Economics of spray-dryer FGD system: the two-stage open-loop processes

Preliminary economics of the Rockwell International Corporation - Wheelabrator Frye, Inc., (RI/WF) two-stage open-loop flue gas desulfurization (FGD) process were determined for both lime and soda ash absorbents. This two-stage open-loop process is a throwaway system in which the alkali raw material (as a solution or slurry) is sprayed into the flue gas stream, dried by the latent heat in the hot flue gas, and collected as dry particulate matter in a baghouse. The fly ash is also collected in the baghouse as an inherent part of the process. An economic evaluation of a limestone slurry FGD process with an electrostatic precipitator (ESP) for particulate matter removal was included for comparison. The basis was a 500-MW power plant burning 3.5% sulfur, 16% ash coal with 90% SO/sub 2/ removal and 0.1 lb/MBtu particulate matter emission. The economic evaluations were made using both TVA and Electric Power Research Institute (EPRI) economic premises. Cost differences between the two-stage open-loop lime and soda ash versions are largely the result of different waste disposal and raw material costs. Both RI/WF versions are more economical than limestone in most process elements except raw material costs. Cost differences between the TVA- and EPRI-based estimates are themore » result of different methods of estimating indirect costs, levelizing operating costs, and different raw material costs.« less