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Use of Alkaline-Earth Hydroxides for Reduction of Plume Visibility in Coal-Fired Power Plants

Overview Of Talk . SO3 removal performance requirementsApplicability of injection of alkaline earth compounds - hydrated lime, magnesium hydroxideFull-scale injection applicationsResults of full-scale demonstrations of SO3 control with calcium and magnesium hydroxides Tests of improved hydrated

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Use of Alkaline-Earth Hydroxides for Reduction of Plume Visibility in Coal-Fired Power Plants

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    1. Use of Alkaline-Earth Hydroxides for Reduction of Plume Visibility in Coal-Fired Power Plants Lewis Benson Carmeuse Technology

    2. Overview Of Talk SO3 removal performance requirements Applicability of injection of alkaline earth compounds - hydrated lime, magnesium hydroxide Full-scale injection applications Results of full-scale demonstrations of SO3 control with calcium and magnesium hydroxides Tests of improved hydrated lime performance with higher surface area and humidification Balance-of-plant effects

    3. Performance Requirements for SO3 Control and Applicable Technology Retrofit Return to pre-SCR SO3 in stack: ~50% reduction Good fit for alkali injection “Clear stack” - < ~5 ppm SO3, ~90% reduction Potential fit for alkali injection Demonstrated with SBS process New Power Plant < 2 ppm SO3 Wet ESP Alkali injection ahead of baghouse

    4. Conditions Favoring Alkali Injection Existing FGD system with difficult retrofit for a WESP Existing FGD system with multiple absorber modules Little impact on sale of fly ash Problems with sulfuric acid corrosion in ductwork.

    5. Compounds Tested for Injection for SO3 Control in Coal-fired Plants

    6. Full-Scale Calcium Hydroxide Injection Applications Hydrated lime – pre-ESP Zimmer – 1300 MW – 20 mo. in service Cumberland – 2 x 1300 MW – in engineering Hydrated lime – pre-wet FGD Widows Creek 8 - 550 MW – 1 yr in service 650 MW – 3 mo. in service

    7. Full-scale Magnesium Hydroxide Injection Applications Magnesium hydroxide Zimmer – upper furnace - 20 mo. in service Fuel Chem TIFI / TDI – furnace / air preheater

    8. Pilot-scale Magnesium Hydroxide Injection Testing NETL DOE / Consol / Alstom / Allegheny Energy - 1.6 MW pilot Injection ahead of Alstom pilot air preheater 4 moles Mg(OH)2 per mole SO3 inlet >90% SO3 capture from ~10-30 ppmv SO3 10 day continuous operation with <240 F flue gas exit Carmeuse / Consol / Alstom / Allegheny Energy – 1.6 MW pilot SCR-like SO3 conc. ~50 ppmv Demonstrate >90% SO3 capture, air preheater cleanliness with <240 F flue gas exit temperature for 3 month continuous operation

    9. Key Properties of Hydrated Limes for SO3 Control

    10. Key Properties of Magnesium Compounds for SO3 Control

    11. Magnesium-enhanced Lime (Thiosorbic®) Wet FGD with Byproduct Mg(OH)2 Production

    12. Injection Locations for Mg(OH)2 in NETL Demonstrations

    13. SO3 Removal in Furnace in 1300 MW NETL Demonstration

    14. SO3 Removal Across 1300 MW Furnace and SCR in NETL Demonstration No adverse impact on SCR catalyst or slagging No significant adverse ESP impact Opacity monitor readings reduced from 16-20% to 10-15% Byproduct and commercial Mg(OH)2 gave similar results No adverse impact on SCR catalyst or slagging No significant adverse ESP impact Opacity monitor readings reduced from 16-20% to 10-15% Byproduct and commercial Mg(OH)2 gave similar results

    15. Injection Locations for Mg(OH)2 and Ca(OH)2 for 1300 MW unit

    16. Balance-of-Plant Issues with Mg(OH)2 and Hydrated Lime Injection in 1300 MW unit Furnace Magnesium salt deposit on economizer tubes ESP Mg(OH)2 no significant effect Hydrated lime No significant adverse effect at addition rate of 3 TPH No accumulation in ESP, downstream ducts Slight build-up at air in-leaks Flyash sales continue for concrete, other

    17. Alkali Injection Short-term Performance Tests Hydrated lime – pre-wet FGD 650 MW Hydrated lime – pre-ESP Zimmer – 1300 MW Gibson 5 - 625 MW

    18. SO3 Reduction w/ Mg(OH)2 and Hydrated Lime Injection 1300 MW, 3 TPH hydrated lime w/ 13 SSA, 75 gpm 15% commercial Mg(OH)2 slurry to furnace, SCR off

    19. Effect of Specific Surface Area of Hydrated Lime on SO3 Reduction 1300 MW, 1.8 TPH hydrated lime, 50 gpm byproduct Mg(OH)2 slurry to furnace, SCR off

    20. Effect of Humidification on Hydrated Lime for SO3 Reduction 625 MW, 1.8 TPH hydrated lime w/~23 SSA, pre-ESP, SCR off

    21. Summary Injection of hydrated lime & magnesium hydroxide applicable for SO3 control Full-scale injection applications Options for hydrated lime injection location: pre-ESP, pre-FGD, pre-baghouse Options for magnesium hydroxide injection: upper furnace, post furnace Improved SO3 performance with higher surface area hydrated lime and humidification

    22. Summary Furnace injection of Mg(OH)2 proven at 1300 MW for efficient capture of furnace-generated SO3; additional injection of hydrated lime ahead of ESP reduced stack SO3 <5 ppm ESP performance with calcium or magnesium hydroxide depends on ESP design, improves with humidification

    23. Contact information: Bob Roden – Carmeuse FGT Technical Marketing Manager – 412-777-0722 office: 412-889-9662 cell; bob.roden@carmeusena.com Lew Benson – Carmeuse FGT Technical Manager – 412-777-0723; 412-818-9839 or 412-225-8816 cell; lew.benson@carmeusena.com Mark Thomas – Cinergy – 513-287-3802: office: 513-312-0124 cell; mark.thomas@cinergy.com

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