comparison of igcc air emissions vs. a conventional coal … · e bit/pet coke prb prb bit/pet coke...

2006 Gasification Technologies Conference

Comparison of IGCC Air Emissions vs.

a Conventional Coal Plant

Robynn AndracsekBurns & McDonnell

2006 Gasification Technologies Conference

The objective is to be objective.

(Just the facts, ma’am)

2006 Gasification Technologies Conference

Agenda

• Actual Emissions Data – SO2, NOX, CO2

• Permitted Emissions – SO2, NOX, PM10, CO

(CO2 is not currently permitted)• Mercury• Control Devices• Trends

2006 Gasification Technologies Conference

Actual Emissions Data

2006 Gasification Technologies Conference

Plants in OperationThe specific PC and CFB plants were chosen

since they were the most recent ones with several years of operating data available.

E Bit/pet coke

PRB

PRB

Bit/pet coke

Bit/pet coke

Fuel

4/02-6/06

4/03-6/06

8/01-6/06

1/01-6/06

1/01-6/06

Data Range

265FLJEA 1 and 2CFB

80WYWygen 1 (Black Hills)PC

570MOHawthorn 5PC

250FLTECO PolkIGCC

262INWabashIGCC

MWStateNameType

2006 Gasification Technologies Conference

EPA’s Acid Rain Database

• Clean Air Markets - Data and Maps – http://cfpub.epa.gov/gdm/index.cfm– Emissions Prepackaged Data Sets

• Hourly Data – Only “Boiler operating days” were used– “24-hour period during which fossil fuel is

combusted in a steam-generating unit for the entire 24 hours”

– Applicable to units operating before 2005

2006 Gasification Technologies Conference

-

0.100

0.200

0.300

0.400

0.500

0.600

0.700

Qualified Operating Hours

lb/M

MB

tu

SO2 30 Day Rolling Average•Variability of fuel sulfur content•Effect of time to recover from startup/ shutdown/ upsets•No distinct differences

CFBIGCCPC

2006 Gasification Technologies Conference

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

0.20

Q ualified O perating Hours

lb/M

MB

tu

NOx 30 Day Rolling Average•Variability in early life as plants are commissioned•Lines converge as plants age

CFBIGCCPC

SCR

2006 Gasification Technologies Conference

0.070

0.080

0.090

0.100

0.110

0.120

0.130

0.140

Qualified Operating Hours

lb/M

MB

tu

CO2 30 Day Rolling Average

•Values are calculated, not measured•Data is suspect:

•Tight grouping between plant types •Lack of noise

CFBIGCCPC

2006 Gasification Technologies Conference

Statistics

0.103 0.093 0.137Hawthorn 50.103 0.119 0.116Wygen 10.125 0.085 0.153Polk0.121 0.1290.228Wabash0.106 0.067 0.162JEA20.105 0.066 0.231JEA1

CO2lb/MMBtu

NOxlb/MMBtu

SO2lb/MMBtuFacility

Average

•Reflect compliance with limits, not best achievable rates

2006 Gasification Technologies Conference

Permitted Levels

(including levels in the applicationif the permit is not yet issued)

2006 Gasification Technologies Conference

Plants in this Review - IGCC

• Wabash • Polk • Kentucky Pioneer • Lima• Elm Road

• Taylorville• Cash Creek• Mesaba• Stanton

2006 Gasification Technologies Conference

Plants in this Review - CFB

• Red Hills • AES Puerto Rico • JEA Northside• North Hampton• Seward - Repowering• EnviroPower - KMP• Southern Illinois Coop. • Alcoa - Sandow 5 - #1,2• Indeck-Elwood,IL• Estill County Energy• Hugh L. Spurlock (#3)

• Sevier Power • Beach Hollow (Robinson

Power)• Gascoyne • Greene Energy Resource• Formosa Plastics (TX)• Bonanza Power Plant• South Heart Power Project• River Hill Waste Coal• Rodemacher (Unit 3)• Western Greenbrier• Highwood Generating

2006 Gasification Technologies Conference

Plants in this Review - PC

• Black Hills• Hawthorn #5• Weston Bend • Mustang• Baldwin Expansion • Tucson - Springerville• Rocky Mountain Power• Thoroughbred• Holcomb #2• Prairie Energy Power Plant• Roundup Power (Bull

Mountain)

• Plum Point Power Station• Hunter Power Plant (# 4)• Two Elk• MidAmerican #4• Elm Road• Cross Generating Station - #

3 & 4• Whelan Energy Center • Longview Power • Intermountain Power - #3• Weston 4 • Southwest Power Station -#2

2006 Gasification Technologies Conference

Plants in this Review – PC (cont)

• Longleaf Energy-PRB• Longleaf Energy-Central

Appalachian • Prairie State• Nebraska City # 2• TS Power Plant (Newmont)• Twin Oaks (Sempra Energy)• Comanche Plant (Unit #3)• WYGEN II• Oak Grove, TX• Hugo (# 2)• Big Cajun II #4• Trimble County

• J.K. Spruce Plant - # 2• Sandy Creek Energy • Cliffside - # 6 & 7• Iatan (# 2)• Holcomb Station (# 2-4)• Dallman - #4 • Big Stone II• Palatka (# 3)• TXU 8 Pack • AMP Generating Station• Desert Rock• Dallman - #4

2006 Gasification Technologies Conference

SO2 Comparison•Fuel sulfur variability•IGCC trends lower

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

1992 1994 1996 1998 2000 2002 2004 2006 2008

Year

lb/M

MB

tu

CFB

PC

IGCC

Year of Application/Permit

2006 Gasification Technologies Conference

NOx Comparison•Similar limits between all plant types•Slight downward trend

0

0.05

0.1

0.15

0.2

0.25

1992 1994 1996 1998 2000 2002 2004 2006 2008

Year

lb/M

MB

tu

CFBPCIGCC

Year of Application/Permit

2006 Gasification Technologies Conference

0

0.01

0.02

0.03

0.04

0.05

0.06

1992 1994 1996 1998 2000 2002 2004 2006 2008

Year

lb/M

MB

tu

CFBPCIGCC

PM10 Comparison• Mix of “filterable only” and “filterable plus condensible” limits• Upward trend reflects concerns about “condensible” test methods•IGCC trends lower

Year of Application/Permit

2006 Gasification Technologies Conference

0

0.05

0.1

0.15

0.2

0.25

0.3

1992 1994 1996 1998 2000 2002 2004 2006 2008

Year

lb/M

MB

tu

CFBPCIGCC

CO Comparison (not CO2)•Variability reflects lack of emphasis on CO•IGCC trends lowest

Year of Application/Permit

2006 Gasification Technologies Conference

Mercury

Clean Air Mercury Rule• Makes comparisons of Hg limits before

and after the rule moot• Note the redefinition of “wet” and “dry”

2006 Gasification Technologies Conference

Clean Air Mercury Rule

2“Wet” and “Dry”refer to 30-yr average rainfall

Subcategory Final[1] Re-Proposed[2]

Bituminous Coal 21 x 10-6 20 x 10-6

Subbituminous Coal "Wet" 42 x 10-6 66 x 10-6

"Dry" 78 x 10-6 97 x 10-6

Lignite 145 x 10-6 175 x 10-6

Coal Refuse 1.4 x 10-6 1.0 x 10-6

IGCC 20 x 10-6 20 x 10-6

Emission Limit (lb/MWh)

1“Wet” and “Dry”refer to Flue Gas Desulfurization technology used

DRY WET

2006 Gasification Technologies Conference

Control Devices

2006 Gasification Technologies Conference

0

10

20

30

40

50

CC DI

LNB NH3 R

ecOFA SCR SISNCR

# of

Uni

ts

CFBIGCCPC

NOx

CC - Combustion Control DI - Diluent Injection LNB - Low NOx Burners NH3 Rec - Ammonia RecoveryOFA - Over Fired Air SCR - Selective Catalytic Reduction SI- Steam Injection SNCR - Selective Non Catalytic Reduction

2006 Gasification Technologies Conference

0

2

4

6

8

10

ACI DSI MRS

# of

Uni

ts

CFBIGCCPC

MercuryACI - Activated Carbon Injection DSI - Dry Sorbent Injection MRS - Mercury Removal System

2006 Gasification Technologies Conference

0

5

10

15

20

25

30

35

40

45

ESP FF or BH PFS WESP

# of

Uni

ts

CFBIGCCPC

PM10

ESP - Electrostatic Precipitator FF or BH - Fabric Filter or Bag House PFS - Particulate Filtration System WESP - Wet Electrostatic Precipitator

2006 Gasification Technologies Conference

0

5

10

15

20

25

30

AGR

FDA

HARSDA/D

FGD/CDS

SRS

WFGD

# of

Uni

ts

CFBIGCCPC

SO2AGR - Acid Gas Removal FDA- Flash Dryer

Absorber HAR- Hydrated Ash

Reinjection (Polishing Scrubber)

SDA-Spray Dry Absorber/ DFGD-Dry Flue Gas

Desulfurization/CDS-Cent. Dry Scrubber SRS - Sulfur Removal

System (SO2 & H2SO4) WFGD - Wet Flue Gas

Desulfurization

2006 Gasification Technologies Conference

Trends

• More applications each year• Boiler operating day (NSPS Subpart Da)

– Redefined for units after February 28, 2005 – “24-hour period…during which any fuel is combusted

at any time in the steam-generating unit”– Makes before and after comparisons unequal

• Next generation of plants – Permitted rates are lower– Not yet in operation

• In the future, will CO2 be measured instead of calculated?

2006 Gasification Technologies Conference

Thank you.

2006 Gasification Technologies Conference

Acronyms

• CFB-circulated fluidized bed• CO-carbon monoxide• CO2-carbon dioxide• Hg-mercury• IGCC-integrated gasification combined cycle • NOx-nitrogen oxides• NSPS-New Source Performance Standards• PC-pulverized coal• PM10-particulate matter less than 10 microns in diameter• SO2-sulfur dioxide