The Effective Collection of Fly Ash At Pulverized Coal-Fired Plants

The relationship between sulfur in coal, boiler exit gas temperature, and the carbon portion of fly ash have a major effect on the electrical properties of fly ash. Whether effective collection of fly ash is obtained by the electrostatic precipitator installation alone or the precipitator—mechanical combination depends primarily on a knowledge of this relationship. Fly ash electrical properties can range from a highly "resistive" to a highly "conductive" state which can appreciably alter the precipitator collection performance. A correlation of coal sulfur and boiler exit flue gas temperature is given to indicate the probability of expecting an optimum voltage—current relationship with different combinations of these factors. Carbon affects the electrical conditioning of fly ash by providing parallel paths of current leakage through the deposited dust layer. Therefore, removal of the carbon particles in a mechanical collector placed before the precipitator can alter the precipitator electrical characteristics.     

Mercury Balance on a Large Pulverized Coal-Fired Furnace

This paper presents results of a survey of mercury concentrations in coal, ash, water, fly ash, and flue gas discharges from a 5.5 × 10⁶ Ib/hr steam generator serving a 775 MW (net) turbine-generator set. Representative composite or grab samples were obtained for inlet coal and outlet ash and water. Stack samples were obtained for fly ash and mercury vapor emissions while the unit was operated at 660 MW (net) (85% of full load). Samples were analyzed by anodic stripping voltammetry, plasma emission spectroscopy, and neutron activation analysis to determine mercury concentration entering the furnace in the coal and leaving the furnace in the flue gas, fly ash, bottom and hopper ash, and water. Method inter-comparisons are discussed. A material balance for mercury has been calculated from fuel, ash, and stack gas flow rates. About 90% of the mercury in the coal is released and appears as vapor discharged in the stack gas while 10% remains in the residual ash. For a 700 MW (net) unit, about 5 lb/day of mercury vapor is released to the atmosphere.     

Predicting extents of mercury oxidation in coal-derived flue gases

The proposed mercury (Hg) oxidation mechanism consists of a 168-step gas phase mechanism that accounts for interaction among all important flue gas species and a heterogeneous oxidation mechanism on unburned carbon (UBC) particles, similar to established chemistry for dioxin production under comparable conditions. The mechanism was incorporated into a gas cleaning system simulator to predict the proportions of elemental and oxidized Hg species in the flue gases, given relevant coal properties (C/H/O/N/S/Cl/Hg), flue gas composition (O2, H2O, HCl), emissions (NO(X), SO(X), CO), the recovery of fly ash, fly ash loss-on-ignition (LOI), and a thermal history. Predictions are validated without parameter adjustments against datasets from lab-scale and from pilot-scale coal furnaces at 1 and 29 MWt. Collectively, the evaluations cover 16 coals representing ranks from sub-bituminous through high-volatile bituminous, including cases with Cl2 and CaCl2 injection. The predictions are, therefore, validated over virtually the entire domain of Cl-species concentrations and UBC levels of commercial interest. Additional predictions identify the most important operating conditions in the furnace and gas cleaning system, including stoichiometric ratio, NO(X), LOI, and residence time, as well as the most important coal properties, including coal-Cl.     

Predicting Extents of Mercury Oxidation in Coal-Derived Flue Gases

Abstract

The proposed mercury (Hg) oxidation mechanism consists of a 168-step gas phase mechanism that accounts for interaction among all important flue gas species and a heterogeneous oxidation mechanism on unburned carbon (UBC) particles, similar to established chemistry for dioxin production under comparable conditions. The mechanism was incorporated into a gas cleaning system simulator to predict the proportions of elemental and oxidized Hg species in the flue gases, given relevant coal properties (C/H/O/N/S/Cl/Hg), flue gas composition (O₂, H₂O, HCl), emissions (NO_X, SO_X, CO), the recovery of fly ash, fly ash loss-on-ignition (LOI), and a thermal history. Predictions are validated without parameter adjustments against datasets from lab-scale and from pilot-scale coal furnaces at 1 and 29 MW_t. Collectively, the evaluations cover 16 coals representing ranks from sub-bituminous through high-volatile bituminous, including cases with Cl₂ and CaCl₂ injection. The predictions are, therefore, validated over virtually the entire domain of Cl-species concentrations and UBC levels of commercial interest. Additional predictions identify the most important operating conditions in the furnace and gas cleaning system, including stoichiometric ratio, NO_X, LOI, and residence time, as well as the most important coal properties, including coal-Cl.     

Comparative assessment of coal tars obtained from 10 former manufactured gas plant sites in the eastern United States

A comparative analysis was performed on eleven coal tars obtained from former manufactured gas plant sites in the eastern United States. Bulk properties analyzed included percent ash, Karl Fisher water content, viscosity and average molecular weight. Chemical properties included monocyclic- and polycyclic-aromatic hydrocarbon (PAH) concentrations, alkylated aromatic concentrations, and concentrations of aliphatic and aromatic fractions. It was found that there was at least an order-of-magnitude variation in all properties measured between the eleven coal tars. Additionally, two coal tars obtained from the same manufactured gas plant site had very different properties, highlighting that there can be wide variations in coal tar properties from different samples obtained from the same site. Similarities were also observed between the coal tars. The relative chemical distributions were similar for all coal tars, and the coal tars predominantly consisted of PAHs, with naphthalene being the single-most prevalent compound. The C(9-22) aromatic fraction, an indicator of all PAHs up to a molecular weight of approximately 276 gmole(-1), showed a strong power-law relationship with the coal tar average molecular weight (MW (ct)). And the concentrations of individual PAHs decreased linearly as MW (ct) increased up to ca. 1000 gmole(-1), above which they remained low and variable. Implications of these properties and their variation with MW (ct) on groundwater quality are discussed. Ultimately, while these similarities do allow generalities to be made about coal tars, the wide range of coal tar bulk and chemical properties reported here highlights the complex nature of coal tars.     

粉煤灰烧制陶粒过程中二氧化硫的释放规律与形成机理

研究了粉煤灰烧制陶粒过程中烟气二氧化硫的释放规律,同时对烧结前后粉煤灰与陶粒中不同形态硫含量和硫平衡进行了分析,探讨了烟气中二氧化硫的来源和转化机理.结果表明,烟气中约55％的二氧化硫来源于硫酸盐的还原,其余主要来自有机硫燃烧和亚硫酸盐的分解.烧制每千克陶粒所产生的二氧化硫量约为7.8g.高温烧结过程中粉煤灰球内形成的还原性气氛导致了粉煤灰中硫酸盐向二氧化硫的还原转化.     

Investigations of ash fouling with cattle wastes as reburn fuel in a small-scale boiler burner under transient conditions

Fouling behavior under reburn conditions was investigated with cattle wastes (termed as feedlot biomass [FB]) and coal as reburn fuels under a transient condition and short-time operation. A small-scale (30 kW or 100,000 Btu/hr) boiler burner research facility was used for the reburn experiments. The fuels considered for these experiments were natural gas (NG) for the ashless case, pure coal, pure FB, and blends of coal and FB. Two parameters that were used to characterize the ash "fouling" were (1) the overall heat-transfer coefficient (OHTC) when burning NG and solid fuels as reburn fuels, and (2) the combustible loss through ash deposited on the surfaces of heat exchanger tubes and the bottom ash in the ash port. A new methodology is presented for determining ash-fouling behavior under transient conditions. Results on the OHTCs for solid reburn fuels are compared with the OHTCs for NG. It was found that the growth of the layer of ash depositions over longer periods typically lowers OHTC, and the increased concentration of ash in gas phase promotes radiation in high-temperature zones during initial periods while decreasing the heat transfer in low-temperature zones. The ash analyses indicated that the bottom ash in the ash port contained a smaller percentage of combustibles with a higher FB percentage in the fuels, indicating better performance compared with coal because small particles in FB burn faster and the FB has higher volatile matter on a dry ash-free basis promoting more burn out.     

粉煤灰和电石渣对聚丙烯塑料裂解的影响研究

研究了粉煤灰和电石渣对聚丙烯塑料裂解的影响,讨论了加入量对裂解速度和裂解产物的影响.结果表明:粉煤灰和电石渣都使裂解产物中的轻质部分(汽油和裂解气)增加、重油降低;粉煤灰比电石渣更能加快反应的进行,而且加入量越多,反应越快,需时越短;粉煤灰比电石渣对聚丙烯塑料的裂解具有明显的催化促进效果.     

Distribution of mercury in the combustion products from coal-fired power plants in Guizhou,southwest China

Method 30B and the Ontario Hydro Method (OHM) were used to sample the mercury in the flue gas discharged from the seven power plants in Guizhou Province, southwest China. In order to investigate the mercury migration and transformation during coal combustion and pollution control process, the contents of mercury in coal samples, bottom ash, fly ash, and gypsum were measured. The mercury in the flue gas released into the atmosphere mainly existed in the form of Hg°. The precipitator shows a superior ability to remove Hg^p (particulate mercury) from flue gas. The removal efficiency of Hg²⁺ by wet flue gas desulfurization (WFGD) was significantly higher than that for the other two forms of mercury. The synergistic removal efficiency of mercury by the air pollution control devices (APCDs) installed in the studied power plants is 66.69–97.56%. The Hg mass balance for the tested seven coal-fired power plants varied from 72.87% to 109.67% during the sampling time. After flue gas flowing through APCDs, most of the mercury in coal was enriched in fly ash and gypsum, with only a small portion released into the atmosphere with the flue gas. The maximum discharge source of Hg for power plants was fly ash and gypsum instead of Hg emitted with flue gas through the chimney into the atmosphere. With the continuous upgrading of APCDs, more and more mercury will be enriched in fly ash and gypsum. Extra attention should be paid to the re-release of mercury from the reutilization of by-products from APCDs.

Implications: Method 30B and the Ontario Hydro Method (OHM) were used to test the mercury concentration in the flue gas discharged from seven power plants in Guizhou Province, China. The concentrations of mercury in coal samples, bottom ash, fly ash, and gypsum were also measured. By comparison of the mercury content of different products, we found that the maximum discharge source of Hg for power plants was fly ash and gypsum, instead of Hg emitted with flue gas through the chimney into the atmosphere. With the continuous upgrading of APCDs, more and more mercury will be enriched in fly ash and gypsum. Extra attention should be paid to the re-release of mercury from the reutilization of by-products from APCDs.     

Ca/S比小于1条件下半干半湿法烟气脱硫技术的研究

通过对煤中灰分、粉煤灰中碱性物质成分、含量的分析 ,证明在Ca/S小于 1的条件下进行半干半湿法烟气脱硫是可行的。阐述了粉煤灰中碱性物质被有效利用的条件为高温、高湿和高压 ,该条件可以通过蒸汽输送粉煤灰来实现。     

Trace metal emissions from co-combustion of refuse derived and packaging derived fuels in a circulating fluidized bed boiler

Energy recovery from refuse derived fuels (RDF) and packaging derived fuels (PDF) is one option in integrated waste management. Nine RDF and PDF co-combustion tests with peat and coal in a circulating fluidized bed boiler were carried out in this work. Heavy metal emissions in flue gas and fly ash were measured. Multivariate data analyses were used to find out the most important parameters affecting metal emissions in the flue gas.

The results showed that total heavy metal emissions were low. Although RDF and PDF had more heavy metals than peat and coal, the multivariate data analysis showed that an increase of the RDF or PDF share in the fuel mixture up to 20% did not correlate directly with the metal emissions in the flue gas. Distribution of Cd, Cu, Zn and Sn between flue gas and fly ash correlated with each other. Injection of limestone to bind sulphur and chlorine did not have a significant effect on heavy metal emissions in the flue gas. Heavy metals concentrated on the fly ash, but all fly ashes passed the EPA-TCLP tests.     

Medium-Sulfur Coal and Fly Ash Resistivity

Electric generating plants burning medium-sulfur coal need a way to predict when ESP performance will be limited by high electrical resistivity of the collected fly ash. The main uncertainty in mathematical predictions of fly ash resistivity lies in the marginal effect of naturally occurring SO₃ vapor in the flue gas. This paper results from a project to expand the data base of SO₃/SO₂ concentrations and fly ash resistivities measured in utility fly ash precipitators. Complete data sets are presented from three plants in the Southern Company electric system. In situ resistivity data are compared with laboratory measurements and with two different mathematical predictions of resistivity based on coal and ash analyses. The revised version of the resistivity predictor gives results in good agreement with resistivity values measured both in situ and in the laboratory.     

Removal of hydrogen sulfide gas and landfill leachate treatment using coal bottom ash.

Coal bottom ashes produced from three thermal power plants were used in column and batch experiments to investigate the adsorption capacity of the coal ash. Hydrogen sulfide and leachates collected from three sanitary landfill sites were used as adsorbate gas and solutions, respectively. Experimental results showed that coal bottom ash could remove H2S from waste gas or reduce the concentrations of various pollutants in the leachate. Each gram of bottom ash could remove up to 10.5 mg of H2S. In treating the landfill leachate, increasing ash dosage increased the removal efficiency but decreased the adsorption amount per unit mass of ash. For these tested ashes, the removal efficiencies of chemical oxygen demand (COD), NH3-N, total Kjeldhal nitrogen (TKN), P, Fe3+, Mn2+, and Zn2+ were 36.4-50, 24.2-39.4, 27.0-31.1, 82.2-92.9, 93.8-96.5, 93.7-95.4, and 80.5-82.2%, respectively; the highest adsorption capacities for those parameters were 3.5-5.6, 0.22-0.63, 0.36-0.45, 0.027-0.034, 0.050-0.053, 0.029-0.032, and 0.006 mg/g of bottom ash, respectively. The adsorption of pollutants in the leachate conformed to Freundlich's adsorption model.     

Release of mercury vapor from coal combustion ash

The long-term stability of Hg in coal combustion by-products (CCBs) was evaluated at ambient and near-ambient temperatures. Six CCB samples with atypically high levels of total Hg were selected for study assuming a greater potential for release of measurable amounts of Hg vapor. The samples selected included two fly ash samples from U.S. eastern bituminous coal, two fly ash samples from South African low-rank coal, one fly ash from Powder River Basin (PRB) subbituminous coal blended with petroleum coke, and one PRB subbituminous coal fly ash incorporated with flue gas desulfurization material. Air scrubbed of Hg was passed through compacted 100-g aliquots of each sample at 1 mL/min and vented to a gold-coated quartz trap to collect released Hg vapor. The samples were maintained at ambient and near-ambient (37 degrees C) temperatures. All samples released low-picogram levels of Hg after 90 days. No pattern was evident to link the total Hg content to the rate of release of Hg vapor. An average of 0.030 pg Hg/g CCB/day was released from the samples, which equates to 2.2 x 10(-8) lb Hg/ton CCB/year. If this were applied to a coal-fired power plant production of 200,000 tons of fly ash per year, there would be a maximum potential release of 0.0044 lb, or 2.00 g, of Hg per year. Experiments are continuing to determine long-term vapor release of Hg from CCBs. All samples have been set up in duplicate at ambient temperature with an improved apparatus to reevaluate results reported in this article.     

Improving Baghouse Performance at the Monticello Generating Station

At the Monticello station, operated by the Texas Utilities Generating Company, lignite coal obtained locally in Titus and Hopkins Counties fuels each of the three units. Units 1 and 2 are identical 575-MW Combustion Engineering (CE) boilers, each of which discharges its effluent to a 36- compartment shake/deflate cleaned baghouse paralleled with four electrostatic precipitators (ESP). Unit 3 is a larger boiler and is followed by an ESP and a scrubber. The Unit 1 and 2 baghouses were designed to clean 80 percent of the flue gas. Since startup, these baghouses have regularly experienced flange-to-flange pressure drops in excess of 10 in. H₂O, with large opacity spikes caused by ash bleeding through the bags after compartment cleanings. Because of higher-than-expected pressure drop, the baghouses receive only about 45-50 percent of the flue gas. Analysis has shown the Monticello lignite ash significantly differs from most other coal ashes. Testing has shown that the Monticello ash is not filtered effectively by many "standard" bag materials. However, this testing indicates that there are fabrics that show promise of eliminating the ash bleedthrough with little pressure drop penalty. Testing has also shown that injection of low concentrations (10-15 ppm) of ammonia (NH₃) into the flue gas significantly decreases ash bleedthrough, so that with NH₃ injection "standard" bag materials may perform adequately. Currently, fullcompartment testing of four fabrics, with and without NH₃ injection, is under way at the Unit 1 baghouse. The research conducted at the Monticello station is reviewed in this paper and the encouraging results from the full-compartment tests are presented.     

粉煤灰资源化特性及路面工程应用技术研究

对粉煤灰的各项技术参数进行了试验研究,揭示出粉煤灰的不同成分和形貌对其资源化特性的影响规律,初步完成了消除不利于粉煤灰资源化的有害成分炭的优化实验工作,进行了脱炭粉煤灰混凝土配合比等试验研究,并在路面修复工程中予以应有,结果表明,经脱炭处理的粉煤灰应用于混凝土工程可以明显改善混凝土的工作性能,实际道路运营和技术性能符合路面工程的要求,具有重大的经济效益和环境效益。     

Gas Cleaning Systems for the High Temperature,High Pressure Fluidized Bed Coal Combustor

The high temperature, high pressure fluidized bed coal combustor concept is intended to deliver a low dust content combustion gas at 1600°F and 11 atmospheres to a gas turbine for electricity generation. The perceived advantages of the system are 1) 15-20% increase in fuel efficiency and 2) flue gas desulfurization by adding crushed limestone to the fluidized bed combustor. A major R & D effort, supported by DOE, EPA, EPRI, and others, was undertaken to identify one or more gas cleaning systems of commercial size capable of 1) meeting EPA’s new source performance standards for coal burning power plants and 2) operating reliably under the severe environmental conditions specified. The principal gas cleaning systems that have been investigated for this service include: ceramic cleanable cloth filters, granular bed filters, rigid, porous ceramic structures, and electrostatic precipitators. Some of the fly ash collectors have been operated up to pilot scale size under realistic conditions. In spite of several years of intensive effort and many millions of dollars expended, production of a commercial unit has not been realized. A major content of this paper is a review of the accomplishments and failures of each of the fly ash collector concepts and a series of recommendations to guide future R & D efforts.     

钙质煤渣吸附剂脱除烟气中二氧化硫的实验研究

利用锅炉本身排出的煤渣作脱硫剂的基本核粒,配人少量的石灰,加水搅拌均匀,使石灰裹覆在煤渣颗粒表面,制成具有较大比表面积的钙质煤渣脱硫剂,用于烟气脱硫实验研究.实验结果表明,钙制煤渣脱硫剂比未经处理的煤渣脱硫率高,在一定的石灰添加范围内(10%～20%),脱硫率随石灰添加量的增加而增加,并存在一最佳用量.     

Joint US/USSR Test Program for Reducing Fly Ash Resistivity

An electrostatic precipitator preceded by a wet scrubber was tested at the Reftinskaya Power Station. The unit collects a high resistivity fly ash from the combustion of low sulfur Ekibastuz coal. The operating parameters of the precipitator were measured as well as the mass emissions and the in-situ electrical resistivity of the fly ash. Density, particle size distribution, electrical resistivity, and chemical composition were determined for collected samples of the fly ash. The fly ash was also characterized by x-ray diffraction and scanning electron microscopy. When a centrifugal wet wall scrubber was installed ahead of the electrostatic precipitator, the temperature of the flue gas entering the precipitator was decreased and the moisture content increased. The electrical resistivity of the fly ash was attenuated a decade, but not enough to overcome the adverse effects of back corona in the precipitator. Lowering the flue gas temperature to about 85°C by the addition of a venturi scrubber ahead of the centrifugal scrubber reduced the electrical resistivity of the fly ash another decade and allowed the operation of the precipitator without back corona.     

Understanding selected trace elements behavior in a coal-fired power plant in Malaysia for assessment of abatement technologies

The Proposed New Environmental Quality (Clean Air) Regulation 201X (Draft), which replaces the Malaysia Environmental Quality (Clean Air) 1978, specifies limits to additional pollutants from power generation using fossil fuel. The new pollutants include Hg, HCl, and HF with limits of 0.03, 100, and 15 mg/N-m³ at 6% O₂, respectively. These pollutants are normally present in very small concentrations (known as trace elements [TEs]), and hence are often neglected in environmental air quality monitoring in Malaysia. Following the enactment of the new regulation, it is now imperative to understand the TEs behavior and to assess the capability of the existing abatement technologies to comply with the new emission limits. This paper presents the comparison of TEs behavior of the most volatile (Hg, Cl, F) and less volatile (As, Be, Cd, Cr, Ni, Se, Pb) elements in subbituminous and bituminous coal and coal combustion products (CCP) (i.e., fly ash and bottom ash) from separate firing of subbituminous and bituminous coal in a coal-fired power plant in Malaysia. The effect of air pollution control devices configuration in removal of TEs was also investigated to evaluate the effectiveness of abatement technologies used in the plant. This study showed that subbituminous and bituminous coals and their CCPs have different TEs behavior. It is speculated that ash content could be a factor for such diverse behavior. In addition, the type of coal and the concentrations of TEs in feed coal were to some extent influenced by the emission of TEs in flue gas. The electrostatic precipitator (ESP) and seawater flue gas desulfurization (FGD) used in the studied coal-fired power plant were found effective in removing TEs in particulate and vapor form, respectively, as well as complying with the new specified emission limits.

Implications:Coals used by power plants in Peninsular Malaysia come from the same supplier (Tenaga Nasional Berhad Fuel Services), which is a subsidiary of the Malaysia electricity provider (Tenaga Nasional Berhad). Therefore, this study on trace elements behavior in a coal-fired power plant in Malaysia could represent emission from other plants in Peninsular Malaysia. By adhering to the current coal specifications and installation of electrostatic precipitator (ESP) and flue gas desulfurization, the plants could comply with the limits specified in the Malaysian Department of Environment (DOE) Scheduled Waste Guideline for bottom ash and fly ash and the Proposed New Environmental Quality (Clean Air) Regulation 201X (Draft).