DIOXIDE REMOVAL FROM STACK GASES

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1 Report No. 63 SULFUR DIOXIDE REMOVAL FROM STACK GASES by EARL D. OLIVER July 1970 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION , SUMMARY INDUSTRY STATUS... History... Plants... Pilot Plants... Promotional Agreements... Potential Recovery... Potential Markets... Outlook GENERAL CONSIDERATIONS... Power Generation and Gas Composition... Recovery Process Power Requirements... Process Materials Costs... Design Criteria... Attractiveness Criteria... 5 REMOVAL OF FLY ASH... Design Requirements... Wet Scrubbers... Cyclone Separators... Electrostatic Precipitators... Combinations of Cyclone Separators and Electrostatic Precipitators... Cost Estimates... Capital Costs... Production Costs... 6 ADDITIVE INJECTION PROCESS... Introduction... Chemistry... Review of Processes... Process Description... Process Discussion... Cost Estimates... Capital Costs... Production Costs V

3 CONTENTS 7 CEMENT SULFURIC ACID PROCESSES Introduction Chemistry Review of Commercial Processes Process Description Process Discussion Cost Estimates Capital Costs Production Cost;... 8 ALKALIZED ALUMINA PROCESS Introduction... : Chemistry Review of Processes Process Description Process Discussion Cost Estimates Capital Costs Production Costs CATALYTIC OXIDATION PROCESSES Introduction Chemistry Review of Processes Process Description Process Discussion Cost Estimates Capital Costs Production Costs CARBON ADSORPTION PROCESSES Introduction Chemistry Review of Processes Process Description Process Discussion Cost Estimates Capital Costs Production Costs vi

4 CONTENTS ALKALI SULFITE ABSORPTION PROCESSES Chemistry Review of Processes Process Description Process Discussion Cost Estimates Capital Costs Production Costs Sodium Sulfite System MODIFIED CHAMBER PROCESS Introduction Chemistry Review of Processes Process Description Process Discussion Cost Estimates Capital Costs Production Costs OTHER PROCESSES Introduction Dry Metal Oxides and Hydroxides Aqueous Scrubbing Irorganic Liquid Processes Organic Liquid Processes Inorganic Solids Other Than Oxides Organic Solid Processes Direct Reduction Processes Physical Methods of Separation APPENDIX A DESIGN AND COST BASIS... APPENDIX B PHYSICAL DATA... APPENDIX C RAW MATERIAL AND PRODUCT SPECIFICATIONS... APPENDIX D SAFETY AND HANDLING... CITED REFERENCES... PATENT REFERENCES BY COMPANY vii

5 ILLUSTRATIONS Comparison of Plant Size and Heat Rate... Stack Gas Rates... Proposed Revision to ASME Model Ordinance for Permissible Fly-Ash Emissions... Purchase Cost of Dry Centrifugal Collectors in Purchase Cost of High-Voltage Electrostatic Precipitators in Installed Capital Cost of Electrostatic Precipitator Systems Excluding Disposal Turbulent Contact Absorber... Dust Removal Alkalized Alumina Process... Solids Entraining Device... Cat-Ox Process... Cat-Ox Process Effect of Variables... Reinluft Process... Condensed System MsSaOs-MsSO,-Ha Phase Diagram... Battery Limits Plus Utilities Cost... Effect of Operating Level and Plant Capacity on Production Cost... Cost of Acid Making Section of a Sulfuric Acid Plant Effect of Operating Level and Plant Capacity on Production Cost... ix

6 TABLES Summary of Evaluations for 800 Megawatt Power Plant... 7 Commercial Stack Gas Treating Plants Prototype and Semi-Works Stack Gas Treating Plants Stack Gas Treating Processes in Pilot Plant Stage Data on Sulfur Products Summary of Capital Charges Calculation of Levelized Charges Air Cleaning Equipment Installed Cost Based on 1,000 Megawatt Unit Electrostatic Precipitator Production Costs Additive Injection Processes Studies of Sulfur Dioxide Sorption by Limestone Major Process Equipment and Utilities Summary Stream Flows Total Capital Investment Operating Costs Credits Cement Sulfuric Acid Plants in Operation at End of Analysis of Portland Cements Typical Composition Limits of U.S. Coal Ash Chlorine Content of Selected U.S. Coals es for License Major Process Equipment and Utilities Summary Stream Flows xi

7 TABLES Total Capital Investment , Production Costs Licenser's Estimate of Total Capital Investment Licenser's Estimate of Production Costs Alkalized Alumina Processes Catalytic Oxidation Processes Cat-Ox Process Major Process Equipment and Utilities Summary., Cat-Ox Process Stream Flows Monsanto Cat-Ox Process Total Capital Investment Monsanto Cat-Ox Process Production Costs Carbon Adsorption Processes Reinluft Process Major Process Equipment and Utilities Summary., Reinluft Process Stream Flows Reinluft Process Total Capital Investment Reinluft Process Production Costs Wellman-Lord Alkali Sulfite Processes Major Process Equipment and Utilities Summary Stream Flows Total Capital Investment xii

8 TABLES Production Costs Wellman-Lord Sodium Sulfite Process Total Capital Investment Wellman-Lord Sodium Sulfite Process Production Costs Major Process Equipment and Utilities Summary Stream Flows Total Capital Investment Production Costs Dry Metal Oxide Processes Aqueous Scrubbing Processes Inorganic Liquid Processes Organic Liquid Processes Processes Using Solids Other Than Oxides Organic Solid Processes Direct Reduction Processes xiii

PROCESS ECONOMICS PROGRAM

7 Report No. 34 PHTHALIC ANHYDRIDE by LLOYD M. ELKIN contributions by Kenneth E. Lunde March 1968 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE MENLO PARK, CALIFORNIA CONTENTS