STACK EMISSION TEST RESULTS FROM EXISTING AND NEW HIGH TEMPERATURE FLUID BED MUNICIPAL SLUDGE INCINERATORS OPERATING IN US AND ONTARIO (CA)

K. Dangtran, Ph.D., DFBC Consulting, LLC L. Takmaz, Ph.D., SUEZ

NJWEA 103rd ANNUAL CONFERENCE & EXPOSITION

BALLY’S ATLANTIC CITY

ATLANTIC CITY, NJ

May 8th, 2018

High Temperature Fluid Bed Municipal Sludge Incinerators

(Thermylis®, SSI, HTFB, Thermal Oxidizer)

MACT Background Information & MACT Limits

MACT Compliance Equipment

Stack Emission Test Results

Conclusions

TOPICS OF DISCUSSION

High Temperature Municipal Sludge Incinerators

NEW INCINERATOR TO MEET US EPA MACT

High Pressure Water Pump

Fluidizing

Air Blower

Preheat Burner

Combustion Air

Venturi

Scrubber

Primary Secondary

Heat Exchangers

Stack

Tray

Scrubber Wet

ESP

Service Water

Compressed Air

Sand

Storage

Exhaust

Gas Duct

Feed Pump

Sludge Dewatering

Sludge

Sand

Purge Air Blower

Gas

Feed

Purge

Blower

CEMS

Ash Treatment

Settling Lagoon

Caustic

Service Water

Carbon Bed Adsorber

Demister

Urea (or Ammonia) Injection

Hg

Dioxin

Furan

Cd

Pb

PM

NOx

SO2

HCl

PM

PROCESS BLOCK DIAGRAM

FLUID BED REACTOR

Preheat Burner

Sand Port

Sand Bed

Tuyere

Windbox

Fluidized Bed

Hot Air Inlet

(1200F)

Sand

Removal Nozzle

Sludge

Feed Nozzle

Freeboard

Tear Drop

Reactor Design

Self Supporting

Refractory Roof Freeboard

Auxiliary Fuel

Injectors

FLUID BED REACTOR

TYPICAL HEAT INPUT / OUTPUT

MUNICIPAL SLUDGE

27-28%TS

AUX FUEL

PREHEAT AIR

EXHAUST GAS & HEAT LOSS

AUXILIARY FUEL REQUIREMENT

Basis: Excess Air 40%, Feed Rate 454 kgDS/hr (1,000 lbs /hr), 75% VS,

5,556 kcal/kg (10,000 btu/lb) VS, 1550 F Freeboard, Auxiliary Fuel HHV

10,500 kcal/kg (18,900 btu/lb)

0

50

100

150

200

250

300

350

400

450

500

18% 20% 22% 24% 26% 28% 30% 32% 34% 36% 38% 40%

Sludge DS%

Auxil

iary F

uel L

b/hr

1200 F 1000 F 800 F 600 F 120 F

PRIMARY HEAT RECOVERY

Primary Heat Exchanger

(Tube & Shell)

• Preheat Combustion Air

• Eliminate Auxiliary Fuel Usage

SECONDARY HEAT RECOVERY

Secondary Heat Exchanger (Tube & Shell), Waste Heat Boiler, Thermal Oil Economizer, Hot Water Economizer

• Plume Suppression

• Process Steam Generation

• Seasonal Building Heating

• Thermal Fluid Heating

• Electricity Production (Turbine Generator )

WET ASH SYSTEM (WET APCS)

High Pressure Water Pump

Fluidizing

Air Blower

Preheat Burner

Combustion Air

Venturi

Scrubber

Primary Secondary

Heat Exchangers

Stack

Tray

Scrubber Wet

ESP

Service Water

Compressed Air

Sand

Storage

Exhaust

Gas Duct

Feed Pump

Sludge Dewatering

Sludge

Sand

Purge Air Blower

Gas

Feed

Purge Blower

Circulating

Pump

CEMS

Ash Treatment

Settling Lagoon

Caustic

Service Water

Carbon Bed Adsorber

Demister

Urea (or Ammonia) Injection

DRY ASH SYSTEM (DRY APCS)

Inlet Sludge

Sand Silo

Incinerator

Flue Gas

Natural Gas

Air for

Fluidization

Heat

Exchanger Economizer

Expansion

Tank

Hot

Water

Circuit

Building Usage

Fin Fan

Cooler

Stack

Bag Filter

Ash

Silo

ID Fan

k

Sodium Bicarbonate

and Activated Carbon

SEMI-DRY ASH SYSTEM (SEMI-DRY APCS)

Inlet Sludge

Sand

Silo THERMYLIS

Incinerator

Flue Gas

Natural Gas

Air for

Fluidization

Heat

Exchanger Economizer

Expansion Tank

Hot Water

Circuit

Building

Heat Exchanger

Fin Fan Cooler

Scrubber

Drain

Caustic Soda

Circuit

Water

Stack

Bag Filter

Ash

Silo

ID Fan

FLUID BED INCINERATION ADVANGATES

Continuous Autothermic Process

Flexible Process for Variations in Total Solids

Turbulence Without Moving Parts

Nearly Isothermal Conditions

Quick Response to Variations in Feed Rate

Minimum Heat Loss During Shutdowns

High Combustion Efficiency at Low Excess Air

Power Generation

HOT WINDBOX

REACTOR

PRIMARY

HEAT EXCHANGER

DUFFIN CREEK, ON

2 Trains – 115 DTP each with Steam Generation

MILL CREEK, OH

3 Trains – 96 DTP each

GREEN BAY, WI

1 Train – 51 dry TPD

LITTLE BLUE VALLEY, MO

1 Train – 60 dry DTP

SLUDGE PORT AND AUXILIARY FUEL GUNS

Sludge Lines Fuel Injectors

SNCR FOR NOx REMOVAL

Urea, when combined with NOX of the flue gas at high temperatures,

transforms the noxious substances into N2, CO2 and H2O

SNCR = Selective Non-Catalytic Reduction

VENTURI SCRUBBER FOR PM, HCl and SO2

Caustic

Injection

REACTOR REHAB

MACT Background Information

MACT Limits

MACT (Maximum Achievable Control Technology)

Issued by US EPA on March 21st, 2011

Applies to new and existing municipal sludge fluid bed incineration

plants in US

Compliance by March 21st, 2016 for all plants in operation

Plants not in compliance with MACT should be retrofitted to meet the

new emission limits

Retrofit Equipment: Wet ESP, Mercury Removal System, Scrubber

Caustic Addition, NOx Removal System

MACT BACKGROUND INFORMATION

US EPA MACT LIMITS

EPA Guideline for NEW and EXISTING FB Incinerators

Pollutant Units Existing FB

(@ 7% O2)

New FB

(@ 7% O2) Cd mg/dscm 0.0016 0.0011

CO ppmvd 64 27

HCl ppmvd 0.51 0.24

Hg mg/dscm 0.037 0.0010

NOx ppmvd 150 30

Pb mg/dscm 0.0074 0.00062

PCDD/PCDF,TEQ ng/dscm 0.1 0.0044

PCDD/PCDF,TMB ng/dscm 1.2 0.013

PM mg/dscm 18 9.6

SO2 ppmvd 15 5.3

EMISSIONS CONTROL FOR NEW FACILITY

Pollutant based equipment selection

Pollutant Equipment

CO High Efficiency Combustion

NOx Ammonia/Urea Injection at Freeboard (SNCR)

SO2

Caustic injection at Wet Scrubber

HCl

PM

Cd Venturi Scrubber + Wet ESP

Pb

Hg

Fixed Carbon Bed Adsorber PCDD/PCDF,TEQ

PCDD/PCDF,TMB

MACT Compliance Equipment

TYPICAL PROCESS FLOW DIAGRAM (RETROFIT EQUIPMENT)

SPC: Sorbent Polymer Composite

To Ash Treatment

Sludge

Fluidizing Air Blower

Primary Heat

Exchanger

Compressed Air

Sand Storage

Silo

Exhaust Gas Duct

Centrifuge

Decanter

High Pressure

Water Pump

Sand

Purge Air Blower

Fuel Oil

Natural Gas

Feed Pump

Fuel Oil Pump

Fuel Oil Pump

Urea or Ammonia

Quench Scrubber

Stack

Plant Water

Continuous Emissions

Monitoring System

Tray Cooler

Venturi Section

Fixed Carbon Bed Adsorber

or SPC Modules

Wet ESP

Caustic

Injection

TYPICAL PROCESS FLOW DIAGRAM (RETROFIT EQUIPMENT)

Quench Scrubber

Stack

Plant Water

Continuous Emissions

Monitoring System

Tray Cooler

To Ash Treatment

Fluidizing Air Blower

Primary Heat

Exchanger

Compressed Air

Sand Storage

Silo

Exhaust Gas Duct

Centrifuge

Decanter

Sludge

High Pressure

Water Pump

Sand

Purge Air Blower

Fuel Oil

Natural Gas

Feed Pump

Venturi Section

Deaerator

Softener

Waste Heat Boiler & Economizer

Steam Turbine

Fuel Oil Pump

Fuel Oil Pump

ID Fan

Fixed Carbon

Bed Adsorber

or SPC Modules

Steam Recovery & Condensate

System

Secondary Heat Exchanger

Electricity Generator

Wet ESP

Caustic

Injection

Urea or Ammonia

SPC: Sorbent Polymer Composite

Stack Emission Test Results

RETROFIT PLANT INFORMATION (SPC MODULES)

From

Waste Heat

Recovery

To Stack

Scrubber SPC Modules

Flue Gas Flow

MERCURY REMOVAL

Stand alone installation

Guaranteed to achieve up to 70% removal of Hg*

Proprietary expanded PTFE material

MERCURY REMOVAL

THERMYLIS PLANT EMISSIONS (EXISTING INCINERATORS)

0

0.0005

0.001

0.0015

0.002

Cd

00.20.40.60.8

11.21.4

CDD/CDF, TMB

0

0.02

0.04

0.06

0.08

0.1

0.12

CDD/CDF, TEQ

010203040506070

CO

THERMYLIS PLANT EMISSIONS (EXISTING INCINERATORS)

0

2

4

6

8

10

12

14

16

18

20

PM

0

2

4

6

8

10

12

14

16

SO2

THERMYLIS PLANT EMISSIONS (EXISTING INCINERATORS)

00.10.20.30.40.50.6

HCl

0

0.01

0.02

0.03

0.04

Hg

0

50

100

150

200

NOx

0

0.002

0.004

0.006

0.008

Pb

Average mercury removal efficiency for Incinerator 4, 5, 6 and 7 = 87%

NEW PLANT INFORMATION (FIXED CARBON BED)

From

Waste Heat

Recovery To Stack

Scrubber

Conditioner

Adsorber

Start Up Heater Skid Flue Gas Flow

INCINERATOR NO. 1

Incinerator No. 1 is equipped with fixed carbon bed installed after scrubber (Canadian Installation)

0

10

20

30

40

50

60

70

80

90

100

110

Em

issio

n

0.15

ppm

0.5

microgram/m3

2

pg/m3

0.6

mg/m3

INCINERATOR NO. 2

Incinerator No. 2 is equipped with fixed carbon bed installed after scrubber (Canadian Installation)

0

10

20

30

40

50

60

70

80

90

100

110

Em

issio

n

0.517

ppm

0.35

mg/m3

0.91

microgram/m3

3.7

pg/m3

INCINERATOR NO. 3

Incinerator No. 3 is equipped with fixed carbon bed installed after wet ESP (US Installation)

020406080

100120140160

Em

issio

n

00.20.40.60.8

11.21.41.61.8

2

Em

issio

n

0

0.02

0.04

0.06

0.08

0.1

0.12

Em

issio

n

00.0010.0020.0030.0040.0050.0060.0070.0080.009

0.01

Em

issio

n

A B

C D

INCINERATOR NO. 4 & 5

Incinerators No. 4 & 5 are equipped with fixed carbon bed installed after scrubber (Canadian Installation)

0

10

20

30

40

50

60

70

80

90

Em

issio

n

Incinerator No. 4

0102030405060708090

Em

issio

n

Incinerator No. 5

0.499

ppm

0.587

ppm

INCINERATOR NO. 6

Incinerators No. 6 is equipped with fixed carbon bed installed after scrubber (Canadian Installation)

0

10

20

30

40

50

60

70

80

90

100

110

Min. Oxygen (%) Total Hydrocarbons(ppm) 10 min Avg.

Total Hydrocarbons(ppm) 30 min Avg.

TSP (mg/m3) HCl (ppm) Mercury(microgram/m3)

Dioxin-Furan (TEQ)(pg/m3)

Em

issio

n

0.791

ppm

INCINERATOR NO. 7

Incinerators No. 7 is equipped with fixed carbon bed installed after scrubber (Canadian Installation)

0

10

20

30

40

50

60

70

80

90

TSP (mg/DRm3) Hg (microgram/DRm3) HCl (mg/DRm3) Dioxin-Furan (TEQ) (pg/DRm3)

Em

issio

n

0.289

ppm

INCINERATOR NO. 8

Incinerator No. 8 is equipped with fixed carbon bed installed after wet ESP (US Installation)

0102030405060708090

100

Em

issio

n

0

2

4

6

8

10

Em

issio

n

0

1

2

3

4

5

6

Em

issio

n

0

0.001

0.002

0.003

0.004

0.005

Em

issio

n

A B

C D

MERCURY EMISSIONS (SPC)

0.0000

0.0100

0.0200

0.0300

0.0400

0.0500

0.0600

0.0700

0.0800

Hg

Em

issio

n (

mg

/dscm

)

Existing Incinerators (US Installation) -vs- MACT

0.0000

0.0100

0.0200

0.0300

0.0400

0.0500

0.0600

0.0700

0.0800

Hg

Em

issio

n (

mg

/drc

m)

Existing Incinerators (US Installation) -vs- Ontario (CA)

MACT Limit For Existing Incinerator

Ontario Limit For New Incinerator

MERCURY EMISSIONS (FIXED CARBON BED)

0.00000

0.00050

0.00100

0.00150

0.00200

0.00250

0.00300

0.00350

0.00400

Incinerator 1 Incinerator 2 Incinerator 3 Incinerator 4 Incinerator 5 Incinerator 6 Incinerator 7 Incinerator 8

Hg

Em

issio

n (

mg

/dscm

)

New Incinerators (US Installation) -vs- MACT

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

Incinerator 1 Incinerator 2 Incinerator 3 Incinerator 4 Incinerator 5 Incinerator 6 Incinerator 7 Incinerator 8

Hg

Em

issio

n (

mg

/dscm

)

New Incinerators (Canadian Installation) -vs- Ontario (CA)

Designed and Built

Before MACT

Designed and Built

After MACT

0.037 mg/dscm (MACT Limit for Existing Installation)

0.001 mg/dscm

(MACT Limit for New Installation)

Ontario Limit For New Incinerator

FIXED CARBON BED MERCURY REMOVAL EFFICIENCY

60

70

80

90

100

0 1 2 3 4 5 6

Hg

Rem

ov

al

Eff

icie

ncy (

%)

Test Points

Low Inlet Mercury Level in Sludge

High Inlet Mercury Level in Sludge

Conclusions

CONCLUSIONS

o 9 existing and 8 new incinerators have been considered for this

study. Incinerators are located in US and Ontario (CA).

o Retrofitted plants are meeting the MACT emission limits in US.

o For new incineration systems in US, we recommend fixed carbon

bed adsorber to be able to meet 1 micron/dscm mercury emission

requirement in stack. Extremely high efficiency (>95%).

o For existing incineration systems in US, we recommend SPC

modules to be able to meet 37 micron/dscm mercury emission

requirement. Low removal efficiency (>70%).

o Fixed carbon bed adsorber is difficult to operate compared to SPC

modules. However, it has significantly higher removal efficiency.

o For new incineration systems in Ontario (CA) (70 microgram/drm3),

we recommend SPC modules for mercury removal.

Thank you