Reaction behavior of SO2 in the sintering process with flue gas recirculation

The primary goal of this paper is to reveal the reaction behavior of SO₂ in the sinter zone, combustion zone, drying–preheating zone, and over-wet zone during flue gas recirculation (FGR) technique. The results showed that SO₂ retention in the sinter zone was associated with free-CaO in the form of CaSO₃/CaSO₄, and the SO₂ adsorption reached a maximum under 900ºC. SO₂ in the flue gas came almost from the combustion zone. One reaction behavior was the oxidation of sulfur in the sintering mix when the temperature was between 800 and 1000ºC; the other behavior was the decomposition of sulfite/sulfate when the temperature was over 1000ºC. However, the SO₂ adsorption in the sintering bed mainly occurred in the drying–preheating zone, adsorbed by CaCO₃, Ca(OH)₂, and CaO. When the SO₂ adsorption reaction in the drying–preheating zone reached equilibrium, the excess SO₂ gas continued to migrate to the over-wet zone and was then absorbed by Ca(OH)₂ and H₂O. The emission rising point of SO₂ moved forward in combustion zone, and the concentration of SO₂ emissions significantly increased in the case of flue gas recirculation (FGR) technique.

Implications: Aiming for the reuse of the sensible heat and a reduction in exhaust gas emission, the FGR technique is proposed in the iron ore sintering process. When using the FGR technique, SO₂ emission in exhaust gas gets changed. In practice, the application of the FGR technique in a sinter plant should be cooperative with the flue gas desulfurization (FGD) technique. Thus, it is necessary to study the influence of the FGR technique on SO₂ emissions because it will directly influence the demand and design of the FGD system.     

Eliminating Reheat from Existing FGD Systems

The Clean Air Act Amendments of the early 1970_s required coal burning utilities to reduce their emissions of sulfur dioxide. Lime or limestone based wet systems were employed for flue gas desulfurization (FGD). These systems reduced flue gas temperatures to below acid dew point conditions. Concerned about the prospect of ductwork exposed to a saturated, acid-rich environment, most utilities turned to stack gas reheat (SGR) to increase flue gas temperatures. By 1980, 82 percent of all FGD facilities employed SGR. Today there are about 130 FGD systems of which 101 employ some form of stack gas reheat.     

Environmental Irradiation Test Facility

Results from a detailed analysis of sulfur dioxide (SO₂) reductions achievable through “deep” physical coal cleaning (PCC) at 20 coal-fired power plants in the Ohio-Indiana-Illinois region are presented here. These plants all have capacities larger than 500 MWe, are currently without any flue gas desulfurization (FGD) systems, and burn coal of greater than l%sulfur content (in 1980). Their aggregate emissions of 2.4 million tons of SO₂ per year represents 55% of the SO₂ inventory for these states. The principal coal supplies for each power plant were identified and characterized as to coal seam and county of origin, so that published coal-washability data could be matched to each supplier. The SO₂ reductions that would result from deep cleaning each coal (Level 4) were calculated using an Argonne computer model that assumes a weight recovery of 80%. Percentage reductions in sulfur content ranged from zero to 52%, with a mean value of 29%, and costs ranged from a low of $364/ton SO₂ removed to over $2000/ton SO₂ removed. Because coal suppliers to these power plants employ some voluntary coal cleaning, the anticipated emissions reduction from current levels should be near 20%. Costs then were estimated for FGD systems designed to remove the same amount of SO₂ as was achieved by PCC through the use of partial scrubbing with bypass of the remaining flue gas. On this basis, PCC was more cost-effective than FGD for about 50% of the plants studied and had comparable costs for another 25% of the plants. Possible governmental actions to either encourage or mandate coal cleaning were identified and evaluated     

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.     

Simplified Models of U.S. Acid Rain Control Costs

Simplified algorithms are presented for estimating the cost of controlling sulfur dioxide (SO₂) emissions from existing coal-fired power plants on a state-by-state basis. Results are obtained using the detailed Utility Control Strategy Model (UCSM) to calculate the Impacts of emission reductions ranging from approximately 30 percent to 90 percent of projected 1995 emissions for 18 different scenarios and 36 states. Scenarios include the use of two dry SO₂ removal technologies (lime spray dryers and LIMB) as potential options for power plant retrofit, in addition to currently available emission control options including coal switching, coal cleaning and wet flue gas desulfurization (FGD). Technical assumptions relating to FGD system performance and the upgrading of existing cold-side electrostatic precipitators (ESP) for reduced sulfur levels are also analyzed, along with the effects of interest rates, coal prices, coal choice restrictions, plant lifetime, and plant operating levels. Results are summarized in the form of a 3-term polynomial equation for each state, giving total annualized SO₂ control cost as a function of the total SO₂ emissions reduction for each scenario. Excellent statistical fits to UCSM results are obtained for these generalized equations.     

Modeling and optimization of wet flue gas desulfurization system based on a hybrid modeling method

Sulfur dioxide (SO₂) is one of the main air pollutants from many industries. Most coal-fired power plants in China use wet flue gas desulfurization (WFGD) as the main method for SO₂ removal. Presently, the operating of WFGD lacks accurate modeling method to predict outlet concentration, let alone optimization method. As a result, operating parameters and running status of WFGD are adjusted based on the experience of the experts, which brings about the possibility of material waste and excessive emissions. In this paper, a novel WFGD model combining a mathematical model and an artificial neural network (ANN) was developed to forecast SO₂ emissions. Operation data from a 1000-MW coal-fired unit was collected and divided into two separated sets for model training and validation. The hybrid model consisting a mechanism model and a 9-input ANN had the best performance on both training and validation sets in terms of RMSE (root mean square error) and MRE (mean relative error) and was chosen as the model used in optimization. A comprehensive cost model of WFGD was also constructed to estimate real-time operation cost. Based on the hybrid WFGD model and cost model, a particle swarm optimization (PSO)-based solver was designed to derive the cost-effective set points under different operation conditions. The optimization results demonstrated that the optimized operating parameters could effectively keep the SO₂ emissions within the standard, whereas the SO₂ emissions was decreased by 30.79% with less than 2% increase of total operating cost.

Implications: Sulfur dioxide (SO₂) is one of the main pollutants generated during coal combustion in power plants, and wet flue gas desulfurization (WFGD) is the main facility for SO₂ removal. A hybrid model combining SO₂ removal mathematical model with data-driven model achieves more accurate prediction of outlet concentration. Particle swarm optimization with a penalty function efficiently solves the optimization problem of WFGD subject to operation cost under multiple operation conditions. The proposed model and optimization method is able to direct the optimized operation of WFGD with enhanced emission and economic performance.     

Comparison of particle emissions from small heavy fuel oil and wood-fired boilers

Flue gas emissions of wood and heavy fuel oil (HFO) fired district heating units of size range 4–15 MW were studied. The emission measurements included analyses of particle mass, number and size distributions, particle chemical compositions and gaseous emissions. Thermodynamic equilibrium calculations were carried out to interpret the experimental findings.In wood combustion, PM1 (fine particle emission) was mainly formed of K, S and Cl, released from the fuel. In addition PM1 contained small amounts of organic material, CO₃, Na and different metals of which Zn was the most abundant. The fine particles from HFO combustion contained varying transient metals and Na that originate from the fuel, sulphuric acid, elemental carbon (soot) and organic material. The majority of particles were formed at high temperature (>800 °C) from V, Ni, Fe and Na. At the flue gas dew point (125 °C in undiluted flue gas) sulphuric acid condensed forming a liquid layer on the particles. This increases the PM1 substantially and may lead to partial dissolution of the metallic cores.Wood-fired grate boilers had 6–21-fold PM1 and 2–23-fold total suspended particle (TSP) concentrations upstream of the particle filters when compared to those of HFO-fired boilers. However, the use of single field electrostatic precipitators (ESP) in wood-fired grate boilers decreased particle emissions to same level or even lower as in HFO combustion. On the other hand, particles released from the HFO boilers were clearly smaller and higher in number concentration than those of wood boilers with ESPs. In addition, in contrast to wood combustion, HFO boilers produce notable SO₂ emissions that contribute to secondary particle formation in the atmosphere. Due to vast differences in concentrations of gaseous and particle emissions and in the physical and chemical properties of the particles, HFO and wood fuel based energy production units are likely to have very different effects on health and climate.     

Simulation of Stack Plume Opacity

ABSTRACT

The visual impact of primary particles emitted from stacks is regulated according to stack opacity criteria. In-stack monitoring of the flue gas opacity allows plant operators to ensure that the plant meets U.S. Environmental Protection Agency opacity regulations. However, the emission of condensable gases such as SO₃ (that hydrolyzes to H₂SO₄), HCl, and NH₃, which may lead to particle formation after their release from the stack, makes the prediction of stack plume opacity more difficult.

We present here a computer simulation model that calculates the opacity due to both primary particles emitted from the stack and secondary particles formed in the atmosphere after the release of condensable gases from the stack. A comprehensive treatment of the plume rise due to buoyancy and momentum is used to calculate the location at which the condensed water plume has evaporated (i.e., where opacity regulations apply).

Conversion of H₂SO₄ to particulate sulfate occurs through nucleation and condensation on primary particles. A thermodynamic aerosol equilibrium model is used to calculate the amount of ammonium, chloride, and water present in the particulate phase with the condensed sulfate. The model calculates the stack plume opacity due to both primary and secondary particles. Examples of model simulations are presented for three scenarios that differ by the emission control equipment installed at the power plant: (1) electrostatic precipitators (ESP), (2) ESP and flue gas desulfurization, and (3) ESP and selective catalytic reduction. The calculated opacity is most sensitive to the primary particulate emissions. For the conditions considered here, SO₃ emissions showed only a small effect, except if one assumes that most H₂SO₄ condenses on primary particles. Condensation of NH₄Cl occurs only at high NH₃ emission rates (about 25 ppm stack concentration).     

The study on biomass fraction estimate methodology of municipal solid waste incinerator in Korea

In Korea, the amount of greenhouse gases released due to waste materials was 14,800,000 t CO₂eq in 2012, which increased from 5,000,000 t CO₂eq in 2010. This included the amount released due to incineration, which has gradually increased since 2010. Incineration was found to be the biggest contributor to greenhouse gases, with 7,400,000 t CO₂eq released in 2012. Therefore, with regards to the trading of greenhouse gases emissions initiated in 2015 and the writing of the national inventory report, it is important to increase the reliability of the measurements related to the incineration of waste materials.

This research explored methods for estimating the biomass fraction at Korean MSW incinerator facilities and compared the biomass fractions obtained with the different biomass fraction estimation methods. The biomass fraction was estimated by the method using default values of fossil carbon fraction suggested by IPCC, the method using the solid waste composition, and the method using incinerator flue gas.

The highest biomass fractions in Korean municipal solid waste incinerator facilities were estimated by the IPCC Default method, followed by the MSW analysis method and the Flue gas analysis method. Therefore, the difference in the biomass fraction estimate was the greatest between the IPCC Default and the Flue gas analysis methods. The difference between the MSW analysis and the flue gas analysis methods was smaller than the difference with IPCC Default method. This suggested that the use of the IPCC default method cannot reflect the characteristics of Korean waste incinerator facilities and Korean MSW.

Implications: Incineration is one of most effective methods for disposal of municipal solid waste (MSW). This paper investigates the applicability of using biomass content to estimate the amount of CO₂ released, and compares the biomass contents determined by different methods in order to establish a method for estimating biomass in the MSW incinerator facilities of Korea. After analyzing the biomass contents of the collected solid waste samples and the flue gas samples, the results were compared with the Intergovernmental Panel on Climate Change (IPCC) method, and it seems that to calculate the biomass fraction it is better to use the flue gas analysis method than the IPCC method. It is valuable to design and operate a real new incineration power plant, especially for the estimation of greenhouse gas emissions.     

Carbon dioxide emission tallies for 210 U.S. coal-fired power plants: A comparison of two accounting methods

Annual CO₂ emission tallies for 210 coal-fired power plants during 2009 were more accurately calculated from fuel consumption records reported by the U.S. Energy Information Administration (EIA) than measurements from Continuous Emissions Monitoring Systems (CEMS) reported by the U.S. Environmental Protection Agency. Results from these accounting methods for individual plants vary by ± 10.8%. Although the differences systematically vary with the method used to certify flue-gas flow instruments in CEMS, additional sources of CEMS measurement error remain to be identified. Limitations of the EIA fuel consumption data are also discussed. Consideration of weighing, sample collection, laboratory analysis, emission factor, and stock adjustment errors showed that the minimum error for CO₂ emissions calculated from the fuel consumption data ranged from ± 1.3% to ± 7.2% with a plant average of ± 1.6%. This error might be reduced by 50% if the carbon content of coal delivered to U.S. power plants were reported.

Implications:

Potentially, this study might inform efforts to regulate CO₂ emissions (such as CO₂ performance standards or taxes) and more immediately, the U.S. Greenhouse Gas Reporting Rule where large coal-fired power plants currently use CEMS to measure CO₂ emissions. Moreover, if, as suggested here, the flue-gas flow measurement limits the accuracy of CO₂ emission tallies from CEMS, then the accuracy of other emission tallies from CEMS (such as SO₂, NO_x, and Hg) would be similarly affected. Consequently, improved flue gas flow measurements are needed to increase the reliability of emission measurements from CEMS.     

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.     

Total life cycle emissions of post-Panamax containerships powered by conventional fuel or natural gas

This study proposes an easy-to-apply method, the Total Life Cycle Emission Model (TLCEM), to calculate the total emissions from shipping and help ship management groups assess the impact on emissions caused by their capital investment or operation decisions. Using TLCEM, we present the total emissions of air pollutants and greenhouse gases (GHGs) during the 25-yr life cycle of 10 post-Panamax containerships under slow steaming conditions. The life cycle consists of steel production, shipbuilding, crude oil extraction and transportation, fuel refining, bunkering, and ship operation. We calculate total emissions from containerships and compare the effect of emission reduction by using various fuels. The results can be used to differentiate the emissions from various processes and to assess the effectiveness of various reduction approaches. Critical pollutants and GHGs emitted from each process are calculated. If the containerships use heavy fuel oil (HFO), emissions of CO₂ total 2.79 million tonnes (Mt), accounting for 95.37% of total emissions, followed by NO_x and SO_x emissions,which account for 2.25% and 1.30%, respectively.The most significant emissions are from the operation of the ship and originate from the main engine (ME).When fuel is switched to 100% natural gas (NG), SO_x, PM₁₀, and CO₂ emissions show remarkable reductions of 98.60%, 99.06%, and 21.70%, respectively. Determining the emission factor of each process is critical for estimating the total emissions. The estimated emission factors were compared with the values adopted by the International Maritime Organization (IMO).The proposed TLCEM may contribute to more accurate estimates of total life cycle emissions from global shipping.

Implications: We propose a total life cycle emissions model for 10 post-Panamax container ships. Using heavy fuel oil, emissions of CO₂ total 2.79 Mt, accounting for approximately 95% of emissions, followed by NO_x and SO_x emissions. Using 100% natural gas, SO_x, PM₁₀, and CO₂ emissions reduce by 98.6%, 99.1%, and 21.7%, respectively. NO_x emissions increase by 1.14% when running a dual fuel engine at low load in natural gas mode.     

Simultaneous removal of NOx,SO2, and Hg from flue gas in FGD absorber with oxidant injection (NaClO2)– full-scale investigation

ABSTRACT

This article presents the results of an industrial-scale study (on 400 MW_e lignite fired unit) of simultaneous NO_x, SO₂, and Hg^T removal in FGD absorber with oxidant injection (NaClO₂) into flue gas. It was confirmed that the injection of sodium chlorite upstream the FGD (Flue Gas Desulfurization) absorber oxidize NO to NO₂, Hg⁰ to Hg²⁺, and enhancing NO_x and Hg^T removal efficiency from exhaust gas in FGD absorber. Mercury removal efficiency grows with the rise of degree of oxidation NO to NO₂ and was limited by the phenomenon of re-emission. For NO_x removal the most critical parameters is slurry pH and temperature. There was no negative effect on sulfur dioxide removal efficiency caused by oxidant injection in tested FGD absorber. Based on the data provided, NO_x and Hg^T emissions can be reduced by adjusting the FGD absorber operating parameters combined with oxidant injection.     

PM2.5 chemical source profiles for vehicle exhaust, vegetative burning, geological material, and coal burning in Northwestern Colorado during 1995

PM_2.5 (particles with aerodynamic diameters less than 2.5 μm) chemical source profiles applicable to speciated emissions inventories and receptor model source apportionment are reported for geological material, motor vehicle exhaust, residential coal (RCC) and wood combustion (RWC), forest fires, geothermal hot springs; and coal-fired power generation units from northwestern Colorado during 1995. Fuels and combustion conditions are similar to those of other communities of the inland western US. Coal-fired power station profiles differed substantially between different units using similar coals, with the major difference being lack of selenium in emissions from the only unit that was equipped with a dry limestone sulfur dioxide (SO₂) scrubber. SO₂ abundances relative to fine particle mass emissions in power plant emissions were seven to nine times higher than hydrogen sulfide (H₂S) abundances from geothermal springs, and one to two orders of magnitude higher than SO₂ abundances in RCC emissions, implying that the SO₂ abundance is an important marker for primary particle contributions of non-aged coal-fired power station contributions. The sum of organic and elemental carbon ranged from 1% to 10% of fine particle mass in coal-fired power plant emissions, from 5% to 10% in geological material, >50% in forest fire emissions, >60% in RWC emissions, and >95% in RCC and vehicle exhaust emissions. Water-soluble potassium (K⁺) was most abundant in vegetative burning profiles. K⁺/K ratios ranged from 0.1 in geological material profiles to 0.9 in vegetative burning emissions, confirming previous observations that soluble potassium is a good marker for vegetative burning.     

Influence of sulfur dioxide-related interactions on PM2.5 formation in iron ore sintering

The formation of PM_2.5 (aerosol particulate matter less than 2.5 µm in aerodynamic diameter) in association with SO₂ emission during sintering process has been studied by dividing the whole sintering process into six typical sampling stages. A low-pressure cascade impactor was used to collect PM_2.5 by automatically segregating particulates into six sizes. It was found that strong correlation existed between the emission properties of PM_2.5 and SO₂. Wet mixture layer (overwetted layer and raw mixture layer) had the function to simultaneously capture SO₂ and PM_2.5 during the early sintering stages, and released them back into flue gas mainly in the flue gas temperature-rising period. CaSO₄ crystals constituted the main SO₂-related PM_2.5 during the disappearing process of overwetted layer, which was able to form perfect individual crystals or to form particles with complex chemical compositions. Besides the existence of individual CaSO₄ crystals, mixed crystals of K₂SO₄-CaSO₄ in PM_2.5 were also found during the first half of the temperature-rising period of flue gas. The interaction between fine-grained Ca-based fluxes, potassium vapors, and SO₂ was the potential source of SO₂-related PM_2.5.

Implications: The emission property of PM_2.5 and SO₂ throughout the sintering process exhibited well similarity. This phenomenon tightened the relationship between the formation of PM_2.5 and the emission of SO₂. Through revealing the properties of SO₂-related PM_2.5 during sintering process, the potential interaction between fine-grained Ca-based fluxes, potassium vapors, and SO₂ was found to be the source of SO₂-related PM_2.5. This information can serve as the guidance to develop efficient techniques to control the formation and emission of PM_2.5 in practical sintering plants.     

The Evolution of Particles in the Plume from a Large Coal-Fired Boiler with Flue Gas Desulfurization

ABSTRACT

Airborne measurements were made of gaseous and particulate species in the plume of a large coal-fired power plant after flue gas desulfurization (FGD) controls were installed. These measurements were compared with measurements made before the controls were installed. The light scattering and number and volume distributions of plume excess particles were determined by nephelometry and optical particle counting techniques. The plume impact based on optical techniques was much lower than that observed in earlier measurements. Indeed, plume excess volumes as a function of particle size were of the same magnitude as the variability of the background volume distribution. In situ excess plume scattering actually decreased with distance from the source, in contrast to pre-FGD conditions. The upper limit for the dry rate of SO₂-to-SO₄ ^2- conversion was estimated from plume excess volume measurements to be about 4% lir¹. This is slightly greater than the upper limit, 3.5% lir¹, estimated by earlier researchers, but the same as that estimated using the present technique with the earlier data. The cross-plume profile of volume suggests SO₂-to-SO₄ ^2- conversion is highest at the plume edges. The greatest benefit of SO₂ reduction on plume excess volume and visibility appears to occur far downwind of the source.     

Regional effects and efficiency of flue gas desulphurization in the Carpathian Basin

Although sulphur emissions (mainly as SO₂) have been continuously decreasing over the last 20 years in most western industrialized countries, localized SO₂ problems still exist in conjunction with strong local emission, meteorological, and topographical factors. In this study, the effect of supplementary installed flue gas desulphurization (FGD) units at high-capacity power plants on regional air pollution in the Carpathian Basin is investigated. The dispersion and accumulation of the SO₂ air pollutant are studied with the regional three-dimensional on-line atmosphere-chemistry model REMOTE. The changes in the SO₂ air pollution are investigated by parallel simulations in a case study, where the single modified parameter is the SO₂ emission rate. The results show that FGD units significantly reduce the horizontal and the vertical dispersion of the emitted SO₂, and its transboundary transport, too. Beside the SO₂ removal efficiency, the dispersion and accumulation also depend on the seasonal weather conditions. During winter, the dispersion and accumulation are higher than in other seasons. Due to this phenomenon, higher SO₂ removal efficiency is needed to guarantee similar air quality features like in the other seasons.     

Identification of sources of atmospheric PM at the Pittsburgh Supersite—Part III: Source characterization

Single-particle mass spectrometry data collected during the Pittsburgh Supersite experiment was used to isolate an episode on 27 October 2001 when the measurement site was primarily influenced by emissions from coal combustion sources. Results showed that (a) 60–80% of the particles detected during this event belonged to the Na/Si/K/Ca/Fe/Ga/Pb particle class associated with coal combustion emissions, (b) observation of this class was an isolated event occurring only during the hours of 06:00–14:00 EST, and (c) the detection of these particles was highly correlated with shifts in wind direction. Coincident SMPS, TEOM PM_2.5, SO₂, NO_x, and O₃ measurements were in excellent agreement with the single-particle results in terms of both identifying and characterizing this event. The three most likely point sources of these particles were isolated and Gaussian plume dispersion models were used in reverse to predict their particle number, particle mass, and gas phase emissions. Calculated mass emission rates were in general agreement with the US EPA National Emissions Inventory (NEI) database emissions estimates and the Title V PM₁₀ limit. The largest of the three sources emits about 2.4×10¹⁷ fine and ultrafine particles per second.     

Flue Gas Desulfurization: The State of the Art

ABSTRACT

Coal-fired electricity-generating plants may use SO₂ scrubbers to meet the requirements of Phase II of the Acid Rain SO₂ Reduction Program. Additionally, the use of scrubbers can result in reduction of Hg and other emissions from combustion sources. It is timely, therefore, to examine the current status of SO₂ scrubbing technologies. This paper presents a comprehensive review of the state of the art in flue gas desulfurization (FGD) technologies for coal-fired boilers.

Data on worldwide FGD applications reveal that wet FGD technologies, and specifically wet limestone FGD, have been predominantly selected over other FGD technologies. However, lime spray drying (LSD) is being used at the majority of the plants employing dry FGD technologies. Additional review of the U.S. FGD technology applications that began operation in 1991 through 1995 reveals that FGD processes of choice recently in the United States have been wet limestone FGD, magnesium-enhanced lime (MEL), and LSD. Further, of the wet limestone processes, limestone forced oxidation (LSFO) has been used most often in recent applications.

The SO₂ removal performance of scrubbers has been reviewed. Data reflect that most wet limestone and LSD installations appear to be capable of ~90% SO₂ removal. Advanced, state-of-the-art wet scrubbers can provide SO₂ removal in excess of 95%.

Costs associated with state-of-the-art applications of LSFO, MEL, and LSD technologies have been analyzed with appropriate cost models. Analyses indicate that the capital cost of an LSD system is lower than those of same capacity LSFO and MEL systems, reflective of the relatively less complex hardware used in LSD. Analyses also reflect that, based on total annualized cost and SO₂ removal requirements: (1) plants up to ~250 MW_e in size and firing low- to medium-sulfur coals (i.e., coals with a sulfur content of 2% or lower) may use LSD; and (2) plants larger than 250 MW_e and firing medium- to high-sulfur coals (i.e., coals with a sulfur content of 2% or higher) may use either LSFO or MEL.