|
Ross Ardell
WELCOME
Weekly selected highlights in flow
control, treatment and combustion from the many McIlvaine publications.
· Dry Scrubber Market
will grow to $5 billion/yr.
· Industrial
and IIOT and Remote O&M Newsletter
· Validating
Lime Choices for Dry Scrubbing
Dry Scrubber Market will grow to $5 billion/yr.
Dry scrubbers are taking market
share away from the wet scrubbing alternative in coal fired power, biomass
combustion, cement, steel, waste to energy and other applications involving
hot acid gases and particulate.
The advantages of dry scrubbers
are the reduced need for water, the elimination of wastewater, and the
capture of mercury, dioxins, and sulfuric acid mist. The negative aspect is
the elimination of valuable byproducts.
If the acid gas ratio in the fuel is low dry scrubbing has the
lowest total cost of ownership. The higher the acid content the less
competitive dry scrubbing is to wet.
Dry scrubbing is the preferred
choice in glass plants, waste to energy, and cement plants. In some other
applications it has half the market share.
In coal fired power generation it has less than a 6 percent
share. A major change is taking
place in India where coal fired power plants are expected to use dry
scrubbing for one third of the requirements. As a result India will be a
leading purchaser of dry scrubber hardware, lime and services in the
future. It will spend just under $3 billion for dry scrubber hardware and
construction over the seven year period ending in 2025. It will be spending $650 million/yr for
lime for dry scrubbing by 2025 and $325 million for service, repair and
remote operation and maintenance.
|
|
2025
CFM (millions)
|
2025
MW
Equivalent
|
2018-2015
CFM Additions
(millions)
|
2018-2025
MW Equivalent
Additions
|
Lime Market
$ millions
(2025)
|
Hardware
Market 2018-25
$ millions
|
Service, Repair
Remotely Operate
$ millions 2025
|
|
U.S
|
135
|
45,000
|
15
|
5,000
|
675
|
400
|
225
|
|
China
|
180
|
60,000
|
45
|
15,000
|
600
|
675
|
300
|
|
India
|
195
|
65,000
|
134
|
64,000
|
650
|
2,880
|
325
|
|
ROW
|
270
|
90,000
|
120
|
40,000
|
900
|
3,200
|
450
|
|
Total
|
780
|
260,000
|
314
|
124,000
|
2825
|
7155
|
1300
|
Cement, waste to energy and
furnace applications are sized based on CFM. Equivalent MW is provided as a
convenience.
MW - CFM equivalent is 3000 CFM
at 240F
U.S lime at $150/ton and 100
tons per equivalent MW
Lime in China, India, and ROW at
$100/ton and 100 tons per equivalent MW
Hardware for new plants is
$45,000/equivalent MW in India and China and $80,000/equivalent MW in U.S.
and ROW.
Service, repair and remotely
operate is $5000/ MW/yr
The world market for dry
scrubbing hardware will average $710 million/yr over the period to 2025.
Lime purchases will be just under $3 billion by 2025 while service, repair
and remote O&M will rise to over $1.3 billion/yr.
Forecasts for both wet and dry
scrubbing for each country are contained in two McIlvaine reports. One is
focused on coal fired boilers and the other on the industrial market. More information is available at
N027 FGD Market and Strategies
N008 Scrubber/Adsorber/Biofilter World
Markets
Bob Mcilvaine can answer any
questions at cell 847 226 2391 or rmcilvaine@mcilvainecompany.com
Industrial
and IIOT and Remote O&M Newsletter August 2019
No. 478
This
monthly newsletter is available for just $ 350/yr. and is also included in N031
Industrial IOT and Remote O&M
Table
of Contents
- Coal-Fired Plant Decisions
Provides Guide to Lowest Cost of Ownership
- Selling To the 500 Coal
Plant Owners Who Make 99 Percent of the Purchases
- Would You Rather Share
Sales Leads with Your Allies or With Your Competitors?
- Sales Program Based On the
500 Coal Plant Operators That Buy 99 Percent of the Combust, Flow and
Treat Products
- Coal By-products Including
Rare Earths Will Be A Game Changer
INDIA
- Mostly Combustion
Modification for NOx Reduction at Delhi Area Plants
- Fortum Has Combustion
Modification Order from Hindalco
- BHEL Has 13 Orders
for Selective Catalytic Reduction (SCR) System to Reduce NOx
- BHEL Has Order for FGD
Systems At the 4x250 MW Nabinagar Project of BRBCL
- Condensibles Become a
Sematic Problem with FGD
- Indian FGD Status
- SEIL Floats Tender to Set
Up Two FGD Units in Its Two Power Plants
- 63,000 MW of Precipitator
Upgrades Planned
- ECOMAK Supplies
Precipitator Upgrades and the Venturi Option Could Be Combined With
FGD
- United Conveyor Has Dadri
Order for DSI
- A Number of FGD and DeNOx
Papers at Electric Power
- Envea Pursuing FGD CEMs Market
in India
- Johnsen Chemicals Has A
Combustion Catalyst That Lowers Pollutants
- Steam Equipments Supplied
CEMS to Tata Power
- EPP Provides FRP Scrubber
Vessels
- Uniphos Provides
Particulate and Gas CEMS
- LeBracs Supplies Rubber
Lining for Vessels and Ducts
- CSL - Chemtron Science
Laboratories Provides Cannisters and Gas Handling Equipment
- Speakers at SOx-NOx 2019
ARTICLES
IN THE INTELLIGENCE SYSTEM
- Acquire Control Supplies
System for MBR at Landfill Site
- Automatic Control Systems
for MBRs
- Innovative Treatment Products
Has Control System to Adjust to Widely Varying MBR Flow
- Automatic Control for Koch
AnMBR
INDUSTRY
NEWS
- MHPS Establishes New
Company In the Philippines Specialized In the Service Business
- Dry Scrubber Users Will
Meet To “Work Smarter Not Harder”
- Dry Scrubber Silo Busting
- IEA Is an Important
Resource
- Repeal of the Clean Power
Plan; and Emission Guidelines for Greenhouse Gas Emissions From
Existing Electric Utility Generating Units
- Keynote Speakers at Clean
Coal 2019
- Flexible Coal Plants as
Clean as Gas
- India Could Double
Coal-fired Power Capacity
- Major Developments in CO2
Capture and Use
Validating
Lime Choices for Dry Scrubbing
Some
people attending the September DSUA conference will be making lime
purchasing decisions. Those attending SOx-NOx India have many questions
about lime availability and use options.
Coal Fired
Power Plant Decisions (CFPPD) is free of charge to plant operators.
It can be used to facilitate decision making through access to the relevant
information and ease with which operators can contact experts and
conference attendees. The information in CFPPD can provide the evidence and
interface at the conferences can facilitate the validation.
The
DSUA/SOx-NOx India webinar analysis and recording is an example of the way
periodic webinars can be spaced between conferences. DSUA and SOx-NOx India can be a
foundation for a whole program to validate Lowest Total Cost of Ownership
(LTCOV) for lime. These two conferences can be the nucleus and the activity
extended to PowerGen U.S. and PowerGen Europe and many other conferences.
It
is useful to know which supplier personnel will be attending conferences
and encourage operators to make arrangements for meetings in advance. Here is an example of the database we are
creating relative to conference participation by lime suppliers.
|
Lime Personnel in Attendance
at Upcoming Conferences
|
|
Company
|
Person
|
DSUA
Sept 10-12
U.S.
|
SOx-NOx
Sept 11-13
India
|
PowerGen
U.S.
|
PowerGen
Europe
|
Waste to Energy
Nov 28-29
India
|
|
Carmeuse
|
Agarwal
|
|
x
|
|
|
|
|
Carmeuse
|
Fraley
|
x
|
|
|
|
|
|
Lhoist
|
Hunt
|
x
|
|
|
|
|
Personnel
(Product - Lime)
The
information in CFPPD will be used
by subject matter experts who become subject matter ultra-experts (SMUEs)
and provide input for data analytics software. The cycle than continues
with new information in CFPPD analyzed
by the SMUE and then integrated into the software.
This
cycle was explained by Scott Affelt of XMPLR in the August 29 webinar. Various lime company personnel should
become subject matter ultra-experts in narrow niches e.g. Jerry Hunt of
Lhoist gave a paper on SO3 capture with hydrated lime. He can help add additional information on
SO3 capture in the system and become an SMUE on this subject. Commercial
subjects such as the quality and availability of lime in India should be
addressed by one or more SMUEs.
XMPLR,
McIlvaine, and Tata Consultancy will be conducting a half-day session on
Monday at PowerGen New Orleans. The
theme will be on how smaller companies can leverage their products and
knowledge internationally.
This
personnel database plus selected evidence from CFPPD will be displayed in CFPPD
for the convenience of those focusing on lime.
LIME
INSIGHTS IN COAL FIRED POWER PLANT DECISIONS
TABLE OF CONTENTS
Sept 2019 FGD Newsletter
·
Carmeuse exporting lime to India from Oman
·
Wet lime
systems have a number of benefits compared to limestone systems
·
India needs additional high-quality hydrated lime
production
· Circulating
Fluid Bed Scrubber could be the best choice for many Indian Power
Plants
· Sorbacal®
SPS used in CDS and DSI systems
· Lhoist
announced possible price increases of 11% last December
· Lhoist
market share in Asia
· United
Conveyor has Dadri order for DSI
· Tata
Power March 2019 bid request for 1 x 67.5 MW DSI FGD System
· Bids
close for DSI for 4 x 210 MW of DSI systems at Punjab State Power
Roopnagar in September 2019
August 2019
FGD Newsletter
· Case
for Dry Scrubbers for Indian Power Plants
· India
Will Be A Major Purchaser of Dry Scrubbers
· NTPC
March 2018 Tender for DSI for Dadri
April
2019 FGD Newsletter
· Cement
Kiln Dust for SO2 removal
March 2019 Newsletter
· Dry
Scrubbing Discussions at the Cement Conference in St. Louis
November
2018 Newsletter
· Dry Hydrate
Users Group is another Resource
Articles in Intelligence System
· Mississippi
Lime Presentation 2017: Targeted DSI Improvements
· Costs
for DSI
Lhoist Presentations in the Intelligence System
· MACT Update
Webinar - Hot Topic Hour - May 7, 2015
· Flue Gas
Treatment Specialist, by Marty Dillion, Lhoist - HTH 5-7-15
· Dry Sorbent
Injection Options and Issues Webinar Recording - Hot Topic Hour April 9,
2015
· MATS Compliance
Choices Webinar - Hot Topic Hour January 29, 2015
· DSI for MATS and
CSAPR by Jim Dickerman, Lhoist / Chemical Lime - Hot Topic Hour January 29,
2015
· Lhoist Has Lots
of Ceramic Filter Hot Gas Experience
· Ceramic Filter
with Embedded Catalyst and DSI Achieves High SOx, NOx and ROx Removal
· Advances in Dry
Sorbent Injection (DSI) Reagents by Mike Schantz, Lhoist - Hot Topic Hour
July 11, 2013.
· New Developments
in Air Pollution Control Technology Webinar - Hot Topic Hour July 11, 2013
· Overview of SO3
Emission Control with Hydrated Lime by Jim Dickerman, Lhoist. Hot Topic
Hour March 8, 2012
· SO3
Measurement and Control - Webinar - Hot Topic Hour March 8, 2012
· Sorbacal
Dry Sorbent Injection - a Low Capital Solution for HCl Control by Mike
Schantz, Lhoist / Chemical Lime Co. - Hot Topic Hour November 18, 2010
· Industrial
MACT Webinar - Hot Topic Hour November 18, 2010 - Part 1
Lhoist Articles in Older FGD Newsletters
· Dry
Scrubbing Discussions at the Cement Conference in St. Louis- March 2019
· Lhoist
Unveils Hydratex™ Proprietary Technology---Dec 2016
· SO3 removal
with Sorbacal will solve the bag blinding problem at PacifiCorp August 2016
· MACT
Update Provided in Hot Topic Discussion May 7, 2015
· MACT
Compliance Options, by Pat Mongoven, Mississippi Lime, HTH 5-7-15
· Flue
Gas Treatment Specialist, by Marty Dillon, Lhoist - HTH 5-7-15
· MACT
Update Webinar - Hot Topic Hour - May 7, 2015
· SO3 removal
with Sorbacal will solve the bag blinding problem at PacifiCorp
· Lhoist
North America Sorbacal Hydration Facility at Ste. Genevieve Plant-April
2013
· SO3 Measurement
and Control” – Hot Topic Hour on March 8, 2012 (in the Monitoring Newsletter)
Carmeuse Newsletter Articles and Papers in the
Intelligence System
· Carmeuse
is Positioned to Offer Lime and Provide Remote Operating Advice to Solid
Fuel Combustion Operators Around the World - September 2017
ARTICLES AND LINKS
Sept 2019 FGD Newsletter
Carmeuse
exporting Lime to India from Oman
Carmeuse
Majan, a Salalah Free Zone company, operates a lime kiln at
full capacity of 400 tons per day (tpd). It is ready for growth
depending upon availability of natural gas, which is crucial for any
expansion.
Wael
Abdalla, Carmeuse Majan’s General Manager, presented an ambitious picture.
“Development
of four kilns is our current expansion plan. Of that, the second kiln
investment preparations have already started and gas allocation to the
second kiln at the soonest is an absolute necessity,” he said and added
that in 10 to 15 years from now Carmeuse Majan would have eight kilns.
He,
however, reiterated the urgent need of gas to meet the company’s target.
“This will require gas allocation to support a third and fourth kiln within
three to five years and to support fuel needs for four kilns in 8 to 15
years.”
Carmeuse
lime, according to Abdalla, is in very good demand in India and other
countries and called for seizing the opportunity of organic market growth
and be ahead of competition from UAE, Malaysia, Vietnam, etc.
Commenting
on some of the broad industry trends and developments taking place in his
market, Abdalla termed India as the main target market at the current stage
as the steel industry is the main consumer of quick lime in the Indian
market.
“Lime
demand in India is projected to grow from seven to 12 million tons by 2020
driven by the fast-growing steel industry. Reports suggest that India aims
to achieve 300 million tons of annual steel production by 2025-30,” he
said.
The
lime is ideal for a large variety of high demanding applications such as
steel, paper, water and waste water, agri-food, construction, flue gas
cleaning, chemical industry and others. The majority of the production is
exported to India.
Wet lime
systems have a number of benefits compared to limestone systems.
Carmeuse
has made of process comparison high magnesium lime to limestone (Thiosorbic
vs. Limestone Forced Oxidation (LSFO) • Lower Power Consumption §
1.4% versus 2.0% for LSFO for high-sulfur coal • Higher Reagent Utilization
§ 99.9% vs. up to 97%
for LSFO • Better Gypsum Quality §
98-99% pure, bright white vs. 95%, brown or tan for lime
India needs additional high
quality hydrated lime production
The present existing
manufacturing capacity in India for
the manufacture of hydrated lime is not sufficient to meet the growing
demand of its dependent chemical and other industries. Raw materials,
process equipment’s, and the necessary know-how involved in the manufacture
of hydrated lime are available indigenously but are not sufficient to
produce quality Hydrated Lime using high reactive quicklime produced from
modern twin shaft kilns. It is most important to automatically control
the feed rate of the water and quicklime to produce maximum high quality
hydrated lime of A Grade, especially when we have to hydrate the high
reactive lime coming from Twin Shaft Kilns. Further the design should take
care of all the points mentioned above. The Indian designed plants are not
very effective to handle the high reactive lime.
https://medium.com/limeglobalbrain/hydrated-lime-market-in-india-4bab4d0ba667
Circulating Fluid Bed Scrubber could be the best choice for many Indian Power
Plants
Sumitomo
SHI FW has
made a detailed analysis comparing CFB scrubbers to wet limestone scrubbers
without wallboard quality gypsum production. The lower quality
of limestone available, the expected 15-year life for the older plants to
which the system may be applied, and the much lower capital cost of the CFB
design are key aspects in the determination. Here are the factors and
calculations for a 300 MWe pulverized boiler contained in the linked
paper.
This
full paper will be posted to the Coal-Fired Boiler Intelligence
System and further analyzed in the FGD & DeNOx
Newsletter. It will be available for discussion in a pre-conference
webinar taking place in late August and to attendees at DSUA in Kansas
City, SOx-NOx India and registrants to the Power-Gen New Orleans emerging
market tutorial. The creation of specific cost factors is very valuable as
a foundation for discussions of various alternatives in India, the U.S. and
other countries.
http://home.mcilvainecompany.com/images/Article_Show_me_the_Money_CFBS_vs_Wet_FGD_Aug19.pdf
Sorbacal® SPS
used in CDS and DSI Systems
As
an effective control strategy for all acid gas pollutants, Sorbacal® SPS
can be used in the following applications: • DSI as the main SO2 control
technology, even when moderate-to-high removals are needed • DSI as a boost
to an existing flue gas treatment (FGT) system • Circulating dry scrubber
(CDS) technology with demonstrated improved performance in specific
conditions • Dry injection over a wide range of temperatures: from 120 to
2,000°F (50 to 1,100°C) • Both baghouse filter and ESP particulate control
devices, with high effectiveness • Existing DSI systems without added
expense • Existing sodium systems without the need for on-site milling
https://www.lhoist.com/sites/lhoist/files/brochure_sorbacalr_sps_-_en_8.pdf
Lhoist
announced possible price increases of 11% last December
Lhoist Dec 2018 statement “As we head
into 2019, we are faced with significant cost increases from the markets
that supply critical inputs to our plants. In particular, we
are facing :
Energy – Coal (up 15%), Oil (up 30%),
Natural Gas (up 6%)
Steel products (up to 40% depending on
product)
Employee wages and benefits
Regulatory requirements and the
associated cost of compliance
The unprecedented headwinds facing the
transportation industry, including regulatory pressures and a severe
shortage of drivers that affects the cost of virtually everything we
purchase as well as the products we ship via barge, rail, and truck.
As a result, we will adjust prices for
lime, limestone, and clay products by up to 11% in most cases effective
January 1, 2019 or as contracts allow so that we can continue to be a
reliable supplier into the future.
While we continue to make a favorable
impact with our Continuous Improvement focus, we are only able to partially
offset the cost pressures we are facing. As a result, we must
increase prices in order to be able to remain a sustainable supplier to our
customers in the long term”
https://www.lhoist.com/sites/lhoist/files/2019_lna_price_guidance_3.pdf
Lhoist Market
Share in Asia
Lhoist Group is a global leader in lime, hydrated
lime and derived products, established over 125 years ago in Belgium. The
Lhoist Group is present in 25 countries with more than 90 facilities around
the globe. Lhoist offers local solutions to Asia, by its regional
headquarter in Kuala Lumpur, and production facilities in Malaysia.
27%
of Lhoist $ 2.4 billion revenue is environmental. Only 2% of revenue is in
Asia. 53% is in Europe and 38% in
North America
https://www.slideshare.net/PnlopeFabre/lhoist-group-presentation-2018
Enhanced
Hydrated Lime (EHLS) has a number of advantages
According to Lhoist, EHLSs provide the following
benefits compared to standard hydrated lime:
- Operating cost savings:
EHLSs typically reduce sorbent usage by = 30% over standard hydrated
lime sorbents. This results in a lower annual spend on sorbents.
- Less impact on the ESP/BH
filter: lower sorbent dosage rates will result in less dust loading to
particulate capture equipment. Less dust to an ESP may directly impact
particulate collection efficiency, and for a BH filter this could
impact bag cleaning cycle frequency. Particle sizes play a critical role
in ESP/BH operational efficiencies. Respective equipment manufacturers
should be consulted on particle size guidelines.
- Fuel and raw material
flexibility: if a lower cost fuel or raw material becomes available
but results in increased acid gas emissions, then an EHLS can provide
additional flexibility. This is because it has the ability to achieve
higher acid gas removal efficiencies than standard hydrated limes,
without having to modify the existing DSI system.
- Increased storage silo
capacity: lower sorbent consumption using EHLSs results in more days
of available storage in a fixed silo volume. Hence, reducing sorbent
consumption by 50% equates to doubling the silo storage capacity.
- One DSI system for acid gas
and Hg control: EHLS blended with PAC is available and precludes the
need for two separate systems.
These benefits are a result of the EHLS’s engineered and
improved physical properties, which are designed to enhance acid gas
reactivity.
https://www.worldcement.com/special-reports/06032019/optimising-dry-sorbent-injection/
United Conveyor has Dadri order for DSI
United Conveyor Corp (UCC) is installing the dry injection systems at
the 4 x 250 MW Dadri plant of NTPC. Here are some of the past
FGD newsletter articles about UCC. Rest
of article deleted
August 2019 FGD Newsletter
Case
for Dry Scrubbers for Indian Power Plant
Bob
Giglio of SHI FW makes a case for CFB dry scrubbers for the 60,000 MW of
coal-fired power plants in India, which are less than 500 MW and are older.
SHI-FW has provided CFB dry scrubbers with a capacity of 300 MW both to
China and the U.S. Advantages include the low water requirements.
https://www.shi-fw.com/wp-content/uploads/2019/03/CFB-scrubbers-make-a-Case-for-India-SHI-FW-TEI-Times-March-2019.pdf
Bids close for DSI for 4
x 210 MW of DSI systems at Punjab State Power Roopnagar in
September 2019
The bid scope includes Design,
Engineering, Manufacture, Shop Fabrication, Preassembly, Shop Testing/type
Testing at Manufacturer’s Works, Packing, Transportation, Unloading,
Handling and Conservation of Equipment at Site, Complete Services of
Construction, including Erection, Supervision, Pre-commissioning,
Commissioning and Performance Testing of Equipments Under Bidder’s Scope of
Work of Dry Sorbent Injection (DSI) System using Sodium Bicarbonate as
Reagent and its Associated Auxiliaries including all Associated Electrical,
Control & Instrumentation, Civil, Structural and Architecture Works as
detailed in Tender Specifications for Flue Gas Desulfurization (FGD) System
Package At 4 x 210 MW Units (stage- Ii & Iii) of Ggsstp, Roopnagar
https://bidassist.com/punjab-tenders/punjab-state-power-corporation-limited/detail-74185446-f6bd-4800-839b-100a744c725b
Tata Power March 2019 bid request for 1 x 67.5 MW DSI FGD System
Design,
engineering, manufacture, shop fabrication, assembly, shop testing, type
testing at manufacturer's works, inspection, packing, supply, loading,
unloading, transportation, proper preservation at site, storage &
handling at site, erection/installation, construction, site testing and
commissioning and performance testing of DSI-based Flue Gas Desulfurization
(FGD) System for 100% of the flue gas flow rate for the 1 x 67.5 Unit No 1
of Jojobera Thermal power plant located at near Jamshedpur, East Singhbum
District, Jharkhand State, India.
In order
to limit the SO2 emissions in the thermal power units, it
is proposed to install Flue Gas Desulfurization (FGD) system at Jojobera
for Unit 1 for treating 100% of flue gas coming out of this unit. The
outlet SO2 emissions shall be limited to 600 mg/Nm3 as
per latest standards stipulated by MoEF&CC under
Environment (Protection) Amendment Rules 2015 for thermal power plants.
Bidder to offer a Sodium Bicarbonate-based dry sorbent injection system
(DSI).
https://www.tatapower.com/TenderDocument/Tender_EOI_JOJO_FGD_Rev_R1_0bb5c34d9c.pdf
India
will be a Major Purchaser of Dry Scrubbers
India is
predicted to purchase dry scrubbers to clean 180 million CFM over the next
five years. This is the latest forecast in N027 FGD Market and Strategies. The bulk of the investment will be for coal-fired
power plants. There will be some installations in waste-to-energy, cement,
steel and other industrial applications.
India
will join China and the U.S. as the leading three dry scrubber purchasers.
Dry scrubbing includes semi dry scrubbers, circulating dry scrubbers and
direct sorbent injection. United Conveyor Corp. has an order for 4 x
250-MW direct sorbent injection systems at the Dadri plant
of NTPC.
The
market surge will be due to new rules that allow older smaller power plants
to discharge higher levels of SO2 than others. It is
anticipated that 50,000 MW of Indian power plans will be fitted with dry
scrubbers over the next three years.
Dry
scrubbers are more economical than wet scrubbers when the emission rates
are higher and the sulfur in the fuel is lower. Dry scrubbers use higher
cost lime or sodium compounds whereas wet scrubbers utilize ground
limestone. However, the capital cost of wet scrubbers is more than twice
that of CDS and semi dry scrubbers. Direct sorbent injection is very low in
capital cost but very high in reagent cost.
Direct
sorbent injection can be used to supplement other systems. DSI can be used
in conjunction with semi dry systems to maintain efficiency at higher
sulfur levels. DSI can also be used ahead of the air heater to react with
SO3 and allow the air heater to be operated to extract more
heat without corrosion.
For more
information on this report click on N027 FGD Market and Strategies.
Bob
McIlvaine can answer your questions at office 847-784-0013 cell
847-226-2391 or email him at rmcilvaine@mcilvainecompany.com.
NTPC
March 2018 Tender for DSI for Dadri
The scope of Dry Sorbent Injection (DSI) System Package
for NCTPP, Dadri, Stage-I (4x210 MW) for four units of 210 MW shall cover
design, engineering, manufacture, shop fabrication, preassembly, shop
testing/type testing at manufacturer’s works, packing, transportation,
unloading handling and conservation of equipment at site, complete services
of construction including erection, supervision, pre-commissioning,
commissioning and performance testing of equipment under bidder’s scope of
work of Dry Sorbent Injection (DSI) System and its associated auxiliaries
including all associated Electrical, Control & Instrumentation, Civil,
Structural and Architecture works. Dry Sorbent Injection System shall use
Sodium Bicarbonate as reagent.
http://www.ntpctender.com/uploads/job_23882.html
April
2019 FGD Newsletter
Cement
Kiln Dust for SO2 removal
From 10 to 12 million tons of cement kiln dust
accumulates annually at domestic cement plants. This finely divided dust is
emitted from cement kilns to prevent the buildup of excessive salts in the
cement product. If separated into its valuable components, waste
cement kiln dust could become a significant source of potassium and a raw
material for making cement. This article does not include the use of this
dust for SO2 removal from coal-fired boilers, but potassium
is very reactive and would be a good reagent. One question is its use in
direct sorbent injection or DSI.
There is widespread use of drinking water plant lime
sludge as an FGD reagent. So other alternatives should also be explored.
The use would be primarily where a small boiler is near a source or where
multiple sources can be included so that enough reagent for a large
application is available.
https://www.911metallurgist.com/portland-cement-kiln-dust-reprocessing/
March
2019 FGD Newsletter
Dry Scrubbing Discussions at the Cement Conference in
St. Louis
The 61st Annual IEEE-IAS/PCA Cement Industry Technical
Conference will be held in the St, Louis Convention Center, April 28-May 2,
2019. This is the largest conference in the cement industry and will
include presentations of the latest technology covering a variety of topics
important to the industry. There will also be Tutorials, Professional
Training sessions, a state-of-the-industry-report and much more. There will
be 150 exhibitors
McIlvaine has interviewed exhibitors in the past and
posted this coverage plus other cement industry analyses and articles in a
free site. These articles and interviews can be viewed at
http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/UnivDB/appl3.asp?ref1=806&ref2=0&ref3=0&ref4=0&ref5=0&ref6=0
There is lots of dry scrubbing activity in the cement
industry. For applications where Hg control is either intermittent or low
injection rates are needed, a blended hydrated lime (HL) and powdered
activated carbon (PAC) sorbent allows for a single feed system to be used.
For example, Lhoist North America’s blended HL-PAC product enables
concurrent acid gas and Hg control, using a single sorbent injection system
(instead of installing and maintaining two nearly identical systems), to
inject the sorbents simultaneously as a pre-blended, homogeneous product.
Lhoist North America produces customized enhanced hydrated lime blends
(branded Sorbacal® SP and SPS) with brominated PAC. These
are produced either in bag or bulk, in 5 percent PAC (weight by weight)
blend increments up to 30 percent.
Over the past twenty years, calcium-based sorbents have
evolved, driven by the need to improve acid gas capture efficiencies.
Realization of the importance of physical properties, such as particle size
distribution, pore volume, and surface area, led to the development of
enhanced hydrated lime sorbents (EHLSs) by engineering these properties to
create more reactive hydrated lime sorbents. Sorbent physical properties
directly impact material handling properties and acid gas removal
performance, ultimately dictating annual operating expenditures.
Lhoist’s EHLS products are branded Sorbacal®.
The second generation product is Sorbacal® SP and third
generation is Sorbacal® SPS. Sorbacal® SPS
is a chemically-activated formulation of Sorbacal® SP,
specifically designed to provide best-in-class acid gas capture
performance. Surface area and pore volume are the key performance drivers
for acid gas capture.
Sorbent particle size dictates material handling
properties and removal efficiencies in electrostatic precipitators (ESPs)
and BH filters. Empirical data from the field, as well as laboratory flow
testing, has demonstrated that larger median particle diameters (i.e., D50)
are recommended for optimum handling. Specifically, a 32% improvement in
flow properties was demonstrated between particles with D50 =
2 µm and particles with D50 = 11 µm.7,8This is
likely due to small particle-sized hydrated lime sorbents being more
cohesive than larger particles; small particles can facilitate pluggage in
the conveying system.
Additionally, fine particle-sized hydrated lime can
become irreversibly lodged in BH filter bags and bin vents (this is called
‘blinding’) and can result in premature wear and poor bag cleaning
efficiencies. Users should refer to their manufacturer’s design information
regarding particle size and carefully weigh the impacts of introducing
particles outside of the design range. Likewise, ESP particulate capture
efficiencies decrease below approximately 6 µm and can result in increased
particulate emissions.
November 2018 FGD Newsletter
Dry Hydrate Users
Group is Another Resource
Hydrated lime is
a proven sorbent for the removal of acid gases from flue gas. The Dry
Hydrate Users Group (DHUG) is an organization focused on the exchange of
current research and best practices for using pneumatic systems to inject
hydrated lime into flue gas. Discussion areas include storage and material
handling issues, injection practices and optimization of system
performance. Members include plant operators, equipment vendors,
engineering firms and lime producers. Originally formed to address
power industry applications, discussions now also include other industrial
boiler and kiln applications.
The annual meeting in Nashville, TN, February 20-21,
2019 will provide discussions related to the latest developments in
hydrated lime injection techniques. The meeting also provides an
opportunity to develop contacts with others involved in this
application. The group is sponsored by four major lime producers
– Carmeuse NA, Graymont Inc., Lhoist North America and Mississippi Lime
Articles in the Dry
Scrubber Decisions Intelligence System
Here are some of the links in the Dry Scrubber Decisions
Intelligence System. These are all recent postings but reflect a literature
review from the past to capture older but relevant data.
Mississippi Lime Presentation 2017: Targeted DSI
Improvements
Curt Biehn of Mississippi Lime made this presentation in
2017 which shows the following list of targeted DSI improvement: (1) Reduce
scale and plugs, (2) Optimize distribution for O&M benefits, (3) Reduce
minimum operating temperature requirement, (4) use prior to wet scrubbing
for selenium and HCl removal (SO3 was not listed but would
be another in this category)
Revision Date: 2/25/2019
Tags: 221112
- Fossil Fuel ????, Mississippi Lime, Dry Sorbent Injection
Costs for DSI
This study by Sargent & Lundy provides methods to
determine costs of DSI for acid gas removal. The sorbent requirement is a
function of particle size, particulate control device, and other factors.
2016 cost factors are utilized. Based on commercial testing, removal
efficiencies with DSI are limited by the particulate capture device
employed. Trona, when captured in an ESP, typically removes 40 to 50
percent of SO2 without an increase in particulate emissions,
whereas hydrated lime may remove an even lower percentage of SO2.
A baghouse used with sodium-based sorbents generally achieves a higher SO2 removal
efficiency (70 to 90%) than that of an ESP. DSI technology, however, should
not be applied to fuels with sulfur content greater than 2 lb SO2/MMBtu.
Revision Date: 2/25/2019
Lhoist presentations in the intelligence system
MACT Update Webinar - Hot Topic Hour -
May 7, 2015
There
are unique site specific factors which are more important in MACT than in
MATS. The reason is that in cement, brick and other industrial processes
the material being processed may create more air toxics than the fuel. The
special focus for this Hot Topic Hour was on dry sorbent injection. The use
of hydrated lime was also discussed.
Flue Gas Treatment Specialist, by Marty
Dillion, Lhoist - HTH 5-7-15
Sorbacal
SPS is a lime hydrate which combines porosity and chemical treatment to
provide much higher SO2 and HCl capture than alternatives. A number of
trial and actual installations support the claim.
Revision Date:
5/7/2015
Tags: 221112 - Fossil Fuel ????,
327310 - Cement Manufacturing ????, Lhoist North America, Lime, MACT
Dry Sorbent Injection Options and
Issues Webinar Recording - Hot Topic Hour April 9, 2015
DSI
is an effective Route for SO3, SO2, and HCl reduction.
Revision Date:
4/10/2015
Tags: 221112 - Fossil Fuel ????,
Mississippi Lime, Lhoist North America, AECOM, ClearChem Development LLC,
Mobotec (USA), Sodium, Limestone, Sodium Bisulfate, Lime, HCl, SO2, SO3,
CFD
Dry Sorbent Injection Options and Issues - Sorbacal HCl
Removal by Marty Dillon, Lhoist North America - Hot Topic Hour April 9,
2015
Martin
Dillon of Lhoist explained how a high surface area hydrated lime, Sorbacal®
SP, is able to achieve HCl removal close to 80 percent.
Revision Date:
4/10/2015
Tags: 221112 - Fossil Fuel ????,
Lhoist North America, Lime, HCl, SO2, SO3
MATS Compliance Choices Webinar - Hot
Topic Hour January 29, 2015
Speakers
at the Hot Topic Hour provided recent data which shows that improved
activated carbon and absorbents will allow plants to meet MATS emission
limits with lower amounts of consumables.
Revision Date:
1/29/2015
Tags: 221112 - Fossil Fuel ????,
KC Cottrell, McIlvaine, Lhoist, Calgon Carbon, Precipitator, Fabric Filter,
Dry Sorbent Injection, Activated Carbon, MATS, Mercury Removal, HCl, SO2,
Particulate
DSI for MATS and CSAPR by Jim
Dickerman, Lhoist / Chemical Lime - Hot Topic Hour January 29, 2015
Jim
Dickerman provided recent data to show what a unique hydrate achieved.
Revision Date:
1/29/2015
Tags: 221112 - Fossil Fuel ????,
Lhoist, Dry Sorbent Injection, MATS, SO2, HCl
Lhoist Has Lots of Ceramic Filter Hot
Gas Experience
Lhoist
was a presenter in the McIlvaine hot topic hour May 1, 2014 on hot gas
filtration. The highly porous lime sorbent is achieving more than 95%
SO2/HCl removal efficiency when used at 850F temperature preceding the
ceramic filter. Product: lime, dry sorbent injection
Revision Date:
5/5/2014
Tags: 562213 - Solid Waste
Combustors and Incinerators , Lhoist, Lime, Dry Sorbent Injection, Ceramic
Filter, Fabric Filter
Ceramic Filter with Embedded Catalyst
and DSI Achieves High SOx, NOx and ROx Removal
Richard
Lydon of Clear Edge Filtration Group presented the case for using a ceramic
media with an embedded catalyst. The result is high dust removal and high
NOx reduction. DSI ahead of the filter allows acid gas removal as well.
There are many thousands of these filter elements already in operation on
various industrial operations. Recent installations in the U.S. show high
efficiencies.
Revision Date:
4/24/2014
Tags: Neuman, Lhoist, Clear
Edge Filtration, Ceramic Filter, Fabric Filter
Advances in Dry Sorbent Injection (DSI)
Reagents by Mike Schantz, Lhoist - Hot Topic Hour July 11, 2013.
New
hydrated lime with more surface area and some chemical enhancement is
performing better.
Revision Date:
7/11/2013
Tags: 221112 - Fossil Fuel ????,
Lhoist, Hydrated Lime, MATS
New Developments in Air Pollution
Control Technology Webinar - Hot Topic Hour July 11, 2013
Revision Date:
7/11/2013
Tags: 221112 - Fossil Fuel ????,
NeuCo, Lhoist, Novinda, ADA Carbon Solutions, Dry Sorbent Injection,
Hydrated Lime, Optimization Software, Activated Carbon, MATS, PM2.5,
Condensibles, NOx
New Developments in Power Plant Air Pollution Control
Part 1 - Webinar July 11, 2013 - Presenter Bios
Revision Date:
7/11/2013
Tags: 221112 - Fossil Fuel ????,
ADA Carbon Solutions, Novinda, Lhoist, NeuCo
Overview of SO3 Emission Control with
Hydrated Lime by Jim Dickerman, Lhoist. Hot Topic Hour March 8, 2012
Jim
presented an overview of SO3 emission control with hydrated lime.
Revision Date:
3/8/2012
Tags: 221112 - Fossil Fuel ????,
Lhoist, Direct Injection System, Lime, Mercury, SO2, SO3, HCl
SO3 Measurement and Control - Webinar - Hot Topic Hour
March 8, 2012
The
effect of SO3 in the flue gas stream, emissions from the stack, particulate
emissions and removal of mercury from the flue gas with ACI.
Revision Date:
3/8/2012
Tags: 221112 - Fossil Fuel ????,
URS Corp., Industrial Monitor and Control Corp, Solvay Chemicals, Thermo
Fisher Scientific, Lhoist, SO3 Monitoring, Sodium Bisulfate, Direct
Injection System, Sodium Bicarbonate, Trona, SO3, HCl, Mercury, SO2,
Monitoring
Sorbacal Dry Sorbent Injection - a Low Capital Solution
for HCl Control by Mike Schantz, Lhoist / Chemical Lime Co. - Hot Topic
Hour November 18, 2010
Mike
Schantz, Director of New Business Development at Lhoist/Chemical Lime
Company, explained that all hydrated lime is not the same. Sorbacal SP
performs much better than typical hydrated lime on HCl. Sources using
Sorbacal injection should be able to meet the 3 ppm HCl anticipated limit
providing temperature, moisture, competing acid gases (SO3 and HF) and CO2
are within the normal range.
Revision Date:
11/18/2010
Tags: 221112 - Fossil Fuel ????,
Lhoist / Chemical Lime, Hydrated Lime, MACT, Industrial Boiler
Industrial MACT Webinar - Hot Topic Hour November 18,
2010 - Part 1
Sodium
Bicarbonate, Lime, CDS and Regulations were among the Topics covered on the
First Day of the Industrial MACT Webinar. In 60 days or so we will know the
specific changes for the final Industrial MACT. Correction - we will know what is final until it is
changed again. Unfortunately it will be three more years to find out if
litigants are successful in causing changes. However, it will take three
years to install the equipment and run it long enough to make sure of
compliance. So it would seem there are two choices. Litigate and gamble you
won’t have to shut down your plant or go ahead with the assumption that the
rule will stand. Password: hth107
Revision Date:
11/18/2010
Tags: Babcock & Wilcox
Power Generation Group, Trinity Consultants, Lhoist / Chemical Lime,
Troutman Sanders, Solvay Chemicals, Graymont, MACT, Industrial Boiler
Lhoist Articles in Older FGD Newsletters
Dry Scrubbing Discussions at the Cement Conference in
St. Louis- March 2019
The 61st Annual IEEE-IAS/PCA Cement Industry Technical
Conference will be held in the St, Louis Convention Center, April 28-May 2,
2019. This is the largest conference in the cement industry and will
include presentations of the latest technology covering a variety of topics
important to the industry. There will also be Tutorials, Professional
Training sessions, a state-of-the-industry-report and much more. There will
be 150 exhibitors
McIlvaine has interviewed exhibitors in the past and
posted this coverage plus other cement industry analyses and articles in a
free site. These articles and interviews can be viewed at
http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/UnivDB/appl3.asp?ref1=806&ref2=0&ref3=0&ref4=0&ref5=0&ref6=0
There is lots of dry scrubbing activity in the cement
industry. For applications where Hg control is either intermittent or low
injection rates are needed, a blended hydrated lime (HL) and powdered
activated carbon (PAC) sorbent allows for a single feed system to be used.
For example, Lhoist North America’s blended HL-PAC product enables
concurrent acid gas and Hg control, using a single sorbent injection system
(instead of installing and maintaining two nearly identical systems), to
inject the sorbents simultaneously as a pre-blended, homogeneous product.
Lhoist North America produces customized enhanced hydrated lime blends
(branded Sorbacal® SP and SPS) with brominated PAC. These
are produced either in bag or bulk, in 5 percent PAC (weight by weight)
blend increments up to 30 percent.
Over the past twenty years, calcium-based sorbents have
evolved, driven by the need to improve acid gas capture efficiencies.
Realization of the importance of physical properties, such as particle size
distribution, pore volume, and surface area, led to the development of
enhanced hydrated lime sorbents (EHLSs) by engineering these properties to
create more reactive hydrated lime sorbents. Sorbent physical properties
directly impact material handling properties and acid gas removal
performance, ultimately dictating annual operating expenditures.
Lhoist’s EHLS products are branded Sorbacal®.
The second generation product is Sorbacal® SP and third
generation is Sorbacal® SPS. Sorbacal® SPS
is a chemically-activated formulation of Sorbacal® SP,
specifically designed to provide best-in-class acid gas capture
performance. Surface area and pore volume are the key performance drivers
for acid gas capture.
Sorbent particle size dictates material handling
properties and removal efficiencies in electrostatic precipitators (ESPs)
and BH filters. Empirical data from the field, as well as laboratory flow
testing, has demonstrated that larger median particle diameters (i.e., D50)
are recommended for optimum handling. Specifically, a 32% improvement in
flow properties was demonstrated between particles with D50 =
2 µm and particles with D50 = 11 µm.7,8This is
likely due to small particle-sized hydrated lime sorbents being more
cohesive than larger particles; small particles can facilitate pluggage in
the conveying system.
Additionally, fine particle-sized hydrated lime can
become irreversibly lodged in BH filter bags and bin vents (this is called
‘blinding’) and can result in premature wear and poor bag cleaning
efficiencies. Users should refer to their manufacturer’s design information
regarding particle size and carefully weigh the impacts of introducing
particles outside of the design range. Likewise, ESP particulate capture
efficiencies decrease below approximately 6 µm and can result in increased
particulate emissions.
Lhoist Unveils Hydratex™ Proprietary Technology - Dec 2016
The
Lhoist Group continues to invest in the international development of
Sorbacal® for flue gas treatment applications. Over the
years, Sorbacal® SP has become one of the leading sorbents
for the dry sorbent injection market worldwide. Sorbacal® SP
is currently used by industrial and utility customers across the five
continents. Since 2012, Lhoist has commissioned three new Sorbacal® SP
plants in the USA and one in Asia. This expansion has enabled the Lhoist
Group to build a unique and strong network of more than ten Lhoist Sorbacal® SP
production plants and to enter into licensing agreements with third
parties.
This
unique worldwide exposure has built up a pool of dedicated experts with
very specific know-how on flue gas treatment applications and sorbent
manufacturing based on the diversity of operational and compliance-driven
challenges they are facing every day. Lhoist has optimized plant operations
for quality and throughput based on the initial patented Sorbacal® SP
technology. These innovative solutions and know-how have not only been
developed for new plants but they have also recently been implemented in
all existing plants producing Sorbacal® SP products.
Lhoist
has filed a number of international patents applications. They cover
innovative Sorbacal® SP technology, implementing a specific
selection of new conditions. Sorbacal® SP customers will
benefit from the resulting improved consistency of product quality. These
innovations establish the cornerstone of the newly branded Hydratex™
technology.
SO3 removal with Sorbacal will solve the
bag blinding problem at PacifiCorp August
2016
Gerald
Hunt of Lhoist writes “Mitigating concern over blinding the bags should
just be a matter of achieving sufficient SO3 removal which
can be driven by proper injection location (further upstream the better,
not to mention taking advantage of the co-benefits of injecting upstream of
air heater) and a well-designed injection grid system. We have
several DSI/SO3 installations demonstrating the
effectiveness of Sorbacal SP to provide very effective SO3 capture
which we can back up with references. We are happy to work with
PacifiCorp on providing technical expertise regarding injection location(s)
and injection grid design if they desire.”
McIlvaine
is trying to arrange a recorded video interview with Lhoist and post it
later this week. If you are interested in asking questions or making
comments, we can include you as a participant.
MACT Update Provided in Hot Topic Discussion May 7, 2015
A
MACT route map and summary was reviewed as a way to launch the MACT
discussion on May 7, 2015. There are unique site specific factors which are
even more important in MACT than in MATS. The reason is that in cement,
brick and other industrial processes the material being processed may
create more air toxics than the fuel.
The
MACT route map cataloged the issues and options:
Issues
Options
for
- Mercury
- Particulate
- Acid gases
The
special focus is technology has risen to the top of the list in terms of
relative importance. One reason is that it does not require much capital.
Another is that the process is quickly implemented. Many industrial
facilities have waited to make a MACT choice and therefore are now limited
to those solutions which can meet the deadlines. The complete MACT route
map and summary is found in “Power Plant Air Quality Decisions.”
There
were two speakers on May 7. Both addressed the use of hydrated lime.
Pat
Mongoven of Mississippi Lime compared several types of
hydrated lime.
- DSI with hydrated lime can
allow SO2 and HCl reduction for both industrial
boilers and cement manufacturers.
- Depending on the
application and the facilities goals, a High Reactivity Hydrate may
allow better removal or lower costs.
- In cement scrubber towers,
DSI gave comparable removal rates to feeding a liquid slurry of
hydrated lime directly to the scrubber tower.
MACT Compliance Options, by Pat Mongoven, Mississippi Lime, HTH
5-7-15
DSI
with hydrated lime can allow SO2 and HCl reduction for both
industrial boilers and cement manufacturers. Depending on the application
and the facilities goals, a High Reactivity Hydrate may allow better
removal or lower costs. In cement scrubber towers, DSI gave comparable
removal rates to feeding a liquid slurry of hydrated lime directly to the
scrubber tower.
Revision
Date: 5/7/2015 Tags: 221112 - Fossil
Fuel ????, 327310 - Cement Manufacturing ????,
Mississippi Lime, Lime, MACT
Marty
Dillon of Lhoist enumerated advantages of a unique lime product.
Sorbacal
SPS is a lime hydrate which combines porosity and chemical treatment to
provide much higher SO2 and HCl capture than alternatives.
A number of trial and actual installations support the claim.
There was considerable discussion relative to balance of plant impacts.
Marty cites information showing the at Sorbacal SPS results in lower
pressure drop in baghouses and lower particulate emissions in precipitators
than finely ground lime such as is provided by others. Curt Biehn of
Mississippi Lime wanted more evidence. He cited papers showing that lime
injection may enhance precipitator performance. He also pointed out that
the lime reacts with acid gases to form larger particles.
Marty
showed evidence that the Sorbacal greatly reduced the leachate potential of
selenium and other air toxics, so there can be a positive benefit relative
to landfill alternatives and cost.
Flue Gas Treatment Specialist, by Marty
Dillon, Lhoist - HTH 5-7-15
Sorbacal
SPS is a lime hydrate which combines porosity and chemical treatment to
provide much higher SO2 and HCl capture than alternatives.
A number of trial and actual installations support the claim.
Revision
Date: 5/7/2015 Tags: 221112 - Fossil
Fuel ????, 327310 - Cement Manufacturing ????,
Lhoist North America, Lime, MACT
The
entire May 7 recording can be heard at MACT Update – 71
minutes
MACT Update Webinar - Hot Topic Hour -
May 7, 2015
There
are unique site specific factors which are more important in MACT than in
MATS. The reason is that in cement, brick and other industrial processes
the material being processed may create more air toxics than the fuel. The
special focus for this Hot Topic Hour was on dry sorbent injection. The use
of hydrated lime was also discussed.
Revision
Date: 5/7/2015 Tags: 221112 - Fossil
Fuel ????, 327310 - Cement Manufacturing ????,
Lhoist North America, Mississippi Lime, Lime, MACT
SO3 removal with Sorbacal will solve the
bag blinding problem at PacifiCorp
Gerald
Hunt of Lhoist writes “Mitigating concern over blinding the bags should
just be a matter of achieving sufficient SO3 removal which
can be driven by proper injection location (further upstream the better,
not to mention taking advantage of the co-benefits of injecting upstream of
air heater) and a well-designed injection grid system. We have
several DSI/SO3 installations demonstrating the
effectiveness of Sorbacal SP to provide very effective SO3 capture
which we can back up with references.
Lhoist North America Sorbacal
Hydration Facility at Ste. Genevieve Plant - April 2013
Lhoist
North America’s (LNA) new hydration facility at its Ste. Genevieve, MO
plant is on schedule, and the facility was expected to begin production in
March 2013. LNA’s Ste. Genevieve plant was selected as the optimal site to
receive the first U.S. Sorbacal® facility due to its
proximity to the utility market.
This
facility is being designed to produce Sorbacal® SP,
Lhoist’s proprietary emission control reagent that is the leading calcium
hydroxide reagent for dry sorbent injection (DSI) in Europe and Japan.
Sorbacal® SP is a unique hydrated lime product with twice
the surface area and three times the porosity of standard hydrated lime
products. In addition, Sorbacal® is ready to use in
existing DSI systems without any special handling provisions or further
processing.
SO3 Measurement and Control” – Hot Topic
Hour on March 8, 2012 (in the
Monitoring Newsletter)
SO3 in
the flue gas stream from a fossil-fueled boiler has long been a concern for
plant operators because of the potential for fouling and corrosion in the
air heater and corrosion in ducts and equipment downstream caused by the
sulfuric acid formed from the SO3. Excessive SO3 in
emissions from the stack can also cause opacity (blue plume) and acid mist
deposition problems. In addition, the presence of SO3 adversely
affects the removal of mercury from the flue gas with ACI. The effect of SO3 aerosols
on particulate emissions has also been a concern - more so in some plants
than others.
But
SO3 in flue gas will soon be a much bigger concern for all.
Because SO3 contributes to the formation of condensable or
fine particle emissions, the recent changes in the National Ambient Air
Quality Standards (NAAQS) for particulates and ozone may force even greater
control of SO3 under local standards or under regulations
dealing with particulates. The utility MATS with lower limits on mercury
and SO2 will further complicate the issue.
Control
of SO3 is a complex problem that can be highly dependent on
the control technology utilized for NOx, SO2, mercury
and particulates. In addition, measurement of SO3 can be
difficult which further complicates the control problem. In the March 8 Hot
Topic Hour, five very knowledgeable speakers presented the current “state
of the art” for SO3 measurement and control.
James
(Jim) C. Dickerman, Director of Flue Gas Treatment Applications at Lhoist
North America (formerly Chemical Lime Company), presented an overview of SO3emission
control with hydrated lime. He discussed the development history of the
technology as well as the key design parameters that need to be considered
for successful operations. Initial problems (primarily plugging of lances)
were resolved and the technology is fully commercialized now with
installations at over 30 utility boilers. Future development is focused on
the control of other acid gases such as HCl and SO2. He
said they have demonstrated that hydrated lime can be injected downstream
of the ESP (upstream of a scrubber) and not increase particulate emissions.
Also, injecting hydrated lime at two locations is more effective than one
location. Injection upstream of the air heater can reduce ABS formation
with no downstream impacts.
James
(Jim) B. Jarvis, Project Manager at URS Corp., stood in for Sterling
Gray, Manager of SBS Injection Technology. He described the application of
a liquid sodium based reagent (SBS) to reduce SO3 and
mercury emissions at power plants. He stated that since 2005 they have
learned that injection of SBS upstream of the air preheater provides
maximum benefits. Since 2005, they have had 24 boilers operating with
upstream injection, some of which had downstream injectors relocated. They
also have four installations ahead of the SCR that have been operating for
three years. He stated that SBS injection can significantly reduce SO3levels
prior to the air heater and reduce stack emissions of SO3 to
less than 1ppm and 0.003 lbs/MMBtu SAM. He presented a number of graphs
showing that mercury capture rates of 50 to 90 percent can be achieved with
high-efficiency SO3 control and with little to no carbon
injection.
Curtis
(Curt) Laush, Ph.D., Senior Scientist at Industrial Monitor and
Control Corp. (IMACC), described the capabilities, operation and
field-testing of a CEM-type analyzer based on a quantum cascade laser (QCL)
absorption spectrometer for real time continuous monitoring of SO3 and
SO2 across flue gas ducts. The in-situ design eliminates
sample extraction issues allowing a truly representative measurement of SO2,
SO3 and water vapor with fast response (less than 1 minute)
and high resolution (500 ppb in a 5 meter duct). In May IMACC will
begin field-testing a second-generation instrument and expects to have it
commercialized by the end of the year. Potential applications include
tracking SO2 oxidation in real time across catalysts and
downstream, tracking potential SO3 dew points when
optimizing air heater operation and optimizing sorbent usage for SO3 mitigation.
Dr.
Yougen Kong, P.E., Technical Development Manager at Solvay Chemicals,
Inc., discussed the interactions between SO3, HCl, HBr, PM and
Trona in flue gas. Trona injected before and after the air heater can be
very effective at controlling acid gases as well as enhancing mercury
removal. However, he emphasized that flue gas treatment at a coal-fired
power plant has become a chemical processing plant and a solution for one
plant may not fit another plant. Treating one component in the gas can
affect the other components. Therefore to be successful, you must
understand the chemistry of the gas, apply a systems approach and all
suppliers of APC equipment and the design engineers must work closely
together.
Jeff
Socha, R & D Project Leader for the SO3 CEMS at Thermo
Fisher Scientific Air Quality Instruments described capabilities of and
initial field test results for a dilution extractive SO3 monitor
being developed for real time monitoring of SO3 in flue
gas. The instrument uses a cascade laser and has an integrated SO3 gas
generator for daily calibrations and dynamic spiking to detect bias. The
detection limit is 0.4 ppm. Two systems are currently undergoing beta evaluations
at two power plants – one downstream of an FGD and one downstream of an
ESP. An instrument with a 100-foot sample line has a response time of 19
minutes.
The
entire March 8 recording can be heard at: SO3 Measurement & Control – 112 minutes – Password:
hth881
The
presentations are as follows:
? SO3 Measurement and Control - Webinar - Hot Topic Hour
March 8, 2012
? Overview of SO3 Emission Control with Hydrated Lime by
Jim Dickerman, Lhoist. Hot Topic Hour March 8, 2012
? Effective SO3 and Mercury Control Using SBS Injection by
Jim Jarvis, URS Corporation. Hot Topic Hour March 8, 2012.
? Real Time Continuous Monitoring of SO3 and SO2 Across
Flue Gas Ducts by Curtis Laush, Industrial Monitor and Control Corp
(IMACC). Hot Topic Hour March 8, 2012
? Real-Time Monitoring of SO3 in Flue Gas by Jeff Socha,
ThermoFisher Scientific. Hot Topic Hour March 8, 2012
? Interactions Between SO3, HCl, HBr, PM and Trona
Injection in DSI by Yougen Kong, Solvay - Hot Topic Hour March 8, 2012
Carmeuse Newsletter
Articles in the Intelligence System
Carmeuse
is Positioned to Offer Lime and Provide Remote Operating Advice to Solid
Fuel Combustion Operators Around the World - September 2017
The huge difference in lime consumption depending on the
lime quality and operational skills makes it possible for an international
lime company such as Carmeuse to compete for FGD business on a worldwide
basis. McIlvaine started reporting about the Dravo lime
technologies in the mid-1970s. the pilot plant operated by Dravo
lime in Ohio was designed to demonstrate the ability of wet lime to compete
favorably with limestone. This was due to compact size of a lime scrubber
vs. a limestone scrubber and the lower use of reagent. What made
this option particularly attractive was the rod deck or venturi rod
scrubber originally introduced in the 1960s by Environeering of which Bob
McIlvaine was president. Dravo Lime was able to demonstrate favorable economics
at the time using the rod deck scrubber design which could remove both
particulate and SO2.
Dravo Lime and then its new owner Carmeuse have
pioneered in other FGD technologies. One uses magnesium enhanced
lime. It becomes a double alkali system with a clear mag oxide
scrubbing loop and then production of magnesium oxide and calcium sulfate.
The full potential of this design has not yet been reached.
The point is that here is a lime company with enough
understanding of the processes to innovate several of its own competitive
processes. With this process knowledge, it can contribute subject
matter expertise to help FGD operators around the world achieve lowest
total cost of ownership of their lime consumption.
Lime can be shipped by barge much more inexpensively
than by land. Carmeuse is taking advantage of this low cost of
transport at its Oman plant. Carmeuse Majan, located in Oman’s Salalah Free
Zone, is a joint venture operated by Carmeuse Group. It has direct access
to some of the best limestone deposits in the Middle East and Asia. The
proximity of the Salalah seaport allows it to compete for industrial
customers in India, Oman, neighboring GCC countries and parts of Africa.
The lime calcination plant has a daily production capacity of 800 tons.
Where Carmeuse does not have competitive facilities, it
can form joint ventures. Carmeuse has signed an agreement with Handyman’s
Lime and Astro Quarries shareholders for management of a. 200 kt/year
modern Lime plant located in Ndola/Zambia. The plant and the quarry
currently employ 111 people.
Carmeuse brings its geological and technical
expertise as well as its market knowledge to manage
Handyman’s Lime assets in the same sustainable way as if it was a Carmeuse
owned plant. The actual takeover of the management was on July 1, 2017.
Carmeuse Overseas has been commercially active on the
copper belt market since 2010 and now rises as an industrial player to
better serve its clients, primarily the copper and cobalt mines of Zambia
and Democratic Republic of Congo. Late last year Carmeuse, together with
its partner GP Group, acquired a 45 percent stake in Golden Lime Public
Company Limited Thailand’s leading lime company. The transaction triggered
a tender offer to acquire the remaining publicly traded shares. The
founding family will retain a minority interest in the company.
Thailand is one of the largest consumers of lime and
lime derived products in South East Asia thanks to a large and diversified
industrial and agricultural base. The country is among the largest
producers of sugar in the world and continues to expand its capacity. It
also targets major expansion of its core infrastructure to improve its
appeal and competitiveness in the region.
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