Evaluating MATS Options with

Field Demonstration Tests

SESSION A1
Hg Control – Sorbent Injection (I)
Air Quality IX
October 21, 2013

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 Disclaimer

THE INFORMATION CONTAINED IN THIS PRESENTATION IS

FOR GENERAL INFORMATIONAL PURPOSES ONLY, AND IS
NOT INTENDED AS LEGAL ADVICE. YOU SHOULD
CONSULT AN ATTORNEY OR OTHER APPROPRIATE
PROFESSIONAL FOR ADVICE REGARDING YOUR
INDIVIDUAL SITUATION.

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 Authors

Noah Meeks Robert Huston

Sheila Glesmann
Joe Wong

Southern Company ADA Carbon Solutions, LLC

600 North 18th Street, 1460 West Canal Court
Birmingham, AL 35291 Littleton, CO 80120

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 Background

• Southern Company is one of the largest producers of electricity in the

United States and the largest wholesale provider in the Southeast.
• ADA Carbon Solutions is a leading provider of powder activated carbon
(PAC) products optimized for performance in emission control
applications.
• EGU and PAC producer collaborations grounded in fundamental science,
commercialization of new advanced PACs, and rigorous field testing, have
provided better MATS Compliance options.
• Over 65 full plant tests support and exemplify the benefits of an
integrated approach.

We have synthesized experiences and learnings into Guiding Principles as a

framework for developing MATS Compliance strategies.
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 1. Use Science to Understand
Your Mercury Capture Needs

Contact Conversion Capture

of mercury, which is of elemental mercury and sequestration of
in very dilute (Hg0) to an oxidized the mercury in the
concentrations in the state (Hg+ or Hg++) to capture media’s
flue gas, with the enhance mercury’s structure
capture media receptivity to the
capture media

Mercury Capture = (Yield Contact) x (Yield Conversion) x (Yield Capture)

Effectiveness 90% x 90% x 90% = 73%

All three mechanisms must occur with high effectiveness in

seconds or less to achieve compliance

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 2. Move Mercury Capture
Upstream in Your System

Optimal Temperature and

Removal Regime

• Multiple phase partitioning of Hg in gas, Increasing complexity for Hg removal in

water and solid phases
downstream Air Pollution Equipment
• Introduction of competing chemistries and
contaminant by-products
• Lower concentration driving force for Hg
Single-phase approach simplifies
removal or eliminates downstream
interactions – move it upstream.
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 3. Active Control Rather
Than Passive
6.0
• > 200 MW EGU
Steep, Rapid Capture • PRB Fired
5.0
• Emission Train
Hg Emissions (Lb/TBtu)

4.0 Configuration:
Low Hg Residual
& Secure Capture Economizer-ACI-APH-
3.0
GEN2 2
GEN ESP-Stack
FastPAC TM Premium
FastPAC Premium™
2.0
• Hg CEMS
US Emission Standard 1.2 Lb/TBtu
1.0

0.0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Lb Activated Carbon/MMacf
Use Advanced “Generation 2+” PACs, such as FastPAC Premium™, to
accomplish rapid Hg capture to low residual levels, thus allowing active,
responsive “dial-up” and “dial-down” control on demand.
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 4. Retain and Preserve Original
Purpose of Equipment
Technology solutions need to be cost effective and favorable to Balance-of-
Plant considerations. Different configurations and changing process needs
at the plant require innovative responses.

Wet/Dry
Coal Combustion Dry Sorbent Sorbent Injection Scrubber Post Scrubber
Pretreatment Oxidation Injection Additives Treatments

Effective system design adapts technology options to integrate

the operation of upstream and downstream equipment for
cost-effective MATS Compliance.
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 5. Minimize Balance-of-Plant and
Other Emission Interactions

What Are Your Balance-of-Plant Considerations???

Enhanced Hg Capture Efficiency, Co-Benefit
SO3 / DSI Tolerant PAC
Hot-Side Versus Cold-Side APH Injection of PAC
Halogen Addition on Coal ~Downstream Corrosion and Process Issues
Ash Utilization
PAC Halogen Volatility
PM Control / Opacity
Scrubber Hg Re-Emissions
Multi-Contaminant Capture or Buildup in Scrubber & Wastewater
Gypsum Purity
Waste Solids Contaminant Control

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 5. Minimize Balance-of-Plant and
Other Emission Interactions:
Ash Utilization
Concrete Foam Stability vs. Time*
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Drops of Air Entrainment Agent

Competitor 1
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22
20
(50µL=1drop)

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The rapid achievement of foam stability
14 provides assurance for ash marketers
12 ADA FastPAC
Premium™
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8
6 No Carbon Baseline
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0 10 20 30 40 50 60 70 80 90 100 110 120
Time (Minutes) *PAC at ~3 Lb/MMacf equivalent

Use Highly Advanced PACs, such as FastPAC Premium™ to Conserve

Air Entrainment Agent Usage and Provide Rapid Foam Stability.
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 5. Minimize Balance-of-Plant and
Other Emission Interactions:
Ash Utilization
Generation 2 Generation 1
35% More Consistent Less Consistent

30%

Less Impact on Fly Ash

25%

20%

15%

10%

5%

0%
1 1.3 1.6 1.9 2.2 2.5 2.8 3.1 3.4 3.7 4 4.3 4.6 4.9 5.2 5.5 5.8 6.1 6.4 6.7 7

Pounds per Million ACF of Sorbent *John Kline Consulting 2013

Lower injection rates and a tighter control range mean improved repeatability of fly
ash AEA demand. Advanced “Generation 2+” FastPAC Premium™ allows low PAC
injection for high Hg capture and greater active engineering control (steeper capture
curves), resulting in more consistent fly ash properties.
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 5. Minimize Balance-of-Plant and
Other Emission Interactions:
Bromine in Flue Gas
• Bromine and Bromine Derivatives are effective in assisting the oxidation of Hg, but are
used in orders of magnitude in excess of stoichiometric requirements
• In the presence of water, Br2 and Bromide Salts form HBr (Hydrobromic Acid), which is
highly corrosive
• With respect to the activated carbon, the type of Bromine counter-ion will affect the
Bromine species’ volatility, resulting in more or less free Bromine in the flue gas

Br2 NH4Br KBr NaBr

Temperature at
Vapor Pressure of 1 -56°F 388°F 1,463°F 1,483°F
mmHg*

Most Volatile Least Volatile

*Perry’s Chemical Engineers’ Handbook, 4th Edition, McGraw Hill, New York, NY, Pages 3-44 to 3-46

The Form of [Br] Affects the Amount of Free Bromine in the Flue
Gas – Use PACs with a Low Volatility Form.
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 5. Minimize Balance-of-Plant and
Other Emission Interactions:
Impacts of DSI on PAC
2.5
• Mercury emissions
2 increase at 100 Lb/Hr
Hg Emissions (Lb/TBtu)

ACI with 1,000 Lb/Hr

1.5 DSI on PRB Fuel

1
PAC - Trona
PAC - Lime
0.5
PAC – No DSI
0
0 50 100 150 200 250
Activated Carbon Injection Rate (Lb/Hr)
Dry Sorbent Injection can Adversely Impact the Hg Capture
Effectiveness of “Generation 1” PACs – Use “Generation 3” SO3/Acid
Tolerant PACs to Reduce DSI Requirements and Dampen Impacts
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 Summary

1. Take a scientific approach with focus on Contact, Conversion

and Capture effectiveness.
2. Move mercury capture as far as logical upstream in your APC
and to a single point if possible.
3. Seek active control not passive of mercury capture with
engineering controls such as advanced “Generation 2 and 3”
PACs to dial-up and dial-down control as needed.
4. Retain the original, critical purpose of your APC system by
adapting technology options to integrate the operation of
upstream and downstream equipment for cost-effective MATS
Compliance.
5. Minimize Balance-of-Plant Impacts and other emission
interactions by applying technologies that are complementary
and mitigate collateral effects.
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 Acknowledgments and
Contacts

The authors would like to thank:

 The personnel at Southern Plants: Barry, McIntosh
and Smith
 The organizers of Air Quality IX

• Noah Meeks • Robert Huston

– ndmeeks@southernco.com – robert.huston@ada-cs.com
– Research Engineer – Sr. Director of Technical Services
– Southern Company – ADA Carbon Solutions, LLC
– Booth # 209

Thank You
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