Determination of Baghouse Performance from Coal and Ash Properties: Part II

Baghouse performance at utility coal-fired power plants is determined by baghouse design, operating procedures, and the characteristics of the ash that is collected as a dustcake on the fabric filter. The Electric Power Research Institute has conducted laboratory research to identify the fundamental variables that influence baghouse performance. A database was assembled including measured characteristics of coal and dustcake ash, and data describing operating parameters and performance of full-scale and pilotscale baghouses. Predictions of performance can be based on physical characteristics of the ash to be filtered (discussed in Part I of this article), as well as chemical characterizations of the ash, or empirical correlations with the alkali content of the source coal The effects of design and operational variables can be included in these predictions. Baghouse performance can be optimized by exercising proper operating practices and by selecting a filtering fabric and cleaning method matched to the cohesivity of the ash to be collected.     

Impact of Free Calcium Oxide Content of Fly Ash on Dust and Sulfur Dioxide Emissions in a Lignite-Fired Power Plant

Abstract

Emitted pollutants from the Agios Dimitrios lignite-fired power plant in northern Greece show a very strong linear correlation with the free calcium oxide content of the lignite ash. Dust (fly ash) emissions are positively correlated to free calcium oxide content, whereas sulfur dioxide (SO₂) emissions are negatively correlated. As a result, at present, the Agios Dimitrios Power Plant operates very strictly within the legislative limits on atmospheric particulate emission. In the present study, the factors to be considered in assessing the impact of lignite combustion on the environment are presented and evaluated statistically. The ash appears to have a remarkable SO₂ natural dry scrubbing capability when the free calcium oxide content ranges between 4 and 7%. Precipitator operating problems attributable to high ash resistivity can be overcome by injecting sulfur trioxide to reduce the ash resistivity, with, of course, a probable increase in operating costs.     

粉煤灰协同微波-Fenton氧化法处理活性艳蓝KN-R染料废水

以粉煤灰联合微波-Fenton氧化工艺处理活性艳蓝KN-R生产废水,考察了粉煤灰投加量及吸附时间对处理效果的影响,并通过正交实验对微波-Fenton工艺参数进行了优化。实验结果表明,粉煤灰絮凝吸附与微波-Fenton氧化具有协同效应;在粉煤灰投加量为40 g/L,搅拌吸附时间为20 min,滤液pH值为4,Fe2＋和H2O2投加量分别为3.6 mmol/L和0.15 mol/L,微波功率为200 W,辐射反应时间为4 min的优化条件下,染料废水的处理效果最好,COD和色度的去除率分别达到90.90%和99.98%。     

基于响应曲面法优化烧结烟气脱硫灰改性工艺

采用BOX-Behnken的中心组合实验设计及响应面分析方法对半干法烧结烟气脱硫灰进行改性研究,得到脱硫灰转化率的预测模型。结果表明:通过该预测模型可以很好地描述脱硫灰的转化率与反应温度、反应时间和气固比等重要操作参数之间的关系,R2=0.9903。因素分析表明,反应温度对脱硫灰的转化率影响最大,同时反应温度和气固比的交互作用与反应温度和时间的交互作用对脱硫灰的转化率的影响作用相同。利用得到的改进预测模型可以计算脱硫灰的转化率。     

Determination of Baghouse Performance from Coal and Ash Properties: Part I

Baghouse performance at utility coal-fired power plants is determined by baghouse design, operating procedures, and the characteristics of the ash that is collected as a dustcake on the fabric filter. The Electric Power Research Institute has conducted laboratory research to identify the fundamental properties of dustcake ash that influence baghouse performance. A database was assembled including measured characteristics of dustcake ash and data describing operating parameters and performance of full-scale and pilot-scale baghouses. Semi-empirical models were developed that describe the effects of particle morphology, particle size, ash cohesivity and ash chemistry on filtering pressure drop and particulate emissions. Cohesivity was identified as the primary ash characteristic affecting baghouse performance. Predictions of performance can be based on physical or chemical characterizations of the ash to be filtered. Part II of this article will discuss the effects of ash and coal chemistry, and baghouse design and operation on performance.     

Application of the Active Soda Process for Removing Sulphur Dioxide from Flue Gases

The active soda process1 was applied for desulfurlzatlon of flue gases emitted by a plant burning heavy fuel oil In a rotary drum drier for stone aggregate. The flue gas capacity of the plant was about 6,7 m³/s at normal conditions. The SO₂ concentration varied between 400– 500 ppm. The solid, dry and fine-grained NaHCO₃ of good quality was fed directly into the hot gas stream at the outlet of the rotary drier In two variants—with and without grinding. The mean particle size was 0.180 m^-3 or 0.070 m^-3, respectively. The achieved desulfurizatlon degree was shown to be directly dependent on the flue gas temperature and on the grinding effect, as well as on the normalized stoichiometric ratio. The highest achieved desulfurization degree amounted up to 74 percent. During the design of the desulfurization process no pilot plant installations and tests were necessary, and for the final process no special chemical reactor was used.     

Minnesota Power’s Operating Experience with Integrated Particulate and SO2 Scrubbing

Minnesota Power currently has in commercial operation a 500 MW gas cleaning system consisting of a venturi particulate scrubber, integrated with a spray tower SO₂ absorber. The system was designed to achieve 99.7% particulate removal and 90% SO₂ removal based upon burning a 2.8 % sulfur coal.

Initially the concept of using a venturi for wet particulate collection was selected based upon a significant cost saving of $25 million compared to dry particulate collection devices. Subsequently, the Interaction of particulate collection with SO₂ removal provided additional operating cost benefits. Prior to start-up of the commercial system, a pilot plant was used to evaluate various modes of operation. Results showed that alkali contained in the fly ash removed with the venturi was sufficient to meet the alkali requirement for SO₂ removal.

Clay Boswell Station Unit No. 4 was started up during March 1980. Since initial start-up the system has exhibited almost 100% availability. EPA compliance testing has confirmed that the system Is meeting its emission standards. The unit is operating with fly ash as the only source of alkali. Since commercial operation started, no external alkali has been purchased.

This paper will discuss the design details of the system and performance of the commercial system.     

Effect of Flue Dust on the Vanadium Oxide Catalyst Utilized by the Contact Oxidation Process

Concepts for controlling SO₂ from fossil fuels can be separated into two main categories: (1) Residual and vacuum gas oil desulfurization and (2) Flue gas desulfurization. The Kiyoura-T.I.T. process confines itself to the desulfurization of flue gas. It employs vandium oxide as a catalyst which oxidizes the sulfur dioxide to trioxide, followed by a gaseous phase reaction of ammonia. The end product, ammonium sulfate is removed by an electrostatic precipitator. (The details were presented at annual meetings of APCA in 1966 and 1967 as 1 and II.) Flue gas is passed through cyclone and dust filter to remove dust. Under normal operating conditions almost all of the dust is removed at the filters. The author carried out experiments to determine whether there was any effect on the activity of the catalyst, assuming that a portion of the dust escapes into the stream along the flue. It has been generally accepted that in fuel oil firing steam power plants, about 100 mg./nm³ of dust including carbon, hydrocarbon, and ash are normally contained in the flue stream. The carbon and hydrocarbon is oxidized readily at the filters and exists only as ash. An amount of ash equivalent to the amount assumed to have settled on the catalyst over a period of 3–12 months, was placed on the catalyst, and experiments were carried out. The SO₂ conversion efficiency was measured and found to be over 93%. The results showed that at the actual operational temperature of 450°C, ash had practically no effect at all.     

The Effective Collection of Fly Ash At Pulverized Coal-Fired Plants

The relationship between sulfur in coal, boiler exit gas temperature, and the carbon portion of fly ash have a major effect on the electrical properties of fly ash. Whether effective collection of fly ash is obtained by the electrostatic precipitator installation alone or the precipitator—mechanical combination depends primarily on a knowledge of this relationship. Fly ash electrical properties can range from a highly "resistive" to a highly "conductive" state which can appreciably alter the precipitator collection performance. A correlation of coal sulfur and boiler exit flue gas temperature is given to indicate the probability of expecting an optimum voltage—current relationship with different combinations of these factors. Carbon affects the electrical conditioning of fly ash by providing parallel paths of current leakage through the deposited dust layer. Therefore, removal of the carbon particles in a mechanical collector placed before the precipitator can alter the precipitator electrical characteristics.     

The Beginning of Survival

The majority of coal ash generated by electric utilities and power plants of industrial manufacturers is disposed of in landfills; the remainder is used primarily as admixtures in construction materials. Predictive computer models used to assess the environmental impact of disposal or utilization need quantitative information on ash composition and mineralogy. Typically, compositions are reported as elemental concentrations, but this data does not indicate the mineral or glass (amorphous) phases in which the elements are contained. Such phases affect the leaching mechanisms and rates. X-ray diffraction and scanning electron microscopy combined with energy dispersive X-ray spectrometry, common methods for qualitative mineral identification and particle characterization, were used to quantify coal ash mineral compositions. Samples of industrial coal ash from a stoker boiler and a fluidized bed combustion (FBC) system were analyzed and the results were compared to those for a standard sample of coal ash from the National Institute of Standards and Testing (NIST1633a). The results show that the stoker-boiler ash is similar in composition to the NIST sample. Mullite (AI₆Si₂O₁₃) dominates the composition of the crystalline fraction and silica (SiO₂,) dominates the composition of the amorphous fraction. The FBC ash contains the same minerals, but with large proportions of calcium-based phases: anhydrite (CaSO₄), lime (CaO), calcite (CaCO₃), and portlandite (Ga(OH)₂).     

Immobilization and volume reduction of heavy metals in municipal solid waste fly ash using nano-size calcium and iron-dispersed reagent

This study was conducted to examine the synthesis and application of novel nano-size calcium/iron-based composite material as an immobilizing and separation treatment of the heavy metals in fly ash from municipal solid waste incineration. After grinding with nano-Fe/Ca/CaO and with nano-Fe/Ca/CaO/[PO₄], approximately 30 wt% and 25 wt% of magnetic fraction fly ash were separated. The highest amount of entrapped heavy metals was found in the lowest weight of the magnetically separated fly ash fraction (i.e., 91% in 25% of treated fly ash). Heavy metals in the magnetic or nonmagnetic fly ash fractions were about 98% and 100% immobilized, respectively. Additionally, scanning electron microscopy combined with energy-dispersive X-ray spectrometry (SEM-EDS) observations indicate that the main fraction of enclosed/bound materials on treated fly ash includes Ca/PO₄-associated crystalline complexes. After nano-Fe/Ca/CaO/[PO₄] treatment, the heavy metal concentrations in the fly ash leachate were much lower than the Japan standard regulatory limit for hazardous waste landfills. These results appear to be extremely promising. The addition of a nano-Fe/Ca/CaO/PO₄ mixture with simple grinding technique is potentially applicable for the remediation and volume reduction of fly ash contaminated by heavy metals.

Implications: After grinding with nano-Fe/Ca/CaO and nano-Fe/Ca/CaO/[PO₄], approximately 30 wt% and 25 wt% of magnetic fraction fly ash were separated. The highest amount of entrapped heavy metals was found in the lowest weight of the magnetically separated fly ash fraction (i.e., 91% in 25% of treated fly ash), whereas heavy metals either in the magnetic or nonmagnetic fly ash fractions were about 98% and 100% immobilized. These results appear to be very promising, and the addition of nano-Fe/Ca/CaO/PO₄ mixture with simple grinding technique may be considered potentially applicable for the remediation and volume reduction of contaminated fly ash by heavy metals.     

Filtration of fly ash using a fluidized-bed filter

This study focuses on the control of particulates with a fluidized-bed filter in exhaust gas stream. The fluidized-bed filter classified in the granular bed filtration technology was employed to demonstrate the performance for removal of fly ash at indicated operating velocities, fixed bed heights, and bed temperatures; then the collecting mechanisms of particulates by fluidized-bed filter were studied. The size distribution of fly ash passing through the fluidized-bed filter was also analyzed. The results indicate that at higher operating velocities and fixed bed heights, the removal of fly ash is more efficient and inertial impaction is the main mechanism when the fluidized-bed is operated at room temperature (25 degrees C). While operating at higher temperatures (200 degrees C), efficiency of 93.2% to 99.4% can be achieved for submicron particles. It is supposed to be the diffusion mechanism that is responsible for collecting such small particles, and high temperature is a favorable condition because of diffusion.     

Predicting Extents of Mercury Oxidation in Coal-Derived Flue Gases

Abstract

The proposed mercury (Hg) oxidation mechanism consists of a 168-step gas phase mechanism that accounts for interaction among all important flue gas species and a heterogeneous oxidation mechanism on unburned carbon (UBC) particles, similar to established chemistry for dioxin production under comparable conditions. The mechanism was incorporated into a gas cleaning system simulator to predict the proportions of elemental and oxidized Hg species in the flue gases, given relevant coal properties (C/H/O/N/S/Cl/Hg), flue gas composition (O₂, H₂O, HCl), emissions (NO_X, SO_X, CO), the recovery of fly ash, fly ash loss-on-ignition (LOI), and a thermal history. Predictions are validated without parameter adjustments against datasets from lab-scale and from pilot-scale coal furnaces at 1 and 29 MW_t. Collectively, the evaluations cover 16 coals representing ranks from sub-bituminous through high-volatile bituminous, including cases with Cl₂ and CaCl₂ injection. The predictions are, therefore, validated over virtually the entire domain of Cl-species concentrations and UBC levels of commercial interest. Additional predictions identify the most important operating conditions in the furnace and gas cleaning system, including stoichiometric ratio, NO_X, LOI, and residence time, as well as the most important coal properties, including coal-Cl.     

烧结烟气脱硫剂性能的研究

为了提高脱硫效率和合理利用烧结过程中产生的机头灰,在半干法烟气脱硫剂生石灰中,加入一定量的烧结机头灰作为脱硫催化剂。在测定机头灰与生石灰化学成分、粒度和比表面积的基础上,研究和分析了机头灰与生石灰的质量配比对于脱硫效率的影响。结果表明,脱硫剂与机头灰在粒径分布和比表面积上都较接近,但经过消化活化后的混合脱硫剂的比表面积明显增大。当机头灰添加量为脱硫剂质量的2%～5%时,脱硫效率提高了2%～3%。机头灰与生石灰的胶凝反应以及机头灰中Fe2O3的催化作用是主要的作用机理。     

An Analysis of Extinction Coefficients of Particles and Water Moisture in the Stack after Flue Gas Desulfurization at a Coal-Fired Power Plant

ABSTRACT

Two important factors that affect in-stack opacity—light extinction by emitted particles and that by water moisture after a flue gas desulfurization (FGD) unit—are investigated. The mass light extinction coefficients for particles and water moisture, k _p and k _w, respectively, were determined using the Lambert-Beer law of opacity with a nonlinear least-squares regression method. The estimated k _p and k _w values vary from 0.199 to 0.316 m²/g and 0.000345 to 0.000426 m²/g, respectively, and the overall mean estimated values are 0.229 and 0.000397 m²/g, respectively. Although k _w is 3 orders of magnitude smaller than k _p, experimental results show that the effect on light extinction by water moisture was comparable to that by particles because of the existence of a considerable mass of water moisture after a FGD unit. The mass light extinction coefficient was also estimated using Mie theory with measured particle size distributions and a complex refractive index of 1.5-ni for fly ash particles. The k _p obtained using Mie theory ranges from 0.282 to 0.286 m²/g and is slightly greater than the averaged estimated k _p of 0.229 m²/g from measured opacity. The discrepancy may be partly due to a difference in the microstructure of the fly ash from the assumption of solid spheres because the fly ash may have been formed as spheres attached with smaller particles or as hollow spheres that contained solid spheres. Previously reported values of measured k _p obtained without considering the effects of water moisture are greater than that obtained in this study, which is reasonable because it reflects the effect of extinction by water moisture in the flue gas. Additionally, the moisture absorbed by particulate matter, corresponding to the effect of water moisture on the particulates, was clarified and found to be negligible.

IMPLICATIONS In-stack opacity is used as a surrogate for particle concentration and can be measured using light transmission meters as part of a continuous emission monitoring system. Because emission standards have become increasingly strict, FGD with wet scrubbing is generally used for coal-fired power plants. However, after a FGD unit with wet scrubbing is set up, the concentration of water moisture increases, affecting the measured opacity. This study evaluates the contributions of particles and water moisture to opacity. The results should provide useful information and can be utilized for modifying measurements for monitoring particulate emissions using opacity.     

Thermal removal of PCDD/Fs from medical waste incineration fly ash--effect of temperature and nitrogen flow rate

The fly ash used in this study was collected from a bag filter in a medical waste rotary kiln incineration system, using lime and activated carbon injection followed by their collection as mixed fly ash. Experiments were conducted on fly ash in a quartz tube, heated in a laboratory-scale horizontal tube furnace, in order to study the effect of temperature and nitrogen flow rate on the removal of PCDD/Fs. Results indicated that in this study PCDD/Fs in the fly ash mostly were removed and desorbed very little into the flue gas under thermal treatment especially when the heating temperature was higher than 350 °C, and dechlorination and destruction reactions took important part in the removal of PCDD/Fs. However, in terms of flow rate, when flow rate was higher than 4 cm s⁻¹, destruction efficiency of PCDD/Fs decreased dramatically and the main contributors were P₅CDF, H₆CDF and H₇CDF desorbed to flue gas, the PCDD/Fs in the fly ash decreased with enhanced flow rate.     

Utilization of nSiO2, fly ash, and nSiO2/fly ash composite for the remediation of triphenyltin (TPT) from contaminated seawater

The removal of triphenyltin chloride from contaminated simulated seawater with adsorption method was discussed. The adsorbents used are fly ash, nSiO₂, and nSiO₂/fly ash composite. The results showed that the adsorption of the adsorbents increases with increase in the adsorbent dose, contact time, pH, stirring speed, initial TPT concentration, and decreased with increase in temperature. The adsorption fitted well with the Freundlich isotherm, showing that the adsorbent and TPT combined with function groups and the adsorption kinetics followed the pseudo-second-order kinetic model. The thermodynamic parameters were also evaluated. Optimal conditions for the adsorption of TPT from simulated seawater were applied to TPT removal from natural seawater. A higher removal efficiency of TPT (>99 %) was obtained for the nSiO₂/fly ash composite but not for fly ash and nSiO₂.     

Application of the Fenton’s process in a bubble column reactor for hydroquinone degradation

The aim of this study was to assess the degradation and mineralization of hydroquinone (HQ) by the Fenton’s process in a bubble column reactor (BCR). The effect of the main operating variables, namely, air flow rate, effluent volume, hydrogen peroxide (H₂O₂) concentration, catalyst (Fe²⁺) dose, initial pH, and temperature, were assessed. For all air flow rates tested, no concentration gradients along the column were noticed, evidencing that a good mixing was reached in the BCR. For the best conditions tested ([H₂O₂] = 500 mg/L, [Fe²⁺] = 45 mg/L, T = 24 °C, Q _air = 2.5 mL/min, pH = 3.0, and V = 5 L), complete HQ degradation was reached, with ~ 39% of total organic carbon (TOC) removal, and an efficiency of the oxidant use—η _H2O2—of 0.39 (ratio between TOC removed per H₂O₂ consumed normalized by the theoretical stoichiometric value); moreover, a non-toxic effluent was generated. Under these conditions, the intermediates and final oxidation compounds identified and quantified were a few carboxylic acids, namely, maleic, pyruvic, and oxalic. As a strategy to improve the TOC removal, a gradual dosage of the optimal H₂O₂ concentration was implemented, being obtained ~ 55% of mineralization (with complete HQ degradation). Finally, the matrix effect was evaluated, for which a real wastewater was spiked with 100 mg/L of HQ; no reduction in terms of HQ degradation and mineralization was observed compared to the solution in distilled water.     

Potential Use of Olive-Waste Ash from Cogeneration Plants as a Soil Amendment

A greenhouse study was conducted to evaluate the potential use of olive-cake ash as a soil amendment, using pepper (Capsicum annuum, L. cv Italian sweet). Three soils of different pH (acidic, neutral and calcareous) were used. Treatments included a control (no fertilizer application), NPK fertilizer, and two ash-application rates that provided a complete dose (equivalent to the K₂O amount in the fertilizer) and a half dose (equivalent to half the K₂O amount in the fertilizer), respectively. The ash was effective in raising soil pH. Ash treatments increased the pepper (stems and leaves) dry matter yield over control; although these increases were lower than treatment including NPK. Application of ash significantly increased leaf P concentration and AB-DTPA extractable P in soil, especially in the acidic and neutral soils. Leaf K concentrations and readily and slowly available K forms in soils were affected positively by the addition of the ash. These results demonstrate that ash from the combustion of wet olive cake can be used as a beneficial organic soil amendment.     

Joint US/USSR Test Program for Reducing Fly Ash Resistivity

An electrostatic precipitator preceded by a wet scrubber was tested at the Reftinskaya Power Station. The unit collects a high resistivity fly ash from the combustion of low sulfur Ekibastuz coal. The operating parameters of the precipitator were measured as well as the mass emissions and the in-situ electrical resistivity of the fly ash. Density, particle size distribution, electrical resistivity, and chemical composition were determined for collected samples of the fly ash. The fly ash was also characterized by x-ray diffraction and scanning electron microscopy. When a centrifugal wet wall scrubber was installed ahead of the electrostatic precipitator, the temperature of the flue gas entering the precipitator was decreased and the moisture content increased. The electrical resistivity of the fly ash was attenuated a decade, but not enough to overcome the adverse effects of back corona in the precipitator. Lowering the flue gas temperature to about 85°C by the addition of a venturi scrubber ahead of the centrifugal scrubber reduced the electrical resistivity of the fly ash another decade and allowed the operation of the precipitator without back corona.