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.     

Release of Mercury Vapor from Coal Combustion Ash

Abstract

The long-term stability of Hg in coal combustion byproducts (CCBs) was evaluated at ambient and near-ambient temperatures. Six CCB samples with atypically high levels of total Hg were selected for study assuming a greater potential for release of measurable amounts of Hg vapor. The samples selected included two fly ash samples from U.S. eastern bituminous coal, two fly ash samples from South African low-rank coal, one fly ash from Powder River Basin (PRB) subbituminous coal blended with petroleum coke, and one PRB subbituminous coal fly ash incorporated with flue gas desulfurization material.

Air scrubbed of Hg was passed through compacted 100-g aliquots of each sample at 1 mL/min and vented to a gold-coated quartz trap to collect released Hg vapor. The samples were maintained at ambient and near-ambient (37 °C) temperatures. All samples released low-picogram levels of Hg after 90 days. No pattern was evident to link the total Hg content to the rate of release of Hg vapor. An average of 0.030 pg Hg/g CCB/day was released from the samples, which equates to 2.2 x 10^-8 lb Hg/ton CCB/year. If this were applied to a coal-fired power plant production of 200,000 tons of fly ash per year, there would be a maximum potential release of 0.0044 lb, or 2.00 g, of Hg per year. Experiments are continuing to determine long-term vapor release of Hg from CCBs. All samples have been set up in duplicate at ambient temperature with an improved apparatus to reevalu-ate results reported in this article.     

Zeolite Formation from Coal Fly Ash and Its Adsorption Potential

Abstract

The possibility in converting coal ?y ash (CFA) to zeolite was evaluated. CFA samples from the local power plant in Prachinburi province, Thailand, were collected during a 3-month time span to account for the inconsistency of the CFA quality, and it was evident that the deviation of the quality of the raw material did not have significant effects on the synthesis. The zeolite product was found to be type X. The most suitable weight ratio of sodium hydroxide (NaOH) to CFA was approximately 2.25, because this gave reasonably high zeolite yield with good cation exchange capacity (CEC). The silica (Si)-to-aluminum (Al) molar ratio of 4.06 yielded the highest crystallinity level for zeolite X at 79% with a CEC of 240 meq/100 g and a surface area of 325 m²/g. Optimal crystallization temperature and time were 90 °C and 4 hr, respectively, which gave the highest CEC of approximately 305 meq/100 g. Yields obtained from all experiments were in the range of 50–72%.     

Medium-Sulfur Coal and Fly Ash Resistivity

Electric generating plants burning medium-sulfur coal need a way to predict when ESP performance will be limited by high electrical resistivity of the collected fly ash. The main uncertainty in mathematical predictions of fly ash resistivity lies in the marginal effect of naturally occurring SO₃ vapor in the flue gas. This paper results from a project to expand the data base of SO₃/SO₂ concentrations and fly ash resistivities measured in utility fly ash precipitators. Complete data sets are presented from three plants in the Southern Company electric system. In situ resistivity data are compared with laboratory measurements and with two different mathematical predictions of resistivity based on coal and ash analyses. The revised version of the resistivity predictor gives results in good agreement with resistivity values measured both in situ and in the laboratory.     

Filtration Properties of Fly Ash from Fluidized Bed Combustion

Some of the features of the fluidized-bed combustion (FBC) process have a direct bearing on the particulate properties that most strongly influence filtering pressure drop. A laboratory program was conducted to experimentally determine the relative pressure drop characteristics of ashes from the TVA-EPRI 20-MW bubbling bed, atmospheric pressure FBC (AFBC) pilot plant and six pulverized-coal combustion (PC) units. The combined influences of measured particle and dust cake properties on filtering pressure drop were estimated with existing filtration theories. These theories predict a higher pressure drop for a dust cake produced with the AFBC ash than for one consisting of any of the PC ashes. Laboratory measurements were made of the flow resistance of idealized, simulated dust cakes to confirm these predictions. Field operating data from the fabric filters collecting some of the tested ashes were available to validate the laboratory results. The laboratory and field data show relatively good agreement. The AFBC ash must be treated as a special case for fabric filters, and careful selection of cleaning method and fabric must be made to minimize the inherently high pressure drop characteristics of this ash.     

Improved TITRILOG Sensitivity Part II. Field Performance and Evaluation

Air pollution forecasting is not a new field but is certainly an area with only modest development since its early beginnings. Because ozone Is not a source emission but instead is formed from precursors, ozone episodes should be more readily forecasted than other pollutants by simply monitoring the precursors. The ozone empirical model developed within the course of this study is very site specific, therefore the major goal of the study was to establish the techniques which can be used to develop an ozone forecasting model for specific monitoring networks. The results of using the ozone forecasting model showed that even though errors as high as 25 % occurred the typical error In forecasting was in the 5-10% range.     

Hydration Properties of Eco-Cement Pastes from Waste Sludge Ash Clinkers

Abstract

Three types of hydraulic cements have been developed by incorporating sludge ash from a primary sewage treatment plant and a water purification plant, as well as slag from steelworks (ferrate), as a partial replacement for clay, silica, alumina, and iron oxide in raw cement meal. The raw meal for the pre-determined recipes was prepared by heating it to 1400 °C for 6 hr in a clinkerization process, using a simulated incinerator and smelter. The major components of ordinary Portland cement, C₃S, C₂S, C₃A, and C₄AF, were all found in the clinkers. Of the three types of eco-cements, the eco-cement A paste was most similar to ordinary Portland cement in terms of composition and compressive strength development, while the eco-cement B paste showed early strength development. The differential thermal analysis species analyses indicated that the hydrates in the eco-cement pastes were mainly calcium hydroxide and CSH gels, like those found in ordinary Portland cement paste. Moreover, the degree of hydration, as determined by nuclear magnetic resonance, increased in all eco-cement pastes with an increasing curing age. The results indicate that it indeed is feasible to use sludge ash and ferrate to replace up to 20% of the mineral components of raw materials for cement.     

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 Potential of Pulse-Jet Baghouses for Utility Boilers Part 3: Comparative Economics of Pulse-Jet Baghouse,Precipitators and Reverse-Gas Baghouses

Pulse-jet fabric filters (PJFFs) are widely used in U.S. industrial applications, and in both utility and industrial boilers abroad. Their smaller size and reduced cost relative to more conventional baghouses make PJFFs an attractive particulate control option for utility boilers. This article which is the third in a three-part series, compares the cost of PJFFs with electrostatic precipitators (ESPs) and reverse-gas baghouses (RGBs).

This article presents the capital, operating and maintenance (O&M), and level-ized costs for ESPs, RGBs and PJFFs. The particulate control equipment design and pricing are supplied by manufacturers of the control equipment. A comparison of costs for a base case 250-MW boiler indicates that the PJFF capital cost is 22 percent lower than the cost of an ESP with 400 SCA and 12-inch plate spacing; in addition the PJFF is 35 percent lower than the cost of an RGB. The levelized cost for a PJFF is about equal to the cost of the ESP but 14 percent lower than the cost of the RGB. Overall, the attractiveness of a PJFF versus an ESP depends on the coal type and the outlet emissions limit required. PJFF is favored when low-sulfur coal is fired due to the high-resistivity fly ash. Also, PJFF is favored as more stringent outlet emission rates are required.     

Analysis of an APCA Baghouse Operation and Maintenance Survey

Baghouse operation and maintenance is probably the most serious problem area of fabric filter operations. Committee TC-1 (Particulates) of the Air Pollution Control Association recently surveyed baghouse installations in'the United States for the purpose of gathering information on operation and maintenance procedures and problems. One hundred thirty-three questionnaires were completed and returned. In this paper, the results of a comprehensive analysis of these data are described and interpreted. A multiple-choice type of compilation of the responses has been used to permit statistical interpretation of the results. Due to the length of the questionnaire and the tables which resulted from the analysis, these are described but not included in the following paper. They are available from the TC-1 Committee c/o APCA.     

Geotechnical Engineering Properties of Incinerator Ash Mixes

Abstract

The incineration of solid waste produces large quantities of bottom and fly ash. Landfilling has been the primary mode of disposal of these waste materials. Shortage in landfill space and the high cost of treatment have, however, prompted the search for alternative uses of these waste materials. This study presents an experimental program that was conducted to determine the engineering properties of incinerator ash mixes for use as construction materials. Incinerator ash mixes were tested as received and around optimum compacted conditions. Compaction curves, shear strength, and permeability values of fly ash, bottom ash, and their various blends were investigated. Bottom ash tends to achieve maximum dry density at much lower water content than does fly ash. The mixes displayed a change in their cohesion and friction angle values when one of the two mix components was altered or as a result of the addition of water. The permeability of bottom ash is quite comparable to that of sand. The permeability of fly ash lies in the range of those values obtained for silts and clays. A 100% bottom ash compacted at the optimum water content has a lower density value and yields a higher friction angle and cohesion values than most construction fills. This would encourage the use of bottom ash as a fill or embankment material because free drainage of water will prevent the buildup of pore water pressures.     

The Development of a Sampling System for the Determination of Odor Emission Rates from Areal Surfaces: Part II. Mathematical Model

Abstract

An improved design for an odor emission hood was examined in the laboratory using ammonia emission from a water surface. The experimental ammonia convective mass transfer coefficients from a diluted ammonia solution were determined at velocities of 0.3 m/s to 0.8 m/s using the odor emission hood. The theoretical ammonia convective mass transfer coefficients were also predicted by boundary layer theory under laminar flow conditions. It was found that experimental data were only 10% below theoretical predictions at an air velocity of 0.3 m/s to 0.6 m/s. The maximum velocity was limited to 0.6 m/s by the geometric size, shape and aerodynamic stability of the hood. At 0.33 m/s, the smallest variation of mass transfer coefficients was measured. The odor emission rate was found to be a function of air velocity to the power 0.5 in accordance with boundary layer theory. An odor sampling system based upon the odor emission hood provides a way to quantify the potential odor emission strength in sewage treatment plants, for odor dispersion modeling and odor control.     

Monitoring the fate of chlorine from MSW sampling through combustion Part II: Combustion studies

Combustion measurements were carried out in a multi-kilogram capacity flow calorimeter on cellulose and cellulose/sand samples in 100% oxygen and several oxygen/nitrogen mixtures. Some measurements were made on cellulose/sand samples, which had 1 mass % of polyvinylchloride (PVC) as part of their composition, to study the conditions related to the formation/destruction of chlorinated organic compounds as combustion products. Qualitative identifications of a significant variety of chlorinated organic compounds have been made.     

Critical Review of Environmental Forensic Techniques: Part II

A multitude of forensic techniques are available for age dating and source identification, including aerial photography interpretation, corrosion models, the commercial availability of a chemical, chemical associations with discrete types of equipment, chemical profiling, degradation models and contaminant transport models. The success of these techniques in environmental litigation and their applicability to a particular fact situation is rarely discussed in the literature. When these techniques are introduced as scientific evidence, their governing assumptions and the adequacy of the underlying data are rigorously scrutinized and often, successfully challenged. The purpose of this paper is to review selected forensic techniques and discuss their merits so that the user can select the technique or combination of techniques most appropriate for the factual elements of the case.     

Critical Review of Environmental Forensic Techniques: Part II

A multitude of forensic techniques are available for age dating and source identification, including aerial photography interpretation, corrosion models, the commercial availability of a chemical, chemical associations with discrete types of equipment, chemical profiling, degradation models and contaminant transport models. The success of these techniques in environmental litigation and their applicability to a particular fact situation is rarely discussed in the literature. When these techniques are introduced as scientific evidence, their governing assumptions and the adequacy of the underlying data are rigorously scrutinized and often, successfully challenged. The purpose of this paper is to review selected forensic techniques and discuss their merits so that the user can select the technique or combination of techniques most appropriate for the factual elements of the case.     

Sizing and Costing of fabric Filters Part II: Costing Considerations

This is the second of a two-part article that reviews baghouse filtration theory, presents size estimating methods, and gives costing procedures for a variety of baghouse types and sizes. Part I of the article discussed theory and sizing; this part presents costing. Information is given for estimating total capital investment including separate costs for the bare baghouse (five types), bags, and, where needed, cages and Venturis. Factors are given for installation and for indirect costs. Direct and indirect annual costs are discussed. An example problem is given. The material in this article is taken primarily from the EAB Control Cost Manual.     

Fly Ash from Electrostatic Precipitators: Characterization of Large Spheres

The body of information contained in this paper is directed towards individuals concerned with the toxicology and physical state of airborne effluents from pulverized coal-fired stationary sources. A flotation/sedimentation technique was used to separate fly ash from power plant clean-up devices into light, medium, and high density fractions. Large spherical particles were selected from each fraction and examined by optical and scanning electron microscopy. Attempts were made to identify pleurospheres (filled hollow spheres) by crushing the spheres in situ under the optical microscope. In no cases were filled spheres observed, suggesting that they are not a common structure in fly ash. Several phenomena which generate hollow spheres are discussed.     

Utilization of Modified Attapulgite for the Removal of Sr(II), Co(II), and Ni(II) Ions from Multicomponent System,Part I: Kinetic Studies

Radionuclide sorption by natural and modified clays is extensively accepted to be an important process from the radioactive waste point of view. This work focused on modification of natural attapulgite with a layered double hydroxide to produce a novel chemisorbent for Sr2+, Ni2+, and Co2+ removal from multicomponent solution. The structural and surface characteristics of both attapulgite (ATP) and modified attapulgite (LDH-ATP) were investigated using XRD, FTIR, SEM, and thermal analysis. Comparison of sorption features of Sr2+, Ni2+, and Co2+ onto ATP and LDH-ATP was achieved; the results indicated that LDH-ATP was the most efficient sorbent for Sr2+, Ni2+, and Co2+. Kinetic studies established that the sorption is fast and reaching >90% within 30 min. The sorption of Sr2+, Ni2+, and Co2+ are well defined by non-linear pseudo-second-order model and controlled by an intra-particle diffusion mechanism. The diffusivity was determined using homogeneous surface diffusion (HSDM) model and found in the order 10−13 m2/min; this confirmed that the sorption of the three ions is chemisorption process. LDH-ATP can be employed as a candidate chemisorbent for the removal of some metal ions from waste solution.