Material Handling For Dry Sorbent Injection in Coal-fired Power Plants is the
Hot Topic Hour on June 21, 2012
Because we have had so much interest in this subject, we scheduled two sessions
in order to keep the Hot Topic Hour within 90 minutes and to accommodate all of
the persons who desired to make a presentation. All persons that register for
the first session on June 7th will automatically be registered for the second
session on June 21st at no additional cost.
Dry Sorbent Injection (DSI) is a process in which a powdered sorbent material
such as Trona (sodium sesquicarbonate, a naturally occurring mineral mined in
Wyoming), sodium bicarbonate, hydrated lime or activated carbon is injected into
the flue gas from fossil-fueled boilers to control acid gases, such as sulfur
dioxide (SO2), hydrogen chloride (HCl), sulfuric acid (H2SO4) and more recently
mercury (Hg). Although DSI has been used for more than twenty years, now that
the U.S. EPA has finalized the MATS rule establishing low limits on Hg, HCl and
filterable particulate matter (fPM) emissions for all U.S. coal- and oil-fired
power plants greater than 25 MW, DSI is gaining even greater attention.
DSI advantages include lower equipment costs (first cost) as well as decreases
in operations and maintenance costs and a lower life cycle cost than other
pollution control technologies. DSI can be an effective, low cost,
multi-pollutant control solution that can help plants meet or even exceed their
MATS and CSAPR emission limits. DSI is a viable alternative for units in which
the investment for wet or dry flue gas desulfurization (FGD) cannot be justified
and for power plants that just need to improve the performance of existing
pollution control equipment.
However, DSI is not as simple as it may appear. The relationship between various
acid gases and other controlled gases in the flue gas can be very complex. DSI
can also have an impact on the performance of other existing control equipment
and vice-versa. Careful study is necessary to select the sorbent and sorbent
particle size that will achieve control goals at the lowest operating cost.
Study is also necessary to determine how the sorbent will affect or be affected
by other emission control equipment installed.
Selection of the correct delivery system components is also critical. Dry
materials can solidify and plug critical conveying tubes and injection devices.
And to obtain the lowest sorbent usage (and usually cost), the sorbent particle
size needs to be appropriate to the flue gas conditions and the sorbent needs to
be uniformly delivered to the gas stream.
The speakers listed below will address the issues related to sorbent selection
(which sorbent, which particle size and when it is cost effective and
appropriate to use and when it is not) and the design, installation, operation
and maintenance of DSI systems for various applications, provide suggestions for
reducing acquisition, installation, operation and maintenance costs while
improving efficiency and update us on new technology or designs under
development to improve the performance and reliability of DSI systems. They may
also compare DSI system costs and performance to other control technologies that
could be used.
Note: Speakers are listed for each day alphabetically by company and not
necessarily in the order in which they will be presenting
Speakers on Thursday, June 21, 2012 at 10:00 a.m. (Central time) will be:
Tony Licata, Vice President of Babcock Power Environmental, Inc, will discuss
the “Impact of Mixing on Performance of Dry Sorbent Injection (DSI) /Activated
Carbon Systems.” Most people in the industry expect that DSI will play a
significant role in the planning and implementation strategies for air quality
compliance in the next few years. To date most of the published papers and
technology interest has centered on which sorbent to use -- lime or sodium and
types of injection equipment. There has been little interest in the optimization
of mass transfer. Optimization of sorbent utilization may impact the viability
of DSI on many projects. This presentation will discuss methods of enhancing
mass transfer and the impacts of poor gas/sorbent mixing.
Mike Tate, Technical Manager of Research & Development for Graymont, Inc, will
address the following questions: What are the key properties of hydrated lime
that impact sorbent performance? How can these properties affect the design of
sorbent injection systems? His presentation will describe lime characteristics
and how they should be considered in the design of lime handling and storage
systems.
Curt Biehn, Manager of Technical Sales & Marketing at Mississippi Lime, will
present “Meeting Regulatory Needs with Hydrated Lime DSI.” The presentation will
highlight hydrated lime's performance for SO3 mitigation in a variety of
scenarios. Examples of full-scale applications that used hydrated lime to meet
2015 MATS guidelines will be provided. Comments on hydrated lime's flexibility
towards injection location optimization will also be presented.
Yougen Kong, P.E., Ph.D., Technical Development Manager at Solvay Chemicals,
Inc, will present “Dry Injection of Sodium Sorbents for HCl and SO2 Mitigation -
Effects of Using Mills.” The presentation will describe the technologies of
milling trona and sodium bicarbonate, pros and cons of each technology, capital
and maintenance costs of mill systems and good system design principles. The dry
injection of sodium bicarbonate or trona is a low-cost solution and has shown
over 99 percent removal of HCl and 95 percent removal of SO2. The trona shipped
out of production has a mean diameter of about 30 µm and can be used as is. On
the other hand, the sodium bicarbonate has a mean diameter of about 150 µm and
needs to be milled before being injected into the flue gas. While it is optional
to mill trona, milling trona can reduce the particle sizes and thus improve the
dispersion of trona particles inside the flue gas. Better mixing between the
particles and flue gas, in combination with higher surface areas of finer trona
particles, can result in better mitigation performance of HCl and SO2. Since
sodium bicarbonate out of production is too coarse to be injected directly into
the flue gas, it needs to be milled in order to have good mitigation performance
of HCl and SO2.
Steve Baloga, P.E., Southern Air Solutions Corporation, will present “Dry
Reagent Injection for Utility MATS, ICI Boiler and Portland Cement Kiln NESHAP
Compliance.” Since Steve does not represent trona or DSI equipment providers, he
will give an unbiased assessment of trona for DSI and associated issues based on
experience gained over many trials. Results of trona injection for SO2 and HCl
reduction for a utility boiler with ESP, an industrial boiler with ESP and a
cement kiln with FFBH will be presented. The effect of particle size reduction
for trona will be discussed. In the course of the presentation, additional
considerations will be mentioned that users must consider when evaluating sodium
based reagents: impact on PM emissions (including PM2.5/CPM), impact to Hg
emissions, impact to flyash quality, flue gas temperature limitations, material
handling considerations (avoiding pre-calcination), removal and potential
leaching of volatile HAP metals in trona laden flyash and cement alkali silica
reactivity issues related to sodium sorbents.
To register for the Hot Topic Hour on June 7 and June 21, 2012 at 10:00 a.m.
(Central time) click on:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.
McIlvaine Hot Topic Hour Registration
On Thursday at 10:00 a.m. Central time, McIlvaine hosts a 90 minute web meeting
on important energy and pollution control subjects. Power webinars are free for
subscribers to either Power Plant Air Quality Decisions or Utility Environmental
Upgrade Tracking System. The cost is $125.00 for non-subscribers. Market
Intelligence webinars are free to McIlvaine market report subscribers and are
$400.00 for non-subscribers.
DATE Non-Subscribers Cost SUBJECT Webinar Type
June 21, 2012 $125.00 Material Handling for Dry Sorbent Injection Power
June 28, 2012 $125.00 Greenhouse Gas Strategies for Coal-fired Plant Operators
Power
July 12, 2012 $125.00 CFB Technology and Clean Coal
(Update on CFB Reactor Technology) Power
July 19, 2012 $400.00 Future for Coal, Gas, Nuclear and Renewables (forecasts by
region and discussion of market drivers and regulatory constraints) Market
Intelligence
July 26, 2012 $125.00 Beneficial Byproducts of Coal Combustion and Gasification
Power
August 2, 2012 $125.00 Mercury Control and Removal Status and Cost Power
August 9, 2012 $400.00 Filter Media (forecasts and market drivers for media used
in air, gas, liquid, fluid applications both mobile and stationary) Market
Intelligence
August 16, 2012 $125.00 Report from Coal-gen (highlights of speeches and
exhibitions) Power
August 23, 2012 $125.00 Report from Mega Symposium (highlights of speeches and
exhibitions at this important air pollution conference) Power
August 30, 2012 $400.00 Instrumentation for Air, Gas, Water, Liquids (forecasts
, market shares, growth segments) Market Intelligence
September 6, 2012 $125.00 Production of Fertilizer and Sulfuric Acid at
Coal-fired Power Plants Power
Here are the Headlines for the June 8, 2012 – Utility E-Alert
UTILITY E-ALERT
#1078– June 8, 2012
Table of Contents
COAL – US
B&W PGG to supply SDA Systems for 835 MW Campbell 3
Trailblazer Project gets 18-month Extension for Air Permits
COAL – WORLD
B&W PGG awarded Engineering Contract for 180 MW Termotasajero 2 Project in
Colombia
Uttar Pradesh Government extends Deadline for Nine Firms to set up Power
Plants
FGC System proposed in Korba, Chhattisgarh, India
Ecoprag predicts more Coal-fired Power Plant Construction in Europe
Mahanadi Coalfields to seek Bids for 1600 MW Power Project
GAS / OIL – US
558 MW Carlsbad Combined Cycle Power Plant approved in California
GAS / OIL – WORLD
New 1,000 MW Latrobe Valley (Australia) Power Station Plan
BUSINESS
MHI to develop Triple Combined Cycle Power Generation System
Shaw Group, Exelon to develop New Gas-fired Power Generation Technology
1 Billon Market for Chemicals to Capture Mercury
HOT TOPIC HOUR
DSI activity is High according to Hot Topic Hour Speakers on June 7, 2012
Hot Topic Hour Next Week will be from Power-Gen Europe
Upcoming Hot Topic Hours
For more information on the Utility Environmental Upgrade Tracking System, click
on: http://www.mcilvainecompany.com/brochures/energy.html#42ei.
$1 Billon Market for Chemicals to Capture Mercury
Power and industrial plants will be accelerating their annual spending on
chemicals to remove mercury. By 2015 the purchases will exceed $1 billion. This
is the latest finding in the McIlvaine online report, Mercury Air Reduction
Markets.
New standards limiting discharges of mercury from power plants, cement kilns and
incinerators in the U.S. will boost the market for treatment chemicals. Until
recently, it appeared that the bulk of the business would be captured by
activated carbon manufacturers. Now it appears that bromine suppliers will be
carving out a significant share.
When halogens such as bromine and chlorine react with elemental mercury they
form soluble compounds e.g. mercury chloride which can be absorbed in
conventional FGD scrubbers. Furthermore, when activated carbon is impregnated
with halogens it is considerably more effective in capturing the elemental
mercury. Bromine has proven to be considerably more effective than chlorine.
Calcium bromide can be added to the coal and at various points in the air
pollution control system prior to the wet scrubber. The wet FGD system has
proven effective in removing more than 90 percent of the mercury in the ionic
form. Therefore, the calcium bromide-wet scrubber combination offers an
alternative to the activated carbon-dry injection approach. However, not all
power plants will want to make the investment in the wet scrubbers and will
consider alternatives for SO2 removal.
The U.S. represents more than 90 percent of the total market for capture of
mercury from stack gases. The U.S. electricity generators will be making most of
the purchases. However, there will be significant markets in cement and
industrial boilers. There is already a market in waste incinerators.
Most of the non-U.S. market is presently in waste incineration. This includes
both municipal and hazardous waste. There are additional markets in sewage
sludge incineration, crematories and mining.
One reason that European, Japanese and Korean power generators are not
specifically regulated for mercury emissions is that nearly all the power plants
have wet scrubbing systems and are already removing most of the mercury. These
power plants can increase mercury removal with bromide additions.
China is seriously investigating mercury removal technologies. It operates more
coal-fired boilers than all the countries of Europe combined, so it is the
largest mercury emitter. It has equipped most of its plants with SO2 wet
scrubbers. Therefore, it is focusing on chemical additives such as bromine to
improve scrubber capture.
In the U.S. the market for removal of mercury has now been quantified by the new
proposed Utility Toxic Rules (MATS), the final Industrial Boiler Rules and the
final Cement MACT Rules. The Utility Rules will have most of the impact on the
mercury control market. The original rule covered just mercury, but was struck
down. The rule which is in place covers air toxics including metals other than
mercury and toxic gases such as hydrogen chloride.
For more information on Mercury Air Reduction Markets, click on:
http://www.mcilvainecompany.com/brochures/air.html#n056
Air Pollution Control Revenues Will be $35 Billion This Year
The market for air pollution control equipment and consumables will be $35
billion in 2012 according to a McIlvaine company recorded presentation and
discussion on May 31, 2012. In this 90 minute analysis, the opportunities were
ranked by size:
World Air Pollution Control Revenues $ Billions 2012
Product Revenues $ Billions
Scrubbers 12
Electrostatic Precipitators 8
DeNOx 7
Fabric Filters 6
Thermal Treatment 2
Power plants will purchase more than 50 percent of the scrubbers. Limestone
forced oxidation will be the prevalent technology. More than half of the power
plant purchases will be in Asia.
The fabric filter segment will grow at a faster rate than the other segments
over the next decade. Within this segment the sales of membrane media will grow
faster than other options. The precipitator segment will grow at the lowest
rate.
Industrial plants in the U.S. will be spending over $1 billion/yr over each of
the next four years to comply with toxic air pollution control standards for
their boilers, kilns and incinerators. The biggest investments will be in fabric
filters and continuous emissions monitors.
Sales of chemicals for the purposes of air pollution control will exceed $13.8
billion. Twenty five percent of this market will be in the U.S. Purchases of
activated carbon and bromine will grow at double-digit rates over the next five
years. Ammonia DeNOx purchases are presently $1.5 billion in the U.S. and $6
billion worldwide. Lime usage will grow robustly as power plants address the new
U.S. air toxic rules.
A big potential use of lime is for inhibited oxidation wet scrubbing systems.
The purchases will be driven by the ability of the chemically fixed waste
product to encapsulate toxic metals. This is one of the most economical ways to
ensure that an air pollution problem does not turn into a water pollution
problem.
One of the biggest variables in the size of the future market is the price and
availability of natural and non-conventional gas. However, it is the perception
of future prices rather than the accurate prediction of them which will most
affect the markets. To some extent, the perception and the ultimate reality are
guaranteed to be different.
If the perception is that gas prices will remain low, then there will be large
numbers of gas turbine power plants, LNG export facilities and gas to liquids
plants built. This will cause the price of gas to soar. If, on the other hand
investors fear a return to high gas prices, they will not invest in gas
consuming facilities and this will cause the price of gas to remain low.
The 90 minute recording and the extensive printed presentation are available
from the McIlvaine Company. Click here for more information: Click here to order
recordings access.
Residential Solar Market Continues to Grow
More and more people are installing solar panels to lower their electricity
bills. McIlvaine’s Renewable Energy Projects and Updates tracks community
efforts along this line.
OneRoof Energy Brings Hundreds of Green Jobs to San Diego
CleanTECH San Diego and Mayor Jerry Sanders joined OneRoof Energy at a newly
solarized home to announce the creation of 100-plus new green jobs.
OneRoof Energy is the first U.S. residential solar company to work directly with
roofers to sell and install its systems. The nation’s demand for solar, rising
sales and OneRoof Energy’s SolarSelect® Lease program, has led to the company’s
extraordinary growth and local hiring opportunities.
Last year, OneRoof Energy received $50 million in financing to create the
SolarSelect® Lease program. The simple lease program allows homeowners the
ability to integrate solar into their roof with little to no upfront payment.
Customers make a monthly lease payment for the system, which when combined with
their new, lower electric bill, is lower than their existing bill without solar.
SolarCity and Shea Homes® Introduce the “No Electric Bill” Home
SolarCity®, a national leader in clean energy services, and Shea Homes, one of
the country’s largest privately-held home builders, have partnered to make a “no
electric bill” home available to homebuyers in all Shea Homes Active Lifestyle®
and Trilogy® communities in Arizona, California, Florida, Nevada and Washington.
Branded as SheaXero the no electric bill home™, the partnership with SolarCity
will make net-zero the standard offering at all ten of Shea’s Active Lifestyle
and Trilogy Communities. SheaXero homes aim to achieve net-zero electric bills
by generating as much electricity as they consume through a blend of
energy-efficient features and a solar power system that is included in the
home’s purchase price.
Shea’s partnership with SolarCity is expected to be one of the largest net-zero
electric home projects in the U.S. when completed. The partnership allows
SolarCity to provide solar services to homeowners in Florida and Nevada for the
first time.
Envision Solar and 360 Commercial Partners Join Forces to Bring Landmark-Quality
Solar Tree® Structures to Orange County, CA
Envision Solar International, Inc., a leading sustainable infrastructure product
designer and developer, announced it has executed a business development
partnership with 360 Commercial Partners, Orange County.
360 Commercial Partners will promote Envision’s solar shaded parking products to
their discerning commercial real estate clients. The agreement covers Envison’s
unique 100 percent clean energy product offerings including the patented line of
Solar Tree® structures which feature cutting-edge & proprietary EnvisonTrak™ sun
tracking systems and CleanCharge™ sun tracking systems and CleanCharge™ CI™
Column Integrated™ Electric Vehicle charging stations.
SolarCity Expands to Connecticut, Will Allow Homeowners and Businesses to
Install Solar for Free and Pay Less for Electricity
SolarCity®, a national leader in clean energy services, is expanding to
Connecticut to make it possible for many homeowners and businesses to install
solar panels for free and pay less for solar electricity than they pay for
utility power. SolarCity is expanding to Connecticut in large part due to the
efforts of the state – through programs at Connecticut Clean Energy Finance and
Investment Authority (CEFIA) and the DOE and Environmental Protection (DEEP) to
promote, develop and invest in clean energy and energy efficiency projects.
SolarCity gives customers the option to purchase their systems and installation,
or to have the panels installed for free and pay only for the solar electricity
they produce. The company expects to be able to allow many Connecticut
homeowners and businesses to save thousands of dollars on electricity costs by
bringing back a popular model the state itself offered until its program became
oversubscribed in 2009. SolarCity will also perform comprehensive energy
efficiency evaluations to provide recommendations for further opportunities for
cost savings and to improve indoor air quality and comfort.
For more information on Renewable Energy Projects and Update please visit
http://www.mcilvainecompany.com/brochures/Renewable_Energy_Projects_Brochure/renewable_energy_projects_brochure.htm
----------
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http://www.mcilvainecompany.com/brochures/Free_Newsletter_Registration_Form.htm.
Bob McIlvaine
President
847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
www.mcilvaine@mcilvainecompany.com
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191 Waukegan Road Suite 208 | Northfield | IL 60093
Ph: 847-784-0012 | Fax: 847-784-0061
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