reduction of boiler stack particulate emissions and scrubber water ...

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INTRODUCTION Voluntary compliance tests for particulate emissions were performed in October of 1995 at the Western Sugar Company's Fort Morgan sugar beet processing plant. The boilerhouse contains two Babcock & Wilcox stoker-fired boilers. The units were placed in service in 1947 and, except for a short time using natural gas, have used Detroit Stoker stokers as the coal-firing system. Each boiler has an American Standard Series 361 fly-ash collector and an in-house (Great Western Sugar Company) designed low-pressure venturi scrubber. Exhaust gas streams from each boiler are combined in a common stack which has a chevron-type mist eliminator. BOILER STACK TESTS - 22 OCTOBER 1995 Normal intercampaign maintenance was performed on the boiler equipment and the Detroit Stoker field service representative "tuned" the boiler combustion system the week prior to the October 1995 tests. The particulate emission limit is 0.14 Ib.lMMBTU. The first day's test results were under the limit (see Table 1). The second day the limit was exceeded twice and the average for the three compliance runs was 0.16 Ib.lMMBTU. The information was presented to the State of Colorado under the State's program of voluntary disclosure and a second test was scheduled as quickly as possible. Also, several boiler consultants were contacted to observe the compliance retest. TABLE 1 OCTOBER STACK TESTS PARTICULATE EMISSIONS OCTOBER 2 AND 3; 1995 ITEM RUNNO.1 RUNNO.2 RUN NO.3 AVERAGE Boiler No.1 PLUG CONE 250 gpm 285 gpm 250 gpm 280 gpm 250 gpm 280 gpm 250 gpm 282 gpm Boiler No.2 PLUG CONE 280 gpm 260 gpm 275 gpm 250 gpm 275 gpm 250 gpm 277 gpm 253 gpm PARTICULATE EMISSIONS (lb.lMMBTU) 0.128 0.189 0.163 0.160 306 - - .... - -
RETESTS - 15 NOVEMBER 1995 The coal supplier provided a consultant to review the coal as-delivered and as-fired, and also to observe the boiler operation. Detroit Stoker provided the same technician who was on site in October to "tune" the boilers. He also observed the boiler operation during the tests in order to advise us if any mechanical problems may have developed. A scrubber manufacturer was contacted to observe the venturi scrubber operation during the tests and to inspect it prior to the tests. This individual had been previously employed as a "stack tester" and also observed the stack testing company during the compliance runs. The November tests were run with more scrubber water flow, higher pressure drops across the scrubber, but no "hands-on" operation by any of the consultants. The average of the three compliance runs for particulates was 0.271 Ib.lMMBTU (see Table 2), which is nearly twice the permitted limit. TABLE 2 NOVEMBER STACK TESTS P ARTICULATE EMISSIONS NOVEMBER 15 AND 16, 1995 ITEM RUN NO.] RUN NO. 2 RUN NO.3 AVERAGE Boiler No.1 PLUG 335 gpm 334 gpm 333 gpm 334 gpm CONE 340 gpm 338 gpm 337 gpm 338 gpm Boiler No.2 PLUG 323 gpm 321 gpm 328 gpm 324 gpm CONE 335 gpm 332 gpm 332 gpm 333 gpm PARTICULATE EMISSIONS (lb. / MMBTU) 0.269 0.280 0.265 0.271 SODIUM EMISSIONS (lb. / MMBTU) 0.110 0.123 0.122 0.118 SODIUM OXIDE (% in ASH) 8.015 6.685 8.05 7.58 During the tests, the opacity of the stack was observed (not using Method 9) by all the consultants and a "blue haze" was evident after the vapor break of the "plume". The coal consultant suggested that the "blue haze" might be due to sodium and was a condition he had observed before with Northern Powder River Basin coal. The scrubber consultant agreed that this was possible, and 307
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