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W. L. Gore & Associates
Gas Remediation Technologies from W.L. Gore and Associates
GORE Mercury Control System
Jeff Kolde / John Knotts /
Chris Polizzi / John Tomanovich
August 26, 2013
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W. L. Gore & Associates
Particulate Filtration
GORE® Filter Bags
GORE® Filter Cartridges
GORE® Liquid Filtration Products
Expanded PTFE (ePTFE)
Industrial Filtration
Airflow / DP / Cleanability
Durability / Longer life
Efficiency / Emissions / Product Collection
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W. L. Gore & Associates
Particulate Filtration
GORE® Filter Bags
GORE® Filter Cartridges
GORE® Liquid Filtration Products
Catalytic Filter BagsFilled ePTFE PM + Dioxin/Furan
???
PM + NOx
Expanded PTFE (ePTFE)
Industrial Filtration
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W. L. Gore & Associates
The Safest and Simplest Way to Destroy Dioxin
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W. L. Gore & Associates
REMEDIATM Catalytic Filter System
Existing pulse-jet baghousesoperating at 180-250C
• Municipal Waste Incinerators
• Medical Waste Incinerators
• Industrial Waste Incinerators
• Crematoriums
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W. L. Gore & Associates
Field Performance
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W. L. Gore & Associates
NH3
NOx NOx
(NH3)
Gore® DeNOx Filter Technology
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W. L. Gore & Associates
Gore® DeNOx Filter Technology
Combines the removal of Particulates and NOxApplied in Existing Pulse-Jet Baghouses
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W. L. Gore & Associates
Particulate Filtration
GORE® Filter Bags
GORE® Filter Cartridges
GORE® Liquid Filtration Products
SPC Technology
Catalytic Filter BagsFilled ePTFE PM + Dioxin/Furan
???
PM + NOx
Mercury Capture
SOx Removal
???
Expanded PTFE (ePTFE)
Industrial Filtration
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W. L. Gore & Associates
Fixed Sorbent Technology– Low pressure drop sorbent
modules placed directly in flue gas after baghouse or ESP
– Continuous mercury adsorption for long period of time without deactivation - no regeneration needed
– Does not require any injection of sorbents or chemicals
GORE™ Mercury Control System
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W. L. Gore & Associates
Material Innovation at Gore• Sorbent Polymer Catalyst (SPC) composite
– Captures elemental and oxidized mercury
– High capacity for mercury capture
– Does not require regeneration
• Unique physical-chemical nature of the SPC material– Sulfur dioxide is converted into an aqueous sulfuric acid solution and expelled to
SPC material’s outer surfaces
– SO2 reduction is a co-benefit of this technology
SPC Material
H2SO4 formation from humidified SO2 gas feed
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W. L. Gore & Associates
Sorbent Polymer Catalyst (SPC) Composite
GORE® Mercury Control Module
2’
2’
1’
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W. L. Gore & Associates
h = Efficiency
Discrete Modules
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W. L. Gore & Associates
Scalable Mercury Control
50
5560
6570
7580
8590
95
2 3 4 5 6Module Stack Height
Mer
cury
Rem
oval
(%)
5 f t/s10 ft/s15 ft/s
Gas Velocity
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W. L. Gore & Associates
Module Design
~1/8th - 1/3rd inch H2O per module
Square Footprint+
Open Channels
Low Pressure Drop
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W. L. Gore & Associates
Installation in Wet Scrubber
• “Zero-footprint” approach
• Lowest capital cost installation
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W. L. Gore & Associates
Typical Cement Installation
Preferred Operating Temperature: <200°F
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W. L. Gore & Associates
Applications
• Coal-fired Power Plants– In-scrubber installations– Un-scrubbed power plants– Preserves fly ash quality (no sorbent injection)
• Cement Plants– Post baghouse installation– Preserves CKD quality (no sorbent injection)
• Metals, incinerators, etc.
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W. L. Gore & Associates
Pilot Testing Experience
• Minerals/Metals– 3 completed (4-12 months each)– 1 in progress, more under discussion
• Incinerators– 1 completed (4 months)– 1 in progress
• Coal-Fired Power– 3 completed (8-12 months each)– 1 in progress– 2 more under discussion
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W. L. Gore & Associates
Pilot Testing at Cement Plants
1000 cfm slip-stream test skidInstalled at cement plant test site
Evaporative Cooler
Gas
Inle
t
Gas
Out
let
Control room Mercury control modulehousingModules
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W. L. Gore & Associates
Data Acquisition / ControlsInlet + Outlet Tekran Hg CEMs
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W. L. Gore & Associates
Daily Average Readings
-10
2030
405060
7080
90100
0 10 20 30 40 50 60 70 80 90
Days on Test
Total Hg Inlet (ug/Nm3)Total Hg Outlet (ug/Nm3)Hg Removal Efficiency (%)
Normal Plant Operation
Experimentation / Optimization
Pilot Test at U.S. Cement Plant
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W. L. Gore & Associates
Variable Mercury Emissions – No AdjustmentsField Data from Cement Plant trial with Gore Mercury Control System (4-module stack height)
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W. L. Gore & Associates
Xcel Sherburne County (Sherco)Becker, Minnesota
Full-Scale Installation
216 Gore Modules
Started operation July 2013
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W. L. Gore & Associates
Sherco Module Arrangement
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W. L. Gore & Associates
Xcel ShercoFull-Scale Installation
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W. L. Gore & Associates
0%10%20%30%40%50%60%70%80%90%
100%
0.0% 1.0% 2.0% 3.0% 4.0% 5.0% 6.0% 7.0%Mercury Loading on SPC (wt%)
Mer
cury
Rem
oval
Effi
cien
cy (%
)
Measured removal on 6” SPC length scaled to 48” removal efficiency
2 million ton clinker/year plant needing 80% Hg reduction:
~2000 modules Projected capacity: ~2 tons Hg
Module Lifetime Projections
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W. L. Gore & Associates
Status of Commercialization• High volume module
manufacturing lines starting up end of this year– Gore’s Elkton Maryland plants
• Multiple full-scale installations are planned for 2014– Commercial installations with
guarantees
• Strong partnerships in place in target industries
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W. L. Gore & Associates
GORE™ Mercury Control System
SimpleNo adjustments
No sorbent injection
No CKD contamination
RobustCaptures elemental and oxidized mercury
Insensitive to common sorbent poisons (SO3, VOCs)
90+% mercury removal possible
Guaranteed mercury control
Cost-EffectiveLong module lifetime / low operating cost
Low pressure drop
Acid gas reduction co-benefit
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W. L. Gore & Associates
Summary• Gore continues to focus research on new products
to address air pollution control challenges– Particulate collection
– Gas phase remediation
• New approach to mercury control– Attractive alternative to sorbent injection
• Field testing has demonstrated high efficiency and long module lifetime
• Commercial installations starting in 2014
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W. L. Gore & Associates
Contact Information
• John Knotts– [email protected]– 610/937-1000
• Jeff Kolde – [email protected]– 410/506-7545
• John Tomanovich– [email protected]– 410/506-5581