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October 2012 www.power-eng.com POWER-GEN INTERNATIONAL READY FOR ORLANDO NUCLEAR SAFETY HOW TO PREPARE FOR A HURRICANE HANDLING PRB COAL POWER STATION UPGRADES HANDLING SYSTEM the magazine of power generation MATS Compliance: THINKING OUTSIDE BOX the 1 1 6 YEARS

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Page 1: YEARS MATS Compliance: Thinking OuTSide theBOx 2014/Alternatives...north Omaha ower Station uprades coal handlin system 48 he Eouton o ower nt WterStem Chemstr Contributin editor Brad

October 2012 • www.power-eng.com

POWER-GEN INTERNATIONAL READY FOR ORLANDO

NUCLEAR SAFETY HOW TO PREPARE FOR A HURRICANE

HANDLING PRB COAL POWER STATION UPGRADES HANDLING SYSTEM

the magazine of power generation

MATS Compliance:Thinking OuTSide BOx the

116YEARS

Page 2: YEARS MATS Compliance: Thinking OuTSide theBOx 2014/Alternatives...north Omaha ower Station uprades coal handlin system 48 he Eouton o ower nt WterStem Chemstr Contributin editor Brad

FEATURES No. 10, October 2012

22 Alternatives to Activated Carbon for Mercury Control

Learn about cost effective, low capital alternatives to activated carbon.

Power Engineering ®

Corporate Headquarters—PennWell Corp. 1421 South Sheridan Road • Tulsa, OK 74112

P.O. Box 1260, Tulsa, OK 74101Telephone: (918) 835-3161 • Fax: (918) 831-9834

E-mail: [email protected] World Wide Web: http://www.power-eng.com

Managing editor — Russell Ray (918) 832-9368 [email protected]

senior editor — Brian Wheeler (918) 832-9214 [email protected]

assoCiate editor — Lindsay Morris (918) 831-9492 [email protected]

on-line editor — Sharryn Dotson (918) 832-9339 [email protected]

Contributing editor—Robynn Andracsek, P.E. Contributing editor—Brad Buecker Contributing editor—Brian Schimmoller

produCtion supervisor — Deanna Priddy Taylor (918) 832-9378 [email protected]

subsCriber serviCeP.O. Box 3271, Northbrook, IL 60065

Phone: (847) 559-7501Fax: (847) 291-4816

E-mail: [email protected]

Marketing Manager — Wendy Lissau (918) 832-9391 [email protected]

senior viCe president, nortH aMeriCanpower generation group — Richard Baker (918) 831-9187 [email protected]

national brand Manager — Rick Huntzicker (770) 578-2688 [email protected]

CHairMan — Frank T. Lauingerpresident/Ceo — Robert F. Biolchini

CHief finanCial offiCer/senior viCe president — Mark C. Wilmoth

CirCulation Manager — Linda ThomasproduCtion Manager — Katie Noftsger

POWER ENGINEERING, ISSN 0032-5961, USPS 440-980, is published 12 times a year, monthly by PennWell Corp., 1421 S. Sheridan Rd., Tulsa, OK 74112; phone (918) 835-3161. ©Copyright 2012 by PennWell Corp. (Registered in U.S. Patent Trademark Office). Authorization to photocopy items for internal or personal use, or the internal or personal use of specific clients, is granted by POWER ENGINEERING, ISSN 0032-5961, provided that the appropriate fee is paid directly to Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923 USA 508-750-8400. Prior to photocopying items for educational classroom use, please contact Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923 USA 508-750-8400. Periodicals postage paid at Tulsa, OK and additional mailing offices. Subscription: U.S.A. and possessions, $88 per year; Canada and Mexico, $98 per year; international air mail, $242 per year. Single copies: U.S., $14, Outside U.S. $23. Back issues of POWER ENGINEERING may be purchased at a cost of $14 each in the United States and $16 elsewhere. Copies of back issues are also available on microfilm and microfiche from University Microfilm, a Xerox Co., 300 N. Zeeb Rd., Ann Arbor, MI 48103. Available on LexisNexis, Box 933, Dayton, OH 45402; (800) 227-4908. POSTMASTER: Send change of address, other circulation information to POWER ENGINEERING, PO Box 3271, Northbrook, IL 60065-3271. “POWER ENGINEERING” is a registered trademark of PennWell Corp. Return undeliverable Canadian addresses to P.O. Box 122, Niagara Falls, ON L2E 6S4.

MemberAmerican Business Press

BPA International

PRINTED IN THE U.S.A. GST NO. 126813153Publications Mail Agreement No. 40052420

Power Engineering is the flagship media sponsor for

TM

DEPARTMENTS 2 Opinion 4 Clearing the Air 6 Gas Generation

8 View on Renewables 10 Nuclear Reactions

12 Industry Watch 14 What Works

40 Preparing for Hurricanes at Nuclear Power Plants

Senior Editor Brian Wheeler examines the precautions nuclear power plants take to prepare for severe storms.

54 POWER-GEN International: Back in Orlando!

POWER-GEN comes to Orlando with three co-located events: Nuclear Power International, Renewable Energy World Conference & Expo, and the POWER-GEN Financial Forum.

PowER ENgiNEERiNg oNliNE : www.power-eng.comNewsletter:Stay current on industry news, events, features and more.

Newscast:A concise, weekly update of all the top power generation news

Industry News:Global updates throughout the day

32 Handling PRB CoalNorth Omaha Power Station upgrades coal handling system.

48 The Evolution of Power Plant Water/Steam Chemistry

Contributing Editor Brad Buecker explains how to avoid corrosion, boiler tube failures and shutdowns related to the operation and maintenance of heat recovery steam generators.

58 Southern Co. Stays True to Coal and Nuclear

Associate Editor Lindsay Morris examines Southern Co.’s strategy for meeting demand and its investments in coal, nuclear and renewable power.

116VOL.

Page 3: YEARS MATS Compliance: Thinking OuTSide theBOx 2014/Alternatives...north Omaha ower Station uprades coal handlin system 48 he Eouton o ower nt WterStem Chemstr Contributin editor Brad

No. 10, October 2012

22 Alternatives to Activated Carbon for Mercury Control

Learn about cost effective, low capital alternatives to activated carbon.

Power Engineering ®

Corporate Headquarters—PennWell Corp. 1421 South Sheridan Road • Tulsa, OK 74112

P.O. Box 1260, Tulsa, OK 74101Telephone: (918) 835-3161 • Fax: (918) 831-9834

E-mail: [email protected] World Wide Web: http://www.power-eng.com

Managing editor — Russell Ray (918) 832-9368 [email protected]

senior editor — Brian Wheeler (918) 832-9214 [email protected]

assoCiate editor — Lindsay Morris (918) 831-9492 [email protected]

on-line editor — Sharryn Dotson (918) 832-9339 [email protected]

Contributing editor—Robynn Andracsek, P.E. Contributing editor—Brad Buecker Contributing editor—Brian Schimmoller

produCtion supervisor — Deanna Priddy Taylor (918) 832-9378 [email protected]

subsCriber serviCeP.O. Box 3271, Northbrook, IL 60065

Phone: (847) 559-7501Fax: (847) 291-4816

E-mail: [email protected]

Marketing Manager — Wendy Lissau (918) 832-9391 [email protected]

senior viCe president, nortH aMeriCanpower generation group — Richard Baker (918) 831-9187 [email protected]

national brand Manager — Rick Huntzicker (770) 578-2688 [email protected]

CHairMan — Frank T. Lauingerpresident/Ceo — Robert F. Biolchini

CHief finanCial offiCer/senior viCe president — Mark C. Wilmoth

CirCulation Manager — Linda ThomasproduCtion Manager — Katie Noftsger

POWER ENGINEERING, ISSN 0032-5961, USPS 440-980, is published 12 times a year, monthly by PennWell Corp., 1421 S. Sheridan Rd., Tulsa, OK 74112; phone (918) 835-3161. ©Copyright 2012 by PennWell Corp. (Registered in U.S. Patent Trademark Office). Authorization to photocopy items for internal or personal use, or the internal or personal use of specific clients, is granted by POWER ENGINEERING, ISSN 0032-5961, provided that the appropriate fee is paid directly to Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923 USA 508-750-8400. Prior to photocopying items for educational classroom use, please contact Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923 USA 508-750-8400. Periodicals postage paid at Tulsa, OK and additional mailing offices. Subscription: U.S.A. and possessions, $88 per year; Canada and Mexico, $98 per year; international air mail, $242 per year. Single copies: U.S., $14, Outside U.S. $23. Back issues of POWER ENGINEERING may be purchased at a cost of $14 each in the United States and $16 elsewhere. Copies of back issues are also available on microfilm and microfiche from University Microfilm, a Xerox Co., 300 N. Zeeb Rd., Ann Arbor, MI 48103. Available on LexisNexis, Box 933, Dayton, OH 45402; (800) 227-4908. POSTMASTER: Send change of address, other circulation information to POWER ENGINEERING, PO Box 3271, Northbrook, IL 60065-3271. “POWER ENGINEERING” is a registered trademark of PennWell Corp. Return undeliverable Canadian addresses to P.O. Box 122, Niagara Falls, ON L2E 6S4.

MemberAmerican Business Press

BPA International

PRINTED IN THE U.S.A. GST NO. 126813153Publications Mail Agreement No. 40052420

Power Engineering is the flagship media sponsor for

TM

DEPARTMENTS 2 Opinion 4 Clearing the Air 6 Gas Generation

8 View on Renewables 10 Nuclear Reactions

12 Industry Watch 14 What Works

40 Preparing for Hurricanes at Nuclear Power Plants

Senior Editor Brian Wheeler examines the precautions nuclear power plants take to prepare for severe storms.

54 POWER-GEN International: Back in Orlando!

POWER-GEN comes to Orlando with three co-located events: Nuclear Power International, Renewable Energy World Conference & Expo, and the POWER-GEN Financial Forum.

PowER ENgiNEERiNg oNliNE : www.power-eng.comNewsletter:Stay current on industry news, events, features and more.

Newscast:A concise, weekly update of all the top power generation news

Industry News:Global updates throughout the day

32 Handling PRB CoalNorth Omaha Power Station upgrades coal handling system.

48 The Evolution of Power Plant Water/Steam Chemistry

Contributing Editor Brad Buecker explains how to avoid corrosion, boiler tube failures and shutdowns related to the operation and maintenance of heat recovery steam generators.

58 Southern Co. Stays True to Coal and Nuclear

Associate Editor Lindsay Morris examines Southern Co.’s strategy for meeting demand and its investments in coal, nuclear and renewable power.

1 Mercury Concentrations at the Inlet & Outlet of the SDA

14.1

12.1

10.1

8.1

6.1

4.1

2.1

0.1

14.1

12.1

10.1

8.1

6.1

4.1

2.1

0.1

Mer

cury

Con

cent

ratio

n

Demonstrating MerControl 6012 ProductInjection Rates Reported as lb/MMacf Actives.

5/14

12:

30

5/14

14:

54

5/14

17:

18

5/14

19:

42

5/14

22:

06

5/14

0:3

0

Date and TimeInlet Total Outlet Total Outlet Element

MATS Limit

Off O.55 1.1 Off

Alternatives to Activated Carbon for Mercury Control

These technologies are lower cost than

capital projects and envelop the power

plant from coal to wastewater to pro-

vide balance of plant mercury control.

The first mercury control product,

MerControl 6012 technology, is a pat-

ented non-halogenated, non-carbon

breakthrough sorbent for the capture

of mercury in flue gas for plants with

spray dry absorber (SDA) or circulating

dry scrubber (CDS) AQCDs.

For those with downstream particu-

late control devices and scrubbers, mer-

cury capture is greatly enhanced when

the mercury is in the oxidized form

(Hg2+) as opposed to the elemental

form (Hg0). To facilitate the conver-

sion to the oxidized state, the patented

With the issuance

of the Mercury

Air Toxics Stan-

dards (MATS) in

December 2011,

the U.S. EPA has succeeded in passing

lasting federal guidelines for mercury air

emissions from coal-fired power plants.

In the midst of all the legal wrangling

and debate, the agency has maintained

that much of the mercury control will

be obtained as a co-benefit of existing

and retrofitted air quality control devices

(AQCDs) that were designed to control

other pollutants such as particulate, sul-

fur oxides (SOx), and nitrogen oxides

(NOx). While for some power plants this

is indeed the case, for most plants, addi-

tional products and technologies will be

necessary to boost the mercury control

benefits of these devices in order to reach

the 1.2 lb Hg/TBtu air emission limit

specified in the MATS.

In the past, activated carbon, often

in combination with halogen injection

for mercury oxidation, has been the de

facto industry standard for controlling

mercury emissions; however, carbon

has been shown to negatively impact

the resale value of fly ash. This paper

presents an overview and three case

studies of cost-effective, low capital al-

ternatives to activated carbon that low-

er overall mercury air and water emis-

sions from coal-fired power plants.

ExAmplES oF NoN-CAR-boN mERCURy CoNTRol TEChNologiES

The four proprietary non-carbon

mercury control technologies present-

ed here are changing the way the in-

dustry approaches MATS compliance.

MerControl 7895 oxidant can be applied

prior to combustion or injected directly

into the furnace. In numerous commer-

cial trials, the fraction of mercury in the

oxidized form has exceeded 90 percent.

Because Hg2+ is highly soluble in

water, application of MerControl 7895

technology is especially well-suited to

those plants that have wet flue gas desul-

furization (WFGD) scrubbers installed.

AuthorsSteven Smokey Senior Generation Engineer at Great River Energy

Gregg Finigan Superintendent of Production at City Water Light and Power

Rebecca Stiles, PhD Senior Research Chemist at Nalco

Bruce Keiser, PhD Research Fellow at Nalco

John Meier Global Product Line Manager at Nalco

Nicholas Ergang, PhD Senior Research Chemist at Nalco

Jianwei Yuan, PhD Senior Research Scientist at Nalco

Raul Espinosa Technical Specialist at Nalco

Wayne Carlson Research Director at Nalco

Page 4: YEARS MATS Compliance: Thinking OuTSide theBOx 2014/Alternatives...north Omaha ower Station uprades coal handlin system 48 he Eouton o ower nt WterStem Chemstr Contributin editor Brad

2

MerControl 6012 50, 100,150 off 6012 offppm 14.1

12.1

10.1

8.1

6.1

4.1

2.1

0.1

14.1

12.1

10.1

8.1

6.1

4.1

2.1

0.1

Mer

cury

Con

cent

ratio

n

MATS Limit

Off

Mercury Concentration at the Inlet & Outlet of the SDADemonstrating Mercontrol 7895 Oxidant

Injection at Different Feed Rates

Liquid sorbent MerControl6012 slurry was fed at 0.27actives/MMacf. The largeincrease in Hg during sorbentinjection was due to a soot blow.

Liquid sorbent MerControl6012 slurry was fed at 0.27actives/MMacf. The largeincrease in Hg during sorbentinjection was due to a soot blow.

Inlet Total Outlet Total Outlet Element Mats Limit

5/16

10:

00

5/16

12:

24

5/16

14:

48

5/16

17:

12

5/16

19:

36

5/16

22:

00

Date And Time

0.27 lb/MMacf

Soot Blow Bag Pulse Started

3

Percent of mercury in the incoming �ue gas to the WFGD that is oxidized(in purple) and percent of total mercury captured in the WFGD (in blue)correspond to the y-axis on the left. Relative MerControl 8034 technologyfeed rate (solid black line) corresponds to the y-axis on the right.

Percent of Mercury in Incoming Flue Gasto WFGD that is Oxidized

Inle

t Oxid

ized

Hg

and

% o

f Hg

Capt

ure 100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%

1.0

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.0

Rela

tive

Mer

çont

rol 8

034

Feed

Rat

e

8/8 8/10 8/12 8/14 8/16 8/18 8/20 8/22Date

Inlet Oxidized Hg Hg Capture Relative MerControl 8034 Feed Rate

However, once absorbed into the WFGD

liquor, ionic mercury can undergo

chemical reduction to become insoluble

and volatile elemental mercury, which

is re-emitted into the scrubbed flue gas.

MerControl 8034 technology can be

added directly to the WFGD liquor to

efficiently capture and precipitate ionic

mercury without any impact on gypsum

quality, thereby preventing it from being

re-emitted into the flue gas and lowering

overall mercury emission.

The last product, Nalmet 1689 tech-

nology, is a polymeric chelant de-

signed to meet challenging industrial

wastewater discharge limitations. It

has an exceptionally high affinity for

mercury and forms large precipitates

that readily settle and filter to consis-

tently attain extremely low mercury

levels in the parts-per-trillion (ppt)

range in wastewater effluents.

These non-carbon mercury control

technologies can be applied individu-

ally or in concert to reduce and control

mercury emissions. Three case stud-

ies are presented here demonstrating

these mercury control strategies at

coal-fired utilities in the US.

CASE STUdy #1: mERCURy CoNTRol iN AN SdA

At Great River Energy Stanton Station

in Stanton, N.D., the non-carbon, non-

halogen MerControl 6012 mercury

sorbent technology was demonstrated

on flue gas from a 60 MW base-loaded,

PRB-fired boiler. The liquid MerCon-

trol 6012 technology was injected di-

rectly into the spray dry absorber (SDA)

along with the slaked lime used for SOx

removal. Inlet mercury measurements

were made upstream of the spray dryer,

prior to the sorbent injection location at

the scrubber inlet, and outlet mercury

measurements were made downstream

of the fabric filter baghouse, which fol-

lows the SDA unit. MerControl 6012

technology was demonstrated on its

own, in combination with MerCon-

trol 7895 oxidant, and compared to

was started at 0.55 lb actives/MMacf,

at which point the outlet mercury

dropped from about 8.5 mg/m3 to sta-

bilize around 2.1 mg/m3. The flow rate

was doubled to 1.1 lb actives/MMacf,

commercially available brominated

powdered activated carbon (PAC).

Figure 1 shows results from the dem-

onstration of MerControl 6012 tech-

nology on its own. The initial flow rate

Page 5: YEARS MATS Compliance: Thinking OuTSide theBOx 2014/Alternatives...north Omaha ower Station uprades coal handlin system 48 he Eouton o ower nt WterStem Chemstr Contributin editor Brad

4Stack Emissions of Total & Elemental MercuryDemonstrating Function of MerControl 7895 Oxidant Feed Rate

0 0 121 162 226 292 294 347 381 386

0.025

0.020

0.015

0.010

0.005

0

Stac

k Hg

(tot

al) (

lb/G

Wh)

MerControl 7895 Boiler Additive (mg/kg Coal)

Hg (Total)Hg (Elemental)

Emission Limit

0.022

0.018

0.012

0.015

0.010

0.0070.006

0.002

0.004

0.006

0.019

0.014

0.0110.010

0.004

0.007

0.004

0.002 0.002

0.004

5

FGD wastewater mercury concentration plotted versus percentmercury capture from air. As more mercury is captured from theair (with the feeding of MerControl 7895 oxidant) the applicationof Nalmet 1689 chemistry maintains mercury concentrations inthe clari�ed wastewater well below 200 ppt.

FGD Wastewater Mercury Concentration

Tota

l Mer

cury

(Ppt

)

240

200

160

120

80

40

065 70 75 80 85 90 95

Air Mercury Capture (%)

Clari�er In�uent = 10,000 To 30,000 Ppt

Target = 200 ppt

Clari�er Ef�uent Hgt

Part Per Trillion = Ppt

Nalmet 1689 Clari�er Application

bringing the mercury concentration

down to approximately the limit of

detection of the analyzer, around 0.4

mg/m3. This corresponds to a mercu-

ry air emission of 0.42 lb Hg/TBtu, a

level significantly below the 1.2 lb Hg/

TBtu MATS limit. After the MerCon-

trol 6012 feed was turned off, mercury

emission slowly increased back to 4

mg/m3 over three hours.

In the second demonstration at Stan-

ton Station, low dosages (<150 ppm) of

MerControl 7895 oxidant were added

to the coal at the same time the Mer-

Control 6012 technology was injected

into the SDA. It can be seen in Figure

2 that once again mercury emissions

were held below the limit of detection

of the analyzer (0.4 mg/m3), only this

time the MerControl 6012 flowrate was

only 0.28 lb actives/MMacf. The effect

of the MerControl 7895 oxidant on the

sorbent performance was observed af-

ter the oxidant and slurry feeds were

turned off and the mercury emission

remained below the MATS limit for

greater than three hours, returning to

baseline after bag cleaning.

For comparison, commercially

available brominated PAC was injected

into the duct prior to the SDA inlet.

The brominated PAC was fed at 1 and 2

lb/MMacf and achieved mercury emis-

sion levels of 3.9 and 2.4 mg/m3, re-

spectively, well above the MATS limit.

Besides the disadvantages of dry sor-

bent injection including added capital

equipment and difficulty in homog-

enous distribution of the sorbent, this

benchmark technology was not able to

meet the MATS limit at nearly double

the highest dose of the MerControl

6012 technology tested. For this unit,

MerControl 6012 technology provided

better cost-performance than bromi-

nated PAC, and reduced the mercury

concentration well below MATS limit.

CASE STUdy #2: mERCURy CoNTRol iN A WFgd

In Case Study #2, MerControl 8034

technology was demonstrated at a pul-

verized coal-fired utility power plant

firing high sulfur bituminous coal

with two identical units generating

about 500 MWe each. The air pollu-

tion control devices present on each

unit include a cold-side electrostatic

precipitator (ESP) and a wet flue gas

desulfurization (WFGD) scrubber.

The plant was experiencing unex-

pectedly low mercury capture across

their WFGD scrubbers due to the oc-

currence of “mercury re-emission,”

whereby soluble oxidized mercury

undergoes chemical reduction back to

the volatile and insoluble elemental

state. Mercury in the flue gas coming

into the WFGD scrubbers was approxi-

mately 80 percent oxidized yet the to-

tal mercury capture across the WFGD

was much lower at approximately 20 to

40 percent. This difference indicated

that the oxidized mercury was most

likely being chemically reduced in so-

lution and re-emitted out the stack.

In Figure 3, it can be seen that once

Page 6: YEARS MATS Compliance: Thinking OuTSide theBOx 2014/Alternatives...north Omaha ower Station uprades coal handlin system 48 he Eouton o ower nt WterStem Chemstr Contributin editor Brad

the MerControl 8034 technology was

applied (feed rate is shown in black), the

amount of mercury captured increases

and becomes equivalent to the amount

of oxidized mercury entering the WFGD

scrubber, indicating that MerControl

8034 technology leads to the complete

capture of oxidized mercury from the

flue gas. It was concluded from the data

in Figure 3 that the amount of mercury

re-emitted in the WFGD becomes neg-

ligible once the MerControl 8034 tech-

nology is fed into the system.

The successful prevention of mercury

re-emission was also evident in the mea-

surements of mercury concentrations in

the WFGD liquors. Once the MerCon-

trol 8034 treatment began in Unit 1, the

soluble mercury concentration dropped

rapidly until it reached a steady state at

nearly zero. The significant decrease in

soluble mercury concentration in Unit 1,

which was not observed in the untreated

Unit 2, indicated that the MerControl

8034 technology was reacting and pre-

cipitating the soluble mercury out of

solution before it could be re-emitted

out the stack. These results demonstrate

that the addition of MerControl 8034

technology effectively removes the solu-

ble mercury from the WFGD and stops

mercury re-emission from occurring,

leading to the capture of all oxidized

mercury in the flue gas.

CASE STUdy #3: mERCURy EmiSSioNS CoNTRol FoR AiR ANd WATER

For compliance with state mercury

limits of 0.008 lb Hg/GWh, City Water

Light and Power Dallman Power Sta-

tion, a 190 MWe coal-fired utility in

Springfield, Ill., needed to reach greater

than 85 percent flue gas mercury cap-

ture while maintaining mercury water

discharge limits. The unit fires bitumi-

nous coal and has AQCDs including an

SCR, a cold-side ESP, and a WFGD. The

plant faced two major challenges. First,

despite having an SCR and a WFGD

Reprinted with revisions to format, from the October 2012 edition of Power EngineeringCopyright 2012 by PennWell Corporation

scrubber to capture oxidized mercury,

the plant was still unable to meet its

emissions target. Therefore, to further

enhance mercury oxidation and cap-

ture, MerControl 7895 oxidant was in-

jected into the coal feeders. The second

challenge the plant faced was that any

changes to air mercury removal must

result in wastewater effluent mercury

concentrations remaining below exist-

ing mercury discharge limits. For this

purpose, the polymeric chelant Nalmet

1689 solution was added to the WFGD

wastewater treatment system.

Figure 4 shows the emissions of to-

tal and elemental mercury at the stack

plotted against a range of feed rates of

MerControl 7895 oxidant. Application

at 265 mg MerControl 7895/kg of coal

and above afforded greater than 85

percent mercury capture and achieved

the target of 0.008 lb Hg/GWh. Treat-

ment with MerControl 7895 oxidant

successfully resulted in air emissions

compliance by increasing efficiency of

the WFGD and enabling the mercury

to be captured in the WFGD liquor.

Historically at this plant, the mercury

concentration in the WFGD wastewa-

ter was observed to be in the range of

10,000 – 30,000 ppt. Moreover, with the

treatment of MerControl 7895 chemis-

try causing the oxidized mercury in the

flue gas to increase, it would be expect-

ed that the amount of mercury in the

wastewater would be substantially high-

er. Figure 5 shows that treatment of the

WFGD wastewater with Nalmet 1689

chemistry lowered and maintained mer-

cury concentrations in the clarifier efflu-

ent stream to well below 200 ppt. From

other measurements performed, it was

concluded that Nalmet 1689 technology

shifts the captured mercury from the

wastewater to the clarifier solids. With

the mercury partitioned to the clarifier

solids, it is then easily removed by stan-

dard wastewater treatment equipment

and the solids can be safely landfilled.

For many coal-fired utilities in the

U.S., achieving MATS compliance can

seem complex and expensive. Back-end

AQCDs require long lead times, are high

capital cost, and can have inefficiencies

that require additional mercury capture

technology. Injection of brominated ac-

tivated carbon is more capital intensive

than the technologies presented here.

Furthermore, it can have a negative ef-

fect on fly ash quality and thereby im-

pact resale. Additionally, with current

and anticipated mercury emissions lim-

its for wastewater, it is critical for utili-

ties to adjust their wastewater mercury

removal plans when implementing any

new air emissions technologies.

REFERENCES(1) U.S. Environmental Protection Agency,

Final Mercury and Air Toxic Standards (MACT) for Power Plants, http://www.epa.gov/mats/actions.html.

(2) Blythe, G. M.; Currie, J.; DeBerry, D. W. “Bench-scale Kinetics Study of Mercury Reactions in FGD Liquors, Final Report: DE-FC26-04NT42314 for the National Energy Technology Laboratory”, 2008.

(3) Stiles, R. L.; Zinn, P. J.; Lu, J. V.; Michels, J. J.; Leigh, A. M.; Keiser, B. A. “Prevent-ing mercury re-emissions in wet flue gas desulfurization scrubbers at coal-fired power plants using Mercontrol 8034 additive” Preprints of Symposia - Ameri-can Chemical Society, Division of Fuel Chemistry 2010, 55, 164-166.

(4) Chang, J. C. S., Ghorishi, S.B. “Simula-tion and evaluation of elemental mer-cury concentration increase in flue gas across a wet scrubber” Environ. Sci. Technol. 2003, 37, 5763–5766.

(5) Liu, Y., Wang, Y. , Wu, Z., Zhou, S., Wang, H. “A mechanism study of chloride and sulfate effects on Hg2+ reduction in sul-fite solution” Fuel 2011, 90, 2501-2507

(6) Wang, Y., Liu, Y., Wu, Z., Mo, J., Cheng, B. “Experimental study on the absorp-tion behaviors of gas phase bivalent mercury in Ca-based wet flue gas desul-furization slurry system” Journal of Haz-ardous Materials 2010, 183, 902-907.

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Reprinted with revisions to format, from the October 2012 edition of Power EngineeringCopyright 2012 by PennWell Corporation

NAlCo AiR pRoTECTioN TEChNologiES

The Nalco Air Protection Technologies (APT) family of mercury control

products addresses the entire spectrum of mercury emissions compliance for

coal fired power plants. The Nalco team boasts some of the industry’s foremost

mercury experts and leading-edge technologies that are changing the way the

industry approaches mercury control for both air and water. Nalco solutions

are customized to fit the needs of the plant, are lower cost than the industries

other leading technologies, and envelop the power plant from the coal to the

wastewater to provide balance of plant mercury control.

The proprietary line of MerControl® mercury control technologies includes:

MerControl 7895 mercury oxidation catalyst, MerControl 8034 technology for

mercury re-emission control, and MerControl 6012 sorbent, a non-halogen,

non-carbon mercury sorbent used in spray dry absorber (SDA) or circulating dry

scrubber (CDS). The Nalco Predict Hg line of technologies facilitates mercury

removal in the wastewater effluent to meet challenging wastewater discharge

limits. Our leading-edge technologies are changing the way the coal-fired power

industry approaches mercury control.

For more information or to schedule a demonstration:

Visit www.nalco.com/mercury

Call Nalco at (630) 305-1000

Nalco and MerControl are Trademarks of Nalco Company

Ecolab is a trademark of Ecolab USA, Inc.

©2012 Ecolab USA Inc. All Rights Reserved

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