Baghouse TeamRyan Fu-Sum

Anthony MazzaZach

Troy Ansley

Particulate Control

EmissionsGeneration

22,600 lbs/hr fly ash operating at 600 MW 103.6x10-6 lb/MWh

Limits on output68 lbs/hr (0.14 lb/MWH gross energy output)20x10-6 lb/MWH gross energy output

Baghouse DesignsShaker Baghouse

Mechanical cleaningLarge footprint

Reverse Air BaghouseGentle cleaningLargest Footprint

Pulse-JetSmall footprintContinuous operationFelt bagsPulse on demand

Table of Comparison

ShakerReverse-

AirPulse Jet

Air-to-cloth ratio

(fly ash)3 2 5

Weave Woven Woven Felt

Bag structure none Rings Cage

Operation Intermittent IntermittentContinuo

us

Why Pulse Jet? Dependability

increased filter bag lifelower maintenance costslower fluctuations in ventilation/emissions

on-line cleaning efficiency of felt bags

Capacityincreased airflowsmaller footprint

Flexibilityclean-on-demand systemaccess to newer bag technology

Mercury ControlRegulations limit Mercury output to 20x10-6

lb per MWh gross power output

Uncontrolled Output is 103.6x10-6 lb per MWh

Overall Required Hg Removal is 81%

Types of MercuryParticulate – Stuck to fly ash or added

sorbentsElemental – Form of Mercury within coalOxidized – Formed in the combustion of coal

A Fabric Filter can potentially remove all forms

Factors Affecting OxidationResidence time of reactionChlorine Content in CoalExistence of Selective Catalytic Reduction

(SCR)Age of CatalystReaction TemperatureAmmonia (NH3) concentration

(hinders oxidation, can even reduce oxidized)

How is removal Achieved?The Fabric Filter can remove Mercury once it

has adsorbed onto PM or added sorbents.Added sorbents such as powered activated

carbon only required for high removal efficiency.

A Wet Scrubber(Wet FGD) can remove particulate and oxidized mercury but not elemental.

System relies on SCR to oxidize a large fraction of the mercury.

Why no PAC?Unnecessary for removal <90% if a system

containing SCR/FF/Wet Scrubber .

COST

If PAC was used, Annual Operating Costs for the fabric filter would increase by nearly 30%!

Pulse-Jet Design ConsiderationsAir-to-Cloth RatioCan VelocityFiltration MediaPressure DropPulsed Air Parameters

Air-to-Cloth RatioSuperficial Filtering VelocityMigration

Can Velocity

Filtration MediaBag Types and SpecificationsPressure DropEmpirical Relationship

Pulsed Air ParametersPulse IntervalPulse Strength

Ancillary EquipmentBaffle Plates

Ancillary EquipmentCages

Ancillary EquipmentCompressor

Ancillary EquipmentPressure Valves with Integrated Solenoids

Particulate RemovalHoppersSonic Horns

Particulate RemovalScrew Conveyor

Cost

Annual Operating Costs

Bag Failures

Failure Rate 33.00% per year

2640 bags per year

Cloth Replacement Rate 174227.4926 ft2 cloth per year

Replacement Cost $633,323 /yr in Q3 2010

Depreciation Losses

Salvage Value 0 $

Service Life 20 yrs

Annual Depreciation $1,785,000 $/yr

Solid Waste Disposal Costs

Cost of Waste Disposal $19 /ton (in 2004)

Generation Rate 22476.77 lbs/hr

  269.7212016 tons/day

Cost $1,870,517 /year

  $2,200,000 /year (in Q3 2010)

Power Costs - $ lost to compressor power

Power cost within plant $0.07 /kwh

Consumption By compressor 1471.48399 kwh/hr

Cost $103.00 /hr

  $832,905 /yr (in 2011)

PAC Cost $0 /yr (in Q3 2010)

Applicable Taxes $0 /yr

  (See Florida Statute 212.051)

Insurance (1% of TCC) $357,000.00 /yr

Administrative (2% of TCC) $714,000.00 /yr

Annual Operating Costs $6,600,000 /yr