[]
....°
6.3.5
R A W W A T E R TREATI'NG-UNIT 44
6.3.5.1 D E S I G N
BASIS
Purpose of Unit
The Raw Water Treating unit provides for storage and treatment of the
influent raw water td.. a suitable quality for feed to the Boiler Feed Water
Treating unit.
Scope of Unit
The Raw'Water Treating Unit 4.4 includes storage for seven days of plant
mal~oup water requirements in the Raw Water Pond, lime softening with
attendaL~, additive makeup, sludge dewatering and disposal, clarification,
and sand filtration.
General Desi~m Criteria
Unit 44 consists of a single train; the water treating section is designed
for a flow of 6428 gpm.
All pumps and mixers have spares; other major equipment is not spared.
The unit design is comparable with an onstream factor of 332 d a y s / y e a r .
The equipment in the unit is designed to operate continuously without a
scheduled t u r n a r o u n d .
The unit is designed to operate at 100 percent capacity although a t u r n down capability of lower than 60 percent is possible.
.
j
6-263
•
• ,L i
,,
u ~ o l oiKt,,~s~lu~I~" llEr.311DATA
is - q U ~ ~ WL ~
¢# 1N~
NOTiC~PJUaEM lxr. fmulr ~ ; s ~ n[~u~
!
m
m
i
fi
a
I
•
•
<' I
i::i L.
:i
i"
r.
,:.,.
6.3.5.1
(Continued )
Process Specifications
,.~
i
. *
/
.'.
" .
The Raw Water Treatment unit r e d u c e s t h e total s u s p e n d e d solids ( T S S ) in
f_he treated water to l e s s t h a n 5 ppm, t h e total alkalinity to 25 ppm CaCO s
)
e q u i v a l e n t , and t h e total h a r d n e s s to 194 ppm CaCO s equivalent.
~ii "i
i:/,5;11
Feed
Feed to t h e Raw Water Pond is b y p i p e l i n e from t h e Bighorn River.
d e s i g n analysis of this water is as follows:
.Component
t/
•
/
185
Mg
1",?.4
Na
190
K
14
Cation Total
l
o
/
ppm as CaCO s
Ca
•
.
The
513
HCOa
164
COs
0
OH
0
SO~,
."~7
C1
27
NO3
F
3
2
Anion Total
513
;i, ¢
t"
,
>
ppm as Ions
0.2
0.1
Fe
Mn
6-264
i
L: ,L ;?:
us~m~t~..uu or le~m
~
II
8 SUILl[~'lilrlm
~lnr.,~'iramld~iioM~e~ t M .
I
L
°.
~
8.3.5.1
t
CContinued)
Component
ppm as Ions
B
0.2,
SiOz
13
COs
Battery Limit Conditions
9
pH
Turbidity
TSS
TDS
Temperature
7.6
118 T u r b i d i t y Units
20 ppm
774 ppm
60 °F
Additives to the Raw Water Treatment unit include lime, sodium aluminate,
sulfuric acid, and polyelectrolytes.
Product
The analysis of the product water is as specified above including changes
in other component concentrations as r e q u i r e d to reach the p r o d u c t
specifications.
The Battery Limit Conditions will be:
pH
TSS
TDS
Temp.
6.8
0-1 ppm
554 ppm
60OF
Utilities Required
Power 1670 kW
--
USf" 011DI~'L,?SUI~ Of B£1~II! I ~
|t .~l|nlfl~
110 Tl~tl~ I b l r n i u o * v ~
e
L m_
6.3.5.2
PROCESS DESCRIPTION
Drawing Number 835704-44-4-101 is the flow diagram for the unit.
unit
material
balance
(Table 6.3.5-1)
follows
the
drawing.
The
Drawing
No. 6~5704-44-4-050 shows the plot plan and Table 6.3.5-2 lists equipment.
Raw water is brought 12 miles to the plant site via a 30 inch pipeline
originating at the Bighorn River and terminating at the raw water storage
pond. The 775 x 775 x 15 feet deep pond is lined to prevent water loss
and
has
a
working
capacity of
61.0
million gallons.
Approximately
3.6 million gallons in the bottom of the pond is dedicated to firewater.
From the storage pond raw
water is pumped
to three process units,
54 "gpm to Potable Water Treating, 488 gpm to Flue Gas Desulfurization,
and the remaining 6221 gpm to R a w Water Treatment.
Raw water treatment includes the following steps:
Temperature Adjustment
Cold Lime Softening
Sludge Dewatering and Disposal
Sand Filtration
The treated water flows to Boiler Feed Water and Condensate Treating
Unit 45.
Cold LAme Softening and Sludge Dewaterin~
A cold ~me softening process utilizing gravity sedimentation is provided to
achieve:
Suspended Solids Reduction
Precipitation/Sedimentation of Calcium, Magnesium Hardness
Colloidal Silica Reduction
6-266
ii
I
6.3.5.2
(Continued)
The raw
water
is
chlorinated
flowing i n t o t h e clarifier.
to
reduce
the
o r g a n i c l o a d i n g p r i o r to
T h e i n t e n t is to d e s t o r y t h e o r g a n i c material
and oxidize a n y h e a v y metals t h a t may be p r e s e n t .
Chemicals u t i l i z e d in t h e p r o c e s s c o n s i s t of:
Chlorine as d e s c r i b e d above
Aluminum s u l f a t e for s u s p e n d e d material coagulation
P o l y e l e e t r o l y t e to e n h a u e e s e t t l i n g c o a g u l a t e d materials
L i m e / s o d a a s h for alkaline a n d n o n a l k a l i n e h a r d n e s s p r e c i p i t a t i o n
Magnesium h y d r o x i d e f o r m e d in c o n j u n c t i o n with t h e e l e v a t e d 'w.ater
t e m p e r a t u r e r e s u l t s in an a p p r e c i a b l e r e d u c t i o n of colloidal st~e.a.
.:.
The basic p r o c e s s t a k i n g place in t h e e l a r i f i e r is an a c c e l e r a t e d chemical
reaction followed b y g r a v i t y s e d i m e n t a t i o n .
Chemical r e a c t a n t s are,
i n t r o d u c e d i n t o t h e c e n t r a l r a p i d mix/slow mix r e a c t i o n zone w h e r e t h e ""
p~cipitate formation occurs.
low
to
allow
assemblies
removal.
are
the
Upflow v e l o c i t y in t h e s e d i m e n t a t i o n zone is
precipitates
provided
to
to
draw
agglomerate
the
sludge
and
to
settle
the
out.
central
T h i c k e n e d cold lime s o f t e n e r s l u d g e is r o u t e d to a f i l t e r p r e s s
further
dewatering.
Sludge
cake
from
landfill.
T h e clarified water from t h e
recycled to t h e s o f t e n e r .
this
sludge
unit
is
routed
dewatering
Rake
sump
for
u n i t for
offsite
to
o p e r a t i o n s is
Sand F i l t r a t i o n
Dual-media p r e s s u r e
type
sand
filters
are
p r o v i d e d to
remove residual
t u r b i d i t y a n d p r e c i p i t a t e c a r r y o v e r from t h e cold lime s o f t e n i n g p r o c e s s .
The filters a r e c h a r g e d with an a n t h r a c i t e / s a n d media.
6-267
o~
I
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R~W W~,'T1ERPC~O
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CHLORIN&'[OR
441K-On O2
RECOVERY P(~ID
441~-01 O]
POL¥£LEC'~R-EYT[
44U£-010t
COLD LIME ~ ' r E N E H
50D
Of.SIGlll 45,100 r , ~
- F E E D I N G $~ STEM
LINI uaG! I(1~[
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LIME ~ ¥ S T E M
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835704-44-4-101
|-
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T A B L E 6.3.5-1
MATERIAL BALANCE
R A W W A T E R T R E A T M E N T - U N I T 44
Stream N u m b e r
Stream Name
44~1
44-2
44-3
44-4
Raw Water
Makeup
To Potable
Water
Treating
To FGD
Unit 43
RO Reject
From
Unit 49
Water
lb/hr
(gpm)
3,406,500
(6813)
27,000
(54)
244,000
(488)
1000
(2)
Total
lb/hr
3,406,500
27,000
244,000
1000
13.7
60
63.7
60
88.7
60
300
80
Pressure, Psia
Temperature, °F
NOTE:
Flow q u a n t i t i e s , p r e s s u r e s a n d t e m p e r a t u r e s s h o w n a r e f o r t h e
total u n i t on a s t r e a m - d a y b a s i s , are to be u s e d solely for
process design purposes, and are not necessarily the conditions
which will b e a t t a i n e d d u r i n g a c t u a l o p e r a t i o n s .
i.
¸¸•
i,"
..... ~:i •:i~¸•1:~ t
TABLE 6.3.5-1 (Continued)
MATERIAL BALANCE
RAW WATER TREATMENT-UNIT 44
Stream Number
Stream Name
i
44-5
44-6
To U. C . T .
Makeup
To Boiler
Feed Water
Treatment
i, ~
~i/••iI
Water
lb/hr
(gpm)
1,732,500
(3465)
1,435,000
(2870)
Total
Ib/hr
1,732,500
i,435,000
43.7
80
33.7
80
Pressure, psia
Temperature, °F
i
i
6-270
USE Oil OIXlI.~SdU I~ | [ ~ l n DATA
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TABLE 6 . 3 . 5 - 2
EQUIPMENT L I S T
RAW WATER T R E A T I N G ' U N I T 44
Number Required
Item No.
Equipment Name
44TE-0101
Raw Water Pond
Recovery Pond
Thickener Holding Tank
Alum Storage Tank
1
0
1
0
1
1
0
0
Potable Water Feed Pump
1
1
1
1
1
1
44P-0108 A/B
44P-0109 A / B
44P-0110 A/B
Raw Water Treatment Feed Pump
Lime Softener Bottoms Pump
Softened Water Pump
Recovery Pond Pump
Thickener Sludge Pump
Polyelectrolyte Feed Pump
Lime Feed Pump
Soda Ash Feed Pump
Alum Feed Pump
44P-0111 A/B
44P-0112 A/B
44TK-0102
44TK-0103
44TK-0104
44P-0101
44P-0102
44P-0103
44P-0104
44P-0105
A/B
A/B
A/B
A/B
A/B
Operating
'I
1
1
1
1
1
1
1
1
1
1
1
1
1
Polyelectrolyte Cleanout Pump
1
1
1
1
44P-0113 A/B
Potstble Water Treatment Backflush
FGD Slaking Water Pump
1
1
44TH-0101
Thickener
1
0
44FT-0101A-J
S a n d Filter Unit
9
1
44ME-0101
44ME-0102
44ME-0103
44ME-0104
44ME-0105
44ME-0106
Cold Lime Softener
Chlotqnator
Polyelectrolyte System
Lime Feeding System
Soda Ash Feed£ug System
1
0
1
0
1
0
1
0
1
0
1
0
44P-0106 A/B
44P-0107 A / B
Sludge Press
R-9,79
......_'
.....
~°
,,
a4~
6.3.6
6.3.6.1
t" .
.
.
.
.
.
.
.
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e
BFW AND CONDENSATE T R E A T I N G - U N I T 45
DESIGN BASIS
P u r p o s e of Unit
The Boiler Feed Water (BFW) and C o n d e n s a t e T r e a t i n g u n i t filters a n d
demineralizes t r e a t e d w a t e r makeup to t h e boilers and purifies r e t u r n i r i g
c o n d e n s a t e for r e u s e i n t h e boilers.
Scope of Unit
RFW and Condensate T r e a t i n g Unit 45 i n c l u d e s a c t i v a t e d c a r b o n and c a r t ridge
filtration,
demineralization
reverse
for
osmosis
(RO)
purification,
t r e a t e d : raw
water
makeup.
and
ion
Separate
exchange
systems
of
purification equipment a r e included for t r e a t i n g t h e r e t u r n i n g steam
c o n d e n s a t e . Cold c o n d e n s a t e from the power plant flows t h r o u g h polishing
filters and mixed bed demineralizers before b e i n g r e t u r n e d to t h e boiler
feed water d e a e r a t o r . Vacuum condensate from t h e SNG compressor drivez~s
is combined with p r o c e s s c o n d e n s a t e , and p u m p e d t h r o u g h a f i l t e r / s o f t e n e r
uni~ into storage w h e r e clean low p r e s s u r e
c o n d e n s a t e is a d d e d .
combined stream feeds t h e p r o c e s s waste h e a t boiler d e a e r a t o r .
This
Potentially
oily low p r e s s u r e condexlsate flows t h r o u g h t h e de-oil filter and into t h e
low p r e s s u r e boiler d e a e r a t o r .
Makeup to t h e LP d e a e r a t o r is t a k e n ~rom
'.i t h e RO effluent a n d softened b y a sodium zeolite softener before t h e flow
joins t h e de-oiled condez~sate stream.
Also within the
scope of t h e u n i t are ta~zks for additive makeup a n d
storage of acid a n d caustic u s e d for ion e x c h a n g e r e s i n r e g e n e r a t i o n .
'..
6-273
:
t
.
......
iS SUIIJ.'CT1 I/.~, ~slrs:~ION ¢~ IK|
IIf/L12rf
~
&q.
auf
e ~
~
.a..~
~....
I
.f
i,~ •
6.3.6.1
(Continued)
General Design Criteria
Unit
45
consists
of
a
single
train.
Filtration
and
demineralization
equipment within Unit 45 have at least one component on backflush or
r e g e n e r a t i o n as a spare with the remaining number onstream. All pumps
and mixers have spares.
i
The unit design is compatible with an overall plant onstream factor of
832 days/year.
A!I equipment are motor driven.
The turndown capability of the unit is to 33 p e r c e n t or less to provide
feed for one of the three plant boilers.
Process Specifications
The BFW and Condensate T r e a t i n g unit produces 392 gpm of boiler feed
water mee~ng the American Boiler Manufacturers Association specifications
for 1500 psig boiler s e r v i c e , 794 gpm of boiler feed water for 600 psig
boiler service, 1,t.,~3 gpm of boiler feed water for 100 psig boiler service
and t r e a t s 7677 ~ ' ~ of r e t u r n i n g condensate for r e - u s e in the boilers.
Teed
The feed to the demineralization section of the unit is the product of the
Raw Water Treatment Unit 44.
Total Hardness
Alkalinity
194 ppm (CaCO.~ equivalent)
23 ppm
TSS
0-1 ppm
6~-274
18 ~ C ~
111~
IIIC,SIIIII~ION CN THE
./
°.
6.3.6.1
(Continued)
TDS
554 p p m
pH
6.8
Temperature
*
60OF
The c o n d e n s a t e r e t u r n i n g to
impurities that are removed.
Unit
45
for
treatment
contains
dissolved
Products
The boiler •feed w a t e r p r o d u c t
Manufacturers
follows:
Association
from U n i t . 45 meets t h e
Specifications.. ~for
the
American Boiler
respective
boilers,
as
Con~entrstlon in. pl~m
Total Sotids
Sodium (as CaCO 3)
O H (as CaCO s)
Silica (as SiO~)
0.S
0.5
0.5
0:005
Oxygen
0.005
pH
7
- 8
.':; .'.
The w a t e r c o n t a i n i n g t h e c o n c e n t r a t e d i m p u r i t i e s from b a c k f l u s h i n g a n d
r e g e n e r a t i o n w i t h i n t h e unit is d i v i d e d into streams with higl{br TDS t h a n
t h e RO i n l e t a n d t h o s e with lower TDS. T h e low TDS s t e a m s a r e s e n t to
the Utility Cooling T o w e r .
T h e h i g h TDS s t r e a m s a r e r o u t e d to A s h
Handling Unit 03.
Utility Requirements
Power
15,200 kW
6-2?5
i
,11 iii
I l l ~1 Ill¢l,.~tJRl ~ IIIF~|T IJLI&
IIIUIUIITITNII
IIIIIIIlIIN
IN fill
l f O l l l l PJ~,l IT IHE FIMIII e l ~ l ~ :)cenav
i !
m
6.3.6.9
PROCESS DESCRIPTION
Drawing Numbers 835704-45-R-101 and 835~04-45-R-102 are the flow diagrams for Unit 45.
The unit material balance (Table 6.3.6-1) and equip-
ment list (Table 6.3.6-2) follow the drawings.
Deminerallzation
Treated Raw Water flows from Unit 44 at a rate o.~ 6335 gpm into the clear-.
well. From there 3465 g p m is pumped to the Utility Cooling tower and
sm+~ll streams are p u m p e d
makeup w a t e r .
back to Unit 44 as backflush and chemical
T h e b a l a n c e of t h e f e e d w a t e r ,
t h e BFW p u r i f i c a t i o n s e c t i o n where it u n d e r g o e s
2870 gpm, is p u m p e d to
t h e following t r e a t m e n t
steps:
Activated Carbon snd Micron Cartridge _~511tration
p H Adjustment
Reverse Osmosis
Cation Demineralization
Anion Demineralization
Mixed B e d Demineralizati~)n
a n d flows to s t o r a g e i n t h e demineralized w a t e r s t o r a g e t a n k .
This w a t e r
is makeup for 1500 and 600 psig boilers.
After the R O unit, 1130 gpm is diverted to sodium zeolite softening. This
flows to the medium/low pressure deaerator as mal~eup.
Pretreated Raw Water Classification
A clearweU is p r o v i d e d to classify raw w a t e r a n d low TDS waste w a t e r s f o r
makeup and further treatment processes.
Water from s a n d f i l t r a t i o n flows
i n t o t h e f i r s t c o m p a r t m e n t , w h e r e water is w i t h d r a w n for u s e as chemical
"
~
ii
i iii
i
6-276
111 ~
OIP.~
'~ ~
III~+~IIIII~1011 CPl l l l l t
i
I
I
ii
m R
6.3.6.2
(Continued)
dilution water, and utility cooling tower makeup.
Water ;overflowing the
weir is pumped to activated carbon filters for further treatment.
Activated Carbon Filtration
i~,
The water exiting the clearwelI is routed through activated carbon drums,
where remaining organic material and residual f r e e chl0z,tne are removed.
The main function of the activated carbon is to protect the downstream
reverse osmosis unit membranes.
4
/
F
&
Boiler Feed Water Demineralization
i"~
Pretreated raw water is pumped to demineralization after activated carbon
filtration. Upon entering the demineralizer section, the water undergoes a
pretreatment phase designed to condition the water for treatment by reverse
osmosis. The water is processed as follows:
Micron filtration by cartridge filters to avoid R e m¢:,~brance
fouling,
pH adjustment by acid addition and feed of a phosphate based chemical to prevent membrane scaling,
Temperature adjustment to attain optimum membrane permeability.
The water is boosted
pumps.
to Reverse
Osmosis system pressure
by in-line
Reverse Osmosis ( R e )
This process forces the water at a high pressure through semi-permeable
membrances which produces a product water relatively free of dissolved
salts.
The permeating water carries a percentage of the dissolved salts
6-277
i
aS~DJI:L"? 1ruTH| Kb'SiliCItON aN IHI[
N~TICI[I~LGEAT tBF.~
OSln4~: N ~ a T
......
B
--|
6.3.6.2
(Continued)
through the membrane, while t h e bulk of the dissolved salts are retained
on the inlet side of the membrance.
The concentrated brine is collected
and d i s c h a r g e d to the Utility Cooling Tower Blowdown System for additional r e c o v e r y . The RO unit is of modular design and will treat 2863 gpm
of feed water, based on an 87 p e r c e n t conversion r a t e , :with a product
water p r o d u c t i o n rate of 2491 gpm.
Ion-Exchange Demineralizers
~e
i o n - e x c h a n g e deminerelizers are multiple, parallel operating trains,
~ t h each train consisting of a cation unit and an anion unit.
A strong
acid cation resin operating on t h e h y d r o g e n cycle is u s e d to c a r r y out the
cation e x c h a n g e . Cation resin is r e g e n e r a t e d using 66 ° Be' sulfuric acid
diluted to four percent to shift t h e equilibrium to the h y d r o g e n ion form.
Purity of the decationized water is monitored by a sodium probe at the
outlet of each cation exchanger.
The anion units are designed" to operate on the h y d r o x y l cycle using a
strong base anion resin.
Anion plus dissolved carbon dioxide and silica
accumulated on the anion resin sites d u r i n g the process cycle are removed
during r e g e n e r a t i o n by a four p e r c e n t solution of sodium hydroxide.
High
silica concentration and high conductivity probes are provided to signal
bed exhaustion.
The r e g e n e r a t e waste disposal is g o v e r n e d by the following:
Waste effluent with a TDS content h i g h e r than the Reverse Osmosis system
influent is r o u t e d to the Ash Handling unit.
Waste effluent with a TDS content at or below the TDS level of the
Revers~ .... .mosis system is collected and, following pH adjustment, injected
into the Utility Cooling Tower Blowdown Treatment System.
i
,Tl
•
u_
•
,g
6.3.6.2
~
(Continued)
|
The
ion-exchange
demineralizer system
consists of cation/anion
units
designed to produce a total of 1316 g p m of product water with two units in
operation, one in regeneration standby.
The demineralizer system is sized
and provided with resin quantifies to operate with 100 percent Reverse
Osmosis system and treated influent.
•
,L
.
:i : / '
iI
Mixed B e d P o l i s h e r s
il
The effluent frGm t h e cation/anion u n i t s contain some l e a k a g e s of dissolved
solids ( p r e d o m i n e n t l y sodium and silica) w h e n t h e e x c h a n g e r s are operating
near the e n d of their cycles.
Two mixed b e d polishing u n i t s are provided
as a final treatment step to e n s u r e water quality as s p e c i f i e d b y ABMA.
The" units contain a homogenous mixture of s t r o n g acid cation and s t r o n g
base anion r e s i n , ope ated in t h e h y d r o g e n and h y d r o x y l form similar to
the cation and anion u n i t s . The "polished" water is e s s e n t i a l l y p u r e and
flows to the demineralized water storag~ tank.
Regeneration waste is
handled in the same manner as the c a t i o n / a n i o n train r e g e n e r a t i o n waste.
One polisher i s continuously in s e r v i c e , with the remaining one either
regenerating or at s t a n d b y .
• ....
1
Condensate Collection
:\
,
"
)
Influents to t h i s u n i t also include the c o n d e n s a t e r e t u r n from t h e boilers
I
and the other plant u n i t s . Cold c o n d e n s a t e from the power p l a n t is processed in a mixed b e d polishing unit a n d r e t u r n e d to the boilers at a flow
rate of 5821 gpm. Vacuum condensate from the S N G compressors is treated
in two filter softeners and sent to a storage tank where it As combined
with flashed and cooled medium and low pressure condensate.
•
;
r
This conden-
sate is u s e d as 600 p s i g deaerator f e e d and has a flow rate of 683 gpm.
Low p r e s s u r e c o n d e n s a t e that h a s a potential for contamination with oil is
•
....
de-oil filtered
a n d sent to the medium/low p r e s s u r e
deaerator
with the
ze:olite s o f t e n e d makeup at a total of 1542 gpm.
'k"
6-279
'
HI
m
IS ~UIU£C?R| 1trill IIrSTBICltON ~1 IHE
I
|
6.3.6.2
(Continued)
Process steam condensate is recovered in four collection systems.
Cold Condensate Return
This system collects condensate from surface condensers supporting
turbine drivers connected to the turbogenerators in the power plant.
Condensate from this source is pumped into the Cold Condensate Return
header and flows through a mixed bed polishing unit and is collected in
the condensate storage tank.
Piping design conditions for the Cold Condensate Return header is specified as 150 psig at 175OF outside process unit battery limits.
Vacuum Condensate Return
Vacuum Condensate is collected from surface condensers in Unit 23, S N G
Compression.
A
stream of three gpm
is sent to Ash Handling.
The
remainder flows to a set of filter/sodium softeners within Unit 45 end on to
the high pressure deaerator feed storage tank.
HP Condensate Return
This system collects condensate from the H P S A T
traps
in
the
plant.
Condensate
from
Tar
steam users and header
Distillation. Naphtha
Hydrotreating and Phenosolvan units is collected in the HP
return header.
condensate
The conden ,,':,is flashed in a centrally located drum to
recover LP Steam. The c~,,,.:nsate from the flash drum is process and
returned to the High Pressure Service Deaerator.
Piping design conditions for the HP Condensate Return header
specified at 610 psig and 530oF outside process unit battery limits.
6-280
are
±l
: i/. ¸¸¸~ i /:/
i¸!¸¸:i:¸ ` /i~
i ~
.
(Continued)
6.3.6.2
M P Condensate Return
Condensate
.
..
.
......
•
.
. i*i
!
,
-~
j
from Rectis01,
Phenosolvan,
Ammonia R e c o v e r y ,
Tank
Farm
u n i t s as well as Steam T r a c i n g and E j e c t o r s i s collected in the MP
C o n d e n s a t e Return h e a d e r .
T h e condensate is f l a s h e d in a drum and the
v a p o r c o n d e n s e d by air cooling.
The c o n d e n s a t e from the flash drum is
s t o r e d - - . d returned to the h i g h p r e s s u r e service deaerator.
i'
" "i
Piping
design
conditions
for
the
MP
Condensate
~eturn
header
are
s p e c i f i e d as 170 paig and 420°F outside p r o c e s s u n i t s b a t t e r y limits.
.
i
LP Condensate Return
'
i I
q
T h i s s y s t e m collects c o n d e n s a t e from the LP steam u s e r s and header traps
in t h e plant.
Condensate
Recovery,
from Rectisol, Naphtha
and Tar Distillation
R e t u r n header.
Hydrotreating,
Unit is
collected
Phenosolvan,
in
the
LP Cc;~densate
CondenSate from t h e s e sources i s subject to potential oil
contamination from the process aide of the heat exchanger.
.I
Sulfur
As a precau-
tionary measure against contamination, a de-oil filter unit is provided to
treat tolerable levels of oil contamination in the condensate ~.,before it is
1
r e t u r n e d to the Low P r e s s u r e Service Deaerator.
c o n d e n s a t e is sewered.
Alteri(ately contaminated
LP c o n d e n s a t e from non-off contaminating u s e r s i s colleeted:..Jn a separate
.L
.
h e a d e r and r e t u r n e d to t h e Low Pressure Service Deaeratori: ''~ Sources of
clean LP condensate are: Ammonia Recovery, BFW Treatment; a n d Waste
Water Treatment.
Piping
design
conditions
for
the
LP
Condensate
Return
header
are
s p e c i f i e d as T5 p s i g and 360oF o u t s i d e process u n i t s b a t t e r y limits.
6-261
U~ ~11B1SCL,?SUREOF I~F'~m BAT&
B S U O ~ , ~ m l r H f l l r S T | ~ O N ¢X INE
|
!
6.3.6.2
(Continued)
B F W Deaeration
Deaerated B F W requirement for process steam generation is supplied by
high and low pressure service deaerators:
High Pressure Service Deaerator - This deaerator supplies the BFW
requirement for steam
Synthesis, Methanation,
generation in Coal Gasification, Methanol
Process Steam Superheating, and Partial
Oxidation units. It also provides the desuperheating water needs of
steam desuperheater stations.
Water to the High Pressure Deaerator consists of condensate from HP
steam condensate flash drum, M P and clean LP Condensate headers
and makeup water from the treated water storage tank.
The deaerator is operated at 7 psig and reduces the dissolved oxygen
content in B F W to less than 5 ppb.
The deaerator design condition is specified at 75 psig external, fu£t
vacuum, and 290OF.
Medium and Low P r e s s u r e Service Deaerator - This d e a e r a t o r supplies
the BFW requirement for steam generation in the Coal Gasification,
Gas Cooling, Sulfur Recovery, POX and for Rectisol unit wash water.
Water to Low Pressure Service Deaerator consists of potentially oily
LP Condensate and makeup water from the zeolite softeners in Unit 45.
The deaerator is normally operated at 7 psig and reduces
dissolved oxygen content in the B F W to Less than 15 ppb.
i I~TA '
¢N IHI~
' '[
6-282
[
.
.
the
.
.
~i ¸ ! / |
• i:.i~
i~
6.3.6.2
,1
(Continued)
The deaerator d e s i [ n condition is specified at 75 p s i g extez.-nal full
vacuum, and 290oF.
.I I
The high pressure and Low Pressure Service Deaerators are operated at
the same temperature.
The deaerators
are also of equal size and are
provided with interconnections to ensure continuous BFW supply to both
pressure levels of steam generators when one of the deaerator units is not
available.
" ~
'
Condensate Polishing
Cold condensate is collected from the
•
•
surface condensers in the power
plant and pumped to mixed bed ion exchange units followed b y activated
caz.bon filtration.
:.!;
The cold condensate is monitored at each major source for conductivity.
At high conductivity levels, the condensate is automatically sewered until
the problem is rectified.
?
i
Mixed Bed Ion Exchange
m
Mixed bed ion exchange units are provided to function primarily as guard
vessels,
ensuring fully demineralized condensate to the 1500 psig boiler
feed water system at all times. Inherent in the design of the units is the
ability to retain suspended material in the resin bed.
,
.;2
"T,
-
The ion exchange media consists of strong anion and strong cation resins,
operating on h y d r o g e n , h y d o x y l cycles.
External regeneration is provided
to facilitate complete regeneration of each resin and thorough f l u s h i n g of
•
!
,.
!
suspended-.olids.
i
Higher flow rates are allowable in this type of system
compared to internally regenerated e x c h a n g e r s , reducing the size of units
required.
6-283
J~
.£ r
u ~ ol olscusuR! n; a[r'.~ ~ m
i
UI=S'~aI[~ I I THA|[STIU~IOll_f*~l INI[ i
i
I
II
6.3.6.2
(Continued)
The basic regeneration process consists of sluicing the spent resin into a
cation regeneration vessel. The resin is backwashed, causing the anion to
migrate to the top portion. Once the resins are segregated, demineralized
water is used to sluice the anion resin to the anion vessel for regeneration. Upon completion of the regeneration process, the resins are sluiced
to a mixing tank where they are mixed and then sluiced to the polishing
units. Air is used to obtain a homogenous mixture in the mixing chamber.
The condensate polishing unit is designed to produce the following water
quality:
Dissolved Silica- 0.005 p p m
Total Dissolved Solids - 0.i p p m
Activated Carbon Filtration
Polished cold condensate is sent through activated carbon filters as a final
step prior to being reused as BFW.
Pressurized activated carbon filters
are provided to guard against organic contamination that could result from
coollng water leakage into the condensate.
The carbon drums act as filters for suspended material as well as removing
dissolved organics. The units are periodically backwashed to remove suspended material. In-situ steam regeneration cycle is not provided for the
activated carbon due to the low organic loading that is anticipated.
~ ml
I
¢~--OOA
"a'
--
'
'~
|
6.3.6.2
(Continued)
Waste Water Disposal
Backwash and regeneration wastes from the condensate polishing units and
the activated carbon filters are classified into high TDS and low TDS
streams.
The high TDS stream is collected as feed to the Ash Handling
System, while the low T D S
stream is collected in the raw water recovery
sump and recycled .to the R a w Water Treating System.
"'
(
6-285
IS SYB.KG'I' 110IHi[ ItTS1[iiCllOli ,ON l#l[
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TABLE 6.3.6-1
MATERIAL B A L A N C E
BOILER FEED W A T E R A N D C O N D E N S A T E T R E A T M E N T - U N I T 45
Stream N u m b e r
45-1
45-2
BFW Feed
Stream Name
Detain.
From
45-3
Cold Cond.
Water
Unit 44
To
45-4
Polished Vacuum
For
Cold
Cond.
Polishing
Cond.
From
Distr.
lb/hr
45-5
Unit 23
1,435,000
658,000
2,912,800
2,912,800
144,300
(2870)
(1316)
(5821)
(5821)
(288)
1,435,000
658,000
2,912,800
2,912,800
144,300
P r e s s u r e , psia
T e m p e r a t u r e °F
33.7
88.7
40
88.7
40
NOTE:
pressures
Water
(gpm)
Total
lb/hr
80
Flow q u a n t i t i e s ,
total
unit
on
a
100
285
100
a n d t e m p e r a t u r e s shown are for t h e
stream-day
basis,
are
to be
used
solely
for
process design purposes, and are not necessarily the conditions
which will be a t t a i n e d d u r i n g a c t u a l o p e r a t i o n s .
6-288
285
. ..+
.+.
;
•.
'
.
c.
J
+
.
•
):
•
2
'
+
'
T A B L E 6.3.6-1 (Continued)
MATERIAL BALANCE
BOILER FEED W A T E R A N D C O N D E N S A T E
Stream Number
45-6
TREATMENT-UNIT
45-7
45
45-8
45-9
45-10
High TDS
Low TDS
Softened
i
Stream Name
,+
<.
'
Process Cond. Softened
•i
From
Vac. and
to A s h
to UCT
Water to
Unit 22
Process
Handling
Makeup
Deaerator
Cond.
L
.
LP
2
Water
i .....
1, hr
175,000
319,000
13,500
10,000
(gpm)
(350)
(638)
(27)
(20)
lb/hr
175,000
319,600
13,500
10,000
564,500
88.7
'/8.7
63 ."/
63.7
88.7
564,500
(1128)
?i.,
:
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Total
'i
Pressure,
....
i
•
?
C."
psia
Temperature °F
100
100
100
100
100
2
.
~
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6-289
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T A B L E 6.3.6-2
EQUIPMENT
B O I L E R FEED W A S T E
Item No.
45TK-0101
45TE-0102
LIST
& CONDENSATE
TREATING-UNIT
45
Number Required
Operatin~ Spares
1
0
Ecluipment Name
Clearwell
1
1
1
0
45TK-0104
RO Product Storage Tank
Sulfuric Acid Storage Tank
Caustic Storage Tank
45TK-0105
Mixing/Holding Tank
1
0
45TK-0106
Polished Condensate Storage Tank
1
0
45TK-0107
Demineralized Water Storage Tank
I
0
45TK-0108
Low T D S Waste Collection Sump
1
0
45TK-0110
Vacuum and Process Cond. Storage Tank 1
0
45DM-0101
LP Condensate Flash D r u m
Oily Conden.~ate Flash D r u m
Medium Pressure Flash D r u m
1
0
1
0
1
0
45E-0102
RO Stream Preheater
Flashed •Condensate
1
1
0
0
45E-0103
Flashed Oily Condensate Cooler
1
0
45E-0104
Medium P r e s s u r e Makeup Preheater
1
0
45P-0101 A/B
BFW Treatment Feed Pump
1
1
45P-0102 A/B
Activated Carbon Filter Backflush
Sand Filters Backflush
RO Feed Pump
1
1
1
1
1
1
45TK-0103
45DM-0102
45DM-0103
45E-0101
45P-0103 A/B
45P-0104 A/B
45P-0105 A/B
0
0
Demineralizer Feed Pump
Low TDS Sump Pump
1
1
45P-0106 A/B
1
1
45P-0107 AIB
Hexametaphosphate Feed Pump
1
1
45P-0108 A/B
Sulfuric Acid Injection Pump
1
1
45P-0109 AJB
Sulfuric Acid Injection Pump
1
1
6-290
i
inl nn
USE OAOI~I,..~JLJI~C~ EF.J~.ItibATA
t5 SUB,K.C;T1QI[H[ IW,SlIIP,I~IOIO¢N SHE
n!
T A B L E 6.3.6-2 (Continued)
E Q U I P M E N T LIST
BOILER FEED W A S T E & C O N D E N S A T E
T R E A T I N G - U N I T 45
Number Required
Item No.
Equipment Name
45P-0110 A/B
4SP-0111 A/B
Sulfuric Acid Injection Pump
Sulfuric Acid Injection Pump
1
1
1
1
45P-0112 A/B
46P-0113 A/B
Sulfuric Acid Injection Pump
Caustic Injection Pump
1
"1
1
1
45P-0114 A/B
Caustic Injection Pump
1
1
45P-0115 A/B
Caustic Injection Pump
1
1
45P-0116 A/B
Caustic Injection Pump
1
1
45P-0117 A/B
Raw Water Treatment Slaking Water
1
1
45P-0118 A/B
Polished Condensate Return Pump
1
1
45P-0119 A/B
45P-0121 A/B
Demineralized B F W Feed Pump
Flashed Cond. Cooler Pump
45P-0122 A/B
LP Condensate Pump
MP Deaerator Feed Pump
1
1
1
1
1
1
1
i
45P-0125 A/B
Oily Condensate Cooler Pump
LP Deaerator Feed Pump
1
1
1
1
45P-0126 A/B
LP B F W Pump
1
i
45P-0127 A/B
MP BFW Pump
1
1
4SDA-0101
Low Pressure Service Deaerator
1
0
45DA-0102
Medium Pressure Service Deaerator
1
0
46MX-0101 A/B
Low TDS Waste Sump Mixer
1
1
45FT-0101 A-F
Activated Carbon Filter
5
1
45FT-0102 A-G
Cartridge Filter
6
1
45FT-0103 A-D
Activated Carbon Filter
3
1
45P-0123 A/B
45P-0124 A/B
Operating
_
6-291
m i|nm
n
USIEM OISCL.'~'SLAR[OIr lULIP'~R1bil'A
IS ~UOJC~P10 I H l IrSIIU£~I"Ii C~I I#IE
NOZiC~PA~ AT |X 6"FtoNlr ~ TH|~ REr~T
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TABLE
6.3.6-2 (Continued)
EQUIPMENT
B O I L E R FEED W A S T E
• .
LIST
& CONDENSATE
" •
TREATING-UNIT
45
Number Required
Item No.
,Equipment Name
Operal/n~
Spares
46ME-0101 AIB/C Cation Demineralizer
45ME-0102 AIB/C Anion Demineralizer
45ME-0163 AIB
Mixed Bed Demineralizer
2
2
1
1
1
45ME-0104 AIB
1
1
4SME-010S
1
0
45ME-0106
Anion Regeneration Unit
1
o
45ME-0107 A / B / C Sodium Zeolite Softener
45ME-0108 A/B/C Filter/Softener
2
1
2
1
45ME-0109
1
8
1
0
1
0
1
0
45ME-0110
45ME-0111
45ME-0112
,d
g
'
1
Condensate Polisher
Cation Regeneration Unit
Hexametaphosphate System
Reverse Osmosis (RO)
De-Oiling Filter
Salt Regeneration Dilution
•
!,
,.
¢-
6-292
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|
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6.3.?
6,3.7.1
AIR A N D N I T R O G E N
SYSTEMS-UNIT
46
DESIGN BASIS
]
•
•
,
Purpose of Unit
.
The Air and Nitrogen Systems unit provides compressed plant air for maintenance and plant u s e s , dry compressed air for pneumatic instrumentation,
and a high purity nitrogen for purging of tanks, lines, and process
vessels handling flammable materials.
..
Scope of Unit
The scope of the Air and Nitrogen System unit includes compressors and
receivers for the plant and instrument air system, dryers for tl~e plant
air, and distribution networks throughout the plant for the plant air,
instrument air, and nitrogen.
General Design Criteria
The compressors for plant and instrument air each have two 106 percent
units. The plant air driers are designed for one onstream and the other
on regeneration or standby.
r
[
.r
The design onstream factor is for continuous operation of the unit without
shutdown and is
332 days/year.
compatible with the overall plant onstream
factor of
The compressors are motor driven.
The turndown capability of Unit 46 is controlled by compressor controls
and/or purge rates.
6-293
IS SUOJCCtP10 THI[ IP'STIU~ION¢,~ tHE
|--NONCEPAgE AT IHL FRg/ITK THS~;REI'AM
s-r . |
/
• •
6.3.7.1
• "•
,
• cJ
i:|
(Continued)
P r o c e s s Specifications
1
.
The plant and instrument air are delivered at the following conditions:
Pressure
Dew Point
I00 psig
-40°F rain.
T h e nitrogen is delivered at a purity of 99.9 p e r c e n t
maximum o x y g e n content o f 100 ppm.
at 35 p s i g with a
Feed
J
Feed streams to the n i t r o g e n and instrument air s e c t i o n s of the Air and
Nitrogen S u p p l y unit are from the Air Separation Unit 40. Plant air i s
directly compressed from t h e atmosphere.
,,
%.
.
Nitrogen
99.9%
Nitrogen
Pressure
I n s t r u m e n t Air
-
50
50
-
-100
Dew Point
Plant Air
atm
65
Design Rate
1 5 . 0 M M SCFD 5.0 MM SCFD
15.0 MlVl SCFD
Operating Rate
12.9 M M S C F D
13.8 M M S C F D
4.4 M M S C F D
Products
T h e plant and i n s t r u m e n t air are compressed and dried to the s p e c i f i c a tions p r e s e n t e d
in the
Process
Specifications
p r e s e n t e d in Table 6 . 3 . 7 - 1 , 6 . 3 . 7 - 2 ,
air, and nitrogen r e s p e c t i v e l y .
Section.
Unit u s a g e s
are
and 6 . 3 . 7 - 3 for plant air, i n s t r u m e n t
4
L
6-294
!
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I$ SUSK~ ~l TH[ llEI~J'WCU;ONCN |HE
ROT~ PAQ[ AT IN[ F ~ m M THL~ B
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1
6.3.7.1
-
.j
(Continued)
i
Utfllty Requirements
.
. .
.
J
• .[
Power
Cooling Water
6.3.7.2
3400 kW
433 gpm
PROCESS DESCRIPTION
Drawing Number 835704-46-R-101 is the flow diagram for Unit 46.
unit material balance (Table 6 . 3 . 7 - 4 )
follow the drawing.
The
and equipment list (T~ble 6.3.7-5)
Plant Air
-:i]
'.
B
[
Plant air is supplied to the Unit 46 battery limits at a pressure of 120
psig and is available to plant users at 100 psig minimum.
Two package centrifugal compressors are provided for plant air compression. These compressors take suction from the atmosphere through filters.
Each compressor is designed to supply 4800 scfm of air. Sizing flow rate
is based upon supporting maintenance operations
turnaround with both compressors operating.
during a major plant
The plant air compressors also provide back-up support to the instrument
air systems during initial startup when instrument air is not available from
the Oxygen Production unit. A plant air receiver is provided for water/
oil knockout for the plant air.
Instrument Air
The Oxygen Production Unit 40 supplies instrument air to Unit 46 at a
pressure of 50 psig and with a dew point of -100oF at 55 psig.
The
instrument air booster compressor(s) boost the pressure to 125 psig for
6-295
U~. Oil• nl$CL,.~tJIU[
_
i C~ I [ ~ M b&T& i
LSSUOJLCTl / H I |I[b'TIUCTION¢N IHl[
NOTI~CPAGEM IKE FMIII~ (IT THe2R[rOM
i
B
6.3.7.2
(Continued)
delivery to the Unit 46 battery limits. An instrument air receiving drum
is the provided surge capacity. Instrument air is distributed to plant
user battery limits at a minimum pressure of 90 psig.
T w o instrument air booster compressors are provided; each has a capacity
of 3650 scfm.
Each conipressor is sized to provide 1.20 times the total
consumption quantity indicated on Table 6.3.7-2.
Excess capacity accom-
modstes undefined needs and emergency operating conditions.
T h e second
compressor increases the reliability of the system and provides additional
contingency.
As stated above, the plant air system can provide makeup to the i n s t r u ment air system.
Compressed plant air passes through desiccant driers
and after-filters before entering the i n s t r u m e n t air system, a s s u r i n g that
only dry air is utilized in the instrument air system.
Nitrogen
Low p r e s s u r e n i t r o g e n is available from the Oxygen Plant at an expected
pressure
of 60 psig
at the
Unit 40 b a t t e r y limits.
This n i t r o g e n is
available to the most distant u s e r plant b a t t e r y limit at a minimum expected
pressure of 40 p s i g .
,
6-296
!
USE OIt OI$CL'~JURE 0~" liEPr, M bMA
L! ~U~lr CT 'iB THJEItESlflU~lON ¢N =HE
|
!
m
i ¸ ~ • ;
L
T A B L E 6.3.7-1
PLANT
AIR R E Q U I R E M E N T S
Unit
02
10
Consumption (M SCFD)
Coal Preparation
Coal Gasification
CO Shift
167.8
175.4
11
14
Gas Liquor S e p a r a t i o n
566.1
16
19
22
Naphtha Hydrogenation
Sulfur Recovery
Methanation
501.1
1026.6
3152.2 (2)
7632.0
Buildings and Maintenance
TOTAL
NOTE:
H
3864.9 (2)
ii
13,933.9 (1)
Other u n i t s ' u s a g e s are i n t e r m i t t e n t at u t i l i t y s t a t i o n s o n l y .
(1)
If the plant air requirement is exceeded,
supplied by the instrument air system.
makeup can be
(2)
Intermittent use for catalyst regeneration.
The plant air
L
system is designed to produce the constant usage plus the
single largest intermittent u s e , Unit 11.
6-297
i
UU GI DISCL'v~dRE~' NI[I"C~R,b&TA
LSSUOJCCTM TI~ KSIII~T~N C~ IHIt
NOTICE/'~E &l IHE Frail'l"J THt2 Ut'qUkT
vT I
E
= ' - ' = "
TABLE 6 . 3 . 7 - 2
INSTRUMENT AIR REQUIREMENTS
Unit
02
10
11
12
13
14
Consumption (M SCFD)
Coal Distribution
Coal Gasification
C O Shift
R a w Gas Cooling
Rectisol
20
467
250
15
310
Gas Liquor Separation
30
15
Tar Distillation
33
16
Naphtha Hydrotreating
25
17
Phenosolvan
95
18
Ammonia Recovery
80
19
20
Sulfur Recovery
Process Steam Superheating
21
24
Methanol S y n t h e s i s
Methanation
POX
103
31
389
250
500
40
O x y g e n Production
3?2
41
Steam Generation
300
42
Power generation
300
43
FGD
22
{i /
.c.-
"
f
!
?
3S
44, 4 5 ,
& 49
46
47
48
Water Treating
Air & Nitrogen Supply
Process Cooling Water
Utility Cooling Water
50 & 51 Utility and Firewater
52
Fuel Gas
20
40
25
10
30
30
53
Flare
10
54
Waste Water Treating
30
6-298
US~.O;I O~SClL~u~ Of ItE~ln L'AI'&
m SUWr.CTI0 T'~ IIESTIUCIIObe . ~ wu,~
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•
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. .
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.
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T A B L E 6.3.7-2
/
r' .
(Continued)
I N S T R U M E N T AIR R E Q U I R E M E N T S
/
Unit
•
.,
:~'+
~ ,~,:i,
•
.' 2 .
Consumption (~l SCH~)
55
T a n k Farm & D i s p a t c h
56
S anita,s, Sewer
Cable P u r E e
TOTAL
....
• i,.
~:
165
4
405
4,377
]
'
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6-299
.
a -.
•
l
I
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• . . .
~ :
~
~
T A B L E 6.3.7-3
NITROGEN
REQUIREMENTS
Unit
j
Consumption (M SCFD)
•2
10
Gasification
11
Shift
12
Cooling
13
15
Rectisol
Gas Liquor Separation
Tar Distillation
16
Naphtha Hydrotreating
17
Phenosolvan
407.5
19
Sulfur Recovery
373.0
22
Methanation
718,6
24
POX
720.0
41
Steam Generation
61.9
Power Generation
45 & 54 Water Treatment
53
Flare
55
Tank Parm
67.7
14
":.
.i
i
470.9
'
"L
370.1
149.8
2836.8
623.1
40.3
331.2
43
--]--:
'12
214.6
259.2
•
.U, ~
6850.1
TOTAL
/2:1
.:-
14,494.8
,~i'i '
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.2
6-300
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46DU-Ol O!
PLAN'r AIR RECEIVER
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NOTES:
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46C-0102A/B
,'NSTRuMENT,~|R COXPRE$SOR5
R~'CE! VER
46~R-0101
PLANT AIR DRYER
46Du-OIO;
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PL~N~"~SSOR
46FT-01 O!
PLANT AIR FILTER
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PROCESS FLOW DIAGRAM
,~IR AND NITROGEN SYSTEMS
[
I
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-
.
.
.
.
.
.
.
.
.
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T A B L E 6.3.'/-4
~IATERIAL B A L A N C E
AIR A N D N I T R O G E N S Y S T E M - U N I T
46
ALL CASES
Stream Numbel'
i
Stream Name
46-1
46-2
46-3
46-4
Plant Air
Instrument
Air From
Unit 40
Nitrogen
From Unit 40
Instrument
Air
ii
l b - m o l / h r Mol%
Component
Air
Nitrogen
1477.6
Total Dry. Gas
HsO
Total Wet Gas
1477.6
33.8
1511.4
Dry Gas
Iblhr
100.0
100.0
42,555
Ib-mol/hr Mol%
480.5
Ib-mol/hr Mol%
100.0
480.5
I00.0
1592.1
100,0
1592,1
....100.0
Ib-mol/hr Mol%
480.5
100.0
480.5
100,0
13,920
44,604
13,9Z0
13,920
Water
lb/hr
608
Total
lblhr
43,163
13,920
44,604
125
80
63
75
63
75
Pressure, psia
T e m p e r a t u r e , °F
o
, , i s
125
80
NOTE:
Flow quantities, pressures and temperatures shown are for the
tot--~unit on a stream-day basis, are to be used solely for process design
purposes, and are not necessarily the conditions which will be attained
during actual operations.
6-302
i
_ _~ ,i
ii
~ ~'~ i~!iI ~i~ J~
~i ¸ i~ :.i
TABLE 6.3.7-5
EQUIPMIZNT L I S T
AIR AND NITROGEN SYSTEMS-UNIT 46
,,':'.,/
,
Number Required
Item No.
Equipment Name
46DM-0101
46DM-0102
Plant Air Receiver
Instrument Air Receiver
Operating
i ;' i. ¸¸
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1
0
1
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46C-0101 A I B
4 6 C - 0 1 0 2 AIB
Plant Air Compressor
Instrument Air Compressor
1
1
1
46DR-0101
Plant Air Drier
1
0
1
I
46E-0104
Plant Air Aftercooler
1
0
46E-0105
Instrument Air Aftercooler
1
0
/
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6-303
i
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USi OR OtSCL"~UI~[ 4IF Itl[~lIT bJ~A
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6.3.8
PROCESS COOLING WATER
-
UNIT 47
;i ' :.::
L
6.3.8.1
."
:
DESIGN BASIS
Purpose of Unit
•: " i¢ .
The Process Cooling Water System p r o v i d e s heat rejection for the cooling
i,
i
water u s e d b y t h e plant process u n i t s u s i n g i n d u c e d draft cooling t o w e r s .
g
•. ::i;::.)i
Unit 47 i n c l u d e s the distribution a n d collection p i p i n g n e t w o r k n e c e s s a r y
for cooling water service to s n d from t h e power generation and p r o c e s s
¢
/'
.
/
//, :
.,
units of the plant a n d the cooling towers and peripherals
i}'(~
to reject the
..
process
heat p i c k e d up b y the water.
Also i n c l u d e d are a side stream
treating system to remove suspended solids from the cooling water and a
cooling
-
water
makeup
treating
system
zeolite s o f t e n i n g , and Reverse Osmosis
effluent to p r o c e s s cooling water.
2:
consisting
to u p g r a d e
of filtration,
the waste
sodium
treatment
General Desil~n Criteria
The Process
,il
Cooling Water unit c o n s i s t s of four ~ ~bsystems of one train
each: Cooling t o w e r s , cooling water distribution, chemical treatment,
side stream treatment.
•
and
I
..
:
2
l
The cooling water pumps are designed with a minimum of one spare per tower.
" ":
,,2
T h e equipment d e s i g n is compatible v;ith t h e overall plant stream factor of
3 3 2 d a y s / y e a r operation.
" "
"J
:
.,'~
j
The cooling tower fans and cooling water pumps are motor d r i v e n .
. /
•
i
:
'2 :
"
...
.
.
"
~
2
/ .
6-304
/
J
Is SUl~:~' m mE ItE~lt~to~ ¢~ I#[
N01llC[ PAG[AT IHr.. rMJiT M 1H|~ IRrO~T
~!i:. 'i ¸
1• :
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:+ ~ /
:.,2
:
+
:!•i¸~:••i:
~
~
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.:
i 2:
6.3.8.1
(Continued)
The system is designed for continuous operation without a major turnaround.
L
I
T h e turndown capability is designed as needed.
Process Specifications
The Process Cooling Water Unit is designed to circulate 168,060 gpm based
on 110 percent capacity.
2279 x 106 Btu/hr.
The total process cooling water heat removal is
This duty is rejected from the Process Cooling Towers
/' • ,i,~I. i
• ~•~ •i~ ~+~ i
which are designed for a 17°F approach to design wet bulb temperature
based on the five percent corresponding summer dry bulb temperature.+
The feed water, to the cooling tower consists of cooling water from process
heat exchangers in the following units:
Uni__t
10
=
Flow (gpm)
551
Gasification
12
Gas CooLing
13
Rectisol
14
Gas Liquor Separation
15
Tar Distillation
240
16
Naphtha Hydrotreating
1T
Phenosolvan
206
TT9
18
Ammonia
19
21
Sulfur Recovery
Methanol Synthesis
609
:
'.
!~, 613
5,548
r
Recovery
.
"i!
:
,
8,165
~,i ~
22
Methanation
23
SNG Compression
24
Partial Oxidation
25
H~ Production
24
Partial Oxidation
2,900
80
~
~
,-
• ~.:
2.
293
i
10,200
465
25
465
•i i i ~.~:,
r.
•
6-305
t
USi ~'q Dl|G~SUIt[ OF liE~.ltl r,ATA
IS SUDIL~' TQl~Hi RESTilICI~ ¢:i THE
NOrli:E PAGE&1 |Hr. FRgliT O~ TH~ RF~'~tm,
.....
!
.
+
:
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•
i
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• .?
6.3.8.1
.: ,?
•
(Continued)
Unit
42
Power Generation
55
Tank Farm
Flow (gpm)
108,200
100
?
Inlet Temperature to the Tower is ll0OF
2 :'
'
,
.,:
."
Makeup water flow to the cooling towers is 4617 gpm.
:'.from the wastewater treatment unit is recycled into
Additives to the makeup treatment include sulfurio
hexametaphosphate for the RO unit.
Additives to
; .2
;
.
i f : ~" , , :
i
iii!iii
.
ii
,
water include dispersant chemicals,
inhibitors.
pH control,
The
the
acid
the
treated effluent
makeup stream.
pH control and
process cooling
biocides and corrosion
The outputs of Cooling Towers I and II are 108,200 gpm and 44,674 gpm
respectively of 80OF water. The cooling water pumps discharge at 75 psig
fol- distribution to the process units.
Utility Requirements
•
5
4
..
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,
•[
•.%
l
.,.i-i ¸ :.
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Power
9,600 kW
Treated Water
Makeup
4,617 gpm
• • i ¸
i; ,¸.~;i/i~
6.3.8.2
PROCESS DESCRIPTION
Drawing No. 835704-47-R-).01, 835704-47-4-102, and 835704-47-4-103 are the
flow diagrams for Unit 47. The unit material balance and equipment list
(Tables 6.3.8-1
and 6 . 3 . 8 - 2 )
follow the drawings.
Drawing No.
835704-47-4-050 shows the plot plan.
"':51
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6-306
'
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• aEIl~JL1 tJAlrA
, |1,r O~
I | SIIOJLCT11 IIII~KSIIJL'II|M ¢,'1 I f l i
II~ICE PAgEAT |H grFRONT~ 1Ht~JR | ~ r
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6.3.8.2
(Continued)
I " 3"c
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,
Cooling Towers
i
J
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' i
The Process Cooling Water System has two induced draft cooling towers.
The first tower is situated near the Steam and Power Generation Unit to
,.
/
.
service two of the three power turbine surface condensers.
'/
/
The second
tower is situated near the process units to provide cooling to the rest of
the process units.
/
/ ,/.,~t
f -
-.
/
•
/
Makeup water to the two towers is pumped at 4617 gpm from the Process
Cooling Water Pond. The cooling water makeup from waste water treating
.
/
:
undergoes the following treatment steps within Unit 47:
,
Activated Carbon Filtration
Sodium Zeolite Softening
(
. h. i i
,
7
.
.
)
'
,
Micron Cartridge Filtration, pH Adjustment, Reverse Osmosis
.
N..
'7
Side stream
handling.
treatment
for both
towers
includes
filtration
and
solids
,/)
Cooling towers are designed to evaporate the total amount of waste water
produced throughout the year.
During cold weather operation, the ability
of the ambient air to absorb water at saturation is substantially reduced.
/
:
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1
~
• I
:/
/"
'I
Maintenance of the cold water temperature and waste water evaporation is
by computer control, which supervises
and cooling cell isolation.
fan operation, hot water bypass
Protection of the towers against fire is an important consideration. The
design incorporates a deluge system in compliance with NFPA standards
and firestops to prevent propagation of fire between cells, thereby n~inimizing the amount of fire water required.
==
i
6-307
i
.
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i ii i
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_
Oil |ISCI,."JOII+[ Ot" II[KIA DATA
IS $UIIJP.C)11 lill. II[SlllgllOll G,~lll4[
IIOIIL"Ei'AO| 14I I H [ I r U l ~ OI ~lt;'~ mlPOll|
!
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6.3.8.2
,.
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-
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(Continued)
Reversible fans are provided to allow air circulation to be r e v e r s e d
p r e v e n t f r e e z e - u p d u r i n g winter.
to
~
Coolin~ Water D i s t r i b u t i o n
, ,~'~.
"....
Centralized cooling water distribution p i p i n g i s p r o v i d e d to s u p p l y p r o c e s s
;
.:t
u n i t s throughout t h e plant.
Selection o f a central system
individual units is b a s e d on cost and o p e r a t i n g considerations.
versus
Circulation of cooling water is provided b y vertical mixed flow impeller
p u m p s . Three 54,000 gpm capacity and t h r e e 22,000 gpm capacity p u m p s
, o
are provided, each r a t e d at 75 psig d i s c h a r g e .
°-
.
the motor driven p u m p s operate.
Normally, two of e a c h o f
T h e . s t a n d b y pumps are moto~ d r i v e n .
The philosophy in d r i v e r selection is b a s e d u p o n h a v i n g sufficient cooling
/."
.
water available to s h u t d o w n the plant in a safe and orderly f a s h i o n in t h e
event of p l a n t - g e n e r a t e d power failure.
~2
~i ~
The pumps are a r r a n g e d in a pit which r e c e i v e s , b y gravity flow, cold
water from the cooling tower basins.
Each pump pit is e q u i p p e d with
t r a s h racks and s c r e e n s which are periodically manually cleaned.
Due to the large
cooling
water circulation,
consideration
was
given
dynamic changes in t h e piping system as a r e s u l t of pump t r i p o u t ,
to
etc.
To accommodate s u d d e n s u r g e s , the pumps are e q u i p p e d with h y d r a u l i c a l l y
operated a u t o - c l o s i n g v a l v e s on each d i s c h a r g e .
The valve is d e s i g n e d to
close in two s t a g e s u p o n pump failure to p r e v e n t e x c e s s i v e p r e s s u r e from
developing in t h e d i s t r i b u t i o n system as a r e s u l t of s u d d e n s h u t o f f .
The
first stage is a rapid, closure to approximately 75 percent of ~.ravel with
the second stage set at a lower rate to a c h i e v e complete c l o s u r e .
,..~z
6-308
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(Continued)
Chemical Treatment
The
use of biologically upgraded
makeup
process waste waters as cooling water
has the inherent problems associated with conventional systems.
Without extensive testing, it is impossible to predict the impact of the
upgraded waste water in the circulation system with respect to scaling,
corrosion, and biological fouling. However, approximations can be made on
the water quality and the tendency it has to scale, etc. The following
chemical addition systems are considered essential to provide...the flexibility
required to develop a successful cooling water treatment program and are
i n c l u d e d in the process cooling t o w e r design:
.:
D i s p e r s a n t chemical injection
pH control
Biocide injection
Corrosion inhibitor
)"
The makeup waste water is p r o c e s s e d through a s e c t i o n o f five activated
carbon filters and four sodium zeolite softPners followed b y ndcron cart r i d g e filtration and r e v e r s e o s m o s i s .
Acid and a n t i - s c a l e agents are
added to the makeup prior to temperature adjustment a n d feed to the RO
unit.
,..
."
The t r e a t e d makeup flows to t h e P r o c e s s Cooling Water Makeup Pond and is
•.
-
..
pumped to the two cooling t o w e r b a s i n s .
Waste Water Evaporator in Unit 54.
The reject stream flows to the
x
°"
6-309
i
1
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. . . . . .
4.
:i/i~
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4
6.3.8.2
(Continued)
Side S t r e a m T r e a t i n g
To control the buildup of suspended solids in the cooling water a flow of
813T gpm total from both"towers is diverted to eight gravity filters and
returned.
The solids from these filters are flushed into a clarifier and
combined w i t h t h e blowdown from b o t h t o w e r s .
T h e o v e r f l o w o f t h e clari-
t i e r i s s e n t t o t h e Waste Water E v a p o r a t o r in Unit 54 while t h e s l u d g e i s
d e w a t e r e d a n d s e n t offplot to d i s p o s a l a s landfill.
•
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6-310
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47-3
PCT To Side
Process Cooling
Side Strea
Filtration
Stream Filter
Tower Blowdown
to P C T
Stream Name
i ' '2 .:
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4,068,500
2,000
3,917,000
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(4)
(7834)
4,068,500
2,000
3,917,000
13.7
13.7
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TABLE 6 . 3 . 8 - 1
: :'./,~
b~ATERIAL BALANCE
~ 1.2 ~
COOLING WATER ~ UNIT 47
~.!
t?-4
47-5
4?-6
47-7
47-8
47-9
h TDS
Treated Waste
From UCT
uent to
Water to PCT
Blowdown
From
Makeup Water
po~:ation
Makeup
Treatment
Evaporator
Treatment
"~"
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4.?-10
From PCT
. ..
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To
To PCT
Evaporator
t0,000
1,185,500
992,000
415,000
884,500
2,291,500
295,000
(280)
(2371)
(1984)
(830)
(1T69)
(4583)
(590)
iO,600
1,185,500
992,000
415,000
884,500
2,291,500
295,000
63.7
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TABLE 6.3.8-2
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E Q U I P M E N T LIST
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PROCESS COOLING W A T E R - UNIT 47
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Number Requiped
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q
Item No.
Equip m.ent Name
47TK-OI01
47TK-0102
47TK-0103
Acid Day Tank
Acid Day Tank
Side Stream Sump
47TK-0104
Operating
Spare
1
0
1
0
1
0
Process C.W. Makeup Pond
1
0
47E-0101
R O Preheater
1
0
47P-0101 A/B/C
Cooling Water Pumps
47P-0102
47P-0103
4YP-01O4
47P-0106
47P-0106
47P-0107 A/B
Acid Pump
Side Stream Sump P u m p
Clarifier Sludge Pump
High TDS Clarifier P u m p
R O Feed Pump
P.C.W. Makeup Pump
2
1
1
1
1
1
1
1
1
1
1
1
1
1
47P-0108 A/B
47P-0109 A / B / C
Unit 48 Bao.kflush Pump
Cooling Water Pump
1
1
2
1
47FT-0101 A-H
Side Stream Gravity Filter
7
1
47FT-0102 A-E
4
1
47FT-0103 A - G
Filter Unit (Activated Charcoal)
Filter Unit (Cartridge)
6
1
47CT-0101
47CT-0102
Process Cooling Tower (Power)
Process Cooling Tower (Process)
1
0
1
0
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A/B
A/B
A/B
A/B
A/B
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TABLE 6 . 3 . 8 - 2 (Continued)
EQUIPMENT LIST
PROCESS COOLING WATER
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-
UNIT 47
Number Required
Operating
Spare
Item No.
Equipment Name
4TME-OlOl
47ME-0102
Chlorine Injection System
Inhibitor Injection System
1
1
O
0
4TME-0103
4TME-0104
4TME-0105 A-D
4TME-0106
47ME-0107
47ME-0108
47ME-0109
4TME-0110
4TME-0111
Dispersent Injection System
(Jlarifier Chemicals Injection System
Sodium Zeolite Softener
Hexa-Metaphosphate Package Unit
Sul~c
Acid Package Unit
Reverse Osmosis
Chlorine Injection System
Inhibitor Injection System
Dispersant Injection System
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
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4TME-0112
NaC1 Dillution Package
1
0
4?CA-0101
Side Stream Clarifier
1
0
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6,3.9.1
UTILITY COOLING WATER - UNIT 48
DESIGN BASIS
P u r p o s e of Unit
T h e Utility Cooling Water System p r o v i d e s
....
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heat rejection for the cooling
water u s e d in the O x y g e n Production, Air and Nitrogen S y s t e m s ,
Power Generation units u s i n g an i n d u c e d draft cooling tower.
and
Scope o f Unit
t
•
Unit 48 includes the distribution and collection grids n e c e s s a r y for cooling
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water circulation for the u n i t s mentioned above.
:
cooling tower and peripherals to reject the heat a b s o r b e d b y the water.
- '21 ~
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Also i n c l u d e d are the
iq
%
A cooling tower blowdown treatment s y s t e m
is i n c l u d e d in this unit to
u p g r a d e the water for use e l s e w h e r e in the plant.
The blowdown treatment consists of chlorination, lime s o f t e n i n g , filtration, and sodium
zeolite s o f t e n i n g . A s l u d g e t h i c k e n i n g and disposal system i s n e c e s s a r y to
p r o c e s s the waste from the s o f t e n e r s .
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General Design Criteria
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T h e Utility Cooling Water u n i t c o n s i s t s of a single train.
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The Utility Cooling Water p u m p s are d e s i g n e d with one s p a r e .
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The system d e s i g n is compatible with an ove:rall plant onstream factor of
332 d a y s / y e a r .
,
The Cooling Water pumps are motor driven.
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6-318
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