Industrial Accessories Company 4800 Lamar Ave Mission, Kansas 66202

Transcription

1 Industrial Accessories Company 4800 Lamar Ave Mission, Kansas PAC TECHNOLOGY ACI FOR FLUE GAS MERCURY MITIGATION PP

2 2 IAC PRODUCTS - SYSTEMS - SERVICES PRODUCTS: SYSTEMS: SERVICES: APC BAGHOUSES; HEAT EXCHANGERS BULK MATERIAL HANDLING DRY FGD & ACID GAS CONTROL HAP CONTROL MERCURY; ARSENIC BIOMASS PROCESING & HANDLING DEMONSTRATION TESTING OEM PARTS & COMPONENTS RETROFIT & BAGHOUSE CONVERSIONS MECHANICAL INSTALLATION STRUCTURAL STEEL FABRICATION

3 IAC SUBSIDIARY CONSTRUCTION COMPANY 3

4 MACT AND CATR 4

5 UTILITY MACT REQUIREMENT 5

6 TOXICS RULE EMISSION LIMITS 6

7 7 MACT STANDARDS FOR BIOMASS Major Source Boiler MACT Subcategory Pollutant Proposed Rule Heat Input Emission Limit Final Rule Heat Input Emission Limit PM 0.02 lbs/mmbtu lbs/mmbtu Existing Biomass Stoker/other HCl lbs/mmbtu lbs/mmbtu Hg 9.00E E-06 CO 560 3% O % O2 PM lbs/mmbtu lbs/mmbtu New Biomass Stoker HCl lbs/mmbtu lbs/mmbtu Hg 2.00E E-06 CO 560 3% O % O2 Area Source Boiler MACT Subcategory Pollutant Proposed RuleEmission Limit Final Rule Emission Limit New Biomass fired boilers 30 MMBtu/hr New Biomass fired boilers 10 MMBtu/hr and < 30 MMbtu/hr PM 0.03 lbs/mmbtu 0.03 lbs/mmbtu CO 100 ppm 7% O2 Management Practice PM 0.03 lbs/mmbtu 0.07 lbs/mmbtu CO 100 ppm 7% O2 Management Practice Boilers Burning less than 15% biomass

8 8 PAC INJECTION FOR MERCURY REMOVAL SCR / SNCR De-NO x SCR Converts Hg to oxidized form Absorbs Oxidized Hg Activated Carbon Oxidizes Elemental Hg and Adsorbs SO 2 Scrubber ESP Fabric Filter PC Fired Boiler Salable Ash Desired Fabric Filter

9 9 Hg Removal with Existing Equipment Controls Bituminous PM Only CS-ESP 46% HS-ESP 12% FF 83% PM Scrubber 14% Dry FGD SDA + ESP SDA + FF 98% Wet FGD CS-ESP+Wet FGD 81% HS-ESP+Wet FGD 55% FF+Wet FGD 96% Subbituminous 16% 13% 72% 0% 38% 25% 35% 33%

10 10 Mercury Emissions with Average Capture for Bituminous (46%) & Subbituminous (16%) Coals Cumulative Distribution (%) Other Bituminous Subbituminous Mercury in Coal (lb/tbtu)

11 CFD MODELLING FOR LANCE LOCATION 11

12 Particle Trajectories Particle Velocity (mps)

13 Normalized Dust Loading at Dust Collector Outlet Superimposed on Gas Velocity Distribution CFD Design - Significantly improved sorbent distribution

14 14 IAC PAC TEST RIG WITH SCALES Super-Sack Test Rig w/screw Feeder & Weigh Scales

15 PAC LANCE OPTIONS Open Pipe Discharge Low Pressure / Low Risk of Pluggage Multiple Nozzles per Lance High Pressure /High Velocity Distribution 15

16 PAC DISTRIBUTION & HEADER DESIGN Tapered Manifold with Multiple Lance Connections & Shut-off Valve Distributor with Multiple discharge (up to 20) Shut-off at Distributor & at Lance Connection 16

17 MERCURY TESTING 132 MW PLANT / AIR HEATER OUTLET 17

18 MERCURY TESTING 315 MW PLANT / AIR HEATER OUTLET 18

19 19 ACI SYSTEM OVERVIEW PAC DELIVERY IN TRUCKS OR RAIL SILO WITH UP TO THREE HOPPERS FOR PRODUCT DELIVERY HOPPER FLUIDIZING SYSTEM MODULAR DESIGN APPROACH PAC STORAGE ELECTRICAL ROOM FEEDER ROOM BLOWER & COMPRESSOR ROOM (*1) DILUTE PHASE PNEUMATIC CONVEYING OPTIONS REGENERATIVE BLOWERS FOR OPEN DISCHARGE LANCES LOW VOLUME COMPRESSOR & PD BLOWER COMBINATION COMPRESSOR: LOW VOLUME TO CONVEY PAC THRU EDUCTOR PD BLOWER: REQUIRED MOTIVE AIR; LANCE W/MULTIPLE NOZZLES (*1) SEPARATE BLOWER/COMPRESSOR ROOM CAN BE CONSIDERED IMPROVED ACCESS & MAINTENANCE CONTAINMENT / SEPARATION OF NOISE AND EMISSIONS ELIMINATING HEAT DISSIPATION TO PAC ELIMINATION OF MULTIPLE MEZZANINE LEVELS

20 20 ACI SYSTEM COMPONENTS SILO: 14-0 DIAMETER; SSH DETERMINED BY REQUIRED STORAGE CAPACITY SILO BIN VENT WITH DISCHARGE FAN SILO PRV. SILO CAN BE DESIGNED FOR 3 PSI CONSTRUCTION FOR NFPA LEVEL INDICATORS TRUCK FILL LINE AND LOCAL CONTROLS TROUGH TYPE HOPPER AIR FLUIDIZING PADS KNIFE GATE AND ROTARY VALVE W/FLEX CONNECTOR TO FEEDER HOPPER SCREW FEEDER WITH VFD EDUCTOR COMPRESSOR(S) & PD BLOWER(S) PIPING AS REQUIRED ELECTRICAL PANEL; MCC AND PLC AS REQUIRED

21 ACTIVATED CARBON FIRE EXPLOSION RISKS

22 IAC- MULTI MIX SORBENT (IN DEVELOPMENT) SOx & Hg MITIGATION 22

23 PERFORMANCE OF IAC- MULTI MIX MERCURY REDUCTION 23

24 24

25 25 CALCIUM SORBENT REACTIONS Ca(OH) 2 + SO 2 CaSO 3 + H 2 O Ca(OH) 2 + SO 3 CaSO 4 + H 2 O Ca(OH) 2 + 2HCL CaCl 2 + 2H 2 O Ca(OH) 2 + 2HF CaF 2 + 2H 2 O CaSO 3, CaSO 4, CaCl 2 and CaF 2 are collected in fly ash.

26 26 SODIUM BICARBONATE / TRONA REACTIONS 2NaHCO 3 Na 2 CO 3 + H 2 O + CO 2 2(Na 2 CO 3.NaHCO 3.2 H 2 O) 3Na 2 CO 3 + 5H 2 O + CO 2 Na 2 CO 3 + SO 2 + 1/2O 2 Na 2 SO 4 + CO 2 Na 2 CO 3 + SO 3 Na 2 SO 4 + CO 2 Na 2 CO 3 + 2HCl 2NaCl + H 2 O + CO 2 Na 2 CO 3 + 2HF 2NaF + H 2 O + CO 2 Na 2 CO 3 + NO x NaNO 3 + CO 2 Na 2 SO 4, NaCl, NaF and NaNO 3 are collected in fly ash.

27 SOLVAir(R) Select 200 Trona w/baghouse) 27

28 28

29 TYPICAL TRONA SILO & INJECTION DESIGN 29

30 30 IAC DSI LANCE TIP DESIGN LANCE TIP DESIGNS 1. Bayonet Tip for even dispersion. 2. Flat end at staggered depths. 3. Flared end for co-current flow. 4. Dispersion V tip end. Note: 1. Lance tip design is based on duct layout and arrangement 2. Lance diameter based on flow rates and quantity of lances utilized.

31 31 DSI DEMONSTRATION TESTING (36,000) PPH Trona; sodium Bicarbonate; Hydrated Lime Three DSI Bins with 3 Blowers Bins on Scales for Varied Feed Rates PD Blower in Sound Enclosure One 6-Ton/Hr Pin Mill per Silo Pin Mill in Sound/Weather Enclosure

32 32 DSI TESTING EQUIPMENT PD Blower in Enclosure Pin Mill w/contriols in Enclosure Bin Discharge with Live Bottom & Feeder

33 DSI TESTING EQUIPMENT 33

34 34 IAC M Intermediate Pressure Pulse Jet Baghouse 12 x 318TB-BHTP-500 Electric Arc Furnace Baghouse 1,200, F

35 35 IAC M Intermediate Pressure Pulse Jet Baghouse 12 x 318TB-BHTP-500 ASME 14 Headers with 3 Pulse Valves 25 Rows; 20 Bags per Row; Bag: 6 Dia x 26-6 Long

36 SUCTION CONVEYING FROM HOPPER TO STORAGE AND LOAD-OUT SILO Pneumatic Conveying from Flap Valve(s) at Hopper Discharge Receiver Filter at top of Silo Articulating Arm w/telescoping Load-Out Chute for Rail Car/Truck Loading 36

37 PEBBLE LIME ADDITION FOR ARSENIC MITIGATION 37

38 38 IAC Representative DSI Installations Plant Unit MW Pollutant DSI Location Sorbent Date OG&E; Sooner Station Unit SO2 AH Inlet Trona; SBC Nov-11 Constellation Energy Crane HCL AH Inlet & Outlet Trona; Hydrated Lime Sep-11 Constellation Energy Wagner HCL AH Inlet & Outlet Trona; Hydrated Lime Aug-11 Constellation Energy Wagner HCL AH Inlet & Outlet Trona; SBC Aug-11 OG&E; Sooner Station Unit SO2 AH Inlet Trona; SBC Jul-11 GRE, Stanton Station Unit SO2 AH Inlet Trona; SBC Jul-11 Luminant, Sandow Station Unit SO3 AH Inlet MgO May-10 Constellation Energy Wagner Hg & SO2 AH Inlet & Outlet PAC; Trona Apr-09 Constellation Energy Wagner Hg & SO2 AH Inlet & Outlet PAC; Trona; SBC Apr-09 Temple Inland N/A Steam SO3 N/A Trona Feb-09 GRU; Deerhaven Gen. Sta. Unit As Coal Belt Feed Pebble Lime Nov-08 Heron Lake Bio Energy, Steam SO2 AH Inlet Trona Nov-08 Constellation Energy Wagner HCL AH Inlet & Outlet PAC; Trona; SBC Apr-08 Constellation Energy Crane HCL AH Inlet & Outlet PAC Apr-08 Lincolnway Energy Steam SO2 Trona Apr-08 Red Trail Energy, LLC Steam SO2 SBC Jun-07 Constellation Energy Wagner Hg AH Outlet PAC May-07 Constellation Energy Wagner Hg AH Outlet PAC; Trona; SBC May-07 Constellation Energy Crane Hg AH Outlet PAC May-07 Corning N/A HCL & HF N/A Hydrated Lime Nov-04 Wabash Alloys Dickson, TN N/A HCL Baghouse Inlet Enviroblend Jul-01 Wabash Alloys Cleveland, OH N/A HCL Baghouse Inlet Enviroblend Jul-01 Wabash Alloys Tipton, IN N/A HCL Baghouse Inlet Enviroblend Jul-01 Wabash Alloys Wabash, IN N/A HCL Baghouse Inlet Enviroblend Jul-01 Excel Energy; Red Wing Unit 2 N/A SO2 Boiler Limestone May-00 Excel Energy; Red Wing Unit 1 N/A SO2 Boiler Limestone May-99

39 39 IAC Intermediate M-Pulse Baghouse Installations Lincolnway Energy- Nevada, IA Coal Fired Boiler 220,000 ACFM 400F Corn Products- LP Goldfield, IA Coal Fired Boiler 220,000 ACFM 400F Red Trail- Richardton, ND Coal Fired Boiler 220,000 ACFM 400F Heron Lake Bio Energy, MN Coal Fired Boiler 220,000 ACFM 400F Caterpillar- Mapleton, IL Foundry Melt Shop 240,000 ACFM 250F Nucor Steel-Blytheville, AR LMF and Meltshop 200,000 ACFM 250F Drake Cement, Drake, AZ Raw Mill / Kiln 206,000 ACFM 482F Drake Cement, Drake, AZ Clinker Cooler ACFM 392F Nucor Steel, Decatur, AL Electric Arc Furnace 1,200,000 ACFM 250F IAC Intermediate M-Pulse Installations in India Dalmia Cement Ltd. Cement Mill 443,200 ACFM 194F Krupp Polysius India Ltd. Kiln / Raw Mill 80,046 ACFM 464F Birla / Satna Cement ESP Conversion 40,023 ACFM 203F Birla / Satna Cement ESP Conversion 22,366 ACFM 203F

40 40 IAC Representative Hi-Pulse Baghouse Installations Ashgrove Cement- Springfield, MO Lime Kiln 30,000 ACFM 400F Cemex- Louisville, KY Clinker Hot Tank 25,000 ACFM 400F IAT Incineration- Richmond, WA Medical/Bio-Waste 5,000 ACFM 500F Continental Carbon- Ponca City, OK Carbon Black Reactor 20,000 ACFM 500F PPG- Lake Charles, LA Glass Furnace 35,000 ACFM 480F Phila Electric- Eddystone, PA Magnesium Oxide 225,000 ACFM 450F Carbo Ceramics- Toomsboro, GA Lime Kiln 87,000 ACFM 450F Ashgrove Cement- Portland, OR Lime Kiln 20,000 ACFM 425F BMH/James Hardie- Nashville, AR Gypsum Dryer 120,000 ACFM 400F BMH/Ga Pacific- Gypsum Dryer 80,000 ACFM 400F Reynolds Metals- Anode Bake Fce 141,000 ACFM 450F Intalco Aluminium- Ferndale, WA Anode Bake Fce 168,000 ACFM 450F Cemex- Fairborn,OH Alkali By-Pass 65,000 ACFM 500F Clow Corp- Oskaloosa, IA Electric Arc Furnace 2x27,500 ACFM 250F Drake Cement, AZ Coal Mill 20,598 ACFM 194 F Vienna Correctional Inst. Coal Fired Boiler 2x25,000 ACFM 450 F Carbo Ceramics- Toomsboro, GA Lime Kiln#1 80,000 ACFM 425 F Carbo Ceramics- Toomsboro, GA Lime Kiln#2 80,000 ACFM 425 F Carbo Ceramics-Toomsboro, GA Lime Kiln#3 80,000 ACFM 425 F Victaulic Foundry, Easton, Pa Induction Furnaces 80,000 ACFM 250 F Victaulic Foundry, Chihuahua, MX Induction Furnaces 86,000 ACFM 250F

41 41 Contact Information Corporate Address: Corp Tel: (913) Sales Tel: (800) Corp Fax: (913) Knoxville Address: 4800 Lamar Avenue Mission, Kansas Pramodh Nijhawan 318 Saint Andrews Drive Knoxville, TN Tel: (865) Cell: (865) Fax: (865) Web: