Ramsay Chang

Factors affecting mercury control in utility flue gas using activated carbon

The Electric Power Research Institute (EPRI) is conducting research to investigate mercury removal in utility flue gas using sorbents. Bench-scale and pilot-scale tests have been conducted to determine the abilities of different sor-bents to remove mercury in simulated and actual flue gas streams. Bench-scale tests have investigated the effects of various sorbent and flue gas parameters on sorbent performance. These data are being used to develop a theoretical model for predicting mercury removal by sorbents at different conditions. This paper describes the results of parametric bench-scale tests investigating the removal of mercuric chloride and elemental mercury by activated carbon. Results obtained to date indicate that the adsorption capacity of a given sorbent is dependent on many factors, including the type of mercury being adsorbed, flue gas composition, and adsorption temperature. These data provide insight into potential mercury adsorption mechanisms and suggest that the removal of mercury involves both physical and chemical mechanisms. Understanding these effects is important since the performance of a given sorbent could vary significantly from site to site depending on the coal- or gas-matrix composition.

Low-Temperature SCR of NO with NH3 over USY-Supported Manganese Oxide-Based Catalysts

A series of catalysts of manganese oxide, manganese–cerium and iron–manganese oxide supported on USY (ultra-stable Y zeolite) were studied for the low-temperature selective catalytic reduction (SCR) of NO with ammonia in the presence of excess oxygen. It was found that MnOx/USY have high activity and high selectivity to N2 in the temperature range 80-180 °C. The addition of iron and cerium oxide increased NO conversion significantly although the single-component Fe/USY and Ce/USY catalysts had low activities. Among the catalysts studied in this work, the 14% Ce-6% Mn/USY showed the highest activity. The results showed that this catalyst yielded nearly 100% NO conversion at 180 °C at a space velocity of 30 000 cm3 g-1 h-1. The only product is N2 (with no N2O) below 150 °C. The effects of the concentration of oxygen, NO and NH3 were studied and the steady-state kinetics were also investigated. The reaction order is 1 with respect to NO and zero with respect to NH3 on the 14% Ce-6% Mn/USY catalyst at 150 °C.

Effect of NOx Control Processes on Mercury Speciation in Utility Flue Gas

Abstract The speciation of Hg in coal-fired flue gas can be important in determining the ultimate Hg emissions as well as potential control options for the utility. The effects of NOx control processes, such as selective catalytic reduction (SCR) and selective non-catalytic reduction (SNCR), on Hg speciation are not well understood but may impact emissions of Hg. EPRI has investigated the reactions of Hg in flue gas at conditions expected for some NOx control processes. This paper describes the methodology used to investigate these reactions in actual flue gas at several power plants. Results have indicated that some commercial SCR catalysts are capable of oxidizing elemental Hg in flue gas obtained from the inlets of SCR or air heater units. Results are affected by various flue gas and operating parameters. The effect of flue gas composition, including the presence of NH3, has been evaluated. The influence of NH3 on fly ash Hg reactions also is being investigated.

Modeling Mercury Removal by Sorbent Injection

Sorbents for removing mercury from flue gases of coal-fired power plants are presently being evaluated due to potential regulation of mercury emissions under Title III of the 1990 Clean Air Act Amendments. Laboratory tests have been conducted to evaluate the adsorption characteristics of potential sorbents and the effects of flue gas constituents on these characteristics. This paper presents a theoretical model that combines the adsorption characteristics measured in the lab with mass transfer considerations to predict mercury removal by the duct injection process in actual flue gas streams. The model was used to determine the effect of various sorbent properties on mercury removal when injecting a powdered sorbent upstream of either an electrostatic precipitator (ESP) or fabric filter. Mercury removal is expected to differ between these configurations since the mass transfer conditions are different in an ESP and fabric filter. The model was used to determine when mercury removal is limited by mass transfer and when it is limited by sorbent capacity. This information defines conditions when removal can be improved by reducing particle size or increasing sorbent capacity. In both cases, removal can be increased by injecting more sorbent.

An X-ray Photoelectron Spectroscopy Study of Surface Changes on Brominated and Sulfur-Treated Activated Carbon Sorbents during Mercury Capture: Performance of Pellet versus Fiber Sorbents

This work explores surface changes and the Hg capture performance of brominated activated carbon (AC) pellets, sulfur-treated AC pellets, and sulfur-treated AC fibers upon exposure to simulated Powder River Basin-fired flue gas. Hg breakthrough curves yielded specific Hg capture amounts by means of the breakthrough shapes and times for the three samples. The brominated AC pellets showed a sharp breakthrough after 170-180 h and a capacity of 585 μg of Hg/g, the sulfur-treated AC pellets exhibited a gradual breakthrough after 80-90 h and a capacity of 661 μg of Hg/g, and the sulfur-treated AC fibers showed no breakthrough even after 1400 h, exhibiting a capacity of >9700 μg of Hg/g. X-ray photoelectron spectroscopy was used to analyze sorbent surfaces before and after testing to show important changes in quantification and oxidation states of surface Br, N, and S after exposure to the simulated flue gas. For the brominated and sulfur-treated AC pellet samples, the amount of surface-bound Br and reduced sulfur groups decreased upon Hg capture testing, while the level of weaker Hg-binding surface S(VI) and N species (perhaps as NH4(+)) increased significantly. A high initial concentration of strong Hg-binding reduced sulfur groups on the surface of the sulfur-treated AC fiber is likely responsible for this sorbents minimal accumulation of S(VI) species during exposure to the simulated flue gas and is linked to its superior Hg capture performance compared to that of the brominated and sulfur-treated AC pellet samples.

Low temperature selective catalytic reduction (SCR) of NO with NH3 over Fe–Mn based catalysts

Fe-Mn based transition metal oxides (Fe-Mn, Fe-Mn-Zr and Fe-Mn-Ti) show nearly 100% NO conversion at 100-180 degrees C for selective catalytic reduction of NO with NH3 under the applied conditions with a space velocity of 15,000 h-1.

Assessing Sorbents for Mercury Control in Coal-Combustion Flue Gas

Abstract Sorbent injection for Hg control is one of the most promising technologies for reducing Hg emissions from power-generation facilities, particularly units that do not require wet scrubbers for SO2 control. Since 1992, EPRI has been assessing the performance of Hg sorbents in pilot-scale systems installed at full-scale facilities. The initial tests were conducted on a 5000-acfm (142-m3/min) pilot baghouse. Screening potential sorbents at this scale required substantial resources for installation and operation and did not provide an opportunity to characterize sor-bents over a wide temperature range. Data collected in the laboratory and in field tests indicate that sorbents are affected by flue gas composition and temperature. Tests carried out in actual flue gas at a number of power plants also have shown that sorbent performance can be site-specific. In addition, data collected at a field site often are different from data collected in the laboratory, with simulated flue gas mixed to match the major components in the site’s gas. To effectively estimate the costs of Hg sorbent systems at different plants, a measure of sorbent performance in the respective flue gases must be obtained. However, injection testing at multiple facilities with large pilot systems is not practical. Over the past five years, fixed-bed characterization testing, modeling studies, and bench-scale injection testing have been undertaken to develop a low-cost technique to characterize sorbent performance in actual flue gas and subsequently to project normalized costs for Hg removal prior to full-scale demonstration. This article describes the techniques used and summarizes field-testing results from two plants burning Powder River Basin (PRB) coal for commercial activated carbon and several other sorbent types. Full-scale projections based on the results and data collected on larger-scale systems also are included.

The potential of pulse-jet baghouses for utility boilers. Part 2: Performance of pulse-jet fabric filter pilot plants

Pulse-jet fabric filters (PJFFs) are widely used in U.S. industrial boiler applications and in utility and industrial boilers abroad. Their small size and reduced cost relative to more conventional reverse-gas baghouses makes the use of PJFFs appear to be an attractive particulate control option for utility boilers. This paper (Part 2 of a three-part series) summarizes the results of pilot PJFF studies sponsored by the Electric Power Research Institute at different utility sites in the United States. The purpose of these tests is to evaluate PJFF performance for U.S. fossil-fuel-fired applications. These data are also used to corroborate the results of a recent worldwide survey of PJFF user experience, as described in Part 1 of this series. Part 3 will provide a cost comparison of PJFFs to other particulate control options such as electrostatic precipitators and reverse-gas baghouses.

The potential of pulse-jet baghouses for utility boilers. Part 1: A worldwide survey of users

Pulse-jet fabric filters (PJFFs) are widely used in U.S. industrial boiler applications and in utility and industrial boilers abroad. Their smaller size and reduced cost relative to more conventional baghouses make PJFFs appear to be a particularly attractive particulate control option for utility boilers. This paper summarizes the results of a survey co-funded by the Electric Power Research Institute and the Canadian Electric Association to characterize the performance of and operating experiences with PJFFs applied to coal-fired boilers. The survey involved site visits to interview technical and plant personnel involved in the design, installation and day-to-day operation of PJFFs worldwide. Actual field experiences with PJFF performance in terms of outlet emissions, pressure drop and bag life for different types of pulse-jet cleaning methods, fabrics and boilers are compared. The second part of this series will present results of pilot PJFF studies conducted by EPRI at different U.S. utility sites on d...

The potential of pulse-jet baghouses for utility boilers part 3: Comparative economics of pulse-jet baghouse, precipitators and reverse-gas baghouses

Pulse-jet fabric filters (PJFFs) are widely used in U.S. industrial applications, and in both utility and industrial boilers abroad. Their smaller size and reduced cost relative to more conventional baghouses make PJFFs an attractive particulate control option for utility boilers. This article which is the third in a three-part series, compares the cost of PJFFs with electrostatic precipitators (ESPs) and reverse-gas baghouses (RGBs). This article presents the capital, operating and maintenance (OM in addition the PJFF is 35 percent lower than the cost of an RGB. The levelized cost for a PJFF is about equal to the cost of the ESP but 14 percent lower than the cost of the RGB. Ove...