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(c) 2012 Babcock Power, All rights reservedSlide 1

ONE SOURCE ● ONE PURPOSE ● MANY SOLUTIONS

Circulating Dry Scrubbers (CDS)

Webinar Presentation2012 Mid-Atlantic Regional Air Management Association

SO2/HCl Control Technology July 19, 2012


Agenda

A. U.S. EPA Standards & Rules

B. Circulating Dry Scrubbers

-Technology

-Experience

-Performance

C. Summary


Agenda

A. U.S. EPA Standards & Rules

B.B.B. Circulating Dry Scrubbers Circulating Dry Scrubbers Circulating Dry Scrubbers

---TechnologyTechnologyTechnology

---ExperienceExperienceExperience

---PerformancePerformancePerformance

C.C.C. SummarySummarySummary


U.S. EPA Standard & Rules

• Cross State Air Pollution Rule

(CSAPR)

• Mercury and Air Toxic Standards

(MATS)

• New Source Review Program

U.S. EPA Standards & Rules

1970 Clean Air Act


Cross State Air Pollution Rules

• SO2 contributes to PM2.5,

NOx contributes to Ozone

• 27 upwind states must meet state

by state allocations

• EPA has developed database of

power stations and required

reductions of SO2 and NOx



*>8300 Btu/lb Moist and mineral matter free

0.0002 lb/GWh0.40 lb/GWh0.007 lb/MWhNew coal firing not

low rank virgin

coal*

1.2 lb/E12 Btu

(0.013 lb/GWh)

0.0020 lb/E06 Btu

(0.020 lb/MWh)

0.030 lb/E06 Btu

(0.30 lb/MWh)

Existing coal firing

not low rank virgin

coal*

MercuryHydrogen Chloride

Filterable

Particulate Matter

EGU

Subcategory

1 lb/E06 Btu * E06 Btu/1,000,000 Btu * 10,000 Btu/kWh * 1,000 kWh/MWh = 10 lb/MWh

1 lb/E12 Btu * E06 Btu/1x1012 Btu * 10,000 Btu/kWh * 1x106 kWh/GWh = 0.01 lb/GWh

Mercury & Air Toxic Standards



New Source Review Program


• SO2, NOx, CO, Particulate, HAPS,

Green House Gases

• Best Available Control Technology

• PM, PM2.5, PM10, Condensable PM

– Condensables measured using

Method 202 mostly affecting PM2.5

– Proposed revision: Condensables not

included in PM, but in PM2.5 & PM10.



Andracsek. R. The Air is Getting Cleaner, Power Engineering, June 2012.


Agenda

A.A.A. U.S. EPA Standards & RulesU.S. EPA Standards & RulesU.S. EPA Standards & Rules


-Technology





SO2 95 – 98 %

SO3 95 – 99 %

HCl 95 – 99 %

HF 95 – 99 %

Mercury 90 – 95 %

Coals up to 6 lbs of SO2/E06Btu

SO2 down to 0.03 lb/E06Btu

Reduces Condensables

Emissions Summary

Circulating Dry Scrubbers


( )( )

( )( ) OHCaFOHCaHF

OHCaClOHCaHCl

OHCaSOOHCaSO

OHCaSOOHCaOSO

OHCaSOOHCaSO

222

222

2423

24222

2322

22

22

)(

½

+→++→++→+

+→+++→+

CHEMISTRY



Process




Flue Gas (From Air Heater/ID Fans)

Control Damper

Turbosorp®

Fabric Filter

Air Slide

Surge Bin

Stack

Ash Disposal

Hydrated Lime Silo

Hydrated Lime Blower(s)

Process Water Tank

Process Water Pump(s)

SO2

F

T

∆P

L

ID / Booster Fan

Air SlideBlower

SO2

P

OUTLET SO2 CONTROL LOOP

f(x)

CONTROL PARAMETERS:- Feed Forward Inlet SO2 and Flue Gas Flow- Feedback trim Outlet SO2

- Controls Lime Injection Rate- Percent Removal or Outlet Concentration

BOILER LOAD TURNDOWN CONTROL LOOP

CONTROL PARAMETERS:- Direct control outlet flue gas flow- Maintains minimum required velocity through

Venturi- Controls damper position

OUTLET FLUE GAS TEMPERATURE (APPROACH TO SATURATION) CONTROL LOOP

CONTROL PARAMETERS:- Direct control outlet flue gas temperature- Maintains approach temperature regardless of

reagent demand by adjusting water injection rate

REACTOR BED DENSITY CONTROL LOOP

CONTROL PARAMETERS:- Direct control of the bed density / pressure loss

through reactor- Maintains bed density by product recirculation

PRODUCT DISCHARGE / AIR SLIDE LEVEL CONTROL LOOP

CONTROL PARAMETERS:- Direct control of air slide air pressure- Level alarms to ensure proper operation- Discharge rate maintains product level within air

slide

f(x)

Process Control

Reactor


Internal Solids Recirculation Enhances Reactions

Flue Gas and Solids Path Diagram

High Solids Recirculation

Turbulent Reactor Mixing

No Slurry Handling



CaSO ½ H O3 2

Ca(OH)2

CaSO ½ H O3 2

Ca(OH)2

CaSO ½ H O3 2

Ca(OH)2

Formation of reaction

products layer

Reactivation of Reacted Sorbent


Reaction after

first pass

Water added to

surface during

recirculation

Sulfite crystal

forms, exposing

fresh surfaces



• Turbulent Mixing in Reactor

– High flue gas solid contact

– Internal reactor solid recirculation

– No flue gas sneakage

– High apparent reactor stoichiometry

Features

• High Solids Circulation

– Reactor solids rewetting

– Secondary Removals with Fabric Filter



• Construction

– Mild Steel

– Modular

– Dry Stack

• Water Injected Separately

– No slurries

– No limit on hydrated lime injection rate

– No waste water

Features (continued)


Agenda




-Experience




Suppliers

• Graf-Wulff

• Allied Environmental

• Alstom Novel Integrated Desulfurization

• Babcock Power Environmental

– Turbosorp® Circulating Dry Scrubber

– Licensee to Austrian Energy & EnvironmentFor North American Coal-Fired Applications

CDS Experience

Buecker B., Hovey, L. Circulating Dry Scrubbers: A New Wave in FGD?, Power Engineering, November 2011.


•Systems have been operating since 1994

•60 CDS systems in Europe

– 34 units on coal

•14 CDS projects in China

•24 CDS projects in the U.S.

•Five Turbosorp® CDS Coal-fired Systems

Operating in the U.S.

World Wide Experience

CDS Experience


AES Greenidge Turbosorp®

Dresden, NY

Boiler 115 MW

Fuel Bituminous Coal

S-Content in Coal 2.9%

By-Product Stabilized Product

Volume Flow 277,800 SCFM

SO2 Inlet 2,100 ppmv

SO2 Removal > 95 %

Startup 2006

Design Data Turbosorp ®

Absorber Vessel

Baghouse

Lime Hydration

System

Quicklime Silo

~0.4 acre

Booster Fan

Turbosorp ®

Absorber Vessel

Baghouse

Lime Hydration

System

Quicklime Silo

~0.4 acre~0.4 acre

Booster Fan

CDS Experience


CDS Experience

Roquette Turbosorp®

Keokuk, Iowa

Design Data

Boiler: 80 MW CFB boiler

Fuel: Coal+ pet coke

Flue gas capacity: 210,000 SCFM

SO2 concentration: 400 ppmv

SO2 Removal: > 90%

Sorbent: Carryover from CFB boiler

Start-up: 2007


CDS Experience

AES Westover Turbosorp®

Johnson City, NY

• Boiler 90 MW

• Fuel Bituminous coal

• S-Content in coal 2.2 %

• By-product Stabilized product

• Volume flow 258,300 SCFM

• SO2 inlet 650 ppmv dry @ 6%O 2

• SO2 removal > 95 %

• Startup 2008

Design Data


CDS Experience

First Light – Mount Tom Turbosorp®

Holyoke, MA

Boiler 155 MW


S-Content in Coal 1.5 %




SO2 Removal > 95 %

Startup 2009

Design Data


CDS Experience

Gainesville Regional Utilities

Deerhaven Turbosorp®

Gainesville, FL

Boiler 238 MW


S-Content in Coal 1.5 %




SO2 Removal > 95 %

Startup 2009

Design Data


Agenda





-Performance



75

80

85

90

95

100

0.0 1.0 2.0 3.0 4.0 5.0 6.0Inlet SO 2 (lb/E06 Btu)

SO

2 R

emov

al (

%)

Existing EGUNew EGUMeasured Removal

EPA MATS

Turbosorp® SO2 Removal

Compared to EPA MATS

CDS Performance

Ake, T. et. al. Measured Particulate, HCl, and Hg Emissions from Circulating Dry Scrubbers Compared to the EPA Mercury Air Toxic Standards,

To be presented at AWMA MegaSymposium, Baltimore MD, August 2012.


0.00

0.50

1.00

1.50

2.00

3.0 3.5 4.0 4.5 5.0Inlet SO 2 (lb/E06 Btu)

Sta

ck S

O2

(lb/M

Wh)

New-EGU EPA MATS Limit

U.S. DOE CDS Parametric Tests * >95% SO2 Removal

Existing-EGU EPA MATS Limit

* Connell, D. Greenidge Multi-pollutant Control - Project Final Report. U.S. DOE Coop. Agreement DE-FC26-06NT41426, April 2009.

Turbosorp® SO2 Emissions


CDS Performance


Turbosorp® Acid Gas Removal


75

80

85

90

95

100

0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10Inlet (lb/E06 Btu)

Rem

oval

(%

)

Existing EGUNew EGUHClSO3HF

EPA MATS - HCl

Average SO 2

Removal = 96%

Outlet measurements below detection

Both Inlet & Outlet measurements below detection

CDS Performance


CDS Performance

Turbosorp® HCl Emissions


0.0000

0.0020

0.0040

0.0060

0.0080

0.0100

0.0120

0.0140

0.0160

0.0180

0.0200

0.000 0.010 0.020 0.030 0.040 0.050 0.060

Inlet HCl (lb/E06 Btu)

Sta

ck H

Cl (

lb/M

Wh)

New-EGU EPA MATS Limit

Outlet measurements below detection

U.S. DOE CDS Parametric Tests* SO2 Removal > 95%

Existing-EGU EPA MATS Limit

* Connell, D. Greenidge Multi-pollutant Control - Project Final Report. U.S. DOE Coop. Agreement DE-FC26-06NT41426, April 2009.


Turbosorp® PM Emission Data


0.000

0.005

0.010

0.015

0.020

0.025

0.030

1 2 3 4

Power Station Number

Total PM*

Filterable

0.000

0.005

0.010

0.015

0.020

0.025

0.030

EPAMATS

FilterablePM Limit

Em

issi

on (

lb/E

06 B

tu)

Existing EGU

New EGU

* Includes condensables

CDS Performance


Filterable Particulate Emission Data

Figure from U.S.DOE Report*

*Connell, D. Greenidge Multi-pollutant Control - Project Final Report. U.S. DOE Coop. Agreement DE-FC26-06NT41426, April 2009.

Note logarithmic scale.One standard deviation error bar = 0.00011 lb/E06 Btu is shown.

Existing-EGU EPA MATS limit

New-EGU EPA MATS limit0.00074

Average stack emission value shown for 59 particulate measurements for a Turbosorp ® CDS.

CDS Performance


Hg Removal Data

CDS Performance

75

80

85

90

95

100

0.0 5.0 10.0 15.0 20.0Inlet Hg (lb/E12 Btu)

Hg

Rem

oval

(%

)

Existing EGU

New EGU

Performance Tests

U.S. DOE Parametric Tests

EPA MATS

Average SO 2 Removal = 96%

Outlet measurements below detection limit

w/ Activated Carbon

(others w/o)


Agenda


B.B.B. Circulating Dry Scrubbers Circulating Dry Scrubbers Circulating Dry Scrubbers




C. Summary


Summary

Turbosorp® CDSremoves:

SO2

HCl

SO3 & HF

Hg

Filterable Particulate

Condensable Particulate

�� No waste-water

U.S. EPA

Programs:

CSAPR

MATS

NSR


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