Circulating Dry Scrubbers (CDS)€¦ · Boiler 115 MW Fuel Bituminous Coal S-Content in Coal 2.9%...
Transcript of Circulating Dry Scrubbers (CDS)€¦ · Boiler 115 MW Fuel Bituminous Coal S-Content in Coal 2.9%...
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ONE SOURCE ● ONE PURPOSE ● MANY SOLUTIONS
Circulating Dry Scrubbers (CDS)
Webinar Presentation2012 Mid-Atlantic Regional Air Management Association
SO2/HCl Control Technology July 19, 2012
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Agenda
A. U.S. EPA Standards & Rules
B. Circulating Dry Scrubbers
-Technology
-Experience
-Performance
C. Summary
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Agenda
A. U.S. EPA Standards & Rules
B.B.B. Circulating Dry Scrubbers Circulating Dry Scrubbers Circulating Dry Scrubbers
---TechnologyTechnologyTechnology
---ExperienceExperienceExperience
---PerformancePerformancePerformance
C.C.C. SummarySummarySummary
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U.S. EPA Standard & Rules
• Cross State Air Pollution Rule
(CSAPR)
• Mercury and Air Toxic Standards
(MATS)
• New Source Review Program
U.S. EPA Standards & Rules
1970 Clean Air Act
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Cross State Air Pollution Rules
• SO2 contributes to PM2.5,
NOx contributes to Ozone
• 27 upwind states must meet state
by state allocations
• EPA has developed database of
power stations and required
reductions of SO2 and NOx
U.S. EPA Standards & Rules
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*>8300 Btu/lb Moist and mineral matter free
0.0002 lb/GWh0.40 lb/GWh0.007 lb/MWhNew coal firing not
low rank virgin
coal*
1.2 lb/E12 Btu
(0.013 lb/GWh)
0.0020 lb/E06 Btu
(0.020 lb/MWh)
0.030 lb/E06 Btu
(0.30 lb/MWh)
Existing coal firing
not low rank virgin
coal*
MercuryHydrogen Chloride
Filterable
Particulate Matter
EGU
Subcategory
1 lb/E06 Btu * E06 Btu/1,000,000 Btu * 10,000 Btu/kWh * 1,000 kWh/MWh = 10 lb/MWh
1 lb/E12 Btu * E06 Btu/1x1012 Btu * 10,000 Btu/kWh * 1x106 kWh/GWh = 0.01 lb/GWh
Mercury & Air Toxic Standards
U.S. EPA Standards & Rules
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New Source Review Program
U.S. EPA Standards & Rules
• SO2, NOx, CO, Particulate, HAPS,
Green House Gases
• Best Available Control Technology
• PM, PM2.5, PM10, Condensable PM
– Condensables measured using
Method 202 mostly affecting PM2.5
– Proposed revision: Condensables not
included in PM, but in PM2.5 & PM10.
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U.S. EPA Standards & Rules
Andracsek. R. The Air is Getting Cleaner, Power Engineering, June 2012.
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Agenda
A.A.A. U.S. EPA Standards & RulesU.S. EPA Standards & RulesU.S. EPA Standards & Rules
B. Circulating Dry Scrubbers
-Technology
---ExperienceExperienceExperience
---PerformancePerformancePerformance
C.C.C. SummarySummarySummary
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SO2 95 – 98 %
SO3 95 – 99 %
HCl 95 – 99 %
HF 95 – 99 %
Mercury 90 – 95 %
Coals up to 6 lbs of SO2/E06Btu
SO2 down to 0.03 lb/E06Btu
Reduces Condensables
Emissions Summary
Circulating Dry Scrubbers
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( )( )
( )( ) OHCaFOHCaHF
OHCaClOHCaHCl
OHCaSOOHCaSO
OHCaSOOHCaOSO
OHCaSOOHCaSO
222
222
2423
24222
2322
22
22
)(
½
+→++→++→+
+→+++→+
CHEMISTRY
Circulating Dry Scrubbers
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Process
Circulating Dry Scrubbers
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Circulating Dry Scrubbers
Flue Gas (From Air Heater/ID Fans)
Control Damper
Turbosorp®
Fabric Filter
Air Slide
Surge Bin
Stack
Ash Disposal
Hydrated Lime Silo
Hydrated Lime Blower(s)
Process Water Tank
Process Water Pump(s)
SO2
F
T
∆P
L
ID / Booster Fan
Air SlideBlower
SO2
P
OUTLET SO2 CONTROL LOOP
f(x)
CONTROL PARAMETERS:- Feed Forward Inlet SO2 and Flue Gas Flow- Feedback trim Outlet SO2
- Controls Lime Injection Rate- Percent Removal or Outlet Concentration
BOILER LOAD TURNDOWN CONTROL LOOP
CONTROL PARAMETERS:- Direct control outlet flue gas flow- Maintains minimum required velocity through
Venturi- Controls damper position
OUTLET FLUE GAS TEMPERATURE (APPROACH TO SATURATION) CONTROL LOOP
CONTROL PARAMETERS:- Direct control outlet flue gas temperature- Maintains approach temperature regardless of
reagent demand by adjusting water injection rate
REACTOR BED DENSITY CONTROL LOOP
CONTROL PARAMETERS:- Direct control of the bed density / pressure loss
through reactor- Maintains bed density by product recirculation
PRODUCT DISCHARGE / AIR SLIDE LEVEL CONTROL LOOP
CONTROL PARAMETERS:- Direct control of air slide air pressure- Level alarms to ensure proper operation- Discharge rate maintains product level within air
slide
f(x)
Process Control
Reactor
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Internal Solids Recirculation Enhances Reactions
Flue Gas and Solids Path Diagram
High Solids Recirculation
Turbulent Reactor Mixing
No Slurry Handling
Circulating Dry Scrubbers
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CaSO ½ H O3 2
Ca(OH)2
CaSO ½ H O3 2
Ca(OH)2
CaSO ½ H O3 2
Ca(OH)2
Formation of reaction
products layer
Reactivation of Reacted Sorbent
Circulating Dry Scrubbers
Reaction after
first pass
Water added to
surface during
recirculation
Sulfite crystal
forms, exposing
fresh surfaces
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Circulating Dry Scrubbers
• Turbulent Mixing in Reactor
– High flue gas solid contact
– Internal reactor solid recirculation
– No flue gas sneakage
– High apparent reactor stoichiometry
Features
• High Solids Circulation
– Reactor solids rewetting
– Secondary Removals with Fabric Filter
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Circulating Dry Scrubbers
• Construction
– Mild Steel
– Modular
– Dry Stack
• Water Injected Separately
– No slurries
– No limit on hydrated lime injection rate
– No waste water
Features (continued)
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Agenda
A.A.A. U.S. EPA Standards & RulesU.S. EPA Standards & RulesU.S. EPA Standards & Rules
B. Circulating Dry Scrubbers
---TechnologyTechnologyTechnology
-Experience
---PerformancePerformancePerformance
C.C.C. SummarySummarySummary
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Suppliers
• Graf-Wulff
• Allied Environmental
• Alstom Novel Integrated Desulfurization
• Babcock Power Environmental
– Turbosorp® Circulating Dry Scrubber
– Licensee to Austrian Energy & EnvironmentFor North American Coal-Fired Applications
CDS Experience
Buecker B., Hovey, L. Circulating Dry Scrubbers: A New Wave in FGD?, Power Engineering, November 2011.
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•Systems have been operating since 1994
•60 CDS systems in Europe
– 34 units on coal
•14 CDS projects in China
•24 CDS projects in the U.S.
•Five Turbosorp® CDS Coal-fired Systems
Operating in the U.S.
World Wide Experience
CDS Experience
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AES Greenidge Turbosorp®
Dresden, NY
Boiler 115 MW
Fuel Bituminous Coal
S-Content in Coal 2.9%
By-Product Stabilized Product
Volume Flow 277,800 SCFM
SO2 Inlet 2,100 ppmv
SO2 Removal > 95 %
Startup 2006
Design Data Turbosorp ®
Absorber Vessel
Baghouse
Lime Hydration
System
Quicklime Silo
~0.4 acre
Booster Fan
Turbosorp ®
Absorber Vessel
Baghouse
Lime Hydration
System
Quicklime Silo
~0.4 acre~0.4 acre
Booster Fan
CDS Experience
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CDS Experience
Roquette Turbosorp®
Keokuk, Iowa
Design Data
Boiler: 80 MW CFB boiler
Fuel: Coal+ pet coke
Flue gas capacity: 210,000 SCFM
SO2 concentration: 400 ppmv
SO2 Removal: > 90%
Sorbent: Carryover from CFB boiler
Start-up: 2007
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CDS Experience
AES Westover Turbosorp®
Johnson City, NY
• Boiler 90 MW
• Fuel Bituminous coal
• S-Content in coal 2.2 %
• By-product Stabilized product
• Volume flow 258,300 SCFM
• SO2 inlet 650 ppmv dry @ 6%O 2
• SO2 removal > 95 %
• Startup 2008
Design Data
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CDS Experience
First Light – Mount Tom Turbosorp®
Holyoke, MA
Boiler 155 MW
Fuel Bituminous Coal
S-Content in Coal 1.5 %
By-Product Stabilized Product
Volume Flow 452,950 SCFM
SO2 Inlet 1,300 ppmv
SO2 Removal > 95 %
Startup 2009
Design Data
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CDS Experience
Gainesville Regional Utilities
Deerhaven Turbosorp®
Gainesville, FL
Boiler 238 MW
Fuel Bituminous Coal
S-Content in Coal 1.5 %
By-Product Stabilized Product
Volume Flow 584,600 SCFM
SO2 Inlet 1,450 ppmv
SO2 Removal > 95 %
Startup 2009
Design Data
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Agenda
A.A.A. U.S. EPA Standards & RulesU.S. EPA Standards & RulesU.S. EPA Standards & Rules
B. Circulating Dry Scrubbers
---TechnologyTechnologyTechnology
---ExperienceExperienceExperience
-Performance
C.C.C. SummarySummarySummary
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75
80
85
90
95
100
0.0 1.0 2.0 3.0 4.0 5.0 6.0Inlet SO 2 (lb/E06 Btu)
SO
2 R
emov
al (
%)
Existing EGUNew EGUMeasured Removal
EPA MATS
Turbosorp® SO2 Removal
Compared to EPA MATS
CDS Performance
Ake, T. et. al. Measured Particulate, HCl, and Hg Emissions from Circulating Dry Scrubbers Compared to the EPA Mercury Air Toxic Standards,
To be presented at AWMA MegaSymposium, Baltimore MD, August 2012.
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0.00
0.50
1.00
1.50
2.00
3.0 3.5 4.0 4.5 5.0Inlet SO 2 (lb/E06 Btu)
Sta
ck S
O2
(lb/M
Wh)
New-EGU EPA MATS Limit
U.S. DOE CDS Parametric Tests * >95% SO2 Removal
Existing-EGU EPA MATS Limit
* Connell, D. Greenidge Multi-pollutant Control - Project Final Report. U.S. DOE Coop. Agreement DE-FC26-06NT41426, April 2009.
Turbosorp® SO2 Emissions
Compared to EPA MATS
CDS Performance
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Turbosorp® Acid Gas Removal
Compared to EPA MATS
75
80
85
90
95
100
0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10Inlet (lb/E06 Btu)
Rem
oval
(%
)
Existing EGUNew EGUHClSO3HF
EPA MATS - HCl
Average SO 2
Removal = 96%
Outlet measurements below detection
Both Inlet & Outlet measurements below detection
CDS Performance
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CDS Performance
Turbosorp® HCl Emissions
Compared to EPA MATS
0.0000
0.0020
0.0040
0.0060
0.0080
0.0100
0.0120
0.0140
0.0160
0.0180
0.0200
0.000 0.010 0.020 0.030 0.040 0.050 0.060
Inlet HCl (lb/E06 Btu)
Sta
ck H
Cl (
lb/M
Wh)
New-EGU EPA MATS Limit
Outlet measurements below detection
U.S. DOE CDS Parametric Tests* SO2 Removal > 95%
Existing-EGU EPA MATS Limit
* Connell, D. Greenidge Multi-pollutant Control - Project Final Report. U.S. DOE Coop. Agreement DE-FC26-06NT41426, April 2009.
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Turbosorp® PM Emission Data
Compared to EPA MATS
0.000
0.005
0.010
0.015
0.020
0.025
0.030
1 2 3 4
Power Station Number
Total PM*
Filterable
0.000
0.005
0.010
0.015
0.020
0.025
0.030
EPAMATS
FilterablePM Limit
Em
issi
on (
lb/E
06 B
tu)
Existing EGU
New EGU
* Includes condensables
CDS Performance
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Filterable Particulate Emission Data
Figure from U.S.DOE Report*
*Connell, D. Greenidge Multi-pollutant Control - Project Final Report. U.S. DOE Coop. Agreement DE-FC26-06NT41426, April 2009.
Note logarithmic scale.One standard deviation error bar = 0.00011 lb/E06 Btu is shown.
Existing-EGU EPA MATS limit
New-EGU EPA MATS limit0.00074
Average stack emission value shown for 59 particulate measurements for a Turbosorp ® CDS.
CDS Performance
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Hg Removal Data
CDS Performance
75
80
85
90
95
100
0.0 5.0 10.0 15.0 20.0Inlet Hg (lb/E12 Btu)
Hg
Rem
oval
(%
)
Existing EGU
New EGU
Performance Tests
U.S. DOE Parametric Tests
EPA MATS
Average SO 2 Removal = 96%
Outlet measurements below detection limit
w/ Activated Carbon
(others w/o)
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Agenda
A.A.A. U.S. EPA Standards & RulesU.S. EPA Standards & RulesU.S. EPA Standards & Rules
B.B.B. Circulating Dry Scrubbers Circulating Dry Scrubbers Circulating Dry Scrubbers
---TechnologyTechnologyTechnology
---ExperienceExperienceExperience
---PerformancePerformancePerformance
C. Summary
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Summary
Turbosorp® CDSremoves:
SO2
HCl
SO3 & HF
Hg
Filterable Particulate
Condensable Particulate
���� No waste-water
U.S. EPA
Programs:
CSAPR
MATS
NSR
(c) 2012 Babcock Power, All rights reservedSlide 36