ADA Carbon Solutions SO3 Tolerance
- 1. Expertise. Reliability. Compliance. 1 Next-Generation SO3 Tolerant PACs EUEC – San Diego, CA February 16, 2015 C2.5 Activated Carbon HG Robert Huston, Roger Cayton, Jacob Lowring & Joe Wong
- 2. Expertise. Reliability. Compliance. 2 THE INFORMATION CONTAINED IN THIS PRESENTATION IS FOR GENERAL INFORMATIONAL PURPOSES ONLY, AND IS NOT INTENDED AS LEGAL ADVICE. YOU SHOULD CONSULT AN ATTORNEY OR OTHER APPROPRIATE PROFESSIONAL FOR ADVICE REGARDING YOUR INDIVIDUAL SITUATION.
- 3. Expertise. Reliability. Compliance. 3 1. The SO3 problem: Hg capture historically hindered 2. Taking a fundamental scientific view...potential mechanisms that impact Hg capture 3. Development process from lab to field 4. Product generations / SO3-specific evolution 5. Full-scale field test results 6. Further development / test opportunities for utilities 7. Summary Next-Generation SO3 Tolerant PACs
- 4. Expertise. Reliability. Compliance. 4 Hg Capture Historically Hindered PAC Injection Rate (lb/MMacf) 0 100 90 80 70 60 50 40 30 20 10 0 2 4 6 8 10 12 14 16 18 20 VaporHgRemovalAcrossPMDevice(%) Western Coal, FF Western Coal, ESP Low Sulfur, Eastern Bituminous, ESP High sulfur, Eastern Bituminous, ESP
- 5. Expertise. Reliability. Compliance. 5 Achieving Reliable Compliance in a Diverse Set of Conditions All three mechanisms must occur uninhibited in seconds or less to achieve compliance Conversion of elemental mercury (Hg0) to an oxidized state (Hg+ or Hg++) to enhance mercury’s receptivity to the capture media. Contact of mercury, which is in very dilute concentrations in the flue gas, with the capture media. Capture of the mercury in the capture media’s structure for removal from the system.
- 6. Expertise. Reliability. Compliance. 6 Potential Impact of SO3 on Activated Carbon and Mercury Capture 1. SO2 oxidation to SO3 in carbon Mesopores 2. Occupies Carbon Pore Volume a. As SO3 b. As SO3 + H2O <- -> H2SO4 3. H2SO4 solubilizes adsorbed Hg a. Emits back into flue gas 4. Interferes with Hg oxidation catalytic pathways H2SO4 Carbon Particle Surface SO3 Hg+ HSO4 -1
- 7. Expertise. Reliability. Compliance. 7 Potential Sources of Sulfur Trioxide (SO3) 1. Oxidation of sulfur in coal in boiler 2. Oxidation of SO2 in flue gas at SCR 3. Injection of SO3 as an ESP conditioner
- 8. Expertise. Reliability. Compliance. 8 FastPAC Premium 80 (DEV Q) Increase Sacrificial Reactivity (DEV T) Increase Bromine Oxidation Effectiveness (M0122/ DEV QV) Enhance Catalytic Oxidation Enhance Other Capture Mechanisms Future FastPAC Premium 80 SO3 Tolerant PAC Development Roadmap HgRemovalImprovement The cumulative performance enhancement potential beyond the Baseline PAC approaches an additional 80% increase in mercury capture performance through stepwise mechanistic advancements. 30% 30% 10% 10% 80% Next Gen SO3 Tolerant PAC Baseline PAC Improved Sacrificial Capability Enhanced Oxidation Technology Secondary Hg Conversion Mechanism Improved Hg Capture Component Next-Gen SO3 Tolerant PAC
- 9. Expertise. Reliability. Compliance. 9 Our Next-Generation Developmental PACs Show Enhanced Sacrificial Protection 1.0 1.5 2.0 2.5 NormalizedSulfuricAcidConsumption Developmental PAC 1st Generation Sacrificial We have further enhanced the SO3 Sacrificial Protection Performance of our developmental PACs 0.5 Baseline PAC 2nd Generation Sacrificial Next-Gen SO3 Tolerant PAC
- 10. Expertise. Reliability. Compliance. 10 Southern Plant Gorgas: Developmental Gen-3 SO3 Tolerant Carbon For Bituminous Coal (~10 ppm SO3) PAC Injection Rate (lb/MMacf) 0 100 90 80 70 60 50 40 30 20 10 0 2 4 6 8 10 12 14 16 18 20 HgRemovalAcrossPMDevice(%) Gen 2 FastPAC Premium™ Only FastPAC Premium™ Gen 3 SO3 Tolerant Carbon FastPAC Premium™ + Hydrated Lime Gen 2 FastPAC Premium™ + Hydrated Lime Gen 3 SO3 Tolerant Carbon Only •Unit 7 Load: 100 MW •Fuel Sulfur: 1.5 – 2.5 wt% •SCR: No •Flue Gas Temperature: 310°F •Emission Train Configuration: Econ-APH-DSI-ACI-ESP-Stack Gen 1 Carbons in High Sulfur Eastern Bituminous Coal
- 11. Expertise. Reliability. Compliance. 11 Gen-2 High-Efficiency Hg Removal and FastPAC Premium 80 Gen-3 SO3 Tolerant Carbons • 600 Megawatt Unit • PRB Coal • Emission Train Configuration APH-ACI-SO3-ESP-Stack • SO3 injected for ESP conditioning • ESP inlet at ~350°F • CEMs on ESP outlet 0 2 4 6 8 10 12 0 1 2 3 4 5 6 7 8 HgRemovalug/m3 ACI Injection lb/MMacf Approximate US Federal Limit FastPAC Premium™ with 2.6 ppm SO3 Injected FastPAC Premium™ with 3.5 ppm SO3 Injected FastPAC Premium™ 80 with 7 ppm SO3 Injected ADA CS Carbon Type Approximate SO3 Injected ppm ACI Injection Rate at Compliance Lb/MMacf FastPAC Premium™ 2.6 2.5 to 3 FastPAC Premium™ 3.5 3 to 3.5 FastPAC Premium™ 80 7 5 to 7
- 12. Expertise. Reliability. Compliance. 12 Next-Generation Product Performance: EGU 4 - High Sulfur Fuel Blend (18-24 ppm SO3) 0% 10% 20% 30% 40% 50% 60% 70% A B C D E % Hg Removal Relative to Baseline Removal PACFormulation EGU 4 - Comparative Hg Removal Across ESP Baseline PAC Enhanced Oxidation/SO3 Tolerance #1 Enhanced Oxidation SO3 Tolerance Enhanced Oxidation/SO3 Tolerance #2 High sulfur fuel blend, 18-24 ppm SO3 Stepwise mechanistic formulation enhancements
- 13. Expertise. Reliability. Compliance. 13 1. The SO3 problem is better understood mechanistically leading to rigorous R&D technology roadmaps for building the next- generation SO3 Tolerant PACs 2. Rapid PAC prototyping from lab to field is available to advancing technologies for commercial use 3. Next-generation ADA Carbon Solution SO3 Tolerant PACs have been introduced and demonstrated high Hg removal efficacy in full-scale utility tests 4. Additional PAC product generations for SO3-specific systems are in development Summary - Next-Generation SO3 Tolerant PACs
- 14. Expertise. Reliability. Compliance. 14 Questions? Robert Huston Senior Director Technical Services robert.huston@ada-cs.com Joe Wong Chief Technology Officer joe.wong@ada-cs.com Roger Cayton Senior Director R&D roger.cayton@ada-cs.com Jacob Lowring Continuous Improvement & Quality Manager jacob.lowring@ada-cs.com