Proprietary and Confidential APCAC September 2010© 2010 The Babcock & Wilcox Company. All rights reserved. .1
Pollution Control for Cement Kilns
APCAC September 6-9, 2010 Presenter: Paul J. WilliamsB&W Technical Fellow
Proprietary and Confidential APCAC September 2010
SO2 and HCl Removal
Presentation Topics
.2
Circulating Fluid Bed Dry Scrubber (CDS) Technology
Technology Comparisons
Wet FGD Technology
Dry FGD – Spray Dryer Absorber (SDA) Technology
© 2010 The Babcock & Wilcox Company. All rights reserved.
Environmental Regulations Review
Proprietary and Confidential APCAC September 2010
U. S. Cement MACT & NSPS Emission Limits
Pollutant Existing Kilns8/17/71 - 6/16/08
New Source KilnsAfter 6/16/08
HCl 5 mg/dry Nm3 @ 7% O2 5 mg/dry Nm3 @ 7% O2
SO2N/A
1-3 kg / Metric Tonne 0.2 kg / tonne
PM(10) 0.02 kg / Tonne 0.005 kg / Tonne
Major Source Definition = emits > 10 TPY of single HAP or > 25 TPY combined HAPs
Mass values based on tonne of clinkerEmissions based on 30 day rolling averagePM(10) is used as surrogate for toxic metals other than HgPM(10) = solid particulate (excludes condensables)
Proprietary and Confidential APCAC September 2010
SO2 and HCl Removal
Presentation Topics
.5
Circulating Dry ScrubberTechnology
Technology Comparisons
Wet FGD Technology
Dry FGD – SDA Technology
© 2010 The Babcock & Wilcox Company. All rights reserved.
Environmental Regulations Review
Proprietary and Confidential APCAC September 2010
Fuels and Scrubber TypesWet Flue Gas Desulfurization (Wet FGD)
Dry FGDSpray Dryer Absorber (SDA)Circulating Dry Scrubbers (CDS)
FuelsCoal, Oil, Petroleum CokeBiomass, Refuse Tires
Fuel Switching Lower Sulfur – Higher sulfur? Lower Cl Lower Hg
© 2010 The Babcock & Wilcox Company. All rights reserved. .6
Proprietary and Confidential APCAC September 2010
HCl Removal in Wet and Dry FGD
≥ 99% Removal Efficiency
HCl Emissions: <1.0 ppmdv (1.7 mg/dNm3)@ 7% O2
MeasurementEPA Method 26APractical Detection Limit: 0.3 ppmdv (0.5 mg/dNm3)
HCl Emission independent of inlet concentration?
© 2010 The Babcock & Wilcox Company. All rights reserved. .7
Proprietary and Confidential APCAC September 2010© 2010 The Babcock & Wilcox Company. All rights reserved. .8
0,0
1,0
2,0
3,0
4,0
5,0
0 50 100 150 200 250
Oul
et H
Cl,
mg/
dNm
3
Inlet HCl, mg/dNm3
HCl Outlet vs. Inlet
Proprietary and Confidential APCAC September 2010
SO2 RemovalWFGD and CDS 98% - 99% Typical Removal Efficiency
SDA – 95% SO2 Removal
MeasurementEPA Method 6Practical Detection Limit: 3-5 ppmdv (8-14 mg/dry Nm3)
ReagentsWFGD – Kiln Dust, Raw Meal or LimestoneCDS and SDA – Lime (hydrated)
© 2010 The Babcock & Wilcox Company. All rights reserved. .10
Proprietary and Confidential APCAC September 2010© 2010 The Babcock & Wilcox Company. All rights reserved. .11
90
91
92
93
94
95
96
97
98
99
100
0,5 1 1,5 2 2,5 3
% R
emov
al
SO2 in coal, kg/kj x 106
SO2 Removal vs. SO2 in Coal 0.2 kg/tonne Emission
7 million kj/tonne6 million kj/tonne5 million kj/tonne4 million kj/tonne
Proprietary and Confidential APCAC September 2010© 2010 The Babcock & Wilcox Company. All rights reserved. .12
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
0 0,5 1 1,5 2 2,5
SO2
out,
kg/to
nne
Inlet SO2, kg/kj x 106
SO2 Emissions at 90% Removal
7 million kj/tonne6 million kj/tonne5 million kj/tonne4 million kj/tonne
Proprietary and Confidential APCAC September 2010
SO2 and HCl Removal
Presentation Topics
.13
Circulating Fluid Bed Technology
Technology Comparisons
Wet FGD Technology
Dry FGD - SDA Technology
© 2010 The Babcock & Wilcox Company. All rights reserved.
Environmental Regulations Review
Proprietary and Confidential APCAC September 2010
Typical Utility Boiler Wet FGD Configuration
.14
Coal Pulverizers
Boiler
SCR
Fabric Filter
SO3 and Mercury
SO2 Scrubber
© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
Characteristics of Wet FGD Systems
Fuel sulfur levels to 8%98-99% Typical RemovalReagent flexibilityCan use Kiln DustExcellent fuel flexibility
.15© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010 .16© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
B&W PGG Overview
CEMEX Environmental Update
Presentation Topics
.17
Circulating Fluid Bed Technology
Technology Comparisons
Wet FGD Technology
Dry FGD – SDA Technology
© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
Typical Spray Dryer Absorber (SDA) Configuration
.18
Boiler
Coal Pulverizers
SCR
Fabric Filter
DryScrubber
© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
Dry Scrubber – Spray Dryer Absorber
.19
Reagent is slaked lime slurry
Slurry is atomized by rotary atomizer
Critical Design Parameters Inlet temperature Drying of lime slurry Approach to saturation Fabric Filter (baghouse) required
SO2 Removal≈95%Approximate limit of 1.5% sulfur
© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010 .20© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
B&W PGG Overview
CEMEX Environmental Update
Presentation Topics
.21
Circulating Fluid Bed Technology
Technology Comparisons
Wet FGD Technology
Dry FGD - SDA Technology
© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010 22
CDS
Fabric Filter
Product Silo
Lime Silo
Raw Gas Duct
Stack
ID-Fan
Typical CDS Arrangement
22© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
Simple and reliable process
Long solids retention time
Very high byproduct recirculation
>98% SO2 removal efficiency
High fuel flexibility-high S fuels
Compact plant arrangement
CDS Process Basics
23© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
B&W PGG Overview
CEMEX Environmental Update
Presentation Topics
.24
Circulating Fluid Bed Technology
Technology Comparisons
Wet FGD Technology
Dry FGD - SDA Technology
© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
Flue Gas Desulfurization
Spray Dryer FGD
• ≥ 98% SO2 removal• High sulfur fuels• Kiln dust reagent – no cost• No second baghouse• Wastewater treatment• Wet stack – converted or
new• Alloy or linings
• ≈ 95% SO2 removal • Lower sulfur fuels <1.5%• Carbon steel• Limited fuel flexibility• Second Baghouse• Expensive Lime reagent
• ≥ 98% SO2 removal• Carbon steel• Compact Footprint• Higher sulfur fuels• Second baghouse• Expensive Lime reagent• Clean gas recirculation
Wet FGD System Circulating Dry Scrubber
.25© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
Selection of FGD System
Capital Cost Lower for SDA and CDSOperating Cost depends on SO2 removal Sulfur in fuel
Reagent Lime = $75 USD per ton Kiln dust = $0 Limestone = $15 per ton
Lower sulfur and lower removal favor SDAHigher sulfur, higher removal favor WFGD or CDS
.26© 2010 The Babcock & Wilcox Company. All rights reserved.
Proprietary and Confidential APCAC September 2010
Thank You.
B&W and PrecipTech
Powerful Solutions for the Cement Industry
Questions?
.27© 2010 The Babcock & Wilcox Company. All rights reserved.
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