Oklahoma Department of Environmental Quality Air Quality Division
Exhibit
99.01
OKLAHOMA
DEPARTMENT OF ENVIRONMENTAL QUALITY
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AIR
QUALITY DIVISION
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IN
THE MATTER OF:
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|
Oklahoma
Gas & Electric Company,
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Seminole
Generating Station,
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CASE
NO. 10-024
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Sooner
Generating Station,
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Muskogee
Generating Station,
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The
parties to this Agreement, the Oklahoma Department of Environmental Quality
(“DEQ”) and the Oklahoma Gas & Electric Company (“OG&E”) hereby agree to
the entry of this Regional Haze Agreement (“Agreement”) in order to satisfy the
Best Available Retrofit Technology (“BART”) requirements associated with the
Regional Haze Rule, 40 C.F.R. Subpart P, and 40 C.F.R. Part 51, Appendix Y
(incorporated by reference at OAC 252:100-8-72).
FINDINGS
OF FACT
1. OG&E
is an Oklahoma corporation with its principal headquarters in Oklahoma City,
Oklahoma.
2. OG&E
owns and operates the following three (3) fossil-fuel fired steam electric
generating plants:
Seminole Generating
Station – This station is located northeast of the City of Konawa,
Seminole County, Oklahoma. The station includes three (3) nominal 567
megawatts (“MW”) steam electric generating units designated as Seminole
Units 1, 2, and 3.
Seminole Units 1 and 2 became operational in 1968, and Unit 3 became
operational in 1970. All three (3) units are Xxxxxxx & Xxxxxx
wall-fired boilers that fire natural gas as their primary
fuel. Each unit is a fossil-fuel fired
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boiler with heat inputs greater than 250-mmBtu/hr. Because the units fire natural gas, there are no sulfur dioxide (“SO2”) or particulate matter (“PM”) emission control systems. Seminole Unit 3 was designed with flue gas recirculation (“FGR”) for nitrogen oxide (“NOx”) control. Each unit has the potential to emit 250 tons per year (“TPY”) of NOx. The facility is currently permitted to operate under DEQ Air Quality Permit No. 2003-400-TVR, which was issued on May 8, 2006. |
Sooner Generating Station – This station is located in Red Rock, Noble County, Oklahoma. The station includes two (2) 570 MW steam electric generating units designated as Sooner Units 1 and 2. Each unit is a fossil-fuel fired boiler with heat inputs greater than 250-mmBtu/hr. Sooner Units 1 and 2 were in existence prior to August 7, 1977, but not in operation prior to August 7, 1962. Both units fire coal as their primary fuel, and both units have the potential to emit 250 TPY or more of NOx, SO2, and PM. The facility is currently permitted to operate under DEQ Air Quality Permit No. 2003-274-TVR, which was issued on February 11, 2006. |
Muskogee Generating Station – This station is located in Muskogee, Muskogee County, Oklahoma. The station includes two (2) 572 MW steam electric generating units designated as Muskogee Units 4 and 5. Each unit is a fossil-fuel fired boiler with heat inputs greater than 250-mmBtu/hr. Both Muskogee Units 4 and 5 were in existence prior to August 7, 1977, but not in operation prior to August 7, 1962. Both units fire coal as their primary fuel, and both units have the potential to emit 250 TPY or more of NOx, SO2, and PM. The facility is currently permitted to operate under DEQ Air Quality Permit No. 2005-271-TVR, which was issued on September 8, 2009. |
3. In
1977, the U.S. Congress enacted § 169 of the federal Clean Air Act, 42 U.S.C. §
7491, to protect the visibility of Class I Federal areas (areas determined to be
of great scenic importance) from impairment. A particular type of
visibility impairment is referred to as “Regional Haze.” See 40 C.F.R. § 51.301
(“Regional Haze means
visibility impairment that is caused by the emission of air pollutants from
numerous sources located over a wide geographic area. Such sources
include, but are not limited to, major and minor stationary sources, mobile
sources, and area sources.”). The federal Clean Air Act requires the
development of emission limitations for pollutants contributing to Regional Haze
which emanate from a variety of sources, including fossil-fuel fired electric
generating power plants having a total energy generating capacity in excess of
750
-2-
MW.
4. In
1980, the U.S. Environmental Protection Agency (“EPA”) promulgated regulations
addressing Regional Haze reasonably attributable to specific sources or small
groups of sources. See 40 Fed.Reg.
80,084. The regulations required States to determine which
sources impair visibility and require the installation of BART on certain of
those sources.
5. In
1999, EPA amended 40 C.F.R. Part 51, Subpart P, to further define the facilities
subject to the Regional Haze requirements. The regulations require
States to develop and implement long-term strategies for reducing air pollutants
that cause or contribute to visibility impairment in Class I Federal
areas.
6. On
July 6, 2005, the EPA published the final “Regional Haze Regulations and
Guidelines for Best Available Retrofit Technology Determinations” (the “Regional
Haze Rule”). See 70 Fed.Reg. 39104. The
federal Clean Air Act, 42 U.S.C. §§ 7401 et seq., and the Regional
Haze Rule, 40 C.F.R. §§ 51.300 – 51.309, require certain States, including
Oklahoma, to make reasonable progress toward the “prevention of any future, and
the remedying of any existing, impairment of visibility in mandatory class I
Federal areas.” 42 U.S.C. §§ 7491(a)(1), (b)(2) and 40 C.F.R. §
51.300. Moreover, the Regional Haze Rule requires the State of
Oklahoma to develop programs to “address regional haze in each mandatory Class I
Federal area located within the State and in each mandatory Class I Federal area
located outside the State which may be affected by emissions from within the
State.” 40 C.F.R. § 51.308(d); see also 40 C.F.R. §
51.300(b).
7. In
order to meet the requirements of the Regional Haze Rule, States must submit
State Implementation Plans (“SIP”) implementing the requirements of the Regional
Haze Rule to EPA for approval. See id. The States
were required to submit their SIPs prior to December 17,
-3-
2007. See 40 C.F.R. §
51.308(b). Each Regional Haze SIP must contain “emission limitations
representing BART and schedules for compliance with BART for each BART-eligible
source that may reasonably be anticipated to cause or contribute to any
impairment of visibility in any mandatory Class I Federal area . . .
..” See 40
C.F.R. § 51.308(e).
8. BART-eligible
sources include those sources that: (1) have the potential to emit 250 tons or
more of a visibility-impairing air pollutant; (2) were in existence on August 7,
1977 but not in operation prior to August 7, 1962; and (3) whose operations fall
within one or more of the specifically listed source categories in 40 CFR 51.301
(including fossil-fuel fired steam electric plants of more than 250 mmBtu/hr
heat input and fossil-fuel boilers of more than 250 mmBtu/hr heat
input). See OAC
252:100-8-71, 40 C.F.R. Part 51, Appendix Y(I)(C)(1), and 42 U.S.C. §
7491(b)(2)(A).
9. “Air
pollutants emitted by sources in Oklahoma which may reasonably be anticipated to
cause or contribute to visibility impairment in any mandatory Class I federal
area are NOx, SO2, PM-10, and PM-2.5.” OAC
252:100-8-73(b).
10. As
stated in Paragraph 2 above, Seminole Units 1, 2 and 3, Sooner Units 1 and 2,
and Muskogee Units 4 and 5, are all: fossil-fuel fired boilers with heat inputs
greater than 250 mmBtu/hr; units that were in existence prior to August 7, 1977,
but not in operation prior to August 7, 1962; and, based on a review of existing
emissions data, units that have the potential to emit more than 250 tons per
year of a visibility impairing pollutant. Consequently, all seven (7)
units meet the definition of a BART-eligible source.
11. XXXX
is required for any BART-eligible source that emits any air pollutant which may
reasonably be anticipated to cause or contribute to any impairment of visibility
in a Class I Area. See OAC 252:100-8-73(a), 42
U.S.C. § 7491(b)(2)(a), and 40 C.F.R. §
51.308(e).
-4-
EPA has
determined that an individual source will be considered to “contribute to
visibility impairment” if emissions from the source result in a change in
visibility, measured as a change in deciviews (Δ-dv), that is
greater than or equal to 0.5 dv in a Class I area. See 40 C.F.R. Part 51,
Appendix Y(III)(A)(1); see
also 70 Fed.Reg. 39,120; and OAC
252:100-8-73(a). Visibility impact modeling indicates that the
maximum predicted visibility impacts from all seven (7) of the OG&E units
listed in Paragraph 2 above exceed the 0.5 Δ-dv
threshold at the Wichita Mountains Class I Area. See State of Oklahoma
Regional Haze SIP, p. 72, table VI-4. Therefore, all seven (7) units
are subject to the BART determination requirements.
12. Since
the Seminole Generating Station, the Sooner Generating Station, and the Muskogee
Generating Station each have a total generating capacity in excess of 750 MW,
the Appendix Y guidelines were used to prepare BART determinations for each
station. Based
on an evaluation of potentially feasible retrofit control technologies,
including an assessment of the costs and visibility improvements associated
therewith, the following control technologies and emission limits as described
in the BART Determinations for each of the three (3) stations (attached as
Exhibits A, B, and C; collectively “BART Determinations”) have been determined
to be BART and shall be implemented within 5 years of EPA’s approval of
Oklahoma’s Regional Haze SIP:
Seminole Generating
Station -
Control
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Unit
1
|
Unit
2
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Unit
3
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NOX
Control
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Combustion controls
including:
Low-NOX
Burners, Overfire
Air,
and Flue Gas
Recirculation
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Combustion controls
including:
Low-NOX
Burners, Overfire
Air,
and Flue Gas
Recirculation
|
Combustion controls
including:
Low-NOX
Burners, Overfire
Air,
and Flue Gas
Recirculation
|
NOx
Emission Rate
(lb/mmBtu)
|
0.203
lb/mmBtu
(30-day
average)
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0.212
lb/mmBtu
(30-day
average)
|
0.164
lb/mmBtu
(30-day
average)
|
-5-
Sooner Generating
Station -
Control
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Unit
1
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Unit
2
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NOX
Control
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LNB
with OFA
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New
LNB with OFA
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Emission
Rate (lb/mmBtu)
|
0.15
lb/mmBtu
(30-day
rolling average)
|
0.15
lb/mmBtu
(30-day
rolling average)
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Emission
Rate lb/hr
|
767
lb/hr
(30-day
rolling average)
|
767
lb/hr
(30-day
rolling average)
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Emission
Rate TPY
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3,361
TPY
(12-month
rolling)
|
3,361
TPY
(12-month
rolling)
|
SO2
Control
|
Low
Sulfur Coal
|
Low
Sulfur Coal
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Hourly
Emission Rate
(lb/mmBtu)
|
0.65
lb/mmBtu
(30-day
rolling average)
|
0.65
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate (lb/hr)
|
3,325
lb/hr
(30-day
rolling average)
|
3,325
lb/hr
(30-day
rolling average)
|
Annual
Emission Rate
(lb/mmBtu)
|
0.55
lb/mmBtu
(12-month
rolling average)
|
0.55
lb/mmBtu
(12-month
rolling average)
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Combined
Annual Emission
Rate
(TPY)
|
19,736
TPY
|
|
PM10
Control
|
Existing
Electrostatic
Precipitator
|
Existing
Electrostatic
Precipitator
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Emission
Rate (lb/mmBtu)
|
0.10
lb/mmBtu
(3-hour
rolling average)
|
0.10
lb/mmBtu
(3-hour
rolling average)
|
Emission
Rate lb/hr
|
512
lb/hr
(3-hour
rolling average)
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512
lb/hr
(3-hour
rolling average)
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Emission
Rate TPY
|
2,241
TPY
(12-month
rolling average)
|
2,241 TPY
(12-month
rolling average)
|
Muskogee Generating Station
Units 4 and 5 -
Control
|
Unit
4
|
Unit
5
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NOX
Control
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LNB
with OFA
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New
LNB with OFA
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Emission
Rate (lb/mmBtu)
|
0.15
lb/mmBtu
(30-day
rolling average)
|
0.15
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
822
lb/hr
(30-day
rolling average)
|
822
lb/hr
(30-day
rolling average)
|
Emission
Rate TPY
|
3,600
TPY
(12-month
rolling)
|
3,600
TPY
(12-month
rolling)
|
SO2
Control
|
Low Sulfur
Coal
|
Low
Sulfur Coal
|
Hourly
Emission Rate
(lb/mmBtu)
|
0.65
lb/mmBtu
(30-day
rolling average)
|
0.65
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate (lb/hr)
|
3,562
lb/hr
(30-day
rolling average)
|
3,562
lb/hr
(30-day
rolling average)
|
-6-
Annual
Emission Rate
(lb/mmBtu)
|
0.55
lb/mmBtu
(12-month
rolling average)
|
0.55
lb/mmBtu
(12-month
rolling average)
|
Combined
Annual Emission
Rate
(TPY)
|
18,096
TPY
|
|
PM10
Control
|
Electrostatic
Precipitator
|
Electrostatic
Precipitator
|
Emission
Rate (lb/mmBtu)
|
0.10
lb/mmBtu
(3-hour
rolling average)
|
0.10
lb/mmBtu
(3-hour
rolling average)
|
Emission
Rate lb/hr
|
548
lb/hr
(3-hour
rolling average)
|
548
lb/hr
(3-hour
rolling average)
|
Emission
Rate TPY
|
2,400
TPY
(12-month
rolling average)
|
2,400
TPY
(12-month
rolling average)
|
13. In
the event that: (i) EPA disapproves the DEQ determination described in the BART
Determinations that Dry-Flue Gas Desulfurization with Spray Dryer Absorber (“Dry
FGD with SDA”) is not cost-effective for SO2 control and (ii) all administrative
and judicial appeals of EPA’s disapproval have been exhausted, then the
low-sulfur coal requirement in Paragraph 12 and the BART Determinations for SO2
(and the related electrostatic precipitator requirement for PM) shall be
replaced with a requirement that Sooner Units 1 and 2 and Muskogee Units 4 and 5
shall, at the election of the owner and operator of the Unit, either: (i)
install Dry FGD with SDA (and install fabric filters for PM control) or meet the
corresponding SO2 and PM emission limits listed below (and further described in
the Section on Contingent BART Determinations, see § IV(F) of Exhibits B and
C, collectively “Contingent BART Determinations”) by January 1, 2018; or (ii)
comply with the approved alternative described in Paragraph 14 prior to December
31, 2026:
Sooner Generating
Station -
Control
|
Unit
1
|
Unit
2
|
SO2
Control
|
Dry
FGD with SDA
|
Dry
FGD with SDA
|
Emission
Rate (lb/mmBtu)
|
0.1
lb/mmBtu
(30-day
rolling average)
|
0.1
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
512
lb/hr
(30-day
rolling average)
|
512
lb/hr
(30-day
rolling average)
|
Emission
Rate TPY
|
2,241
TPY
(12-month
rolling average)
|
2,241
TPY
(12-month
rolling average)
|
-7-
PM10
Control
|
Fabric
Filter
|
Fabric
Filter
|
Emission
Rate (lb/mmBtu)
|
0.015
lb/mmBtu
(3-hour
rolling average)
|
0.015
lb/mmBtu
(30-hour
rolling average)
|
Emission
Rate lb/hr
|
77
lb/hr
(30-hour
rolling average)
|
77
lb/hr
(30-hour
rolling average)
|
Emission
Rate TPY
|
336
TPY
(12-month
rolling average)
|
336
TPY
(12-month
rolling average)
|
Muskogee Generating Station
Units 4 and 5 -
Control
|
Unit
4
|
Unit
5
|
SO2
Control
|
Dry
FGD with SDA
|
Dry
FGD with SDA
|
Emission
Rate (lb/mmBtu)
|
0.1
lb/mmBtu
(30-day
rolling average)
|
0.1
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
548
lb/hr
(30-day
rolling average)
|
548
lb/hr
(30-day
rolling average)
|
Emission
Rate TPY
|
2,400
TPY
(12-month
rolling average)
|
2,400
TPY
(12-month
rolling average)
|
PM10
Control
|
Fabric
Filter
|
Fabric
Filter
|
Emission
Rate (lb/mmBtu)
|
0.015
lb/mmBtu
(3-hour
rolling average)
|
0.015
lb/mmBtu
(30-hour
rolling average)
|
Emission
Rate lb/hr
|
82
lb/hr
(30-hour
rolling average)
|
82
lb/hr
(30-hour
rolling average)
|
Emission
Rate TPY
|
360
TPY
(12-month
rolling average)
|
360
TPY
(12-month
rolling average)
|
14. In
lieu of installing and operating BART for SO2 and PM control at the four (4)
coal fired units (i.e., Sooner Units 1 and 2 and Muskogee Units 4 and 5),
OG&E may elect to implement the fuel switching alternative approved pursuant
to 40 C.F.R. § 51.308(e)(2) and as part of the long-term strategy in fulfillment
of 40 C.F.R. § 51.308(d)(3). See Sections on Greater
Reasonable Progress Alternative Determination, § IV(G) of Exhibits B and C
(collectively “Alternative Determination”). As detailed in the
Alternative Determination, implementation of this alternative requires OG&E
to achieve by December 31, 2026 a combined annual SO2 emission limit that is
equivalent to: (i) the SO2 emission limits provided in Paragraph 13 for
installing and operating Dry FGD with SDA on two of these coal fired units; and
(ii) being at or below the SO2 emissions that
-8-
would
result from switching the other two of the coal fired units to natural
gas. By adopting the emission limits described in the previous
sentence, DEQ and OG&E expect the cumulative SO2 emissions from Sooner Units
1 and 2 and Muskogee Units 4 and 5 to be approximately fifty-seven percent (57%)
less than would be achieved through the installation and operation of Dry FGD
with SDA at all four (4) units. See Alternative
Determination. If OG&E has elected to comply with the
emission limits provided in this Paragraph 14 and if, prior to January 1, 2022,
any of these units is required by any environmental law other than the Regional
Haze Rule to install flue gas desulfurization equipment or achieve an SO2
emissions rate lower than 0.10 lb/mmBtu, and if OG&E proceeds to take all
necessary steps to comply with such legal requirement, the enforceable emission
limits adopted pursuant to this Paragraph 14 in the operating permits for the
affected coal units shall be adjusted, with the reasonable consent of DEQ and
OG&E, as appropriate to reflect the installation of that equipment or the
emission rates specified under such legal requirement.
15. OG&E
and DEQ agree that it is beneficial to resolve this matter promptly and by
agreement.
16. OG&E
and DEQ waive the filing of a petition or other pleading, and OG&E waives
the right to a hearing.
CONCLUSIONS
OF LAW
17. DEQ
has regulatory jurisdiction and authority in this matter, and OG&E is
subject to the jurisdiction and authority of DEQ under Oklahoma law, 27A Okla.
Stat. (“O.S.”) §§ 2-5-101 to -118, and the rules promulgated thereunder at
Oklahoma Administrative Code (“OAC”), Title 252, Chapter 100, Air Pollution
Control. This Order is executed under the authority of, and in
conformity with, 27A O.S. § 2-5-110(G).
-9-
18. OG&E
and DEQ are authorized by 75 O.S. § 309(E) and 27A O.S. § 2-3-506(B) to resolve
this matter by agreement.
19. “Air
pollutants emitted by sources in Oklahoma which may reasonably be anticipated to
cause or contribute to visibility impairment in any mandatory Class I federal
area are NOx, SO2, PM-10, and PM-2.5.” OAC
252:100-8-73(b).
20. DEQ
administrative rules provide that BART applicability “shall be determined using
the criteria in Section III of Appendix of 40 CFR 51 in effect on July 6,
2005.” OAC 252:100-8-73(a); see also OAC 252:100-8-72
(“Appendix Y, Guidelines for BART Determinations Under the Regional Haze Rule,
of 40 CFR 51 is hereby incorporated by reference as it exists July 6,
2005.”). Similarly, the corresponding Federal regulations provide,
“[t]he determination of BART for fossil-fuel fired power plants having a total
generating capacity greater than 750 megawatts [MW] must be made pursuant to the
guidelines in appendix Y of this part (Guidelines for BART Determinations Under
the Regional Haze Rule).” See 40 C.F.R. §
51.308(e)(1)(ii)(B); see also 42 U.S.C. §
7491(b)(2)(B). As described in Paragraph 2 of the Statement of Facts,
each of the Seminole Generating Station, Sooner Generating Station, and Muskogee
Generating Station, has a total generating capacity greater than 750 MW and,
therefore, the BART determinations for each of these stations must be made
pursuant to the “Guidelines for BART Determinations Under the Regional Haze
Rule.” Nothing in this Agreement shall be construed as applying
emission limits to any units that are not subject to BART under the Regional
Haze Rule, including Muskogee Unit 6.
21. State
and Federal rules define BART-eligible sources to include those sources that:
(1) have the potential to emit 250 tons or more of a visibility-impairing air
pollutant; (2) were in existence on August 7, 1977 but not in operation prior to
August 7, 1962; and (3) whose
-10-
operations
fall within one or more of the specifically listed source categories in 40 CFR
51.301 (including fossil-fuel fired steam electric plants of more than 250
mmBtu/hr heat input and fossil-fuel boilers of more than 250 mmBtu/hr heat
input). See OAC
252:100-8-71, 40 C.F.R. Part 51, Appendix Y(I)(C)(1), and 42 U.S.C. §
7491(b)(2)(A). As stated in Paragraphs 2 and 10 of the Statement of
Facts, Seminole Units 1, 2, and 3, Sooner
Units 1 and 2, and Muskogee Units 4 and 5 meet all three (3) criteria listed
above and, therefore, meet the definition of a BART eligible
source.
22. OAC
252:100-8-73(a) provides in part:
Each
BART-eligible source that emits any air pollutant which may reasonably be
anticipated to cause or contribute to visibility impairment in any mandatory
Class I Federal area is subject to BART. This shall be determined
using the criteria in Section III of Appendix Y of 40 CFR 51 in effect on July
6, 2005. Thresholds for visibility impairment are set forth in OAC
252:100-8-73(a)(1) and (2).
|
(1)
|
A
source that is responsible for an impact of 1.0 deciview or more is
considered to cause visibility
impairment.
|
|
(2)
|
A
source that causes an impact greater than 0.5 deciviews contributes to
visibility impairment.
|
As stated
in Paragraph 11 of the Statement of Facts, Seminole Units 1, 2, and 3, Sooner
Units 1 and 2, and Muskogee Units 4 and 5, each contribute greater than 0.5
deciviews to visibility impairment at the Wichita Mountains Class I Area and,
therefore, are considered subject to BART.
23. OAC
252:100-8-75(e) provides that “[t]he owner or operator of each BART-eligible
source subject to BART shall install and operate BART no later than five years
after EPA approves the Oklahoma Regional Haze SIP.” Similarly, the
Federal rule states that each Regional Haze SIP must contain “[a] requirement
that each source subject to BART be required to install and operate BART as
expeditiously as practicable, but in no event later than 5
years
-11-
after
approval of the implementation plan revision.” 40 C.F.R. §
51.308(e)(1)(iv).
24. In
lieu of installing and operating BART, the Federal rules provide that States may
allow BART subject sources to implement an alternative demonstrated to “achieve
greater reasonable progress toward natural visibility
conditions.” See 40 C.F.R. §
51.308(e). Any approved Greater Reasonable Progress Alternative shall
comply with the requirements of 40 C.F.R. § 51.308(e)(2).
25. In
addition to the BART requirements, the Federal rules give States authority to
adopt "emissions limitations, compliance schedules, and other measures as
necessary to achieve the reasonable progress goals" as part of the long-term
strategy that addresses regional haze visibility impairment. See 40 C.F.R. §
51.308(d)(3).
AGREEMENT
26.
Based on the above paragraphs, OG&E and the DEQ agree, and it is ordered by
the Executive Director as follows:
|
A.
|
OG&E,
at its election, shall either: (i) install and operate BART and achieve
the related emission limits at the Sooner Generating Station, the Seminole
Generating Station, and the Muskogee Generating Station as set forth in
Paragraph 12 and the corresponding BART Determinations, within 5 years of
EPA’s approval of Oklahoma’s Regional Haze SIP; or (ii) implement the
approved Greater Reasonable Progress Alternative (i.e., natural gas fuel
switching alternative) described in Paragraph 14 and the Alternative
Determinations by December 31,
2026.
|
|
B.
|
In
the event that EPA disapproves the DEQ determination that Dry FGD with SDA
is not cost-effective for SO2 control at Sooner Units 1 and 2 and Muskogee
Units 4 and 5 and such disapproval is upheld after all judicial and/or
administrative appeals have been exhausted, the SO2 related portions of
the BART Determinations and the related SO2 and PM10 emission limits set
forth in Paragraph 12 shall not have any further force or effect, and
OG&E, at its election, shall either: (i) achieve the SO2 and PM10
emission limits at the Sooner Units 1 and 2 and the Muskogee Units 4 and 5
on or before January 1, 2018 as set forth in Paragraph 13 and the
corresponding Contingent BART Determinations; or (ii) implement the
approved Greater Reasonable Progress Alternative (i.e., natural gas fuel
switching alternative) on or before December 31, 2026 as set forth in
Paragraph 14 and the
Alternative
|
-12-
Determinations.
27. Any
control equipment required to be installed as BART shall be properly operated
and maintained. See 40 C.F.R. §
51.308(e)(v).
28. Nothing
in this Agreement shall constitute or be construed as a release for any claim or
cause of action related to any NSR or New Source Performance Standard (“NSPS”)
liability under the Clean Air Act or the rules promulgated
thereunder.
29. The
emission limits required by this Agreement shall be incorporated into any
otherwise required construction or operating permit issued to OG&E for the
affected units.
30. This
Agreement shall be incorporated into the Regional Haze State Implementation Plan
submitted to EPA for approval by the State of Oklahoma.
GENERAL
PROVISIONS
31. OG&E
agrees to perform the requirements of this Agreement within the time frames
specified unless performance is prevented or delayed by events which are a
“force majeure.” For purposes of this Agreement, a force majeure
event is defined as any event arising from causes beyond the reasonable control
of OG&E or OG&E’s contractors, subcontractors or laboratories which
delays or prevents the performance of any obligation under this
Agreement. Examples are vandalism; fire; flood; labor disputes or
strikes; weather conditions which prevent or seriously impair construction
activities; civil disorder or unrest; and “acts of God.” Force
majeure events do not
include increased costs of performance of the tasks agreed to in this Agreement,
or changed economic circumstances. OG&E must notify DEQ in
writing within thirty (30) days after OG&E knows or should have known of a
force majeure event that is expected to cause a delay in achieving compliance
with any requirement of this Agreement. Failure to submit
notification within thirty (30) days waives the right to claim force
majeure.
-13-
32. No
informal advice, guidance, suggestions or comments by employees of DEQ regarding
reports, plans, specifications, schedules, and other writings affect OG&E’s
obligation to obtain written approval by DEQ, when required by this
Agreement.
33. Unless
otherwise specified, any report, notice or other communication required under
this Agreement must be in writing and must be sent to:
For
the Department of Environmental Quality:
Xxxxx
Xxxxxxx, Director
Air
Quality Division
P.O. Box
1677
Oklahoma
City, OK 73101-1677
With
copies to:
Xxxxxx X.
Xxxxxxxxxx
Environmental
Attorney Supervisor
Oklahoma
Department of Environmental Quality
Office of
General Counsel
P.O. Box
1677
Oklahoma
City, OK 73101-1677
Xxx
Xxxxxx, Environmental Engineering Manager
Air
Quality Division
Oklahoma
Department of Environmental Quality
P.O. Box
1677
Oklahoma
City, OK 73101-1677
For
OG&E:
Ford
Benham
Supervisor,
Air Quality
Oklahoma
Gas & Electric Company
321 X.
Xxxxxx
Oklahoma
City, OK 73102
-14-
With
copies to:
Xxxxxx
Xxxxx
Senior
Attorney
Oklahoma
Gas & Electric Company
321 X.
Xxxxxx
Oklahoma
City, OK 73102
34. This
Agreement is enforceable as a final order of the Executive Director of
DEQ. DEQ retains jurisdiction of this matter for the purposes of
interpreting, implementing and enforcing the terms and conditions of this
Agreement and for the purpose of resolving disputes.
35. Nothing
in this Agreement limits DEQ’s right to take enforcement action for violations
discovered or occurring after the effective date of this
Agreement.
36. Nothing
in this Agreement excuses OG&E from its obligation to comply with all
applicable federal, state and local statutes, rules and
ordinances. OG&E and DEQ agree that the provisions of this
Agreement are considered severable, and if a court of competent jurisdiction
finds any provisions to be unenforceable because they are inconsistent with
state or federal law, the remaining provisions will remain in full
effect.
37. To
ensure continuous and uninterrupted responsibility for the activities required
by this Agreement, OG&E agrees to provide a copy of the Agreement to any
purchaser of an affected unit prior to sale. OG&E agrees to
notify any such purchaser that the obligations under this Agreement are binding
on the purchaser and shall notify DEQ of the sale within ten (10)
days thereof and provide DEQ with the name of the purchaser.
38. The
provisions of this Agreement apply to and bind OG&E and DEQ and their
officers, directors, employees, agents, successors and assigns. No
change in the ownership or corporate status of OG&E will affect OG&E’s
responsibilities under this Agreement.
39. This
Agreement is for the purpose of settlement. Neither the fact that
OG&E and
-15-
DEQ have
agreed to this Agreement, nor the Findings of Fact and Conclusions of Law in it,
shall be used for any purpose in any proceeding except the enforcement by
OG&E and DEQ of this Agreement and, if applicable, a future determination by
DEQ of eligibility for licensing or permitting. As to others who are
not parties to this Agreement, nothing contained in this Agreement is an
admission by OG&E of the Findings of Fact or Conclusions of Law, and this
Agreement is not an admission by OG&E of liability for conditions at or near
the facility and is not a waiver of any right, cause of action or defense
OG&E otherwise has.
40. OG&E
and DEQ agree that the venue of any action in district court for the purposes of
interpreting, implementing and enforcing this Agreement will be Oklahoma County,
Oklahoma.
41. The
requirements of this Agreement will be considered satisfied and this Agreement
terminated when OG&E receives written notice from DEQ that OG&E has
demonstrated that all the terms of the Agreement have been completed to the
satisfaction of DEQ, and that any assessed penalty has been
paid.
42. OG&E
and DEQ may amend this Agreement by mutual consent. Such amendments must be in
writing and the effective date of the amendments will be the date on which they
are filed by DEQ.
43. The
individuals signing this Agreement certify that they are authorized to sign it
and to legally bind the parties they represent.
-16-
44. This
Agreement becomes effective on the date of the later of the two signatures
below.
Date:
|
1/18/10
|
Date:
|
2/17/10
|
FOR
THE OKLAHOMA GAS & ELECTRIC
|
FOR
THE OKLAHOMA DEPARTMENT
|
|||
COMPANY:
|
OF
ENVIRONMENTAL QUALITY:
|
|||
/s/
XXXXX X. XXXXXXX
|
/s/
XXXXXX X. XXXXXXXX
|
|||
XXXXX
X. XXXXXXX
|
XXXXXX
X. XXXXXXXX
|
|||
CHIEF
EXECUTIVE OFFICER
|
EXECUTIVE
DIRECTOR
|
-17-
EXHIBIT
A
Oklahoma
Department of Environmental Quality
Air Quality
Division
BART
Application Analysis
|
September
28, 2009
|
|
COMPANY:
|
Oklahoma
Gas and Electric
|
|
FACILITY:
|
Seminole
Generating Station
|
|
FACILITY
LOCATION:
|
Konawa,
Seminole County, Oklahoma
|
|
TYPE
OF OPERATION:
|
(3)
567 MW Steam Electric Generating Units
|
|
REVIEWER:
|
Xxxxxxx
Xxxxxxx, Senior Engineering Manager
|
|
Xxx
Xxxxxx, Engineering Manager
|
I.
PURPOSE OF APPLICATION
On July
6, 2005, the U.S. Environmental Protection Agency (EPA) published the final
"Regional Haze Regulations and Guidelines for Best Available Retrofit Technology
Determinations" (the "Regional Haze Rule" 70 FR 39104). The Regional Haze Rule
requires certain States, including Oklahoma, to develop programs to assure
reasonable progress toward meeting the national goal of preventing any future,
and remedying any existing, impairment of visibility in Class I Areas. The
Regional Haze Rule requires states
to submit a plan to implement the regional haze requirements (the Regional Haze
SIP). The Regional Haze SIP must provide for a Best Available Retrofit
Technology (BART) analysis of any existing stationary facility that might cause
or contribute to impairment of visibility in a Class I Area.
II.
XXXX ELIGIBILITY DETERMINATION
BART-eligible sources include those
sources that:
(1)
have the potential to emit 250 tons or more of a visibility-impairing air
pollutant;
(2)
were in existence on August 7, 1977 but not in operation prior to August 7,
1962; and
(3) whose operations fall within one or more of the specifically
listed source categories in 40 CFR 51.301 (including fossil-fuel fired steam
electric plants of more than 250 mmBtu/hr heat input and fossil-fuel boilers of
more than 250 mmBtu/hr heat input).
Seminole
Units 1, 2 and 3 are fossil-fuel fired boilers with heat inputs greater than 250
mmBtu/hr. All three units were in existence prior to August 7, 1977 but not in
operation prior to August 7, 1962. Based on a review of existing emissions data,
all three units have the potential to emit more than 250 tons per year of NOx, a
visibility impairing pollutant. Therefore, Seminole Units 1, 2 and 3 meet the
definition of a BART-eligible source.
XXXX
is required for any BART-eligible source that emits any air pollutant which may
reasonably be anticipated to cause or contribute to any impairment of visibility
in a Class I Area.
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
DEQ
has determined that an individual source will be considered to "contribute to
visibility impairment" if emissions from the source result in a change in
visibility, measured as a change in deciviews (∆-dv), that is greater than or
equal to 0.5 dv in a Class I area. Visibility impact modeling conducted by
OG&E determined that the maximum predicted visibility impacts from Seminole
Units 1, 2 and 3 exceeded the 0.5 ∆-dv threshold at the Wichita Mountains Class
I Area. Therefore, Seminole Units 1, 2 and 3 were determined to be BART
applicable sources, subject to the BART determination requirements.
III.
DESCRIPTION OF BART SOURCES
Baseline
emissions from Seminole Units 1, 2 and 3 were developed based on an evaluation
of actual emissions data submitted by the facility pursuant to the federal Acid
Rain Program. In accordance with EPA guidelines in 40 CFR 51 Appendix Y Part
III, emission estimates used in the modeling analysis to determine visibility
impairment impacts should reflect steady-state operating conditions during
periods of high capacity utilization. Therefore, baseline emissions (lb/hr)
represent the highest 24-hour block emissions reported during the baseline
period. Baseline emission rates (lb/mmBtu) were calculated by dividing the
maximum hourly mass emission rates for each boiler by the boiler's full load
heat input.
Table
1: Seminole Generating Station – Plant Operating Parameters for
BART Evaluation
|
||||||
Parameter
|
Seminole
Unit 1
|
Seminole
Unit 2
|
Seminole
Unit 3
|
|||
Plant
Configuration
|
Natural
Gas-Fired
Boiler
|
Natural
Gas-Fired
Boiler
|
Natural
Gas-Fired
Boiler
|
|||
Firing
Configuration
|
Wall-fired
|
Wall-fired
|
Wall-fired
|
|||
Gross
Output (nominal)
|
567
MW
|
567
MW
|
567
MW
|
|||
Maximum
Input to
Boiler
|
5,480
mmBtu/hr
|
5,480
mmBtu/hr
|
5,496
mmBtu/hr
|
|||
Primary
Fuel
|
Natural
gas
|
Natural
gas
|
Natural
gas
|
|||
Existing
NOx Controls
|
None
|
None
|
Flue
gas recirculation
|
|||
Existing
PM10
Controls
|
NA
|
NA
|
NA
|
|||
Existing
SO2
Controls
|
NA
|
NA
|
NA
|
|||
Baseline
Emissions
Pollutant
|
Baseline
Actual
Emissions
|
Baseline
Actual
Emissions
|
Baseline
Actual
Emissions
|
|||
lb/hr
|
lb/mmBtu
|
lb/hr
|
lb/mmBtu
|
lb/hr
|
lb/mmBtu
|
|
NOx
|
1,859
|
0.339
|
1,940
|
0.354
|
1,204
|
0.219
|
2
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
IV.
BEST AVAILABLE RETROFIT TECHNOLOGY (BART)
Guidelines
for making BART determinations are included in Appendix Y of 40 CFR Part 51
(Guidelines for BART Determinations under the Regional Haze Rule). States are
required to use the Appendix Y guidelines to make BART determinations for
fossil-fuel-fired generating plants having a total generating capacity in excess
of 750 MW. The BART determination process described in Appendix Y includes the
following steps:
Step
l. Identify All Available
Retrofit Control Technologies.
Step
2. Eliminate Technically Infeasible Options.
Step
3. Evaluate Control Effectiveness of Remaining Control
Technologies.
Step
4. Evaluate Impacts and Document the Results.
Step
5. Evaluate Visibility Impacts.
Because
the units fire natural gas, emissions of sulfur dioxide (SO2) and
particulate matter (PM) are minimal. There are no SO2 or PM
post-combustion control technologies with a practical application to natural
gas-fired boilers. BART is good combustion practices. A full BART analysis was
conducted for NOx.
Table
2: Proposed BART Controls and Limits
|
||
Unit
|
NOx
BART Emission Limit
|
BART
Technology
|
Seminole
Unit 1
|
0.203
lb/mmBtu (30-day average)
|
Combustion
controls including
LNB/OFA
and FGR
|
Seminole
Unit 2
|
0.212
lb/mmBtu (30-day average)
|
Combustion
controls including
LNB/OFA
and FGR
|
Seminole
Unit 3
|
0.164
lb/mmBtu (30-day average)
|
Combustion
controls including
LNB/OFA
and FGR
|
A.
NOx
IDENTIFY
AVAILABLE RETROFIT CONTROL TECHNOLOGIES
Potentially
available control options were identified based on a comprehensive review of
available information. NOx control technologies with potential application to
Seminole Units 1, 2 and 3 are listed in Table 3.
Table
3: List of Potential Control Options
|
||
Control
Technology
|
||
Combustion
Controls
|
||
Low
NOx Burners and Overfire Air (LNB/OFA)
|
||
Flue
Gas Recirculation (FGR)
|
||
Post
Combustion Controls
|
||
Selective
Noncatalytic Reduction (SNCR)
|
||
Selective
Catalytic Reduction (SCR)
|
||
Innovative
Control Technologies
|
||
Rotating
Overfire Air (ROFA)
|
||
ROFA
+ SNCR (Rotamix)
|
||
Xxxxxxx
Process
|
||
Wet
NOx Scrubbing
|
3
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
In
support of the Regional Haze Rule, EPA also prepared a cost-effectiveness
analysis for retrofit control technologies on oil- and gas-fired units. EPA's
analysis concluded that, although a number of oil- and gas-fired units could
make significant cost-effective reductions in NOx emissions using currently
available combustion control technologies, for a number of units the use of
combustion controls did not appear to be cost effective. As a result, EPA
determined that it would be inappropriate to establish a general presumption
regarding likely BART limits for oil- and natural gas fired units.
ELIMINATE
TECHNICALLY INFEASIBLE OPTIONS (NOx)
Combustion
Controls:
Low
NOx burners (LNB)/ Over Fire Air (OFA)
Low
NOx burners (LNB) limit NOx formation by controlling both the stoichiometric and
temperature profiles of the combustion flame in each burner flame envelope. Over
Fire Air (OFA) allows for staged combustion. Staging combustion reduces NOx
formation with a cooler flame in the initial stage and less oxygen in the second
stage.
LNB/OFA
emission control systems have been installed as retrofit control technologies on
existing natural gas-fired boilers. Boilers of the size and age of the Seminole
Units would be expected to achieve an average emission reduction in the range of
25% to 40% from baseline depending on the baseline emission rate and boiler
operating conditions. Seminole units 1, 2, and 3 do not operate as base load
units. The units have historically operated as "peaking units" responding to
increased demand for electricity. While technically feasible, LNB/OFA may not be
as effective under all boiler operating conditions, especially during load
changes and at low and high operating loads. Based on information available from
burner control vendors and engineering judgment, it is expected that
LNB/OFA on the
wall-fired boilers can be designed to achieve an average efficiency of 25% from
baseline emissions under all normal operating conditions.
Flue
Gas Recirculation
Flue
gas recirculation (FGR) controls NOx by recycling a portion of the flue gas back
into the primary combustion zone. The recycled air lowers NOx emissions by two
mechanisms: (1) the recycled gas, consisting of products which are inert during
combustion, lowers the combustion temperatures; and (2) the recycled gas will
reduce the oxygen content in the primary flame zone. The amount of recirculation
is based on flame stability. Seminole Unit 3 is currently designed with FGR
control.
FGR
may be applied in one of two techniques. Both designs are technically feasible
retrofit options for gas-boilers. Either system would be expected to achieve an
additional 15% reduction above LNB/OFA or approximately 40% overall reduction
from baseline.
Post
Combustion Controls:
Selective
Non-Catalytic Reduction
Selective
non-catalytic reduction (SNCR) involves the direct injection of ammonia or urea
at high flue gas temperatures. The ammonia or urea reacts with NOx in the flue
gas to produce N2 and water.
At temperatures below the desired operating range, the NOx reduction reactions
diminish and NH3 emissions
increase. Above the desired temperature range, NH3 is
oxidized to
4
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
NOx
resulting in low NOx reduction efficiencies. Mixing of the reactant and flue gas
within the reaction zone is also an important factor in SNCR
performance. In large boilers, the physical distance over which the
reagent must be dispersed increases, and the surface area/volume ratio of the
convective pass decreases. Both of these factors make it difficult to
achieve good mixing of reagent and flue gas, reducing overall efficiency.
Performance is further influenced by residence time, reagent-to-NOx ratio, and
fuel sulfur content.
The
size of the Seminole Units would represent several design problems making it
difficult to ensure that the reagent would be injected at the optimum flue gas
temperature, and that there would be adequate mixing and residence time. The
physical size of the Seminole boilers makes it technically infeasible to locate
and install ammonia injection points capable of achieving adequate mixing within
the required temperature zone. Higher reagent injection rates would be required
to achieve adequate mixing. This design would tend to result in relatively high
levels of ammonia slip. Further, because the Seminole boilers are typically used
as peaking units, boiler load is continually changing. Boiler load changes
affect flue gas flow rates and temperatures, which would make it particularly
difficult to inject the needed quantity of reactant.
Installation
of SNCR on large boilers, such as those at Seminole, has not been demonstrated
in practice. Assuming that SNCR could be installed on the Seminole Units, given
the issues addressed above, control effectiveness would be marginal, and
depending on boiler exit temperatures, could actually result in additional NOx
formation. SNCR is not a technically feasible retrofit control for the Seminole
Boilers.
Selective
Catalytic Reduction
Selective
Catalytic Reduction (SCR) involves injecting ammonia into boiler flue gas in the
presence of a catalyst to reduce NOx to N2 and water.
Anhydrous ammonia injection systems may be used, or ammonia may be generated
on-site from a urea feedstock.
SCR
has been installed as NOx control technology on existing gas-fired boilers.
Based on emissions data available from the EPA Electronic Reporting website,
large gas-fired boilers (with heat inputs above approximately 1,000 mmBtu/hr)
have achieved actual long-term average NOx emission rates in the range of
approximately 0.02 to 0.05 lb/mmBtu. Several design and operating variables will
influence the performance of the SCR system, including the volume, age and
surface area of the catalyst (e.g., catalyst layers), uncontrolled NOx emission
rate, flue gas temperature and catalyst activity.
Based
on emission rates achieved in practice at existing gas-fired units, and taking
into consideration long-term operation of an SCR control system (including
catalyst plugging and deactivation) and the fact that the Seminole boilers
typically operate as peaking units, it is anticipated that SCR could achieve a
controlled NOx emission rate of 0.04 lb/mmBtu (30-day rolling average) on
Seminole Units 1, 2 and 3.
Innovative
NOX Control Technologies:
Rotating
Opposed Fire Air and Rotamix
Rotating
opposed fired air (ROFA) is a boosted over fire air system that includes a
patented rotation process which includes asymmetrically placed air nozzles. Like
other OFA systems,
5
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
ROFA
stages the primary combustion zone to burn overall rich, with excess air added
higher in the furnace to burn out products of incomplete
combustion.
As
discussed in for OFA, over fire air control systems are a technically feasible
retrofit control technology, and, based on engineering judgment, the ROFA design
could also be applied on Seminole Units 1, 2 and 3. However, there is no
technical basis to conclude that the ROFA design would provide additional NOx
reduction beyond that achieved with other OFA designs. Therefore, ROFA control
systems are not evaluated as a specific control system, but are included in the
overall evaluation of combustion controls (e.g., LNB/OFA).
ROFA+ SNCR (Rotamix)
The
Rotamix system is a SNCR control system (i.e., ammonia injection system) coupled
with the ROFA rotating injection nozzle design. The technical limitations
discussed in the SNCR section, including the physical size of the boiler,
inadequate NH3/NOx contact, and flue gas temperatures, would apply equally to
the Rotamix control system. There is no technical basis to conclude that the
Rotamix design addresses these unresolved technical difficulties. Therefore,
like other SNCR control systems, the Rotamix system is not a technically
feasible retrofit control for the Seminole Boilers.
Xxxxxxx
Multi-Pollutant Control Process
The
PahlmanTM
Process is a patented dry-mode multi-pollutant control system. The process uses
a sorbent composed of oxides of manganese (the Pahlmanite™ sorbent) to remove
NOx and SO2 from the
flue gas.
To
date, bench- and pilot-scale testing have been conducted to evaluate the
technology on utility-sized boilers. The New & Emerging Environmental
Technologies (NEET) Database identifies the development status of the Xxxxxxx
Process as full-scale development and testing. The process is an
emerging multi-pollutant control, and there is limited information available to
evaluate its technically feasibility and long-term effectiveness on a large
natural gas-fired boiler. It is likely that OG&E would be required to
conduct extensive design engineering and testing to evaluate the technical
feasibility and long-term effectiveness of the control system on Seminole Units
1, 2 and 3. XXXX does not require applicants to experience extended time delays
or resource penalties to allow research to be conducted on an emerging control
technique. Therefore, at this time the Xxxxxxx Process is not a technically
feasible retrofit control for the Seminole Boilers.
Wet
NOx Scrubbing Systems
Wet
scrubbing systems have been used to remove NOx emissions from fluid catalytic
cracking units (FCCUs) at petroleum refineries. An example of a wet scrubbing
system is Balco Technologies' LoTOxTM system.
The LoTOx system is a patented process, wherein ozone is injected into the flue
gas stream to oxidize NO and NO2 to N2O5. This highly
oxidized species of NOx is very soluble and rapidly reacts with water to form
nitric acid. The conversion of NOx to nitric acid occurs as the N2O5 contacts
liquid sprays in the scrubber.
Wet
scrubbing systems have been installed at chemical processing plants and smaller
coal-fired boilers. The NEET Database classifies wet scrubbing systems as
commercially established for
6
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
petroleum
refining and oil/natural gas production. However the technology has not been
demonstrated on large utility boilers and it is likely that OG&E would incur
substantial engineering and testing to evaluate the scale-up potential and
long-term effectiveness of the system. Therefore, at this time wet NOx scrubbing
systems are not technically feasible retrofit controls for the Seminole
Boilers.
EFFECTIVENESS
OF REMAINING CONTROL TECHNOLOGIES (NOx)
Table
4: Technically Feasible NOx Control Technologies – Seminole
Station
|
|||
Seminole
Unit 1
|
Seminole
Unit 2
|
Seminole
Unit 3
|
|
Control
Technology
|
Approximate
NOx
Emission
Rate
(lb/mmBtu)
|
Approximate
NOx
Emission
Rate
(lb/mmBtu)
|
Approximate
NOx
Emission
Rate
(lb/mmBtu)
|
LNB/OFA
+ SCR
|
0.04
|
0.04
|
0.04
|
LNB/OFA
+ FGR
|
0.203
|
0.212
|
0.164
|
LNB/OFA
|
0.254
|
0.266
|
NA
|
Baseline
|
0.339
|
0.354
|
0.219
|
EVALUATE
IMPACTS AND DOCUMENT RESULTS (NOx)
OG&E
evaluated the economic, environmental, and energy impacts associated with the
three proposed control options. In general, the cost estimating methodology
followed guidance provided in the EPA Air Pollution Cost Control Manual. Major
equipment costs were developed based on publicly available cost data and
equipment costs recently developed for similar projects, and include the
equipment, material, labor, and all other direct costs needed to retrofit
Seminole Units 1, 2 and 3 with the control technologies. Fixed and variable
O&M costs were developed for each control system. Fixed O&M costs
include operating labor, maintenance labor, maintenance material, and
administrative labor. Variable O&M costs include the cost of consumables,
including reagent (e.g., ammonia), byproduct management, water consumption, and
auxiliary power requirements. Auxiliary power requirements reflect the
additional power requirements associated with operation of the new control
technology, including operation of any new fans as well as the power
requirements for pumps, reagent handling, and by-product handling. The capital
recovery factor used to estimate the annual cost of control was based on a 7%
interest rate and a control life of 25 years. OG&E provided a summary of
historical capacity factors which typically ranged between approximately 25% to
30%. Annual operating costs and annual emission reductions were calculated
assuming a capacity factor of 50%.
7
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
Table
5: Economic Cost Per Boiler
|
||||
Cost
|
Unit
|
Option
1:
LNB/OFA
|
Option
2:
LNB/OFA
w/EGR
|
Option
3:
LNB/OFA
+ SCR
|
Control
Equipment Capital
Cost
($)
|
Unit
1
|
$9,432,200
|
$16,977,200
|
$104,230,200
|
Unit
2
|
$9,432,200
|
$16,977,200
|
$104,230,200
|
|
Unit
3
|
$9,468,600
|
$9,468,600
|
$104,834,200
|
|
Capital
Recover Factor
($/Yr)
|
Unit
1
|
$809,300
|
$1,456,700
|
$8,943,000
|
Unit
2
|
$809,300
|
$1,456,700
|
$8,943,000
|
|
Unit
3
|
$812,400
|
$812,400
|
$8,994,800
|
|
Annual
O&M Costs
($/Yr)
|
Unit
1
|
$588,600
|
$1,190,900
|
$8,152,800
|
Unit
2
|
$588,600
|
$1,190,900
|
$8,175,600
|
|
Unit
3
|
$590,800
|
$590,800
|
$8,023,800
|
|
Annual
Cost of Control
($)
|
Unit
1
|
$1,397,900
|
$2,647,600
|
$17,095,800
|
Unit
2
|
$1,397,900
|
$2,647,600
|
$17,118,600
|
|
Unit
3
|
$1,403,200
|
$1,403,200
|
$17,018,600
|
Table
6: Environmental Costs per Boiler
|
|||||
Baseline
|
Option
1:
LNB/OFA
|
Option
2:
LNB/OFA
w/EGR
|
Option
3:
LNB/OFA
+
SCR
|
||
NOx
Emission
Rate
(lb/mmBtu)
|
Unit
1
|
0.339
|
0.254
|
0.203
|
0.04
|
Unit
2
|
0.354
|
0.266
|
0.212
|
0.04
|
|
Unit
3
|
0.219
|
0.164
|
0.164
|
0.04
|
|
Annual
NOx
Emission
(TPY)1
|
Unit
1
|
4,068
|
3,048
|
2,436
|
480
|
Unit
2
|
4,248
|
3,192
|
2,544
|
480
|
|
Unit
3
|
2,636
|
1,974
|
1,974
|
481
|
|
Annual
NOx
Reduction
(TPY)
|
Unit
1
|
-
|
1020
|
1632
|
3588
|
Unit
2
|
1056
|
1704
|
3768
|
||
Unit
3
|
662
|
662
|
2155
|
||
Annual
Cost of
Control2
|
Unit
1
|
$1,397,900
|
$2,647,600
|
$17,095,800
|
|
Unit
2
|
$1,397,900
|
$2,647,600
|
$17,118,600
|
||
Unit
3
|
$1,403,200
|
$1,403,200
|
$17,018,600
|
||
Cost
per Ton of Reduction
|
Unit
1
|
$1,370
|
$1,622
|
$4,765
|
|
Unit
2
|
$1,324
|
$1,554
|
$4,543
|
||
Unit
3
|
$2,120
|
$2,120
|
$7,897
|
||
Incremental
Cost
per Ton of Reduction3
|
Unit
1
|
NA
|
---
|
$2,042
|
$7,387
|
Unit
2
|
$1,929
|
$7,011
|
|||
Unit
3
|
---
|
$10,459
|
(1)Emissions
for the BART analysis are based on maximum heat inputs of 5,480 mmBtu/hr (Units
1 & 2) and 5,496 mmBtu/hr (Unit 3). Annual emissions were calculated
assuming 4,380 hours/year per boiler (50% capacity factor).
(2)
Total annual cost for all three units are not additive because Unit 3 is
currently equipped with FGR control and Unit 3 has a slightly higher heat
input.
(3) Incremental cost effectiveness of the
FGR system is compared to costs/emissions associated with LNB/OFA
controls. Similarly, incremental cost
effectiveness of the SCR system is compared to costs/emissions associated with
LNB/OFA+FGR controls.
8
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
B.
VISIBILITY IMPROVEMENT DETERMINATION
The
fifth of five factors that must be considered for a BART determination analysis,
as required by a 40 CFR part 51-Appendix Y, is the degree of Class I area
visibility improvement that would result from the installation of the various
options for control technology. This factor was evaluated for the Seminole
Generating Station by using an EPA-approved dispersion modeling system (CALPUFF)
to predict the change in Class I area visibility. The Division had previously
determined that the Seminole Generating Station was subject to BART based on the
results of initial screening modeling that was conducted using current
(baseline) emissions from the facility. The screening modeling, as well as more
refined modeling conducted by the applicant, is described in detail
below.
Wichita
Mountain Wildlife Refuge, Caney Creek, Upper Buffalo and Hercules Glade are the
closest Class I areas to the Seminole Generating Station, as shown in Figure 1
below.
Only
those Class I areas most likely to be impacted by the Seminole Generating
Station were modeled, as determined by source/Class I area locations, distances
to each Class I area, and professional judgment considering meteorological and
terrain factors. It can be reasonably assumed that areas at greater distances
and in directions of less frequent plume transport will experience lower impacts
than those predicted for the four modeled areas.
IMAGE NOT
SHOWN
Figure
1: Plot of Facility Location in relation to nearest Class I
areas.
9
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
REFINED MODELING:
Because
of the results of the applicants screening modeling for the Seminole Generating
Station, OG&E was required to conduct a refined BART analysis that included
CALPUFF visibility modeling for the facility. The modeling approach followed the
requirements described in the Division's BART modeling protocol, CENRAP BART Modeling Guidelines
(Alpine Geophysics, December 2005) with refinements detailed the
applicants CALMET modeling protocol, CALMET Data Processing Protocol
(Trinity Consultants, January 2008)
CALPUFF
System
Predicted
visibility impacts from the Seminole Generating Station were determined with the
EPA CALPUFF modeling system, which is the EPA-preferred modeling system for
long-range transport. As described in the EPA Guideline on Air Quality Models
(Appendix W of 40 CFR Part 51), long-range transport is defined as modeling with
source-receptor distances greater than 50 km. Because all modeled areas are
located more than 50 km from the sources in question, the CALPUFF system was
appropriate to use.
The
CALPUFF modeling system consists of a meteorological data pre-processor
(CALMET), an air dispersion model (CALPUFF), and post-processor programs
(POSTUTIL, CALSUM, CALPOST). The CALPUFF model was developed as a
non-steady-state air quality modeling system for assessing the effects of time-
and space-varying meteorological conditions on pollutant transport,
transformation, and removal.
CALMET
is a diagnostic wind model that develops hourly wind and temperature fields in a
three-dimensional, gridded modeling domain. Meteorological inputs to CALMET can
include surface and upper-air observations from multiple meteorological
monitoring stations. Additionally, the CALMET model can utilize gridded analysis
fields from various mesoscale models such as MM5 to better represent
regional wind flows and complex terrain circulations. Associated two-dimensional
fields such as mixing height, land use, and surface roughness are included in
the input to the CALMET model. The CALMET model allows the user to "weight"
various terrain influences parameters in the vertical and horizontal directions
by defining the radius of influence for surface and upper-air
stations.
CALPUFF
is a multi-layer, Lagrangian puff dispersion model. CALPUFF can be driven by the
three-dimensional wind fields developed by the CALMET model (refined mode), or
by data from a single surface and upper-air station in a format consistent with
the meteorological files used to drive steady-state dispersion models. All
far-field modeling assessments described here were completed using the CALPUFF
model in a refined mode.
CALPOST
is a post-processing program that can read the CALPUFF output files, and
calculate the impacts to visibility.
All
of the refined CALPUFF modeling was conducted with the version of the CALPUFF
system that was recognized as the EPA-approved release at the time of the
application submittal. Version designations of the key programs are listed in
the table below.
10
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
Table
7: Key Programs in CALPUFF System
|
||
Program
|
Version
|
Level
|
CALMET
|
5.53a
|
040716
|
CALPUFF
|
5.8
|
070623
|
CALPOST
|
5.51
|
030709
|
Meteorological
Data Processing (CALMET)
As
required by the Division's modeling protocol, the CALMET model was used to
construct the initial three-dimensional wind field using data from the MM5 model. Surface and upper-air
data were also input to CALMET to adjust the initial wind field.
The
following table lists the key user-defined CALMET settings that were
selected.
Table
8: CALMET Variables
|
||
Variable
|
Description
|
Value
|
PMAP
|
Map
projection
|
LCC
(Xxxxxxx Conformal
Conic)
|
DGRIDKM
|
Grid
spacing (km)
|
4
|
NZ
|
Number
of layers
|
12
|
ZFACE
|
Cell
face heights (m)
|
0,
20, 40, 60, 80, 100, 150, 200, 250, 500, 1000, 2000,
3500
|
RMIN2
|
Minimum
distance for
extrapolation
|
-1
|
IPROG
|
Use
gridded prognostic model
outputs
|
14
km (MM5 data)
|
RMAX1
|
Maximum
radius of influence
(surface
layer, km)
|
20
km
|
RMAX2
|
Maximum
radius of influence
(layers
aloft, km)
|
50
km
|
TERRAD
|
Radius
of influence for terrain
(km)
|
10
km
|
R1
|
Relative
weighting of first
guess
wind field and
observation
(km)
|
10
km
|
R2
|
Relative
weighting aloft (km)
|
25
km
|
The
locations of the upper air stations with respect to the modeling domain are
shown in Figure 2.
11
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
IMAGE NOT
SHOWN
Figure
2: Plot of surface station locations
IMAGE NOT
SHOWN
Figure
3: Plot of upper air station locations
12
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
IMAGE NOT
SHOWN
Figure 4. Plot of precipitation observation
stations
CALPUFF
Modeling Setup
To
allow chemical transformations within CALPUFF using the recommended chemistry
mechanism (MESOPUFF II), the model required input of background ozone and
ammonia. CALPUFF can use either a single background value representative of an
area or hourly ozone data from one or more ozone monitoring stations. Hourly
ozone data files were used in the CALPUFF simulation. As provided by the
Oklahoma DEQ, hourly ozone data from the Oklahoma City, Glenpool, and Lawton
monitors over the 2001-2003 time frames were used. Background concentrations for
ammonia were assumed to be temporally and spatially invariant and were set to 3
ppb.
Latitude
and longitude coordinates for Class I area discrete receptors were taken from
the National Park Service (NPS) Class I Receptors database and converted to the
appropriate LCC coordinates.
CALPUFF
Inputs-Baseline and Control Options
The
first step in the refined modeling analysis was to perform visibility modeling
for current (baseline) operations at the facility. Emissions of NOx for the
baseline runs were established based on CEM data and maximum 24-hour emissions
averages for years 2001 to 2003. All particulate emissions (PM) were based on
emission rates of 0.00186 lb/mmBtu (filterable) and were treated as PM10 (coarse
PM) and 0.00559 lb/mmBtu (condensable) and were treated as PM2.5 (fine
PM) within CALPUFF and CALPOST. Direct emissions of sulfate were based on the
values calculated for the Toxic Release Inventory (TRI) for the years
modeled.
Baseline
source release parameters and emissions are shown in the table below, followed
by tables with data for the various control options. No attempt was made by the
applicant to estimate the increase in sulfate emissions that would result from
operations of SCR, and as a
13
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
result
the visibility improvement for those scenarios may be overestimated by some
undetermined amount.
Table
9: Baseline Source Parameters
|
|||
Baseline
|
|||
Parameter
|
Natural
Gas-Fired
Unit
1
|
Natural
Gas-Fired
Unit
2
|
Natural
Gas-Fired
Unit
3 (FGR)
|
Heat
Input (mmBtu/hr)
|
5,480
|
5,480
|
5,496
|
Base
Elevation (m)
|
290
|
290
|
290
|
Stack
Height (m)
|
54.27
|
54.27
|
106.71
|
Stack
Diameter (m)
|
4.57
|
4.57
|
5.49
|
Stack
Temperature (K)
|
392.44
|
392.44
|
411.89
|
Exit
Velocity (m/s)
|
42.32
|
42.32
|
30.95
|
SO2
Emissions (lb/mmBtu)
|
0.00055
|
0.00042
|
0.00060
|
SO2
Emissions (TPY)
|
13.20
|
10.08
|
14.44
|
NOX
Emissions1
(lb/mmBtu)
|
0.339
|
0.354
|
0.219
|
NOX
Emissions (TPY)
|
8136.81
|
8496.85
|
5271.87
|
PM10
Fine Emissions2
(lb/mmBtu)
|
0.00745
|
0.00745
|
0.00745
|
PM10
Fine Emissions (TPY)
|
178.82
|
178.82
|
179.34
|
1Baseline
NOx emissions were based on the maximum 24-hr average emission rate (lb/hr)
reported by each unit during the baseline period 2003-2005. Baseline
emissions data were provided by OG&E. Baseline emission rates
(lb/mmBtu) were calculated by dividing the maximum 24-hr lb/hr emission rate by
the maximum heat input to the boiler.
2PM
emissions are based on AP-42 emission factors for natural gas combustion
(filterable and condensable).
Table
10: Source Parameters and Emissions for BART Control
Options
|
|||||
Scenario
|
Control
|
Heat
Input (mmBtu/hr)
|
NOX
emissions (lb/mmBtu)
|
NOX
Emissions (TPY)
|
|
Control
Option
1
|
LNB/OFA
|
5,480
|
0.254
|
6,097
|
|
Natural
Gas-
Fired
Unit
2
|
LNB/OFA
|
5,480
|
0.266
|
6,384
|
|
Natural
Gas-
Fired
Unit
3
|
LNB/OFA
FGR
|
5,496
|
0.164
|
3,948
|
|
Control
Option
2
|
Natural
Gas-
Fired
Unit
1
|
LNB/OFA
FGR
|
5,480
|
0.203
|
4,872
|
Natural
Gas-
Fired
Unit
2
|
LNB/OFA
FGR
|
5,480
|
0.212
|
5,089
|
|
Natural
Gas-
Fired
Unit
3
|
LNB/OFA
FGR
|
5,496
|
0.164
|
3,948
|
14
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
|
|||||
Scenario
|
Control
|
Heat
Input
(mmBtu/hr)
|
NOX
emissions
(lb/mmBtu)
|
NOX
Emissions
(TPY)
|
|
Control
Option
3
|
Natural
Gas-
Fired
Unit
1
|
LNB/OFA
+
SCR
|
5,480
|
0.040
|
960
|
Natural
Gas-
Fired
Unit
2
|
LNB/OFA
+
SCR
|
5,480
|
0.040
|
960
|
|
Natural
Gas-
Fired
Unit
3
|
LNB/OFA
+
SCR
|
5,496
|
0.040
|
963
|
Visibility
Post-Processing (CALPOST) Setup
The
changes in visibility were calculated using Method 6 with the CALPOST
post-processor. Method 6 requires input of monthly relative humidity
factors [f(RH)] for each Class I area that is being modeled. Monthly
f(RH) factors that were used for this analysis are shown in the table
below.
Table
11: Relative Humidity Factors for CALPOST
|
||||
Month
|
Wichita
Mountains
|
Caney
Creek
|
Upper
Buffalo
|
Hercules
Glade
|
January
|
2.7
|
3.4
|
3.3
|
3.2
|
February
|
2.6
|
3.1
|
3.0
|
2.9
|
March
|
2.4
|
2.9
|
2.7
|
2.7
|
April
|
2.4
|
3.0
|
2.8
|
2.7
|
May
|
3.0
|
3.6
|
3.4
|
3.3
|
June
|
2.7
|
3.6
|
3.4
|
3.3
|
July
|
2.3
|
3.4
|
3.4
|
3.3
|
August
|
2.5
|
3.4
|
3.4
|
3.3
|
September
|
2.9
|
3.6
|
3.6
|
3.4
|
October
|
2.6
|
3.5
|
3.3
|
3.1
|
November
|
2.7
|
3.4
|
3.2
|
3.1
|
December
|
2.8
|
3.5
|
3.3
|
3.3
|
EPA’s
default average annual aerosol concentrations for the U.S. that are included in
Table 2-1 of EPA’s Guidance
for Estimating Natural Visibility Conditions Under the Regional Haze
Program were to develop natural background estimates for each Class I
area.
15
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
Visibility
Post-Processing Results
Table
12: CALPUFF Visibility Modeling Results for Seminole Units 1, 2
and 3
|
||||||||
2001
|
2002
|
2003
|
3-Year
Average
|
|||||
Class
I Area
|
98th
Percentile
Value
( ∆
dv)
|
No.
of
Days
>
0.5
∆dv
|
98th
Percentile
Value
(∆dv)
|
No.
of
Days
>
0.5
∆dv
|
98th
Percentile
Value
(∆dv)
|
No.
of
Days
>
0.5
∆dv
|
98th
Percentile
Value
(∆dv)
|
No.
of
Days
>
0.5
∆dv
|
Baseline
|
||||||||
Wichita
Mountains
|
1.073
|
20
|
0.744
|
12
|
1.3
|
25
|
1.039
|
19
|
Caney
Creek
|
1.173
|
18
|
0.455
|
7
|
0.443
|
7
|
0.69
|
11
|
Upper
Buffalo
|
0.635
|
9
|
0.24
|
2
|
0.302
|
2
|
0.39
|
4
|
Hercules
Glade
|
0.403
|
5
|
0.294
|
3
|
0.301
|
3
|
0.33
|
4
|
Scenario
2 – Combustion Control – LNB/OFA/FGR
|
||||||||
Wichita
Mountains
|
0.707
|
13
|
0.476
|
7
|
0.832
|
17
|
0.67
|
12
|
Caney
Creek
|
0.754
|
12
|
0.284
|
1
|
0.284
|
2
|
0.44
|
5
|
Upper
Buffalo
|
0.411
|
4
|
0.157
|
2
|
0.191
|
1
|
0.25
|
2
|
Hercules
Glade
|
0.255
|
2
|
0.186
|
0
|
0.188
|
2
|
0.21
|
1
|
Modeling
for SCR controls resulted in an approximately 80% reduction in visibility
impairment from scenario two.
C.
BART DETERMINATION
After considering: (1) the costs of
compliance, (2) the energy and non-air quality environmental impacts of
compliance, (3) any pollutant equipment in use or in existence at the source,
(4) the remaining useful life of the source, and (5) the degree of improvement
in visibility (all five statutory factors) from each proposed control
technology, the Division determined BART for the three units at the Seminole
Generating Station.
New
LNB with OFA is determined to be BART for NOX control for Units 1-3 based, in
part, on the following conclusions:
1.
|
Installation
of new LNB with OFA and FGR was cost effective, with a capital cost of
$16,977,200 per unit for units 1 and 2 and $9,468,600 for unit 3 and an
average cost effectiveness of $1,554-$2,120 per ton of NOx removed for
each unit over a twenty year operational
life.
|
2.
|
Combustion control using the
LNB/OFA and FGR does not require non-air quality environmental mitigation
for the use of chemical reagents (i.e., ammonia or urea) and there is
minimal energy
impact.
|
16
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
3.
|
After
careful consideration of the five statutory factors, especially the costs
of compliance and existing controls, NOx control levels on 30-day rolling
averages of 0.203 lb/mmBtu for Unit 1, 0.212 lb/mmBtu for Unit 2 and 0.164
lb/mmBtu for Unit 3 are justified.
|
4.
|
Annual
NOx emission reductions from new LNB with OFA and FGR on Units 1, 2, and 3
are 662-1,704 tons for a total annual reduction of 3,998
tons.
|
LNB
with OFA and SCR was not determined to be BART for NOx control for Units 1-3
based, in part, on the following conclusions:
1.
|
The
cost of compliance for installing SCR on each unit is significantly higher
than the cost for LNB with OFA and FGR. Additional capital costs for SCR
on Units 1-3 are on average $89,957,200 per unit. Based on projected
actual emissions, SCR could reduce overall NOx emissions from Seminole
Units 1, 2 and 3 by approximately 5,513 tpy (compared to combustion
controls and flue gas recirculation); however, the incremental cost
associated with this reduction is approximately $44,534,600 per year. or
$8,078/ton.
|
2.
|
Additional
non-air quality environmental mitigation is required for the use of
chemical reagents.
|
3.
|
Operation
of LNB with OFA and SCR is parasitic and requires power from each
unit.
|
4.
|
SCR control may not be as effective on boilers that
operate as peaking units, as NOx reduction in an SCR is a function of flue
gas temperature.
|
5.
|
The cumulative visibility improvement
for SCR, as compared to LNB/OFA and FGR across Wichita Mountains and Caney
Creek (based on the 98th
percentile modeled results) was 0.56-0.60 ∆dv for all three
units.
|
The
Division considers the installation and operation of the BART determined NOx
controls, new LNB with OFA and FGR, to meet the statutory requirements of
BART.
Unit-by-unit
NOx BART determinations:
Seminole Generating Station Unit | 1: New LNB with OFA and FGR and meeting NOx emission limit of 0.203 lb/mmBtu (30-day rolling average), 1,112 lb/hr (30-day rolling average), and 4,872 tpy (l2-month rolling) as BART for NOx. |
Seminole Generating Station Unit | 2: New LNB with OFA and FGR and meeting NOx emission limit of 0.212 lb/mmBtu (30-day rolling average), 1,162 lb/hr (30-day rolling average), and 5,089 tpy (12-month rolling) as BART for NOx. |
Seminole Generating Station Unit | 3: New LNB with OFA and FGR and meeting NOx emission limit of 0.164 lb/mmBtu (30-day rolling |
17
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
average), 901 lb/hr (30-day rolling average), and 3,948 tpy (12-month rolling) as BART for NOx. |
V.
CONSTRUCTION PERMIT
Prevention
of Significant Deterioration (PSD)
Seminole
Generating Station is a major source under OAC 252:100-8 Permits for Part 70
Sources. Oklahoma Gas and Electric should comply with the permitting
requirements of Subchapter 8 as they apply to the installation of controls
determined to meet XXXX.
The
installation of controls determined to meet XXXX will not change NSPS or
NESHAP/MACT applicability for the gas-fired units at the Seminole
Station.
VI.
OPERATING PERMIT
The
Seminole Generating Station is a major source under OAC 252:100-8 and has
submitted an application to modify their existing Title V permit to incorporate
the requirement to install controls determined to meet XXXX. The
Permit will contain the following specific conditions:
1. The
boilers in EUG 2 are subject to the Best Available Retrofit Technology (BART)
requirements of 40 CFR Part 51, Subpart P, and shall comply with all applicable
requirements including but not limited to the following: [40 CFR §§ 51.300-309
& Part 51, Appendix Y]
a.
|
Affected
facilities. The following sources are affected facilities and are subject
to the requirements of this Specific Condition, the Protection of
Visibility and Regional Haze Requirements of 40 CFR Part 51, and all
applicable SIP requirements:
|
EU
ID#
|
Point
ID#
|
EU
Name
|
Heat
Capacity
(MMBTUH)
|
Construction
Date
|
2-B
|
01
|
Unit
1 Boiler
|
5,480
|
1968
|
2-B
|
02
|
Unit
2 Boiler
|
5,480
|
1968
|
2-B
|
03
|
Unit
3 Boiler
|
5,496
|
5/28/70
|
b.
|
Each
existing affected facility shall install and operate the SIP approved BART
as expeditiously as practicable but in no later than five years after
approval of the SIP incorporating the BART
requirements.
|
c.
|
The
permittee shall apply for and obtain a construction permit prior to
modification of the boilers. If the modifications will result
in a significant emission increase and a significant net emission increase
of a regulated NSR pollutant, the applicant shall apply for a PSD
construction permit.
|
d.
|
The
affected facilities shall be equipped with the following current
combustion control technology, as determined in the submitted BART
analysis, to reduce emissions of NOX to below the emission limits
below:
|
i.
|
Low-NOX
Burners,
|
ii.
|
Overfire
Air, and
|
18
OG&E
Seminole Generating Station BART Evaluation September 28,
2009
iii.
|
Flue
Gas Recirculation.
|
e.
|
The
permittee shall maintain the combustion controls (Low-NOX burners,
overfire air, and flue gas recirculation) and establish procedures to
ensure the controls are properly operated and
maintained.
|
f.
|
Within
60 days of achieving maximum power output from each affected facility,
after modification or installation of BART, not to exceed 180 days from
initial start-up of the affected facility the permittee shall comply with
the emission limits established in the construction permit. The
emission limits established in the construction permit shall be consistent
with manufacturer’s data and an agreed upon safety factor. The
emission limits established in the construction permit shall not exceed
the following emission limits:
|
EU
ID#
|
Point
ID#
|
NOX
Emission Limit
|
Averaging
Period
|
2-B
|
01
|
0.203
lb/MMBTU
|
30-day
rolling
|
2-B
|
02
|
0.212
lb/MMBTU
|
30-day
rolling
|
2-B
|
03
|
0.164
lb/MMBTU
|
30-day
rolling
|
g.
|
Boiler
operating day shall have the same meaning as in 40 CFR Part 60, Subpart
Da.
|
h.
|
After
installation of the BART, the affected facilities shall only be fired with
natural gas.
|
i.
|
Within
60 days of achieving maximum power output from each boiler, after
modification of the boilers, not to exceed 180 days from initial start-up,
the permittee shall conduct performance testing as follows and furnish a
written report to Air Quality. Such report shall document
compliance with BART emission limits for the affected
facilities. [OAC
252:100-8-6(a)]
|
i.
|
The
permittee shall conduct NOX, CO, and VOC testing on the boilers at 60% and
100% of the maximum capacity. NOX and CO testing shall also be conducted
at least one additional intermediate point in the operating
range.
|
ii.
|
Performance
testing shall be conducted while the units are operating within 10% of the
desired testing rates. A testing protocol describing how the testing will
be performed shall be provided to the AQD for review and approval at least
30 days prior to the start of such testing. The permittee shall also
provide notice of the actual test date to
AQD.
|
iii.
|
The following USEPA methods shall be used for
testing of emissions , unless otherwise approved by Air
Quality:
|
Method
1: Sample and Velocity
Traverses for Stationary Sources.
Method
2: Determination of
Stack Gas Velocity and Volumetric Flow Rate.
Method
3: Gas Analysis for
Carbon Dioxide, Excess Air, and Dry Molecular Weight.
19
EXHIBIT
B
Oklahoma
Department of Environmental Quality
Air Quality
Division
BART
Application Analysis
|
January
15, 2010
|
|
COMPANY:
|
Oklahoma
Gas and Electric
|
|
FACILITY:
|
Sooner
Generating Station
|
|
FACILITY
LOCATION:
|
Red
Rock, Noble County, Oklahoma
|
|
TYPE
OF OPERATION:
|
(2)
570 MW Steam Electric Generating Units
|
|
REVIEWER:
|
Xxxxxxx
Xxxxxxx, Senior Engineering Manager
|
|
Xxx
Xxxxxx, Engineering Manager
|
I.
PURPOSE OF APPLICATION
On July
6, 2005, the U.S. Environmental Protection Agency (EPA) published the final
"Regional Haze Regulations and Guidelines for Best Available Retrofit Technology
Determinations" (the "Regional Haze Rule" 70 FR 39104). The Regional Haze Rule
requires certain States, including Oklahoma, to develop programs to assure
reasonable progress toward meeting the national goal of preventing any future,
and remedying any existing, impairment of visibility in Class I Areas. The
Regional Haze Rule requires states
to submit a plan to implement the regional haze requirements (the Regional Haze
SIP). The Regional Haze SIP must provide for a Best Available Retrofit
Technology (BART) analysis of any existing stationary facility that might cause
or contribute to impairment of visibility in a Class I Area.
II.
XXXX ELIGIBILITY DETERMINATION
BART-eligible sources include those
sources that:
(1)
have the potential to emit 250 tons or more of a visibility-impairing air
pollutant;
(2)
were in existence on August 7, 1977 but not in operation prior to August 7,
1962; and
(3) whose operations fall within one or more of the specifically
listed source categories in 40 CFR 51.301 (including fossil-fuel fired steam
electric plants of more than 250 mmBtu/hr heat input and fossil-fuel boilers of
more than 250 mmBtu/hr heat input).
Sooner
Units 1 and 2 are fossil-fuel fired boilers with heat inputs greater than 250
mmBtu/hr. Both units were in existence prior to August 7, 1977 but not in
operation prior to August 7, 1962. Based on a review of existing emissions data,
both units have the potential to emit more than 250 tons per year of NOx,
SO2
and PM10,
visibility impairing pollutants. Therefore, Sooner Units 1 and 2 meet the
definition of a BART-eligible source.
XXXX
is required for any BART-eligible source that emits any air pollutant which may
reasonably be anticipated to cause or contribute to any impairment of visibility
in a Class I Area.
OG&E
Sooner Generating Station BART Review
January 15, 2010
DEQ
has determined that an individual source will be considered to "contribute to
visibility impairment" if emissions from the source result in a change in
visibility, measured as a change in deciviews (∆-dv), that is greater than or
equal to 0.5 dv in a Class I area. Visibility impact modeling conducted by
OO&E determined that the maximum predicted visibility impacts from Sooner
Units 1 and 2 exceeded the 0.5 ∆-dv threshold at the Wichita Mountains Class I
Area. Therefore, Sooner Units 1 and 2 were determined to be BART applicable
sources, subject to the BART determination requirements.
III.
DESCRIPTION OF BART SOURCES
Baseline
emissions from Sooner Units 1 and 2 3 were developed based on an evaluation of
actual emissions data submitted by the facility pursuant to the federal Acid
Rain Program. In accordance with EPA guidelines in 40 CFR 51 Appendix Y Part
III, emission estimates used in the modeling analysis to determine visibility
impairment impacts should reflect steady-state operating conditions during
periods of high capacity utilization. Therefore, modeled emissions (lb/hr)
represent the highest 24-hour block emissions reported during the baseline
period. Baseline emission rates (lb/mmBtu) were calculated by dividing the
average annual mass emission rates for each boiler by the boiler's average heat
input over the years 2004 through 2006.
Table
1: Sooner Generating Station – Plant Operating Parameters for
BART Evaluation
|
||||
Parameter
|
Sooner
Unit 1
|
Sooner
Unit 2
|
||
Plant
Configuration
|
Pulverized
Coal-Fired Boiler
|
Pulverized
Coal-Fired Boiler
|
||
Firing
Configuration
|
Tangentially-fired
|
Tangentially-fired
|
||
Gross
Output (nominal)
|
570
MW
|
570
MW
|
||
Maximum
Input to
Boiler
|
5,116
mmBtu/hr
|
5,116
mmBtu/hr
|
||
Primary
Fuel
|
Subbituminous
coal
|
Subbituminous
coal
|
||
Existing
NOx Controls
|
Combustion
Controls
|
Combustion
Controls
|
||
Existing PM10 Controls | Electrostatic precipitator | Electrostatic precipitator | ||
Existing SO2 Controls |
Low-sulfur
coal
|
Low-sulfur coal | ||
Maximum
24-hour Emissions
|
||||
Pollutant
|
lb/hr
|
lb/mmBtu
|
lb/hr
|
lb/mmBtu
|
NOx
|
3,075
|
0.601
|
2,988
|
0.584
|
SO2 | 4,393 | 0.86 | 4,410 | 0.86 |
PM10 | 194 | 0.038 | 200 | 0.039 |
Baseline
Emissions (2004-2006)
|
||||
Pollutant
|
lb/hr
|
lb/mmBtu
|
lb/hr
|
lb/mmBtu
|
NOx
|
1,834
|
0.384
|
1,561
|
0.337
|
SO2 | 2,428 | 0.509 | 2,393 | 0.516 |
IV. BEST AVAILABLE
RETROFIT TECHNOLOGY (BART)
Guidelines
for making BART determinations are included in Appendix Y of 40 CFR Part 51
(Guidelines for BART Determinations under the Regional Haze Rule). States are
required to use the Appendix Y guidelines to make BART determinations for
fossil-fuel-fired generating plants
2
OG&E
Sooner Generating Station BART Review
January 15, 2010
having
a total generating capacity in excess of 750 MW. The BART determination process
described in Appendix Y includes the following steps:
Step
l. Identify All Available
Retrofit Control Technologies.
Step
2. Eliminate Technically Infeasible Options.
Step
3. Evaluate Control Effectiveness of Remaining Control
Technologies.
Step
4. Evaluate Impacts and Document the Results.
Step
5. Evaluate Visibility Impacts.
In
the final Regional Haze Rule U.S. EPA established presumptive BART emission
limits for S02 and
NOx
for certain electric generating units (EGUs) based on fuel type, unit size, cost
effectiveness, and the presence or absence of pre-existing controls. The
presumptive limits apply to EGUs at power plants with a total generating
capacity in excess of 750 MW. For these sources, EPA established presumptive
emission limits for coal-fired EGUs greater than 200 MW in size. The presumptive
levels are intended to reflect highly cost-effective technologies as well as
provide enough flexibility to States to consider source specific characteristics
when evaluating BART. The BART S02
presumptive emission limit for coal-fired EGUs greater than 200 MW in size
without existing S02 control is
either 95% S02 removal,
or an emission rate of 0.15 lb/mmBtu, unless a State determines that an
alternative control level is justified based on a careful consideration of the
statutory factors. For NOx, EPA
established a set of BART presumptive emission limits for coal-fired EGUs
greater than 200 MW in size based upon boiler size and coal type. The BART
NOx
presumptive emission limit applicable to Sooner Units 1 & 2 (tangentially
fired boilers firing subbituminous coal) is 0.15 lb/mmBtu.
Table
2: Proposed BART Controls and Limits
|
||
Unit
|
NOx
BART Emission Limit
|
BART
Technology
|
Sooner
Unit 1
|
0.15
lb/mmBtu (30-day average)
|
Combustion
controls including LNB/OFA
|
Sooner
Unit 2
|
0.15
lb/mmBtu (30-day average)
|
Combustion
controls including LNB/OFA
|
Unit
|
S02 BART Emission Limit
|
BART
Technology
|
Sooner
Unit 1
|
0.65 lb/mmBtu
(30-day average)
|
Low
Sulfur Coal
|
0.55 lb/mmBtu
(annual average)
|
||
Sooner
Unit 2
|
0.65
lb/mmBtu (30-day average)
|
Low
Sulfur Coal
|
0.55
lb/mmBtu (annual average)
|
Unit 1
and 2
|
19,736
TPY
|
Low
Sulfur Coal
|
Unit
|
PM10 BART Emission Limit |
BART
Technology
|
Sooner
Unit 1
|
0.1
lb/mmBtu (3-hour average)
|
Electrostatic
precipitator
|
Sooner
Unit 2
|
0.1
lb/mmBtu (3-hour average)
|
Electrostatic
precipitator
|
A.
NOx
IDENTIFY
AVAILABLE RETROFIT CONTROL TECHNOLOGIES
Potentially
available control options were identified based on a comprehensive review of
available information. NOx control technologies with potential application to
Sooner Units 1 and 2 are listed in Table 3.
3
OG&E
Sooner Generating Station BART Review
January 15, 2010
Table
3: List of Potential Control Options
|
||
Control
Technology
|
||
Combustion
Controls
|
||
Low
NOx Burners and Overfire Air (LNB/OFA)
|
||
Flue
Gas Recirculation (FGR)
|
||
Post
Combustion Controls
|
||
Selective
Noncatalytic Reduction (SNCR)
|
||
Selective
Catalytic Reduction (SCR)
|
||
Innovative
Control Technologies
|
||
Rotating
Overfire Air (ROFA)
|
||
ROFA
+ SNCR (Rotamix)
|
||
Xxxxxxx
Multi-Pollutant Control Process
|
||
Wet
NOx Scrubbing
|
ELIMINATE
TECHNICALLY INFEASIBLE OPTIONS (NOx)
Combustion
Controls:
Low
NOx burners (LNB)/ OverFire Air (OFA)
Low
NOx burners (LNB) limit NOx formation by controlling both the stoichiometric and
temperature profiles of the combustion flame in each burner flame envelope. Over
Fire Air (OFA) allows for staged combustion. Staging combustion reduces NOx
formation with a cooler flame in the initial stage and less oxygen in the second
stage.
LNB/OFA
emission control systems have been installed as retrofit control technologies on
existing coal-fired boilers. Sooner units 1 and 2 operate as base
load units. While technically feasible, LNB/OFA may not be as effective under
all boiler operating conditions, especially during load changes and at low
operating loads. Based on information available from burner control vendors and
engineering judgment, it is expected that LNB/OFA on the
tangentially-fired boilers can be designed to meet the presumptive NOx BART
emission rate of 0.15 lb/mmBtu on a 30-day rolling average and under all normal
operating conditions while maintaining acceptable CO and VOC emission
rates.
Flue
Gas Recirculation
Flue
gas recirculation (FGR) controls NOx by recycling a portion of the flue gas back
into the primary combustion zone. The recycled air lowers NOx emissions by two
mechanisms: (1) the recycled gas, consisting of products which are inert during
combustion, lowers the combustion temperatures; and (2) the recycled gas will
reduce the oxygen content in the primary flame zone. The amount of recirculation
is based on flame stability.
FOR
control systems have been used as a retrofit NOx control strategy on natural
gas-fired boilers, but have not generally been considered as a retrofit control
technology on coal-fired units. Natural gas-fired units tend to have lower
O2
concentrations in the flue gas and low particulate loading. In a
coal-fired application, the FGR system would have to handle hot
particulate-laden flue gas with a relatively high 02
concentration. Although FGR has been used on coal-fired boilers for flue gas
temperature control, it would not have application on a coal-fired boiler
for NOx control. Because of the flue gas characteristics (e.g., particulate
loading and 02
concentration), FGR would not operate effectively as a NOx control system on a
coal-fired
4
OG&E
Sooner Generating Station BART Review
January 15, 2010
boiler. Therefore, FGR is not considered an
applicable retrofit NOx
control option for Sooner
Units 1 & 2, and will not be considered further in
the BART determination.
Post
Combustion Controls:
Selective
Non-Catalytic Reduction
Selective
non-catalytic reduction (SNCR) involves the direct injection of ammonia or urea
at high flue gas temperatures. The ammonia or urea reacts with NOx in the flue
gas to produce N2 and water.
At temperatures below the desired operating range, the NOx reduction reactions
diminish and NH3 emissions
increase. Above the desired temperature range, NH3 is
oxidized to NOx resulting in low NOx reduction efficiencies. Mixing of the
reactant and flue gas within the reaction zone is also an important factor in
SNCR performance. In large boilers, the physical distance over which
the reagent must be dispersed increases, and the surface area/volume ratio of
the convective pass decreases. Both of these factors make it
difficult to achieve good mixing of reagent and flue gas, reducing overall
efficiency. Performance is further influenced by residence time, reagent-to-NOx
ratio, and fuel sulfur content.
The
size of the Sooner Units would represent several design problems making it
difficult to ensure that the reagent would be injected at the optimum flue gas
temperature, and that there would be adequate mixing and residence time. The
physical size of the Sooner boilers makes it technically infeasible to locate
and install ammonia injection points capable of achieving adequate mixing within
the required temperature zone. Higher reagent injection rates would be required
to achieve adequate mixing. Higher ammonia injection rates would result in
relatively high levels of ammonia in the flue gas (ammonia slip), which could
lead to plugging of downstream equipment.
Another
design factor limiting the applicability of SNCR control systems on large
subbituminous coal-fired boilers is related to the reflective nature of
subbituminous ash. Subbituminous coals typically contain high levels of calcium
oxide and magnesium oxide that can result in reflective ash deposits on the
waterwall surfaces. Because most heat transfer in the furnace is radiant,
reflective ash can result in less heat removal from the furnace and higher exit
gas temperatures. If ammonia is injected above the appropriate temperature
window, it can actually lead to additional NOx formation.
Installation
of SNCR on large boilers, such as those at Sooner, has not been demonstrated in
practice. Assuming that SNCR could be installed on the Sooner Units, given the
issues addressed above, control effectiveness would be marginal, and depending
on boiler exit temperatures, could actually result in additional NOx formation.
SNCR is not a technically feasible retrofit control for the Sooner
Boilers.
Selective
Catalytic Reduction
Selective
Catalytic Reduction (SCR) involves injecting ammonia into boiler flue gas in the
presence of a catalyst to reduce NOx to N2 and water.
Anhydrous ammonia injection systems may be used, or ammonia may be generated
on-site from a urea feedstock.
SCR
has been installed as NOx control technology on existing gas-fired boilers.
Based on emissions data available from the EPA Electronic Reporting website,
large coal-fired boilers have achieved actual long-term average NOx emission
rates in the range of approximately 0.04
5
OG&E
Sooner Generating Station BART Review
January 15, 2010
to
0.1 lb/mmBtu. Several design and operating variables will influence the
performance of the SCR system, including the volume, age and surface area of the
catalyst (e.g., catalyst layers), uncontrolled NOx emission rate, flue gas
temperature and catalyst activity.
Based
on emission rates achieved in practice at existing coal-fired units, and taking
into consideration long-term operation of an SCR control system (including
catalyst plugging and deactivation), it is anticipated that SCR could achieve a
controlled NOx emission rate of 0.07 lb/mmBtu (30-day rolling average) on Sooner
Units 1 and 2.
Innovative
NOX Control Technologies:
Rotating
Opposed Fire Air and Rotamix
Rotating
opposed fired air (ROFA) is a boosted over fire air system that includes a
patented rotation process which includes asymmetrically placed air nozzles. Like
other OFA systems, ROFA stages the primary combustion zone to bum overall rich,
with excess air added higher in the furnace to burn out products of incomplete
combustion.
ROFA
and Rotamix® systems have been demonstrated on smaller coal-fired boilers but
have not been demonstrated in practice on boilers similar in size to Sooner
Units 1 & 2. As discussed for OFA, over fire air control
systems are a technically feasible retrofit control technology, and, based on
engineering judgment, the ROFA design could also be applied on Sooner Units 1
and 2. However, there is no technical basis to conclude that the ROFA design
would provide additional NOX reduction beyond that achieved with other OFA
designs. Therefore, ROFA control systems are not evaluated as a specific control
system, but are included in the overall evaluation of combustion controls (e.g.,
LNB/OFA).
ROFA+ SNCR (Rotamix)
The
Rotamix system is a SNCR control system (i.e., ammonia injection system) coupled
with the ROFA rotating injection nozzle design. The technical limitations
discussed in the SNCR section, including the physical size of the boiler,
inadequate NH3/NOx contact, and flue gas temperatures, would apply equally to
the Rotamix control system. There is no technical basis to conclude that the
Rotamix design addresses these unresolved technical difficulties. Therefore,
like other SNCR control systems, the Rotamix system is not a technically
feasible retrofit control for the Sooner Boilers.
Xxxxxxx
Multi-Pollutant Control Process
The
PahlmanTM
Process is a patented dry-mode multi-pollutant control system. The process uses
a sorbent composed of oxides of manganese (the Pahlmanite™ sorbent) to remove
NOx and SO2 from the
flue gas.
To
date, bench- and pilot-scale testing have been conducted to evaluate the
technology on utility-sized boilers. The New & Emerging Environmental
Technologies (NEET) Database identifies the development status of the Xxxxxxx
Process as full-scale development and testing. The process is an
emerging multi-pollutant control, and there is limited information available to
evaluate its technically feasibility and long-term effectiveness on a large
natural gas-fired boiler. It is likely that OG&E would be required to
conduct extensive design engineering and testing to evaluate the technical
feasibility and long-term effectiveness of the control system on
Sooner
6
OG&E
Sooner Generating Station BART Review
January 15, 2010
Units
1 and 2. XXXX does not require applicants to experience extended time delays or
resource penalties to allow research to be conducted on an emerging control
technique. Therefore, at this time the Xxxxxxx Process is not a technically
feasible retrofit control for the Sooner Boilers.
Wet
NOx Scrubbing Systems
Wet
scrubbing systems have been used to remove NOx emissions from fluid catalytic
cracking units (FCCUs) at petroleum refineries. An example of a wet scrubbing
system is Balco Technologies' LoTOxTM
system. The LoTOx system is a patented process, wherein ozone is injected
into the flue gas stream to oxidize NO and NO2 to N205. This
highly oxidized species of NOx is very soluble and rapidly reacts with water to
form nitric acid. The conversion of NOx to nitric acid occurs as the N205 contacts
liquid sprays in the scrubber.
Wet
scrubbing systems have been installed at chemical processing plants and smaller
coal-fired boilers. The NEET Database classifies wet scrubbing systems as
commercially established for petroleum refining and oil/natural gas production.
However the technology has not been demonstrated on large utility boilers and it
is likely that OG&E would incur substantial engineering and testing to
evaluate the scale-up potential and long-term effectiveness of the system.
Therefore, at this time wet NOx scrubbing systems are not technically feasible
retrofit controls for the Sooner Boilers.
EFFECTIVENESS
OF REMAINING CONTROL TECHNOLOGIES (NOx)
Table
4: Technically Feasible NOx Control Technologies – Sooner
Station
|
||
Sooner
Unit 1
|
Sooner
Unit 2
|
|
Control
Technology
|
Approximate
NOx
Emission
Rate
(lb/mmBtu)
|
Approximate
NOx
Emission
Rate
(lb/mmBtu)
|
LNB/OFA
+ SCR
|
0.07
|
0.07
|
LNB/OFA
|
0.15
|
0.15
|
Baseline
|
0.384
|
0.337
|
EVALUATE
IMPACTS AND DOCUMENT RESULTS (NOx)
OG&E
evaluated the economic, environmental, and energy impacts associated with the
three proposed control options. In general, the cost estimating methodology
followed guidance provided in the EPA Air Pollution Cost Control Manual. Major
equipment costs were developed based on publicly available cost data and
equipment costs recently developed for similar projects, and include the
equipment, material, labor, and all other direct costs needed to retrofit Sooner
Units 1 and 2 with the control technologies. Fixed and variable O&M costs
were developed for each control system. Fixed O&M costs include operating
labor, maintenance labor, maintenance material, and administrative labor.
Variable O&M costs include the cost of consumables, including reagent (e.g.,
ammonia), byproduct management, water consumption, and auxiliary power
requirements. Auxiliary power requirements reflect the additional power
requirements associated with operation of the new control technology, including
operation of any new fans as well as the power requirements for pumps, reagent
handling, and by-product handling. The capital recovery factor used to estimate
the annual cost of control was based on a
7
OG&E
Sooner Generating Station BART Review
January 15, 2010
7%
interest rate and a control life of 25 years. Annual operating costs and annual
emission reductions were calculated assuming a capacity factor of
90%.
OG&E
submitted initial cost estimates in 2008 that relied upon a baseline emission
rate representative of the maximum actual 24-hour emission rate, which is
consistent with the modeling demonstration. However, the calculations
overestimate the cost effectiveness by assuming a larger ton per year emissions
reduction with the addition of controls than would be realized given actual
annual average emissions. Using a representative annual average emission rate
(2004-2006), the cost effectiveness ($/ton removed) is much higher, but the
result is representative of more reasonably achievable emissions reductions.
Table
5: Economic Cost Per Boiler
|
|||
Cost
|
Unit
|
Option
1: LNB/OFA
|
Option
2: LNB/OFA + SCR
|
Control
Equipment Capital Cost ($)
|
Unit
1
|
$14,055,900
|
$192,018,500
|
Annualized
Capital Cost ($/Yr)
|
Unit
1
|
$1,206,100
|
$16,477,200
|
Annual
O&M Costs ($/Yr)
|
Unit
1
|
$877,100
|
$14,487,400
|
Annual
Cost of Control ($)
|
Unit
1
|
$2,083,200
|
$30.964,600
|
Table
6: Environmental Costs per Boiler
|
||||
Baseline
|
Option
1: LNB/OFA
|
Option
2: LNB/OFA + SCR
|
||
NOx
Emission Rate (lb/mmBtu)
|
Unit
1
|
0.384
|
0.15
|
0.07
|
Unit
2
|
0.337
|
0.15
|
0.07
|
|
Annual
NOx Emission (TPY)1
|
Unit
1
|
7,266
|
3,025
|
1,412
|
Unit
2
|
5,689
|
3,025
|
1,412
|
|
Annual
NOx Reduction (TPY)
|
Unit
1
|
-
|
4,241
|
5,854
|
Unit
2
|
-
|
2,664
|
4,277
|
|
Annual
Cost of Control
|
Unit
1
|
-
|
$2,091,800
|
$30,795,600
|
Unit
2
|
-
|
$2,091,800
|
$30,795,600
|
|
Cost
per ton of Reduction
|
Unit
1
|
-
|
$493
|
$5,260
|
Unit
2
|
-
|
$785
|
$7,200
|
|
Incremental
Cost per Ton of Reduction2
|
Unit
1
|
-
|
-
|
$17,795
|
Unit
2
|
-
|
-
|
$17,795
|
(1)Emissions
for the BART analysis are based on maximum heat inputs of 4,771 mmBtu/hr and
4,634 mmBtu/hr for Units 1 & 2. Annual emissions were calculated assuming
7,738 and 7,164 hours/year for Units 1 and 2 respectively.
(2) Incremental cost effectiveness of the
SCR system is compared to costs/emissions associated with LNB/OFA
controls.
B.
SO2
IDENTIFY
AVAILABLE RETROFIT CONTROL TECHNOLOGIES (S02)
Potentially
available control options were identified based on a comprehensive review of
available information. S02 control
technologies with potential application to Sooner Units 1 and 2 are listed in
Table 7.
8
OG&E
Sooner Generating Station BART Review
January 15, 2010
Table
7: List of Potential Control Options
|
Control
Technology
|
Pre-Combustion
Controls
|
Fuel
Switching
|
Coal
Washing
|
Coal
Processing
|
Post
Combustion Controls
|
Wet
Flue Gas Desulfurization
|
Wet
Lime FGD
|
Wet
Limestone FGD
|
Wet
Magnesium Enhanced Lime FGD
|
Jet
Bubbling Reactor FGD
|
Dual
Alkali Scrubber
|
Wet FGD
with Wet Electrostatic Precipitator
|
Dry
Flue Gas Desulfurization
|
Spray
Dryer Absorber
|
Dry
Sorbent Injection
|
Circulating
Dry Scrubber
|
ELIMINATE
TECHICALLY INFEASIBLE OPTIONS (SO2)
Pre-Combustion
Control Strategy:
Fuel
Switching
One
potential strategy for reducing S02 emissions
is reducing the amount of sulfur contained in the coal. Sooner Units 1 & 2
fire subbituminous coal as their primary fuel. Subbituminous coal has a
relatively low heating value, low sulfur content, and low uncontrolled S02 emission
rate. No environmental benefits accrue from burning an alternative coal;
therefore, fuel switching is not considered a feasible option for this retrofit
project.
Coal
Washing
Coal washing, or beneficiation, is one
pre-combustion method that has been used to reduce impurities in the coal such
as ash and sulfur. In general, coal washing is accomplished by
separating and removing inorganic impurities from organic coal particles. The
coal washing process generates a solid waste stream consisting of inorganic
materials separated from the coal, and a wastewater stream that must be treated
prior to discharge. Solids generated from wastewater processing and coarse
material removed in the washing process must be disposed in a properly permitted
landfill. Solid wastes from coal washing typically contain pyrites and other
dense inorganic impurities including silica and trace metals. The solids are
typically dewatered in a mechanical dewatering device and disposed of in a
landfill.
Sooner
Units 1 & 2 are designed to utilize subbituminous coals. Based on a review
of available information, no information was identified regarding the
washability or effectiveness of washing subbituminous coals. Therefore, coal
washing is not considered an available retrofit control option for Sooner Units
1 & 2.
9
OG&E
Sooner Generating Station BART Review
January 15, 2010
Coal Processing
Pre-combustion
coal processing techniques have been proposed as one strategy to reduce the
sulfur content of coal and help reduce uncontrolled S02 emissions.
Coal processing technologies are being developed to remove potential
contaminants from the coal prior to use. These processes typically employ both
mechanical and thermal means to increase the quality of subbituminous coal and
lignite by removing moisture, sulfur, mercury, and heavy metals. To date, the
use of processed fuels has only been demonstrated with test bums in a pulverized
coal-fired boiler. No coal-fired boilers have utilized processed fuels as
their primary fuel source on an on-going, long-term basis. Although burning
processed fuels, or a blend of processed fuels, has been tested in a pulverized
coal-fired boiler, using processed fuels in Sooner Units 1 & 2 would require
significant research, test bums, and extended trials to identify potential
impacts on plant systems, including the boiler, material handling, and emission
control systems. Therefore, processed fuels are not considered commercially
available, and will not be analyzed further in this BART analysis.
Post-Combustion
Flue Gas Desulfurization
Wet
Scrubbing Systems
Wet
FGD technology is an established S02 control
technology. Wet scrubbing systems offered by vendors may vary in design;
however, all wet scrubbing systems utilize an alkaline scrubber slurry to remove
S02
from the flue gas.
Wet Lime
Scrubbing
The
wet lime scrubbing process uses an alkaline slurry made by adding lime (CaO) to
water. The alkaline slurry is sprayed in the absorber and reacts with S02 in the
flue gas. Insoluble CaS03 and
CaS04
salts are fanned in the chemical reaction that occurs in the scrubber and are
removed as a solid waste by-product. The waste by-product is made up of mainly
CaS03,
which is difficult to xxxxxxx. Solid waste by-products from wet lime scrubbing
are typically managed in dewatering ponds and
landfills.
Wet Limestone
Scrubbing
Limestone
scrubbers are very similar to lime scrubbers except limestone (CaCO3) is mixed
with water to formulate the alkali scrubber slurry. S02 in the
flue gas reacts with the limestone slurry to form insoluble CaS03 and
CaS04
which is removed as a solid waste by product. The use of limestone
instead of lime requires different feed preparation equipment and a higher
liquid-to-gas ratio. The higher liquid-to-gas ratio typically requires a
larger absorbing unit. The limestone slurry process also requires a ball mill to
crush the limestone feed.
Forced
oxidation of the scrubber slurry can be used with either the lime or limestone
wet FGD system to produce gypsum solids instead of the calcium sulfite
by-product. Air blown into the reaction tank provides oxygen to convert most of
the calcium sulfite (CaS03) to
relatively pure gypsum (calcium sulfate). Forced oxidation of the scrubber
slurry provides a more stable by-product and reduces the potential for
scaling in the FGD. The gypsum by-product from this process must be dewatered,
but may be salable thus reducing the quantity of solid waste that needs to be
landfilled.
10
OG&E
Sooner Generating Station BART Review
January 15, 2010
Wet lime and wet limestone scrubbing systems will achieve the same S02 control efficiencies; however, the higher cost of lime typically makes wet limestone scrubbing the more attractive option. For this reason, wet lime scrubbing will not be evaluated further in this BART determination.
Wet Magnesium Enhanced Lime
Scrubbing
Magnesium
Enhanced Lime (XXX) scrubbers are another variation of wet FGD technology.
Magnesium enhanced lime typically contains 3% to 7% magnesium oxide (MgO) and 90
-95% calcium oxide (CaO). The presence of magnesium effectively increases the
dissolved alkalinity, and consequently makes S02 removal
less dependent on the dissolution of the lime/limestone. XXX scrubbers have been
installed on coal-fired utility boilers located in the Ohio River Valley.
Systems to oxidize the XXX solids to produce a usable gypsum byproduct
consisting of calcium sulfate (gypsum) and magnesium sulfate continue to be
developed. Coal-fired units equipped with XXX FGD typically fire high-sulfur
eastern bituminous coal and use locally available reagent. There are no
subbituminous-fired units equipped with a XXX-FGD system. Because XXX-FGD
systems have not been used on subbituminous-fired boilers, and because of the
cost and limited availability of magnesium enhanced reagent (either naturally
occurring or blended), and because limestone-based wet FGD control systems can
be designed to achieve the same control efficiencies as the magnesium enhanced
systems, XXX-FGD control systems will not be evaluated further as a commercially
available retrofitted control system.
Jet Bubbling
Reactor
Another variation of the wet FGD control
system is the jet bubbling reactor (JBR). Unlike the spray tower wet FGD
systems, where the scrubbing slurry contacts the flue gas in a countercurrent
reaction tower, in the JBR-FGD flue gas is bubbled through a limestone slurry.
Spargers are used to create turbulence within the reaction tank and maximize
contact between the flue gas bubbles and scrubbing slurry. There is currently a
limited number of commercially operating JBR-WFGD control systems installed on
coal-fired utility units in the U.S. Although the commercial deployment of the
control system continues. there is still a very limited number of operating
units in the U.S. Furthermore, coal-fired boilers currently considering the
JBR-WFGD control system are all located in the eastern U.S., and all fire
eastern bituminous coals. The control system has not been proposed as a retrofit
technology on any large subbituminous coal-fired boilers. However, other than
scale-up issues, there do not appear to be any overriding technical issues that
would exclude application of the control technology on a large subbituminous
coal-fired unit. There are no data available to conclude that the
JBR-WFGD control system will achieve a
higher S02 removal efficiency than a more
traditional spray tower WFGD design, especially on units firing low-sulfur
subbituminous coal. Furthermore, the costs associated with JBR-WFGD and the
control efficiencies achievable with JBR-WFGD are similar to the costs and
control efficiencies achievable with spray tower WFGD control
systems. Therefore, the JBR-WFGD will not be
evaluated as a unique retrofit technology, but will be included in the overall
assessment of WFGD controls.
Dual-Alkali Wet
Scrubber
Dual-alkali
scrubbing is a desulfurization process that uses a sodium-based alkali solution
to remove S02 from
combustion exhaust gas. The process uses both sodium-based and
calcium-based compounds. The dual-alkali process requires lower
liquid-to-gas ratios then scrubbing with
11
OG&E
Sooner Generating Station BART Review
January 15, 2010
lime or limestone. The reduced liquid-to-gas ratios generally mean smaller reaction units, however additional regeneration and sludge processing equipment is necessary. The sodium-based scrubbing liquor, typically consisting of a mixture of sodium hydroxide, sodium carbonate and sodium sulfite, is an efficient S02 control reagent. However, the high cost of the sodium-based chemicals limits the feasibility of such a unit on a large utility boiler. In addition, the process generates a less stable sludge that can create material handling and disposal problems. It is projected that a dual-alkali system could be designed to achieve S02 control similar to a limestone-based wet FGD. However, because of the limitations discussed above, and because dual-alkali systems are not currently commercially available, dual-alkali scrubbing systems will not be addressed further in this BART determination.
Wet FGD with Wet
Electrostatic Precipitator
Wet
electrostatic precipitation (XXXX) has been proposed on other coal-fired
projects as one technology to reduce sulfuric acid mist emissions from
coal-fired boilers. WESPs have been proposed for boilers firing high-sulfur
eastern bituminous coals controlled with wet FGD. XXXX has not been widely used
in utility applications, and has only been proposed on boilers firing high
sulfur coals and equipped with SCR. Sooner Units 1 & 2 fire low-sulfur
subbituminous coal. Based on the fuel characteristics, and assuming 1% S02 to
S03 conversion in the boiler, potential uncontrolled H2S04 emissions
from Sooner Units 1 & 2 will only be approximately 5ppm. This emission rate
does not take into account inherent acid gas removal associated with alkalinity
in the subbituminous coal fly ash. Based on engineering judgment, it is unlikely
that a XXXX control system would be needed to mitigate visible sulfuric acid
mist emissions from Sooner Units 1 & 2, even if WFGD control was installed.
WESPs have been proposed to control condensable particulate emissions from
boilers firing a high-sulfur bituminous coal and equipped with SCR and wet FGD.
The combination of coal and control equipment results in relatively high
concentrations of sulfuric acid mist in the flue gas. XXXX control systems have
not been proposed on units firing subbituminous coals, and XXXX would have no
practical application on a subbituminous-fired units. Therefore, the combination
of WFGD+XXXX will not be evaluated further in this BART
determination.
Dry
Flue Gas Desulfurization
Another
scrubbing system that has been designed to remove S02 from coal-fired combustion
gases is dry scrubbing. Dry scrubbing involves the introduction of dry or
hydrated lime slurry into a reaction tower where it reacts with SO2 in the flue
gas to form calcium sulfite solids. Unlike wet FGD systems that produce a slurry
byproduct that is collected separately from the fly ash, dry FGD systems produce
a dry byproduct that must be removed with the fly ash in the particulate control
equipment. Therefore, dry FGD systems must be located upstream of the
particulate control device to remove the reaction products and excess reactant
material.
Spray Dryer
Absorber
Spray dryer absorber (SDA) systems have
been used in large coal-fired utility applications. SDA systems have
demonstrated the ability to effectively reduce uncontrolled S02 emissions from
pulverized coal units. The typical spray dryer absorber uses a slurry of lime
and water injected into the tower to remove S02 from the combustion
gases. The towers must be designed to provide
adequate contact and residence time between the exhaust gas and the slurry to
produce a relatively dry by-product. SDA control systems are a technically
feasible and commercially
12
OG&E
Sooner Generating Station BART Review
January 15, 2010
available
retrofit technology for Sooner Units 1 & 2. Based on the fuel
characteristics and allowing a reasonable margin to account for normal operating
conditions (e.g., load changes, changes in fuel characteristics, reactant
purity, atomizer change outs, and minor equipment upsets) it is concluded that
dry FGD designed as SDA could achieve a controlled S02 emission rate of 0.10
lb/mmBtu (30-day
average) on an on-going long-term basis.
Dry Sorbent
Injection
Dry
sorbent injection involves the injection of powdered absorbent directly into the
flue gas exhaust stream. Particulates generated in the reaction are controlled
in the system's particulate control device. Typical S02 control efficiencies for
a dry sorbent injection system are generally around 50%. OG&E stated that
because the control efficiency of the dry sorbent system is lower than the
control efficiency of either the wet FGD or SDA, the system will not be
evaluated further. As OG&E proposed only the use of low sulfur coal as BART,
it is not clear why they did not include this technology in the full evaluation.
Lacking any data to justify why this might be a more cost effective option than
Dry FGD with SDA, this option is set aside based solely on lower environmental
benefit.
Circulating Dry
Scrubber
A
third type of dry scrubbing system is the circulating dry scrubber (CDS). A CDS
system uses a circulating fluidized bed of dry hydrated lime reagent to remove
S02. The dry by-product produced by this system is similar to the spray dry
absorber by-product, and is routed with the flue gas to the particulate removal
system. Operating experience on smaller pulverized coal boilers in the U.S. has
shown high lime consumption rates, and significant fluctuations in lime
utilization based on inlet S02 loading. Furthermore, CDS systems result in high
particulate loading to the unit's particulate control device. Based on the
limited application of CDS dry scrubbing systems on large boilers, it is likely
that OG&E would be required to conduct extensive design engineering to scale
up the technology for boilers the size of Sooner Units 1 & 2, and that
OG&E would incur significant time and resource penalties evaluating the
technical feasibility and long-term effectiveness of the control system. Because
of these limitations, CDS dry scrubbing systems are not currently commercially
available as a retrofit control technology for Sooner Units 1 & 2, and will
not be evaluated further in this BART determination.
EVALUATE
EFFECTIVENESS OF REMAINING CONTROL TECHNOLOGIES (S02)
Table
8: Technically Feasible S02, Control Technologies – Sooner
Station
|
||
Control
Technology
|
Sooner
Unit 1
|
Sooner
Unit 2
|
Approximate
S02 Emission Rate
(lb/mmBtu)
|
Approximate
S02 Emission Rate
(lb/mmBtu)
|
|
Wet
FGD
|
0.08
|
0.08
|
Dry
FGD – Spray Dryer Absorber
|
0.10
|
0.10
|
Baseline
|
0.86
|
0.86
|
Annual
Average Baseline
|
0.509
|
0.516
|
13
OG&E
Sooner Generating Station BART Review
January 15, 2010
EVALUATE
IMPACTS AND DOCUMENT RESULTS (SO2)
Capital
Costs
In
2008 OG&E evaluated the economic, environmental, and energy impacts
associated with the two proposed control options. In general, the cost
estimating methodology followed guidance provided in the EPA Air Pollution Cost
Control Manual. Sixth Edition" EPA-452/B-02-001, January 2002. The
cost-effectiveness evaluations were "study" estimates of ±30% accuracy, based
on: (I) engineering estimates; (2) vendor quotations provided for similar
projects and similar equipment; (2) S&L's internal cost database; and (4)
cost estimating guidelines provided in U.S.EPA's, EPA Air Pollution Control Cost
Manual. Cost estimates include the equipment. material, labor, and all other
direct costs needed to retrofit Sooner Units 1 and 2 with the control
technologies.
While
generally following the EPA methodology, these cost estimates exploited
weaknesses in the estimate assumptions and resulted in highly exaggerated
capital and particularly annual costs. In response to the ODEQ draft evaluation
and EPA and FLM comments, OG&E submitted revised cost estimates during the
public meeting held for the Oklahoma draft SIP. These revised estimates reflect
vendor quotes for the Sooner facility. In degree of difficulty, the retrofit at
the Sooner facility is described as average. The re-routing of ductwork, storm
sewer systems and other equipment relocations were taken into consideration in
the conceptual cost estimate.
The
new cost estimates use the following methodology:
•
|
Plant
design data were used to develop datasheets to specify the dry FGD,
baghouse, and ID booster fan operating conditions. The datasheets were
issued to various manufacturers to obtain budgetary quotations. Cost
obtained from these quotations were used to derive the pricing used in the
capital cost estimate.
|
•
|
A general arrangement (GA) drawing
was developed using the information received in the budgetary quotations.
The GA drawing was used to estimate the major installation quantities for
the project including ductwork, structural steel, foundations, relocation
cable, and pipelines.
|
•
|
A
motor list was assembled and used to develop the auxiliary power system
sizing and quantities.
|
•
|
Mass
balances were prepared and used to size the flue gas, material handling,
material storage, and piping
systems.
|
•
|
A schedule was developed to
estimate escalation and Allowance for Funds Used During Construction
(AFUDC) costs.
It was assumed the
new DFGDs would come on line at six month intervals with the last unit
being completed at Sooner near the end of
2015.
|
•
|
Range
estimating techniques were used to identify the appropriate amount of
contingency to obtain 95% confidence level. The contingency level was
approximately 14%.
|
•
|
A
design and cost basis document was prepared to document the major
assumptions and inputs for developing the cost
estimate.
|
•
|
Labor cost estimates were
developed using the Oklahoma area wage rates, installation quantities, and
installation rates taken from the Xxxxxxx and Xxxxx database.
|
14
OG&E
Sooner Generating Station BART Review
January 15, 2010
The
described methodology provides a conceptual capital cost estimate with accuracy
in the range of ±20%. This methodology provides a better estimate of the capital
costs associated with installing DFGD control systems, and a more accurate
estimate of the actual costs that OG&E would incur to install DFGD at the
Sooner facility.
The
total capital requirement (TCR) is the sum of direct costs, indirect costs,
contingency, escalation, and AFUDC. Direct costs include equipment, material,
labor, spare parts, special tools, consumables, and freight. Indirect costs
include engineering, procurement, construction management, start-up,
commissioning. operator training, and owner's costs.
Escalation and AFUDC were calculated
from the estimated distribution of cash flows during the construction period and
OG&E's before-tax weighted average cost of capital of 8.66%/year. The 37-day tie-in outage for each unit
is assumed to be coordinated with the normal 5-week scheduled outage such that
incremental replacement cost is negligible.
The
capital recovery factor converts the TCR into equal annual costs over the
depreciable life of the asset. These are also referred to as levelized capital
charges. Property taxes and insurance are sometimes included with the capital
charges, but are classified in the OG&E analysis as part of the Indirect
Operating Costs to be consistent with the BART reports. The economic parameters
used to derive the levelized capital charges are summarized in Table
9.
Table
9: Economic Parameters to Derive Levelized Capital
Charges
|
|
Commercial
Operation Date (Reference Year)
|
2014
|
Depreciable
Life
|
20
years
|
Inflation
Rate
|
2.5%/year
|
Effective
Income Tax Rate-Federal and State
|
38.12%
|
Common
Equity Fraction
|
0.557
|
Debt
Fraction
|
0.443
|
Return
on Common Equity
|
|
Nominal
|
10.75%/year
|
Real
|
8.05%/year
|
Return
on Debt
|
|
Nominal
|
6.03%/year
|
Real
|
3.44%/year
|
Discount
Rate (after-tax cost of capital)
|
|
Nominal
|
7.64%/year
|
Real
|
5.43%/year
|
Tax
Depreciation
|
20-year
straight line
|
Levelized
Capital Charges (real)
|
10.36%/year
|
The
revised estimates based on vendor quotes results in a TCR of $584,589,400 which
is $196,222,600 less than the CUE Cost derived estimates provided in 2008.
OG&E has revised the capital recovery factor and reduced the number of years
of expected depreciation to 20 from 25 resulting in a levelized capital charge
or capital recovery of 30,281,800 per boiler, which is $3,219,100 per boiler per
year less than the 2008 estimate. Cost estimates and assumptions
are
15
OG&E
Sooner Generating Station BART Review
January 15, 2010
reasonable
and application of the previously relied upon capital recovery factor does not
significantly change the cost per ton of control or the conclusion of
this review.
Operating
Costs
Annual operating costs for the DFGD
system consist of variable operating and maintenance (O&M) costs, fixed
O&M costs, and indirect operating costs.
Variable
O&M
Variable
O&M costs are items that generally vary in proportion to the plant capacity
factor. These consist of lime reagent costs, water costs, FGD waste disposal
costs, bag and cage replacement costs, ash disposal costs, and auxiliary power
costs.
Lime
Reagent costs were based on material balances and budgetary lime quotations
received for truck delivery, $118.80/ton, which is 59% of the previously assumed
cost. Water costs were based on 205,256 lb/hr at full load, a 90% capacity
factor and $0.49/1,000 gallons. FGD Waste Disposal was based on material
balances for the average fuel composition and a 90% capacity factor. First year
cost of on-site disposal is $39.60/ton. Bag and cage replacement costs were
based on exhaust gas flow through the baghouse, an air-to-cloth ratio of 3.5 for
pulse jet baghouse, 4% contingency for bag cleaning, and 3-year bag life. The
first year bag cost (including fabric and hangers) is $3.22/ft2. Ash
disposal costs were not assumed to increase from the fabric filter as existing
ESP is remaining in service. Auxiliary power costs were based on auxiliary power
calculations and a 90% capacity factor. The first year auxiliary power cost is
$83.83/MWh, which is 186% of the previously assumed power cost.
Increases
in FGD waste disposal, bag and cage replacement, and auxiliary power costs
offset decreases in water and lime reagent costs resulting in no appreciable
change in expected variable O&M costs from the 2008 estimate.
Fixed
O&M
Fixed
O&M costs are recurring annual costs that are generally independent of the
plant capacity factor. Theses consist of operating labor, supervisor labor,
maintenance materials, and maintenance labor.
Operating labor was based on three
shifts per day 365 days per year. The first year labor rate (salary plus
benefits) is 57.33/hour.
Supervisory labor was based
on 15% of operating labor in accordance with the EPA Control Cost Manual (page
2-31). Maintenance materials were based on 0.6% of the total plant investment.
Previous cost estimates reflecting Cue Cost default assumptions were based on 5%
of capital equipment costs and therefore contributed to the exaggeration of
annual operating costs. Maintenance labor was again based on 110% of operating
labor, which is consistent with the EPA Control Cost Manual (page
2-31).
Due to the difference in cost basis for
maintenance materials, the final fixed O&M costs were decreased by
approximately $11,456,200 per year per boiler.
16
OG&E
Sooner Generating Station BART Review
January 15, 2010
Indirect
Operating Costs
Indirect operating costs are recurring annual
costs for the FGD system that are not part of the direct O&M. These consist of property
taxes, insurance, and
administration.
Property taxes were calculated as 0.60%
of total capital investment, in accordance with OO&E property tax rates.
This rate is significantly lower than the EPA default rate of 1%. Insurance
rates were calculated as 0.0105% of total capital investment in accordance with
OG&E insurance rates.
This rate is significantly
lower than the EPA default rate of 1%. Administrative costs were calculated as
20% of the fixed O&M costs rather the EPA Air Pollution Control Cost Manual
6th Ed guidance of 2% of capital
investment.
Due to the difference in cost basis for all indirect costs, but
most particularly administrative costs, the final indirect operating costs were
decreased by approximately $12,636,500 per year per boiler from the previous
assessment.
Revised O&M estimates are now
consistent with the operating costs documented in the June 2007 report by X.
Xxxxxx Xxxxxxxxxxx for the Utility Air Regulatory Group, "Current Capital Cost
and Cost-Effectiveness of Power Plant Emissions Control Technologies. The
Xxxxxxxxxxx report lists a cost range in $/kW of 15 to 38 for O&M costs.
OG&E estimates are approximately $29-32/kW.
OG&E submitted initial cost
estimates in 2008 that relied upon a baseline emission rate representative of
the maximum actual 24-hour
emission rate, which is consistent with the modeling
demonstration. Following the methodology published in the EPA advanced notice of
proposed rulemaking for the Four Corners Power Plant and the Navajo Generating
Station, cost effectiveness calculations were revised to reflect average annual
emissions from 2004-2006.
Table
10: Economic Cost for Units 1 and 2 – Dry FGD – Spray Dryer
Absorber
|
||
Cost
|
Unit
1
|
Unit
2
|
Total
Capital Investment ($)
|
$292,294,900
|
$292,294,900
|
Total
Capital Investment ($/kW)
|
$514
|
$514
|
Capital
Recovery Cost ($/Yr)
|
$30,281,800
|
$30,281,800
|
Annual
O&M Costs ($/Yr)
|
$16,550,500
|
$16,550,500
|
Total
Annual Cost ($)
|
$46,832,300
|
$46,832,300
|
Table
11: Environmental Costs for Units 1 and 2 – Dry FGD – Spray
Dryer Absorber
|
||
Cost
|
Unit
1
|
Unit
2
|
SO2
Baseline (TPY)1
|
9,394
|
8,570
|
SO2
Controlled (lb/mmBtu)
|
0.1
|
0.1
|
Annual
SO2
Controlled (TPY)2
|
2,017
|
2,017
|
Annual
SO2
Reduction (TPY)
|
7,377
|
6,553
|
Total
Annual Cost ($)
|
$46,832,300
|
$46,832,300
|
Cost
per Ton of Reduction
|
$6,348
|
$7,147
|
1Baseline
annual emissions are calculated as the average actual S02 emission rate during
the baseline years of 2004-2006.
17
OG&E
Sooner Generating Station BART Review
January 15, 2010
2Projected
annual emissions were calculated based on the controlled SO2 emissions
rate, full load heat input of 5,116 mmBtu/hr, and assuming 7,884 hours/year per
boiler (90% capacity factor).
OG&E
did not submit revised cost estimates for Wet FGD; however, in order to be
thorough, some conclusions can be drawn from the estimates provided for Dry FGD.
The total capital requirement for wet scrubbers was assumed to be consistent
with the previous determination. The capital recovery factor was modified to
reflect the current company position of a 20 year depreciation. The annual
operating costs were modified to reflect the cost bases for water, labor,
auxiliary power, taxes, insurance and administrative costs detailed in the
preceding paragraphs.
Table
12: Environmental Costs for Unit 2 – Wet FGD
|
||
Cost
|
OG&E
Cost Estimates
|
|
Unit
1
|
Unit
2
|
|
Total
Capital Investment ($)
|
$441,658,000
|
$441,658,000
|
Total
Capital Investment ($/kW)
|
$775
|
$775
|
Capital
Recovery Cost ($/Yr)
|
$37,898,900
|
$37,898,900
|
Annual
O&M Costs ($/Yr)
|
$16,550,500
|
$16,550,500
|
Total
Annual Cost ($)
|
$54,449,400
|
$54,449,400
|
Control
SO2
Emission Rate (lb/mmBtu)
|
0.08
|
0.08
|
Baseline
Annual Emissions (TPY)1
|
9,394
|
8,570
|
Controlled
Annual SO2
Emission (TPY)2
|
1,613
|
1,613
|
Annual
SO2
Reduction (TPY)
|
7,781
|
6,957
|
Cost
per Ton of Reduction ($/Ton)
|
$6,998
|
$7,827
|
Incremental
Annual Cost ($/Ton)
|
$18,854
|
$18,854
|
1Baseline
annual emissions were calculated based on average annual S02 emissions
for the years 2004-2006.
2Projected
annual emissions were calculated based on the controlled SO2 emissions
rate, full load heat input of 5,116 mmBtu/hr, and assuming 7,884 hours/year per
boiler (90% capacity factor).
C.
PM10
IDENTIFY
AVAILABLE RETROFIT CONTROL TECHNOLOGIES (PM10)
There
are two generally recognized PM control devices that are used to control PM
emission from PC boilers: ESPs and fabric filters (or baghouses). Sooner Units 1
& 2 are currently equipped with ESP control systems.
18
OG&E
Sooner Generating Station BART Review
January 15, 2010
Table
12: Summary of Technically Feasible
Main
Boiler PM10
Control Technologies
|
||
Control
Technology
|
PM10
Emissions1
(lb/mmBtu)
|
%
Reduction
(from
base case)
|
Fabric
Filter Baghouse
|
0.015
|
99.7
|
ESP
- Existing
|
0.039
|
99.3
|
Potential
PM Emissions
|
5.65
|
-
|
1The PM10 emission rate for the baghouse case is based on filterable PM10 emission limits included in recently issued PSD permits
for new coal-fired units. The PM10 emission rate for the ESP case is based
on the Units' baseline PM10 emission rates. Potential PM emissions
were calculated assuming an average fuel heating value of 8,500 Btu/lb and an
ash content of 6.0%, and assuming 80% of the fuel ash will be emitted as fly
ash.
EVALUATE IMPACTS AND DOCUMENT RESULTS
(PM10)
Costs for Fabric Filter Baghouses were
included in the cost estimates provided by OG&E for Dry FGD. Because of the
interdependency of the control systems, a determination of baghouse versus
existing ESP cannot be made without consideration of the eventual sulfur
control. Annual average PM emissions are less than 500 TPY for both boilers. On
a PM basis alone and assuming the current 20 year depreciation, no additional
operating costs, and 100% emission reduction, a resultant cost effectiveness of
$9,324 per ton would support the conclusion that further reductions from the
addition of a $45,000,000
fabric filter are not cost
effective.
D.
VISIBILITY IMPROVEMENT DETERMINATION
The
fifth of five factors that must be considered for a BART determination analysis,
as required by a 40 CFR part 51-Appendix Y, is the degree of Class I area
visibility improvement that would result from the installation of the various
options for control technology. This factor was evaluated for the Sooner
Generating Station by using an EPA-approved dispersion modeling system (CALPUFF)
to predict the change in Class I area visibility. The Division had previously
determined that the Sooner Generating Station was subject to BART based on the
results of initial screening modeling that was conducted using current
(baseline) emissions from the facility. The screening modeling, as well as more
refined modeling conducted by the applicant. is described in detail
below.
Wichita
Mountain Wildlife Refuge, Caney Creek, Upper Buffalo and Hercules Glade are the
closest Class I areas to the Sooner Generating Station, as shown in Figure 1
below.
Only
those Class I areas most likely to be impacted by the Sooner Generating Station
were modeled, as determined by source/Class I area locations, distances to each
Class I area, and professional judgment considering meteorological and terrain
factors. It can be reasonably assumed that areas at greater distances and in
directions of less frequent plume transport win experience lower impacts than
those predicted for the four modeled areas.
19
OG&E
Sooner Generating Station BART Review
January 15, 2010
IMAGE
NOT SHOWN
Figure
1: Plot of Facility location in relation to nearest Class I areas
REFINED
MODELING
Because
of the results of the applicants screening modeling for the Sooner Generating
Station, OG&E was required to conduct a refined BART analysis that included
CALPUFF visibility modeling for the facility. The modeling approach followed the
requirements described in the Division's BART modeling protocol, CENRAP BART Modeling Guidelines
(Alpine Geophysics, December 2005) with refinements detailed the
applicants CALMET modeling protocol, CALMET Data Processing Protocol
(Trinity Consultants, January 2008)
CALPUFF
System
Predicted
visibility impacts from the Sooner Generating Station were determined with the
EPA CALPUFF modeling system, which is the EPA-preferred modeling system for
long-range transport. As described in the EPA Guideline on Air Quality Models
(Appendix W of 40 CFR Part 51), long-range transport is defined as modeling with
source-receptor distances greater than 50 km. Because all modeled areas are
located more than 50 km from the sources in question, the CALPUFF system was
appropriate to use.
The
CALPUFF modeling system consists of a meteorological data pre-processor
(CALMET), an air dispersion model (CALPUFF), and post-processor programs
(POSTUTIL, CALSUM, CALPOST). The CALPUFF model was developed as a
non-steady-state air quality modeling system for assessing the effects of time-
and space-varying meteorological conditions on pollutant transport,
transformation, and removal.
CALMET
is a diagnostic wind model that develops hourly wind and temperature fields in a
three-dimensional, gridded modeling domain. Meteorological inputs to CALMET can
include surface and upper-air observations from multiple meteorological
monitoring stations.
20
OG&E
Sooner Generating Station BART Review
January 15, 2010
Additionally,
the CALMET model can utilize gridded analysis fields from various mesoscale
models such as MM5 to better represent
regional wind flows and complex terrain circulations. Associated two-dimensional
fields such as mixing height, land use, and surface roughness are included in
the input to the CALMET model. The CALMET model allows the user to "weight"
various terrain influences parameters in the vertical and horizontal directions
by defining the radius of influence for surface and upper-air
stations.
CALPUFF
is a multi-layer, Lagrangian puff dispersion model. CALPUFF can be driven by the
three-dimensional wind fields developed by the CALMET model (refined mode), or
by data from a single surface and upper-air station in a format consistent with
the meteorological files used to drive steady-state dispersion models. All
far-field modeling assessments described here were completed using the CALPUFF
model in a refined mode.
CALPOST
is a post-processing program that can read the CALPUFF output files, and
calculate the impacts to visibility.
All
of the refined CALPUFF modeling was conducted with the version of the CALPUFF
system that was recognized as the EPA-approved release at the time of the
application submittal. Version designations of the key programs are listed in
the table below.
Table
13: Key Programs in CALPUFF System
|
||
Program
|
Version
|
Level
|
CALMET
|
5.53a
|
040716
|
CALPUFF
|
5.8
|
070623
|
CALPOST
|
5.6394
|
070622
|
Meteorological
Data Processing (CALMET)
As
required by the Division's modeling protocol, the CALMET model was used to
construct the initial three-dimensional wind field using data from the MMS model. Surface and
upper-air data were also input to CALMET to adjust the initial wind
field.
The
following table lists the key user-defined CALMET settings that were
selected.
Table
14: CALMET Variables
|
||
Variable
|
Description
|
Value
|
PMAP
|
Map
projection
|
LCC
(Xxxxxxx Conformal Conic)
|
DGRIDKM
|
Grid
spacing (km)
|
4
|
NZ
|
Number
of layers
|
12
|
ZFACE
|
Cell
face heights (m)
|
0,
20, 40, 60, 80, 100, 150, 200, 250, 500, 1000, 2000,
3500
|
RMIN2
|
Minimum
distance for extrapolation
|
-1
|
IPROG
|
Use
gridded prognostic model outputs
|
14
km (MM5 data)
|
RMAX1
|
Maximum
radius of influence (surface layer, km)
|
20
km
|
21
OG&E
Sooner Generating Station BART Review
January 15, 2010
Variable
|
Description
|
Value
|
RMAX2
|
Maximum
radius of influence (layers aloft, km)
|
50
km
|
TERRAD
|
Radius
of influence for terrain (km)
|
10
km
|
R1
|
Relative
weighting of first guess wind field and observation (km)
|
10
km
|
R2
|
Relative
weighting aloft (km)
|
25
km
|
The
locations of the upper air stations with respect to the modeling domain are
shown in Figure 2.
IMAGE NOT
SHOWN
Figure
2: Plot of surface station locations
22
OG&E
Sooner Generating Station BART Review
January 15, 2010
IMAGE NOT
SHOWN
Figure
3: Plot of upper air station locations
IMAGE NOT
SHOWN
Figure 4. Plot of precipitation observation
stations
23
OG&E
Sooner Generating Station BART Review
January 15, 2010
CALPUFF
Modeling Setup
To
allow chemical transformations within CALPUFF using the recommended chemistry
mechanism (MESOPUFF II), the model required input of background ozone and
ammonia. CALPUFF can use either a single background value representative of an
area or hourly ozone data from one or more ozone monitoring stations. Hourly
ozone data files were used in the CALPUFF simulation. As provided by the
Oklahoma DEQ, hourly ozone data from the Oklahoma City, Glenpool, and Lawton
monitors over the 2001-2003 time frames were used. Background concentrations for
ammonia were assumed to be temporally and spatially invariant and were set to 3
ppb.
Latitude
and longitude coordinates for Class I area discrete receptors were taken from
the National Park Service (NPS) Class I Receptors database and converted to the
appropriate Xxx coordinates.
CALPUFF
Inputs-Baseline and Control Options
The
first step in the refined modeling analysis was to perform visibility modeling
for current (baseline) operations at the facility. Emissions of NOx and S02 for the
baseline runs were established based on CEM data and maximum 24-hour emissions
averages for years 2001 to 2003.
Baseline
source release parameters and emissions are shown in the table below, followed
by tables with data for the various control options.
Table
15: Baseline Source Parameters
|
||
Baseline
|
||
Parameter
|
Coal-Fired
Unit 1
|
Coal-Fired
Unit 2
|
Heat
Input (mmBtu/hr)
|
5,116
|
5,116
|
Stack
Height (m)
|
152.44
|
152.44
|
Stack
Diameter (m)
|
6.10
|
6.10
|
Stack
Temperature (K)2
|
430.78
|
430.78
|
Exit
Velocity (m/s)2
|
34.12
|
34.12
|
Baseline
SO2
Emissions (lb/mmBtu)
|
0.86
|
0.86
|
Dry
FGD SO2
Emissions (lb/mmBtu)
|
0.10
|
0.10
|
Wet
FGD SO2
Emissions (lb/mmBtu)
|
0.08
|
0.08
|
Baseline
NOx Emissions (lb/mmBtu)
|
0.601
|
0.584
|
LNB/OFA
NOx Emissions (lb/mmBtu)
|
0.15
|
0.15
|
LNB/OFA
+ SCR NOx Emissions (lb/mmBtu)
|
0.07
|
0.07
|
ESP
(Baseline) PM10
Emissions (lb/mmBtu)
|
0.0379
|
0.0391
|
FF
PM10
Emissions (lb/mmBtu)
|
0.012
|
0.012
|
1Baseline
emissions data were provided by OG&E. Baseline emission rates
(lb/mmBtu) were calculated by dividing the maximum 24-hr lb/hr emission rate by
the maximum heat input to the boiler.
2Temperature
and Velocity were decreased for DFGD and WFGD evaluations. For DFGD,
stack temperature was modeled at 359.11K and velocity decreased to 30.61
m/s. For WFGD, stack temperature decreased to 331.89K and velocity
decreased to 28.35 m/s.
24
OG&E
Sooner Generating Station BART Review
January 15, 2010
Visibility
Post-Processing (CALPOST) Setup
The
changes in visibility were calculated using Method 6 with the CALPOST
post-processor. Method 6 requires input of monthly relative humidity
factors [f(RH)] for each Class I area that is being modeled. Monthly
f(RH) factors that were used for this analysis are shown in the table
below.
Table
16: Relative Humidity Factors for CALPOST
|
||||
Month
|
Wichita
Mountains
|
Caney
Creek
|
Upper
Buffalo
|
Hercules
Glade
|
January
|
2.7
|
3.4
|
3.3
|
3.2
|
February
|
2.6
|
3.1
|
3.0
|
2.9
|
March
|
2.4
|
2.9
|
2.7
|
2.7
|
April
|
2.4
|
3.0
|
2.8
|
2.7
|
May
|
3.0
|
3.6
|
3.4
|
3.3
|
June
|
2.7
|
3.6
|
3.4
|
3.3
|
July
|
2.3
|
3.4
|
3.4
|
3.3
|
August
|
2.5
|
3.4
|
3.4
|
3.3
|
September
|
2.9
|
3.6
|
3.6
|
3.4
|
October
|
2.6
|
3.5
|
3.3
|
3.1
|
November
|
2.7
|
3.4
|
3.2
|
3.1
|
December
|
2.8
|
3.5
|
3.3
|
3.3
|
EPA’s
default average annual aerosol concentrations for the U.S. that are included in
Table 2-1 of EPA’s Guidance
for Estimating Natural Visibility Conditions Under the Regional Haze
Program were to develop natural background estimates for each Class I
area.
Visibility
Post-Processing Results
Table
17: CALPUFF Visibility Modeling Results for Sooner Units 1 and
2 - NOx
|
||||||||
2001
|
2002
|
2003
|
3-Year
Average
|
|||||
Class
I Area
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
o f Days
>
0.5
∆dv
|
Baseline
|
||||||||
Wichita
Mountains
|
1.244
|
19
|
0.901
|
16
|
1.199
|
25
|
1.115
|
20
|
Caney
Creek
|
0.577
|
10
|
0.404
|
5
|
0.541
|
10
|
0.507
|
8
|
Upper
Buffalo
|
0.573
|
8
|
0.335
|
4
|
0.337
|
3
|
0.415
|
5
|
Hercules
Glade
|
0.440
|
6
|
0.274
|
5
|
0.388
|
1
|
0.367
|
4
|
Scenario
1 – Combustion Control – LNB/OFA
|
||||||||
Wichita
Mountains
|
0.309
|
0
|
0.236
|
1
|
0.308
|
0
|
0.284
|
0
|
Caney
Creek
|
0.147
|
0
|
0.103
|
0
|
0.14
|
0
|
0.13
|
0
|
Upper
Buffalo
|
0.139
|
0
|
0.085
|
0
|
0.084
|
0
|
0.103
|
0
|
Hercules
Glade
|
0.109
|
3
|
0.064
|
1
|
0.095
|
3
|
0.089
|
2
|
25
OG&E
Sooner Generating Station BART Review
January 15, 2010
Modeling
for SCR controls resulted in an approximately 50% reduction in visibility
impairment from scenario one.
Table
18: CALPUFF Visibility Modeling Results for Sooner Units 1 and
2 – SO2
|
||||||||
2001
|
2002
|
2003
|
3-Year
Average
|
|||||
Class
I Area
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
o f Days
>
0.5
∆dv
|
Baseline
|
||||||||
Wichita
Mountains
|
1.244
|
24
|
1.081
|
24
|
1.792
|
33
|
1.366
|
27
|
Caney
Creek
|
0.709
|
11
|
0.505
|
10
|
0.584
|
11
|
0.599
|
11
|
Upper
Buffalo
|
0.534
|
10
|
0.357
|
4
|
0.43
|
5
|
0.440
|
6
|
Hercules
Glade
|
0.423
|
5
|
0.267
|
2
|
0.34
|
3
|
0.343
|
3
|
Scenario
1 – Dry FGD
|
||||||||
Wichita
Mountains
|
0.169
|
3
|
0.141
|
0
|
0.219
|
3
|
0.176
|
2
|
Caney
Creek
|
0.08
|
0
|
0.062
|
0
|
0.063
|
0
|
0.068
|
0
|
Upper
Buffalo
|
0.051
|
0
|
0.045
|
0
|
0.043
|
0
|
0.046
|
0
|
Hercules
Glade
|
0.05
|
0
|
0.033
|
0
|
0.037
|
0
|
0.04
|
0
|
While
mass emissions are decreased marginally with Wet FGD controls modeled impacts
increase over modeled concentrations in scenario one. This increased degradation
is a result of lower stack temperatures and velocities and higher SO4 emission
estimates.
Modeling
for existing ESP controls with proposed fabric filters indicate the visibility
impairment from direct PM emissions will be improved with the fabric filters but
both technologies control visibility impairment well below 0.5dv at all Class I
areas.
X.
XXXX DETERMINATION
After considering: (1) the costs of
compliance, (2) the energy and non-air quality environmental impacts of
compliance; (3) any pollutant equipment in use or in existence at the source,
(4) the remaining useful life of the source, and (5) the degree of improvement
in visibility (all five statutory factors) from each proposed control
technology, the Division determined BART for the two units at the Sooner
Generating Station.
NOx
New
LNB with OFA is determined to be BART for NOx control for Units 1 and 2based, in
part, on the following conclusions:
1.
|
Installation
of new LNB with OFA was cost effective, with a capital cost of $14,055,900
per unit for units 1 and 2 and an average cost effectiveness of $493-785
per ton of NOx removed for each unit over a twenty-five year operational
life.
|
2.
|
Combustion control using the
LNB/OFA does not require non-air quality environmental mitigation for the
use of chemical reagents (i.e., ammonia or urea) and there is
minimal energy impact.
|
3.
|
After careful consideration of the
five statutory factors, especially the costs
of
|
26
OG&E
Sooner Generating Station BART Review
January 15, 2010
compliance and existing controls,
NOx control levels on 30-day rolling
averages of 0.15 lb/mmBtu for Unit 1 and 2 are justified meet the presumptive
limits prescribed by EPA.
4.
|
Annual NOx emission reductions from new LNB
with OFA on Units 1 and 2 are 2,664- 4,241 tons for a total annual
reduction of 6,905 tons based on actual emissions from 2004-2006 and
projected emissions at maximum heat input and 90%
capacity.
|
LNB
with OFA and SCR was not determined to be BART for NOx control for Units 1 and 2
based, in part, on the following conclusions:
1.
|
The cost of compliance for
installing SCR on each unit is significantly higher than the cost for LNB
with OFA. Additional capital costs for SCR on Units 1 and 2 are on average
$192,018,500 per unit. Based on projected emissions, SCR could reduce
overall NOx emissions from Sooner Units 1 and
2 by approximately 3,226 TPY beyond combustion controls; however, the
incremental cost associated with this reduction is approximately
$17,795/ton.
|
2.
|
Additional
non-air quality environmental mitigation is required for the use of
chemical reagents.
|
3.
|
Operation
of LNB with OFA and SCR is parasitic and requires power from each
unit.
|
4.
|
The cumulative visibility
improvement for SCR, as compared to LNB/OFA across Wichita Mountains and
Caney Creek (based on the 98th percentile modeled results) was
0.15 ∆dv for both units.
|
SO2
Continued
use of low sulfur coal is determined to be BART for SO2 control for Units 1 and 2
based on the capital cost of add-on controls, the cost effectiveness both in
$/ton and $/dv of add-on controls, and the long term viability of coal with
respect to other environmental programs, and national commitments.
Installation of DFGD is not cost
effective. OG&E's revised cost estimates are based on vendor quotes and go
well beyond the default methodology recommended by EPA guidance. The cost estimates are credible,
detailed, and specific for the Sooner facility. The final estimate for both
boilers at $584,589,800 is $175,329,800 greater than the high end costs assumed
by DEQ in the Draft SIP.
These costs put the project well above
costs reported for other BART determinations. The federal land managers have
informally maintained a spreadsheet of BART costs and determinations for
coal-fired facilities. This spreadsheet indicates that the highest reported cost
for control was for the Boardman facility in Oregon at a projected cost of
$247,300,000. While there is some uncertainty on whether this cost will
ultimately be found to be cost effective, it is lower than the cost of
controlling a single boiler at the Sooner facility ($292,294,700). Most
assessments were based on costs of less than $150,000,000 and related cost effectiveness numbers
of $3,053/ton removed for Xxxxxxxx to an average of less than $2,000/ton for the
other determinations tracked by the FLMs.
Table
20 provides a summary of the baseline S02 emission rates included in several
BART evaluations.
27
OG&E
Sooner Generating Station BART Review
January 15, 2010
Table 20: Comparison
of Baseline SO2 Emissions at Several BART
Units
|
||
Station
|
Baseline SO2 Emission Rate
(lb/mmBtu)
|
Baseline SO2 Emissions
(TPY)
|
Muskogee
Unit 4
|
0.507
|
9,113
|
Muskogee
Unit 5
|
0.514
|
9,006
|
Sooner
Unit 1
|
0.509
|
9,394
|
Sooner
Unit 2
|
0.516
|
8,570
|
NPPD
Xxxxxx Gentleman Unit 1
|
0.749
|
24,254
|
NPPD
Xxxxxx Gentleman Unit 2
|
0.749
|
25.531
|
White
Bluff Unit 1
|
0.915
|
31,806
|
White
Bluff Unit 2
|
0.854
|
32,510
|
Xxxxxxxx
unit 1
|
0.614
|
14,902
|
Northeastern
Unit 3
|
0.900
|
16,000
|
Northeastern
Unit 4
|
0.900
|
16,000
|
Xxxxxxxx
Unit 1
|
1.180
|
8,624
|
Xxxxxxxx
Unit 2
|
1.180
|
11,187
|
OPPD
Nebraska City Unit 1
|
0.815
|
24,191
|
Assuming
total annual costs and projected emissions are similar and thereby setting aside
the issues related to pre-2008 cost estimates and the ability to compare them to
December 2009 estimates, cost effectiveness will be a function of the baseline
emissions. This holds true for units firing subbituminous coals with baseline
SO2 emissions rates in the
range of 0.5 lb/mmBtu to approximately 2.0 lb/mmBtu, because removal
efficiencies achievable with DFGD control will vary based on inlet SO2 loading. In general, DFGD
control systems are capable of achieving higher removal efficiencies on units
with higher inlet SO2
loading. DFGD control systems will be more cost effective on units with higher
baseline SO2 emissions
because the control systems will be capable of achieving higher removal
efficiencies and remove more tons of SO2 per year for similar costs.
Conversely, DFGD will be less cost effective, on a $/ton basis, on units with
lower SO2 baseline
emissions. On the basis of baseline emissions alone, with all other factors
being equal, the cost effectiveness of the OG&E units would be about 55 to
185% higher than the other units listed, i.e., less cost effective.
The
average cost effectiveness at Sooner for DFGD is $6,348-$7,147 per ton of
SO2 removed for each unit
over a twenty year operational life. The cost of this control at the Sooner
facility is well above the average cost effectiveness reported for similar BART
projects, well above costs associated with BACT determinations for SO2, and well above the cost of
control originally contemplated in the Regional Haze Rule.
From the
FLM BART tracking spreadsheet, the average cost effectiveness in $/dv was
$5,700,000/dv. The addition of DFGD at the Sooner Facility was anticipated to
reduce impairment by 2.44 dv. Importantly, the cost effectiveness of that
improvement is now calculated to be $38,387,000/dv.
A
majority of the Class I areas are located in the western part of the U.S. Simply
due to the number of Class I areas in the west, it is likely that a BART
applicable unit located in the western U.S. will be closer to a Class I area,
and that emissions from the unit will affect visibility
28
OG&E
Sooner Generating Station BART Review
January 15, 2010
at more
Class I areas. For example, the Xxxxxxxx Generating Station located in the north
central region approximately 150 miles east of Portland, is located within 300
km of 14 Class I areas. By comparison the Sooner station is located with 300 km
of 1 Class I area. Using the sum of modeled visibility improvements at all 14
Class I areas, cost effectiveness of the DFGD control system would be
$3,690,510/dv or 10.4 times more cost effective than DFGD controls at the Sooner
facility. The federal land managers have indicated that costs effectiveness
numbers of less than $10,000,000/dv should be considered cost effective. While
this does not prohibit a determination of cost effectiveness at numbers greater
than $10,000,000/dv, it does imply that numbers greater than that should receive
greater consideration.
An
investment of this magnitude to install DFGD on an existing coal-fired power
plant effectively guarantees the continued use of coal as the primary fuel
source for energy generation in this facility and arguably the state for the
next 20 years and beyond. Therefore, a determination in support of DFGD ignores
the Obama Administration's stated agenda to control carbon dioxide and other
green house gases by restricting the alternatives left open to OG&E and
hence the ratepayers of Oklahoma. Substantial uncertainty currently exists about
the nature and costs of future federal carbon controls on power plants,
including the level of stringency, timing, emissions allowance allocation and
prices, and whether and to what degree emissions "offsets" are allowed. Further,
new federal MACT mercury control requirements may be imposed on the Sooner
facility that would be more stringent than the scrubber can deliver.
Fortunately, other technology options now exist that would likely achieve
greater mercury reductions at lower cost than the scrubber. If EPA determines
that MACT requires greater reductions than those achieved through DFGD, then
ratepayers would be at risk to pay for additional required mercury control
technology.
The cost
for DFGD is too high, the benefit too low and these costs, if borne, further
extend the life expectancy of coal as the primary fuel in the Sooner facility
for at least 20 years and beyond. BART is the continued use of low sulfur
coal.
Wet FGD
was not determined to be BART for SO2 control for Units 1 and 2
based, in part, on the following conclusions:
|
1.
|
The
cost of compliance for installing WFGD on each unit is higher than the
cost for DFGD. Based on projected emissions, WFGD could reduce overall
SO2 emissions from
Sooner Units 1 and 2 by approximately 808 TPY beyond dry scrubbers;
however, the incremental cost associated with this reduction is
approximately $18,854/ton.
|
|
2.
|
SO3 remaining in the flue gas
will react with moisture in the wet FGD to generate sulfuric acid mist.
Sulfuric acid is classified as a condensable particulate. Condensable
particulates from the wet FGD system can be captured using additional
emission controls (e.g., XXXX). However, the effectiveness of a XXXX
system on a subbituminous fired unit has not been demonstrated and the
additional cost of the XXXX system significantly increases the cost of
SO2
controls.
|
|
3.
|
Wet
FGD systems must be located downstream of the unit's particulate control
device; therefore, dissolved solids from the wet FGD system will be
emitted with the wet FGD plume. Wet FGD control systems also generate
lower stack temperatures that can reduce plume rise and result in a
visible moisture plume.
|
29
OG&E
Sooner Generating Station BART Review
January 15, 2010
4.
|
Wet
FGD systems use more reactant (e.g., limestone) than do dry systems,
therefore the limestone handling system and storage piles will generate
more fugitive dust emissions.
|
5.
|
Wet
FGD systems require significantly more water than the dry systems and
generate a wastewater stream that must be treated and discharged. We FGD
wastewater treatment systems typically require calcium sulfate/sulfite
desaturation, heavy metals precipitation, coagulation/precipitation, and
sludge dewatering. Treated wastewater is typically discharged to surface
water pursuant to an NPDES discharge permit, and solids are typically
disposed of in a landfill. Dry FGD control systems are designed to
evaporate water within the reaction vessel, and therefore do not generate
a wastewater stream.
|
6.
|
Because
of a slower exit velocity, lower stack temperature and higher SO4 emissions associated with
Wet FGD, visibility impairment was found to higher under this control
strategy than the Dry FGD.
|
PM10
The
existing ESP control is determined to be BART for PM10
controls for Units 1 and 2 based on the determination of low sulfur coal and the
high cost of fabric filters relative to the low actual emissions of PM10
from the facility.
Table
21: Unit-by-unit BART determinations
|
||
Control
|
Unit
1
|
Unit
2
|
NOx Control
|
New
LNB with OFA
|
New
LNB with OFA
|
Emission
Rate (lb/mmBtu)
|
0.15
lb/mmBtu
(30-day
rolling average)
|
0.15
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
767
lb/hr
(30-day
rolling average)
|
767
lb/hr
(30-day
rolling average)
|
Emission
Rate TPY
|
3,361
TPY
(12-month
rolling)
|
3,361
TPY
(12-month
rolling)
|
SO2 Control
|
Low
Sulfur Coal
|
Low
Sulfur Coal
|
Emission
Rate (lb/mmBtu)
|
0.65
lb/mmBtu
(30-day
rolling average)
|
0.65
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
3,325
lb/hr
(30-day
rolling average)
|
3,325
lb/hr
(30-day
rolling average)
|
Annual
Emission Rate
(lb/mmBtu)
|
0.55
lb/mmBtu
(annual
average)
|
0.55
lb/mmBtu
(annual
average)
|
Emission
Rate TPY
|
19,736
TPY
|
|
PM10 Control
|
Existing
ESP
|
Existing
ESP
|
Emission
Rate (lb/mmBtu)
|
0.1
lb/mmBtu
|
0.1
lb/mmBtu
|
Emission
Rate lb/hr
|
512
lb/hr
|
512
lb/hr
|
Emission
Rate TPY
|
2,241
TPY
(12-month
rolling average)
|
2,241
TPY
(12-month
rolling average)
|
30
OG&E
Sooner Generating Station BART Review
January 15, 2010
F.
CONTINGENT BART DETERMINATION
In the
event that EPA disapproves the BART Determination referenced above in regard to
the DEQ determination that DFGD with SDA is not cost-effective for SO2 control, the low-sulfur coal
requirement in the BART determination for SO2 and the related ESP requirement
for PM referenced above shall be replaced with a requirement that Sooner Units 1
and 2 install DFGD with SDA for SO2 control and fabric filters for
PM control or meet the corresponding SO2 and PM10 emission limits listed below
by December 31, 2018 or comply with the approved alternative described in
section G (Greater Reasonable Progress Alternative).
Table
22: Unit-by-unit Contingent BART
determinations
|
||
Control
|
Unit
1
|
Unit
2
|
SO2 Control
|
DFGD
w/SDA
|
DFGD
w/ SDA
|
Emission
Rate (lb/mmBtu)
|
0.1
lb/mmBtu
(30-day
rolling average)
|
0.1
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
512
lb/hr
(30-day
rolling average)
|
512 lb/hr
(30-day
rolling average)
|
Emission
Rate TPY
|
2,241
TPY
|
2,241
TPY
|
PM10 Control
|
Fabric
Filter
|
Fabric
Filter
|
Emission
Rate (lb/mmBtu)
|
0.015
lb/mmBtu
|
0.015
lb/mmBtu
|
Emission
Rate lb/hr
|
77
lb/hr
|
77
lb/hr
|
Emission
Rate TPY
|
336
TPY
(12-month
rolling average)
|
336
TPY
(12-month
rolling average)
|
The
"contingent" XXXX as defined here and in conjunction with the greater reasonable
progress alternative recognizes the long term importance of achieving reductions
in SO2 while addressing the
need for operational flexibility in response to the eventualities of a federal
carbon trading program and mercury MACT in the nearer term. It must be
understood that DEQ has determined that DFGD is not cost effective. However, if
EPA chooses to ignore that element of the BART determination, DEQ does agree
that DFGD remains an achievable control option for SO2 reductions.
Switching
from coal to natural gas, while physically possible constitutes a significant
modification to a facility process not contemplated by the regional haze role.
However, exploring some combination of both options, while allowing the
uncertainty surrounding other federal environmental programs to settle, is a
more equitable alternative for the ratepayers in Oklahoma than requiring an
overly costly control merely to achieve limited reductions while simultaneously
solidifying the use of a dirty technology from now into the foreseeable
future.
G.
GREATER REASONABLE PROGRESS ALTERNATIVE DETERMINATION
In lieu
of installing and operating BART for SO2 and PM control at Sooner Units
1 and 2 and Muskogee Units 4 and 5. OG&E may elect to implement a fuel
switching alternative. The greater reasonable progress alternative requires
OG&E to achieve a combined annual SO2
emissions limit (identified in table 23) by installing and operating DFGD
with SDA on two of the four boilers and being at or below the SO2 emission that would result from
switching the
31
OG&E
Sooner Generating Station BART Review
January 15, 2010
remaining
two boiler to natural gas. Under this alternative OG&E shall install the
controls (i.e., DFGD with SDA or achieve equivalent emissions) by December 31,
2026. By adopting these emission limits, DEQ and OG&E expect the cumulative
SO2 emissions from Sooner Units 1
and 2 and Muskogee Units 4 and 5 to be approximately 57% less than would be
achieved through the installation and operation of DFGD with SDA at all four
units (assuming 90% capacity).
Table
23: SO2
Emissions with Greater Reasonable Progress
|
||
Muskogee
|
Sooner
|
|
Parameter
|
Unit
4 and Unit 5
|
Unit
1 and Unit 2
|
BART
(Low Sulfur Coal)
|
18,096
TPY
|
19,736
TPY
|
Contingent
BART (DFGD)
|
4,800
TPY
|
4,482
TPY
|
GRP
(DFGD/Natural Gas)
|
3,600
TPY
|
Under no
circumstance will the Greater Reasonable Progress Plan result in less visibility
improvement than would be achieved either through the DEQ determined BART or the
"contingent" BART. By allowing the installation of SO2 controls to be delayed, current
regulatory hurdles to long term natural gas contracts can be addressed and the
best interests of the ratepayers and visitors to our Class I areas can be
preserved for the long term 2064 goal of natural visibility.
V.
CONSTRUCTION PERMIT
Prevention
of Significant Deterioration (PSD)
Sooner
Generating Station is a major source under OAC 252:100-8 Permits for Part 70
Sources. Oklahoma Gas and Electric should comply with the permitting
requirements of Subchapter 8 as they apply to the installation of controls
determined to meet XXXX.
The
installation of controls determined to meet XXXX will not change NSPS or
NESHAP/MACT applicability for the gas-fired units at the Sooner Station. The
permit application should contain PM10 and PM2.5 emission
estimates for filterable and condensable emissions.
VI.
OPERATING PERMIT
The
Sooner Generating Station is a major source under OAC 252:100-8 and has
submitted an application to modify their existing Title V permit to incorporate
the requirement to install controls determined to meet XXXX. The Permit will
contain the following specific conditions:
1.
The boilers in EUG 2 are subject to the Best Available Retrofit Technology
(BART) requirements of 40 CFR Part 51, Subpart P, and shall comply with all
applicable requirements including but not limited to the following: [40 CFR §§
51.300-309 & Part 51, Appendix Y]
|
a.
|
Affected
facilities. The following sources are affected facilities and are subject
to the requirements of this Specific Condition, the Protection of
Visibility and Regional Haze Requirements of 40 CFR Part 51, and all
applicable SIP requirements:
|
32
OG&E
Sooner Generating Station BART Review
January 15, 2010
EU
ID#
|
Point
ID#
|
EU
Name
|
Heat
Capacity
(MMBTUH)
|
Construction
Date
|
2-B
|
01
|
Unit
1 Boiler
|
5,116
|
1974
|
2-B
|
02
|
Unit
2 Boiler
|
5,116
|
1974
|
|
b.
|
Each
existing affected facility shall install and operate the SIP approved BART
as expeditiously as practicable but in no later than five years after
approval of the SIP incorporating the BART
requirements.
|
|
c.
|
The
permittee shall apply for and obtain a construction permit prior to
modification of the boilers. If the modifications will result
in a significant emission increase and a significant net emission increase
of a regulated NSR pollutant, the applicant shall apply for a PSD
construction permit.
|
|
d.
|
The
affected facilities shall be equipped with the following current
combustion control technology, as determined in the submitted BART
analysis, to reduce emissions of NOx to below the emission
limits below:
|
|
i. Low-
NOx Burners,
|
|
ii. Overfire
Air.
|
|
e.
|
The
permittee shall maintain the controls (Low-NOX burners, overfire air) and
establish procedures to ensure the controls are properly operated and
maintained.
|
|
f.
|
Within
60 days of achieving maximum power output from each affected facility,
after modification or installation of BART, not to exceed 180 days from
initial start-up of the affected facility the permittee shall comply with
the emission limits established in the construction permit. The
emission limits established in the construction permit shall be consistent
with manufacturer’s data and an agreed upon safety factor. The
emission limits established in the construction permit shall not exceed
the following emission limits:
|
EU
ID#
|
Point
ID#
|
NOx
Emission
Limit
|
SO2
Emission
Limit
|
Averaging
Period
|
2-B
|
01
|
0.15
lb/mmBtu
|
0.65
lb/mmBtu
|
30-day
rolling
|
2-B
|
02
|
0.15
lb/mmBtu
|
0.65
lb/mmBtu
|
30-day
rolling
|
EU
ID#
|
Point
ID#
|
PM10
|
2-B
|
01
|
0.1
lb/mmBtu
|
2-B
|
02
|
0.1
lb/mmBtu
|
EU
ID#
|
Point
ID#
|
SO2
Emission
Limit
|
SO2
Emission
Limit
|
Averaging
Period
|
2-B
|
01
|
19,736
|
0.55
lb/mmBtu
|
Annual
rolling
|
2-B
|
02
|
0.55
lb/mmBtu
|
Annual
rolling
|
|
g.
|
Boiler
operating day shall have the same meaning as in 40 CFR Part 60, Subpart
Da.
|
|
h.
|
Within
60 days of achieving maximum power output from each boiler, after
modification of the boilers, not to exceed 180 days from initial start-up,
the
|
33
OG&E
Sooner Generating Station BART Review
January 15, 2010
|
permittee
shall conduct performance testing as follows and furnish a written report
to Air Quality. Such report shall document compliance with BART
emission limits for the affected facilities. [OAC
252:100-8-6(a)]
|
i.
|
The
permittee shall conduct SO2, NOx, PM10,
PM2.5, CO, and VOC
testing on the boilers at 60% and 100% of the maximum
capacity. NOX and CO testing shall also be conducted at least
one additional intermediate point in the operating
range.
|
ii.
|
Performance
testing shall be conducted while the units are operating within 10% of the
desired test rates. A testing protocol describing how the
testing will be performed shall be provided to the AQD for review and
approval at least 30 days prior to the start of such
testing. The permittee shall also provide notice of the actual
test date to AQD.
|
34
EXHIBIT
C
Oklahoma
Department of Environmental Quality
Air Quality
Division
BART
Application Analysis
|
January
15, 2010
|
|
COMPANY:
|
Oklahoma
Gas and Electric
|
|
FACILITY:
|
Muskogee
Generating Station
|
|
FACILITY
LOCATION:
|
Muskogee,
Muskogee County, Oklahoma
|
|
TYPE
OF OPERATION:
|
(2)
572 MW Steam Electric Generating Units
|
|
REVIEWER:
|
Xxxxxxx
Xxxxxxx, Senior Engineering Manager
|
|
Xxx
Xxxxxx, Engineering Manager
|
I.
PURPOSE OF APPLICATION
On July
6, 2005, the U.S. Environmental Protection Agency (EPA) published the final
"Regional Haze Regulations and Guidelines for Best Available Retrofit Technology
Determinations" (the "Regional Haze Rule" 70 FR 39104). The Regional Haze Rule
requires certain States, including Oklahoma, to develop programs to assure
reasonable progress toward meeting the national goal of preventing any future,
and remedying any existing, impairment of visibility in Class I Areas. The
Regional Haze Rule requires states
to submit a plan to implement the regional haze requirements (the Regional Haze
SIP). The Regional Haze SIP must provide for a Best Available Retrofit
Technology (BART) analysis of any existing stationary facility that might cause
or contribute to impairment of visibility in a Class I Area.
II.
XXXX ELIGIBILITY DETERMINATION
BART-eligible sources include those
sources that:
(1)
have the potential to emit 250 tons or more of a visibility-impairing air
pollutant;
(2)
were in existence on August 7, 1977 but not in operation prior to August 7,
1962; and
(3) whose operations fall within one or more of the specifically
listed source categories in 40 CFR 51.301 (including fossil-fuel fired steam
electric plants of more than 250 mmBtu/hr heat input and fossil-fuel boilers of
more than 250 mmBtu/hr heat input).
Muskogee
Units 4 and 5 are fossil-fuel fired boilers with heat inputs greater than 250
mmBtu/hr. Both units were in existence prior to August 7, 1977 but not in
operation prior to August 7, 1962. Based on a review of existing emissions data,
both units have the potential to emit more than 250 tons per year of NOx,
SO2
and PM10,
visibility impairing pollutants. Therefore, Muskogee Units 4 and 5 meet the
definition of a BART-eligible source.
XXXX
is required for any BART-eligible source that emits any air pollutant which may
reasonably be anticipated to cause or contribute to any impairment of visibility
in a Class I Area.
OG&E
Muskogee Generating Station BART Review January 15,
2010
DEQ
has determined that an individual source will be considered to "contribute to
visibility impairment" if emissions from the source result in a change in
visibility, measured as a change in deciviews (∆-dv), that is greater than or
equal to 0.5 dv in a Class I area. Visibility impact modeling conducted by
OG&E determined that the maximum predicted visibility impacts from Muskogee
Units 4 and 5 exceeded the 0.5 ∆-dv threshold at the Wichita Mountains, Caney
Creek Upper Buffalo, and Hercules Glade Class I Areas. Therefore, Muskogee Units
4 and 5 were determined to be BART applicable sources, subject to the BART
determination requirements.
III.
DESCRIPTION OF BART SOURCES
Baseline
emissions from Muskogee Units 4 and 5 were developed based on an evaluation of
actual emissions data submitted by the facility pursuant to the federal Acid
Rain Program. In accordance with EPA guidelines in 40 CFR 51 Appendix Y Part
III, emission estimates used in the modeling analysis to determine visibility
impairment impacts should reflect steady-state operating conditions during
periods of high capacity utilization. Therefore, modeled emissions (lb/hr)
represent the highest 24-hour block emissions reported during the baseline
period. Baseline emission rates (lb/mmBtu) were calculated by dividing the
average annual mass emission rates for each boiler by the boiler's average heat
input over the years 2004 through 2006.
Table
1: Muskogee Generating Station – Plant Operating Parameters for
BART Evaluation
|
||||
Parameter
|
Muskogee
Unit 4
|
Muskogee
Unit 5
|
||
Plant
Configuration
|
Pulverized
Coal-Fired Boiler
|
Pulverized
Coal-Fired Boiler
|
||
Firing
Configuration
|
Tangentially-fired
|
Tangentially-fired
|
||
Gross
Output (nominal)
|
572
MW
|
572
MW
|
||
Maximum
Input to Boiler
|
5,480
mmBtu/hr
|
5,480
mmBtu/hr
|
||
2004
– 2006 Average
Heat
Input to Boiler
|
4,594
mmBtu/hr
|
4,739
mmBtu/hr
|
||
Primary
Fuel
|
Subbituminous
coal
|
Subbituminous
coal
|
||
Existing
NOx Controls
|
Combustion
Controls
|
Combustion
Controls
|
||
Existing
PM10
Controls
|
Electrostatic
precipitator
|
Electrostatic
precipitator
|
||
Existing
SO2
Controls
|
Low-sulfur
coal
|
Low-sulfur
coal
|
||
Maximum
24-hour Emissions
|
||||
Pollutant
|
lb/hr
|
lb/mmBtu
|
lb/hr
|
lb/mmBtu
|
NOx
|
2,710
|
0.495
|
2,863
|
0.522
|
SO2
|
4,384
|
0.800
|
4,657
|
0.850
|
PM10
|
101
|
0.018
|
134
|
0.024
|
Baseline
Emissions (2004-2006)
|
||||
Pollutant
|
lb/hr
|
lb/mmBtu
|
lb/hr
|
lb/mmBtu
|
NOx
|
1,342
|
0.292
|
1,545
|
0.326
|
SO2
|
2,329
|
0.507
|
2,436
|
0.514
|
2
OG&E
Muskogee Generating Station BART Review January 15,
2010
IV.
BEST AVAILABLE RETROFIT TECHNOLOGY (BART)
Guidelines
for making BART determinations are included in Appendix Y of 40 CFR Part 51
(Guidelines for BART Determinations under the Regional Haze Rule). States are
required to use the Appendix Y guidelines to make BART determinations for
fossil-fuel-fired generating plants having a total generating capacity in excess
of 750 MW. The BART determination process described in Appendix Y includes the
following steps:
Step
l. Identify All Available
Retrofit Control Technologies.
Step
2. Eliminate Technically Infeasible Options.
Step
3. Evaluate Control Effectiveness of Remaining Control
Technologies.
Step
4. Evaluate Impacts and Document the Results.
Step
5. Evaluate Visibility Impacts.
In
the final Regional Haze Rule U.S. EPA established presumptive BART emission
limits for S02 and
NOx
for certain electric generating units (EGUs) based on fuel type, unit size, cost
effectiveness, and the presence or absence of pre-existing controls. The
presumptive limits apply to EGUs at power plants with a total generating
capacity in excess of 750 MW. For these sources, EPA established presumptive
emission limits for coal-fired EGUs greater than 200 MW in size. The presumptive
levels are intended to reflect highly cost-effective technologies as well as
provide enough flexibility to States to consider source specific characteristics
when evaluating BART. The BART S02
presumptive emission limit for coal-fired EGUs greater than 200 MW in size
without existing S02 control is
either 95% S02 removal,
or an emission rate of 0.15 lb/mmBtu, unless a State determines that an
alternative control level is justified based on a careful consideration of the
statutory factors. For NOx, EPA
established a set of BART presumptive emission limits for coal-fired EGUs
greater than 200 MW in size based upon boiler size and coal type. The BART
NOx
presumptive emission limit applicable to Muskogee Units 4 and 5 (tangentially
fired boilers firing subbituminous coal) is 0.15 lb/mmBtu.
Table
2: Proposed BART Controls and Limits
|
||
Unit
|
NOx
BART Emission Limit
|
BART
Technology
|
Muskogee
Unit 4
|
0.15
lb/mmBtu (30-day average)
|
Combustion
controls including LNB/OFA
|
Muskogee
Unit 5
|
0.15
lb/mmBtu (30-day average)
|
Combustion
controls including LNB/OFA
|
Unit
|
S02 BART Emission Limit
|
BART
Technology
|
Muskogee
Unit 4
|
0.65
lb/mmBtu (30-day average)
|
Low
Sulfur Coal
|
0.55
lb/mmBtu (annual average)
|
||
Muskogee
Unit 5
|
0.65
lb/mmBtu (30-day average)
|
Low
Sulfur Coal
|
0.55
lb/mmBtu (annual average)
|
||
Units
4 and 5
|
18,096
TPY
|
Low
Sulfur Coal
|
Unit
|
PM10
BART Emission Limit
|
BART
Technology
|
Muskogee
Unit 4
|
0.1
lb/mmBtu (3-hour average)
|
Electrostatic
precipitator
|
Muskogee
Unit 5
|
0.1
lb/mmBtu (3-hour average)
|
Electrostatic
precipitator
|
3
OG&E
Muskogee Generating Station BART Review January 15,
2010
A.
NOx
IDENTIFY
AVAILABLE RETROFIT CONTROL TECHNOLOGIES
Potentially
available control options were identified based on a comprehensive review of
available information. NOx control technologies with potential application to
Muskogee Units 4 and 5 are listed in Table 3.
Table
3: List of Potential Control Options
|
Control
Technology
|
Combustion
Controls
|
Low
NOx Burners and Overfire Air (LNB/OFA)
|
Flue
Gas Recirculation (FGR)
|
Post
Combustion Controls
|
Selective
Noncatalytic Reduction (SNCR)
|
Selective
Catalytic Reduction (SCR)
|
Innovative
Control Technologies
|
Rotating
Overfire Air (ROFA)
|
ROFA
+ SNCR (Rotamix)
|
Xxxxxxx
Multi-Pollutant Control Process
|
Wet
NOx Scrubbing
|
ELIMINATE
TECHNICALLY INFEASIBLE OPTIONS (NOx)
Combustion
Controls:
Low
NOx burners (LNB)/ OverFire Air (OFA)
Low
NOx burners (LNB) limit NOx formation by controlling both the stoichiometric and
temperature profiles of the combustion flame in each burner flame envelope. Over
Fire Air (OFA) allows for staged combustion. Staging combustion reduces NOx
formation with a cooler flame in the initial stage and less oxygen in the second
stage.
LNB/OFA
emission control systems have been installed as retrofit control technologies on
existing coal-fired boilers. Muskogee units 4 and 5 operate as base
load units. While technically feasible, LNB/OFA may not be as effective under
all boiler operating conditions, especially during load changes and at low
operating loads. Based on information available from burner control vendors and
engineering judgment, it is expected that LNB/OFA on the
tangentially-fired boilers can be designed to meet the presumptive NOx BART
emission rate of 0.15 lb/mmBtu on a 30-day rolling average and under all normal
operating conditions while maintaining acceptable CO and VOC emission
rates.
Flue
Gas Recirculation
Flue
gas recirculation (FGR) controls NOx by recycling a portion of the flue gas back
into the primary combustion zone. The recycled air lowers NOx emissions by two
mechanisms: (1) the recycled gas, consisting of products which are inert during
combustion, lowers the combustion temperatures; and (2) the recycled gas will
reduce the oxygen content in the primary flame zone. The amount of recirculation
is based on flame stability.
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Muskogee Generating Station BART Review January 15,
2010
FGR control systems
have been used as a retrofit NOx control strategy on natural gas-fired boilers,
but have not generally been considered as a retrofit control technology on
coal-fired units. Natural gas-fired units tend to have lower O2
concentrations in the
flue gas and low particulate loading. In a coal-fired application, the FGR
system would have to handle hot particulate-laden flue gas with a relatively
high 02 concentration.
Although FGR has been used on coal-fired boilers for flue gas temperature
control, it would not have application on a coal-fired boiler for NOx
control. Because of the flue gas characteristics (e.g., particulate loading and
02 concentration), FGR
would not operate effectively as a NOx control system on a coal-fired boiler.
Therefore, FGR is not
considered an applicable retrofit NOx
control option for Muskogee
Units 4 and 5, and will not be considered further in the BART
determination.
Post
Combustion Controls:
Selective
Non-Catalytic Reduction
Selective
non-catalytic reduction (SNCR) involves the direct injection of ammonia or urea
at high flue gas temperatures. The ammonia or urea reacts with NOx in the flue
gas to produce N2 and water.
At temperatures below the desired operating range, the NOx reduction reactions
diminish and NH3 emissions
increase. Above the desired temperature range, NH3 is
oxidized to NOx resulting in low NOx reduction efficiencies. Mixing of the
reactant and flue gas within the reaction zone is also an important factor in
SNCR performance. In large boilers, the physical distance over which
the reagent must be dispersed increases, and the surface area/volume ratio of
the convective pass decreases. Both of these factors make it
difficult to achieve good mixing of reagent and flue gas, reducing overall
efficiency. Performance is further influenced by residence time, reagent-to-NOx
ratio, and fuel sulfur content.
The
size of the Muskogee Units would represent several design problems making it
difficult to ensure that the reagent would be injected at the optimum flue gas
temperature, and that there would be adequate mixing and residence time. The
physical size of the Muskogee boilers makes it technically infeasible to locate
and install ammonia injection points capable of achieving adequate mixing within
the required temperature zone. Higher reagent injection rates would be required
to achieve adequate mixing. Higher ammonia injection rates would result in
relatively high levels of ammonia in the flue gas (ammonia slip), which could
lead to plugging of downstream equipment.
Another
design factor limiting the applicability of SNCR control systems on large
subbituminous coal-fired boilers is related to the reflective nature of
subbituminous ash. Subbituminous coals typically contain high levels of calcium
oxide and magnesium oxide that can result in reflective ash deposits on the
waterwall surfaces. Because most heat transfer in the furnace is radiant,
reflective ash can result in less heat removal from the furnace and higher exit
gas temperatures. If ammonia is injected above the appropriate temperature
window, it can actually lead to additional NOx formation.
Installation
of SNCR on large boilers, such as those at Muskogee, has not been demonstrated
in practice. Assuming that SNCR could be installed on the Muskogee Units, given
the issues addressed above, control effectiveness would be marginal, and
depending on boiler exit temperatures, could actually result in additional NOx
formation. SNCR is not a technically feasible retrofit control for the Muskogee
Boilers.
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OG&E
Muskogee Generating Station BART Review January 15,
2010
Selective
Catalytic Reduction
Selective
Catalytic Reduction (SCR) involves injecting ammonia into boiler flue gas in the
presence of a catalyst to reduce NOx to N2 and water.
Anhydrous ammonia injection systems may be used, or ammonia may be generated
on-site from a urea feedstock.
SCR
has been installed as NOx control technology on existing gas-fired boilers.
Based on emissions data available from the EPA Electronic Reporting website,
large coal-fired boilers have achieved actual long-term average NOx emission
rates in the range of approximately 0.04 to 0.1 lb/mmBtu. Several design and
operating variables will influence the performance of the SCR system, including
the volume, age and surface area of the catalyst (e.g., catalyst layers),
uncontrolled NOx emission rate, flue gas temperature, and catalyst
activity.
Based
on emission rates achieved in practice at existing subbituminous coal-fired
units, and taking into consideration long-term operation of an SCR control
system (including catalyst plugging and deactivation) it is anticipated that SCR
could achieve a controlled NOx emission rate of 0.07 lb/mmBtu (30-day rolling
average) on Muskogee Units 4 and 5.
Innovative
NOX Control Technologies:
Rotating
Opposed Fire Air and Rotamix
Rotating
opposed fired air (ROFA) is a boosted over fire air system that includes a
patented rotation process which includes asymmetrically placed air nozzles. Like
other OFA systems, ROFA stages the primary combustion zone to bum overall rich,
with excess air added higher in the furnace to burn out products of incomplete
combustion.
ROFA
and Rotamix® systems have been demonstrated on smaller coal-fired boilers but
have not been demonstrated in practice on boilers similar in size to Muskogee
Units 4 and 5. As discussed for OFA, over fire air control
systems are a technically feasible retrofit control technology, and, based on
engineering judgment, the ROFA design could also be applied on Muskogee Units 4
and 5. However, there is no technical basis to conclude that the ROFA design
would provide additional NOX reduction beyond that achieved with other OFA
designs. Therefore, ROFA control systems are not evaluated as a specific control
system, but are included in the overall evaluation of combustion controls (e.g.,
LNB/OFA).
ROFA+ SNCR (Rotamix)
The
Rotamix system is a SNCR control system (i.e., ammonia injection system) coupled
with the ROFA rotating injection nozzle design. The technical limitations
discussed in the SNCR section, including the physical size of the boiler,
inadequate NH3/NOx contact, and flue gas temperatures, would apply equally to
the Rotamix control system. There is no technical basis to conclude that the
Rotamix design addresses these unresolved technical difficulties. Therefore,
like other SNCR control systems, the Rotamix system is not a technically
feasible retrofit control for the Muskogee Boilers.
Xxxxxxx
Multi-Pollutant Control Process
The
PahlmanTM
Process is a patented dry-mode multi-pollutant control system. The process uses
a sorbent composed of oxides of manganese (the Pahlmanite™ sorbent) to remove
NOx and SO2 from the
flue gas.
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OG&E
Muskogee Generating Station BART Review January 15,
2010
To
date, bench- and pilot-scale testing have been conducted to evaluate the
technology on utility-sized boilers. The New & Emerging Environmental
Technologies (NEET) Database identifies the development status of the Xxxxxxx
Process as full-scale development and testing. The process is an
emerging multi-pollutant control, and there is limited information available to
evaluate its technically feasibility and long-term effectiveness on a large
natural gas-fired boiler. It is likely that OG&E would be required to
conduct extensive design engineering and testing to evaluate the technical
feasibility and long-term effectiveness of the control system on Muskogee Units
4 and 5. XXXX does not require applicants to experience extended time delays or
resource penalties to allow research to be conducted on an emerging control
technique. Therefore, at this time the Xxxxxxx Process is not a technically
feasible retrofit control for the Muskogee Boilers.
Wet
NOx Scrubbing Systems
Wet
scrubbing systems have been used to remove NOx emissions from fluid catalytic
cracking units (FCCUs) at petroleum refineries. An example of a wet scrubbing
system is Balco Technologies' LoTOxYTM system.
The LoTOx system is a patented process, wherein ozone is injected into the flue
gas stream to oxidize NO and NO2 to N205. This
highly oxidized species of NOx is very soluble and rapidly reacts with water to
form nitric acid. The conversion of NOx to nitric acid occurs as the N205 contacts
liquid sprays in the scrubber.
Wet
scrubbing systems have been installed at chemical processing plants and smaller
coal-fired boilers. The NEET Database classifies wet scrubbing systems as
commercially established for petroleum refining and oil/natural gas production.
However the technology has not been demonstrated on large utility boilers and it
is likely that OG&E would incur substantial engineering and testing to
evaluate the scale-up potential and long-term effectiveness of the system.
Therefore, at this time wet NOx scrubbing systems are not technically feasible
retrofit controls for the Muskogee Boilers.
EFFECTIVENESS
OF REMAINING CONTROL TECHNOLOGIES (NOx)
Table
4: Technically Feasible NOx Control Technologies – Muskogee
Station
|
||
Muskogee
Unit 4
|
Muskogee
Unit 5
|
|
Control
Technology
|
Approximate
NOx Emission Rate
(lb/mmBtu)
|
Approximate
NOx
Emission
Rate
(lb/mmBtu)
|
LNB/OFA
+ SCR
|
0.07
|
0.07
|
LNB/OFA
|
0.15
|
0.15
|
Baseline
|
0.292
|
0.326
|
EVALUATE
IMPACTS AND DOCUMENT RESULTS (NOx)
OG&E
evaluated the economic, environmental, and energy impacts associated with the
two proposed control options. In general, the cost estimating methodology
followed guidance provided in the EPA Air Pollution Cost Control Manual. Major
equipment costs were developed based on publicly available cost data and
equipment costs recently developed for similar projects, and include the
equipment, material, labor, and all other direct costs needed to
retrofit
7
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Muskogee Generating Station BART Review January 15,
2010
Muskogee
Units 4 and 5 with the control technologies. Fixed and variable O&M costs
were developed for each control system. Fixed O&M costs include operating
labor, maintenance labor, maintenance material, and administrative labor.
Variable O&M costs include the cost of consumables, including reagent (e.g.,
ammonia), byproduct management, water consumption, and auxiliary power
requirements. Auxiliary power requirements reflect the additional power
requirements associated with operation of the new control technology, including
operation of any new fans as well as the power requirements for pumps, reagent
handling, and by-product handling. The capital recovery factor used to estimate
the annual cost of control was based on a 7% interest rate and a control life of
25 years. Annual operating costs and annual emission reductions were calculated
assuming a capacity factor of 90%.
OG&E
submitted initial cost estimates in 2008 that relied upon a baseline emission
rate representative of the maximum actual 24-hour emission rate, which is
consistent with the modeling demonstration. However, the calculations
overestimate the cost effectiveness by assuming a larger ton per year emissions
reduction with the addition of controls than would be realized given actual
annual average emissions. Using a representative annual average emission rate
(2004-2006), the cost effectiveness ($/ton removed) is much higher, but the
result is representative of more reasonably achievable emissions reductions.
Table
5: Economic Cost Per Boiler
|
|||
Cost
|
Option
1: LNB/OFA
|
Option
2:
LNB/OFA
+ SCR
|
|
Control
Equipment Capital Cost ($)
|
$14,113,700
|
$193,077,000
|
|
Annualized
Capital Costs ($/Yr)
|
$1,211,100
|
$16,568,000
|
|
Annual
O&M Costs ($/Yr)
|
$880,700
|
$14,227,600
|
|
Annual
Cost of Control ($)
|
$2,091,800
|
$30,795,600
|
Table
6: Environmental Costs per Boiler
|
||||
Baseline
|
Option
1: LNB/OFA
|
Option
2:
LNB/OFA
+ SCR
|
||
NOx
Emission Rate (lb/mmBtu)
|
Unit
4
|
0.292
|
0.15
|
0.07
|
Unit
5
|
0.326
|
0.15
|
0.07
|
|
Annual
NOx Emission (TPY)1
|
Unit
4
|
5,258
|
2,674
|
1,246
|
Unit
5
|
5,709
|
2,628
|
1,227
|
|
Annual
NOx Reduction (TPY)
|
Unit
4
|
-
|
2,587
|
4,012
|
Unit
5
|
-
|
3,081
|
4,482
|
|
Annual
Cost of Control
|
Unit
4
|
-
|
$2,091,800
|
$30,795,600
|
Unit
5
|
-
|
$2,091,800
|
$30,795,600
|
|
Cost
per Ton of Reduction
|
Unit
4
|
-
|
$809
|
$7,676
|
Unit
5
|
-
|
$679
|
$6,871
|
|
Incremental
Cost per Ton of
Reduction2
|
Unit
4
|
-
|
-
|
$20,143
|
Unit
5
|
-
|
-
|
$20,488
|
1Emissions
for the BART analysis are based on average heat inputs of 4,594 and 4,739
mmBtu/hr for Units 4 & 5. Annual emissions were calculated
assuming 7,829 and 7,395 hours/year for Units 4 and 5 respectively.
2Incremental cost effectiveness of the
SCR system is compared to costs/emissions associated with LNB/OFA
controls.
8
OG&E
Muskogee Generating Station BART Review January 15,
2010
B.
SO2
IDENTIFY
AVAILABLE RETROFIT CONTROL TECHNOLOGIES (S02)
Potentially
available control options were identified based on a comprehensive review of
available information. S02 control
technologies with potential application to Muskogee Units 4 and 5 are listed in
Table 7.
Table
7: List of Potential Control Options
|
Control
Technology
|
Pre-Combustion
Controls
|
Fuel
Switching
|
Coal
Washing
|
Coal
Processing
|
Post
Combustion Controls
|
Wet
Flue Gas Desulfurization
|
Wet
Lime FGD
|
Wet
Limestone FGD
|
Wet
Magnesium Enhanced Lime FGD
|
Jet
Bubbling Reactor FGD
|
Dual
Alkali Scrubber
|
Wet FGD
with Wet Electrostatic Precipitator
|
Dry
Flue Gas Desulfurization
|
Spray
Dryer Absorber
|
Dry
Sorbent Injection
|
Circulating
Dry Scrubber
|
ELIMINATE
TECHICALLY INFEASIBLE OPTIONS (SO2)
Pre-Combustion
Control Strategy:
Fuel
Switching
One
potential strategy for reducing S02 emissions
is reducing the amount of sulfur contained in the coal. Muskogee Units 4 and 5
fire subbituminous coal as their primary fuel. Subbituminous coal has a
relatively low heating value, low sulfur content, and low uncontrolled S02 emission
rate. No environmental benefits accrue from burning an alternative coal;
therefore, fuel switching is not considered a feasible option for this retrofit
project.
Coal
Washing
Coal washing, or beneficiation, is one
pre-combustion method that has been used to reduce impurities in the coal such
as ash and sulfur. In general, coal washing is accomplished by
separating and removing inorganic impurities from organic coal particles. The
coal washing process generates a solid waste stream consisting of inorganic
materials separated from the coal, and a wastewater stream that must be treated
prior to discharge. Solids generated from wastewater processing and coarse
material removed in the washing process must be disposed in a properly permitted
landfill. Solid wastes from coal washing typically contain pyrites and other
dense inorganic impurities including silica and trace metals. The solids are
typically dewatered in a mechanical dewatering device and disposed of in a
landfill.
9
OG&E
Muskogee Generating Station BART Review January 15,
2010
Muskogee
Units 4 and 5 are designed to utilize subbituminous coals. Based on a review of
available information, no information was identified regarding the washability
or effectiveness of washing subbituminous coals. Therefore, coal washing is not
considered an available retrofit control option for Muskogee Units 4 and
5.
Coal
Processing
Pre-combustion
coal processing techniques have been proposed as one strategy to reduce the
sulfur content of coal and help reduce uncontrolled S02 emissions.
Coal processing technologies are being developed to remove potential
contaminants from the coal prior to use. These processes typically employ both
mechanical and thermal means to increase the quality of subbituminous coal and
lignite by removing moisture, sulfur, mercury, and heavy metals. To date, the
use of processed fuels has only been demonstrated with test bums in a pulverized
coal-fired boiler. No coal-fired boilers have utilized processed fuels as
their primary fuel source on an on-going, long-term basis. Although burning
processed fuels, or a blend of processed fuels, has been tested in a pulverized
coal-fired boiler, using processed fuels in Muskogee Units 4 and 5 would require
significant research, test bums, and extended trials to identify potential
impacts on plant systems, including the boiler, material handling, and emission
control systems. Therefore, processed fuels are not considered commercially
available, and will not be analyzed further in this BART analysis.
Post-Combustion
Flue Gas Desulfurization
Wet
Scrubbing Systems
Wet
FGD technology is an established S02 control
technology. Wet scrubbing systems offered by vendors may vary in design;
however, all wet scrubbing systems utilize an alkaline scrubber slurry to remove
S02
from the flue gas.
Wet Lime
Scrubbing
The
wet lime scrubbing process uses an alkaline slurry made by adding lime (CaO) to
water. The alkaline slurry is sprayed in the absorber and reacts with S02 in the
flue gas. Insoluble CaS03 and
CaS04
salts are formed in the chemical reaction that occurs in the scrubber and are
removed as a solid waste by-product. The waste by-product is made up of mainly
CaS03,
which is difficult to xxxxxxx. Solid waste by-products from wet lime scrubbing
are typically managed in dewatering ponds and
landfills.
Wet Limestone
Scrubbing
Limestone
scrubbers are very similar to lime scrubbers except limestone (CaCO3) is mixed
with water to formulate the alkali scrubber slurry. S02 in the
flue gas reacts with the limestone slurry to form insoluble CaS03 and
CaS04
which is removed as a solid waste by product. The use of limestone
instead of lime requires different feed preparation equipment and a higher
liquid-to-gas ratio. The higher liquid-to-gas ratio typically requires a
larger absorbing unit. The limestone slurry process also requires a ball mill to
crush the limestone feed.
Forced
oxidation of the scrubber slurry can be used with either the lime or limestone
wet FGD system to produce gypsum solids instead of the calcium sulfite
by-product. Air blown into the reaction tank provides oxygen to convert most of
the calcium sulfite (CaS03) to
relatively pure gypsum (calcium sulfate). Forced oxidation of the scrubber
slurry provides a more stable by-
10
OG&E
Muskogee Generating Station BART Review January 15,
2010
product
and reduces the potential for scaling in the FGD. The gypsum by-product from
this process must be dewatered, but may be salable thus reducing the quantity of
solid waste that needs to be landfilled.
Wet
lime and wet limestone scrubbing systems will achieve the same S02 control
efficiencies; however, the higher cost of lime typically makes wet limestone
scrubbing the more attractive option. For this reason, wet lime scrubbing will
not be evaluated further in this BART determination.
Wet Magnesium Enhanced Lime
Scrubbing
Magnesium
Enhanced Lime (XXX) scrubbers are another variation of wet FGD technology.
Magnesium enhanced lime typically contains 3% to 7% magnesium oxide (MgO) and 90
- 95% calcium oxide (CaO). The presence of magnesium effectively increases the
dissolved alkalinity, and consequently makes S02 removal
less dependent on the dissolution of the lime/limestone. XXX scrubbers have been
installed on coal-fired utility boilers located in the Ohio River Valley.
Systems to oxidize the XXX solids to produce a usable gypsum byproduct
consisting of calcium sulfate (gypsum) and magnesium sulfate continue to be
developed. Coal-fired units equipped with XXX FGD typically fire high-sulfur
eastern bituminous coal and use locally available reagent. There are no
subbituminous-fired units equipped with a XXX-FGD system. Because XXX-FGD
systems have not been used on subbituminous-fired boilers, and because of the
cost and limited availability of magnesium enhanced reagent (either naturally
occurring or blended), and because limestone-based wet FGD control systems can
be designed to achieve the same control efficiencies as the magnesium enhanced
systems, XXX-FGD control systems will not be evaluated further as a commercially
available retrofitted control system.
Jet Bubbling
Reactor
Another variation of the wet FGD control
system is the jet bubbling reactor (JBR). Unlike the spray tower wet FGD
systems, where the scrubbing slurry contacts the flue gas in a countercurrent
reaction tower, in the JBR-FGD flue gas is bubbled through a limestone slurry.
Spargers are used to create turbulence within the reaction tank and maximize
contact between the flue gas bubbles and scrubbing slurry. There is currently a
limited number of commercially operating JBR-WFGD control systems installed on
coal-fired utility units in the U.S. Although the commercial deployment of the
control system continues, there is still a very limited number of operating
units in the U.S. Furthermore, coal-fired boilers currently considering the
JBR-WFGD control system are all located in the eastern U.S., and all fire
eastern bituminous coals. The control system has not been proposed as a retrofit
technology on any large subbituminous coal-fired boilers. However, other than
scale-up issues, there do not appear to be any overriding technical issues that
would exclude application of the control technology on a large subbituminous
coal-fired unit. There are no data available to conclude that the
JBR-WFGD control system will achieve a
higher S02 removal efficiency than a more
traditional spray tower WFGD design, especially on units firing low-sulfur
subbituminous coal. Furthermore, the costs associated with JBR-WFGD and the
control efficiencies achievable with JBR-WFGD are similar to the costs and
control efficiencies achievable with spray tower WFGD control
systems. Therefore, the JBR-WFGD will not be
evaluated as a unique retrofit technology, but will be included in the overall
assessment of WFGD controls.
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Muskogee Generating Station BART Review January 15,
2010
Dual-Alkali Wet
Scrubber
Dual-alkali
scrubbing is a desulfurization process that uses a sodium-based alkali solution
to remove S02 from
combustion exhaust gas. The process uses both sodium-based and
calcium-based compounds. The dual-alkali process requires lower
liquid-to-gas ratios then scrubbing with lime or limestone. The reduced
liquid-to-gas ratios generally mean smaller reaction units, however additional
regeneration and sludge processing equipment is necessary. The sodium-based
scrubbing liquor, typically consisting of a mixture of sodium hydroxide, sodium
carbonate and sodium sulfite, is an efficient S02 control
reagent. However, the high cost of the sodium-based chemicals limits the
feasibility of such a unit on a large utility boiler. In addition, the process
generates a less stable sludge that can create material handling and disposal
problems. It is projected that a dual-alkali system could be designed to achieve
S02
control similar to a limestone-based wet FGD. However, because of the
limitations discussed above, and because dual-alkali systems are not currently
commercially available, dual-alkali scrubbing systems will not be addressed
further in this BART determination.
Wet FGD with Wet
Electrostatic Precipitator
Wet
electrostatic precipitation (XXXX) has been proposed on other coal-fired
projects as one technology to reduce sulfuric acid mist emissions from
coal-fired boilers. WESPs have been proposed for boilers firing high-sulfur
eastern bituminous coals controlled with wet FGD. XXXX has not been widely used
in utility applications, and has only been proposed on boilers firing high
sulfur coals and equipped with SCR. Muskogee Units 4 and 5 fire low-sulfur
subbituminous coal. Based on the fuel characteristics, and assuming 1% S02 to S03 conversion
in the boiler, potential uncontrolled H2S04 emissions
from Muskogee Units 4 and 5 will only be approximately 5ppm. This emission rate
does not take into account inherent acid gas removal associated with alkalinity
in the subbituminous coal fly ash. Based on engineering judgment, it is unlikely
that a XXXX control system would be needed to mitigate visible sulfuric acid
mist emissions from Muskogee Units 4 and 5, even if WFGD control was installed.
WESPs have been proposed to control condensable particulate emissions from
boilers firing a high-sulfur bituminous coal and equipped with SCR and wet FGD;
this combination of coal and control equipment results in relatively high
concentrations of sulfuric acid mist in the flue gas. XXXX control systems have
not been proposed on units firing subbituminous coals, and XXXX would have no
practical application on a subbituminous-fired units. Therefore, the combination
of WFGD+XXXX will not be evaluated further in this BART
determination.
Dry
Flue Gas Desulfurization
Another scrubbing system that has been
designed to remove S02 from coal-fired combustion gases is dry
scrubbing. Dry scrubbing involves the introduction of dry or hydrated lime
slurry into a reaction tower where it reacts with S02 in the flue gas to form calcium sulfite
solids. Unlike wet FGD systems that produce a slurry byproduct that is collected
separately from the fly ash, dry FGD systems produce a dry byproduct that must
be removed with the fly ash in the particulate control equipment. Therefore, dry
FGD systems must be located upstream of the particulate control device to remove
the reaction products and excess reactant material.
Spray Dryer
Absorber
Spray dryer absorber (SDA) systems have
been used in large coal-fired utility applications. SDA systems have
demonstrated the ability to effectively reduce uncontrolled S02 emissions from
12
OG&E
Muskogee Generating Station BART Review January 15,
2010
pulverized coal units. The typical spray
dryer absorber uses a slurry of lime and water injected into the tower to remove
S02 from the combustion gases. The towers must be designed to provide
adequate contact and residence time between the exhaust gas and the slurry to
produce a relatively dry by-product. SDA control systems are a technically
feasible and commercially available retrofit technology for
Muskogee Units 4 and 5. Based on the fuel characteristics and allowing a
reasonable margin to account for normal operating conditions (e.g., load
changes, changes in fuel characteristics, reactant purity, atomizer change outs,
and minor equipment upsets) it is concluded that dry FGD designed as SDA could
achieve a controlled S02 emission rate of 0.10
lb/mmBtu (30-day average) on an on-going
long-term basis.
Dry Sorbent
Injection
Dry sorbent injection involves the
injection of powdered absorbent directly into the flue gas exhaust stream.
Particulates generated in the reaction are controlled in the system's
particulate control device. Typical S02 control efficiencies for a dry sorbent
injection system are generally around 50%. OG&E stated that because the
control efficiency of the dry sorbent system is lower than the control
efficiency of either the wet FGD or SOA, the system will not be evaluated
further. As OG&E proposed only the use of low sulfur coal as BART, it is not
clear why they did not include this technology in the full evaluation. Lacking
any data to justify why this might be a more cost effective option than Dry FGD
with SDA, this option is set aside based solely on lower environmental
benefit.
Circulating Dry
Scrubber
A third type of dry scrubbing system is
the circulating dry scrubber (CDS). A CDS system uses a circulating fluidized
bed of dry hydrated lime reagent to remove S02. The dry by-product produced by this
system is similar to the spray dry absorber by-product, and is routed with the
flue gas to the particulate removal system. Operating experience on smaller
pulverized coal boilers in the U.S. has shown high lime consumption rates, and
significant fluctuations in lime utilization based on inlet S02 loading. Furthermore, CDS systems
result in high particulate loading to the unit's particulate control device.
Based on the limited application of CDS dry scrubbing systems on large boilers,
it is likely that OG&E would be required to conduct extensive design
engineering to scale up the technology for boilers the size of Muskogee Units 4
and 5, and that OG&E would incur significant time and resource penalties
evaluating the technical feasibility and long-term effectiveness of the control
system. Because of these limitations, CDS dry scrubbing systems are not
currently commercially available as a retrofit control technology for Muskogee
Units 4 and 5, and will not be evaluated further in this BART
determination.
13
OG&E
Muskogee Generating Station BART Review January 15,
2010
EVALUATE
EFFECTIVENESS OF REMAINING CONTROL TECHNOLOGIES (S02)
Table
8: Technically Feasible S02, Control Technologies – Muskogee
Station
|
||
Control
Technology
|
Muskogee
Unit 4
|
Muskogee
Unit 5
|
Approximate S02 Emission Rate
(lb/mmBtu)
|
Approximate S02 Emission Rate
(lb/mmBtu)
|
|
Wet
FGD
|
0.08
|
0.08
|
Dry
FGD – Spray Dryer Absorber
|
0.10
|
0.10
|
Modeling
Baseline
|
0.80
|
0.85
|
Annual
Average Baseline
|
0.507
|
0.514
|
EVALUATE IMPACTS AND DOCUMENT RESULTS
(S02)
Capital
Costs
In
2008 OG&E evaluated the economic, environmental, and energy impacts
associated with the two proposed control options. In general, the cost
estimating methodology followed guidance provided in the EPA Air Pollution Cost
Control Manual. Sixth Edition" EPA-452/B-02-001, January 2002. The
cost-effectiveness evaluations were "study" estimates of ±30% accuracy, based
on: (I) engineering estimates; (2) vendor quotations provided for similar
projects and similar equipment; (2) S&L's internal cost database; and (4)
cost estimating guidelines provided in U.S.EPA's, EPA Air Pollution Control Cost
Manual. Cost estimates include the equipment, material, labor, and all other
direct costs needed to retrofit Muskogee Units 4 and 5 with the control
technologies.
While
generally following the EPA methodology, these cost estimates exploited
weaknesses in the estimate assumptions and resulted in highly exaggerated
capital and particularly annual costs. In response to the ODEQ draft evaluation
and EPA and FLM comments, OG&E submitted revised cost estimates during the
public meeting held for the Oklahoma draft SIP. These revised estimates reflect
vendor quotes for the Muskogee facility. In degree of difficulty, the retrofit
at the Muskogee facility is described as average. The re-routing of ductwork,
storm sewer systems and other equipment relocations were taken into
consideration in the conceptual cost estimate.
The
new cost estimates use the following methodology:
•
|
Plant
design data were used to develop datasheets to specify the dry FGD,
baghouse, and ID booster fan operating conditions. The datasheets were
issued to various manufacturers to obtain budgetary quotations. Cost
obtained from these quotations were used to derive the pricing used in the
capital cost estimate.
|
•
|
A general arrangement (GA) drawing
was developed using the information received in the budgetary quotations.
The GA drawing was used to estimate the major installation quantities for
the project including ductwork, structural steel, foundations, relocation
cable, and pipelines.
|
•
|
A
motor list was assembled and used to develop the auxiliary power system
sizing and quantities.
|
•
|
Mass
balances were prepared and used to size the flue gas, material handling,
material storage, and piping
systems.
|
14
OG&E
Muskogee Generating Station BART Review January 15,
2010
•
|
A schedule was developed to
estimate escalation and Allowance for Funds Used During Construction
(AFUDC) costs.
It was assumed the
new DFGDs would come on line at six month intervals with the last unit
being completed at Muskogee near the end of
2015.
|
•
|
Range
estimating techniques were used to identify the appropriate amount of
contingency to obtain 95% confidence level. The contingency level was
approximately 14%.
|
•
|
A
design and cost basis document was prepared to document the major
assumptions and inputs for developing the cost
estimate.
|
•
|
Labor cost estimates were
developed using the Oklahoma area wage rates, installation quantities, and
installation rates taken from the Xxxxxxx and Xxxxx database.
|
The described methodology provides a
conceptual capital cost estimate with accuracy in the range of ±20%. This
methodology provides a better estimate of the capital costs associated with
installing DFGD control systems, and a more accurate estimate of the actual
costs that OG&E would incur to install DFGD at the Muskogee facility.
The
total capital requirement (TCR) is the sum of direct costs, indirect costs,
contingency, escalation, and AFUDC. Direct costs include equipment, material,
labor, spare parts, special tools, consumables, and freight. Indirect costs
include engineering, procurement, construction management, start-up,
commissioning, operator training, and owner's costs.
Escalation and AFUDC were calculated
from the estimated distribution of cash flows during the construction period and
OG&E's before-tax weighted average cost of capital of 8.66%/year. The 37-day tie-in outage for each unit
is assumed to be coordinated with the normal 5-week scheduled outage such that
incremental replacement cost is negligible.
The
capital recovery factor converts the TCR into equal annual costs over the
depreciable life of the asset. These are also referred to as levelized capital
charges. Property taxes and insurance are sometimes included with the capital
charges, but are classified in the OG&E analysis as part of the Indirect
Operating Costs to be consistent with the BART reports. The economic parameters
used to derive the levelized capital charges are summarized in Table
9.
Table
9: Economic Parameters to Derive Levelized Capital
Charges
|
|
Commercial
Operation Date (Reference Year)
|
2015
|
Depreciable
Life
|
20
years
|
Inflation
Rate
|
2.5%/year
|
Effective
Income Tax Rate-Federal and State
|
38.12%
|
Common
Equity Fraction
|
0.557
|
Debt
Fraction
|
0.443
|
Return
on Common Equity
|
|
Nominal
|
10.75%/year
|
Real
|
8.05%/year
|
Return
on Debt
|
|
Nominal
|
6.03%/year
|
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OG&E
Muskogee Generating Station BART Review January 15,
2010
Real
|
3.44%/year
|
Discount
Rate (after-tax cost of capital)
|
|
Nominal
|
7.64%/year
|
Real
|
5.43%/year
|
Tax
Depreciation
|
20-year
straight line
|
Levelized
Capital Charges (real)
|
10.36%/year
|
The
revised estimates based on vendor quotes results in a TCR of $634,386,800 which
is $111,825,200 less than the CUE Cost derived estimates provided in 2008.
However, OG&E has revised the capital recovery factor and reduced the number
of years of expected depreciation to 20 from 25 resulting in a levelized capital
charge or capital recovery of 32,861,300 per boiler, which is $844,900 per
boiler per year more than the 2008 estimate. Cost estimates and assumptions are
reasonable and application of the previously relied upon capital recovery factor
does not significantly change the cost per ton of control or the conclusion of
this review.
Operating
Costs
Annual
operating costs for the DFGD system consist of variable operating and
maintenance (O&M) costs, fixed O&M costs, and indirect operating
costs.
Variable
O&M
Variable
O&M costs are items that generally vary in proportion to the plant capacity
factor. These consist of lime reagent costs, water costs, FGD waste disposal
costs, bag and cage replacement costs, ash disposal costs, and auxiliary power
costs.
Lime Reagent costs were based on
material balances and budgetary lime quotations received for truck delivery,
$105.53/ton, which is 52% of the previously assumed
cost. Water costs were based on 219,839 lb/hr at full load, a 90% capacity
factor and $2.57/1000 gallons. FGD Waste Disposal was based on material
balances for the average fuel composition and a 90% capacity factor. First year
cost of on-site disposal is $40.59/ton. Bag and cage replacement costs were
based on exhaust gas flow through the baghouse, an air-to-cloth ratio of 3.5 for
pulse jet baghouse, 4% contingency for bag cleaning, and 3-year bag
life. The first year bag cost (including fabric and hangers) is
$3.31/ft2. Ash disposal costs were not assumed to
increase from the fabric filter as existing ESP is remaining in service.
Auxiliary power costs were based on auxiliary power calculations and a 90%
capacity factor. The first year auxiliary power cost is $85.92/MWh, which is 180% of the previously assumed
power cost.
Increases in water, FGD waste disposal,
bag and cage replacement, and auxiliary power costs offset decreases in lime
reagent costs resulting in an increase in expected variable O&M costs from
the 2008 estimate by approximately $1,000,000 per boiler per year.
Fixed
O&M
Fixed
O&M costs are recurring annual costs that are generally independent of the
plant capacity factor. These consist of operating labor, supervisor labor,
maintenance materials, and maintenance labor.
16
OG&E
Muskogee Generating Station BART Review January 15,
2010
Operating
labor was based on three shifts per day 365 days per year. The first year labor
rate (salary plus benefits) is 58.76/hour. Supervisory labor was based on 15% of
operating labor in accordance with the EPA Control Cost Manual (page 2-31).
Maintenance materials were based on 0.6% of the total plant investment. Previous
cost estimates reflecting Cue Cost default assumptions were based on 5% of
capital equipment costs and therefore contributed to the exaggeration of annual
operating costs. Maintenance labor was again based on 110% of operating labor,
which is consistent with the EPA Control Cost Manual (page 2-31).
Due
to the difference in cost basis for maintenance materials, the final fixed
O&M costs were decreased by approximately $10,300,000 per year per
boiler.
Indirect
Operating Costs
Indirect
operating costs are recurring annual costs for the FGD system that are not part
of the direct O&M. These consist of property taxes, insurance, and
administration.
Property
taxes were calculated as 0.85% of total capital investment, in accordance with
OG&E property tax rates. This rate is significantly lower than the EPA
default rate of 1%. Insurance rates were calculated as 0.0105% of total capital
investment in accordance with OG&E insurance rates. This rate is
significantly lower than the EPA default rate of 1%. Administrative costs were
calculated as 20% of the fixed O&M costs rather the EPA Air Pollution
Control Cost Manual 6th ED
guidance of 2% of capital investment.
Due
to the difference in cost basis for all indirect costs, but most particularly
administrative costs, the final indirect operating costs were decreased by
approximately $10,980,000 per year per boiler from the previous
assessment.
Revised
O&M estimates are now consistent with the operating costs documented in the
June 2007 report by X. Xxxxxx Xxxxxxxxxxx for the Utility Air Regulatory Group,
"Current Capital Cost and Cost-Effectiveness of Power Plant Emissions Control
Technologies. The Xxxxxxxxxxx report lists a cost range in $/kW of 15 to 38 for
O&M costs. OG&E estimates are approximately $29-32/kW.
OG&E
submitted initial cost estimates in 2008 that relied upon a baseline emission
rate representative of the maximum actual 24-hour emission rate, which is
consistent with the modeling demonstration. Following the methodology published
in the EPA advanced notice of proposed rulemaking for the Four Corners Power
Plant and the Navajo Generating Station, cost effectiveness calculations were
revised to reflect average annual emissions from 2004-2006.
Table
10: Economic Cost for Units 4 and 5 – Dry FGD – Spray Dryer
Absorber
|
||
Cost
|
Unit
4
|
Unit
5
|
Total
Capital Investment ($)
|
$317,193,600
|
$317,193,600
|
Total
Capital Investment ($/kW)
|
$555
|
$555
|
Capital
Recovery Cost ($/Yr)
|
$32,861,300
|
$32,861,300
|
Annual
O&M Costs ($/Yr)
|
$18,438,900
|
$18,438,900
|
Total
Annual Cost ($)
|
$51,300,200
|
$51,300,200
|
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OG&E
Muskogee Generating Station BART Review January 15,
2010
Table
11: Environmental Costs for Units 4 and 5 – Dry FGD – Spray
Dryer Absorber
|
||
Unit
4
|
Unit
5
|
|
SO2
Baseline (TPY)1
|
9,113
|
9,006
|
SO2
Controlled (lb/mmBtu)
|
0.1
|
0.1
|
Annual
SO2
Controlled (TPY)2
|
2,160
|
2,160
|
Annual
SO2
Reduction (TPY)
|
6,953
|
6,846
|
Total
Annual Cost ($)
|
$51,300,200
|
$51,300,200
|
Cost
per Ton of Reduction
|
$7,378
|
$7,493
|
(1)
|
Baseline
annual emissions are calculated as the average actual SO2
emission rate during the baseline years of
2004-2006.
|
(2)
|
Projected
annual emissions were calculated based on the controlled SO2
emissions rate, full load heat input of 5,480 mmBtu/hr, and
assuming 7,884 hours/year per boiler (90% capacity
factor).
|
OG&E
did not submit revised cost estimates for Wet FGD; however, in order to be
thorough, some conclusions can be drawn from the estimates provided for Dry FGD.
The total capital requirement for wet scrubbers was assumed to be consistent
with the previous determination.
The capital recovery factor
was modified to reflect the current company position of a 20 year depreciation.
The annual operating costs were modified to reflect the cost bases for water,
labor, auxiliary power, taxes, insurance and administrative costs detailed in
the preceding paragraphs.
Table
12: Environmental Costs for Units 4 and 5 – Wet
FGD
|
||
OG&E
Cost Estimates
|
||
Cost
|
Unit
4
|
Unit
5
|
Total
Capital Investment ($)
|
$418,567,000
|
$418,567,000
|
Capital
Recovery Cost ($/Yr)
|
$43,363,541
|
$43,363,541
|
Annual
O&M Costs ($/Yr)
|
$21,061,140
|
$21,061,140
|
Total
Annual Cost ($)
|
$64,424,681
|
$64,424,681
|
Control
SO2
Emission Rate (lb/mmBtu)
|
0.08
|
0.08
|
Baseline
Annual Emissions (TPY)1
|
9,113
|
9,006
|
Controlled
Annual SO2
Emission (TPY)2
|
1,728
|
1,728
|
Annual
SO2
Reduction (TPY)
|
7,385
|
7,278
|
Cost
per Ton of Reduction ($/Ton)
|
$8,724
|
$8,852
|
Incremental
Annual Cost ($/Ton)
|
$30,381
|
$30,381
|
(1)
|
Baseline
annual emissions were calculated based on average annual SO2
emissions for the years
2004-2006.
|
(2)
|
Projected
annual emissions were calculated based on the controlled SO2
emissions rate, full load heat input of 5,480 mmBtu/hr, and
assuming 7,884 hours/year per boiler (90% capacity
factor).
|
18
OG&E
Muskogee Generating Station BART Review January 15,
2010
C.
PM10
IDENTIFY
AVAILABLE RETROFIT CONTROL TECHNOLOGIES (PM1O)
There
are two generally recognized PM control devices that are used to control PM
emission from PC boilers: ESPs and fabric filters (or baghouses). Muskogee Units
4 and 5 are currently equipped with ESP control systems.
Table
13: Summary of Technically Feasible
|
||
Main
Boiler PM10
Control Technologies
|
||
PM10
Emissions 1
|
%
Reduction
|
|
Control
Technology
|
(b/mmBtu)
|
(from
base case)
|
Fabric
Filter Baghouse
|
0.015
|
99.7
|
ESP
- Existing
|
0.025
|
99.3
|
Potential
PM Emissions
|
5.65
|
-
|
(1)
|
The
PM10
emission rate for the baghouse case is based on filterable PM10
emission limits included in recently issued PSD permits for new coal-fired
units. The PM10
emission rate for ESP case is based on the Units’ baseline PM10
emission rates. Potential PM emissions were calculated assuming
an average fuel heating value of 8,500 Btu/lb and an ash content of 6.0%,
and assuming 80% of the fuel ash will be emitted as fly
ash.
|
EVALUATE
IMPACTS AND DOCUMENT RESULTS (PM10)
Costs
for Fabric Filter Baghouses were included in the cost estimates provided by
OG&E for Dry FGD. Because of the interdependency of the control systems, a
determination of baghouse versus existing ESP cannot be made without
consideration of the eventual sulfur control. Annual average PM emissions are
less than 500 TPY for both boilers. On a PM basis alone and assuming the current
20 year depreciation, no additional operating costs, and 100% emission
reduction, a resultant cost effectiveness of $9,324 per ton would support the
conclusion that further reductions from the addition of a $45,000,000 fabric
filter are not cost effective.
D.
VISIBILITY IMPROVEMENT DETERMINATION
The
fifth of five factors that must be considered for a BART determination analysis,
as required by a 40 CFR part 51-Appendix Y, is the degree of Class I area
visibility improvement that would result from the installation of the various
options for control technology. This factor was evaluated for the Muskogee
Generating Station by using an EPA-approved dispersion modeling system (CALPUFF)
to predict the change in Class I area visibility. The Division had previously
determined that the Muskogee Generating Station was subject to BART based on the
results of initial screening modeling that was conducted using current
(baseline) emissions from the facility. The screening modeling, as well as more
refined modeling conducted by the applicant, is described in detail
below.
Wichita
Mountain Wildlife Refuge, Caney Creek, Upper Buffalo and Hercules Glade are the
closest Class I areas to the Muskogee Generating Station, as shown in Figure 1
below.
Only those Class I areas most likely to
be impacted by the Muskogee Generating Station were modeled, as determined by
source/Class I area locations, distances to each Class I area, and professional
judgment considering meteorological and terrain factors. It can be reasonably
assumed that areas at greater distances and .in directions of less frequent plume
transport will
19
OG&E
Muskogee Generating Station BART Review January 15,
2010
experience
lower impacts than those predicted for the four modeled areas.
IMAGE NOT
SHOWN
Figure 1: Plot of Facility location in
relation to nearest Class I
areas
REFINED
MODELING
Because of the results of the applicants
screening modeling for the Muskogee Generating Station, OG&E was required to conduct a
refined BART analysis that included CALPUFF visibility modeling for the
facility. The modeling approach followed the requirements described in the
Division's BART modeling protocol, CENRAP BART Modeling Guidelines (Alpine
Geophysics, December 2005) with refinements detailed the applicants CALMET
modeling protocol, CALMET Data Processing Protocol (Trinity Consultants, January
2008)
CALPUFF
System
Predicted
visibility impacts from the Muskogee Generating Station were determined with the
EPA CALPUFF modeling system, which is the EPA-preferred modeling system for
long-range transport. As described in the EPA Guideline on Air Quality Models
(Appendix W of 40 CFR Part 51), long-range transport is defined as modeling with
source-receptor distances greater than 50 km. Because all modeled areas are
located more than 50 km from the sources in question, the CALPUFF system was
appropriate to use.
The
CALPUFF modeling system consists of a meteorological data pre-processor
(CALMET), an air dispersion model (CALPUFF), and post-processor programs
(POSTUTIL, CALSUM, CALPOST). The CALPUFF model was developed as a
non-steady-state air quality modeling
20
OG&E
Muskogee Generating Station BART Review January 15,
2010
system
for assessing the effects of time- and space-varying meteorological conditions
on pollutant transport, transformation, and removal.
CALMET
is a diagnostic wind model that develops hourly wind and temperature fields in a
three-dimensional, gridded modeling domain. Meteorological inputs to CALMET can
include surface and upper-air observations from multiple meteorological
monitoring stations. Additionally, the CALMET model can utilize gridded analysis
fields from various mesoscale models such as MM5 to better represent regional
wind flows and complex terrain circulations. Associated two-dimensional fields
such as mixing height, land use, and surface roughness are included in the input
to the CALMET model. The CALMET model allows the user to "weight" various
terrain influences parameters in the vertical and horizontal directions by
defining the radius of influence for surface and upper-air
stations.
CALPUFF
is a multi-layer, Lagrangian puff dispersion model. CALPUPF can be driven by the
three-dimensional wind fields developed by the CALMET model (refined mode), or
by data from a single surface and upper-air station in a format consistent with
the meteorological files used to drive steady-state dispersion models. All
far-field modeling assessments described here were completed using the CALPUFF
model in a refined mode.
CALPOST
is a post-processing program that can read the CALPUFF output files, and
calculate the impacts to visibility.
All
of the refined CALPUFF modeling was conducted with the version of the CALPUFF
system that was recognized as the EPA-approved release at the time of the
application submittal. Version designations of the key programs are listed in
the table below.
Table
14: Key Programs in CALPUFF System
|
||
Program
|
Version
|
Level
|
CALMET
|
5.53a
|
040716
|
CALPUFF
|
5.8
|
070623
|
CALPOST
|
5.6394
|
070622
|
Meteorological
Data Processing (CALMET)
As
required by the Division's modeling protocol, the CALMET model was used to
construct the initial three-dimensional wind field using data from the MM5
model. Surface and upper-air data were also input to CALMET to adjust the
initial wind field.
The
following table lists the key user-defined CALMET settings that were
selected.
Table
15: CALMET Variables
|
||
Variable
|
Description
|
Value
|
PMAP
|
Map
projection
|
LCC
(Xxxxxxx Conformal Conic)
|
DGRIDKM
|
Grid
spacing (km)
|
4
|
NZ
|
Number
of layers
|
12
|
ZFACE
|
Cell
face heights (m)
|
0,20,40,60,80,100,150,200,250,500
|
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OG&E
Muskogee Generating Station BART Review January 15,
2010
Variable
|
Description
|
Value
|
1000,
2000, 3500
|
||
RMIN2
|
Minimum
distance for
extrapolation
|
-1
|
IPROG
|
Use
gridded prognostic model
outputs
|
14
km (MM5 data)
|
RMAX1
|
Maximum
radius of influence
(surface
layer, km)
|
20
km
|
RMAX2
|
Maximum
radius of influence
(layers
aloft, km)
|
50km
|
TERRAD
|
Radius
of influence for terrain
(km)
|
10
km
|
R1
|
Relative
weighting of first guess
wind
field and observation (km)
|
10
km
|
R2
|
Relative
weighting aloft (km)
|
25
km
|
The
locations of the upper air stations with respect to the modeling domain are
shown in Figure 2.
IMAGE NOT
SHOWN
Figure 2:
Plot of surface station locations
22
OG&E
Muskogee Generating Station BART Review January 15,
2010
IMAGE NOT
SHOWN
Figure 3:
Plot of upper air station locations
IMAGE NOT
SHOWN
Figure 4.
Plot of precipitation observation stations
23
OG&E
Muskogee Generating Station BART Review January 15,
2010
CALPUFF
Modeling Setup
To
allow chemical transformations within CALPUFF using the recommended chemistry
mechanism (MESOPUFF II), the model required input of background ozone and
ammonia. CALPUFF can use either a single background value representative of an
area or hourly ozone data from one or more ozone monitoring stations. Hourly
ozone data files were used in the CALPUFF simulation. As provided by the
Oklahoma DEQ, hourly ozone data from the Oklahoma City, Glenpool, and Lawton
monitors over the 2001-2003 time frames were used. Background concentrations for
ammonia were assumed to be temporally and spatially invariant and were set to 3
ppb.
Latitude and longitude coordinates for
Class I area discrete receptors were taken from
the National Park Service (NPS) Class I Receptors database and converted to the
appropriate LCC coordinates.
CALPUFF
Inputs-Baseline and Control Options
The first
step in the refined modeling analysis was to perform visibility modeling for
current (baseline) operations at the facility. Emissions of NOx and
SO2
for the baseline runs were established based on CEM data and maximum 24-hour
emissions averages for years 2001 to 2003.
Baseline
source release parameters and emissions are shown in the table below, followed
by tables with data for the various control options.
Table
16: Source Parameters
|
||
Baseline1
|
||
Coal-Fired
|
Coal-Fired
|
|
Parameter
|
Unit
4
|
Unit
5
|
Heat
Input (mmBtu/hr)
|
5,480
|
5,480
|
Stack
Height (m)
|
106.71
|
106.71
|
Stack
Diameter (m)
|
7.32
|
7.32
|
Stack
Temperature (K)2
|
430.78
|
430.78
|
Exit
Velocity (m/s)2
|
25.40
|
25.40
|
Baseline
SO2
Emissions (lb/mmBtu)
|
0.80
|
0.85
|
Dry
FGD SO2
Emissions (lb/mmBtu)
|
0.10
|
0.10
|
Wet
FGD SO2
Emissions (lb/mmBtu)
|
0.08
|
0.08
|
Baseline
NOx
Emissions (lb/mmBtu)
|
0.495
|
0.522
|
LNB/OFA
NOx
Emissions (lb/mmBtu)
|
0.15
|
0.15
|
LNB/OFA
+ SCR NOx
Emissions (lb/mmBtu)
|
0.07
|
0.07
|
ESP
(Baseline) PM10
Emissions (lb/mmBtu)
|
0.0184
|
0.0244
|
FF
PM10
Emissions (lb/mmBtu)
|
0.012
|
0.012
|
1Baseline
emissions data were provided by OG&E. Baseline emission rates (lb/mmBtu)
were calculated by dividing the maximum 24-hr lb/hr emission rate by the maximum
heat input to the boiler.
2Temperature
and Velocity were decreased for DFGD and WFGD evaluations. For DFGD,
stack temperature was modeled at 359.11K and velocity decreased to 22.77
m/s. For WFGD, stack temperature decreased to 331.89K and velocity
decreased to 21.10 m/s.
24
OG&E
Muskogee Generating Station BART Review January 15,
2010
Visibility
Post-Processing (CALPOST) Setup
The
changes in visibility were calculated using Method 6 with the CALPOST
post-processor. Method 6 requires input of monthly relative humidity factors
[f(RH)] for each Class I area that is being modeled. Monthly f(RH) factors that
were used for this analysis are shown in the table below.
Table
17: Relative Humidity Factors for CALPOST
|
||||
Month
|
Wichita
Mountains
|
Caney
Creek
|
Upper
Buffalo
|
Hercules
Glade
|
January
|
2.7
|
3.4
|
3.3
|
3.2
|
February
|
2.6
|
3.1
|
3.0
|
2.9
|
March
|
2.4
|
2.9
|
2.7
|
2.7
|
April
|
2.4
|
3.0
|
2.8
|
2.7
|
May
|
3.0
|
3.6
|
3.4
|
3.3
|
June
|
2.7
|
3.6
|
3.4
|
3.3
|
July
|
2.3
|
3.4
|
3.4
|
3.3
|
August
|
2.5
|
3.4
|
3.4
|
3.3
|
September
|
2.9
|
3.6
|
3.6
|
3.4
|
October
|
2.6
|
3.5
|
3.3
|
3.1
|
November
|
2.7
|
3.4
|
3.2
|
3.1
|
December
|
2.8
|
3.5
|
3.3
|
3.3
|
EPA's
default average annual aerosol concentrations for the U.S. that are included in
Table 2-1 of EPA's Guidance
for Estimating Natural Visibility Conditions Under the Regional Haze Program
were to develop natural background estimates for each Class I
area.
Visibility
Post-Processing Results
Table 18: CALPUFF Visibility Modeling Results for
Muskogee Units 4 and 5 - NOx
2001
|
2002
|
2003
|
3-Year
Average
|
|||||
Class
I Area
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
o f Days
>
0.5
∆dv
|
Baseline
|
||||||||
Wichita
Mountains
|
0.511
|
8
|
0.613
|
9
|
0.744
|
12
|
0.623
|
10
|
Caney
Creek
|
0.914
|
37
|
0.939
|
31
|
1.469
|
33
|
1.107
|
34
|
Upper
Buffalo
|
1.021
|
21
|
0.650
|
11
|
0.702
|
13
|
0.791
|
15
|
Hercules
Glade
|
0.574
|
10
|
0.431
|
5
|
0.407
|
4
|
0.471
|
6
|
Scenario
1 – Combustion Control – LNB/OFA
|
||||||||
Wichita
Mountains
|
0.154
|
1
|
0.176
|
2
|
0.225
|
1
|
0.185
|
1
|
Caney
Creek
|
0.280
|
1
|
0.283
|
1
|
0.444
|
4
|
0.336
|
2
|
Upper
Buffalo
|
0.312
|
3
|
0.192
|
1
|
0.211
|
2
|
0.238
|
2
|
Hercules
Glade
|
0.164
|
1
|
0.129
|
1
|
0.119
|
0
|
0.137
|
1
|
25
OG&E
Muskogee Generating Station BART Review January 15,
2010
Modeling
for SCR controls resulted in an approximate 50% reduction in visibility
impairment from scenario one.
Table 19: CALPUFF Visibility Modeling
Results for Muskogee Units 4 and 5 – SO2
2001
|
2002
|
2003
|
3-Year
Average
|
|||||
Class
I Area
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
of Days
>
0.5
∆dv
|
98th
Percentile Value
(∆dv)
|
No.
o f Days
>
0.5
∆dv
|
Baseline
|
||||||||
Wichita
Mountains
|
0.939
|
24
|
1.208
|
18
|
1.218
|
28
|
1.122
|
23
|
Caney
Creek
|
1.081
|
34
|
1.287
|
40
|
1.724
|
50
|
1.364
|
41
|
Upper
Buffalo
|
1.342
|
27
|
0.974
|
22
|
1.286
|
34
|
1.200
|
28
|
Hercules
Glade
|
1.145
|
17
|
0.898
|
21
|
0.845
|
17
|
0.963
|
18
|
Scenario
1 – Dry FGD
|
||||||||
Wichita
Mountains
|
0.117
|
0
|
0.148
|
0
|
0.165
|
1
|
0.143
|
0
|
Caney
Creek
|
0.140
|
0
|
0.171
|
0
|
0.234
|
2
|
0.182
|
1
|
Upper
Buffalo
|
0.160
|
0
|
0.114
|
1
|
0.167
|
0
|
0.147
|
0
|
Hercules
Glade
|
0.119
|
0
|
0.122
|
0
|
0.101
|
0
|
0.114
|
0
|
While
mass emissions are decreased marginally with Wet FGD controls modeled impacts
increase over modeled concentrations in scenario one for all Class I areas but
the Wichita Mountains. Wet FGD reduced visibility impairment by a further 1%
over Dry FGD. This generally increased degradation is a result of lower stack
temperatures and velocities and higher SO4 emission
estimates.
Modeling
for existing ESP controls with proposed fabric filters indicate the visibility
impairment from direct PM emissions will be improved with the fabric filters but
both technologies control visibility impairment well below 0.5dv at all Class I
areas.
X. XXXX
DETERMINATION
After
considering: (1) the costs of compliance, (2) the energy and non-air quality
environmental impacts of compliance, (3) any pollutant equipment in use or in
existence at the source, (4) the remaining useful life of the source, and (5)
the degree of improvement in visibility (all five statutory factors) from each
proposed control technology, the Division determined BART for the two units at
the Muskogee Generating Station.
NOx
New LNB
with OFA is determined to be BART for NOx control for Units 4 and 5 based, in
part, on the following conclusions:
1.
|
Installation
of new LNB with OFA was cost effective, with a capital cost of $14,113,700
per unit for units 4 and 5 and an average cost effectiveness of $260-$281
per ton of NOx removed for each unit over a twenty-five year operational
life.
|
26
OG&E
Muskogee Generating Station BART Review January 15,
2010
2.
|
Combustion control using the
LNB/OFA does not require non-air quality environmental mitigation for the
use of chemical reagents (i.e., ammonia or urea) and there is minimal
energy impact.
|
3.
|
After
careful consideration of the five statutory factors, especially the costs
of compliance and existing controls, NOx control levels on 30-day rolling
averages of 0.15 lb/mmBtu for Unit 4 and 5 are justified meet the
presumptive limits prescribed by
EPA.
|
4.
|
Annual
NOx emission reductions from new LNB with OFA on Units 4 and 5 are
2,018-2,469 tons for a total annual reduction of 4,487 tons based on
actual emissions from 2004-2006 and projected emissions at maximum heat
input and 90% capacity.
|
LNB
with OFA and SCR was not determined to be BART for NOx control for Units 1 and 2
based, in part, on the following conclusions:
1.
|
The
cost of compliance for installing SCR on each unit is significantly higher
than the cost for LNB with OFA. Additional capital costs for SCR on Units
I and 2 are on average $193,077,000 per unit. Based on projected
emissions, SCR could reduce overall NOx emissions from Muskogee Units 4
and 5 by approximately 3,456 TPY beyond combustion controls; however, the
incremental cost associated with this reduction is approximately
$16,611/ton.
|
2.
|
Additional
non-air quality environmental mitigation is required for the use of
chemical reagents.
|
3.
|
Operation
of LNB with OFA and SCR is parasitic and requires power from each
unit.
|
4.
|
The cumulative visibility
improvement for SCR, as compared to LNB/OFA across Wichita Mountains and
Caney Creek (based on the 98th percentile modeled results) was 0.10 and
0.18 ∆dv
respectively.
|
SO2
Continued
use of low sulfur coal is determined to be BART for SO2 control
for Units 4 and 5 based on the capital cost of add-on controls, the cost
effectiveness both in $/ton and $/dv of add-on controls, and the long term
viability of coal with respect to other environmental programs, and national
commitments.
Installation
of DFGD is not cost effective. OG&E's revised cost estimates are based on
vendor quotes and go well beyond the default methodology recommended by EPA
guidance. The cost estimates are credible, detailed, and specific for the
Muskogee facility. The final estimate for both boilers at $634,387,200 is
$223,691,200 greater than the high end costs assumed by DEQ in the Draft
SIP.
These
costs put the project well above costs reported for other BART determinations.
The federal land managers have informally maintained a spreadsheet of BART costs
and determinations for coal-fired facilities. This spreadsheet indicates that
the highest reported cost for control was for the Boardman facility in Oregon at
a projected cost of $247,300,000. While there is some uncertainty on whether
this cost will ultimately be found to be cost effective, it is much lower than
the cost of controlling a single boiler at the Muskogee facility ($317,193,600).
Most assessments were based on costs of less than $150,000,000 and related cost
effectiveness numbers of $3,053/ton removed for Xxxxxxxx to an average of less
than $2,000/ton for the other determinations tracked by the
FLMs.
27
OG&E
Muskogee Generating Station BART Review January 15,
2010
Table 20
provides a summary of the baseline SO2 emission
rates included in several BART evaluations.
Table
20: Comparison of Baseline SO2 Emissions
at Several BART Units
Station
|
Baseline
S02
Emission Rate (lb/mmBtu)
|
Baseline
S02
Emissions (TPY)
|
Muskogee
Unit 4
|
0.507
|
9,113
|
Muskogee
Unit 5
|
0.514
|
9,006
|
Sooner
Unit 1
|
0.509
|
9,394
|
Sooner
Unit 2
|
0.516
|
8,570
|
NPPD
Xxxxxx Gentleman Unit 1
|
0.749
|
24,254
|
NPPD
Xxxxxx Gentleman Unit 2
|
0.749
|
25,531
|
White
Bluff Unit 1
|
0.915
|
31,806
|
White
Bluff Unit 2
|
0.854
|
32,510
|
Xxxxxxxx
unit 1
|
0.614
|
14,902
|
Northeastern
Unit 3
|
0.900
|
16,000
|
Northeastern
Unit 4
|
0.900
|
16,000
|
Xxxxxxxx
Unit 1
|
1.180
|
8,624
|
Xxxxxxxx
Unit 2
|
1.180
|
11,187
|
OPPD
Nebraska City Unit 1
|
0.815
|
24,191
|
Assuming
total annual costs and projected emissions are similar and thereby setting aside
the issues related to pre-2008 cost estimates and the ability to compare them to
December 2009 estimates, cost effectiveness will be a function of the baseline
emissions. This holds true for units firing subbituminous coals with baseline
SO2
emissions rates in the range of 0.5 lb/mmBtu to approximately 2.0 lb/mmBtu,
because removal efficiencies achievable with DFGD control will vary based on
inlet SO2
loading. In general, DFGD
control systems are capable of achieving higher removal efficiencies on units
with higher inlet SO2 loading.
DFGD control systems will be more cost effective on units with higher baseline
SO2emissions
because the control systems will be capable of achieving higher removal
efficiencies and remove more tons of SO2 per year
for similar costs. Conversely, DFGD will be less cost effective, on a $/ton
basis, on units with lower SO2 baseline
emissions. On the basis of baseline emissions alone, with all other factors
being equal, the cost effectiveness of the OG&E units would be about 55 to
185% higher than the other units listed, i.e., less cost effective.
The
average cost effectiveness at Muskogee for DFGD is $7,378-$7,493 per ton of
SO2
removed for each unit over a twenty year operational life. The cost of this
control at the Muskogee facility is well above the average cost effectiveness
reported for similar BART projects, well above costs associated with BACT
determinations for SO2, and well
above the cost of control originally contemplated in the Regional Haze
Rule.
From the
FLM BART tracking spreadsheet, the average cost effectiveness in $/dv was
$5,700,000/dv. The addition of DFGD at the Muskogee Facility was anticipated to
reduce impairment by 4.217 dv. Importantly, the cost effectiveness of that
improvement is now calculated to be $24,330,000/dv.
28
OG&E
Muskogee Generating Station BART Review January 15,
2010
A majority of the Class I areas are
located in the western part of the U.S. Simply due to the number of Class I
areas in the west, it is likely that a BART applicable unit located in the
western U.S. will be closer to a Class I area, and
that emissions from the unit will affect visibility at more Class I areas. For
example, the Xxxxxxxx Generating Station located in the north central region
approximately 150 miles east of Portland, is located within 300 km of 14 Class I
areas. By comparison the Muskogee station is located with 300 km of 14 Class I
areas. Using the sum of modeled visibility improvements at all 14 Class I areas,
cost effectiveness of the DFGD control system would be $3,690,510/dv or 6.5
times more cost effective than DFGD controls at the Muskogee facility. The
federal land managers have indicated that costs effectiveness numbers of less
than $10,000,000/dv should be considered cost effective. While this does not
prohibit a determination of cost effectiveness at numbers greater than
$10,000,000/dv, it does imply that numbers greater than that should receive
greater consideration.
An investment of this magnitude to
install DFGD on an existing coal-fired power plant effectively guarantees the
continued use of coal as the primary fuel source for energy generation in this
facility and arguably the state for the next 20 years and beyond. Therefore, a
determination in support of DFGD ignores the Obama Administration's stated
agenda to control carbon dioxide and other green house gases by restricting the
alternatives left open to OG&E and hence the ratepayers of Oklahoma.
Substantial uncertainty currently exists about the nature and costs of future
federal carbon controls on power plants, including the level of stringency,
timing, emissions allowance allocation and prices, and whether and to what degree emissions
"offsets" are allowed. Further, new federal MACT mercury control requirements
may be imposed on the Muskogee facility that would be more stringent than the
scrubber can deliver. Fortunately, other technology options now exist that would
likely achieve greater mercury reductions at lower cost than the scrubber. If
EPA determines that MACT requires greater reductions than those achieved through
DFGD, then ratepayers would be at risk to pay for additional required mercury
control technology.
The cost for DFGD is too high, the
benefit too low and these costs, if borne, further extend the life expectancy of
coal as the primary fuel in the Muskogee facility for at least 20 years and
beyond. BART is the continued use of low sulfur
coal.
Wet
FGD was not determined to be BART for SO2
control for Units 3 and 4 based, in part, on the following
conclusions:
1.
|
The cost of compliance for
installing WFGD on each unit is higher than the cost for DFGD. Based on
projected emissions, WFGD could reduce overall SO2 emissions from Muskogee Units 4
and 5 by approximately 864 TPY beyond dry scrubbers; however, the
incremental cost associated with this reduction is approximately
$30,381/ton.
|
2.
|
SO3 remaining in the flue gas will
react with moisture in the wet FGD to generate sulfuric acid mist.
Sulfuric acid is classified as a condensable particulate. Condensable
particulates from the wet FGD system can be captured using additional
emission controls (e.g., XXXX). However, the effectiveness of a XXXX
system on a subbituminous fired unit has not been demonstrated and the
additional cost of the XXXX system significantly increases the cost of
SO2
controls.
|
3.
|
Wet
FGD systems must be located downstream of the unit's particulate control
device;
|
29
OG&E
Muskogee Generating Station BART Review January 15,
2010
therefore,
dissolved solids from the wet FGD system will be emitted with the wet FGD plume.
Wet FGD control systems also generate lower stack temperatures that can reduce
plume rise and result in a visible moisture plume.
4.
|
Wet
FGD systems use more reactant (e.g., limestone) than do dry systems,
therefore the limestone handling system and storage piles will generate
more fugitive dust emissions.
|
5.
|
Wet
FGD systems require significantly more water than the dry systems and
generate a wastewater stream that must be treated and discharged. We FGD
wastewater treatment systems typically require calcium sulfate/sulfite
desaturation, heavy metals precipitation, coagulation/precipitation, and
sludge dewatering. Treated wastewater is typically discharged to surface
water pursuant to an NPDES discharge permit, and solids are typically
disposed of in a landfill. Dry FGD control systems are designed to
evaporate water within the reaction vessel, and therefore do not generate
a wastewater stream.
|
6.
|
Because of a slower exit velocity,
lower slack temperature and higher S04 emissions associated with Wet
FGD, visibility impairment was found to higher under this control strategy
than the Dry FGD for three of four Class I
areas.
|
PM10
The
existing ESP control is determined to be BART for PM10
controls for Units 4 and 5 based on the determination of low sulfur coal
and the high cost of fabric filters relative to the low actual emissions of
PM10 from
the facility.
Table
21: Unit-by-unit BART determinations
Control
|
Unit
4
|
Unit
5
|
NOx
Control
|
New
LNB with OFA
|
New
LNB with OFA
|
Emission
Rate (lb/mmBtu)
|
0.15
lb/mmBtu
(30-day
rolling average)
|
0.15
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
822
lb/hr
(30-day
rolling average)
|
822
lb/hr
(30-day
rolling average)
|
Emission
Rate TPY
|
3,600
TPY
(12-month
rolling)
|
3,600
TPY
(12-month
rolling)
|
S02
Control
|
Low
Sulfur Coal
|
Low
Sulfur Coal
|
Emission
Rate (lb/mmBtu)
|
0.65
lb/mmBtu
(30-day
rolling average)
|
0.65
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
3,562
lb/hr
(30-day
rolling average)
|
3,562
lb/hr
(30-day
rolling average)
|
Annual
Emission Rate
(lb/mmBtu)
|
0.55
lb/mmBtu
(annual
average)
|
0.55
lb/mmBtu
(annual
average)
|
Emission
Rate TPY
|
18,096
TPY
|
|
PM10 Control
|
Existing
ESP
|
Existing
ESP
|
Emission
Rate (lb/mmBtu)
|
0.1
lb/mmBtu
|
0.1
lb/mmBtu
|
Emission
Rate lb/hr
|
548
lb/hr
|
548
lb/hr
|
Emission
Rate TPY
|
2,400
TPY
(12-month
rolling average)
|
2,400
TPY
(12-month
rolling average)
|
30
OG&E
Muskogee Generating Station BART Review January 15,
2010
F.
CONTINGENT BART DETERMINATION
In the event that EPA disapproves the
BART Determination referenced above in regard to the DEQ determination that DFGD
with SDA is not cost-effective for S02 control, the low-sulfur coal
requirement in the BART determination for S02 and the related ESP requirement for PM
referenced above shall be replaced with a requirement that Muskogee Units 4 and
5 install DFGD with SDA for S02 control and fabric filters for PM
control or meet the corresponding S02 and PM10 emission limits listed below by
December 31, 2018 or comply with the approved alternative described in section G
(Greater Reasonable Progress Alternative).
Table
22: Unit-by-unit Contingent BART determinations
Control
|
Unit
4
|
Unit
5
|
S02
Control
|
DFGD
w/SDA
|
DFGD
w/SDA
|
Emission
Rate (lb/mmBtu)
|
0.1
lb/mmBtu
(30-day
rolling average)
|
0.1
lb/mmBtu
(30-day
rolling average)
|
Emission
Rate lb/hr
|
548
lb/hr
(30-day
rolling average)
|
548
lb/hr
(30-day
rolling average)
|
Emission
Rate TPY
|
2,400
TPY
|
2,400
TPY
|
PM10 Control
|
Fabric
Filter
|
Fabric
Filter
|
Emission
Rate (lb/mmBtu)
|
0.015
lb/mmBtu
|
0.015
lb/mmBtu
|
Emission
Rate lb/hr
|
82
lb/hr
|
82
lb/hr
|
Emission
Rate TPY
|
360
TPY
(12-month
rolling average)
|
360
TPY
(12-month
rolling average)
|
The
"contingent" BART as defined here and in conjunction with the greater reasonable
progress alternative recognizes the long term importance of achieving reductions
in S02
while addressing the need for operational flexibility in response to the
eventualities of a federal carbon trading program and mercury MACT in the nearer
term. It must be understood that DEQ has determined that DFGD is not cost
effective. However, if EPA chooses to ignore that element of the BART
determination, DEQ does agree that DFGD remains a technically feasible control
option for S02
reductions.
Switching
from coal to natural gas, while physically possible constitutes a significant
modification to a facility process not contemplated by the regional haze rule.
However, exploring some combination of both options, while allowing the
uncertainty surrounding other federal environmental programs to settle, is a
more equitable alternative for the ratepayers in Oklahoma than requiring an
overly costly control merely to achieve limited reductions while simultaneously
solidifying the use of dirty technology from now into the foreseeable
future.
G.
GREATER REASONABLE PROGRESS ALTERNATIVE DETERMINATION
In lieu
of installing and operating BART for S02 and PM
control at Sooner Units 1 and 2 and Muskogee Units 4 and 5, OG&E may elect
to implement a fuel switching alternative. The greater reasonable progress
alternative requires OG&E to achieve a combined annual S02 emissions
limit (identified in table 23) by installing and operating DFGD with SDA on two
of the four boilers and being at or below the S02 emission
that would result from switching the
31
OG&E
Muskogee Generating Station BART Review January 15,
2010
remaining
two boiler to natural gas. Under this alternative OG&E shall install the
controls (i.e., DFGD with SDA or achieve equivalent emissions) by December 31,
2026. By adopting these emission limits, DEQ and OG&E expect the cumulative
S02 emissions
from Sooner Units 1 and 2 and Muskogee Units 4 and 5 to be approximately 57%
less than would be achieved through the installation and operation of DFGD with
SDA at all four units (assuming 90% capacity).
Table
23: S02 Emissions
with Greater Reasonable Progress
Muskogee
|
Sooner
|
|
Parameter
|
Unit
4 and Unit 5
|
Unit
1 and Unit 2
|
BART
(Low Sulfur Coal)
|
18,096
TPY
|
19,736
TPY
|
Contingent
BART (DFGD)
|
4,800
TPY
|
4,482
TPY
|
GRP
(DFGD/Natural Gas)
|
3,600
TPY
|
Under no circumstance will the Greater
Reasonable Progress Plan result in less visibility improvement than would be
achieved either through the DEQ determined BART or the "contingent" BART. By
allowing the installation of S02 controls to be delayed, current
regulatory hurdles to long term natural gas contracts can be addressed and the
best interests of the ratepayers and visitors to our Class I areas can be
preserved for the long term 2064 goal of natural visibility.
V.
CONSTRUCTION PERMIT
Prevention
of Significant Deterioration (PSD)
Muskogee
Generating Station is a major source under OAC 252:100-8 Permits for Part 70
Sources. Oklahoma Gas and Electric should comply with the permitting
requirements of Subchapter 8 as they apply to the installation of controls
determined to meet XXXX.
The installation of controls determined
to meet XXXX will not change NSPS or NESHAP/MACT applicability for the gas-fired
units at the Muskogee Station. The permit application should contain
PM10
and PM2.5 emission estimates for filterable and
condensable emissions.
VI.
OPERATING PERMIT
The
Muskogee Generating Station is a major source under OAC 252:100-8 and has
submitted an application to modify their existing Title V permit to incorporate
the requirement to install controls determined to meet XXXX. The Permit will
contain the following specific conditions:
1.
|
The
boilers in EUG 3 are subject to the Best Available Retrofit Technology
(BART) requirements of 40 CFR Part 51, Subpart P, and shall comply with
all applicable requirements including but not limited to the following:
[40 CFR §§ 51.300-309 & Part 51, Appendix
Y]
|
a.
|
Affected
facilities. The following sources are affected facilities and are subject
to the requirements of this Specific Condition, the Protection of
Visibility and Regional Haze Requirements of 40 CFR Part 51, and all
applicable SIP
requirements:
|
32
OG&E
Muskogee Generating Station BART Review January 15,
2010
EU
ID#
|
Point
ID#
|
EU
Name
|
Heat
Capacity
(MMBTUH)
|
Construction
Date
|
3-B
|
01
|
Unit
4 Boiler
|
5,480
|
1972
|
3-B
|
02
|
Unit
5 Boiler
|
5,480
|
1972
|
b.
|
Each
existing affected facility shall install and operate the SIP approved BART
as expeditiously as practicable but in no later than five years after
approval of the SIP incorporating BART
requirements.
|
c.
|
The
permittee shall apply for and obtain a construction permit prior to
modification of the boilers. If the modifications will result
in a significant emission increase and a significant net emission increase
of a regulated NSR pollutant, the applicant shall apply for a PSD
construction permit.
|
d.
|
The
affected facilities shall be equipped with the following current
combustion control technology, as determined in the submitted BART
analysis, to reduce emissions of NOx to below the emission limits
below:
|
i. Low-NOx
Burners,
ii. Overfire
Air.
e.
|
The
permittee shall maintain the controls (Low-NOx burners, overfire air, dry)
and establish procedures to ensure the controls are properly operated and
maintained.
|
f.
|
Within
60 days of achieving maximum power output from each affected facility,
after modification or installation of BART, not to exceed 180 days from
initial start-up of the affected facility the permittee shall comply with
the emission limits established in the construction permit. The
emission limits established in the construction permit shall be consistent
with manufacturer’s data and an agreed upon safety factor. The
emission limits established in the construction permit shall not exceed
the following emission limits:
|
EU
ID#
|
Point
ID#
|
NOx
Emission
Limit
|
S02
Emission
Limit
|
Averaging
Period
|
3-B
|
01
|
0.15
lb/mmBtu
|
0.65
lb/mmBtu
|
30-day
rolling
|
3-B
|
02
|
0.15
lb/mmBtu
|
0.65
lb/mmBtu
|
30-day
rolling
|
EU
ID#
|
Point
ID#
|
PM10
|
3-B
|
01
|
0.1
lb/mmBtu
|
3-B
|
02
|
0.1
lb/mmBtu
|
EU
ID#
|
Point
ID#
|
S02
Emission
Limit
|
S02
Emission
Limit
|
Averaging
Period
|
3-B
|
01
|
18,096
TPY
|
0.55
lb/mmBtu
|
Annual
rolling
|
3-B
|
02
|
0.55
lb/mmBtu
|
Annual
rolling
|
g.
|
Boiler
operating day shall have the same meaning as in 40 CFR Part 60, Subpart
Da.
|
h.
|
Within
60 days of achieving maximum power output from each boiler, after
modification of the boilers, not to exceed 180 days from initial start-up,
the
|
33
OG&E
Muskogee Generating Station BART Review January 15,
2010
|
permittee
shall conduct performance testing as follows and furnish a written report
to Air Quality. Such report shall document compliance with BART
emission limits for the affected facilities. [OAC
252:100-8-6(a)]
|
i.
|
The
permittee shall conduct SO2, NOx, PM10, PM2.5, CO, and VOC
testing on the boilers at 60% and 100% of the maximum
capacity. NOX and CO testing shall also be conducted at least
one additional intermediate point in the operating
range.
|
ii.
|
Performance
testing shall be conducted while the units are operating within 10% of the
desired test rates. A testing protocol describing how the
testing will be performed shall be provided to the AQD for review and
approval at least 30 days prior to the start of such
testing. The permittee shall also provide notice of the actual
test date to AQD.
|
34