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Section 5 SO2 and Acid Gas Controls

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Section 5 SO2 and Acid Gas Controls Section 5 SO2 and Acid Gas Controls Chapter 1 Wet and Dry Scrubbers for Acid Gas Control John L. Sorrels Air Economics Group Health and Environmental Impacts Division Office of Air Quality Planning and Standards U.S. Environmental Protection Agency Research Triangle Park, NC 27711 Amanda Baynham, David D. Randall, Randall Laxton RTI International Research Triangle Park, NC 27709 April 2021 DISCLAIMER This document includes references to specific companies, trade names and commercial products. Mention of these companies and their products in this document is not intended to constitute an endorsement or recommendation by the U.S. Environmental Protection Agency. i Contents 1.1 Introduction ............................................................................................................................ 1 1.1.1 Process Description .................................................................................................... 2 1.1.2 Gas Absorber System Configurations ........................................................................ 2 1.1.3 Structural Design of Wet Absorption Equipment ...................................................... 5 1.1.4 Factors Affecting the Performance ............................................................................ 6 1.1.5 Structural Design of Dry Absorption Equipment ...................................................... 7 1.1.6 Equipment Life .......................................................................................................... 8 1.2 Flue Gas Desulfurization Systems ......................................................................................... 8 1.2.1 Types of FGD Systems .............................................................................................. 8 1.2.1.1 Wet Flue Gas Desulfurization Systems............................................................................. 9 1.2.1.2 Dry Flue Gas Desulfurization Systems ........................................................................... 10 1.2.1.3 Other Designs .................................................................................................................. 11 1.2.2 Performance of Wet and Dry FGD Systems ............................................................ 12 1.2.3 General Parameters used to Develop Scrubber Design Parameters and Cost Estimates for FGD Systems ................................................................................................. 14 1.2.3.1 Boiler Heat Input ............................................................................................................. 14 1.2.3.2 Capacity Factor ............................................................................................................... 14 1.2.3.3 Heat Rate Factor.............................................................................................................. 15 1.2.3.4 Site Elevation Factor ....................................................................................................... 15 1.2.3.5 Retrofit Factor ................................................................................................................ 16 1.2.4 Wet Flue Gas Desulfurization .................................................................................. 17 1.2.4.1 Wet FGD Systems Process Description .......................................................................... 17 1.2.4.2 Wet FGD System Design Procedures ............................................................................. 26 1.2.4.3 Estimating Total Capital Investment ............................................................................... 28 1.2.4.4 Estimating Total Annual Cost for a Wet FGD System ................................................... 33 1.2.4.5 Cost Effectiveness ........................................................................................................... 36 1.2.4.6 Example Problem for a Wet FGD System ...................................................................... 37 1.2.5 Dry Flue Gas Desulfurization Systems .................................................................... 42 1.2.5.1 Process Description ......................................................................................................... 42 1.2.5.2 Design Criteria ................................................................................................................ 46 1.2.5.3 Design Parameters for Study-Level Estimates for SDA FGD Control Systems ............. 46 1.2.5.4 Capital Costs for SDA Control Systems ......................................................................... 48 1.2.5.5 Total Annual Costs for SDA Systems ............................................................................. 53 ii 1.2.5.6 Cost Effectiveness ........................................................................................................... 56 1.2.5.7 Example Problem ............................................................................................................ 56 1.3 Wet Packed Tower Gas Absorbers ...................................................................................... 61 1.3.1 Process Description .................................................................................................. 61 1.3.1.1 Packed Tower Designs .................................................................................................... 61 1.3.1.2 Packed Tower Operation ................................................................................................. 64 1.3.2 Design Procedures for Packed Tower Absorbers .................................................... 65 1.3.2.1 Determining Gas and Liquid Stream Conditions ............................................................ 66 1.3.2.2 Determining Absorption Factor ...................................................................................... 69 1.3.2.3 Determining Column Diameter ....................................................................................... 70 1.3.2.4 Determining Tower Height and Surface Area ................................................................ 72 1.3.2.5 Calculating Column Pressure Drop ................................................................................. 74 1.3.2.6 Alternative Design Procedure ......................................................................................... 74 1.3.3 Estimating Total Capital Investment ....................................................................... 76 1.3.3.1 Equipment Costs for Packed Tower Absorbers .............................................................. 77 1.3.3.2 Installation Costs ............................................................................................................. 79 1.3.4 Estimating Annual Cost for Wet Packed Tower Absorbers .................................... 81 1.3.4.1 Direct Annual Costs ........................................................................................................ 81 1.3.4.2 Indirect Annual Costs...................................................................................................... 83 1.3.4.3 Total Annual Cost ........................................................................................................... 83 1.3.4.4 Cost Effectiveness ........................................................................................................... 84 1.3.5 Example Problem for a Wet Packed Tower Absorber ............................................. 84 1.3.5.1 Determine the Waste Stream Characteristics .................................................................. 84 1.3.5.2 Determine Gas and Liquid Stream Properties ................................................................. 84 1.3.5.3 Calculate Absorption Factor ........................................................................................... 87 1.3.5.4 Estimate Column Diameter ............................................................................................. 88 1.3.5.5 Calculate Column Surface Area ...................................................................................... 90 1.3.5.6 Calculate Pressure Drop .................................................................................................. 91 1.3.5.7 Equipment Costs ............................................................................................................. 91 1.3.5.8 Total Annual Cost ........................................................................................................... 93 1.3.5.9 Cost Effectiveness ........................................................................................................... 97 1.3.5.10 Alternate Example........................................................................................................... 97 Acknowledgments ............................................................................................................................... 98 References............................................................................................................................................ 99 iii Appendix A ........................................................................................................................................A-1 Appendix B ........................................................................................................................................ B-1 Appendix C .......................................................................................................................................
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