precision re,,lcted by the relative percent deviation (R D) for replicate samples was generally less than 25%. Replicate analysis of the limestone slurry proved to be the most difficult. The replicates are separate preparations of the same sample by acid digestion. Replicates do not apply to liquid samples requiring no digestion or requiring filtration only. - Table 4 Precision Results Relative Percent Deviation of Replicate Samples c-

26 AECDP Phase Find Report Blank Results Trace metal grade acids employed for the Reagent (Method) blanks were used to zero the instruments. Table 5 Method 26 A Reagent (Method) Blanks Fluoride, C < Chloride, C < Bromide, C --- Chloride determinations in the NaOH impingers by SE were not corrected for the blank value of.84 ppm since many of the impinger solutions had C concentrations less than 0 ppm. Get the C blank value to make sure it was contaiminated. c-2

27 AECDP Phase Final Report Table 5 Method 29 Blank Solution Analysis, ppb C-3

28 AECDP Phase Final Report Table 6 Blank Whatman Glass Filter, pg/filter Lot Lot 64737A Whatman Analysis Antimony Arsenic Barium Beryllium e 0.06 e Cadmium Chromium Cobalf Lead < 0. Nickel Manganese 2 22 Mercury --- _-_ < 0. Selnium < 0. Analyte ppm C- 4