Estimating Costs of Flue Gas Desulfurization Systems for Utility Boilers

In September 1973, PEDCo-Environmental Specialists was awarded a study by the U. S. Environmental Protection Agency to evaluate the cost of controlling sulfur dioxide and particulate emissions from selected utility boilers. Since that time, PEDCo has conducted additional studies for the U. S. EPA, state and local control agencies, and private industry on the costs of control technology and the reliability of sulfur dioxide control systems. Current work includes determining the feasibility and environmental impact of converting selected utility boilers to coal-firing to conserve the nation’s gas and oil supplies. This paper presents an overview of the status and costs of flue gas desulfurization (FGD) systems, and the factors relating to the variability in costs. It is based in part upon work performed in developing detailed FGD cost estimating manuals for EPA.     

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.     

Control of Fly Ash from Conventional Coal-Fired Utility Boilers

This paper presents a detailed review and critical evaluation of current technologies as applied to fine particulate emissions from coal-fired utility boilers. Quantitative assessments of the capabilities of both conventional and novel air pollution control devices to meet three different performance standards—the present New Source Performance Standard (NSPS) of 0.03 Ib particulate/MBtu heat input, and standards of 0.05 and 0.1 Ib particulate/MBtu are included. Each of the three conventional devices (electrostatic precipitator, fabric filter baghouse, and wet scrubber) is compared and rated with respect to eight different performance categories. This information can be used to determine the relative effectiveness and attractiveness of these three control devices. Novel devices are compared and rated in the same manner, the conclusions from which may provide the research administrator with a guide for the selection of those novel devices which offer the best potential for commercialization.

The major conclusions of the investigation are: (1) The use of conventional scrubbers for fine particulate control on coal-fired utility boilers may no longer be feasible at the new NSPS of 0.03 Ib/MBtu. (2) At the old NSPS (0.1 Ib/MBtu) conventional electrostatic precipitators and baghouses were often competitive. For the new stricter standard, however, the baghouse generally is the more attractive alternative. (3) Novel devices appear to offer almost no hope for this particular application (at a commercial level) between now and 1985 and only little hope before 1990.     

Air Pollution Control Costs for Coal-to-Electricity Systems

This paper describes a comprehensive set of economic models developed to assess the air pollution control costs of alternative systems for generating electricity from coal. Models of individual system components were formulated based on engineering and statistical analyses of other detailed models and data reported in the literature for currently available technologies. The air pollution control options modeled include 4 levels of physical coal cleaning, 3 types of dry fly ash collectors, a wet limestone FGD system, and 2 options for solid waste disposal. In addition, the cost of a power plant with no air pollution controls was modeled to determine the total system cost, including energy needed to operate environmental control systems. The principal criteria guiding the development of these models were that they be (1) computationally simple and economical to use, with a minimum of detailed data requirements, (2) sensitive to variations in pollutant emission regulations, coal characteristics, and key plant design parameters, and (3) systematic, based on a specified amount of power production and the same constant dollars. Extensive sensitivity analyses and case studies performed with these models indicate excellent agreement with the results of other studies and models applicable only to individual environmental control options. Applications of these models are discussed and illustrative results presented.     

NOX Controls for Utility Boilers: Highlights of the EPRI July 1992 Workshop

More than 325 representatives of utilities, research organizations, vendors, engineering service firms, universities and regulatory agencies attended the EPRI workshop on NOx Controls for Utility Boilers in Cambridge, Massachusetts, July 7–9, 1992. The workshop featured more than 30 presentations on regulatory developments, low-NOx burner (LNB) retrofits for coal?, oil? and gas-fired units, overfire air and reburning retrofits, postcombustion NOx controls and LNB procurement issues.     

A Load Shifting Model for Air Pollution Control in the Electric Power Industry

Load-shifting, a relatively inexpensive approach to air pollution control, involves transferring the generating load from one power plant to another according to meteorological conditions. In this paper, an atmospheric dispersion model is adapted to estimate the exposure of the urban population to sulfur dioxide from operating the power system in different ways. Then a mathematical model of the power system of a metropolitan area is constructed to determine the reduction in pollution exposure which could be achieved, and the costs involved. As a case study, the application of the model to St. Louis, Missouri, is simulated. Under favorable conditions, load shifting could reduce pollution exposure up to 95%, while increasing the costs of electric power generation by only 4%. The load-shifting model has use not only as an operational control strategy, but also as an analytical tool to evaluate alternative pollution control measures in the electric power industry.     

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.     

Problems of Meeting Multiple Air Quality Objectives for Coal-Fired Utility Boilers

Gaseous wastes and particulate emissions are produced in the process of burning coal to produce electrical energy. In attempting to control these gaseous wastes, changes in the operation efficiency of boilers and secondary equipment are likely to result, and in addition liquid and solid waste streams are produced. The interrelationships among the various forms of wastes and the effects of air quality control on process efficiency are often overlooked in studies of environmental quality management.

The study was undertaken to evaluate the technical alternatives for handling gaseous and particulate emissions from coal-fired boilers and to determine the feasibility of meeting several standards simultaneously. The gaseous emissions of major importance in the combustion of coal are parti culates, oxides of sulfur, and oxides of nitrogen. Particulates can be controlled by a tradeoff among further preparation at the mine (for additional ash removal), type of boiler, use of dust control equipment and high stacks for dispersion of residual emissions, if ambient air standards are considered. Oxides of sulfur reduction depends currently on fuel substitution, limestone additives in the boiler and some form of contact process such as wet scrubbing, or the use of high stacks. Oxides of nitrogen control in coal fired boilers is restricted to small reductions by either changes in boiler operation, such as lower excess air levels, adsorption during wet scrubbing or by dispersion from high stacks.     

The Role of the Computer in Air Pollution Control

The search for ways of reducing vehicular emissions has led to numerous investigations of the relationships between fuel composition and the pollutants discharged from automobiles. The most obvious fuel effects result from evaporation of gasoline components from the fuel tanks and carburetors of vehicles which lack effective mechanical devices (such as those required on all 1971 model cars) to control evaporative losses. Thus, several laboratories and cooperative study groups (Coordinating Research Council and American Petroleum Institute) have investigated the ways in which fuel properties (especially the amounts and types of C₄-C₅ hydrocarbons) influence both the amount and the potential atmospheric reactivity of evaporative emissions.^1–6 But fuel evaporation accounts for only a small portion of the total hydrocarbons emitted by automobiles, and gasoline modifications (such as volatility reductions) that reduce evaporative losses can lead to higher levels of hydrocarbons in automobile exhaust.^4–6     

A Simulation Model for Air Pollution over Connecticut

A different approach to mathematically modeling large-scale atmospheric processes is presented. Whereas past approaches have been to develop a model based on an accumulation of information from a specific geographical area, resulting in a model applicable to that area only, we have developed a general mathematical model applicable to any geographical area. The model’s applicability is controlled by specifying the input information describing the meteorological situation and pollution source configuration. A rectangular array of grid points is used to specify both the wind field, by using stream functions, and the average source strength of some pollutant for the area represented by the grid. The diffusion problem is divided into two areas: transport by the mean wind field, and dispersion based on travel time and distance as described by empirical equations. Trajectories of pollutants are traced backwards from the points of interest in the course of the calculations and the contributions of all sources that affect the points of interest are accumulated. The model requires an array of source strength information. An inventory of pollution sources in the State of Connecticut was compiled and maps of source strengths were prepared for five pollutants on a 5000-ft grid-square array. Maps of sulfur dioxide and carbon monoxide source strengths are presented with the resulting concentration distribution for “typical” meteorological conditions. The model permits the changing of meteorological or source values at predetermined intervals so that diurnal changes are incorporated in the calculations. The model has not been verified, but the values of pollution concentration are the right order of magnitude and the resulting patterns are as expected.     

A Status Report: Air Pollution Control in Australia

All but one of the Australian States now have legislation to control Air Pollution. These are similar in broad principle and rely upon the system of prior approval and the use of emission limits. At the present time Victoria is the only State with legislation providing for the recycling of crankcase vent gases on motor cars. Methods being used to control pollution and future outlook and needs are discussed. At least 65 per cent of the crude oil requirements should be met by indigenous low sulfur oil by 1975. This fact and the imminent supply of natural gas to the four major cities and to the centers of heavy industrial development should result in a marked reduction in sulfur dioxide concentrations. A major outstanding problem is the lack of air pollution considerations in planning at regional and local government levels.     

Designing for Air Pollution Control

This paper was one of several presented at the Workshop on Air Pollution Control in Portland, Oregon, on May 6, 1968. The Workshop was sponsored by the Manufacturing Chemists Association and the Chemical Industry Council of the Pacific Northwest in cooperation with the Association of Oregon Industries, Association of Washington Industries, and the Environmental Committee of the Portland Chamber of Commerce. While many of the papers were of localized interest, this paper speaks to anyone designing air pollution control systems.     

A Cost Model for Air Quality Monitoring Systems

A model was developed for remote terminal use to compare the costs of alternate designs of air quality monitoring networks with varying sophistication, ranging from totally manual to completely automated systems. Of special interest is the isolation of manual sample analysis and manual data analysis for comparison with instrumental sensors and automated data processing.

The model allows for 10 levels of sophistication, and 6 were used in sample runs. As many as 50 samplingsite locations, with three different site types, may be specified, and each site type may have any configuration of chemical and/or meteorological sensors. Amortization, labor rates, instrument costs and lifetimes, telephone line charges, and other variables are readily changed by the user as desired.

It was concluded that for systems with fewer than 20–25 sensors, fully automated systems may not be justified on cost alone, at least for producing the same data (hourly) as the manual or semiautomatic systems. (Much more than hourly data is obtained with the automated system, of course.) For larger systems, labor costs put the nonautomated systems at a disadvantage after a few years of operation.     

The Potential of Pulse-Jet Baghouses for Utility Boilers. Part 2: Performance of Pulse-Jet Fabric Filter Pilot Plants

Pulse-jet fabric filters (PJFFs) are widely used in U.S. industrial boiler applications and in utility and industrial boilers abroad. Their small size and reduced cost relative to more conventional reverse-gas baghouses makes the use of PJFFs appear to be an attractive particulate control option for utility boilers. This paper (Part 2 of a three-part series) summarizes the results of pilot PJFF studies sponsored by the Electric Power Research Institute at different utility sites in the United States. The purpose of these tests is to evaluate PJFF performance for U.S. fossil-fuel-fired applications. These data are also used to corroborate the results of a recent worldwide survey of PJFF user experience, as described in Part 1 of this series. Part 3 will provide a cost comparison of PJFFs to other particulate control options such as electrostatic precipitators and reverse-gas baghouses.     

A Cost-Benefit Approach to Air Pollution Control

Air pollution has plagued the urban areas of our Nation for many years, both as a serious health hazard and as a costly economic burden. Users of the air as a waste disposal medium have treated it as a free resource with no regard for the damages incurred by receptors of the dirty air. Unfortunately, no self-regulating market forces exist that will bring this diseconomy into an acceptable equilibrium. An outside regulating force, which can affect abatement of air pollution, is needed to achieve control of air pollution to a level acceptable to a community. A prerequisite of any proposed regulatory action to be applied by an outside force, however, is the need to define an acceptable level of pollution. One means of accomplishing the task is to apply an economic evaluation, in the form of a cost-benefit analysis, to the problem. Previous analyses of the economic aspects of air pollution have stressed only one side of the problem. That is, they have dealt only with the cost of control or the damages caused by air pollution. No analysis has combined both aspects into a meaningful analysis of the overall economic impact. The objective of this paper is to present a technique that can be used to find the level of pollution abatement in an area that balances the cost of controlling pollution with the benefits received from its control. To present a clearer picture of this technique and its results, it has been applied to the Washington, D. C. area to find the optimum level of particulate abatement. This method is generally applicable to any area, in which an air pollution problem exists.     

Industrial Planning for Air Pollution Control

Seven general planning concepts for air pollution control are presented for industry’s consideration in this text of a speech delivered at the Air Pollution Control Workshop, New England Conference on Urban Planning for Environmental Health, Tufts University, Medford, Massachusetts, September 9, 1965.