JV Task 122 - Assessment of Mercury Control Options for the San Miguel Electric Cooperative Power Plant PDF Download
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Languages : en
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In the United States, testing has been under way at electric coal-fired power plants to find viable and economical mercury control strategies to meet pending regulations. San Miguel Electric Cooperative (SMEC) engaged the Energy & Environmental Research Center (EERC) through a request for proposal (RFP) to perform research tests to evaluate sorbent-based technologies at its coal-fired San Miguel Generating Station to identify possible technology options that could be used by SMEC to meet the mercury reduction requirements of future U.S. federal standards. The goal of the testing was to target a mercury removal of ≥90%. The EERC has successfully field-tested several sorbent-based technologies in previous projects that offer promise and potential to achieve a target removal of ≥90%. Based on these field test results, yet recognizing that fuel type and plant operating conditions affect mercury capture significantly, the EERC proposed research tests to evaluate potential sorbent-based technologies provided by Norit Americas and the EERC that could potentially meet SMEC's mercury control objectives. Over the period of May through mid-June 2008, the EERC tested injection of both treated and nontreated activated carbon (AC) provided by Norit Americas and sorbent enhancement additives (SEAs) provided by the EERC. Tests were performed at San Miguel Unit 1 (450 MW) and included injection at the inlet of the air heater (AH) (temperature of 720 F). The test coal was a Texas lignite fuel with an average moisture content of 31.19%, an ash content of 26.6%, a heating value of 5,094 Btu/lb, a sulfur content of 2.7%, and a mercury concentration of 0.182 ppm, all reported on an as-received basis. Pilot-scale testing results identified DARCO{reg_sign} Hg-LH, SEA2 + DARCO{reg_sign} Hg, and the ChemMod sorbents as technologies with the potential to achieve the target mercury removal of ≥90% at the full-scale test. Mercury concentrations were tracked with continuous mercury monitors (CMMs) at the electrostatic precipitator (ESP) inlet (ESP In), scrubber inlet, and scrubber outlet of San Miguel Unit 1, and a dry sorbent trap method was used to take samples periodically to measure mercury concentrations at the each of the CMM sampling locations described above. A limited number of Ontario Hydro (OH) measurements were also conducted. Removal efficiencies were calculated from mercury-in-coal values to scrubber out CMM values. Sorbent trap samples taken at the each sampling location outlet were found to be fairly consistent with CMM values. A maximum mercury removal of 78.5% was achieved with the SEA2 + DARCO Hg sorbent combination at injection rates of 50 ppm and 4 lb/Macf, respectively. An injection rate of 4 lb/Macf for DARCO Hg-LH and DARCO Hg resulted in mercury removals of 70.0% and 64.2%, respectively. These mercury reduction values were achieved at full load and at stable plant operating conditions. Scrubber reemission was observed during sorbent injection and had a significant effect on coal to scrubber out mercury removal values. When the sorbents were injected into San Miguel Unit 1 at the AH inlet, no effects on unit operations were observed. ESP performance throughout the test period was fairly steady, with only one minor breakdown. However, it should be noted that test durations were short.
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Languages : en
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In the United States, testing has been under way at electric coal-fired power plants to find viable and economical mercury control strategies to meet pending regulations. San Miguel Electric Cooperative (SMEC) engaged the Energy & Environmental Research Center (EERC) through a request for proposal (RFP) to perform research tests to evaluate sorbent-based technologies at its coal-fired San Miguel Generating Station to identify possible technology options that could be used by SMEC to meet the mercury reduction requirements of future U.S. federal standards. The goal of the testing was to target a mercury removal of ≥90%. The EERC has successfully field-tested several sorbent-based technologies in previous projects that offer promise and potential to achieve a target removal of ≥90%. Based on these field test results, yet recognizing that fuel type and plant operating conditions affect mercury capture significantly, the EERC proposed research tests to evaluate potential sorbent-based technologies provided by Norit Americas and the EERC that could potentially meet SMEC's mercury control objectives. Over the period of May through mid-June 2008, the EERC tested injection of both treated and nontreated activated carbon (AC) provided by Norit Americas and sorbent enhancement additives (SEAs) provided by the EERC. Tests were performed at San Miguel Unit 1 (450 MW) and included injection at the inlet of the air heater (AH) (temperature of 720 F). The test coal was a Texas lignite fuel with an average moisture content of 31.19%, an ash content of 26.6%, a heating value of 5,094 Btu/lb, a sulfur content of 2.7%, and a mercury concentration of 0.182 ppm, all reported on an as-received basis. Pilot-scale testing results identified DARCO{reg_sign} Hg-LH, SEA2 + DARCO{reg_sign} Hg, and the ChemMod sorbents as technologies with the potential to achieve the target mercury removal of ≥90% at the full-scale test. Mercury concentrations were tracked with continuous mercury monitors (CMMs) at the electrostatic precipitator (ESP) inlet (ESP In), scrubber inlet, and scrubber outlet of San Miguel Unit 1, and a dry sorbent trap method was used to take samples periodically to measure mercury concentrations at the each of the CMM sampling locations described above. A limited number of Ontario Hydro (OH) measurements were also conducted. Removal efficiencies were calculated from mercury-in-coal values to scrubber out CMM values. Sorbent trap samples taken at the each sampling location outlet were found to be fairly consistent with CMM values. A maximum mercury removal of 78.5% was achieved with the SEA2 + DARCO Hg sorbent combination at injection rates of 50 ppm and 4 lb/Macf, respectively. An injection rate of 4 lb/Macf for DARCO Hg-LH and DARCO Hg resulted in mercury removals of 70.0% and 64.2%, respectively. These mercury reduction values were achieved at full load and at stable plant operating conditions. Scrubber reemission was observed during sorbent injection and had a significant effect on coal to scrubber out mercury removal values. When the sorbents were injected into San Miguel Unit 1 at the AH inlet, no effects on unit operations were observed. ESP performance throughout the test period was fairly steady, with only one minor breakdown. However, it should be noted that test durations were short.
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The EERC developed an applied research consortium project to test cost-effective mercury (Hg) control technologies for utilities burning bituminous coals. The project goal was to test innovative Hg control technologies that have the potential to reduce Hg emissions from bituminous coal-fired power plants by ≥90% at costs of one-half to three-quarters of current estimates for activated carbon injection (ACI). Hg control technology evaluations were performed using the EERC's combustion test facility (CTF). The CTF was fired on pulverized bituminous coals at 550,000 Btu/hr (580 MJ/hr). The CTF was configured with the following air pollution control devices (APCDs): selective catalytic reduction (SCR) unit, electrostatic precipitator (ESP), and wet flue gas desulfurization system (WFDS). The Hg control technologies investigated as part of this project included ACI (three Norit Americas, Inc., and eleven Envergex sorbents), elemental mercury (Hg°) oxidation catalysts (i.e., the noble metals in Hitachi Zosen, Cormetech, and Hitachi SCR catalysts), sorbent enhancement additives (SEAs) (a proprietary EERC additive, trona, and limestone), and blending with a Powder River Basin (PRB) subbituminous coal. These Hg control technologies were evaluated separately, and many were also tested in combination.
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Publisher: DIANE Publishing
ISBN: 1428952101
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Languages : en
Pages : 63
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Publisher: Am Cncl on Science, Health
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Category : Coal-fired power plants
Languages : en
Pages : 18
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Western Research Institute (WRI), in conjunction with Western Farmers Electric Cooperative (WFEC), has teamed with Clean Air Engineering of Pittsburgh PA to conduct a mercury monitoring program at the WEFC Hugo plant in Oklahoma. Sponsored by US Department of Energy Cooperative Agreement DE-FC-26-98FT40323, the program included the following members of the Subbituminous Energy Coalition (SEC) as co-sponsors: Missouri Basin Power Project; DTE Energy; Entergy; Grand River Dam Authority; and Nebraska Public Power District. This research effort had five objectives: (1) determine the mass balance of mercury for subbituminous coal-fired power plant; (2) assess the distribution of mercury species in the flue gas (3) perform a comparison of three different Hg test methods; (4) investigate the long-term (six months) mercury variability at a subbituminous coal-fired power plant; and (5) assess operation and maintenance of the Method 324 and Horiba CEMS utilizing plant personnel.
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Languages : en
Pages : 29
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Title 3 of the 1990 Clean Air Act Amendments (CAAA) mandated that the US Environmental Protection Agency (EPA) evaluate the need to regulate mercury emissions from electric utilities. In support of this forthcoming regulatory analysis the U.S. DOE, sponsored a risk assessment project at Brookhaven (BNL) to evaluate methylmercury (MeHg) hazards independently. In the US MeHg is the predominant way of exposure to mercury originated in the atmosphere. In the BNL study, health risks to adults resulting from Hg emissions from a hypothetical 1,000 MW coal-fired power plant were estimated using probabilistic risk assessment techniques. This study showed that the effects of emissions of a single power plant may double the background exposures to MeHg resulting from consuming fish obtained from a localized area near the power plant. Even at these more elevated exposure levels, the attributable incidence in mild neurological symptoms was estimated to be quite small, especially when compared with the estimated background incidence in the population. The current paper summarizes the basic conclusions of this assessment and highlights issues dealing with emissions control and environmental transport.
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This is the final technical report for a three-site project that is part of an overall program funded by the U.S. Department of Energy's National Energy Technology Laboratory (DOE/NETL) and industry partners to obtain the necessary information to assess the feasibility and costs of controlling mercury from coal-fired utility plants. This report summarizes results from tests conducted at MidAmerican's Louisa Generating Station and Entergy's Independence Steam Electric Station (ISES) and sorbent screening at MidAmerican's Council Bluffs Energy Center (CBEC) (subsequently renamed Walter Scott Energy Center (WSEC)). Detailed results for Independence and Louisa are presented in the respective Topical Reports. As no full-scale testing was conducted at CBEC, screening updates were provided in the quarterly updates to DOE. ADA-ES, Inc., with support from DOE/NETL, EPRI, and other industry partners, has conducted evaluations of EPRI's TOXECON II{trademark} process and of high-temperature reagents and sorbents to determine the capabilities of sorbent/reagent injection, including activated carbon, for mercury control on different coals and air emissions control equipment configurations. An overview of each plant configuration is presented: (1) MidAmerican's Louisa Generating Station burns Powder River Basin (PRB) coal in its 700-MW Unit 1 and employs hot-side electrostatic precipitators (ESPs) with flue gas conditioning for particulate control. This part of the testing program evaluated the effect of reagents used in the existing flue gas conditioning on mercury removal. (2) MidAmerican's Council Bluffs Energy Center typically burns PRB coal in its 88-MW Unit 2. It employs a hot-side ESP for particulate control. Solid sorbents were screened for hot-side injection. (3) Entergy's Independence Steam Electric Station typically burns PRB coal in its 880-MW Unit 2. Various sorbent injection tests were conducted on 1/8 to 1/32 of the flue gas stream either within or in front of one of four ESP boxes (SCA = 542 ft2/kacfm), specifically ESP B. Initial mercury control evaluations indicated that although significant mercury control could be achieved by using the TOXECON II{trademark} design, the sorbent concentration required was higher than expected, possibly due to poor sorbent distribution. Subsequently, the original injection grid design was modeled and the results revealed that the sorbent distribution pattern was determined by the grid design, fluctuations in flue gas flow rates, and the structure of the ESP box. To improve sorbent distribution, the injection grid and delivery system were redesigned and the effectiveness of the redesigned system was evaluated. This project was funded through the DOE/NETL Innovations for Existing Plants program. It was a Phase II project with the goal of developing mercury control technologies that can achieve 50-70% mercury capture at costs 25-50% less than baseline estimates of $50,000-$70,000/lb of mercury removed. Results from testing at Independence indicate that the DOE goal was successfully achieved. Further improvements in the process are recommended, however. Results from testing at Louisa indicate that the DOE goal was not achievable using the tested high-temperature sorbent. Sorbent screening at Council Bluffs also indicated that traditional solid sorbents may not achieve significant mercury removal in hot-side applications.
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Languages : en
Pages : 26
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In this project General Electric Energy and Environmental Research Corporation conducts a preliminary field evaluation of a novel technology, referred to as Hg/NO(subscript x), that can reduce emissions of both mercury (Hg) and oxides of nitrogen (NO(subscript x)) from coal-fired power plants. The evaluation takes place in Green Station Unit 2 operated by Western Kentucky Energy. Reduction of Hg and NO(subscript x) emissions in Unit 2 is achieved using coal reburning. Activities during first project year (January 23, 2003--January 22, 2004) included measurements of baseline Hg emissions in Unit 2 and pilot-scale testing. Baseline testing of Hg emissions in Green Unit 2 has been completed. Two fuels were tested with OFA system operating at minimum air flow. Mercury emissions were measured at ESP inlet and outlet, and at the stack using Ontario Hydro revised method. Testing demonstrated that baseline Hg reductions at ESP outlet and stack were 30-45% and 70-80%, respectively. Pilot-scale testing demonstrated good agreement with baseline measurements in Unit 2. Testing showed that fuel composition had an effect on the efficiency of Hg absorption on fly ash. Maximum achieved Hg removal in reburning was close to 90%. Maximum achieved Hg reduction at air staging conditions was 60%. Testing also demonstrated that lowering ESP temperature improved efficiency of Hg removal.
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Pages : 5
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With the Nation's coal-burning utilities facing the possibility of tighter controls on mercury pollutants, the U.S. Department of Energy is funding projects that could offer power plant operators better ways to reduce these emissions at much lower costs. Mercury is known to have toxic effects on the nervous system of humans and wildlife. Although it exists only in trace amounts in coal, mercury is released when coal burns and can accumulate on land and in water. In water, bacteria transform the metal into methylmercury, the most hazardous form of the metal. Methylmercury can collect in fish and marine mammals in concentrations hundreds of thousands times higher than the levels in surrounding waters. One of the goals of DOE is to develop technologies by 2005 that will be capable of cutting mercury emissions 50 to 70 percent at well under one-half of today's costs. ADA Environmental Solutions (ADA-ES) is managing a project to test mercury control technologies at full scale at four different power plants from 2000--2003. The ADA-ES project is focused on those power plants that are not equipped with wet flue gas desulfurization systems. ADA-ES will develop a portable system that will be moved to four different utility power plants for field testing. Each of the plants is equipped with either electrostatic precipitators or fabric filters to remove solid particles from the plant's flue gas. ADA-ES's technology will inject a dry sorbent, such as fly ash or activated carbon, that removes the mercury and makes it more susceptible to capture by the particulate control devices. A fine water mist may be sprayed into the flue gas to cool its temperature to the range where the dry sorbent is most effective. PG and E National Energy Group is providing two test sites that fire bituminous coals and are both equipped with electrostatic precipitators and carbon/ash separation systems. Wisconsin Electric Power Company is providing a third test site that burns Powder River Basin coal and has an electrostatic precipitator for particulate control. Alabama Power Company will host a fourth test at its Plant Gaston, which is equipped with a hot-side electrostatic precipitator and a downstream fabric filter.
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The Energy & Environmental Research Center (EERC) was asked by PPL Montana LLC (PPL) to provide assistance and develop an approach to identify cost-effective options for mercury control at its coal-fired power plants. The work conducted focused on baseline mercury level and speciation measurement, short-term parametric testing, and week long testing of mercury control technology at Colstrip Unit 3. Three techniques and various combinations of these techniques were identified as viable options for mercury control. The options included oxidizing agents or sorbent enhancement additives (SEAs) such as chlorine-based SEA1 and an EERC proprietary SEA2 with and without activated carbon injection. Baseline mercury emissions from Colstrip Unit 3 are comparatively low relative to other Powder River Basin (PRB) coal-fired systems and were found to range from 5 to 6.5 g/Nm3 (2.9 to 3.8 lb/TBtu), with a rough value of approximately 80% being elemental upstream of the scrubber and higher than 95% being elemental at the outlet. Levels in the stack were also greater than 95% elemental. Baseline mercury removal across the scrubber is fairly variable but generally tends to be about 5% to 10%. Parametric results of carbon injection alone yielded minimal reduction in Hg emissions. SEA1 injection resulted in 20% additional reduction over baseline with the maximum rate of 400 ppm (3 gal/min). Week long testing was conducted with the combination of SEA2 and carbon, with injection rates of 75 ppm (10.3 lb/hr) and 1.5 lb/MMacf (40 lb/hr), respectively. Reduction was found to be an additional 30% and, overall during the testing period, was measured to be 38% across the scrubber. The novel additive injection method, known as novel SEA2, is several orders of magnitude safer and less expensive than current SEA2 injection methods. However, used in conjunction with this plant configuration, the technology did not demonstrate a significant level of mercury reduction. Near-future use of this technique at Colstrip is not seen. All the additives injected resulted in some reduction in mercury emissions. However, the target reduction of 55% was not achieved. The primary reason for the lower removal rates is because of the lower levels of mercury in the flue gas stream and the lower capture level of fine particles by the scrubbers (relative to that for larger particles). The reaction and interaction of the SEA materials is with the finer fraction of the fly ash, because the SEA materials are vaporized during the combustion or reaction process and condense on the surfaces of entrained particles or form very small particles. Mercury will have a tendency to react and interact with the finer fraction of entrained ash and sorbent as a result of the higher surface areas of the finer particles. The ability to capture the finer fraction of fly ash is the key to controlling mercury. Cost estimates for mercury removal based on the performance of each sorbent during this project are projected to be extremely high. When viewed on a dollar-per-pound-of-mercury removed basis activated carbon was projected to cost nearly $1.2 million per pound of mercury removed. This value is roughly six times the cost of other sorbent-enhancing agents, which were projected to be closer to $200,000 per pound of mercury removed.
