Status of Air Pollution Control and Monitoring Technologies
Transcript of Status of Air Pollution Control and Monitoring Technologies
Status of Air Pollution Control and Monitoring Technologies
Institute of Clean Air Companies
July 2013
To be the voice of the stationary source air
pollution control and monitoring industry by
providing technical information relevant to flexible
clean air policies based on practical, achievable and
measurable emissions limitations.
2
Nearly 100 Member Companies
Emissions Control Technologies - SO2, NOx, VOC, PM, Hg, air toxics (HAP), and greenhouse gases (GHG)
Emissions Measurement Technologies - CEMS, Portables, Stack Testing, DAHS
Leading Manufacturers of Equipment & Services
For a current list of ICAC members go to:
www.icac.com/members
3
Known as Flue Gas Desulphurization (FGD)
Available control equipment: wet scrubbers, dry scrubbers, semi-dry scrubbers, dry sorbent injection (DSI)
History of the technology (1st unit installed on a US power plant in 1970)
Installed Base (Utility)
◦ U.S., 760 FGD units as of 2012 (251 GW scrubbed)
◦ World-wide, 3419 FGD units as of 2012 (1174 GW scrubbed)
SOx Technology
4
Implementation time roughly 3 - 4 years from contract to start-up
Capacity (760 units were installed between 1993-2012 to meet acid rain regulations)
Performance levels today e.g. scrubbers today are designed for 95%-98% efficiency with guaranteed up time of 90% or greater
SOx Technology
5
NOx control achieved during combustion (LNB) or post combustion (SNCR & SCR)
Low NOx Burners (LNB) development mid 1980’s to meet 1990 CAAA
Selective Non Catalytic Reduction (SNCR) initial patent 1970’s, commercialized in late 1980’s
Selective Catalytic Reduction (SCR) initial patent 1970’s, commercialized in early1980’s
Large installed based for all technologies in US and worldwide
6
Broad Range of Applications ◦ Utility boilers (>150 GW)
Coal and gas fired
◦ Gas and oil fired turbines (> 500 power plants)
Combined (standard) and simple cycle (high temperature)
◦ Industrial boilers
◦ Stationary Engines (thousands of installations)
Diesel and natural gas
◦ Marine
◦ Locomotive
7
Implementation time, 12 to 18 months LNB/SNCR , 24 to 36 months SCR
Capacity ◦ LNB >100 GW 1990 CAAA
◦ SCR & SNCR>150 GW 2002 SIP Call
Performance levels today ◦ LNB ~ (20%-40% removal)
◦ SNCR ~ (20%-60% removal)
◦ SCR ~ (80%-90% removal)
Remaining challenges ◦ Fuels
8
SCR Implementation time, 12 to 24 months new build, 6 to 18 months retrofit
Capacity
◦ SCR ~1000 units
Performance levels today
◦ SCR ~2 ppmv
9
Installed Base by PM Technology
Electrostatic Precipitators
Fabric Filters
United States – 327 GW 70% 30%
Europe – 193 GW ≈ 98% ≈ 2%
China – 667 GW 100% 0%
South Africa (local coal) – 38 GW ≈ 50% ≈ 50%
Australia (local coal) – 28 GW ≈ 30% ≈ 70%
10
Comparison - Electrostatic Precipitators and Fabric Filters
Electrostatic Precipitators Fabric Filters
Emission
Achieves MATS Emission
Achieves MATS Emissions
Emission Performance: • Sensitivity to Gas Flow • Sensitivity to Fuel • Sensitivity to Temperature
Yes Yes Yes
No No No
Power Consumption T/R Power for low emission ESP approximately equal to
Fabric Filter fan power
Fabric Filter fan power approximately equal to T/R Power for low emission ESP
HAP Performance with Sorbents (activated carbon)
Poor to Excellent Low Sorbent Utilization
Excellent High Sorbent Utilization
Acid Gas Performance with Sorbents (lime, sodium)
Poor to Excellent Low Sorbent Utilization
Excellent High Sorbent Utilization
11
Fabric Filters ◦ Increasing Use
Reverse Air Filters ◦ 1st US Installation 1978
◦ 27.2 GW
Pulse Jet Filters ◦ 1st US Installation 1987
◦ 2013 Projected US Installations 53.3 GW
◦ Installed cost approximately 50% of Reverse Air Filter
1978 1983 1988 1993 1998 2003 2008 2013
Reverse Air
Pulse Jet50 GW
30 GW
10 GW
12
Co-Benefits of SO2 and NOx Control Technologies Wet and Dry FGD Scrubbers and SCRs
Sorbent Injection
◦ Activated Carbon (ACI)
◦ Non-Carbon Sorbents
Coal Additives
Oxidizing Catalysts
Barrier Filters with Hg Absorbing Materials
Re-Emission additives
Developmental Technologies
13
First Commercial System: 2006 ◦ EPRI TOXECON technology with ACI
◦ Presque Isle Power Plant; We Energies, Inc. Marquette, Michigan
Experience Base for ACI ◦ Over 80 full-scale demonstrations
conducted
◦ Commercial ACI systems
215 boilers treated
70 GW
12 ACI suppliers
ACI Silo
TOXECON PJFF
14
Technologies available for both Eastern and Western Coals ◦ 80-95% capture on existing plants
◦ 90-98% removal on new plants
◦ Cost effectiveness improved by multiples over time.
Remaining Challenges ◦ Interference with SO3
Can be addressed with DSI
Sulfur tolerant sorbents
◦ Impact on ash sales
TOXECON
Higher efficiency and increased capacity products
15
Acid gases such as HCl and SO3 can be controlled as co-benefits in wet and dry scrubbers
Dry Sorbent Injection (DSI) has been in existence since the 1960s ◦ Milled & unmilled Trona injection systems
◦ Milled SBC system
◦ Hydrated lime injection systems
Standard/FGD grade,
high porosity lime
high reactivity lime
16
Technologies available for both Eastern and Western Coals ◦ 60-90% capture of HCl, SO3
◦ Can use calcium, sodium, or magnesium depending upon application and pollutant of interest
Remaining Challenges ◦ CCR and ash stabilization of DSI products
◦ Leachate control and solubility of metals compounds
◦ Enhancing sorbent utilization and efficiency
17
Instrument/Integration providers have historically developed or adapted technologies to support regulatory initiatives.
Collaboration early in the rule-making process allows:
Determination of what is and isn’t measureable
Definition of technology operating requirements
‣ Quantification limits, precision, QA/QC, calibrations
Full technology commercialization
Healthy competition from multiple suppliers ‣ Leading to cost effective monitoring solutions
18
Increasingly lower emission limits require:
Instruments with higher precision, lower quantification limits, and elimination of interferences
Accurate calibration standards to challenge instrumentation
‣ Better collaboration is suggested between NIST, EPA, and
Instrument & Calibration Gas providers
Establish NIST traceable standards before method development and rule implementation
Prevent delay of method development, implementation, and practical
application
The importance of traceable threshold zero gas
19
ICAC member companies have contributed to substantial advancements in technology for industrial and power applications resulting in high control efficiency at lower costs…
◦ VOC typical destruction of 98%+ for a wide range of applications
◦ PM removal of >95% with wide range of technologies
◦ NOx removal of 95%+, at temperatures ranging from 150°C to 1,100°C.
◦ SO2 removal of 90+% with DSI, 95%+ with WESP
◦ Hg removal demonstrated at 90%+ DRE
◦ Acid gas control using Dry Sorbent Injection of Alkaline Sorbents
HCl >90% control
SO3 > 95% control
◦ CO control up to 99% (>1,000 natural gas power plants and industrial boilers)
◦ N2O control (1°, 2°, and 3° ) for up to 99% DRE
…enabling the enactment of significant cost-effective air pollution control legislation for a broad range of industrial applications.
20
Remaining Challenges/ Uncertainties
Pollutant-by-pollutant litigation – if successful, all MACT methodology / limitations in doubt?
Implementation of new SSM provisions on industrial applications – court challenges ahead?
Surrogates for pollutants: not necessarily supported by science
Particulate definition of condensable and filterable
Pipeline gas quality – shale gas contaminants/biogas – impact on APC equipment?
Uncertainty - rule finalization/ implementation: impacts investment in technology
21
• Over 900 Natural Gas power plants in the US under control
• Typically 8-10 year life
• Up to 98% CO control
General Location of CO/VOC Catalyst on a stationary engine
Remaining Challenges: • Changing
definitions of VOC
CO/VOC/NOx controls routinely used on thousands of stationary engines.
22
• Functional range: 0.5 – 1.2% CH4
• Total flow: 250,000 Nm3/hr • Operational Q2 2012 • Destruction Efficiency: 97% • Plant Availability: 95 – 99% • Up to 16,000 tons CH4
oxidized per year, 336,000 equivalent tons CO2
Operational since April 2012 with integral Durr designed VAM capture hood.
• Functional range: 0.4 – 1.2% CH4
• Enriched CMM fuel source
• Total flow: 1,090,000 Nm3 /hr • Operational Q1 2014 • Destruction Efficiency: up to 97% • Waste heat can provide up to 20
MW power – via downstream steam turbines
• Up to 86,000 tons CH4 oxidized per year, 1,806,000 equivalent tons CO2
Changzhi, China
West Virginia
23
Heat rate improvements via:
• Steam Turbine Upgrades 3-5% • Boiler Upgrades
• Heating surface changes • Pulverizer / Burner upgrades 0.5-1.5%
• Balance of Plant Improvements 1%
Options are limited on existing units. A 5% reduction in heat rate improves overall plant efficiency with an equivalent reduction in CO2 emissions. Under load cycling conditions, typical of today’s coal plant operation, the improvement in efficiency will be even less.
Efforts to reduce water consumption by dry or hybrid cooling systems move efficiency in the opposite direction increasing CO2 emissions/MWHr.
Economics of efficiency improvements will vary by plant size, age and operating characteristics (base load, cycling, on-off operation). They won’t be cost effective at every plant.
24
High Efficiency Ultra Supercritical Plant DesignsTypical size = 350 to 1000MW for PC Designs 37-40% Net eff up to 45% eff for AUSC Designs (still on the drawing board) Higher efficiency results in 20-30% reduction in CO2 emissions/MWHr over older subcritical plant designs.
25
1st Generation CO2 Capture Technologies • Pre-combustion capture using coal gasification (IGCC) • Post Combustion Capture (PCC) with Amine based solvents • Oxy-Coal combustion systems using Air Separation Units
All of theses technologies are in the latter stages of development (PCC, Oxy) or early stage of demonstration (IGCC). If the DOE’s large demonstration projects for PCC and Oxy-Coal are completed (not a given at this point) these technologies are at least 5-7 years away from being commercially proven for first movers to accept and consider deploying these technologies. It could be another 10 years before the first commercial plants are built.
26
All of theses systems are in the early stages of development – lab and small scale pilots. DOE is supporting development of larger pilot scale systems but funding for these efforts is not sufficient to rapidly advance the technology development and there are no clear commercial drivers for private companies to develop these technologies on their own. If these technologies can be proven successful they are still at minimum 15 -20 years away from first commercial deployments.
2nd Generation CO2 Capture Technologies • Oxy-combustion using chemical looping • Membrane technologies for CO2 capture or oxygen separation • Metal oxide frameworks, solid sorbents, other
27
Cost
• First Generation Systems look to be very expensive. Undoubtedly costs would decrease with experience but first generation systems are so expensive it is doubtful that anyone will undertake a new CCS project without significant subsidy.
Legal, Regulatory
• Liabilities surrounding the long-term storage of CO2 remain unknown.
• Public acceptance of CO2 storage is not a given.
• Permitting issues particularly PCC systems that will introduce new waste streams.
• Increased water consumption for CCS technologies
Barriers to the Success of CCS
28