# Gischia, Scott From: Sent: To: 

## Cc: Subject: Attachments: Ms. Fenske, Beth Havlik [bhavlik@barr.com] Tuesday, May 09, 2006 2:32 PM maryjean.fenske@pca.state.mn.us Erik 

# L. Boleman; George Pruchnofski; Mike Hansel; Joel Trinkle; ajhayden@cci-htc.com; beanderson@cci-united.com; clbartovich@uss.com; dskolasinski@cleveland-cliffs.com; dwagner@cci-northshore.com; gjosephson@ispatinlandmining.com; klpylka@uss.com; sg ischia@cleveland-cliffs.com; sg rogers@cci-htc.com Technology Status for Taconite BART DRAFT SOx Control Technologies 2006-05-03.pdf; DRAFT NOx Control Technologies 2006-05-03.pdf On behalf of the Minnesota taconite facilities, Barr is pleased to submit the attached draft technology lists for the BART analysis for Indurating Furnaces. These lists are intended to include all potential NOx and S02 

## technologies and define which technologies are available (commercially available and demonstrated service at full scale) and applicable (could be used on an indurating furnace), and which are not at this time . The technologies which are considered to be both available and applicable will be the basis for the BART analyses, including the source-specific technical feasibility analyses, the control effectiveness reviews, the visibility impacts evaluations, and the selections of BART. Since all subsequent work on the case-by-case BART analyses for the Indurating Furnaces is dependent on this list of available and applicable technologies, it is very important that this list be complete and accurate. Therefore, as we previously discussed, the taconite facilities are requesting that MPCA thoroughly review this list and then provide comments at the May 18 meeting. Please feel free to contact me if you have any questions or comments. Beth T. Havlik, P.E. Barr Engineering 450 South Wagner Road Ann Arbor, Ml 48103 800/270-5017 ext. 1206 toll free 734/327-1200 ext. 1206 phone 734/327-1212 fax 734/255-0269 mobile bhavlik@barr.com

1

## NOxList ofControl Technologies

Induced Flue Gas Recirculation Burners

Low Excess Air



# --- Burners out ofService (BOOS)


# --- Fuel Biasing Reburning



# - Load Reduction
Coal Addition to Pellets with

Low Excess Airin the

Induration Furnace

Ported Kilns 

### I I

I Yes No Yes Yes I X Yes Yes Yes Yes Yes 

### I No Yes 

### I No Yes No Yes No Yes 

### I No

No No X Yes Yes X Y:\23\00 MN Taconite BART (2006)\BART General Documents\List of Control Technologies (03-MAY-06) X X

X air which reduces oxygen content and therefore to reduce NOxformation through restriction ofoxygen, 

### time flue gas to dilute the fuel in order to reduce the flame temperature

oxygen content in flue gas and reduces flame temperature offthe fuel flow from oneburner ormore to create fuel rich and fuel lean 1<..-omousuon is staged by diverting fuel from the upper level burners to the lower ofthe total fuel heatinput is injected into the furnace in a region above the (main burners) flames to create a reducing atmosphere (re-burn zone), hydrocarbon radicals react with NOx to produce elemental nitrogen is a strategy to reduce load on a powerplantbyreducing the electrical

througbt efficiency projects.

oxygen for pellet oxidation which reduces the overall energy
1 of4

## NOx List ofControl Technologies

Alternate Fuels Yes Yes x facilities experience lower**~~v' combu~tion**  temps with solid fuels vs gas. May also reduce fuel NOxby NOx when burning solid usmg a fuel Wlth less mtrogen. fuels. Oxygen Enhanced No No

Combustion Pulverized coal preheated and volatiles and fuel-bound nitrogen compounds are Preheat Combustion No No x Research level released in a controlledreducing atmosphere where the nitrogen compounds are ofOFA and SCR. Wall-fired ortangentially-fired furnace that ROFA-ROTAMIX 

## I Yes 

## I No 

## I I I x**l~v~:~a,~v ~** **~u~~-** 

## ::**~vvlutilizes** him velocity overfire air. Additional NOxreductions are achieved with (Rotarnix) >fcombustion >fcombustion combustion catalyst is directly injected into the air intake stream and delivered No x Research Level to the combustion site. initiating chemical reactions that change the dynamics of the flame. 

### Post Combustion Controls Non-Selective Catalytic For clean services. Too Undernear stoichiometric conditions. in the presence ofa catalyst. NOx is Yes No X x much stuffin flue gas Reduction (NSCR) would poison catalyst reduced by CO.resulting in nitrogen (N2) and carbon dioxide (C02). Low Temperature Oxidation Yes No X •. Used for higher flue gas Utilizes an oxidizing agent such as ozone to oxidize various pollutants including (LTO)- Tri-NOx® Low Temperatnre Oxidation 

## 1 Yes 

# I Yes 

# I X 

# I X 

# I ..**L.:-.:,::_~-~ ,~.:-_:~~---**  fUtilizes an oxidizing agent such as ozone to oxidize various pollutants including (LTO)- LoTOx

Y:\23\00 MN Taconite BART (2006)\BART General Documents\List of Control Technologies (03-MAY-06) 2of4

## NOx List of Control Technologies

Selective Catalytic Reduction (SCR) Selective Non-Catalytic

Reduction (SNCR) Absorption

Oxidizer
SNOX
SOx-NOx-Rox-Box Electron (E-

### Beam) Process Electrocatalytic Oxidation Yes Yes X


### Yes No X


### Yes No Yes Yes
No No
No No No No
No No

Y:\23\00 MN Taconite BART (2006)\BART General Documents\List of Control Technologies (03-MAY-06) X 

### tAIDIDoma (NH 3) 

### is injected into the flue gas streamin the presence ofa catalyst

or ammonia-based chemicals are injected into the flue gas stream to
ofwater, hydroxide and carbonate solutions, sulfuric acid. organic solutions.

alkali 

### carbonates, orhydroxides to absorb oxides ofnitrogen. stream is sent through the regenerative. recuperative, catalytic or direct fired 

### where pollutants are heated to a combustion point and destroyed. reduction ofNOx in the presence ofammonia (NH3). 

### followed by oxidation ofS02 

### to S03• 

### The exit gas from the S03 

### converterpasses a novel glass-tube condenser in which the S03 

### is hydrated to H2

### S04 

### and then condensed to a concentrated liquid sulfuric acid (H 2

### S04). 

### injection upstream ofthebaghouse for removal ofSOx and upstream ofa zeolitic selective catalytic reduction (SCR) catalyst in the**ba~house** 

### to reduce NOx emissions.

irradiation in the presence ofammoniato initiate chemical !conversion ofsulfur and nitrogen oxides into components which canbe easily conventional methods such as an ESP or 

### a reactorin which S02• 

### NOx, and mercury are oxidized to nitrogen (NO:J, sulfuric acid. and mercuric oxide respectively using non-thermal recentproject. the vender was doing final trials on full-scale applications.

3 of4

## NOxList ofControl Technologies

34 NOXSO No


### 35 Copper-Oxide No 36 Cold Plasma No 37 Biofilters Yes 

### 38 Pahhnan Process No No

No
No No No Co=ercial version of adsorption. Limited experience (proof-ofconcept tests). Absorption and SCR. x !Experience limited to pilot

scale.
x !ResearchLevel Uses a regenerable sorbent to simultaneously adsorb S02 and NOxfrom flue gas from coal-fired utility and industrial boilers. In the process. the S02 is converted to a saleable sulfurby-product (liquid S02• elemental sulfur. or sulfuric acid) and the NOx is converted to nitrogen and oxygen. 

## so2 in the flue gas reacts with copper oxide, supported on small spheres of alumina, to form copper sulfate. A=ouiais injected into the flue gas before the absorptionreactor and a selective catalyticreduction-type reaction occurs that reduces the nitric oxides in the flue gas. In the regeneration step. the copper 

### sulfate is reduced in aregenerator with areducing agent such as natural gas, producing a concentrated stream of S02• Gas stream is passed through a filter medium of soil and nticrobes. Pollutants are x !Not applicable to furnaces.ladsorbed and degraded by nticrobial metabolism forming the products carbon dioxide and water. x !Research Level Gas stream is passed through a filter baghonse in which specially-developed, small-particle, high-surface areametal oxide sorbent have been deployed. Pollutants are removed from the gases by adsorption. 1) This number is for reference only. It does not in any wayrank the control teclmologies. 2) a) AirPollution: Its Origin And Control. Wark, Kenneth: Warner. Cecil F.:and Davis,WayneT. 1998. Addison Wesley Longman, Inc.

b) US EPABasic Concepts in Environmental Science, Module 6, http://www.epa.gov/eogapti1/module6/index.htrn c) New and Emerging Environmental Teclmologies. http://neet.rti.org/ d) ND BARTReports

Y:\23\00 MN Taconite BART (2006)\BART General Documents\list of Control Technologies (03-MAY-06) 4of4

## NOx List ofControl Technologies

NOx formation front is not Combustion air is separated into primary and secondary flow sections to achieve Overfire Air (OFA) Yes No x stationary in anindurating furnace completeburnout and to encourage the formation ofN2 rather than NOx 2 I External Flue Gas Yes Yes Mixes flue gas with combustion air wbich reduces oxygen content and therefore Recirculation (EFGR) X X reduces flame temperature 3 I Low-NOx Burners Yes Yes X X X Burners are designed to reduce NOxformation through restriction ofoxygen. flame temperature. and/orresidence time Induced Flue Gas 

# I I I I Need to beup fired. Need 4 I Recirculation Burners Yes Yes X X 

# Ix !convectiveloop to get gas Draws flue gas to dilute the fuel in order to reduce the flame temperarure recirculated Needbigh 

### 0 2 forprocess 

# s I Low Excess Air 

## I Yes 

## I No 

## I I I x !requirements and product !Reduces oxygen content in flue gas andreduces flame temperarure quality Burners out ofService 

# I I I I Need capacity ofall Shut offthe fuel flow from oneburner or more to create fuel rich and fuel lean 6 I Yes No 

# I x lburner_s for worst case (BOOS) zones scenano 7 I Fuel Biasing 

# I Yes 

# I No 

# I I I x !Powerplant technology Combustion is staged by diverting fuel from the upper level burners to the lower ones orfrom the center to the sideburners to create fuel-rich and fuel-lean zones 

# I !Kiln configuration not Part ofthe total fuel heat input is injected into the furnace in a region above the 

# s I Rebuming 

# I Yes 

# I No 

# I I primary (main burners) flames to create a reducing atmosphere (re-burn zone), x correct forthis technology. where hydrocarbon radicals react with NOx toproduce elemental nitrogen

Powerplant technology - 1bisis a strategy to reduce load on a powerplantby reducing the electrical 9 Load Reduction Yes No x product demand side solution demand through! efficiency projects. 10 Energy Efficiency Projects Yes Yes X decrease amount offuelrequired to make an acceptable product 11 Coal Drying Yes Yes x Applies only to facilities Dry coal willincrease the as-burned BTU value, and therefore less fuel is that burn coal required to be burned. Specific energy efficiency project Coal Addition to Pellets with Check on starus of 121 Low Excess Airin the No No X research Reduce flame temperature and energy requirements Induration Furnace 13 I Ported Kilns Yes Yes X X Applicable to grate kilns. Provides additional oxygen for pellet oxidation wbich reduces the overall energy use ofthe kiln Y:\23\00 MN Taconite BART (2006)\BART General Documents\List of Control Technologies (03-MAY-06) 1 of4

## NOx List of Control Technologies

Alternate Fuels Yes Yes x facilities experience lower**~** 

### ..-**combu~tion** 

### temps with solid fuels vs gas. May also reduce fuel NOx by NOx when burning solid usmg a fuel wrth less mtrogen. fuels. Oxygen Enhanced No No

Combustion Pulverized coalpreheated and volatiles and fuel-bound nitrogen compounds are Preheat Combustion No No x Research level released in a controlled reducing atmosphere where the nitrogen compounds are ofOFA and SCR. Wall-fired ortangentially-firedfurnace that ROFA-ROTAMIX 

### I Yes 

### I No 

### I I I x 

# 1:-.::::::.-·=-**··.~-~** 

# .:: ·''!utilizeshigh velocity overfire

# arr. Additional NOx reductions are achieved with injection (Rotarnix)

m ofcombustion m ofcombustion combustion catalyst is directly injected into the

# arr intake stream and delivered the combustion site, initiating chemicalreactions that change the dynamics of flame. Yes 

### I No 

### I X 

### I I x lmuch stnffin fine gas 1 _____ near stoichiometric conditions. in the presence ofa catalyst, NOx is

· ' by CO, resulting in nitrogen 

## (N:J and carbon dioxide (C02). 

### Low Temperature Oxidation Yes No X 

### Used forhigher fine gas Utilizes an oxidizing agent such as ozone to oxidize various pollutants including (LTO)- Tri-NOx® X . 

### NOx concentrahons 

### Has been included as an Low Temperature Oxidation "applicable and available" Utilizes an oxidizing agent such as ozone to oxidize various pollutants including 

### Yes Yes X X --**~--1-~-1--.!-** _____.._ 

### (LTO)- LoTOx

Y:\23100 MN Taconite BART (2006)\BART General Documents\List ol Control Technologies (03-MAY-06) 2 ol4

## NOxList of Control Technologies

X

X Absorption Yes No

Oxidizer Yes Yes
SNOX No No
SOx-NOx-Rox-Box No No Electron (E-Beam) Process No No Electrocatalytic Oxidation No No

Y:\23\00 MN Taconite BART (2006)\BART General Documentsllist of Control Technologies (03-MAY-06) X tfillliiloma (NH3) is injected into the flue gas streamin the presence ofa catalyst

1"1-VU-turt:a or ammonia-based chemicals are injected into the flue gas stream to to molecular nitrogen. N2• and water ofwater. hydroxide and carbonate solutions, sulfuric acid, organic solutions,

alkali carbonates, orhydroxides to absorb oxides ofnitrogen. stream is sent through the regenerative, recuperdtive, catalytic or direct fired where pollutants are heated to a combustion point and destroyed. reduction ofNOxin the presence ofammonia (NH3), followed by oxidation of

# so, to 

# so3. The exit gasfrom the

# so3 converterpasses a novel glass-tube condenserin which the S03 is hydrated to H2S04 injection upstream ofthe baghouse for removal ofSOx and ofa zeolitic selective catalytic reduction (SCR) catalyst in the baghouse to reduce NOx emissions.

irradiation in the presence ofammoniato initiate chemical sulfur and nitrogen oxides into components which canbe easily conventional methods such as an ESP**~-"--"~"""** a reactorin which S02, NOx, and mercury are oxidized to nitrogen (NO,). sulfuric acid. and mercuric oxiderespectively using non-thermal recent project. the vender was doing final trials onfull-scale applications.

3 of4

## NOx List of Control Technologies**~,:;;:;** -

# ,,·.~·.: .. :.11**-~~-;5-~** cooh**~0**

## ,o~-:**~'** 34

35
36 37 38 NOXSO
Copper-Oxide Cold Plasma

Biofilters Pahlman Process No No

No No
No No Yes No No No Co=ercial version of adsorption. Limited experience (proof-ofconcept tests). Absorption and SCR. x !Experiencelimited to pilot

scale.


### x !Research Level Uses a regenerable sorbent to simultaneously adsorb S00 and NOxfrom flue gas from coal-fired utility and industrial boilers. In the process, the S00 is converted to a saleable sulfur by-product (liquid S00• elemental sulfur, or sulfuric acid) and the 

### NOx is converted to nitrogen and oxygen. S00 in the flue gas reacts with copper oxide, supported on small spheres of alumina, to form copper sulfate. A=ouia 

### is injected into the flue gas before the absorption reactor and a selective catalytic reduction-type reaction occurs that reduces the uitric oxides in the flue gas. Inthe regeneration step. the ccpper sulfate

### is reduced in a regenerator with a reducing agent, such as natural gas, producing a ccncentrated stream of S00• Gas stream is passed through a filter medium of soil and microbes. Pollutants are x INot applicable to furnaces. 

# I adsorbed and degraded by microbial metabolism forming the products carbon dioxide and water. 

### x !ResearchLevel Gas stream is passed through a filter bagbouse in which specially-developed. small-particle, high-surface areametal oxide sorbent have been deployed. Pollutants areremoved from the gases by adsorption. I) This number 

### is for reference only. Itdoes notin any way rank the control technologies. 2) a) AirPollution: Its Origin And Control. Wark. Kenneth; Warner, CecilF.; andDavis,Wayne T. 1998. Addison WesleyLongman. Inc.

b) US EPABasic Concepts inEnvironmental Science, Module 6, http://www.epa.gov/eogaptil/module6/index.htm c) New andEmerging Environmental Technologies, http://neet.rti.org/ d) ND BARTReports

Y:\23\00 MN Taccnite BART (2006)\BART General Documents\List of Control Technologies (03-MAY-06) 4of4