Emissions of Sulfur Trioxide from Coal-Fired Power Plants

Abstract

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.     

Fabric Filter Technology for Utility Coal-Fired Power Plants

This is the fifth in a series of papers discussing the experience of electric utilities in applying baghouse technology for the collection of particulate matter at coal-fired electric power generating plants. The series presents new data obtained in research sponsored by the Electric Power Research Institute (EPRI) on reverse-gas and shake/deflate cleaned baghouses, and specifically addresses a number of unresolved issues in the design and operation of these units. This paper describes research to improve reverse-gas cleaning technology, and to characterize reverse-gas sonic assisted and shake/deflate cleaning.     

Fabric Filter Technology for Utility Coal-Fired Power Plants

This is the sixth and last part in a series of papers discussing the experience of electric utilities in applying baghouse technology for the collection of particulate matter at coal-fired electric power generating plants. The series presents new data obtained in research sponsored by the Electric Power Research Institute (EPRI) on reverse-gas and shake/deflate cleaned baghouses, and specifically addresses a number of unresolved issues in the design and operation of these units. This paper discusses research, development and demonstration activities now underway or planned to further understand baghouse technology to ensure efficient, economic and reliable service in utility applications. In addition, it summarizes the major findings reported in Parts I through V.     

New Source Performance Standards For Coal-Fired Power Plants

To preserve and improve environmental quality in a prosperous industrialized nation like the United States, we must use efficient control technology to reduce the pollution which would otherwise accompany our growth. The need for control is especially great in our use of energy. In the near term our country must depend increasingly on coal to meet our energy needs. In his 1977 energy message President Carter declared that it would be this Administration’s policy to require the use of best available control technology for all new coal burning plants. EPA is implementing this policy by adopting a rule that will require such controls on new coal-fired power plants.     

Human Exposure to Sulfates from Coal-Fired Power Plants

Abstract

Increased interest in the health effects of ambient par–ticulate mass (PM) has focused attention on the evaluation of existing mass measurement methodologies and the definition of PM in ambient air. The Rupprecht and Patashnick Tapered Element Oscillating MicroBalance (TEOM^®) method for PM is compared with time–integrated gravimetric (manual) PM methods in large urban areas during different seasons. Comparisons are conducted for both PM₁₀ and PM_2.5 concentrations.

In urban areas, a substantial fraction of ambient PM can be semi–volatile material. A larger fraction of this component of PM₁₀ may be lost from the TEOM–heated filter than the Federal Reference Method (FRM). The observed relationship between TEOM and FRM methods varied widely among sites and seasons. In East Coast urban areas during the summer, the methods were highly correlated with good agreement. In the winter, correlation was somewhat lower, with TEOM PM concentrations generally lower than the FRM. Rubidoux, CA, and two Mexican sites (Tlalnepantla and Merced) had the highest levels of PM₁₀ and the largest difference between TEOM and manual methods.

PM_2.5 data from collocation of 24–hour manual samples with the TEOM are also presented. As most of the semi–volatile PM is in the fine fraction, differences between these methods are larger for PM_2.5 than for PM₁₀.     

Fabric Filter Technology for Utility Coal-Fired Power Plants

This is the third in a series of papers discussing the experience of electric utilities in applying baghouse technology for the collection of particulate matter at coal-fired electric power generating plants. The series presents new data obtained in research sponsored by the Electric Power Research Institute (EPRI) on reverse-gas and shake/deflate cleaned baghouses, and specifically addresses a number of unresolved issues in the design and operation of these units. This paper provides an overview of the design and operating characteristics of baghouses now in place in the utility industry. In addition, it discusses three key issues in design and operation: the relationships among dust cake weight and chemical composition, air-to-cloth ratio, and pressure drop; fabric selection; and bag life.     

Third Conference on Fabric Filter Technology for Coal-Fired Power Plants

This paper summarizes information and results presented at the Third Conference on Fabric Filter Technology for Coal-Fired Power Plants held November 19-21, 1985 in Scottsdale, Arizona. Sponsored by the Electric Power Research Institute (EPRI), in cooperation with the Arizona Public Service Co. and Salt River Project, the conference focused on recent technological developments in the design and operation of fabric filters (baghouses) in electric utility settings. Papers were presented by individuals representing utilities, fabric filter manufacturers, research and development organizations, and regulatory agencies. Approximately 200 individuals attended the sessions. Summaries of the first two conferences and results of other fabric Biter research sponsored bv EPRI have been published previously in JAPCA.^1–9     

Quantification of Hourly Variability in NOx Emissions for Baseload Coal-Fired Power Plants

Abstract

The objectives of this paper are to (1) quantify variability in hourly utility oxides of nitrogen (NO_x) emission factors, activity factors, and total emissions; (2) investigate the autocorrelation structure and evaluate cyclic effects at short and long scales of the time series of total hourly emissions; (3) compare emissions for the ozone (O₃) season versus the entire year to identify seasonal differences, if any; and (4) evaluate interannual variability. Continuous emissions monitoring data were analyzed for 1995 and 1998 for 32 units from nine baseload power plants in the Charlotte, NC, airshed. Unit emissions have a strong 24-hr cycle attributable primarily to the capacity factor. Typical ranges of the coefficient of variation for emissions at a given hour of the day were from 0.2 to 0.45. Little difference was found when comparing weekend emissions with the entire week or when comparing the O₃ season with the entire year. There were substantial differences in the mean and standard deviation of emissions when comparing 1995 and 1998 data, indicative of the effect of retrofits of control technology during the intervening time. The wide range of variability and its autocorrelation should be accounted for when developing probabilistic utility emission inventories for analysis of near-term future episodes.     

Technical Aspects of Lime/Limestone Scrubbers for Coal-Fired Power Plants

This 2-part article deals with the technical aspects of lime/limestone scrubbers for coal-fired power plants. Part I covers process chemistry and scrubber systems. Part II (next month) will cover instrumentation, particulate removal, and sludge disposal.     

Technical Aspects of Lime/Limestone Scrubbers for Coal-Fired Power Plants

This is the conclusion of a 2-part article dealing with the technical aspects of lime/limestone scrubbers for coal-fired power plants, it covers instrumentation, participate removal and sludge disposal. Part I (June JAPCA) covered process chemistry and scrubber systems     

Modeling Atmospheric Mercury Deposition in the Vicinity of Power Plants

Abstract

Two mathematical models of the atmospheric fate and transport of mercury (Hg), an Eulerian grid–based model and a Gaussian plume model, are used to calculate the atmospheric deposition of Hg in the vicinity (i.e., within 50 km) of five coal–fired power plants. The former is applied using two different horizontal resolutions: coarse (84 km) and fine (16.7 km). More than 96% of the power plant Hg emissions are calculated with the plume model to be transported beyond 50 km from the plants. The grid–based model predicts a lower fraction to be transported beyond 50 km: >91% with a coarse resolution and >95% with a fine resolution. The contribution of the power plant emissions to total Hg deposition within a radius of 50 km from the plants is calculated to be <8% with the plume model, <14% with the Eulerian model with a coarse resolution, and <10% with the Eulerian model with a fine resolution. The Eulerian grid–based model predicts greater local impacts than the plume model because of artificially enhanced vertical dispersion; the former predicts about twice as much Hg deposition as the latter when the area considered is commensurate with the resolution of the grid–based model. If one compares the local impacts for an area that is significantly less than the grid–based model resolution, then the grid–based model may predict lower local deposition than the plume model, because two compensating errors affect the results obtained with the grid–based model: initial dilution of the power plant emissions within one or more grid cells and enhanced vertical mixing to the ground.     

An Intelligent Emissions Controller for Fuel Lean Gas Reburn in Coal-Fired Power Plants

ABSTRACT

The application of artificial intelligence techniques for performance optimization of the fuel lean gas reburn (FLGR) system is investigated. A multilayer, feedforward artificial neural network is applied to model static nonlinear relationships between the distribution of injected natural gas into the upper region of the furnace of a coal-fired boiler and the corresponding oxides of nitrogen (NO_x) emissions exiting the furnace. Based on this model, optimal distributions of injected gas are determined such that the largest NO_x reduction is achieved for each value of total injected gas. This optimization is accomplished through the development of a new optimization method based on neural networks. This new optimal control algorithm, which can be used as an alternative generic tool for solving multidimensional nonlinear constrained optimization problems, is described and its results are successfully validated against an off-the-shelf tool for solving mathematical programming problems. Encouraging results obtained using plant data from one of Commonwealth Edison's coal-fired electric power plants demonstrate the feasibility of the overall approach.

Preliminary results show that the use of this intelligent controller will also enable the determination of the most cost-effective operating conditions of the FLGR system by considering, along with the optimal distribution of the injected gas, the cost differential between natural gas and coal and the open-market price of NO_x emission credits. Further study, however, is necessary, including the construction of a more comprehensive database, needed to develop high-fidelity process models and to add carbon monoxide (CO) emissions to the model of the gas reburn system.     

Air Pollutant Emissions from Coal-Fired Power Plants,Report No. 2

The Public Health Service and the Bureau of Mines are conducting a joint study to evaluate a number of flue-gas-stream components from coal-burning power plants. Emissions of fly ash, sulfur oxides, nitrogen oxides, polynuclear hydrocarbons, total gaseous hydrocarbons, formaldehyde, certain metals, and carbon dioxide are determined. A previous paper covered air pollutant emissions from vertical-fired and front-wall-fired power plant boilers. This paper includes a comparative evaluation of emissions from a tangential-fired and a turbo-fired power plant boiler.     

The Mutagenic Activity of Particulate Organic Matter Collected with a Dilution Sampler at Coal-Fired Power Plants

The Deep Creek Lake Study of 1983 provided an opportunity to obtain emission samples from coal-fired power plants with a dilution sampler for mutagenicity testing. Stack and ambient samples of particulate matter were collected with a dilution sampler at three coal-fired power plants in West Virginia. Samples were sequentially extracted with cyclohexane (CX), dichloromethane (DCM) and acetone (ACE) and tested for mutagenicity in the Ames Salmonella/microsome assay using TA98 (-S9). For the stack samples, the CX, DCM and ACE fractions constituted 1.0, 0.7 and 98.1 percent of the total extractable organic material (EOM), respectively, compared to 28.5, 7.4 and 64.1 percent for the ambient samples. In contrast, the mutagenic activity of the organic fractions was concentrated in the CX and DCM fractions.

The cyclohexane- and dichloromethane-soluble fractions of the stack samples from all locations exhibited mutagenicity when tested in the plate incorporation assay. No significant response was observed with the acetone fraction. When tested with Kado's modification of the preincubation assay, the acetone-soluble fraction did exhibit mutagenic activity comparable to that of the other fractions when expressed in units of revertants per milligram of particular matter. Chemical analyses of one of the acetone-soluble fractions indicated that half of the mass was sulfuric acid while the remainder consisted of C, H and O. More than 30 peaks were detected in the high pressure liquid chromatogram of this fraction.

Although little mutagenic activity was detected in the polar ACE fraction of the diluted stack emissions samples with this single bioassay, in view of the large mass of this fraction, further investigation of the chemical composition and genotoxic activity of this fraction would be prudent.     

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.     

Air Quality Impact of the Coal-Fired Power Plants in the Northern Passageway of the China West-East Power Transmission Project

Abstract

This paper analyzes the air quality impacts of coal-fired power plants in the northern passageway of the West-East Power Transmission Project in China. A three-layer Lagrangian model called ATMOS, was used to simulate the spatial distribution of incremental sulfur dioxide (SO₂) and coarse particulate matter (PM₁₀) concentrations under different emission control scenarios. In the year 2005, the emissions from planned power plants mainly affected the air quality of Shanxi, Shaanxi, the common boundary of Inner Mongolia and Shanxi, and the area around the boundary between Inner Mongolia and Ningxia. In these areas, the annually averaged incremental SO₂ and PM₁₀ concentrations exceed 2 and 2.5 µg/m3, respectively. The maximum increases of the annually averaged SO₂ and PM₁₀ concentrations are 8.3 and 7.2 µg/m³, respectively, which occur around Hancheng city, near the boundary of the Shaanxi and Shanxi provinces. After integrated control measures are considered, the maximum increases of annually averaged SO₂ and PM₁₀ concentrations fall to 4.9 and 4 µg/m³, respectively. In the year 2010, the areas affected by planned power plants are mainly North Shaanxi, North Ningxia, and Northwest Shanxi. The maximum increases of the annually averaged SO₂ and PM₁₀ concentrations are, respectively, 6.3 and 5.6 µg/m³, occurring in Northwest Shanxi, which decline to 4.4 and 4.1 µg/m³ after the control measures are implemented. The results showed that the proposed power plants mainly affect the air quality of the region where the power plants are built, with little impact on East China where the electricity will be used. The influences of planned power plants on air quality will be decreased greatly by implementing integrated control measures.     

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.     

Mercury Mass Balances: A Case Study of Two North Dakota Power Plants

ABSTRACT

The Energy & Environmental Research Center (EERC) conducted a mercury-sampling program to provide data on the quantity and forms of Hg emitted and on the Hg removal efficiency of the existing air pollution control devices at two North Dakota power plants—Milton R. Young Station and Coal Creek Station. Minnkota Power Cooperative, Great River Energy, the North Dakota Industrial Commission, and EPRI funded the project. The primary objective was to obtain accurate measurements of Hg released from each plant, as verified by a material balance. A secondary objective was to evaluate the ability of a mercury continuous emission monitor (CEM) to measure total Hg at the stack.

At both plants, speciated Hg measurements were made at the inlets and outlets of both the electrostatic precipi-tators (ESPs) and the flue gas desulfurization (FGD) systems. A Semtech Hg 2000 (Semtech Metallurgy AB) mercury CEM was used to measure the total Hg emissions at the stack in real time. Using these measurements and plant data, the measured Hg concentrations in the coal, FGD slurries, and ESP ash, a Hg mass flow rate was calculated at each sampling location. Excellent Hg mass balances were obtained (±15%). It was also found that the Hg was mostly in the elemental phase (~90%), and the small amount of oxidized Hg that was generated was removed by the FGD systems.

Insignificant amounts of particulate-bound Hg were measured at both plants. However, 10-20% of the elemental Hg measured prior to the ESP was converted to oxidized Hg across the ESP. The data show that, at these facilities, almost all of the Hg generated is being emitted into the atmosphere as elemental Hg. Local or regional deposition of the Hg emitted from these plants is not a concern. However, the Hg does become part of the global Hg burden in the atmosphere. Also, the evidence appears to indicate that elemental Hg is more difficult to remove from flue gas than oxidized Hg is.     

Low Concentration Mercury Sorption Mechanisms and Control by Calcium-Based Sorbents: Application in Coal-Fired Processes

ABSTRACT

The capture of elemental mercury (Hg⁰) and mercuric chloride (HgCl₂) by three types of calcium (Ca)-based sor-bents was examined in this bench-scale study under conditions prevalent in coal-fired utilities. Ca-based sorbent performances were compared with that of an activated carbon. Hg⁰ capture of about 40% (nearly half that of the activated carbon) was achieved by two of the Ca-based sorbents. The presence of sulfur dioxide (SO₂) in the simulated coal combustion flue gas enhanced the Hg⁰ capture from about 10 to 40%. Increasing the temperature in the range of 65-100 °C also caused an increase in the Hg⁰ capture by the two Ca-based sorbents. Mercuric chloride (HgCl₂) capture exhibited a totally different pattern. The presence of SO₂ inhibited the HgCl₂ capture by Ca-based sorbents from about 25 to less than 10%. Increasing the temperature in the studied range also caused a decrease in HgCl₂ capture. Upon further pilot-scale confirmations, the results obtained in this bench-scale study can be used to design and manufacture more cost-effective mercury sorbents to replace conventional sorbents already in use in mercury control.