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TRANSCRIPT
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Portland Cement Association Meeting
August 24, 2009
Potential Solutions for Mercury Controlin the Cement Industry
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Agenda
• Albemarle Sorbent Technologies – Quick Overview
• Mercury Sorbents
• Control Options for Cement Kilns
• Questions
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Albemarle Corporation Net Sales
Catalysts: refinery catalysts, polymer catalysts, etcPolymer Additives: flame retardants, stabilizers, curatives, antioxidantsFine Chemicals: brominated derivatives, pharmaceutical APIs, custom synthesis
Polymer Additives39%
Catalysts 38%
Fine Chemicals23%
Largest producer of bromine and brominated products in NAOne of the three major producers globally
2008 Net Sales - $2.5 billion
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Well Positioned to Grow in Diverse End-Markets
OtherIndustrial
Auto / Transp
ort
Construction
Packaging Chemical Services
Consumer Electronics
Refining8-10%
4-6%
6-10%3-5%
5%
3-5%
2-4%
Net Sales Distribution
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Albemarle Sorbent Technologies Provides Total Mercury Reduction Solutions
Provide brominated chemicals such as CaBr2 , NaBr, and H2Br for addition to coal or to flue gas.
Provide bromine containing activated carbon sorbents to remove Hg from flue gas.
Supply PAC injection systems
A Mobile Demonstration Unit available for Full-scale Trials
Albemarle is active in many parts of the Hg control value chainInjection Systems, Sorbent, and Chemical Additives
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Full Service Mercury Company
Field Trials
Consulting Services
Sorbent Injection Systems
Mercury sorbents
Bromine Chemicals
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Field Trials & Consulting
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Injection Trailer
Easily moved from site to siteand hooked up for inexpensiveB-PAC sorbent injection testing.
Can be used on CS-ESP gasstreams of up to about 500 MW.
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Sorbent Injection Systems
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Sorbent Injection Systems
9 installedto date
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M-PACTTM Sorbent Injection Systems
For use in utility or industrialapplications requiring aninjection rate of less than200 pounds of sorbent per hour.
Less capital cost andless installation cost
Up to 5000 pound sorbent storage capacity and can be fed from a tanker used forsorbent storage
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M-PACTTM Injection Systems
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Sorbent Production
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Commercial Sorbent Production
• Albemarle increased capacity& working on further increases
• B-PAC™ high performance,C-PAC™ concrete-friendly™,H-PAC™ high-temperaturegas-phase brominated Hgsorbents are all now shipping on a daily basis
Load-out at Ohio sorbent production plant
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Security of Supply
Security of Supply:
BromineAlbemarle is the leading supplier of bromine and bromine derivatives in North America and the 2nd largest in the world (plants in USA, Jordan, JV in Asia)
Powdered Activated CarbonA portfolio of international suppliers and a new Domestic Source
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Security of Supply
Security of Supply:
BromineAlbemarle is the leading supplier of bromine and bromine derivatives in North America and the 2nd largest in the world (plants in USA, Jordan, JV in Asia)
Powdered Activated CarbonA portfolio of international suppliers and a new Domestic Source
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Security of Supply
Wickliffe, KYCovington, VA
• To expand its supply capabilities, Albemarle has been partneringwith MeadWestvaco (MWV) on the development of PAC bases
• MWV a $6.6 Billion supplier with two AC plants
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DEMONSTRATIONS AND TRIALS PERFORMED USING ALBEMARLE SORBENTS
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ID
AZ
UT
MT
WY
NM
CO
AL
FL
SC
TN
KY
INOH
NC
SD
KS
NE
MN
WI
IA
IL
MO
AR
MS
OK
ND
OR
CA NV
WA
AK
PA
ME
VA
NY
CT
WV
MDNJ
VT
NH
MA
DE
RI
HI
LA
MI
GA
TX
Locations of Customers and Full- Scale Trials of B-PAC™, C-
PAC™, and H-PAC™
Locations of Customers and Full- Scale Trials of B-PAC™, C-
PAC™, and H-PAC™
Fully Proven Technology
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0
10
20
30
40
50
60
70
80
90
100
0 2 4 6 8 10 12 14 16 18 20
Sorbent Injection Rate (lb/MMacf)
Mer
cury
Rem
oval
(%)
Mercury Removal with Plain PACs
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0
10
20
30
40
50
60
70
80
90
100
0 2 4 6 8 10 12 14 16 18 20
Sorbent Injection Rate (lb/MMacf)
Mer
cury
Rem
oval
(%)
B-PAC
Mercury Removal with B-PAC
Plain PAC
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All sorbents are NOT the same!
Sorbent Specifications• Bromine Level• Thermal Characteristics • Electrostatic Characteristics• Particle Sizes
Different carbon feedstocksDifferent forms of bromineDifferent processing
Frequentlyyields
differentresults
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Gas-Phase Brominated vs. Salt-Impregnated
Gas-Phase Brominated = chemically-reacted bromine(carbon-bromine surface compounds)
Salt-Impregnated = physically-applied bromine(e.g. will wash right off)
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The Key Measurement is Cost Per Pound of Hg Removed!
The cheapest PAC per-poundis not necessarily
the lowest-cost PAC
If 30% more of Br-salt PAC is required to achieve the same Hg removal as a Br-gas PAC and the sorbents cost the same, thenthe gas-phase PAC is really 30% less expensive.
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If we were a carbon company, we’d want you to buy twice the carbon.
7-10 wt%Br
4 wt%?Br
Albemarle Others
One Possible Reason: Bromine Level
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Bromine Impact on Hg Performance
0.10
1.000 2 4 6 8 10 12
Wt% Br in PACFr
actio
n of
Hg
rem
aini
ng in
flue
gas
0.80
0.50
0.60
0.70
0.40
0.90
Removal
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Mercury Control in Cement Kilns
1. Add-on particulate control and sorbent injectionequipment – works but costly
2. Add only a sorbent injection system and injectC-PAC a concrete-friendlyTM mercury sorbent -to be demonstrated but much less costly
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Add-On Baghouses and ACI Systems
ESPESPESP
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Mercury Capture in a Baghouse
2008 Mega Symposium
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High Mercury Level Application
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Long-Term Comparative Trials
Great River Energy
Great River Energy
PRB coal & CS-ESP
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Relative Performance
30 days of B-PAC at 1.6 lb/MMacf
60 days of Norit Hg-LH at 1.8 lb/MMacf
Slide: URS CorpOrange added. 2008 Mega Symposium
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Problem with Add-On Baghouses
Bustard, J., 2006 Mega Symposium
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In-Process Mercury Control Concept
Utilize the existing baghouse
Add only a sorbent injection system (low capital cost)
Use C-PACTM a concrete-friendlyTM sorbent
Inject only at selected times
Direct CKD collected during injection to cement mill rather than recycle to the cement kiln
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In-Process Mercury Control
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In-Process Hg Control Concept
Inject only when Hg emission is the highestSeparate the CKD generated during that timeUse concrete-friendlyTM mercury sorbent to avoid any impact on the cementitous properties of the CKDDirect the separated CKD to the cement grinding millThe mercury won’t leach since it has reacted on the mercury sorbentThe injection length is only long enough to reduce the mercury emission below the MACT standard.
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Summary
Mercury control technology has reached the stage ofcommercial application
Not all sorbents are the same
Customer should select the most cost-effective on $/lb of Hg removed not $/lb of sorbent
Cement kilns have two control options – Add-on baghouse and ACI system or in-process control.
