Overview of Week 4 Testing

Conference Call Meeting

with Sponsors

September 24, 2004

1 Preliminary Data
Agenda

EERC Discussion
Discussion Topic Leader(s)
Welcome and Introductions Steve Benson
Preliminary Results of Week 4 Testing Don McCollor
Final Report Outline Don McCollor
Jill Zola
Future Directions Steve Benson

Other Items?? Steve Benson

2 Preliminary Data
 PTC Suite

ID Fan

Boiling Water HX
Radiant HX Baghouse

Preheater
Spray
Dryer

FD Fan

ESP Combustor

AHPC

Coal
Feeder

3 Preliminary Data
Week 4 Testing

• ESP/FF – Caballo coal

– Baseline
– NORIT carbon
– SEA-1
– SEA-1 + NORIT carbon
– SEA-2
– SEA-2 + NORIT carbon
• FF-only – Caballo coal
– NORIT carbon

4 Preliminary Data
Week 4 Testing
• ESP/FF – Demeter treated Caballo coal
– Baseline
– Demeter additive
– Demeter additive + NORIT carbon
• ESP/FF – WRI treated Caballo coal
– Baseline
– NORIT carbon
• ESP Only – WRI treated Caballo coal
– Baseline
– NORIT carbon

5 Preliminary Data
Week 4 Testing

• SDA/FF – WRI treated Caballo coal

– Baseline
– NORIT carbon
• SDA/FF – Solucorp SDA additive + Caballo coal
– Baseline
– 20%, 33%, 50% gas flow bypass
– SEA-2

6 Preliminary Data
Week 4 Coal Analysis
Coal Characteristics Caballo – Composite Caballo – Demeter Caballo – WRI
Proximate analysis (as fired):
Moisture 17.60 18.90 5.40
Volatile matter 29.45 38.72 42.59
Fixed carbon 47.72 29.24 45.81
Ash 5.22 13.14 6.21
99.99 100.00 100.01
Ultimate analysis (as fired):
Hydrogen 5.70 5.33 4.85
Carbon 54.20 46.50 64.97
Nitrogen 0.94 0.81 1.15
Sulfur 0.50 0.09 0.49
Oxygen 33.44 34.14 22.33
Ash 5.22 13.14 6.21
100.00 100.01 100.00
Heating value, Btu/lb 9357 7648 11084
Hg, ppm 0.1255 0.0990 0.0449
Cl, ppm 32.3 1150.0 28.4

7 Preliminary Data
ESP/FF – Caballo Coal

Comparison of OH and CMM

12

10
Inlet Total Hg
Hg, µg/Nm3

8
Inlet Elemental Hg
6
Outlet Total Hg
4 Outlet Elemental Hg
2

0
CMM OH

8 Preliminary Data
ESP/FF – Caballo Coal
Inlet Total Hg

12

10

8
Hg, µg/Nm3

0
T1-2 T1-3 T1-4

9 Preliminary Data
ESP/FF – Caballo Coal

TOXECONTM – Carbon-Only

12
10
Hg, µg/Nm3

8
6
4
2
0
0.0 2.5 3.9
Carbon, lb/Macf

10 Preliminary Data
ESP/FF – Caballo Coal

TOXECONTM – Carbon-Only

100
% Total Hg Removed

80

60

40

20

0
0.0 1.0 2.0 3.0 4.0 5.0
Carbon, lb/Macf

11 Preliminary Data
ESP/FF – Caballo Coal
TM
TOXECON – Carbon + SEA-1

12
10
Hg, µg/Nm3

8 Inlet Total Hg
6 Outlet Total Hg
4 Outlet Elemental Hg
2
0
Baseline SEA1=2.5 SEA1=2.5 SEA1=2.5
C=2.5 C=3.9
Carbon + SEA-1, lb/Macf

12 Preliminary Data
ESP/FF – Caballo Coal

TOXECONTM – Carbon + SEA-1

100
% Total Hg Removed

80

60

40

20

0
Baseline SEA1=2.5 SEA1=2.5 C=2.5 SEA1=2.5 C=3.9
Carbon + SEA-1, lb/Macf

13 Preliminary Data
ESP/FF – Caballo Coal
TM
TOXECON – Carbon + SEA-1

100
% Total Hg Removed

80

60 Carbon Only
40 Carbon+SEA1

20

0
0.0 1.0 2.0 3.0 4.0 5.0
Carbon, lb/Macf

14 Preliminary Data
ESP/FF – Caballo Coal (Day 2)

Comparison of CMM and OH

12

10
Inlet Total Hg
3

8
Hg, µg/Nm

Inlet Elemental Hg
6
Outlet Total Hg
4 Outlet Elemental Hg
2

0
Baseline Baseline CMM

15 Preliminary Data
ESP/FF – Caballo Coal (Day 2)

Inlet Total Hg

12

10

8
Hg, µg/Nm 3

0
T2-1 T2-1 T2-2 T2-2 T2-3 T2-3 T2-4

16 Preliminary Data
ESP/FF – Caballo Coal

Carbon + SEA-2 Addition

12
10
Hg, µg/Nm 3

8 Inlet Total Hg
6 Outlet Total Hg
4 Outlet Elemental Hg
2
0
Ba Ca SE SE C- 1 C- 2
se l rbo A2 A2
in e n -1 - 0. - 0. .2 SE .5 SE
.2 1 2 A2 A2
-0. -
2 0.2
NORIT Carbon + SEA-2, lb/Macf

17 Preliminary Data
ESP/FF – Caballo Coal

Carbon + SEA-2 Addition

% Total Hg Removed

100
80
60 Inlet Total Hg
40 Outlet Total Hg
20
0
Ba Ca S S C C
sel rb o EA2 EA2 -1. 2 -2. 5
ine n-1 -0. 1 -0. 2 SE S
.2 A2- EA2-
0 .2 0 .2

NORIT Carbon + SEA-2, lb/Macf

18 Preliminary Data
FF-Only – Caballo Coal

Carbon Addition

12
10
Hg, µg/Nm 3

8
Inlet Total Hg
6
Outlet Total Hg
4
2
0
0.00 2.49
NORIT Carbon, lb/Macf

19 Preliminary Data
FF-Only – Caballo Coal

Carbon Addition

100
% Total Hg Removed

80

60

40

20

0
0.00 2.49
NORIT Carbon, lb/Macf

20 Preliminary Data
ESP/FF – Demeter Treated Coal

Demeter Treated Coal – ESP Inlet

500

400
SO2, ppm

300 Baseline
200 Demeter

100

0
0:00 4:48 9:36 14:24 19:12 0:00
Time, hours

21 Preliminary Data
ESP/FF – Demeter Treated Coal

Demeter Treated Coal – ESP Inlet

1000

800
NOx , ppm

600 Baseline
400 Demeter

200

0
0:00 4:48 9:36 14:24 19:12 0:00
Time, hours

22 Preliminary Data
ESP/FF – Demeter Treated Coal

Baseline OH and CMM

12

10
Inlet Total
Hg, µg/Nm 3

8
Inlet Elemental
6
Outlet Total
4 Outlet Elemental
2

0
Ontario Hydro Baseline CMM

23 Preliminary Data
ESP/FF – Demeter Treated Coal

Inlet Hg Concentrations

12
10
3

8
Hg, µg/Nm

Inlet Total
6
Inlet Elemental
4
2
0
T3

T3

T3

T3

T3

T3

T3

T3

T3

T3
-1

-2

-3

-4

-5

-6

-7

-8

-9

-1
0
24 Preliminary Data
ESP/FF – Demeter Treated Coal

EERC Carbon Addition

12
10
Hg, µg/Nm 3

8
Inlet Total
6
Outlet Total
4
2
0
0 2.48 4.30 5.08
Carbon, lb/Macf

25 Preliminary Data
ESP/FF – Demeter Treated Coal

EERC Carbon Addition

100
% Total Hg Removed

80

60

40

20

0
0 1 2 3 4 5 6
Carbon, lb/Macf

26 Preliminary Data
ESP/FF – Demeter Treated Coal

Demeter Solution Injection

100
Total Hg Removed

80

60

40

20

0
Ba

0.

0.

0.

0.

0.

0.
1-

3-

1-

3-

6-
O
se

nl

A+

A+

A+

B+

B+

N
l
in

o
C
C

C
e

C
27 Preliminary Data
ESP/FF – WRI Treated Coal

WRI Inlet Mercury

8
7
6
Hg µg/m 3

5
Hg total
4
3 Hg elemental
2
1
0
T4-1 T4-2 T4-3 T4-3 T4-4 T4-6 T4-6 T4-7 T4-8 T4-8
Test

28 Preliminary Data
ESP/FF – WRI Treated Coal

WRI Inlet Mercury

100
% Elemental Mercury

80

60

40

20

0
T4-1 T4-2 T4-3 T4-3 T4-4 T4-6 T4-6
Test

29 Preliminary Data
ESP/FF – WRI Treated Coal

WRI ESP/FF Mercury

6
Total Hg µg/m3

4 ESP inlet total Hg

ESP inlet elemental Hg
FF outlet total Hg
2 FF outlet elemental Hg

0
CMM CMM OH

30 Preliminary Data
ESP/FF – WRI Treated Coal

WRI ESP/FF Mercury

6
Total Hg µg/m3

ESP inlet
4
FF outlet
2

0
0 0 1.26 1.26
NORIT, lb/macf

31 Preliminary Data
ESP/FF – WRI Treated Coal

WRI ESP/FF Mercury

100
80
% Hg Removed

60
40
20
0
-20 0 0 1.26 1.26

-40
NORIT, lb/macf

32 Preliminary Data
ESP-Only – WRI Treated Coal

WRI ESP-Only Mercury

6
Total Hg µg/m 3

ESP inlet
4
ESP outlet
2

0
0 0 1.26 2.50 2.50
NORIT, lb/macf

33 Preliminary Data
ESP-Only – WRI Treated Coal

WRI ESP-Only Mercury

100

80
% Hg removed

60

40

20

0
0 0 1.26 2.50 2.50
-20
NORIT, lb/macf

34 Preliminary Data
SDA/FF – WRI Treated Coal

WRI SDA/FF Mercury

6
Total Hg µg/m 3

SDA inlet
4
FF outlet
2

0
0 0 1.33
NORIT, lb/macf

35 Preliminary Data
SDA/FF – WRI Treated Coal

WRI SDA/FF Mercury

100

80
% Hg Removed

60

40

20

0
0 0 1.33
NORIT, lb/macf

36 Preliminary Data
SDA–Solucorp Additive/FF – Caballo
Coal
CMM and Ontario Hydro – 50% Bypass

12

10
Hg, µg/Nm 3

8
Total Hg
6 Elemental Hg

0
Inlet CMM Inlet OH Outlet CMM Outlet OH

37 Preliminary Data
SDA–Solucorp Additive/FF – Caballo
Coal
Effect of Bypass

12
10
Inlet Total Hg
Hg, µg/Nm 3

8
Inlet Elemental Hg
6
Outlet Total Hg
4
Outlet Elemental Hg
2
0
0% 20% 33% 50%
Bypass Bypass Bypass Bypass
Bypass

38 Preliminary Data
SDA–Solucorp Additive/FF – Caballo
Coal
Effect of Bypass

40
% Total Hg Removed

35
30
25
20
15
10
5
0
0% Bypass 20% Bypass 33% Bypass 50% Bypass

Bypass

39 Preliminary Data
SDA–Solucorp Additive/FF – Caballo
Coal
Effect of CaCl2

12
10
Hg, µg/Nm 3

8
Total Inlet Hg
6
Total Outlet Hg
4
2
0
0.00 5.29 10.62

CaCl2, lb/Macf

40 Preliminary Data
Week 4 – Summary

• FF-Only
– 80% removal (2.5 lb/Macf NORIT carbon)
• ESP/FF (TOXECONTM)
– 80% removal (2.5 lb/Macf NORIT carbon)
– Similar to FF-only
– SEA-1 reduced elemental Hg, but did not significantly
improve already high removal.
– SEA-2 reduced elemental Hg, but did not significantly
improve already high removal.

41 Preliminary Data
Week 4 – Summary

• Demeter treated coal (ESP/FF)

– Very high sulfur capture
– Moderate NOx reduction
– High Hg removal with EERC treated carbon injected
before ESP
– Solution injection had little effect, probably due to
deposition on injector.
– Additive expected to be more effective in a dry form

42 Preliminary Data
Week 4 – Summary

• Solucorp SDA additive (SDA/FF)

– Lack of residence time
– 35% mercury removal (50% flue gas bypass)
– Demonstration of effectiveness limited by system
conditions (could not increase residence time further)
– SEA-1 had little effect on mercury removal.

43 Preliminary Data
Week 4 – Summary

• WRI treated coal (ESP-only), (ESP/FF), (SDA/FF)

– 64% of mercury is removed by treatment.
– Treated coal is reactive when pulverized.
– ESP/FF – 80% mercury removal (1.25 lb/Macf
NORIT).
– ESP-only – 50–55% mercury removal (2.5 lb/Macf
NORIT)
– SDA/FF – 50–60% mercury removal, carbon did not
improve removal.

44 Preliminary Data
Final Report Outline – Draft by Nov. 1

• Executive Summary
• Introduction
• Background
• Goals and Objectives
• Work Plan
• Description of Pilot-Scale Test Facility
• Depiction of Mercury Sampling and Analysis
• Overview of Pilot-Scale Testing
• Presentation and Discussion of Test Results
• Results of SEA-2 Testing at Ameren
• Comparison of Pilot-Scale Testing with Larger-Scale Testing
• Conclusions
• Recommendations

45 Preliminary Data
 Project Schedule
1st Quarter 2nd Quarter 3rd Quarter 4th Quarter
Task Name Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Task 1. Hg Control for Unscrubbed Systems
Testing – ESP Only
Testing at Ameren
Testing – ESP & Baghouse with TOXECON™
Testing – Baghouse Only
Data Reduction
Task 2. Hg Control in Dry Scrubbers
Testing – Spray Dryer Absorber (SDA) & ESP
Testing – SDA & Baghouse
Data Reduction
Task 3. Blending of Subbituminous & Bituminous
Coals for Enhanced Hg Oxidation
Testing – ESP Only
Testing – SDA, ESP & Baghouse
Data Reduction
Task 4. Project Management & Reporting
Project Kickoff Meeting
Status Review Meeting
Conference Calls
Preliminary Data Interpretation
Draft Final Report
Final Report

46 Preliminary Data
 Future Directions

47 Preliminary Data
Other Items