Sodium Bicarbonate DSI at Kincaid Generating Station

Transcription

1 Sodium Bicarbonate DSI at Kincaid Generating Station

2 AGENDA Plant description Trial results 2009 Trona and Bicarbonate test 2011 S350 test System design Railcar unloading Storage Mills Injection system System performance 2

3 KINCAID STATION Kincaid Power Station is located in Kincaid, Illinois (near Springfield) Kincaid consists of two 550 MW coal-fired generating units (it produces enough electricity to power about 290,000 homes) Kincaid Station was originally a mine mouth plant built next to Peabody Mine and was converted to burn 100% PRB coal (low sulfur) in Unit 1 & Unit 2 began commercial service in 1967 and in 1968 In 2013 Kincaid has been sold from Dominion to EquiPower Resources Corp. 3

4 DRIVERS FOR TREATMENT: SO 2 CONTROL State of Illinois mandated SO2 reductions beginning January 2014 to an outlet level of 0.2 lbs/mmbtu Agreements with the EPA for a lower level of SO2 emissions of about 0.1 lbs/mmbtu. SO 2 content of 0.63 lbs/mmbtu in the coal results in a target removal of 85% Lay-out FGT: DeNOx SCR APH ESP 4

5 LOCATION AND LOGISTIC Distance 1160 miles 1850km The only sustainable solution is to deliver through railcar Green River, WY Kincaid, IL 5

6 AGENDA Plant description Trial results 2009 Trona and Bicarbonate test 2011 S350 test System design Railcar unloading Storage Mills Injection system System performance 6

7 2009 TEST PARAMETERS Sorbents to be tested Trona Select 200 unmilled Trona Select 200 milled with pinmill on site Sodium bicarbonate premilled to d90 < 40 µm Sorbent addition locations Hot side: Before the air heater (SCR Outlet) T= C Cold side: After the air heater T=150 C Objectives Meet SO 2 removal requirements (85%) Determine sorbent NSR Determine PM and Hg removal impacts 7

8 SYSTEM CONFIGURATION 2 emission testing to check the impact on ESP Any information available on the raw gases 8

9 Milled SBC at SCR outlet showed best results SO2 Removal NSR 9

10 2009 TEST MAIN IMPORTANT RESULTS Milled sodium bicarbonate added upstream of the air heater was the most efficient Mercury removal was maintained with a small increase of Powdered Activated Carbon addition (5-10%) Particulate Matter removal targets were met Sodium DSI was demonstrated to be a viable option to meet the consent decree Limited effect on stack opacity Relatively benign impact on the performance of the ESP 10

11 2011 S350 TESTING The purpose of the second round of testing was to confirm removal rates and mercury impact Test various particle sizes to determine effect on efficiency 26.7 µm 36.8 µm 38.2 µm Only premilled sodium bicarbonate was tested Only one sorbent addition location: SCR outlet (hot side) 11

12 2011 TEST RESULTS 100% 90% 80% 70% SO2 Removal (%) 60% 50% 40% 30% 20% 10% 0% NSR Pre-Milled 36.8 um SCR Outlet Pre-Milled 26.7 um SCR Outlet Pre-Milled 38.2 um SCR Outlet 12

13 13 AGENDA Plant description Trial results 2009 Trona and Bicarbonate test 2011 S350 test System design Railcar unloading Storage Mills Injection system System performance

14 KINCAID RAIL UNLOADING Cars unloaded two at a time, 3 hoppers at a time on each car at a rate of 50 tons/hr per car Cars are hopper cars, typically 110 tons per car Bicarbonate gravity flows out of the car and into a pan where it is sucked into a filter receiver silo and then transported to the storage silos using compressed air 14

15 RAILCAR TO SILO - INTERMEDIATE STAGE Dense Phase Compressed Air Cars are unloaded by vacuum into a filter receiver. Dry compressed air is used to move the material to the two storage silos Compressed Air 15

16 STORAGE OF UNMILLED MATERIAL 8 storage silos provide storage capacity of about 424 tons each 2 railcar unloading silos have capacity of 208 tons each Compressed air also used to keep material free flowing in silo 16

17 THE MILLS 8 Air Classifier Mills Design rate is 4 tons/hr at a d90 22 µm d90=15 µm is also achievable but at a lower throughput Conditioned air is provided for the mill 17

18 INJECTION SYSTEM Lances are interlaced with two banks for built in redundancy Allowing one bank to cover the entire duct facilitating turndown 18

19 MORE THAN JUST A SILO AND A BLOWER DSI on this scale is a project that requires attention to detail, planning for logistics, and redundancy on the critical elements. 19

20 20 AGENDA Plant description Trial results 2009 Trona and Bicarbonate test 2011 S350 test System design Railcar unloading Storage Mills Injection system System performance

21 2014 SYSTEM PERFORMANCE The system started full time use January 1, 2014 The extreme cold January temperatures put the units at full load for extended times and no issue with achieving SO2 removal Mills are able to work at 4 tons/hr maximum with a d90<22 µm SO 2 removal of 88% and within the NSR requirements 21

22 All technical advice and recommendations provided, if any, are intended for use by persons having the appropriate education and skill. Solvay Chemicals, Inc. and its affiliates shall not be liable for any use or nonuse of such advice and/or recommendations. Users of our products are solely responsible for the design, construction and operation of their own facilities. Mike Wood SOLVAir Business Manager Michael Atwell Market Development Manager Marco Riccio Technical Development Engineer

23