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 
NOx List of Control Technologies 

Induced Flue Gas 

Recirculation Burners 

Low Excess Air 

--- Burners out of Service 

(BOOS) 

---

Fuel Biasing 

Reburning 

- Load Reduction 

Coal Addition to Pellets with 

Low Excess Air in 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 NOx formation through restriction of oxygen, 

time 

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

oxygen content in flue gas and reduces flame temperature 

off the fuel flow from one burner or more to create fuel rich and fuel lean 

1<..-omousuon is staged by diverting fuel from the upper level burners to the lower 

of the total fuel heat input 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 power plant by reducing the electrical 

througbt efficiency projects. 

oxygen for pellet oxidation which reduces the overall energy 

1 of4 
NOx List of Control Technologies 

Alternate Fuels Yes Yes x facilities experience lower ~~v' combu~tion temps with solid fuels vs gas. May also reduce fuel NOx by 

N Ox 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 controlled reducing atmosphere where the nitrogen compounds are 

of OFA and SCR. Wall-fired or tangentially-fired furnace that 

ROFA-ROTAMIX I Yes I No I I I x l~v~:~a,~v ~ ~u~~- :: ~vvlutilizes him velocity overfire air. Additional NOx reductions are achieved with 

(Rotarnix) 

>f combustion 

>f combustion 

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 Under near stoichiometric conditions. in the presence of a catalyst. NOx is Yes No X x much stuff in 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 (NH3) is injected into the flue gas stream in the presence of a catalyst 

or ammonia-based chemicals are injected into the flue gas stream to 

of water, hydroxide and carbonate solutions, sulfuric acid. organic solutions. 

alkali carbonates, or hydroxides to absorb oxides of nitrogen. 

stream is sent through the regenerative. recuperative, catalytic or direct fired 

where pollutants are heated to a combustion point and destroyed. 

reduction of NOx in the presence of ammonia (NH3). followed by 

oxidation of S02 to S03• The exit gas from the S03 converter passes 

a novel glass-tube condenser in which the S03 is hydrated to H2S04 

and then condensed to a concentrated liquid sulfuric acid (H2S04). 

injection upstream of the baghouse for removal of SOx and 

upstream of a zeolitic selective catalytic reduction (SCR) catalyst 

in the ba~house to reduce NOx emissions. 

irradiation in the presence of ammonia to initiate chemical 

!conversion of sulfur and nitrogen oxides into components which can be easily 

conventional methods such as an ESP or 

a reactor in which S02• NOx, and mercury are oxidized to nitrogen 

(NO:J, sulfuric acid. and mercuric oxide respectively using non-thermal 

recent project. the vender was doing final trials on full-scale applications. 

3 of4 
NOx List of Control 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 !Research Level 

Uses a regenerable sorbent to simultaneously adsorb S02 and NOx from flue gas 

from coal-fired utility and industrial boilers. In the process. the S02 is converted 

to a saleable sulfur by-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=ouia is injected into the flue gas before the 

absorption reactor and a selective catalytic reduction-type reaction occurs that 

reduces the nitric oxides in the flue gas. In the regeneration step. the copper 

sulfate is reduced in a regenerator with a reducing 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 area metal 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 way rank the control teclmologies. 

2) a) Air Pollution: Its Origin And Control. Wark, Kenneth: Warner. Cecil F.: and Davis, Wayne T. 1998. Addison Wesley Longman, Inc. 

b) US EPA Basic 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 BART Reports 

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

furnace complete burnout 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 NOx formation through restriction of oxygen. 

flame temperature. and/or residence time 

Induced Flue Gas I I I I Need to be up fired. Need 

4 I Recirculation Burners Yes Yes X X I x !convective loop to get gas Draws flue gas to dilute the fuel in order to reduce the flame temperarure 

recirculated 

Need bigh 0 2 for process 

s I Low Excess Air I Yes I No I I I x !requirements and product !Reduces oxygen content in flue gas and reduces flame temperarure 

quality 

Burners out of Service I I I I Need capacity of all Shut off the fuel flow from one burner 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 !Power plant technology Combustion is staged by diverting fuel from the upper level burners to the lower 

ones or from the center to the side burners to create fuel-rich and fuel-lean zones 

I !Kiln configuration not Part of the 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 for this technology. where hydrocarbon radicals react with NOx to produce elemental nitrogen 

Power plant technology - 1bis is a strategy to reduce load on a power plant by 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 of fuel required to make an acceptable product 

11 Coal Drying Yes Yes x Applies only to facilities Dry coal will increase 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 Air in 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 of the 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 coal preheated 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 

of OFA and SCR. Wall-fired or tangentially-fired furnace that 

ROFA-ROTAMIX I Yes I No I I I x 1:-.::::::.-·=- ··.~-~ . :: ·''!utilizes high velocity overfire arr. Additional NOx reductions are achieved with 

injection (Rotarnix) 

m of combustion 

m of combustion 

combustion catalyst is directly injected into the arr intake stream and delivered 

the combustion site, initiating chemical reactions that change the dynamics of 

flame. 

Yes I No I X I I x lmuch stnff in fine gas 1 

_____ near stoichiometric conditions. in the presence of a catalyst, NOx is 

· ' by CO, resulting in nitrogen (N:J and carbon dioxide (C02). 

Low Temperature Oxidation Yes No X Used for higher fine gas Utilizes an oxidizing agent such as ozone to oxidize various pollutants including 

(LTO)- Tri-NOx® X . concentrahons NOx 

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 
NOx List 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 stream in the presence of a catalyst 

1"1-VU-turt:a or ammonia-based chemicals are injected into the flue gas stream to 

to molecular nitrogen. N2• and water 

of water. hydroxide and carbonate solutions, sulfuric acid, organic solutions, 

alkali carbonates, or hydroxides to absorb oxides of nitrogen. 

stream is sent through the regenerative, recuperdtive, catalytic or direct fired 

where pollutants are heated to a combustion point and destroyed. 

reduction ofNOx in the presence of ammonia (NH3), followed by 

oxidation of so, to so3. The exit gas from the so3 converter passes 

a novel glass-tube condenser in which the S03 is hydrated to H2S04 

injection upstream of the baghouse for removal of SOx and 

of a zeolitic selective catalytic reduction (SCR) catalyst 

in the baghouse to reduce NOx emissions. 

irradiation in the presence of ammonia to initiate chemical 

sulfur and nitrogen oxides into components which can be easily 

conventional methods such as an ESP ~-"--"~""" 

a reactor in which S02, NOx, and mercury are oxidized to nitrogen 

(NO,). sulfuric acid. and mercuric oxide respectively using non-thermal 

recent project. the vender was doing final trials on full-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 !Experience limited to pilot 

scale. 

x !Research Level 

Uses a regenerable sorbent to simultaneously adsorb S00 and NOx from 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. In the 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 I Not applicable to furnaces. I adsorbed and degraded by microbial metabolism forming the products carbon 

dioxide and water. 

x !Research Level 

Gas stream is passed through a filter bagbouse in which specially-developed. 

small-particle, high-surface area metal oxide sorbent have been deployed. 

Pollutants are removed from the gases by adsorption. 

I) This number is for reference only. It does not in any way rank the control technologies. 

2) a) Air Pollution: Its Origin And Control. Wark. Kenneth; Warner, Cecil F.; and Davis, Wayne T. 1998. Addison Wesley Longman. Inc. 

b) US EPA Basic Concepts in Environmental Science, Module 6, http://www.epa.gov/eogaptil/module6/index.htm 

c) New and Emerging Environmental Technologies, http://neet.rti.org/ 

d) ND BART Reports 

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