Florida Department of Environmental Protection

Alvaro Linero, P.E.Administrator, Special

ProjectsBureau of Air Regulation

Mercury Puzzle

Hg(0), Hg(II), Hgp

Emissions and Processes• DEP Contract to Test some Facilities

• Three Coal- Fueled Power Plants

• Two Cement Kilns, plus a Compliance Test

• Waste-to-Energy (WTE) Compliance Tests

• Miscellaneous Industries• Hg-CEMS (Continuous Emissions Monitoring Systems)

Some Nomenclature, Proportion

• Micrograms Hg per dry standard cubic meter

• Pounds Mercury per Year (lb Hg/yr)

• Little Substantial a Lot Potent

• 0.1 1 10 100 µg Hg/dscm

• 1 10 100 1000 lb Hg/year

More Nomenclature• Kilowatt-hour (KWH)

• 1,000 KWH = Megawatt-hour (MWH)

• Million (or 106) MWH = Terawatt-hour (TWH)

• 1 x 10-6 lb/MWH = 1 lb Hg/TWH = 0.1 lb/TBtu

• ppb = parts per billion

• lb Hg/million tons of clinker = lb Hg/MT clinker

25% Removal

Hgp

Hg0

>2500 °F

Flue GasHigher NOxLower CO

Cold Electrostatic Precipitator (ESP)

Coal & XS Air

200 lb Hg/yr

Eastern Coal

Old 360 MW Coal-fueled Unit High NOX

I don’t actually have data for this case

Hg(0) = Elemental (gas)Hg(II) = Reactive (salts like HgCl2)Hgp = Particle Bound

25%

75%

50 lb Hg/yr

150 lb Hg/yr

Fly Ash to Concrete, Cement Kiln Storage, Waste

45% Removal

Hgp

Hg0

>2500 °F

Flue Gas C Cold Electrostatic Precipitator (ESP)

Coal & Air

200 lb Hg/yr

Overfire Air

Low NOxBurners (LNB)

40 lb/TWH4.9 µg/dscm64% Hg(II)

360 MW Coal-fueled Unit Tuned for Low NOX

Vacated EPA Hg limit for new units was 21 lb/TWH

Carbon and Hg-Enriched Fly Ash to Concrete, Cement Kiln, Storage, Waste

385 ppb

Flue gas carbon (C) can behave much like activated C

45%

90 lb Hg/yr

55%

110 lb Hg/yr

72 lb/TWH90 ppb Hg10.5% AshEastern Coal

Wet Flue Gas Desulfurization (FGD) for SO2

Hg0

>2500 °F

Flue Gas CESP

Coal & Air 200 lb Hg/yr

OFA

LNB

FGD

Limestone or Lime Slurry

45% Removal

45%

16 lb/TWH2 µg/dscm 85% Hg(0)

Hg(II)

90 lb Hg/yr

20%

40 lb Hg/yr

35%

70 lb Hg/yr

Sludge, GypsumHg Salts

Hgp

Soluble Hg salts absorbed or reacted in FGD Scrubber

Carbon and Hg-Enriched Fly Ash to Concrete, Cement Kiln, Storage, Waste

385 ppb

Selective Catalytic Reduction (SCR) for NOX

Hg0

>2500 °F

ESP

Coal & Air

200 lb Hg/yr

Overfire Air

LNB

FGD

Limestone or Lime Slurry

45% Removal

Flue Gas C

3.2 lb/TWH0.5 µg/dscm 69% Hg(0)

45%

Hg(II)

90 lb Hg/yr

Hgp

SCR

Ammonia (NH3)

Elemental Hg (0) oxidized to Hg (II) by catalyst

10 lb Hg/yr

50%

100 lb Hg/yr

Sludge, GypsumHg Salts

Florida Cement Industry

• 10,000,000 tons per year clinker

• Ten cement kilns

• Demand is down

• Five in operation (slack demand)

• Two are temporarily down

• Three new startups (also slack)

Suwannee American

Vulcan

AmericanCEMEX N. Brooksville

CEMEX S. Brooksville

Titan America

CEMEX Miami

1 MT Clinker Cement Kiln, Raw Mill On

Meal & Hg Removed

Meal & Hg Stored

RAW

MEAL

SILO

(Hg)

Filter

1 MT/yr of Clinker

LEGEND

GasSolid

Filter Dust

Raw Mill

Separators

Preheater Exhaust

Preheater Feed

0.8 µg/dscm92% of time

3 lb/yrHg(0)

New Kiln Limit41 µg/dscm

Limestone, Sand, Fly Ash, Mill Scale

Raw Materials Hg

Fuel Hg

Fuel Hg

120 lb Hg/yr in

Clinker

400 µg/dscm8% of time117 lb/yr

Hg(II)

New Kiln Limit41 µg/dscm

Raw Mill Off, Little Hg In

Fuel Hg

Fuel Hg

Raw Meal, Hg Inventory Falls

Raw Meal, HgInventory Increase

To Cement Mill

Scrubber ?

February 10, 2009 | 11

600 tons per day (TPD) WTE Process and Controls

2 - 20 µg/dscm4 to 40 lb/yr

600 TPDMunicipal Waste

All have spray dryer/absorbers and fabric filter baghouses

Activated Carbon Injection (ACI)

ACI means greater certainty

of Continuous ControlFabric Filter

< 5 µg/dscm< 10 lb/yr

Fly Ash Containing Reacted Lime, Spent Carbon, Hg

Bottom Ash

February 10, 2009 | 13

February 10, 2009 | 14

12,000

But are Underlying Tests Truly Representative?

Highly Variable Inputs make Snapshot In-stack Test Unreliable Estimators of Maximum Emissions.

Hg-CEMS• WTE Tests were Short-Term In-Stack Tests

• Sorbent Traps and Speciation at Cement, Power

• Hg-CEMS are in Place at JEA Northside

• Soon American Cement, Hillsborough WTE Unit 4

• Diagnostic Hg-CEMS at CEMEX Brooksville South

• Used for Years at WTE and Cement in Germany

• Incorporate Industry/Instrument-Specific Manuals

Next Steps

• Reports for One Power Plant and Cement Kiln

• EPA Informational Collection Requests (ICR)

• Industrial Boilers, Coal Power, Fertilizer

• Look at Secondary Steel

• Examine Reliability of New Hg-CEMS

• Comments to EPA on Hg Rulemaking

Thank You – From Pompeii