Technology Innovations and Experience Curves for Nitrogen Oxides Control Technologies

Abstract

This paper reviews the regulatory history for nitrogen oxides (NO_x) pollutant emissions from stationary sources, primarily in coal-fired power plants. Nitrogen dioxide (NO₂) is one of the six criteria pollutants regulated by the 1970 Clean Air Act where National Ambient Air Quality Standards were established to protect public health and welfare. We use patent data to show that in the cases of Japan, Germany, and the United States, innovations in NO_x control technologies did not occur until stringent government regulations were in place, thus “forcing” innovation. We also demonstrate that reductions in the capital and operation and maintenance (O&M) costs of new generations of high-efficiency NO_x control technologies, selective catalytic reduction (SCR), are consistently associated with the increasing adoption of the control technology: the so-called learning-by-doing phenomena. The results show that as cumulative world coal-fired SCR capacity doubles, capital costs decline to ~86% and O&M costs to 58% of their original values. The observed changes in SCR technology reflect the impact of technological advance as well as other factors, such as market competition and economies of scale.     

Nitrogen oxides emission control options for coal-fired electric utility boilers

Recent regulations have required reductions in emissions of nitrogen oxides (NOx) from electric utility boilers. To comply with these regulatory requirements, it is increasingly important to implement state-of-the-art NOx control technologies on coal-fired utility boilers. This paper reviews NOx control options for these boilers. It discusses the established commercial primary and secondary control technologies and examines what is being done to use them more effectively. Furthermore, the paper discusses recent developments in NOx controls. The popular primary control technologies in use in the United States are low-NOx burners and overfire air. Data reflect that average NOx reductions for specific primary controls have ranged from 35% to 63% from 1995 emissions levels. The secondary NOx control technologies applied on U.S. coal-fired utility boilers include reburning, selective noncatalytic reduction (SNCR), and selective catalytic reduction (SCR). Thirty-six U.S. coal-fired utility boilers have installed SNCR, and reported NOx reductions achieved at these applications ranged from 15% to 66%. Recently, SCR has been installed at >150 U.S. coal-fired utility boilers. Data on the performance of 20 SCR systems operating in the United States with low-NOx emissions reflect that in 2003, these units achieved NOx emission rates between 0.04 and 0.07 lb/10(6) Btu.     

Recent increases in nitrogen oxide (NOx) emissions from coal-fired electric generating units equipped with selective catalytic reduction

The most effective control technology available for the reduction of oxides of nitrogen (NO_x) from coal-fired boilers is selective catalytic reduction (SCR). Installation of SCR on coal-fired electric generating units (EGUs) has grown substantially since the onset of the U.S. Environmental Protection Agency’s (EPA) first cap and trade program for oxides of nitrogen in 1999, the Ozone Transport Commission (OTC) NO_x Budget Program. Installations have increased from 6 units present in 1998 in the states that encompass the current Cross-State Air Pollution Rule (CSAPR) ozone season program to 250 in 2014. In recent years, however, the degree of usage of installed SCR technology has been dropping significantly at individual plants. Average seasonal NO_x emission rates increased substantially during the Clean Air Interstate Rule (CAIR) program. These increases coincided with a collapse in the cost of CAIR allowances, which declined to less than the cost of the reagent required to operate installed SCR equipment, and was accompanied by a 77% decline in delivered natural gas prices from their peak in June of 2008 to April 2012, which in turn coincided with a 390% increase in shale gas production between 2008 and 2012. These years also witnessed a decline in national electric generation which, after peaking in 2007, declined through 2013 at an annualized rate of ?0.3%. Scaling back the use of installed SCR on coal-fired plants has resulted in the release of over 290,000 tons of avoidable NO_x during the past five ozone seasons in the states that participated in the CAIR program.

Implications: To function as designed, a cap and trade program must maintain allowance costs that function as a disincentive for the release of the air pollutants that the program seeks to control. If the principle incentive for reducing NO_x emissions is the avoidance of allowance costs, emissions may be expected to increase if costs fall below a critical value, in the absence of additional state or federal limitations. As such, external factors as the cost of competing fuels and a low or negative growth of electric sales may also disincentivize the use of control technologies, the continuation of desirable emission rates will be best maintained by the implementation of performance standards that supplement and complement the emissions trading program.     

Performance/Cost Estimates for Retrofitting Control Technologies

The U.S. EPA’s Air and Energy Engineering Research Laboratory is responsible for assessing control technology performance and costs under the National Acid Precipitation Assessment Program. A major part of this assessment involves developing site-specific estimates of the performance and costs of retrofitting SO₂ and NO_x control technologies for the top 200 SO₂- emitting (1980) coal-fired power plants in the 31-state eastern region. This effort includes detailed evaluation of a small number of plants (30 or less) representing a cross-section of the top 200 population. In cooperation with the states of Ohio and Kentucky (in conjunction with the U.S. EPA’s State Acid Rain Grant Program), efforts were undertaken to visit and conduct detailed evaluation of 12 coal-fired plants—five in Ohio, seven in Kentucky and the Tennessee Valley Authority System. A variety of commercial and advanced SO₂ and NO_x control technologies—including precombustion, combustion (in-furnace), and postcombustion (flue gas cleanup) technologies—were applied to each plant through conceptual designs. Retrofit factors (applied to the capital cost of a new pollution control system), cost “adders” (e.g., movement of existing equipment), and costs were developed for applying the control technologies to the boilers of each plant. Results of these and subsequent efforts will be valuable in evaluations of acid deposition control strategies by federal and state agencies and by electric utilities.     

SCR performance on a hydrogen reformer furnace

In late 1993, Air Products and Chemicals, Inc. began operating a new steam-methane reformer at the Tosco Refining Co.'s Avon refinery in Martinez, CA, to provide hydrogen and steam to the refinery under a long-term supply agreement. The hydrogen plant--owned, operated, and maintained by Air Products--includes a selective catalytic reduction (SCR) unit on the reformer-furnace flue gas for environmental control. SCR is a commercially proven process capable of abating emissions of nitrogen oxides (NOx) to extremely low levels; however, documented experience in a refinery setting has been limited. This paper discusses performance of the SCR, primarily during its first two years of operation; it incorporates theory and prior research findings sufficient to understand the relationship between key system variables and SCR performance. Test results demonstrate that NOx, ammonia (NH3) slip, and carbon monoxide (CO) emissions are in compliance with permit limits. NOx removal efficiency is nearly linear with the inlet NH3:NOx molar ratio up to almost 90% NOx conversion, where ammonia slip begins to rise steeply. The stoichiometric reaction ratio of NH3 to NOx is close to the theoretical 1.0. Catalyst life is estimated at four years, in line with published figures for SCR catalysts in clean-gas service.     

Simultaneous control of Hg0, SO2, and NOx by novel oxidized calcium-based sorbents

Efforts to develop multipollutant control strategies have demonstrated that adding certain oxidants to different classes of Ca-based sorbents leads to a significant improvement in elemental Hg vapor (Hg0), SO2, and NOx removal from simulated flue gases. In the study presented here, two classes of Ca-based sorbents (hydrated limes and silicate compounds) were investigated. A number of oxidizing additives at different concentrations were used in the Ca-based sorbent production process. The Hg0, SO2, and NOx capture capacities of these oxidant-enriched sorbents were evaluated and compared to those of a commercially available activated carbon in bench-scale, fixed-bed, and fluid-bed systems. Calcium-based sorbents prepared with two oxidants, designated C and M, exhibited Hg0 sorption capacities (approximately 100 microg/g) comparable to that of the activated carbon; they showed far superior SO2 and NOx sorption capacities. Preliminary cost estimates for the process utilizing these novel sorbents indicate potential for substantial lowering of control costs, as compared with other processes currently used or considered for control of Hg0, SO2, and NOx emissions from coal-fired boilers. The implications of these findings toward development of multipollutant control technologies and planned pilot and field evaluations of more promising multipollutant sorbents are summarily discussed.     

Effect of NOx control processes on mercury speciation in utility flue gas

The speciation of Hg in coal-fired flue gas can be important in determining the ultimate Hg emissions as well as potential control options for the utility. The effects of NOx control processes, such as selective catalytic reduction (SCR) and selective non-catalytic reduction (SNCR), on Hg speciation are not well understood but may impact emissions of Hg. EPRI has investigated the reactions of Hg in flue gas at conditions expected for some NOx control processes. This paper describes the methodology used to investigate these reactions in actual flue gas at several power plants. Results have indicated that some commercial SCR catalysts are capable of oxidizing elemental Hg in flue gas obtained from the inlets of SCR or air heater units. Results are affected by various flue gas and operating parameters. The effect of flue gas composition, including the presence of NH3, has been evaluated. The influence of NH3 on fly ash Hg reactions also is being investigated.     

Investigation of selective catalytic reduction impact on mercury speciation under simulated NOx emission control conditions

Selective catalytic reduction (SCR) technology increasingly is being applied for controlling emissions of nitrogen oxides (NOx) from coal-fired boilers. Some recent field and pilot studies suggest that the operation of SCR could affect the chemical form of mercury (Hg) in coal combustion flue gases. The speciation of Hg is an important factor influencing the control and environmental fate of Hg emissions from coal combustion. The vanadium and titanium oxides, used commonly in the vanadia-titania SCR catalyst for catalytic NOx reduction, promote the formation of oxidized mercury (Hg2+). The work reported in this paper focuses on the impact of SCR on elemental mercury (Hg0) oxidation. Bench-scale experiments were conducted to investigate Hg0 oxidation in the presence of simulated coal combustion flue gases and under SCR reaction conditions. Flue gas mixtures with different concentrations of hydrogen chloride (HCl) and sulfur dioxide (SO2) for simulating the combustion of bituminous coals and subbituminous coals were tested in these experiments. The effects of HCl and SO2 in the flue gases on Hg0 oxidation under SCR reaction conditions were studied. It was observed that HCl is the most critical flue gas component that causes conversion of Hg0 to Hg2+ under SCR reaction conditions. The importance of HCl for Hg0 oxidation found in the present study provides the scientific basis for the apparent coal-type dependence observed for Hg0 oxidation occurring across the SCR reactors in the field.     

Characterization of urea SCR using Taguchi technique and computational methods

Use of biodiesel in diesel engine helps to reduce HC, CO, and smoke emissions due to their enormous oxygen content, whereas NOx emissions formed by Zeldovich mechanism shoot up. Implementation of Bharat Stage (BS) VI by April 2020 in India has created extreme pressure on automobile manufacturers to include after treatment technology in their systems. Selective catalytic reduction (SCR), a NOx control technology, is operated using aqueous urea solution as the reductant. There are several parameters that need to be monitored to enhance the NOx conversion efficiency of SCR retrofit. The uniformity index of ammonia, which determines the conversion efficiency, is greatly influenced by parameters like exhaust gas temperature, injection angle, injector position, mass flow rate, and SCR geometry. This paper considers two types of SCR design, namely SCR with and without mixer design and their impact on NOx reduction. The effect of mass flow rate on urea conversion in SCR design without mixer is 27%, but the impact is reduced greatly in SCR design with mixer with less than 2% variation. The UI resulting from different cases ranges from 0.59 to 0.83. Using Taguchi technique and CFD tool, the impact of parameters on both the SCR designs has been investigated and the optimum SCR design is reported.

     

电厂NO_x控制政策与技术：美国的经验及对我国的启示

我国NOx排放的快速增长导致其环境和生态影响日益加剧,已经引起全球关注,但是现行的NOx污染控制技术和政策远远落后于实际需求。为减少酸雨、臭氧和颗粒物带来的环境问题,美国采取排放控制和排污交易等方式削减了燃煤电厂的NOx排放。系统分析了美国NOx污染控制法规、标准、规划和控制技术应用情况,总结了其NOx控制的成功经验,进一步提出了符合我国国情的NOx控制对策和技术选择。     

Nitrogen Oxides Emission Control Options for Coal-Fired Electric Utility Boilers

Abstract

Recent regulations have required reductions in emissions of nitrogen oxides (NO_x) from electric utility boilers. To comply with these regulatory requirements, it is increasingly important to implement state-of-the-art NO_x control technologies on coal-fired utility boilers. This paper reviews NO_x control options for these boilers. It discusses the established commercial primary and secondary control technologies and examines what is being done to use them more effectively. Furthermore, the paper discusses recent developments in NO_x controls. The popular primary control technologies in use in the United States are low-NO_x burners and overfire air. Data reflect that average NO_x reductions for specific primary controls have ranged from 35% to 63% from 1995 emissions levels. The secondary NO_x control technologies applied on U.S. coal-fired utility boilers include reburning, selective noncatalytic reduction (SNCR), and selective catalytic reduction (SCR). Thirty-six U.S. coal-fired utility boilers have installed SNCR, and reported NO_x reductions achieved at these applications ranged from 15% to 66%. Recently, SCR has been installed at >150 U.S. coal-fired utility boilers. Data on the performance of 20 SCR systems operating in the United States with low-NO_x emissions reflect that in 2003, these units achieved NO_x emission rates between 0.04 and 0.07 lb/10⁶ Btu.     

Mercury oxidation promoted by a selective catalytic reduction catalyst under simulated Powder River Basin coal combustion conditions

A bench-scale reactor consisting of a natural gas burner and an electrically heated reactor housing a selective catalytic reduction (SCR) catalyst was constructed for studying elemental mercury (Hg(o)) oxidation under SCR conditions. A low sulfur Powder River Basin (PRB) subbituminous coal combustion fly ash was injected into the entrained-flow reactor along with sulfur dioxide (SO2), nitrogen oxides (NOx), hydrogen chloride (HCl), and trace Hg(o). Concentrations of Hg(o) and total mercury (Hg) upstream and downstream of the SCR catalyst were measured using a Hg monitor. The effects of HCl concentration, SCR operating temperature, catalyst space velocity, and feed rate of PRB fly ash on Hg(o) oxidation were evaluated. It was observed that HCl provides the source of chlorine for Hg(o) oxidation under simulated PRB coal-fired SCR conditions. The decrease in Hg mass balance closure across the catalyst with decreasing HCl concentration suggests that transient Hg capture on the SCR catalyst occurred during the short test exposure periods and that the outlet speciation observed may not be representative of steady-state operation at longer exposure times. Increasing the space velocity and operating temperature of the SCR led to less Hg(o) oxidized. Introduction of PRB coal fly ash resulted in slightly decreased outlet oxidized mercury (Hg2+) as a percentage of total inlet Hg and correspondingly resulted in an incremental increase in Hg capture. The injection of ammonia (NH3) for NOx reduction by SCR was found to have a strong effect to decrease Hg oxidation. The observations suggest that Hg(o) oxidation may occur near the exit region of commercial SCR reactors. Passage of flue gas through SCR systems without NH3 injection, such as during the low-ozone season, may also impact Hg speciation and capture in the flue gas.     

Mercury emission trend influenced by stringent air pollutants regulation for coal-fired power plants in Korea

Regulatory control of mercury emission from anthropogenic sources has become a global concern in the recent past. Coal-fired power plants are one of the largest sources of anthropogenic mercury emission into the atmosphere. This paper summarizes the current reducing trend of mercury emission as co-beneficial effect by more stringent regulation changes to control primary air pollutants with introducing test results from the commercial coal-fired facilities and suggesting a guideline for future regulatory development in Korea. On average, mercury emission concentrations ranged 16.3–2.7 μg Sm^?3, 2.4–1.1 μg Sm^?3, 3.1–0.7 μg Sm^?3 from anthracite coal-fired power plants equipped with electrostatic precipitator (ESP), bituminous coal-fired power plants with ESP + flue gas desulphurization (FGD) and bituminous coal-fired power plants with selective catalytic reactor (SCR) + cold side (CS) ? ESP + wet FGD, respectively. Among the existing air pollution control devices, the best configuration for mercury removal in coal-fired power plants was SCR + CS ? ESP + wet FGD, which were installed due to the stringent regulation changes to control primary air pollutants emission such as SO₂, NOx and dust. It was estimated that uncontrolled and controlled mercury emission from coal-fired power plants as 10.3 ton yr^?1 and 3.2 ton yr^?1 respectively. After the installation of ESP, FGD and SCR system, following the enforcement of the stringent regulation, 7.1 ton yr^?1 of mercury emission has been reduced (nearly 69%) from coal-fired power plants as a co-benefit control. Based on the overall study, a sample guideline including emission limits were suggested which will be applied to develop a countermeasure for controlling mercury emission from coal-fired power plants.     

Economics of an integrated approach to control SO2, NOX,HCl, and particulate emissions from power plants

An integrated approach for the simultaneous reduction of major combustion-generated pollutants from power plants is presented along with a simplified economic analysis. With this technology, the synergistic effects of high-temperature sorbent/coal or sorbent/natural gas injection and high-temperature flue gas filtration are exploited. Calcium-based (or Na-based, etc.) sorbents are sprayed in the post-flame zone of a furnace, where they react with S- and Cl-containing gases to form stable salts of Ca (or Na, etc.). The partially reacted sorbent is then collected in a high-temperature ceramic filter, which is placed downstream of the sorbent injection point, where it further reacts for a prolonged period of time. With this technique, both the likelihood of contact and the length of time of contact between the solid sorbent particles and the gaseous pollutants increase, because reaction takes place both in the furnace upstream of the filter and inside the filter itself. Hence, the sorbent utilization increases significantly. Several pollutants, such as SO2, H2S, HCl, and particulate (soot, ash, and tar), may be partially removed from the effluent. The organic content of the sorbents (or blends) also pyrolyzes and reduces NOx. Unburned carbon in the ash may be completely oxidized in the filter. The filter is cleaned periodically with aerodynamic regeneration (back pulsing) without interrupting furnace operation. The effectiveness of this technique has been shown in laboratory-scale experiments using either rather costly carboxylic salts of Ca or low- to moderate-cost blends of limestone, lime, or sodium bicarbonate with coal fines. Injection occurred in the furnace at 1150 degrees C, while the filter was maintained at 600 degrees C. Results showed that 65 or 40% SO2 removal was obtained with calcium formate or a limestone/coal blend, respectively, at an entering calcium-to-sulfur molar ratio of 2. A sodium bicarbonate/coal blend resulted in 78% SO2 removal at a sodium-to-sulfur molar ratio of 2. HCl removal efficiencies have been shown to be higher than those for SO2. NOx reductions of 40% have been observed with a fuel (coal)-to-air equivalence ratio, phi, around 2. The filter has been shown to be 97-99% efficient in removing PM2.5 particulates. Calculations herein show that this integrated sorbent/filter method is cost-effective, in comparison with current technologies, on both capital cost ($/kW) and levelized cost ($/ton pollutant removed) bases, if a limestone/coal mixture is used as the sorbent for fossil fuel plants. Capital costs for the filter/sorbent combination are estimated to be in the range of $61-$105/kW for a new plant. Because current technologies are designed for removing one pollutant at a time, both their cost and space requirements are higher than those of this integrated technique. At the minimum projected removal efficiencies for HCl/SO2/NOx of about 40%, the levelized costs are projected to be $203-$261/ton of combined pollutant SO2/HCl/NOx and particulates removed from coal-fired power plants.     

Preliminary estimates of performance and cost of mercury control technology applications on electric utility boilers.

Under the Clean Air Act Amendments of 1990, the U.S. Environmental Protection Agency (EPA) determined that regulation of mercury emissions from coal-fired power plants is appropriate and necessary. To aid in this determination, preliminary estimates of the performance and cost of powdered activated carbon (PAC) injection-based mercury control technologies were developed. This paper presents these estimates and develops projections of costs for future applications. Cost estimates were developed using PAC to achieve a minimum of 80% mercury removal at plants using electrostatic precipitators and a minimum of 90% removal at plants using fabric filters. These estimates ranged from 0.305 to 3.783 mills/kWh. However, the higher costs were associated with a minority of plants using hot-side electrostatic precipitators (HESPs). If these costs are excluded, the estimates range from 0.305 to 1.915 mills/kWh. Cost projections developed using a composite lime-PAC sorbent for mercury removal ranged from 0.183 to 2.270 mills/kWh, with the higher costs being associated with a minority of plants that used HESPs.     

Effectiveness of emission control technologies for auxiliary engines on ocean-going vessels

Large auxiliary engines operated on ocean-going vessels in transit and at berth impact the air quality of populated areas near ports. This paper presents new information on the comparison of emission ranges from three similar engines and the effectiveness of three control technologies: switching to cleaner burning fuels, operating in the low oxides of nitrogen (NOx) mode, and selective catalytic reduction (SCR). In-use measurements of gaseous (NOx, carbon monoxide [CO], carbon dioxide [CO2]) and fine particulate matter (PM2.5; total and speciated) emissions were made on three auxiliary engines on post-PanaMax class container vessels following the International Organization for Standardization-8178-1 protocol. The in-use NOx emissions for the MAN B&W 7L32/40 engine family vary from 15 to 21.1 g/kW-hr for heavy fuel oil and 8.9 to 19.6 g/kW-hr for marine distillate oil. Use of cleaner burning fuels resulted in NOx reductions ranging from 7 to 41% across different engines and a PM2.5 reduction of up to 83%. The NOx reductions are a consequence of fuel nitrogen content and engine operation; the PM2.5 reduction is attributed to the large reductions in the hydrated sulfate and organic carbon (OC) fractions. As expected, operating in the low-NOx mode reduced NOx emissions by approximately 32% and nearly doubled elemental carbon (EC) emissions. However, PM2.5 emission factors were nearly unchanged because the EC emission factor is only approximately 5% of the total PM2.5 mass. SCR reduced the NOx emission factor to less than 2.4 g/kW-hr, but it increased the PM2.5 emissions by a factor of 1.5-3.8. This increase was a direct consequence of the conversion of sulfur dioxide to sulfate emissions on the SCR catalyst. The EC and OC fractions of PM2.5 reduced across the SCR unit.     

Energy consumption and energy-saving potential analysis of pollutant abatement systems in a 1000-MW coal-fired power plant

Pollutant abatement systems are widely applied in the coal-fired power sector, and the energy consumption is considered an important part of the auxiliary power. An energy consumption analysis and assessment model of pollutant abatement systems in a power unit was developed based on the dynamic parameters and technology. The energy consumption of pollutant abatement systems in a 1000-MW coal-fired power unit that meets the ultra-low emission limits and the factors of operating parameters, including unit load and inlet concentration of pollutants, on the operating power were analyzed. The results show that the total power consumption of the pollutant abatement systems accounted for 1.27% of the gross power generation during the monitoring period. The wet flue gas desulfurization (WFGD) system consumed 67% of the rate, whereas the selective catalytic reduction (SCR) and electrostatic precipitator (ESP) systems consumed 8.9% and 24.1%, respectively. The power consumption rate of pollutant abatement systems decreased with the increase of unit load and increased with the increase of the inlet concentration of pollutants. The operation adjustment was also an effective method to increase the energy efficiency. For example, the operation adjustment of slurry circulation pumps could promote the energy-saving operation of the WFGD system.

Implications: The application of pollutant abatement technologies increases the internal energy consumption of the power plant, which will lead to an increase of power generation costs. The real-time energy consumption of the different pollutant abatement systems in a typical power unit is analyzed based on the dynamic operating data. Further, the influence of different operating parameters on the operating power of the system and the possible energy-saving potential are analyzed.     

Control strategies of atmospheric mercury emissions from coal-fired power plants in China

Atmospheric mercury (Hg) emission from coal is one of the primary sources of anthropogenic discharge and pollution. China is one of the few countries in the world whose coal consumption constitutes about 70% of total primary energy, and over half of coals are burned directly for electricity generation. Atmospheric emissions of Hg and its speciation from coal-fired power plants are of great concern owing to their negative impacts on regional human health and ecosystem risks, as well as long-distance transport. In this paper, recent trends of atmospheric Hg emissions and its species split from coal-fired power plants in China during the period of 2000-2007 are evaluated, by integrating each plant's coal consumption and emission factors, which are classified by different subcategories of boilers, particulate matter (PM) and sulfur dioxide (SO2) control devices. Our results show that the total Hg emissions from coal-fired power plants have begun to decrease from the peak value of 139.19 t in 2005 to 134.55 t in 2007, though coal consumption growing steadily from 1213.8 to 1532.4 Mt, which can be mainly attributed to the co-benefit Hg reduction by electrostatic precipitators/fabric filters (ESPs/FFs) and wet flue gas desulfurization (WFGD), especially the sharp growth in installation of WFGD both in the new and existing power plants since 2005. In the coming 12th five-year-plan, more and more plants will be mandated to install De-NO(x) (nitrogen oxides) systems (mainly selective catalytic reduction [SCR] and selective noncatalytic reduction [SNCR]) for minimizing NO(x) emission, thus the specific Hg emission rate per ton of coal will decline further owing to the much higher co-benefit removal efficiency by the combination of SCR + ESPs/FFs + WFGD systems. Consequently, SCR + ESPs/FFs + WFGD configuration will be the main path to abate Hg discharge from coal-fired power plants in China in the near future. However advanced specific Hg removal technologies are necessary for further reduction of elemental Hg discharge in the long-term.     

Preliminary Estimates of Performance and Cost of Mercury Control Technology Applications on Electric Utility Boilers

ABSTRACT

Under the Clean Air Act Amendments of 1990, the U.S. Environmental Protection Agency (EPA) determined that regulation of mercury emissions from coal-fired power plants is appropriate and necessary. To aid in this determination, preliminary estimates of the performance and cost of powdered activated carbon (PAC) injection-based mercury control technologies were developed. This paper presents these estimates and develops projections of costs for future applications.

Cost estimates were developed using PAC to achieve a minimum of 80% mercury removal at plants using electrostatic precipitators and a minimum of 90% removal at plants using fabric filters. These estimates ranged from 0.305 to 3.783 mills/kWh. However, the higher costs were associated with a minority of plants using hot-side electrostatic precipitators (HESPs). If these costs are excluded, the estimates range from 0.305 to 1.915 mills/kWh. Cost projections developed using a composite lime-PAC sorbent for mercury removal ranged from 0.183 to 2.270 mills/kWh, with the higher costs being associated with a minority of plants that used HESPs.     

Emissions of sulfur trioxide from coal-fired power plants

Emissions of sulfur trioxide (SO3) are a key component of plume opacity and acid deposition. Consequently, these emissions need to be low enough to not cause opacity violations and acid deposition. Generally, a small fraction of sulfur (S) in coal is converted to SO3 in coal-fired combustion devices such as electric utility boilers. The emissions of SO3 from such a boiler depend on coal S content, combustion conditions, flue gas characteristics, and air pollution devices being used. It is well known that the catalyst used in the selective catalytic reduction (SCR) technology for nitrogen oxides control oxidizes a small fraction of sulfur dioxide in the flue gas to SO3. The extent of this oxidation depends on the catalyst formulation and SCR operating conditions. Gas-phase SO3 and sulfuric acid, on being quenched in plant equipment (e.g., air preheater and wet scrubber), result in fine acidic mist, which can cause increased plume opacity and undesirable emissions. Recently, such effects have been observed at plants firing high-S coal and equipped with SCR systems and wet scrubbers. This paper investigates the factors that affect acidic mist production in coal-fired electric utility boilers and discusses approaches for mitigating emission of this mist.