## A Novel Approach for Mercury Capture Christopher L. Poling, BEng, MSc Melissa Harrison, PE Paul Longo, PE1. PCA Report, R&D Serial No. 2888, ”Mercury and Lead Content in Raw Materials”, Hills and Stevenson, 2006 2. Sikkems, Joel K., “ Fate and transport of mercury in portland cement manufacturing facilities” ( 2011). Graduate Thesis and Dissertations . Paper 11907. http://lib.dr.iastate.edu/etd/11907 3. * Data gathered during various SCB Trial s ( 2010 – 2012 ) C.Poling , T.Lesniak CKD Generated during Raw Mill Off scenario 

## Cement Kiln Raw Materials (mercury concentrations, ppb) Limestone 17 – 1,753 Sand 29 – 585 Clay 52 – 425 Mill Scale 12 – 50 Shale 57 – 445 Bottom Ash 48 – 390 Slag 12 – 180 Iron Ore 78 – 745 Fly Ash 50 – 755 CKD 253 - 41,000* on site quarry
d elivered to the plant

continually returned to the process

## Break the internal mercury cycle 

## Remove the mercury from the kiln system 

## Reduce the mercury emissions at the stack 

## Return the CKD as a raw material 

## Prevent the mercury from ever getting back into the environment...cooler millstack
cement kiln dust
CKD silo VRM

kiln baghouse raw materials

coalcooler millstack

CKD silo VRM

kiln baghouse cement kiln dust raw materials

coalcooler millstack

CKD silo VRM

kiln baghouse coal raw materials

cement kiln dustcooler millstack VRM

kiln baghouse cement kiln dust 

## Mercury Capture Systems Mercury Sulfide raw materials

coal

## MCS residue created from the introduction of a particulate free gas stream. The collected residue settles out leaving very clear water above it. MCS General Process

### MCS Technologies Downcomer Injection Cement Manufacturing

Thermal Desorber and Gas Reactor Cement Manufacturing (CKD) Power Industry (Fly Ash) Activated Carbon Regeneration Gas Reactor Other Industries (Gold Mining)

### MCS Technologies Downcomer Injection Cement Manufacturing

Thermal Desorber and Gas Reactor Cement Manufacturing (CKD) Power Industry (Fly Ash) Activated Carbon Regeneration Gas Reactor Other Industries (Gold Mining)Cement Kiln Dust Treatment System and Method  Prototype confirmed mercury reduction of CKD  Confirmed the ability of the reagents to remove mercury from the gas stream  Confirmed generation of concentrated residue CKD Feed Heavy Metal Vapor Capture

Tube Screw Furnace
Gas Reactor

Thermal Desorber Gas Reactor Prototype

## Prototype Results: June – October 2012

a nalyzed from samples collected after test completion The mercury is removed from the CKD and captured in the residue...

## Prototype Results: June – October 2012 Average CKD Mercury Concentration Before and After ProcessingAverage Gas Stream Mercury Reduction Inlet vs. Outlet 

## Prototype Results: June – October 2012

70% 75% 80% 85% 90% 95% 100%

82.5% 98.4%

Including Particulate Gas Stream Only Hand- Held Analyzers Sorbent Trap Section II

## Mercury Capture Effectiveness : What does this mean to a cement plant? Conservatively we can remove 87% of the mercury present on the CKD. Actual test results have shown this to be as high as 99% Analysis of SCB data indicates that mercury concentrations on the CKD increase when the vertical raw mill is down. 34,426 ppb Hg CKD in 4,387 ppb Hg CKD out 87% ppb Hg reduction
8,760 92% 8,059 10% 805.9 hours per year utilization operational hours per year raw mill down time raw mill down hours per year Analysis of mercury concentrations within various cement kiln dusts have illustrated a range of 25 ppb Hg – 41,000 ppb Hg  1,000 ppb Hg removed from 1 ton of CKD represents 0.0020 lb Hg

 Cement kilns produce up to +/ - 20 tph of CKD. 

## Mercury Capture Effectiveness : What does this mean to a cement plant?

1, 000 = 1 = , , 

### = = .

. . 

### =

### In 2012 we designed a full scale industrial unit

 

### 20 tph CKD throughput rate

 

### CKD input temperature +/- 70 degrees F minimum input

 

### CKD Hg concentration up to 60,000 parts per billion

 

### CKD output to have 90% of the mercury removed or better Cement Kiln Dust Treatment System and Method: Patented Process

CKD TREATMENTFEED SILO


### T HERMAL 

### D ESORBER DISCHARGE PUGMILL

BAGHOUSE

CONDENSER 

### GAS 

### R EACTOR Over the past 24 months we built our first 

### Thermal Desorber Gas ReactorREAGENT MIXING

TANK

CONCENTRATED NON - LEACHABLE RESIDUE COLLECTION CLEAN GAS STREAM OUTLET

REAGENT CHEMICAL CONCENTRATED HEAVY METAL INLET GAS STREAM FROM DESORBER 

### MCS General Process

## Gas Reactor relocated near a smaller Thermal Desorber. MCS General Process

## S mall Thermal Desorber allows testing of batch materials in drums rather than 25 ton loads for full scale Thermal Desorber. MCS General Process

## Inside of the reagent mixing tank, we mix the chemicals to a desired concentration. This particular case was a 10:1 ratio achieved by 60 gallons of water mixed with 6 gallons of reagent. MCS General Process

## After mixing the liquid is transferred to the residue collection /recirculation tank. RETURN PIPE FROM SCRUBBER FILL PIPE FROM MIXING TANK

DILUTE REAGENT PUMP IS BEHIND THE WEIR AND CIRCULATES FLUID FROM THIS TANK INTO THE SCRUBBER 

### MCS General Process

## TDGR Unit Results 2014 Average CKD Mercury Concentration Before and After Processing

0.0 0.5 1.0 1.5 2.0 2.5 2.16 ppm

ND Unprocessed CKD Processed CKDmercury concentration, ppm80% 85% 90% 95% 100%

88.1% 99.2%

Including Particulate Gas Stream Only Average Gas Stream Mercury Reduction Inlet vs. Outlet

Hand- Held Analyzers Sorbent Trap Section II 

## TDGR Unit Results 2014Average Gas Stream Mercury Reduction Inlet vs. Outlet

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 88.08% 99.18%
82.5% 98.40%Mercury Reduction

Including Particulate Gas Stream Only Hand Held Analyzer Hand Held Analyzer Sorbent Trap Sorbent Trap

# Costs of Dust Shuttling
• 20,000 tons per year dust shuttled • Dust @$24/ton • Limestone @$7.50/ton $480,000 – 150,000 = $330,000 additional cost • Raw mix replacement @$8.82/ton $180,000 additional raw mix for same clinker Total: $510,000 per year

# Costs in Sold Out Market
• Raw mill limited • 20,000 tons per year dust sent to finish mills • Lost additional clinker production ≈ 16,000 tpy • 18,000 tpy cement @$98.50/ton $1,700,000 sales revenue lost

### MCS Technologies Downcomer Injection Cement Manufacturing

Thermal Desorber and Gas Reactor Cement Manufacturing (CKD) Power Industry (Fly Ash) Activated Carbon Regeneration Gas Reactor Other Industries (Gold Mining)

### MCS for Raw Materials Coal Fly Ash0 200 400 600 800 1,000 1,200 1,400 1,600

Raw Fly Ash Processed Fly Ash 1,500 ppb

<20 ppbmercury concentration, ppb Coal Fly Ash Mercury Concentration Before and After Processing

FLY ASH TREATMENT

### MCS Technologies Downcomer Injection Cement Manufacturing

Thermal Desorber and Gas Reactor Cement Manufacturing (CKD) Power Industry (Fly Ash) Activated Carbon Regeneration Gas Reactor Other Industries (Gold Mining)

## During a recent demonstration on a landfilled activated carbon the mercury reduction was over 99% with material concentration levels started as high as 240 ppm. The concentrated gas stream which was treated by our MCS Gas Reactor measured up to 8,388 ppm Hg at various times during the demonstration. Carbon content was reduced to 1.4% LOI . For the first pass the carbon was left and only the mercury was removed. For the second pass the carbon was combusted in order to recover other precious metals... A cement kiln using MCS technology could process spent activated carbon into a viable fuel source and potentially get paid to take the material... MCS for Raw Materials Activated CarbonAverage Activated Carbon Mercury Concentration Before and After Processing

FLY ASH TREATMENT 148.31 ppm Hg

2.25 ppm Hg 195.16 ppm Hg

0.7 ppm Hg Unprocessed Activated Carbon Processed Activated Carbonmercury concentation , ppmMoisture Hg Concentration LOI @ 1000 C ACTIVATED CARBON: BLEND 1 23.27% 148.31 ppm 78.14 ACTIVATED CARBON: BLEND 2 26.92% 195.16 ppm 78.40Processed Hg Concentration Processed LOI @1000 C Hg Reduction LOI Reduction ACTIVATED CARBON: BLEND 1 2.25 ppm 1.4 98.48% 98.21% ACTIVATED CARBON: BLEND 2 0.7 ppm 1.5 99.64% 98.09% 

# Potential Recovery of Rare Earth Elements13,502

215 5,384
383 5,840

223 Gas Reactor Inlet Gas Reactor Outletmercury concentration,ug/m3 

### Gas Stream Mercury Inlet vs. OutletTOTAL HG GAS REACTOR INLET GAS REACTOR OUTLET Gas Reactor Inlet Gas Reactor Outlet Removal Particulate Bound Ionic Hg Elemental Hg Particulate Bound Ionic Hg Elemental Hg ug/m 3 ug/m 3 % ug/m 3 ug/m 3 ug/m 3 ug/m 3 ug/m 3 ug/m 3 13,502 215 98.4 10 13,492 215 5,384 383 92.9 32 2 5,850 1 3 380 3,564 244 93.1 9 3,655 244 4,882 324 93.4 25 14 4,843 1 2 321 5,840 223 96.2 14 5,826 223

## MCS residue created from the introduction of a particulate free gas stream. The collected residue settles out leaving very clear water above it. MCS General Process

## Heavy Metals MCS RESIDUE LIQUID SOLID UNIT Total Mercury ND 2360 mg/kg Metals SM3120 B Arsenic 0.043 147 mg/kg Barium 0.054 141 mg/kg Cadmium ND 49 mg/kg Chromium ND 166 mg/kg Lead ND 16 mg/kg Selenium ND ND mg/kg Silver ND 514 mg/kg Activated Carbon - MCS Residue MCS for Raw MaterialsHEAVY METAL 2015 MCS COLLECTED RESIDUE 2015 TCLP TEST RESULT HAZARDOUS WASTE CODE liquid solid unit result test limit EPA limit unit Total Mercury ND 2360 ppm 0.0538 0.0002 0.2 ppm D009 Metals SM3120 B Arsenic 0.043 147 ppm ND 0.100 5 ppm D004 Barium 0.054 141 ppm 0.627 0.100 100 ppm D005 Cadmium ND 49 ppm ND 0.100 1 ppm D006 Chromium ND 166 ppm ND 0.100 5 ppm D007 Lead ND 16 ppm ND 0.100 5 ppm D008 Selenium ND ND ppm ND 0.100 1 ppm D010 Silver ND 514 ppm ND 0.100 5 ppm D011Total Mercury Arsenic Barium Cadmium Chromium Lead Silver TCLP Result EPA Limit MCS Residuemercury concentration,ppm

### MCS Technologies Downcomer Injection Cement Manufacturing

Thermal Desorber and Gas Reactor Cement Manufacturing (CKD) Power Industry (Fly Ash) Activated Carbon Regeneration Gas Reactor Other Industries (Gold Mining)Downcomer Injection

### MCS Technologies Downcomer Injection Cement Manufacturing

Thermal Desorber and Gas Reactor Cement Manufacturing (CKD) Power Industry (Fly Ash) Activated Carbon Regeneration Gas Reactor Other Industries (Gold Mining)

# Alternative Process

VAPOR PRESSURE SYSTEM: ELIMINATES THE HEATING PROCESS & SEPARATES THE MERCURY

### Reagent catalysts have been in use for a long time in the cleanup of soils and waterways. MCS utilizes these to effectively bind mercury from CKD as HgS . This technology has been successfully adapted:

- removal of mercury from powdered activated carbon

- fly ash and other coal combustion products

- various industrial dust streams 

### Additional testing is planned for work related to:

- hexavalent chrome

- selenium

- cadmium

- other heavy metals resulting from the use of natural oresFor more information please contact: SCB INTERNATIONAL MATERIALS 

### MERCURY CAPTURE SYSTEMS 153 South Main Street Newtown Connecticut 06470 (203) 270 - 2766 Peter D’Amico ( pdamico@scbinternational.com ) Tom Lesniak (tlesniak@scbinternational.com ) Chris Poling ( cpoling@scbinternational.com ) Melissa Harrison ( mharrison@scbinternational.com ) Paul Longo ( plongo@scbinternational.com )