Status of Air Pollution Control and Monitoring Technologies

Institute of Clean Air Companies

July 2013

To be the voice of the stationary source air

pollution control and monitoring industry by

providing technical information relevant to flexible

clean air policies based on practical, achievable and

measurable emissions limitations.

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Nearly 100 Member Companies

Emissions Control Technologies - SO2, NOx, VOC, PM, Hg, air toxics (HAP), and greenhouse gases (GHG)

Emissions Measurement Technologies - CEMS, Portables, Stack Testing, DAHS

Leading Manufacturers of Equipment & Services

For a current list of ICAC members go to:

www.icac.com/members

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Known as Flue Gas Desulphurization (FGD)

Available control equipment: wet scrubbers, dry scrubbers, semi-dry scrubbers, dry sorbent injection (DSI)

History of the technology (1st unit installed on a US power plant in 1970)

Installed Base (Utility)

◦ U.S., 760 FGD units as of 2012 (251 GW scrubbed)

◦ World-wide, 3419 FGD units as of 2012 (1174 GW scrubbed)

SOx Technology

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Implementation time roughly 3 - 4 years from contract to start-up

Capacity (760 units were installed between 1993-2012 to meet acid rain regulations)

Performance levels today e.g. scrubbers today are designed for 95%-98% efficiency with guaranteed up time of 90% or greater

SOx Technology

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NOx control achieved during combustion (LNB) or post combustion (SNCR & SCR)

Low NOx Burners (LNB) development mid 1980’s to meet 1990 CAAA

Selective Non Catalytic Reduction (SNCR) initial patent 1970’s, commercialized in late 1980’s

Selective Catalytic Reduction (SCR) initial patent 1970’s, commercialized in early1980’s

Large installed based for all technologies in US and worldwide

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Broad Range of Applications ◦ Utility boilers (>150 GW)

Coal and gas fired

◦ Gas and oil fired turbines (> 500 power plants)

Combined (standard) and simple cycle (high temperature)

◦ Industrial boilers

◦ Stationary Engines (thousands of installations)

Diesel and natural gas

◦ Marine

◦ Locomotive

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Implementation time, 12 to 18 months LNB/SNCR , 24 to 36 months SCR

Capacity ◦ LNB >100 GW 1990 CAAA

◦ SCR & SNCR>150 GW 2002 SIP Call

Performance levels today ◦ LNB ~ (20%-40% removal)

◦ SNCR ~ (20%-60% removal)

◦ SCR ~ (80%-90% removal)

Remaining challenges ◦ Fuels

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SCR Implementation time, 12 to 24 months new build, 6 to 18 months retrofit

Capacity

◦ SCR ~1000 units

Performance levels today

◦ SCR ~2 ppmv

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Installed Base by PM Technology

Electrostatic Precipitators

Fabric Filters

United States – 327 GW 70% 30%

Europe – 193 GW ≈ 98% ≈ 2%

China – 667 GW 100% 0%

South Africa (local coal) – 38 GW ≈ 50% ≈ 50%

Australia (local coal) – 28 GW ≈ 30% ≈ 70%

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Comparison - Electrostatic Precipitators and Fabric Filters

Electrostatic Precipitators Fabric Filters

Emission

Achieves MATS Emission

Achieves MATS Emissions

Emission Performance: • Sensitivity to Gas Flow • Sensitivity to Fuel • Sensitivity to Temperature

Yes Yes Yes

No No No

Power Consumption T/R Power for low emission ESP approximately equal to

Fabric Filter fan power

Fabric Filter fan power approximately equal to T/R Power for low emission ESP

HAP Performance with Sorbents (activated carbon)

Poor to Excellent Low Sorbent Utilization

Excellent High Sorbent Utilization

Acid Gas Performance with Sorbents (lime, sodium)

Poor to Excellent Low Sorbent Utilization

Excellent High Sorbent Utilization

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Fabric Filters ◦ Increasing Use

Reverse Air Filters ◦ 1st US Installation 1978

◦ 27.2 GW

Pulse Jet Filters ◦ 1st US Installation 1987

◦ 2013 Projected US Installations 53.3 GW

◦ Installed cost approximately 50% of Reverse Air Filter

1978 1983 1988 1993 1998 2003 2008 2013

Reverse Air

Pulse Jet50 GW

30 GW

10 GW

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Co-Benefits of SO2 and NOx Control Technologies Wet and Dry FGD Scrubbers and SCRs

Sorbent Injection

◦ Activated Carbon (ACI)

◦ Non-Carbon Sorbents

Coal Additives

Oxidizing Catalysts

Barrier Filters with Hg Absorbing Materials

Re-Emission additives

Developmental Technologies

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First Commercial System: 2006 ◦ EPRI TOXECON technology with ACI

◦ Presque Isle Power Plant; We Energies, Inc. Marquette, Michigan

Experience Base for ACI ◦ Over 80 full-scale demonstrations

conducted

◦ Commercial ACI systems

215 boilers treated

70 GW

12 ACI suppliers

ACI Silo

TOXECON PJFF

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Technologies available for both Eastern and Western Coals ◦ 80-95% capture on existing plants

◦ 90-98% removal on new plants

◦ Cost effectiveness improved by multiples over time.

Remaining Challenges ◦ Interference with SO3

Can be addressed with DSI

Sulfur tolerant sorbents

◦ Impact on ash sales

TOXECON

Higher efficiency and increased capacity products

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Acid gases such as HCl and SO3 can be controlled as co-benefits in wet and dry scrubbers

Dry Sorbent Injection (DSI) has been in existence since the 1960s ◦ Milled & unmilled Trona injection systems

◦ Milled SBC system

◦ Hydrated lime injection systems

Standard/FGD grade,

high porosity lime

high reactivity lime

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Technologies available for both Eastern and Western Coals ◦ 60-90% capture of HCl, SO3

◦ Can use calcium, sodium, or magnesium depending upon application and pollutant of interest

Remaining Challenges ◦ CCR and ash stabilization of DSI products

◦ Leachate control and solubility of metals compounds

◦ Enhancing sorbent utilization and efficiency

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Instrument/Integration providers have historically developed or adapted technologies to support regulatory initiatives.

Collaboration early in the rule-making process allows:

Determination of what is and isn’t measureable

Definition of technology operating requirements

‣ Quantification limits, precision, QA/QC, calibrations

Full technology commercialization

Healthy competition from multiple suppliers ‣ Leading to cost effective monitoring solutions

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Increasingly lower emission limits require:

Instruments with higher precision, lower quantification limits, and elimination of interferences

Accurate calibration standards to challenge instrumentation

‣ Better collaboration is suggested between NIST, EPA, and

Instrument & Calibration Gas providers

Establish NIST traceable standards before method development and rule implementation

Prevent delay of method development, implementation, and practical

application

The importance of traceable threshold zero gas

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ICAC member companies have contributed to substantial advancements in technology for industrial and power applications resulting in high control efficiency at lower costs…

◦ VOC typical destruction of 98%+ for a wide range of applications

◦ PM removal of >95% with wide range of technologies

◦ NOx removal of 95%+, at temperatures ranging from 150°C to 1,100°C.

◦ SO2 removal of 90+% with DSI, 95%+ with WESP

◦ Hg removal demonstrated at 90%+ DRE

◦ Acid gas control using Dry Sorbent Injection of Alkaline Sorbents

HCl >90% control

SO3 > 95% control

◦ CO control up to 99% (>1,000 natural gas power plants and industrial boilers)

◦ N2O control (1°, 2°, and 3° ) for up to 99% DRE

…enabling the enactment of significant cost-effective air pollution control legislation for a broad range of industrial applications.

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Remaining Challenges/ Uncertainties

Pollutant-by-pollutant litigation – if successful, all MACT methodology / limitations in doubt?

Implementation of new SSM provisions on industrial applications – court challenges ahead?

Surrogates for pollutants: not necessarily supported by science

Particulate definition of condensable and filterable

Pipeline gas quality – shale gas contaminants/biogas – impact on APC equipment?

Uncertainty - rule finalization/ implementation: impacts investment in technology

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• Over 900 Natural Gas power plants in the US under control

• Typically 8-10 year life

• Up to 98% CO control

General Location of CO/VOC Catalyst on a stationary engine

Remaining Challenges: • Changing

definitions of VOC

CO/VOC/NOx controls routinely used on thousands of stationary engines.

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• Functional range: 0.5 – 1.2% CH4

• Total flow: 250,000 Nm3/hr • Operational Q2 2012 • Destruction Efficiency: 97% • Plant Availability: 95 – 99% • Up to 16,000 tons CH4

oxidized per year, 336,000 equivalent tons CO2

Operational since April 2012 with integral Durr designed VAM capture hood.

• Functional range: 0.4 – 1.2% CH4

• Enriched CMM fuel source

• Total flow: 1,090,000 Nm3 /hr • Operational Q1 2014 • Destruction Efficiency: up to 97% • Waste heat can provide up to 20

MW power – via downstream steam turbines

• Up to 86,000 tons CH4 oxidized per year, 1,806,000 equivalent tons CO2

Changzhi, China

West Virginia

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Heat rate improvements via:

• Steam Turbine Upgrades 3-5% • Boiler Upgrades

• Heating surface changes • Pulverizer / Burner upgrades 0.5-1.5%

• Balance of Plant Improvements 1%

Options are limited on existing units. A 5% reduction in heat rate improves overall plant efficiency with an equivalent reduction in CO2 emissions. Under load cycling conditions, typical of today’s coal plant operation, the improvement in efficiency will be even less.

Efforts to reduce water consumption by dry or hybrid cooling systems move efficiency in the opposite direction increasing CO2 emissions/MWHr.

Economics of efficiency improvements will vary by plant size, age and operating characteristics (base load, cycling, on-off operation). They won’t be cost effective at every plant.

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High Efficiency Ultra Supercritical Plant DesignsTypical size = 350 to 1000MW for PC Designs 37-40% Net eff up to 45% eff for AUSC Designs (still on the drawing board) Higher efficiency results in 20-30% reduction in CO2 emissions/MWHr over older subcritical plant designs.

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1st Generation CO2 Capture Technologies • Pre-combustion capture using coal gasification (IGCC) • Post Combustion Capture (PCC) with Amine based solvents • Oxy-Coal combustion systems using Air Separation Units

All of theses technologies are in the latter stages of development (PCC, Oxy) or early stage of demonstration (IGCC). If the DOE’s large demonstration projects for PCC and Oxy-Coal are completed (not a given at this point) these technologies are at least 5-7 years away from being commercially proven for first movers to accept and consider deploying these technologies. It could be another 10 years before the first commercial plants are built.

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All of theses systems are in the early stages of development – lab and small scale pilots. DOE is supporting development of larger pilot scale systems but funding for these efforts is not sufficient to rapidly advance the technology development and there are no clear commercial drivers for private companies to develop these technologies on their own. If these technologies can be proven successful they are still at minimum 15 -20 years away from first commercial deployments.

2nd Generation CO2 Capture Technologies • Oxy-combustion using chemical looping • Membrane technologies for CO2 capture or oxygen separation • Metal oxide frameworks, solid sorbents, other

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Cost

• First Generation Systems look to be very expensive. Undoubtedly costs would decrease with experience but first generation systems are so expensive it is doubtful that anyone will undertake a new CCS project without significant subsidy.

Legal, Regulatory

• Liabilities surrounding the long-term storage of CO2 remain unknown.

• Public acceptance of CO2 storage is not a given.

• Permitting issues particularly PCC systems that will introduce new waste streams.

• Increased water consumption for CCS technologies

Barriers to the Success of CCS

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