Full-scale evaluation of mercury control with sorbent injection and COHPAC at Alabama Power E.C. Gaston

The overall objective of this project was to determine the cost and impacts of Hg control using sorbent injection into a Compact Hybrid Particulate Collector (COHPAC) at Alabama Power's Gaston Unit 3. This test is part of a program funded by the U.S. Department of Energy's National Energy Technology Laboratory (NETL) to obtain the necessary information to assess the costs of controlling Hg from coal-fired utility plants that do not have scrubbers for SO2 control. The economics will be developed based on various levels of Hg control. Gaston Unit 3 was chosen for testing because COHPAC represents a cost-effective retrofit option for utilities with existing electrostatic precipitators (ESPs). COHPAC is an EPRI-patented concept that places a high air-to-cloth ratio baghouse downstream of an existing ESP to improve overall particulate collection efficiency. Activated carbons were injected upstream of COHPAC and downstream of the ESP to obtain performance and operational data. Results were very encouraging, with up to 90% removal of Hg for short operating periods using powdered activated carbon (PAC). During the long-term tests, an average Hg removal efficiency of 78% was measured. The PAC injection rate for the long-term tests was chosen to maintain COHPAC cleaning frequency at less than 1.5 pulses/bag/hr.     

Mercury Mass Balances: A Case Study of Two North Dakota Power Plants

ABSTRACT

The Energy & Environmental Research Center (EERC) conducted a mercury-sampling program to provide data on the quantity and forms of Hg emitted and on the Hg removal efficiency of the existing air pollution control devices at two North Dakota power plants—Milton R. Young Station and Coal Creek Station. Minnkota Power Cooperative, Great River Energy, the North Dakota Industrial Commission, and EPRI funded the project. The primary objective was to obtain accurate measurements of Hg released from each plant, as verified by a material balance. A secondary objective was to evaluate the ability of a mercury continuous emission monitor (CEM) to measure total Hg at the stack.

At both plants, speciated Hg measurements were made at the inlets and outlets of both the electrostatic precipi-tators (ESPs) and the flue gas desulfurization (FGD) systems. A Semtech Hg 2000 (Semtech Metallurgy AB) mercury CEM was used to measure the total Hg emissions at the stack in real time. Using these measurements and plant data, the measured Hg concentrations in the coal, FGD slurries, and ESP ash, a Hg mass flow rate was calculated at each sampling location. Excellent Hg mass balances were obtained (±15%). It was also found that the Hg was mostly in the elemental phase (~90%), and the small amount of oxidized Hg that was generated was removed by the FGD systems.

Insignificant amounts of particulate-bound Hg were measured at both plants. However, 10-20% of the elemental Hg measured prior to the ESP was converted to oxidized Hg across the ESP. The data show that, at these facilities, almost all of the Hg generated is being emitted into the atmosphere as elemental Hg. Local or regional deposition of the Hg emitted from these plants is not a concern. However, the Hg does become part of the global Hg burden in the atmosphere. Also, the evidence appears to indicate that elemental Hg is more difficult to remove from flue gas than oxidized Hg is.     

The Fate and Behavior of Mercury in Coal-Fired Power Plants

Abstract

For the past 22 years in the Netherlands, the behavior of Hg in coal-fired power plants has been studied extensively. Coal from all over the world is fired in Dutch power stations. First, the Hg concentrations in these coals were measured. Second, the fate of the Hg during combustion was established by performing mass balance studies. On average, 43 ± 30% of the Hg was present in the flue gases downstream of the electrostatic precipitator (ESP; dust collector). In individual cases, this figure can vary between 1 and 100%. Important parameters are the Cl content of the fuel and the flue gas temperature in the ESP. On average, 54 ± 24% of the gaseous Hg was removed in the wet flue-gas desulfurization (FGD) systems, which are present at all Dutch coal-power stations. In individual cases, this removal can vary between 8% (outlier) and 72%.

On average, the fate of Hg entering the power station in the coal was as follows: <1% in the bottom ash, 49% in the pulverized fuel ash (ash collected in the ESP), 16.6% in the FGD gypsum, 9% in the sludge of the wastewater treatment plant, 0.04% in the effluent of the wastewater treatment plant, 0.07% in fly dust (leaving the stack), and 25% as gaseous Hg in the flue gases and emitted into the air. The distribution of Hg over the streams leaving the FGD depends strongly on the installation. On average, 75% of the Hg was removed, and the final concentration of Hg in the emitted flue gases of the Dutch power stations was only ~3 μg/m_STP ³ at 6% O₂. During co-combustion with biomass, the removal of Hg was similar to that during 100% coal firing.

Speciation of Hg is a very important factor. An oxidized form (HgCl₂) favors a high degree of removal. The conversion from Hg⁰ to HgCl₂ is positively correlated with the Cl content of the fuel. A catalytic DENOX (SCR) favors the formation of oxidized Hg, and, in combination with a wet FGD, the total removal can be as high as 90%.     

Assessing Sorbents for Mercury Control in Coal-Combustion Flue Gas

Abstract

Sorbent injection for Hg control is one of the most promising technologies for reducing Hg emissions from power-generation facilities, particularly units that do not require wet scrubbers for SO₂ control. Since 1992, EPRI has been assessing the performance of Hg sorbents in pilot-scale systems installed at full-scale facilities. The initial tests were conducted on a 5000-acfm (142-m³/min) pilot baghouse. Screening potential sorbents at this scale required substantial resources for installation and operation and did not provide an opportunity to characterize sor-bents over a wide temperature range.

Data collected in the laboratory and in field tests indicate that sorbents are affected by flue gas composition and temperature. Tests carried out in actual flue gas at a number of power plants also have shown that sorbent performance can be site-specific. In addition, data collected at a field site often are different from data collected in the laboratory, with simulated flue gas mixed to match the major components in the site’s gas. To effectively estimate the costs of Hg sorbent systems at different plants, a measure of sorbent performance in the respective flue gases must be obtained. However, injection testing at multiple facilities with large pilot systems is not practical.

Over the past five years, fixed-bed characterization testing, modeling studies, and bench-scale injection testing have been undertaken to develop a low-cost technique to characterize sorbent performance in actual flue gas and subsequently to project normalized costs for Hg removal prior to full-scale demonstration. This article describes the techniques used and summarizes field-testing results from two plants burning Powder River Basin (PRB) coal for commercial activated carbon and several other sorbent types. Full-scale projections based on the results and data collected on larger-scale systems also are included.     

Mercury mass balances: a case study of two North Dakota power plants

The Energy & Environmental Research Center (EERC) conducted a mercury-sampling program to provide data on the quantity and forms of Hg emitted and on the Hg removal efficiency of the existing air pollution control devices at two North Dakota power plants--Milton R. Young Station and Coal Creek Station. Minnkota Power Cooperative, Great River Energy, the North Dakota Industrial Commission, and EPRI funded the project. The primary objective was to obtain accurate measurements of Hg released from each plant, as verified by a material balance. A secondary objective was to evaluate the ability of a mercury continuous emission monitor (CEM) to measure total Hg at the stack. At both plants, speciated Hg measurements were made at the inlets and outlets of both the electrostatic precipitators (ESPs) and the flue gas desulfurization (FGD) systems. A Semtech Hg 2000 (Semtech Metallurgy AB) mercury CEM was used to measure the total Hg emissions at the stack in real time. Using these measurements and plant data, the measured Hg concentrations in the coal, FGD slurries, and ESP ash, a Hg mass flow rate was calculated at each sampling location. Excellent Hg mass balances were obtained (+/- 15%). It was also found that the Hg was mostly in the elemental phase (approximately 90%), and the small amount of oxidized Hg that was generated was removed by the FGD systems. Insignificant amounts of particulate-bound Hg were measured at both plants. However, 10-20% of the elemental Hg measured prior to the ESP was converted to oxidized Hg across the ESP. The data show that, at these facilities, almost all of the Hg generated is being emitted into the atmosphere as elemental Hg. Local or regional deposition of the Hg emitted from these plants is not a concern. However, the Hg does become part of the global Hg burden in the atmosphere. Also, the evidence appears to indicate that elemental Hg is more difficult to remove from flue gas than oxidized Hg is.     

Modeling Sorbent Injection for Mercury Control in Baghouse Filters: I—Model Development and Sensitivity Analysis

Abstract

A two-stage mathematical model for Hg removal using powdered activated carbon injection upstream of a bag-house filter was developed, with the first stage accounting for removal in the ductwork and the second stage accounting for additional removal caused by the retention of carbon particles on the filter. The model shows that removal in the ductwork is minimal, and the additional carbon detention time from the entrapment of the carbon particles in the fabric filter enhances the Hg removal from the gas phase. A sensitivity analysis on the model shows that Hg removal is dependent on the isotherm parameters, the carbon pore radius and tortuosity, the C/Hg ratio, and the carbon particle radius.     

Assessment of PCDD/F and PBDD/F emissions from coal-fired power plants during injection of brominated activated carbon for mercury control

The effect of the injection of brominated powdered activated carbon (Br-PAC) on the emission of brominated and chlorinated dioxins and furans in coal combustion flue gas has been evaluated. The sampling campaigns were performed at two U.S. Department of Energy (DOE) demonstration sites where brominated PAC was being injected for control of mercury emissions. The results of the sampling campaigns showed that injection of the brominated PAC upstream of the electrostatic precipitator (ESP) did not increase the emissions of total and Toxic EQuivalent (TEQ) chlorinated and brominated dioxin compounds. Rather, the data suggested the sorbent may capture these compounds and reduce their concentration in the flue gas stream. This effect, when seen, was small, and independent of the type of plant emission controls, temperature at the point of injection, or fuel-chlorine content. The addition of the brominated PAC sorbent resulted in slight increases the total content of chlorinated dioxins and furan in the particulate matter (ash) collected in the ESP, but did not increase its overall toxicity.     

A real-time optimization method for economic and effective operation of electrostatic precipitators

ABSTRACT

Electrostatic precipitators (ESP) have been considered as the main particulate matter (PM) removal facility in the energy industry. This paper presents a real-time optimization method for a one-chamber industrial ESP in an ultra-low emission power plant with an intelligent optimization system (IOS). The IOS seeks to optimize the energy consumption of ESP subject to the outlet concentration requirement in real-time. A coordination control logic is designed to regulate the optimized operation set points with varying operation conditions. The operation optimized by the IOS is compared with the operations under PID (proportion-integral-derivative) and manual control. The results show that the IOS improves the emission compliance rate from 95% of manual control to 100% and the medium concentration is tuned to be 46.6% closer to the emission target. Furthermore, a good balance between emission and energy consumption is achieved, with 35.50% energy conservation for the same emission upper limit of 30 mg/m³. These results prove that the IOS significantly contributes to the efficient operation and economic PM removal by ESP for the energy industry.     

Modeling sorbent injection for mercury control in baghouse filters: II--pilot-scale studies and model evaluation

Activated carbon injection for Hg control in a 500-lb/hr pilot-scale coal-fired furnace equipped with a fabric filter for particulate control was evaluated at different operating conditions. The pilot-scale tests showed that Hg removal was improved at lower temperatures and higher C/Hg ratios. The two-stage mathematical model developed to describe Hg removal using powdered activated carbon injection upstream of a baghouse filter was used to obtain Langmuir isotherm parameters as a function of temperature by fitting the model to a subset of experimental data. The predictive capability of the model was then tested by comparing model calculations with additional experimental data from this system obtained using different operating temperatures and sorbent to Hg ratios. Model predictions were in good agreement with experimentally measured Hg removal efficiency. Based on the model predictions, Hg removal in the duct appears to be limited and higher C/Hg ratio, lower operating temperature, and longer cleaning cycle of the baghouse filter should be utilized to achieve higher Hg removal in this system.     

Control of Mercury Emissions from a Municipal Solid Waste Incinerator in Japan

Abstract

The control of Hg emissions from a municipal solid waste incinerator (MSWI) is very important, because more than 78% of municipal solid waste (MSW) is incinerated. The Hg content of coal used in utility boilers is relatively low in Japan. In this study, recent trends in the Hg content of MSW in Japan and activated carbon (AC) injection as a control technology of Hg emission from an MSWI are discussed. The effect of AC injection on Hg removal from flue gas in an MSWI was investigated by pilot-scale experiments using a bag filter (BF). The injection of AC increases the Hg reduction ratio by 20–30% compared with cases without AC injection. The Hg reduction ratio increases as the flue gas temperature decreases. The Hg reduction ratio is closely related to the inlet Hg concentration and was expressed with a Langmuir-type adsorption isotherm.     

Characterization of Municipal Solid Waste Incineration Residues From Facilities with Different Air Pollution Control Systems

Abstract

Municipal Solid Waste incinerator residues produced in two types of facilities were exhaustively characterized: granulometry, mineralogy, chemical composition, leaching behavior, and elemental distribution as a function of particle size. Air Pollution Control (APC) residues coming from a semi-dry scrubber have shown higher solubility than fly ashes originating in an Electrostatic Precipitator (ESP), as well as higher contents in volatile metals (Cd, Hg). Different metal speciation and distribution as a function of particle size have been found in fly ashes (ESP residues) and APC residues. In APC residues, heavy metals (with the exception of Hg) show a parabolic distribution with maxima in the smallest and largest particles, following the same profile as soluble salts. Metal distribution for APC residues exhibits that metals generally are not associated with silicate aluminate matrix. Results show the effect of adding lime to APC residues in metal speciation and distribution.     

Performance of Copper Chloride-Impregnated Sorbents on Mercury Vapor Control in an Entrained-Flow Reactor System

Abstract

An entrained-flow system has been designed and constructed to simulate in-flight mercury (Hg) capture by sorbent injection in ducts of coal-fired utility plants. The test conditions of 1.2-sec residence time, 140 °C gas temperature, 6.7 m/sec (22 ft/sec) gas velocity, and 0–0.24 g/m³ (0–15 lbs of sorbent per 1 million actual cubic feet of flue gas [lb/MMacf]) sorbent injection rates were chosen to simulate conditions in the ducts. Four kinds of sorbents were used in this study. Darco Hg-LH served as a benchmark sorbent with which Hg control capability of other sorbents could be compared. Also, Darco-FGD was used as a representative raw activated carbon sorbent. Two different copper chloride-impregnated sorbents were developed in our laboratory and tested in the entrained-flow system to examine the possibility of using these sorbents at coal-fired power plants. The test results showed that one of the copper chloride sorbents has remarkable elemental mercury (Hg⁰) oxidation capability, and the other sorbent demonstrated a better performance in Hg removal than Darco Hg-LH.     

A New Method to Assess Mercury Emissions: A Study of Three Coal-Fired Electric-Generating Power Station Configurations

Abstract

U.S. Environmental Protection Agency (EPA) Method 7473 for the analysis of mercury (Hg) by thermal decomposition, amalgamation, and atomic absorption spectroscopy has proved successful for use in Hg assessment at coal-fired power stations. In an analysis time of ～5 min per sample, this instrumental methodology can directly analyze total Hg—with no discrete sample preparation—in the solid matrices associated with a coal-fired power plant, including coal, fly ash, bottom ash, and flue gas desulfurization (FGD) material. This analysis technique was used to investigate Hg capture by coal combustion byproducts (CCBs) in three different coal-fired power plant configurations. Hg capture and associated emissions were estimated by partial mass balance. The station equipped with an FGD system demonstrated 68% capture on FGD material and an emissions estimate of 18% (11 kg/yr) of total Hg input. The power plant equipped with low oxides of nitrogen burners and an electrostatic precipitator (ESP) retained 43% on the fly ash and emitted 57% (51 kg/yr). The station equipped with conventional burners and an ESP retained less than 1% on the fly ash, emitting an estimated 99% (88 kg/yr) of Hg. Estimated Hg emissions demonstrate good agreement with EPA data for the power stations investigated.     

Improving Baghouse Performance at the Monticello Generating Station

At the Monticello station, operated by the Texas Utilities Generating Company, lignite coal obtained locally in Titus and Hopkins Counties fuels each of the three units. Units 1 and 2 are identical 575-MW Combustion Engineering (CE) boilers, each of which discharges its effluent to a 36- compartment shake/deflate cleaned baghouse paralleled with four electrostatic precipitators (ESP). Unit 3 is a larger boiler and is followed by an ESP and a scrubber. The Unit 1 and 2 baghouses were designed to clean 80 percent of the flue gas. Since startup, these baghouses have regularly experienced flange-to-flange pressure drops in excess of 10 in. H₂O, with large opacity spikes caused by ash bleeding through the bags after compartment cleanings. Because of higher-than-expected pressure drop, the baghouses receive only about 45-50 percent of the flue gas. Analysis has shown the Monticello lignite ash significantly differs from most other coal ashes. Testing has shown that the Monticello ash is not filtered effectively by many "standard" bag materials. However, this testing indicates that there are fabrics that show promise of eliminating the ash bleedthrough with little pressure drop penalty. Testing has also shown that injection of low concentrations (10-15 ppm) of ammonia (NH₃) into the flue gas significantly decreases ash bleedthrough, so that with NH₃ injection "standard" bag materials may perform adequately. Currently, fullcompartment testing of four fabrics, with and without NH₃ injection, is under way at the Unit 1 baghouse. The research conducted at the Monticello station is reviewed in this paper and the encouraging results from the full-compartment tests are presented.     

An Assessment of the Significance of Mercury Release from Coal Fly Ash

Abstract

Some mercury (Hg) naturally present in coal is retained in the fly ash remaining after combustion. Concern has been raised regarding the potential for release of this Hg to the environment. The exchange of Hg between fly ash and the atmosphere was measured in the laboratory and in situ at a fly ash landfill. All samples of fly ash used in the laboratory study, with the exception of that derived from lignite-type coal, acted as a sink for atmospheric Hg. Deposition rates were found to increase as air Hg concentrations increased and to decrease with incident light and increased temperature. Addition of water to fly ash samples resulted in re-emission of deposited atmospheric Hg. Deposition was the dominant flux measured in situ at a fly ash landfill. Atmospheric Hg was deposited to all samples collected as part of two demonstration projects using carbon injection for enhanced Hg capture. Hg concentrations of extracts derived using U.S. Environmental Protection Agency Method 1312 (Synthetic Precipitation Leaching Procedure) were ≤14.4 ng/L. Data developed demonstrate that fly ash, including that collected from Hg removal projects, will release little Hg to the air or water, and under certain conditions, absorbs Hg from the air.     

The Bechtel Confined Zone dispersion Process for FGD Retrofit Situations Proof-of-Concept Tests

The Bechtel Confined Zone Dispersion (CZD) process for FGD retrofit situations was tested at two sites: one at a level of 5 MWe; the other at 70 MWe. The CZD process involves injecting a finely atomized slurry of hydrated lime into a straight run of duct between a boiler's air heater and its electrostatic precipitator (ESP). The effect of process variables on SO₂ removal and ESP performance was investigated for dolomitic/calcitic lime. Removals of SO₂ in excess of 50 percent were achieved for either lime type at the 5 MWe site. A very short duct length limited injection rate at the 70 MWe site, limiting sulfur removals to a maximum of 30 percent. SO₂ removal data for both sites were successfully correlated on a common basis. ESP performance was not fully acceptable during lime injection at both sites, but it is felt that optimization of ESP operations should eliminate this problem. Additional testing is recommended to further explore ESP performance and to optimize lime injection parameters. The results obtained to date continue to indicate that the CZD process is an attractive and economical candidate for FGD retrofit situations.     

The fate and behavior of mercury in coal-fired power plants

For the past 22 years in the Netherlands, the behavior of Hg in coal-fired power plants has been studied extensively. Coal from all over the world is fired in Dutch power stations. First, the Hg concentrations in these coals were measured. Second, the fate of the Hg during combustion was established by performing mass balance studies. On average, 43 +/- 30% of the Hg was present in the flue gases downstream of the electrostatic precipitator (ESP; dust collector). In individual cases, this figure can vary between 1 and 100%. Important parameters are the Cl content of the fuel and the flue gas temperature in the ESP. On average, 54 +/- 24% of the gaseous Hg was removed in the wet flue-gas desulfurization (FGD) systems, which are present at all Dutch coal-power stations. In individual cases, this removal can vary between 8% (outlier) and 72%. On average, the fate of Hg entering the power station in the coal was as follows: <1% in the bottom ash, 49% in the pulverized fuel ash (ash collected in the ESP), 16.6% in the FGD gypsum, 9% in the sludge of the wastewater treatment plant, 0.04% in the effluent of the wastewater treatment plant, 0.07% in fly dust (leaving the stack), and 25% as gaseous Hg in the flue gases and emitted into the air. The distribution of Hg over the streams leaving the FGD depends strongly on the installation. On average, 75% of the Hg was removed, and the final concentration of Hg in the emitted flue gases of the Dutch power stations was only -3 microg/m3(STP) at 6% O2. During co-combustion with biomass, the removal of Hg was similar to that during 100% coal firing. Speciation of Hg is a very important factor. An oxidized form (HgCl2) favors a high degree of removal. The conversion from Hg0 to HgCl2 is positively correlated with the Cl content of the fuel. A catalytic DENOX (SCR) favors the formation of oxidized Hg, and, in combination with a wet FGD, the total removal can be as high as 90%.     

Inhibition and promotion of trace pollutant adsorption within electrostatic precipitators

Among the technologies available for reducing mercury emissions from coal-fired electric utilities is the injection of a powdered sorbent, often some form of activated carbon, into the flue gas upstream of the particulate control device, most commonly an electrostatic precipitator (ESP). Detailed measurements of mercury removal within ESPs are lacking due to the hazardous environment they pose, increasing the importance of analysis and numerical simulation in understanding the mechanisms involved. Our previous analyses revealed that mercury adsorption by particles suspended in the gas and mercury adsorption by particles collected on internal ESP surfaces are not additive removal mechanisms but rather are competitive. The present study expands on this counterintuitive finding. Presented are results from numerical simulations reflecting the complete range of possible mass transfer boundary conditions representing mercury adsorption by the accumulated dust cake covering internal ESP collection electrodes. Using the two mercury removal mechanisms operating concurrently and interdependently always underperforms the sum of the two mechanisms’ individual contributions.

Implications: The dual use of electrostatic precipitators (ESPs) for particulate removal and adsorption of trace gaseous pollutants such as mercury is increasing as mercury regulations become more widespread. Under such circumstances, mercury adsorption by particles suspended in the gas and mercury adsorption by particles collected on internal ESP surfaces are competitive. Together, the two mercury removal mechanisms always underperform the sum of their two independent contributions. These findings can inform strategies sought by electric utilities for reducing the usage costs of mercury sorbents.     

A Model to Predict the System Performance of an Electrostatic Precipitator for Collecting Polydisperse Particles

Abstract

This paper presents a model for predicting the performance of an electrostatic precipitator (ESP) for collecting polydisperse particles. The particle charge was obtained by modifying Cochet’s charge equation; the particle size distribution was approximated by a lognormal function; and then the statistic method of moments was employed to obtain a set of the first three moment equations. The continuous evolution of the particle size distribution in an ESP is easily taken into account by the first three moment equations. The performance of this model was validated by comparing its predictions with the existing data available in the literature. Effects of the particle size distribution on the ESP performance were examined, and the results indicated that both overall mass and number efficiencies are lower for inlet particles with a larger mass median diameter and a higher geometric standard deviation. The methodology introduced may be applied to develop design criteria and determine optimal operating conditions of an ESP for improving the collection efficiency of the submicron particles.     

Mass transfer within electrostatic precipitators: trace gas adsorption by sorbent-covered plate electrodes

Varying degrees of mercury (Hg) capture have been reported within the electrostatic precipitators (ESPs) of coal-fired electric utility boilers. There has been some speculation that the adsorption takes place on the particulate-covered plate electrodes. This convective mass transfer analysis of laminar and turbulent channel flows provides the maximum potential for Hg adsorption by the plate electrodes within an ESP under those conditions. Mass transfer calculations, neglecting electrohydrodynamic (EHD) effects, reveal 65% removal of elemental Hg for a laminar flow within a 15-m-long channel of 0.2-m spacing and 42% removal for turbulent flow within a similar configuration. Both configurations represent specific collection areas (SCAs) that are significantly larger than conventional ESPs in use. Results reflecting more representative SCA values generally returned removal efficiencies of <20%. EHD effects, although potentially substantial at low Reynolds numbers, diminish rapidly with increasing Reynolds number and become negligible at typical ESP operating conditions. The present results indicate maximum Hg removal efficiencies for ESPs that are much less than those observed in practice for comparable ESP operating conditions. Considering Hg adsorption kinetics and finite sorbent capacity in addition to the present mass transfer analyses would yield even lower adsorption efficiencies than the present results. In a subsequent paper, the author addresses the mass transfer potential presented by the charged, suspended particulates during their collection within an ESP and the role they potentially play in Hg capture within ESPs.