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U.S. DOE s Hg Control Technology RDD Program Significant Progress, But More Work to be Done

Outline. BackgroundResults from sorbent injection field testsAcid gas interference issuesResults from FGD enhancement field testsByproduct-Hg issues/potential economic impactsConclusion. . . . Mercury Control Technology Program Performance/Cost Objectives . Have technologies ready for commercial demonstration by: 2007 that can reduce

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U.S. DOE s Hg Control Technology RDD Program Significant Progress, But More Work to be Done

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    1. U.S. DOE’s Hg Control Technology RD&D Program—Significant Progress, But More Work to be Done! Mercury 2006 – Conference on Mercury as a Global Pollutant August 6-11, 2006 Madison, Wisconsin

    2. Outline Background Results from sorbent injection field tests Acid gas interference issues Results from FGD enhancement field tests Byproduct-Hg issues/potential economic impacts Conclusion

    3. Mercury Control Technology Program Performance/Cost Objectives Have technologies ready for commercial demonstration by: 2007 that can reduce “uncontrolled” Hg emissions by 50-70% 2010 for all coals that can reduce “uncontrolled” Hg emissions by +90% Reduce cost by 25-50% compared to baseline cost estimates

    5. Sorbent Injection Technology Sorbent injection involves injection of sorbent, commonly powdered activated carbon, upstream of particulate collection device to capture gas-phase Hg

    6. Conventional ACI DARCO Hg is a conventional PAC developed by NORIT Americas Super HOK is an untreated sorbent developed in Germany by RWE RheinbraunDARCO Hg is a conventional PAC developed by NORIT Americas Super HOK is an untreated sorbent developed in Germany by RWE Rheinbraun

    7. Conventional ACI with Chemical Additives Sorbent Enhancement Additives (SEA) Additional field testing scheduled for: 1) subbituminous-fired unit equipped with SCR and SDA/FF 2) bituminous-fired unit equipped with an SCR, CS-ESP and wet FGDSorbent Enhancement Additives (SEA) Additional field testing scheduled for: 1) subbituminous-fired unit equipped with SCR and SDA/FF 2) bituminous-fired unit equipped with an SCR, CS-ESP and wet FGD

    8. Chemically-Treated ACI DARCO Hg-LH is a brominated PAC developed by NORIT Americas B-PAC is a brominated PAC developed by Sorbent Technologies Corp. MerClean 8 is a chemically-treated PAC developed by ALSTOMDARCO Hg-LH is a brominated PAC developed by NORIT Americas B-PAC is a brominated PAC developed by Sorbent Technologies Corp. MerClean 8 is a chemically-treated PAC developed by ALSTOM

    9. ACI Upstream of a Hot-side ESP H-PAC is a chemically-treated PAC developed by Sorbent Technologies for HS-ESP applicationsH-PAC is a chemically-treated PAC developed by Sorbent Technologies for HS-ESP applications

    10. TOXECON II™ Configuration Low-Cost Options for Moderate Levels of Mercury Control – ADA-ES will test two new mercury control technologies: TOXECON II™ and unique sorbents for injection into hot-side ESPs. The TOXECON II technology injects activated carbon directly into the downstream collecting fields of an electrostatic precipitator (ESP). The majority of the fly ash is collected in the upstream collecting fields, resulting in only a small portion of carbon-contaminated ash.Low-Cost Options for Moderate Levels of Mercury Control – ADA-ES will test two new mercury control technologies: TOXECON II™ and unique sorbents for injection into hot-side ESPs. The TOXECON II technology injects activated carbon directly into the downstream collecting fields of an electrostatic precipitator (ESP). The majority of the fly ash is collected in the upstream collecting fields, resulting in only a small portion of carbon-contaminated ash.

    12. Enhancing Mercury Removal with FGD

    13. Demonstrations at sites equipped with ESP and wet FGD: Monticello Station Unit 3 (TX Lignite/Subbit blend) After 17 months, oxidation of elemental mercury is currently: Previous pilot-scale testing at Coal Creek Station (CCS) and J.K. Spruce Plant. Fly ash build-up deteriorating the performance of the Hg oxidation catalysts 70 – 80% Hg oxidation after in-situ cleaning Currently refining S-CEM measurement techniques (problems may stem from high selenium levels in the TX Lignite coal leading to the formation of a mercury selenide precipitate during sampling)Previous pilot-scale testing at Coal Creek Station (CCS) and J.K. Spruce Plant. Fly ash build-up deteriorating the performance of the Hg oxidation catalysts 70 – 80% Hg oxidation after in-situ cleaning Currently refining S-CEM measurement techniques (problems may stem from high selenium levels in the TX Lignite coal leading to the formation of a mercury selenide precipitate during sampling)

    14. Field Testing of a Wet FGD Additive for Enhanced Mercury Control URS Group TXU’s Monticello Station burns TX lignite/PRB coal blend pilot-scale testing completed September 2005 re-emissions of elemental mercury were reduced Field Testing of a Wet FGD Additive for Enhanced Mercury Control - URS will demonstrate the use of an additive in wet lime or limestone FGD systems. The additive is designed to prevent oxidized mercury from being reduced and subsequently re-emitted into power plant flue gas streams as elemental mercury. The additive also assists in the removal of mercury from by-products and its separate disposal. This project represents the first known application demonstration in the United States of the additive to prevent mercury re-emissions from wet FGD systems in coal-fired power plants municipal waste incinerators. Testing will be conducted at three sites: (1) TXU’s Monticello Station which burns lignite coal; (2) 1. Southern Company’s Plant Yates which burns bituminous coal; and (3) AEP’s Conesville Station which burns bituminous coal. The research team also includes EPRI, TXU Energy, AEP, the Southern Company, and Degussa Corporation. NETL Project Manager: Charles Miller (charles.miller@netl.doe.gov) Field Testing of a Wet FGD Additive for Enhanced Mercury Control - URS will demonstrate the use of an additive in wet lime or limestone FGD systems. The additive is designed to prevent oxidized mercury from being reduced and subsequently re-emitted into power plant flue gas streams as elemental mercury. The additive also assists in the removal of mercury from by-products and its separate disposal. This project represents the first known application demonstration in the United States of the additive to prevent mercury re-emissions from wet FGD systems in coal-fired power plants municipal waste incinerators. Testing will be conducted at three sites: (1) TXU’s Monticello Station which burns lignite coal; (2) 1. Southern Company’s Plant Yates which burns bituminous coal; and (3) AEP’s Conesville Station which burns bituminous coal. The research team also includes EPRI, TXU Energy, AEP, the Southern Company, and Degussa Corporation. NETL Project Manager: Charles Miller (charles.miller@netl.doe.gov)

    15. Key Challenges to Continued/Increased By-Product Use Installation of additional FGD to meet CAIR (SO2) will increase volume of scrubber solids Installation of additional advanced combustion technology and SCR to meet CAIR (NOx) will increase UBC and NH3 in fly ash Use of sorbent injection or FGD for Hg control could negatively impact fly ash or scrubber solids utilization due to increased carbon content (for fly ash) and/or increased public “concern” about fate of Hg in fly ash and scrubber solids

    16. Projection of U.S. Coal-Fired Power Plant CUB Production 2004 production estimates per ACAA Survey 2020 projection based on EIA AEO 2006 coal-fired generation and EPA analysis of CAIR/CAMR regulations This slide is intended to drive home the point that additional coal-based power generation and compliance with the SO2 requirements of the Clean Air Interstate Rule and Clean Air Mercury Rule will lead to increases in the production of fly ash (due to additional coal combustion) and significant increases in FGD solids (due to additional coal combustion and installation of FGD). With concerns being raised about the fate of mercury in these materials, it is crucial that research continues to be carried out to ensure that these materials can be used/disposed in an environmentally safe manner. If not, the Nation will potentially be faced with higher electricity rates due to lost revenue from sale of byproducts and increase cost of disposal.2004 production estimates per ACAA Survey 2020 projection based on EIA AEO 2006 coal-fired generation and EPA analysis of CAIR/CAMR regulations This slide is intended to drive home the point that additional coal-based power generation and compliance with the SO2 requirements of the Clean Air Interstate Rule and Clean Air Mercury Rule will lead to increases in the production of fly ash (due to additional coal combustion) and significant increases in FGD solids (due to additional coal combustion and installation of FGD). With concerns being raised about the fate of mercury in these materials, it is crucial that research continues to be carried out to ensure that these materials can be used/disposed in an environmentally safe manner. If not, the Nation will potentially be faced with higher electricity rates due to lost revenue from sale of byproducts and increase cost of disposal.

    17. Incremental Cost of 70% ACI Mercury Control IEP Short-term Goal – 25% of baseline cost ($60,000)IEP Short-term Goal – 25% of baseline cost ($60,000)

    18. Key Takeaways from Field Testing Halogenated activated carbon and halogen-based additives have shown to be effective in capturing elemental Hg from low-rank coals with both ESP and fabric filters Estimated cost of Hg control on a $/lb removed basis continues to decline under “no by-product impact” scenario Further long-term field testing is needed to bring technologies to commercial-demonstration readiness, particularly related to potential BOP issues such as increasing particulate loading and impacts of sulfur/SO3 and small SCA ESP on ACI effectiveness Potential coal combustion byproduct impacts on cost of mercury control remain a “wild card” DOE’s RD&D model projects broad commercial availability in 2012-2015

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