ada carbon solutions so3 tolerance
TRANSCRIPT
Expertise. Reliability. Compliance.
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Next-Generation SO3 Tolerant PACs
EUEC – San Diego, CAFebruary 16, 2015
C2.5 Activated Carbon HG
Robert Huston, Roger Cayton, Jacob Lowring & Joe Wong
Expertise. Reliability. Compliance.
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THE INFORMATION CONTAINED IN THIS PRESENTATION IS FOR GENERAL
INFORMATIONAL PURPOSES ONLY, AND IS NOT INTENDED AS LEGAL
ADVICE. YOU SHOULD CONSULT AN ATTORNEY OR OTHER APPROPRIATE
PROFESSIONAL FOR ADVICE REGARDING YOUR INDIVIDUAL SITUATION.
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1. The SO3 problem: Hg capture historically hindered
2. Taking a fundamental scientific view...potential mechanisms that impact Hg capture
3. Development process from lab to field
4. Product generations / SO3-specific evolution
5. Full-scale field test results
6. Further development / test opportunities for utilities
7. Summary
Next-Generation SO3 Tolerant PACs
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Hg Capture Historically Hindered
PAC Injection Rate (lb/MMacf)
0
100
90
80
70
60
50
40
30
20
10
02 4 6 8 10 12 14 16 18 20
Vapo
r Hg
Rem
oval
Acr
oss
PM D
evic
e (%
)
Western Coal, FF Western Coal, ESPLow Sulfur, Eastern Bituminous, ESP
High sulfur, Eastern Bituminous, ESP
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Achieving Reliable Compliance in a Diverse Set of Conditions
All three mechanisms must occur uninhibited in seconds or less to achieve compliance
Conversion of elemental mercury
(Hg0) to an oxidized state (Hg+ or Hg++) to enhance mercury’s receptivity to the capture media.
Contact of mercury, which is in
very dilute concentrations in the
flue gas, with the capture media.
Capture of the mercury in the
capture media’s structure for removal
from the system.
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Potential Impact of SO3 on Activated Carbon and Mercury Capture
1. SO2 oxidation to SO3 in carbon Mesopores
2. Occupies Carbon Pore Volume
a. As SO3
b. As SO3 + H2O <- -> H2SO4
3. H2SO4 solubilizes adsorbed Hg
a. Emits back into flue gas
4. Interferes with Hg oxidation catalytic pathways
H2SO4
Carbon Particle SurfaceSO3
Hg+ HSO4
-1
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Potential Sources of Sulfur Trioxide (SO3)
1. Oxidation of sulfur in coal in boiler
2. Oxidation of SO2
in flue gas at SCR3. Injection of SO3 as
an ESP conditioner
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SO3 Tolerant PAC Development Roadmap
Hg
Rem
oval
Impr
ovem
ent
The cumulative performance enhancement potential beyond the Baseline PAC approaches an additional 80% increase in mercury capture performance through stepwise mechanistic advancements.
30%
30%10%
10% 80%
Next Gen SO3 Tolerant PAC
Baseline PAC Improved Sacrificial Capability
Enhanced Oxidation
Technology
Secondary Hg Conversion Mechanism
Improved Hg Capture
Component
Next-Gen SO3 Tolerant PAC
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Our Next-Generation Developmental PACs Show Enhanced Sacrificial Protection
1.0
1.5
2.0
2.5
Nor
mal
ized
Sulfu
ric A
cid
Cons
umpti
on
Developmental PAC
1st Generation Sacrificial
We have further enhanced the SO3 Sacrificial Protection Performance of our developmental PACs
0.5
Baseline PAC
2nd Generation Sacrificial
Next-Gen SO3 Tolerant PAC
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Southern Plant Gorgas: Developmental Gen-3 SO3 Tolerant Carbon For Bituminous Coal (~10 ppm SO3)
PAC Injection Rate (lb/MMacf)0
100
90
80
70
60
50
40
30
20
10
0
2 4 6 8 10 12 14 16 18 20
Hg
Rem
oval
Acr
oss
PM D
evic
e (%
)
Gen 2 FastPAC Premium™ Only
FastPAC Premium™
Gen 3 SO3 Tolerant Carbon
FastPAC Premium™ + Hydrated Lime
Gen 2 FastPAC Premium™ + Hydrated Lime
Gen 3 SO3 Tolerant Carbon Only
•Unit 7 Load: 100 MW•Fuel Sulfur: 1.5 – 2.5 wt%•SCR: No•Flue Gas Temperature: 310°F•Emission Train Configuration:
Econ-APH-DSI-ACI-ESP-Stack
Gen 1 Carbons in High SulfurEastern Bituminous Coal
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Gen-2 High-Efficiency Hg Removal and FastPAC Premium 80 Gen-3 SO3 Tolerant Carbons
• 600 Megawatt Unit• PRB Coal• Emission Train Configuration
APH-ACI-SO3-ESP-Stack• SO3 injected for ESP conditioning• ESP inlet at ~350°F• CEMs on ESP outlet
0 1 2 3 4 5 6 7 80
2
4
6
8
10
12
ACI Injection lb/MMacf
Hg
Rem
oval
ug/
m3
Approximate US Federal Limit
FastPAC Premium™ with 2.6 ppm SO3 Injected
FastPAC Premium™ with 3.5 ppm SO3 Injected
FastPAC Premium™ 80 with 7 ppm SO3 Injected
ADA CS Carbon Type
Approximate SO3 Injected
ppm
ACI Injection Rate at
ComplianceLb/MMacf
FastPAC Premium™ 2.6 2.5 to 3
FastPAC Premium™ 3.5 3 to 3.5
FastPAC Premium™ 80
7 5 to 7
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Next-Generation Product Performance:EGU 4 - High Sulfur Fuel Blend (18-24 ppm SO3)
A
B
C
D
E
0% 10% 20% 30% 40% 50% 60% 70%
EGU 4 - Comparative Hg Removal Across ESP
% Hg Removal Relative to Baseline Removal
PAC
Form
ulati
on
Baseline PAC
Enhanced Oxidation/SO3 Tolerance #1
Enhanced Oxidation
SO3 Tolerance
Enhanced Oxidation/SO3 Tolerance #2
High sulfur fuel blend, 18-24 ppm SO3
Stepwise mechanistic formulation
enhancements
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1. The SO3 problem is better understood mechanistically leading
to rigorous R&D technology roadmaps for building the next-generation SO3 Tolerant PACs
2. Rapid PAC prototyping from lab to field is available to advancing technologies for commercial use
3. Next-generation ADA Carbon Solution SO3 Tolerant PACs have
been introduced and demonstrated high Hg removal efficacy in full-scale utility tests
4. Additional PAC product generations for SO3-specific systems
are in development
Summary - Next-Generation SO3 Tolerant PACs
Expertise. Reliability. Compliance.
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Questions?
Robert HustonSenior Director Technical Services
Joe WongChief Technology [email protected]
Roger CaytonSenior Director R&D
Jacob LowringContinuous Improvement & Quality