Guide to Low-Emission Boiler and Combustion Equipment Selection

Transcription

1 ORNL/TM-2002/19 Guide to Low-Emission Boiler and Combustion Equipment Selection C. B. Oland

2 ORNL/TM-2002/19 GUIDE TO LOW-EMISSION BOILER AND COMBUSTION EQUIPMENT SELECTION C. B. Oland Date Published: April 2002 Prepared for the U.S. Department of Energy Office of Industrial Technologies Prepared by OAK RIDGE NATIONAL LABORATORY Oak Ridge, Tennessee managed by UT-BATTELLE, LLC for the U.S. DEPARTMENT OF ENERGY under contract DE-AC05-00OR22725

3 CONTENTS LIST OF FIGURES... vii LIST OF TABLES... ix ACRONYMS... xi ACKNOWLEDGMENTS... xiii EXECUTIVE SUMMARY... xv 1. INTRODUCTION SCOPE AND OBJECTIVES APPROACH REFERENCE INDUSTRIAL, COMMERCIAL, AND INSTITUTIONAL BOILERS TYPES OF ICI BOILERS Firetube Boilers Watertube Boilers Other Combustion Boilers FUEL FEED SYSTEMS Stokers Underfeed stokers Overfeed stokers Burners EMISSION RATES Uncontrolled Emissions Controlled Emissions REFERENCES FUELS, EMISSIONS, AND EFFICIENCY FUELS Coal Lignite Subbituminous Bituminous Anthracite Fuel Oil Natural Gas Biomass Refuse-Derived Fuel Other Fuels Mixed Fuels EMISSIONS Nitrogen Oxides Thermal NO x Fuel NO x Prompt NO x Sulfur Dioxide Particulate Matter Carbon Monoxide Hazardous Air Pollutants Page iii

4 3.3 EFFICIENCY Combustion Losses Boiler Losses REFERENCES EMISSIONS STANDARDS AND COMPLIANCE ISSUES CLEAN AIR ACT National Ambient Air Quality Standards Ozone Nitrogen oxides Sulfur dioxide Carbon monoxide Particulate matter Emissions from Existing Steam Generating Units Sulfur dioxide reduction program Nitrogen oxides reduction program New Source Performance Standards Performance standards for new steam generating units Performance standards for new municipal waste combustion units Permitting Requirements Acid Rain Program Permits State Operating Permit Programs INFORMATION SOURCES PERMITTING BASICS LESSONS LEARNED REFERENCES EMISSION CONTROL TECHNIQUES PRECOMBUSTION COMBUSTION Nitrogen Oxides Control Techniques Peak flame temperature reduction Operational modifications Staged combustion Natural gas reburning Low-NO x burners Ultra low-no x burners Sulfur Dioxide Control Techniques Particulate Matter Control Techniques POSTCOMBUSTION Nitrogen Oxides Flue-Gas Treatment Techniques Selective catalytic reduction Selective noncatalytic reduction Emerging nitrogen oxides flue-gas treatment technologies Sulfur Dioxide Flue-Gas Treatment Techniques Nonregenerable processes Regenerable processes Particulate Matter Flue-Gas Treatment Techniques Mechanical collectors Wet scrubbers iv

5 Electrostatic precipitators (ESPs) Fabric filters REFERENCES SELECTION CONSIDERATIONS BOILERS AND COMBUSTION EQUIPMENT Coal-Fired Boilers Fuel-Oil-Fired and Gas-Fired Boilers Nonfossil-Fuel-Fired Boilers EMISSION CONTROL EQUIPMENT Nitrogen Oxides Reduction Sulfur Dioxide Reduction Particulate Matter Reduction SYSTEM CONFIGURATION REFERENCES SELECTED BIBLIOGRAPHY... S-1 GLOSSARY... G-1 Appendix A. NEW SOURCE PERFORMANCE STANDARDS UNDER TITLE IV OF THE CLEAN AIR ACT... A-1 v

6 LIST OF FIGURES Figure Page ES.1 Format used to present emission control options for various fuel and boiler combinations... xvii 2.1 Configuration of HRT firetube boiler Configuration of Scotch package firetube boiler Configuration of firebox firetube boiler Configuration of package watertube boiler Configuration of field-erected watertube boiler Configuration of watertube boiler for burning RDF Configuration of watertube boiler for burning MSW Configuration of watertube boiler for burning solid fuel such as wood, biomass, or stoker coal Configuration of watertube boiler for burning PC Configuration of bubbling FBC watertube boiler Configuration of circulating FBC watertube boiler Configuration of pressurized FBC boiler system Configuration of tubes for A package watertube boiler Configuration of tubes for D package watertube boiler Configuration of tubes for O package watertube boiler Configuration of cast iron boiler Configuration of vertical tubeless boiler Cross section of underfeed, side-ash discharge stoker Cross section of overfeed, water-cooled, vibrating-grate, mass-feed stoker Cross section of overfeed, traveling-grate, mass-feed stoker Cross section of overfeed, traveling-grate, spreader stoker Cross section of overfeed air-cooled, vibrating-grate, spreader stoker Cross section of overfeed, water-cooled, vibrating-grate, spreader stoker Configuration of SCR reaction chamber Configuration of wet scrubber Configuration of dry scrubber Configuration of ESP Configuration of fabric filter or baghouse Emission control options for coal-fired, stoker-fed, watertube boilers Emission control options for PC-fired watertube boilers Emission control options for coal-fired FBC watertube boilers Emission control options for coal-fired, stoker-fed, firetube boilers Emission control options for fuel-oil-fired watertube and firetube boilers Emission control options for natural-gas-fired watertube and firetube boilers Emission control options for biomass-fired, stoker-fed, watertube boilers Emission control options for biomass-fired FBC watertube boilers Emission control options for biomass-fired, stoker-fed, firetube boilers Emission control options for RDF-fired, stoker-fed, watertube boilers Emission control options for RDF-fired FBC watertube boilers Emission control options for RDF-fired, stoker-fed, firetube boilers Examples of flue-gas treating system configurations for solid-fuel-fired boilers vii

7 LIST OF TABLES Table Page ES.1 Emission control techniques discussed in the guide... xvi 2.1 Fuels typically fired in ICI firetube boilers Fuels typically fired in ICI watertube boilers Terminology used to identify burners Fuels fired in boilers to generate hot water or steam Key properties for selected fuels Lignite coals Subbituminous coals Bituminous coals Anthracitic coals Fuel oil grades established by ASTM Nitrogen oxides Summary of NAAQS under Title I of the CAA Emissions by source of NO x and SO 2 in the United States Selected NO x reduction regulations under Titles I and IV of the CAA BACT and LAER applicability and requirements Compliance options for SO 2 emissions Compliance options for NO x emissions General guidance for obtaining a permit for a new air pollution source Techniques for controlling emissions before combustion Techniques for controlling emissions during combustion Guidance for installation and operation of boilers Techniques for controlling emissions after combustion Common boiler and fuel feed system combinations Typical capacity ranges for combustion boilers Performance summary for NO x control techniques on ICI firetube boilers Performance summary for NO x control techniques on ICI watertube boilers Performance summary for NO x flue-gas treatment techniques on ICI boilers A.1 Summary of new source performance standards (NSPS) for electric utility steam-generating units... A-3 A.2 Summary of NSPS for industrial-commercial-institutional (ICI) steam-generating units... A-5 A.3 Summary of NSPS for small industrial ICI-generating units... A-11 A.4 Summary of NSPS for large municipal waste combustion units... A-14 ix