Advancements in Activated Carbons

Transcription

1 Advancements in Activated Carbns Sheila Glesmann SVP Envirnmental and External Affairs McIlvaine Ht Tpic Hur New Develpments in Pwer Plant Air Pllutin Cntrl July 11,

2 1990s Multiple-pllutant cntrl labratry and pilt-scale studies t start evaluating c-benefits and srbent injectin Technlgy transfer f Activated Carbn Injectin (ACI) frm Municipal Sewer Waste ver t Cal Firing, but mercury cncentratins much lwer frm cal Majr issues with measurement f Hg at these lw levels in actual flue gas matrix Genesis f Activated Carbn Injectin fr Mercury Capture Early 2000s Significant field studies and demnstratins f same PACs used fr water treatment and MSW plants Intrductin f halgentreated activated carbns Measurement imprvements and ptins expand Issues such as ash dispsal identified, studied Tday ADA Carbn Slutins as first, fully fcused PAC manufacturer fr mercury remval intrduces new prducts tailred t this applicatin Identificatin f critical aspects f carbn that drive perfrmance in mercury capture Fcused prduct develpment in specific applicatin challenges Measurements still challenging and highmaintenance Cal-fired mercury cntrl has been studied by EPRI, EPA, DOE and thers since 1990 Activated Carbn Injectin (ACI) has been cmmercial in cal fired pwer plants since 2007 As f mid-2012, there were 63 GW f ACI bkings (ICAC) Onging Develpment Meaningful quality criteria that crrelate with mercury capture perfrmance Rapid innvatin targeting specific applicatin challenges High Acid Gases Cncrete Cmpatibility Faster Kinetics Slutins tailred fr specific circumstances t achieve the ptimal cmpliance slutins 2

3 Emissin Rate (lb/tbtu) Advances in High Hg Capture Efficiency - Gen 2 - FastPAC Premium EGU Test Steep, Rapid Capture Gen 1 PwerPAC Premium Lw Hg Residual & Secure Capture > 200 MW EGU PRB cal fired Cld-side ESP Hg CEMS 2.0 Emissin Standard 1.2 lb/tbtu 1.0 GEN 2 FastPAC TM Premium Lbs Activated Carbn / MMacf Our patent-pending FastPAC Premium Reduced PAC usage by 50% and Imprved Hg Remval t >95% 3

4 Innvatin Fcused n Mercury Capture Water Prducts Re- Purpsed fr Mercury Capture Gen 1 Pwer PAC TM Pwer PAC Premium TM First Generatin f Design-fr-Purpse Mercury Capture PAC Prducts Generatin 2 Pwer PAC Premium Plus TM FastPAC TM Platfrm Generatin 3 SO 3 Tlerant Cncrete Cmpatible Others Future A Scientific Apprach t PAC Design Guided by Fcused Applicatins Expertise 4

5 Three Critical Mechanisms fr Efficient Mercury Capture Cnversin f elemental mercury (Hg 0 ) t an xidized state (Hg + r Hg ++ ) t enhance mercury s receptivity t activated carbn Cntact f mercury, which is in very dilute cncentratins in the flue gas, with the activated carbn Mercury Capture Capture f the mercury in the activated carbn structure All Three Mechanisms Must Occur in Secnds r Less t Achieve Cmpliance 5

6 Emissin Treatment Fate f Mercury What des it take t capture mercury? Predminant Mercury Capture Mechanisms Oxidize Mercury Cntact with Capture Media Secure Mercury Capture & Remval Cal Pretreatment Effective Effective Effective? Pre- & Pst Cmbustin Oxidatin Effective Fly Ash / LOI Effective Effective? Selective Catalytic Reductin Effective Activated Carbn Injectin Effective Effective Effective Nn-carbn Srbents Effective Effective Effective? Wet Scrubber Effective Effective? Technlgies that d nt fulfill all three mechanisms require supplemental prcess steps that culd add capital and/r perating csts 6

7 Technlgy Philsphy Engineered cntrls are required. Cmplementary systems are beneficial. Reduce Hg emissins int the dwnstream wet scrubber t reduce ptential f Hg re-emissins. Increasing Hg cncentratin challenge & increasing cmplexity f chemistry and cnsistent prcess cntrl. The cmbinatin f SCR and wet FGD des nt guarantee cmpliance with MATS. Expertise. Reliability. Cmpliance. 7

8 Hg Remval Acrss PM Device (%) Suthern Plant Grgas: Gen-3 FastPAC Premium 80 SO 3 Tlerant Carbn Gen 2 FastPAC Premium + Hydrated Lime Gen 3 FastPAC Premium 80 SO 3 Tlerant Carbn Only Gen 2 FastPAC Premium Only Lad: ~100 MW Alabama Bituminus Cal Fuel Sulfur: wt% SCR: N Gen 1 Carbns in High Sulfur Eastern Bituminus Cal Flue Gas Temperature: 310 F DSI-ACI-Cld Side ESP PAC Injectin Rate (lb/mmacf) Expertise. Reliability. Cmpliance. 8

9 Hg Emissin Rate lb/tbtu Full-Scale Utility Test: FastPAC Premium 80 & Develpmental SO 3 Tlerant Carbns DEV FastPAC 2 chsen fr subsequent 30-day trial >700 Megawatt Unit Lignite Cal High Hg, lb/tbtu High SO 3, 15+ppm Cld Side ESP CEMS FastPAC Premium 80 DEV FastPAC 2 DEV FastPAC PAC Injectin Rate lb/mmacf SO 3 Tlerant Carbns Highly Effective fr High Mercury, High Sulfur Lignite Cal 9

10 Advances in SO 3 Tlerant Carbns FastPAC Premium 80 Over 18 full-scale utility tests f ur FastPAC Premium 80 SO 3 tlerant PAC MATS cmpliance ptins fr efficient Hg capture fr high-sulfur cal demnstrated Cmbinatin f DSI and ACI enhances mercury remval n high sulfur fuels and cmplements the perfrmance f FGD cbenefit. Cmbinatin f DSI and ACI prvide sufficient mercury remval fr MATS cmpliance n sub bituminus and select bituminus cal. New Generatin-3 ADA Carbn Slutins SO 3 Tlerant carbns allw effective peratinal ptins with reduced PAC and DSI requirements Expertise. Reliability. Cmpliance. 10

11 Drps f Air Entrainment Agent (50µL=1drp) Advances in Cncrete Cmpatibility Frm Our FastPAC TM Premium Cncrete Fam Stability vs. Time at ~ 3 lb/mmacf ACI Cmpetitr ADA PwerPAC Premium Plus TM ADA FastPAC Premium 8 6 N Carbn Baseline Time (Minutes) Our patent-pending FastPAC TM Premium PAC cnserves Air Entrainment Agent Usage and prvides Rapid Fam Stability Expertise. Reliability. Cmpliance. 11

12 Advances in Hg Capture Efficiency & Cncrete Cmpatibility with Our Gen-2 FastPAC Premium Prduct Platfrm 53 Full plant utility tests cmpleted in 2012 thrugh the end f May % lwer activated carbn cnsumptin Lwer particulate lad n ESP Reduced maintenance requirements & less equipment wear Ptential fr baghuse capital avidance Steeper Hg capture efficiency Greater than 95+% Hg capture capability Active cntrl capabilities Brader peratinal flexibility t meet cmpliance Extend useful life f plant peratins as ppsed t shutdwn Cncrete Capability Acceptance by fly ash marketer Lwer ash carbn cntent Rapid Fam Stability Expertise. Reliability. Cmpliance. 12

13 We Take Pride in Leading the Activated Carbn Perfrmance Landscape PAC Platfrm Intrductin Attributes FastPAC Premium Spring 2011 Fast Reactin & Adsrptin Kinetics High Hg capture efficiency - lw PAC dsage Lw Hg residual in flue gas Cncrete Cmpatible Summer 2011 Lw Fam Index lw AEA requirement Rapid Fam Stability cnstant AEA ver time FastPAC Premium 80 Spring 2012 SO 3 Tlerant Lw r n DSI requirements Other Develpmental Prducts Fall 2012 Spring 2014 Address niche cncerns identified by custmers such as ptimizatin fr specific unit cnfiguratins, higher flue gas temperatures We cntinue t fcus R&D resurces n develping new carbns that lead the industry in prviding cst-effective, reliable ptins fr MATS cmpliance Expertise. Reliability. Cmpliance. 13

14 Cntact Us Thank yu! Sheila Glesmann Sr. Vice President ADA Carbn Slutins, LLC 1460 W. Canal Curt, Suite 100 Littletn, CO (303) (410)