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.     

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 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.     

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.     

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.     

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     

The Fate and Behavior of Mercury in Coal-Fired Power Plants

Abstract

For the past 22 years in the Netherlands, the behavior of Hg in coal-fired power plants has been studied extensively. Coal from all over the world is fired in Dutch power stations. First, the Hg concentrations in these coals were measured. Second, the fate of the Hg during combustion was established by performing mass balance studies. On average, 43 ± 30% of the Hg was present in the flue gases downstream of the electrostatic precipitator (ESP; dust collector). In individual cases, this figure can vary between 1 and 100%. Important parameters are the Cl content of the fuel and the flue gas temperature in the ESP. On average, 54 ± 24% of the gaseous Hg was removed in the wet flue-gas desulfurization (FGD) systems, which are present at all Dutch coal-power stations. In individual cases, this removal can vary between 8% (outlier) and 72%.

On average, the fate of Hg entering the power station in the coal was as follows: <1% in the bottom ash, 49% in the pulverized fuel ash (ash collected in the ESP), 16.6% in the FGD gypsum, 9% in the sludge of the wastewater treatment plant, 0.04% in the effluent of the wastewater treatment plant, 0.07% in fly dust (leaving the stack), and 25% as gaseous Hg in the flue gases and emitted into the air. The distribution of Hg over the streams leaving the FGD depends strongly on the installation. On average, 75% of the Hg was removed, and the final concentration of Hg in the emitted flue gases of the Dutch power stations was only ~3 μg/m_STP ³ at 6% O₂. During co-combustion with biomass, the removal of Hg was similar to that during 100% coal firing.

Speciation of Hg is a very important factor. An oxidized form (HgCl₂) favors a high degree of removal. The conversion from Hg⁰ to HgCl₂ is positively correlated with the Cl content of the fuel. A catalytic DENOX (SCR) favors the formation of oxidized Hg, and, in combination with a wet FGD, the total removal can be as high as 90%.     

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     

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.     

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.     

Filtration CharacteristicsOf Fly Ash from a Pulverized Coal-Fired Power Plant

The operating characteristics of a pilot baghouse and the filtering characteristics of fly ash filtered from the flue gas of a pulverized coal-fired power plant were studied by techniques developed in the engineering research laboratories of the National Center for Air Pollution Control in Cincinnati. The permeability of the dust cake varied with the operating conditions of the baghouse in a way that significantly affects the pressure drop and power requirements of the system.     

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.     

Atmospheric Sulfates from Biological Sources

Bacteriogenic production of H₂S occurs in fine-grained anoxic muds, is promoted by organic and nutrient pollution of water, peaks in the warm months of the year, and is the source of most of the estimated 100 to 200 million tons of biogenic sulfur annually contributed to the global atmosphere. We tested the hypothesis that biogenic sulfur contributes to the atmospheric load of sulfate in urban and nonurban sites by statistical analyses of the 24 hour sulfate levels measured in 4 coastal and 3 Inland nonurban sites where pollutant sulfur dioxide emissions are absent or negligible, and in 8 coastal and 10 inland urban sites, all located in New England or Middle Atlantic states.

Comparisons of annual and seasonal mean sulfate levels show that in nonurban groups summertime sulfate levels significantly exceed wintertime levels, and in summer, sulfate levels in urban sites are nearly the same as in nonurban sites. Comparisons of group sulfate means in 4 New York cities near extended bodies of polluted water with those in 10 inland upstate New York cities show significantly higher levels in the cities near polluted water in spring, summer, and fall and for the year as a whole, but not in winter, when the levels were similar. When the nonurban and urban sites are grouped for proximity to coasts (where bacterial sulfate reduction is active in sediments) paired groups of coastal and inland urban and nonurban sites show no significant differences in sulfate levels in summer and fall.

Studies of the summertime sulfate means in New York state show no evidence of an elevated anthropogenic background which could explain the high summertime sulfate level observed in one nonurban site in that state, while analyses of the day to day fluctuations in urban and nonurban sites support the conclusion that nonurban sites have large local (biogenic) sulfate sources in summer and fall, and that local sulfate sources also exist in spring and may exist in winter.

We conclude that biogenic sulfate sources contribute most of the sulfate observed in the cities studied during summer and fall, and in some cities also contribute in other seasons. These biogenic contributions vary with local conditions and are estimated to contribute up to 6 µg/m³ (50%) or more to the annual geometric mean sulfate levels observed in some cities located near extensive bodies of polluted water.     

Characterization of Particulates from Power Plants

The emphasis on participate control from industrial processes has been shifted recently towards fine particulates, having diameters less than 3 microns. There exists an urgent need for more scientific information of fine particle characterization.^1,2 Coal and oil fired power plants are among the largest anthropogenic point sources of particulate matter.³ Limited knowledge is available on particle size distribution and trace metal composition in power plant emissions.^4-7 The morphological properties of particle emissions have been largely neglected. In this report we present some information on particle characteristics for an oil-fired and coal-fired power plant.     

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.     

Assessment of Human Exposure to Ambient Particulate Matter

ABSTRACT

Recent epidemiological studies have consistently shown that the acute mortality effects of high concentrations of ambient particulate matter (PM), documented in historic air pollution episodes, may also be occurring at the low to moderate concentrations of ambient PM found in modern urban areas. In London in December 1952, the unexpected deaths due to PM exposure could be identified and counted as integers by the coroners. In modern times, the PM-related deaths cannot be as readily identified, and they can only be inferred as fractional average daily increases in mortality rates using sophisticated statistical filtering and analyses of the air quality and mortality data. The causality of the relationship between exposure to ambient PM and acute mortality at these lower modern PM concentrations has been questioned because of a perception that there is little significant correlation in time between the ambient PM concentrations and measured personal exposure to PM from all sources (ambient PM plus indoor-generated PM).

This article shows that the critical factor supporting the plausibility of a linear PM mortality relationship is the expected high correlation in time of people's exposure to PM of ambient origin with measured ambient PM concentrations, as used in the epidemiological time series studies. The presence of indoor and personal sources of PM masks this underlying relationship, leading to confusion in the scientific literature about the strong underlying temporal relationship between personal exposure to PM of ambient origin and ambient PM concentration. The authors show that the sources of PM of non-ambient origin operate independently of the ambient PM concentrations, so that the mortality effect of non-ambient PM, if any, must be independent of the effects of the ambient PM exposures.     

A Simplified Technique Used to Evaluate Atmospheric Dispersion of Emissions from Large Power Plants

A simplified method which is used by the Tennessee Valley Authority to estimate ambient concentrations of atmospheric emissions from its large power plants is presented. The technique requires the use of three nomogrdms for the rapid graphic solution of three dispersion models—coning, inversion breakup, and trapping. A discussion of the meteorological conditions that are associated with these dispersion models, supporting appendices, and a worked example are also presented.