Sorbent Injection for Sma

Mercury Control 

Katherine Dombrowski

URS Corporation

DOE/NETL Mercury Control Tec

Conference

December 11, 2006

DE-FC26-03NT41987
DE-FC26-03NT41987 

Project Team Project Team

Pierina Noceti

(COR) Nick Irvin Ken McBee

CK

Ramsay Chang

Mark Berry

S

Greg Newman

Larry Rapski
DE-FC26-03NT41987 

Project Objectives Project Objectives

Evaluate sorbent injection for Hg c

bituminous flue gas across smaelectrostatic precipitators (ESPs

• Mercury removal performance & var

• Optimal process conditions

• Balance of plant effects

• ESP performance• FGD operation• Effects on byproduct ash, gypsum
DE-FC26-03NT41987 

Project Background Project Background

■ Financial Assistance Program DE-FC2

03NT41987

■ Most previous ACI testing with ESPs 

on relatively large units

- High levels of Hg removal possible- No apparent detrimental effects on ESP 

■ 70% of utility ESPs have SCA <300 ft2

- Sorbent injection performance in this siz

currently known

- Effects on ESP performance
DE-FC26-03NT41987 

Project Background Project Background

■ Full-scale activated carbon injection tes

Southern Company’s Georgia Power Pl

- Units 1 and 2 

■ 100 MW; low-sulfur eastern bitum

- ESPs with SCA <200 ft2/1000 acfm

■ Full-scale sorbent injection tests at Rel

Shawville Station Unit 3

- 175 MW; medium-sulfur eastern bit- Two ESPs configured in series

■ SCA = 82, 230 ft2/1000 acfm, resp
DE-FC26-03NT41987 

Project Status Project Status

All field testing completed

■ Plant Yates Testing

- Units 1 and 2 Parametric Tests 

(Spring-04)

- Unit 1 Long-term test (Fall-04)- Site Reports Completed- Economic Analysis Completed

■ Shawville-3 Testing

- Parametric tests (July-06)- Data analysis on-going
DE-FC26-03NT41987 

Plant Yates Unit 1 Config

Plant Yates Unit 1 Confi

JBR 

Absorber

Boiler

S

APH

Inlet Flue Gas 

Sampling

ESP Outlet 

Sampling

Sorbent

Injection

ESP
DE-FC26-03NT41987 

Summary – Plant Yates Resu

Summary – Plant Yates Res

Carbon 

Name Manufacturer Carbon Descriptio

Darco FGDTM Norit Americas

Tx lignite-derived activated cbaseline carbon; 19 μm mean 

size

Super HOK RWE Rhinebraun German lignite-derived activa

carbon; 23 μm mean particle 

NH Carbon

Ningxia 

Huahui

Activated 

Carbon Co.

Chinese chemically treated bituminous-derived activated 24 μm mean particle size
DE-FC26-03NT41987 

Summary – Plant Yates Resu

Summary – Plant Yates Res

Hg Removal Across Unit 1 ES
DE-FC26-03NT41987 

Summary – Plant Yates Resu

Summary – Plant Yates Res

ESP Hg Removal Due to Activate

Unit 1
DE-FC26-03NT41987 

Summary – Plant Yates Resu

Summary – Plant Yates Res

0%

10%20%30%40%50%60%70%80%90%

100%

02468 10 

FGD Carbon Injection Rate (lb/MM acf)

% Hg Total Removal at ESP Outlet 

ESP Hg Removal Due to Activate

Unit 2
DE-FC26-03NT41987 

Mercury Removal during Lo

Mercury Removal during Lo

0%

10%20%30%40%50%60%70%80%90%

100%

11/13/04 11/18/04 11/23/04 11/28/04 12/3/04 12/8/0

Vapor Phase Hg Removal (%)

% Hg % Hg HOK 

Injection Rate

System Removal

ESP Removal
DE-FC26-03NT41987 

ESP Arcing During Long-ter

ESP Arcing During Long-ter

05

10152025303540

10/12 10/19 10/26 11/2 11/9 11/16 11/23 11/30 12/7 12/14 

Carbon Injection Rate (lb/Macf);

Arc Rate (apm)

Field 1A arc rateCarbon Injection Rate (lb/Macf)

1A Arc Rate

LT Injection Test
DE-FC26-03NT41987 

ESP Outlet Particulate Conc

ESP Outlet Particulate Conc
DE-FC26-03NT41987 

$0

$500,000

$1,000,000$1,500,000$2,000,000$2,500,000$3,000,000$3,500,000$4,000,000$4,500,000$5,000,000

HOK Darco Hg-2004 Darco Hg-2005 Dar

Annual Cost ($/year)

Capital Equipment AmortizationCarbon TransportationCarbon Cost

Annual Costs for a Targeted 35% Reduction in ESP Outlet VaporPhase Mercury Concentration

Economic Analysis – Plant Y

Economic Analysis – Plant Y
DE-FC26-03NT41987 

Summary of Results Summary of Results

■ Large variations in ESP inlet Hg con■ Vapor Hg removals typically 65 to 85

at 4 lb/Macf

- With ACI only, outlet emissions were 0- Combination of ACI/JBR, outlet emissi

than 2 lb/TBtu

■ ESP Effects

- Increase in ESP arcing with ACI- Particulate breakthrough measured at - Carbon particles found in M17 filters an
DE-FC26-03NT41987 

Shawville 3 Configuratio

Shawville 3 Configurati

•

Unit 3 Boiler

ESP

1A

ESP 1B

ESP 2A

ESP 2B

Location A

Location B

Locat

Carbon Injection 

Phase I

Carbon Injection 

Phases II

APH

APH
DE-FC26-03NT41987 

Sorbents Evaluated at Shaw

Sorbents Evaluated at Shaw

Sorbent Supplier 

Super HOK RWE 

(Germany) 

Activatd50 = 24 

HOK – Coarse RWE 

(Germany) 

Activatd50 = 63 

Darco Hg Norit Americas 

(Marshall, TX) Activat

Darco Hg-LH Norit Americas 

(Marshall, TX) 

Activatwith bro

Darco Hg/High Calcium Hydrated Lime 

Norit Americas (Marshall, TX /Chemical Lime (Dallas, TX) 

30/70 mhigh sur(for SO
DE-FC26-03NT41987 

Shawville 3 Summary Shawville 3 Summary

■ Baseline Testing

- Hg values range: 26 – 43 μg/Nm3 @ 3

- Oxidation high: >80% at ESP-2 outle- Hg removal to fly ash occurs upstrea- Little to no Hg removal across ESPs

■ Sorbent Injection Testing

- Effect of injection rate and location- Co-injection of high surface area lim

■ Pre-mixed; separate injection con

- Impact of SNCR operation
DE-FC26-03NT41987 

Shawville 3 Summary – SupeInjection

Shawville 3 Summary – SupeInjection

0

102030405060708090

100

0.0 2.0 4.0 6.0 8.0 10.0 12.0 

Injection Rate (lb/MMacf)

Total Mercury Removal (%)

ESP 1/2 HOKESP 1 only HOKESP 2 HOKESP 2 HOK CoarseESP 2 HOK 48-hour

Parametric Testing - H
DE-FC26-03NT41987 

Shawville 3 Summary – Super HO

Shawville 3 Summary – Super H

0

102030405060708090

100

7/30/06

3:00

7/30/06

9:00

7/30/06

15:00

7/30/06

21:00

7/31/06

3:00

7/31/06

9:00

7/31/06

15:00

Percent Removal, Total Mercury (%)

48-hour continuous injection at 10.6 lb/M
DE-FC26-03NT41987 

Shawville 3 Summary Shawville 3 Summary

Darco-Hg Parametric Testing

0

102030405060708090

100

0 2 4 6 8 10 12 

Injection Rate (lb/MMacf)

Total Vapor-Phase Mercury Removal (%) ESP 

ESP ESP ESP 

Parametric Testing – Darco Hg
DE-FC26-03NT41987 

Shawville 3 Summary - HOK 

Shawville 3 Summary - HOK 

0

102030405060708090

0.0 2.0 4.0 6.0 8.0 10.0 12.0 

Carbon Injection Rate (lb/MMacf)

Total Mercury Removal (%) 

SNCR Off
DE-FC26-03NT41987 

Shawville 3 Summary – ComparLevels and Sorbent Mercury Rem

Shawville 3 Summary – Compar

Levels and Sorbent Mercury Rem

0

102030405060708090

0.0 0.5 1.0 1.5 

ESP 2 Outlet SO3 (ppmv)

Total Mercury Removal (%)

Lime ESP 1/ CarboInjection (ESP 2 RPremix ESP 1 Injec1/2 Removal)

SNCR OFF

Carbon 4.9 lb/MMacfLime 200 lb/hr

SNCR ONCarbon 3.8 lb/MMacfLime 50 lb/hr

SNCR OFFCarbon 4.9 lb/MMacfLime 100 lb/hr

SNCR OFFCarbon 4.8 lb/MMacfLime 0 lb/hr

SNCR OFF

Carbon 0 lb/MMacfLime 0 lb/hr

SNCR ON

Carbon 5.5 lb/MMacfLime 181 lb/hr

SNCR ON

Carbon 3.5 lb/MMacfLime 116 lb/hr

SNCR ON

Carbon 0 Lime 0 lb/h
DE-FC26-03NT41987 

Shawville Summary Shawville Summary

■ High levels of mercury removal achieve

small ESPs

■ Better performance with Darco-Hg than ■ Apparent effect of SO3 at very low leve

■ ESP performance

- Electrical properties (TBD)- PM removal (single-point M17)

■ Baseline outlet emissions

– 0.013 to 0.020 gr/dscf

■ ACI outlet emissions

– 0.009 to 0.030 gr/dscf
DE-FC26-03NT41987 

Future Project Plans Future Project Plans

■ Completion of Shawville dat

characterization (Q1FY07)

■ Complete Shawville Site Rep

(Q1FY07)

■ Project Close-out