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.     

Balance Corrections for Buoyancy

This paper describes a versatile experimental facility for evaluating the collection of high resistivity fly ash by advanced electrostatic precipitator designs at near full scale. The unit will operate on a slipstream of up to 424 m³/min (15,000 acfm) from a boiler firing pulverized low sulfur Western coal with an ash resistivity of 10¹³ ohm-cm at 149°C (300°F). The test unit is designed so that if can be configured as either a single-stage or a two-stage unit and allows for easy installation of different charger and collector components for evaluation. A dampered heat exchanger provides control over the gas temperature from 93°C (200°F) to 370°C (700°F) so that tests can be run at either hot-side or cold-side conditions. Support equipment includes a gas circulating fan, venturi meter for measurement and control of the flow, an instrumentation trailer housing a computerized system for data collection and control of the ESP, and a gas analysis trailer and particulate sampling station for a comprehensive evaluation of the system.     

Recent Electrostatic Precipitator Experience with Ammonia Conditioning of Power Boiler Flue Gases

Motivated by heightened recent interest, Koppers Co. has been experimenting with ammonia conditioning of power boiler flue gases for the purpose of improving the precipitability of the emitted fly ash. Chemical reactions resulting from ammonia injection are postulated. Measurements on three pulverized coal and two cyclone fired boilers, all of which emit acidic ash, are described. In all five cases, considerable but varying, increase in precipitator power input and collection efficiency resulted when gaseous ammonia in the amount of 1 5 ppm was injected between the economizer and air preheater. The conditioned fly ash showed decreased acidity and inconsistent change in electrical resistivity. Unless air heater temperatures were unusually high (>400°F), tendency of the air heater to plug was an additional, but unwanted, result. At one station with high air heater outlet temperature ammonia injection has been adopted as a permanent solution to community pressure for reduction of stack discharge. Ammonia injection downstream of the air heater produced no effect. Future plans are presented to continue the program beyond results described here.     

Conditioning of Fly Ash with Ammonia

This paper presents the results of an investigation of the conditioning of fly ash with ammonia in electrostatic pre-cipitators of power plants operated by the Tennessee Valley Authority. It focuses attention primarily on the mechanisms of conditioning encountered under the particular circumstances available for study. No effect of ammonia on the electrical resistivity of fly ash was evident. Instead, the effect of ammonia appeared to be an enhancement pf the space-charge component of the electric field used for charging and precipitating particles of fly ash. In addition, a second effect appeared to be an increase in the cohesiveness of precipitated ash and a reduction in the quantity of ash reentrained during electrode rapping. Data demonstrating the value of ammonia conditioning for lowering the emission pf fly ash during three precipitator studies are presented. Reasons for the ineffectiveness of ammonia conditioning during a fourth precipitator study are discussed. In conclusion, comments are made about the effects to be expected from ammonia conditioning under circumr stances different from those investigated experimentally, particularly with ammonia as a conditioning agent for fly ash from low sulfur western coal.     

Boiler briquette coal versus raw coal: Part II--Energy, greenhouse gas, and air quality implications

The objective of this paper is to conduct an integrated analysis of the energy, greenhouse gas, and air quality impacts of a new type of boiler briquette coal (BB-coal) in contrast to those of the raw coal from which the BB-coal was formulated (R-coal). The analysis is based on the source emissions data and other relevant data collected in the present study and employs approaches including the construction of carbon, energy, and sulfur balances. The results show that replacing R-coal with BB-coal as the fuel for boilers such as the one tested would have multiple benefits, including a 37% increase in boiler thermal efficiency, a 25% reduction in fuel demand, a 26% reduction in CO2 emission, a 17% reduction in CO emission, a 63% reduction in SO2 emission, a 97% reduction in fly ash and fly ash carbon emission, a 22% reduction in PM2.5 mass emission, and a 30% reduction in total emission of five toxic hazardous air pollutant (HAP) metals contained in PM10. These benefits can be achieved with no changes in boiler hardware and with a relatively small amount of tradeoffs: a 30% increase in PM10 mass emission and a 9-16% increase in fuel cost.     

Precipitator Design

The various design philosophies and methods used in the engineering design of precipitators for fly ash are reviewed and assessed in light of current stringent environmental standards. The basic precipitator size and electrical parameters are individually analyzed and related to particle and flue gas properties. Actual precipitator design practice is illustrated by data for a wide cross section of power plant installations.     

Boiler Briquette Coal versus Raw Coal: Part II—Energy,Greenhouse Gas,and Air Quality Implications

ABSTRACT

The objective of this paper is to conduct an integrated analysis of the energy, greenhouse gas, and air quality impacts of a new type of boiler briquette coal (BB-coal) in contrast to those of the raw coal from which the BB-coal was formulated (R-coal). The analysis is based on the source emissions data and other relevant data collected in the present study and employs approaches including the construction of carbon, energy, and sulfur balances. The results show that replacing R-coal with BB-coal as the fuel for boilers such as the one tested would have multiple benefits, including a 37% increase in boiler thermal efficiency, a 25% reduction in fuel demand, a 26% reduction in CO₂ emission, a 17% reduction in CO emission, a 63% reduction in SO₂ emission, a 97% reduction in fly ash and fly ash carbon emission, a 22% reduction in PM_2.5 mass emission, and a 30% reduction in total emission of five toxic hazardous air pollutant (HAP) metals contained in PM₁₀. These benefits can be achieved with no changes in boiler hardware and with a relatively small amount of tradeoffs: a 30% increase in PM₁₀ mass emission and a 9–16% increase in fuel cost.     

The Smogless Automobile

Demands for high performance and reliability of electrostatic precipitators for collection of fly ash from low sulfur fuels has led to rapid escalation of sizes and uncertainties in sizings of cold-side precipitators. This has led to utilization of the so-called “hot-side” precipitator. The underlying concept of hot-side precipitation is the avoidance of the necessity to operate the precipitator under high resistivity conditions. Data on in-situ measurements of resistivity of low sulfur fuel ash, as well as performance parameters of a number of operating installations, will be reviewed. These data will demonstrate the reduced sensitivity of hot-side precipitator sizing to fuel conditions. Other advantages of hot-side precipitators will be discussed.

Operating experience with hot-side precipitators has focused on structural problems which are peculiar to the larger, higher temperature installations. The nature and solution of these problems will be discussed. General comparative economics of hot-side and cold-side precipitators as they relate to fuel properties will be reviewed.     

Changes in PCDD/PCDF formation processes during instationary phases of combustor operation--exemplified by the use of Cl4DD isomer patterns

In this paper results of various measurement campaigns at different municipal waste incineration (MWI) plants concerning the change of the PCDD/PCDF isomer distribution in the crude gas during transiently impaired combustion conditions are presented. The focus is on the Cl4DD isomer distributions exemplarily for all other homologue groups to demonstrate the change in PCDD/PCDF formation mechanism at transient combustion conditions. Additionally to crude gas samples, at one plant filter and boiler ash were investigated simultaneously to determine if there is any difference in the isomer distribution between the matrices. For the ash from an electrostatic precipitator (ESP ash), the boiler ash and the corresponding crude gas sample, nearly identical changes in the Cl4DD isomer distribution under transient combustion conditions in relation to the normal operation process could be detected. By comparing the Cl4DD isomer distributions from different incineration plants (two municipal waste incinerators and one little incinerator burning wood chips for heating domestic household) under transient combustion conditions, in all cases the 1,3,6,8- and 1,3,7,9-Cl4DD were dominating the isomer distribution, whereas under normal operation other isomers were predominant. Obviously PCDD/PCDF formation mechanisms under transient combustion conditions are independent from the type of incinerator and of the burned fuel, respectively. Data sets were analyzed with respect to the possible reaction mechanism via chlorophenols and a good correlation of 2,4,6-trichlorophenol during the second phase of a start-up process and during a CO experiment was found. To get more detailed information about possible formation mechanisms, at one plant the dependence of the PCDD/PCDF isomer distribution on the different matrices was studied. Separate analysis of fly ash collected at the boiler exit, subsequent gas phase, ESP ash and boiler ash under normal operation conditions showed that, apart from the fly ash, the Cl4DD isomer distributions are nearly the same in the different matrices. Surprisingly, the Cl4DD isomer distribution of the fly ash was more similar to the distributions found under transient combustion conditions.     

Asbestos: Rationale Behind A Proposed Air Quality Standard

A computerized simulation model has been developed to compute energy requirements of a limestone slurry flue gas desulfurization (FGD) system as a function of FGD system design parameters, power plant characteristics, coal properties, and sulfur dioxide emission regulation. Results are illustrated for a "base case" plant of 500 MW, burning 3.5% sulfur coal, meeting the federal new source performance standard of 1.2 lb SO₂/10⁶ Btu. The flue gas is cleaned by an electrostatic precipitator followed by a limestone FGD system with a TCA scrubbing vessel and an optimized in-line steam reheater. The total FGD system energy requirement for this case was found to be 3.4% of the total energy input to the boiler. Sensitivity analyses were then performed in which the nominal values of ten system parameters were individually varied. This caused the total FGD system energy requirement to vary between 2.5 % and 6.1 % of the gross plant output for the range of parameters tested. The most sensitive parameters were found to be scrubbing slurry pH, which affects pumping requirements, and stack gas exit temperature, which affects reheat requirements. In all cases, FGD energy requirements were minimized when the SO₂ emission standard was met by partially bypassing the scrubber. In light of the recent Clean Air Act Amendments this option may not be feasible in the future.     

Dioxins and their fingerprint in size-classified fly ash fractions from municipal solid waste incinerators in China—Mechanical grate and fluidized bed units

The distribution of polychlorinated dibenzo-p-dioxins/dibenzofurans (PCDD/Fs), in brief dioxins, has seldom been addressed systematically in fly ash from municipal solid waste incinerators (MSWIs). This study shows the amount and fingerprint of PCDD/Fs in fly ash from four different Chinese MSWIs, that is, three mechanical grate units and one circulating fluidized bed unit. In these fly ash samples, dioxins-related parameters (international toxic equivalent quantity, total amount of PCDD/Fs, individual isomer classes, and 17 toxic 2,3,7,8-substituted congeners) all tend to increase with decreasing particle size for mechanical grate incinerators, yet only for the finest fraction for fluidized bed units. Moreover, the fluidized bed incinerator seems superior to grate incineration in controlling dioxins, yet a comparison is hampered by internal differences in the sample, for example, the fluidized bed fly ash has much lower carbon and chlorine contents. In addition, the presence of sulfur from mixing coal as supplemental fuel to the MSW may poison the catalytic steps in dioxins formation and thus suppress the formation of dioxins. With more residual carbon and chlorine in the fly ash, it is easier to form dioxins during cooling. Nevertheless, there is no apparent relation between Fe, Cu, and Zn contents and that of dioxins in fly ash.

Implications This paper is of interest because it presents the amounts and distribution of PCDD/Fs in fly ash samples from some typical waste incineration plants in China, featuring distinct incinerator types, combustion conditions, fuel composition, or residual carbon, chloride, and heavy metal contents in fly ash.     

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.     

Source profiles of particulate matter emissions from a pilot-scale boiler burning North American coal blends.

Recent awareness of suspected adverse health effects from ambient particulate matter (PM) emission has prompted publication of new standards for fine PM with aerodynamic diameter less than 2.5 microm (PM2.5). However, scientific data on fine PM emissions from various point sources and their characteristics are very limited. Source apportionment methods are applied to identify contributions of individual regional sources to tropospheric particulate concentrations. The existing industrial database developed using traditional source measurement techniques provides total emission rates only, with no details on chemical nature or size characteristics of particulates. This database is inadequate, in current form, to address source-receptor relationships. A source dilution system was developed for sampling and characterization of total PM, PM2.5, and PM10 (i.e., PM with aerodynamic diameter less than 10 pm) from residual oil and coal combustion. This new system has automatic control capabilities for key parameters, such as relative humidity (RH), temperature, and sample dilution. During optimization of the prototype equipment, three North American coal blends were burned using a 0.7-megawatt thermal (MWt) pulverized coal-fired, pilot-scale boiler. Characteristic emission profiles, including PM2.5 and total PM soluble acids, and elemental and carbon concentrations for three coal blends are presented. Preliminary results indicate that volatile trace elements such as Pb, Zn, Ti, and Se are preferentially enriched in PM2.5. PM2.5 is also more concentrated in soluble sulfates relative to total PM. Coal fly ash collected at the outlet of the electrostatic precipitator (ESP) contains about 85-90% PM10 and 30-50% PM2.5. Particles contain the highest elemental concentrations of Si and Al while Ca, Fe, Na, Ba, and K also exist as major elements. Approximately 4-12% of the materials exists as soluble sulfates in fly ash generated by coal blends containing 0.2-0.8% sulfur by mass. Source profile data for an eastern U.S. coal show good agreement with those reported from a similar study done in the United States. Based on the inadequacies identified in the initial sampling equipment, a new, plume-simulating fine PM measurement system with modular components for field use is being developed for determining coal combustion PM source profiles from utility boiler stacks.     

Distribution of mercury in the combustion products from coal-fired power plants in Guizhou,southwest China

Method 30B and the Ontario Hydro Method (OHM) were used to sample the mercury in the flue gas discharged from the seven power plants in Guizhou Province, southwest China. In order to investigate the mercury migration and transformation during coal combustion and pollution control process, the contents of mercury in coal samples, bottom ash, fly ash, and gypsum were measured. The mercury in the flue gas released into the atmosphere mainly existed in the form of Hg°. The precipitator shows a superior ability to remove Hg^p (particulate mercury) from flue gas. The removal efficiency of Hg²⁺ by wet flue gas desulfurization (WFGD) was significantly higher than that for the other two forms of mercury. The synergistic removal efficiency of mercury by the air pollution control devices (APCDs) installed in the studied power plants is 66.69–97.56%. The Hg mass balance for the tested seven coal-fired power plants varied from 72.87% to 109.67% during the sampling time. After flue gas flowing through APCDs, most of the mercury in coal was enriched in fly ash and gypsum, with only a small portion released into the atmosphere with the flue gas. The maximum discharge source of Hg for power plants was fly ash and gypsum instead of Hg emitted with flue gas through the chimney into the atmosphere. With the continuous upgrading of APCDs, more and more mercury will be enriched in fly ash and gypsum. Extra attention should be paid to the re-release of mercury from the reutilization of by-products from APCDs.

Implications: Method 30B and the Ontario Hydro Method (OHM) were used to test the mercury concentration in the flue gas discharged from seven power plants in Guizhou Province, China. The concentrations of mercury in coal samples, bottom ash, fly ash, and gypsum were also measured. By comparison of the mercury content of different products, we found that the maximum discharge source of Hg for power plants was fly ash and gypsum, instead of Hg emitted with flue gas through the chimney into the atmosphere. With the continuous upgrading of APCDs, more and more mercury will be enriched in fly ash and gypsum. Extra attention should be paid to the re-release of mercury from the reutilization of by-products from APCDs.     

Effects of Design and Fuel Moisture on Incinerator Effluents

The particle and gas properties that profoundly affect design and performance of fly ash precipitators are discussed and evaluated in this section. Relation of the coal burned to these properties and to the precipitator gas cleaning problem is broadly examined. The need for a high order of technology consistently applied to cope successfully with the wide and often uncertain variations in coal and ash properties encountered in precipitation practices is emphasized.     

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.     

Understanding selected trace elements behavior in a coal-fired power plant in Malaysia for assessment of abatement technologies

The Proposed New Environmental Quality (Clean Air) Regulation 201X (Draft), which replaces the Malaysia Environmental Quality (Clean Air) 1978, specifies limits to additional pollutants from power generation using fossil fuel. The new pollutants include Hg, HCl, and HF with limits of 0.03, 100, and 15 mg/N-m³ at 6% O₂, respectively. These pollutants are normally present in very small concentrations (known as trace elements [TEs]), and hence are often neglected in environmental air quality monitoring in Malaysia. Following the enactment of the new regulation, it is now imperative to understand the TEs behavior and to assess the capability of the existing abatement technologies to comply with the new emission limits. This paper presents the comparison of TEs behavior of the most volatile (Hg, Cl, F) and less volatile (As, Be, Cd, Cr, Ni, Se, Pb) elements in subbituminous and bituminous coal and coal combustion products (CCP) (i.e., fly ash and bottom ash) from separate firing of subbituminous and bituminous coal in a coal-fired power plant in Malaysia. The effect of air pollution control devices configuration in removal of TEs was also investigated to evaluate the effectiveness of abatement technologies used in the plant. This study showed that subbituminous and bituminous coals and their CCPs have different TEs behavior. It is speculated that ash content could be a factor for such diverse behavior. In addition, the type of coal and the concentrations of TEs in feed coal were to some extent influenced by the emission of TEs in flue gas. The electrostatic precipitator (ESP) and seawater flue gas desulfurization (FGD) used in the studied coal-fired power plant were found effective in removing TEs in particulate and vapor form, respectively, as well as complying with the new specified emission limits.

Implications:Coals used by power plants in Peninsular Malaysia come from the same supplier (Tenaga Nasional Berhad Fuel Services), which is a subsidiary of the Malaysia electricity provider (Tenaga Nasional Berhad). Therefore, this study on trace elements behavior in a coal-fired power plant in Malaysia could represent emission from other plants in Peninsular Malaysia. By adhering to the current coal specifications and installation of electrostatic precipitator (ESP) and flue gas desulfurization, the plants could comply with the limits specified in the Malaysian Department of Environment (DOE) Scheduled Waste Guideline for bottom ash and fly ash and the Proposed New Environmental Quality (Clean Air) Regulation 201X (Draft).     

The effects of temperature and oxygen content on the PCDD/PCDFs formation in MSW fly ash

In this study, the effects of the temperature, oxygen content in the gas stream and carbon content in ash particles on PCDD/Fs formation on the fly ash surface were investigated. The optimum temperatures for dioxin formation were found at 350 degrees C for boiler ash, 300 degrees C for cyclone ash and 250 degrees C for ESP ash, respectively. Preliminary results indicate that the optimum temperature will decrease as the particle size decreases. When the O2 concentration is varied between 0% and 100%, the optimum oxygen content for PCDD/Fs formation is found to be at 7.5% for cyclone ash, and the PCDD/PCDF ratio increases with the increase of oxygen content. Dioxin formation is observed even for the gas containing no oxygen passed through the fly ash. Hence, other reacted routes that do not need O2 for dioxin formation take place on fly ash. The carbon content in fly ash is varied between 0% and 20% in this study, and the results have indicated that the maximum dioxin formation is to be found at 5%. The precursors are not injected into the fly ash or gas stream in all formation experiments, however, dioxin is still formed in fly ash. Consequently, other chlorinated routes besides Deacon reactions may take place on the fly ash surface.     

Ca/S比小于1条件下半干半湿法烟气脱硫技术的研究

通过对煤中灰分、粉煤灰中碱性物质成分、含量的分析 ,证明在Ca/S小于 1的条件下进行半干半湿法烟气脱硫是可行的。阐述了粉煤灰中碱性物质被有效利用的条件为高温、高湿和高压 ,该条件可以通过蒸汽输送粉煤灰来实现。     

A pilot study of mercury liberation and capture from coal-fired power plant fly ash

The coal-fired electric utility generation industry has been identified as the largest anthropogenic source of mercury (Hg) emissions in the United States. One of the promising techniques for Hg removal from flue gas is activated carbon injection (ACI). The aim of this project was to liberate Hg bound to fly ash and activated carbon after ACI and provide high-quality coal combustion products for use in construction materials. Both bench- and pilot-scale tests were conducted to liberate Hg using a thermal desorption process. The results indicated that up to 90% of the Hg could be liberated from the fly ash or fly-ash-and-activated-carbon mixture using a pilot-scale apparatus (air slide) at 538 degrees C with a very short retention time (less than 1 min). Scanning electron microscope (SEM) evaluation indicated no significant change in fly ash carbon particle morphology following the thermal treatment. Fly ash particles collected in the baghouse of the pilot-scale apparatus were smaller in size than those collected at the exit of the air slide. A similar trend was observed in carbon particles separated from the fly ash using froth flotation. The results of this study suggest a means for power plants to reduce the level of Hg in coal-combustion products and potentially recycle activated carbon while maintaining the resale value of fly ash. This technology is in the process of being patented.