Attachment
2
DOE/
NETL
Environmental
&
Water
Resources
Program
Mercury
Control
Technology
R&
D
Project
Fact
Sheets
Prepared
by
Department
of
Energy
Office
of
Fossil
Energy
and
National
Energy
Technology
Laboratory
June
2003
Activated
carbon
injection
Full­
scale
field
demonstration
testing
of
powdered
activated
carbon
injection
at
four
power
plants.
Gaston
Bit.
Testing
completed
April
2001.

Mercury
capture
based
on
three
Ontario
Hydro
tests
averaged
from
87
to
90%
with
a
carbon
injection
rate
of
1.5
lbs/
MMacf.

However,
the
mercury
S­
CEM
data
indicated
an
average
capture
of
78%
that
varied
from
36%
to
90%.
Average
COHPAC
inlet
mercury
concentration
was
approximately
11
µ
g/
dncm,
and
40%

of
it
was
elemental.
 
The
variation
in
capture
efficiency
was
attributed
to
changing
coal
and
operating
conditions.
For
example,
the
COHPAC
inlet
mercury
concentration
ranged
from
approximately
5
to
20
µ
g/
dncm.

 
There
was
no
improvement
in
mercury
capture
using
the
spray­
cooling
system.

 
An
undesired
side
effect
of
carbon
injection
was
an
increase
in
the
required
cleaning
frequency
of
the
COHPAC
baghouse.

 
Representativeness:
COHPAC
operated
at
approximately
270
oF
which
is
significantly
different
than
most
fabric
filter
systems
and
may
have
enhanced
mercury
removed.
The
air­
to­
cloth
ratio
was
relatively
high
(
8:
1)
and
a
larger
fabric
filter
may
have
improved
performance
albeit
at
a
higher
cost.

Pleasant
Prairie
PRB
Testing
completed
Nov.
2001.

Norit's
Darco
FGD
activated
carbon
was
used
during
the
three
5­

day
long­
term
tests
at
feed
rates
of
1.6,
3.7,
and
11.3
lb/
MMacf.

Mercury
capture
averaged
approximately
46%,
57%,
and
73%,

respectively.
Average
ESP
inlet
mercury
concentration
was
approximately
17
µ
g/
dncm,
and
85%
of
it
was
elemental.
 
The
carbon
injection
did
not
deteriorate
ESP
performance.

However,
the
ESP
is
relatively
large
(
468
SCA)
and
additional
testing
needs
to
be
conducted
on
other
units
with
smaller
ESPs
to
evaluate
possible
degradation
of
particulate
collection
efficiency.

 
There
was
no
improvement
in
mercury
capture
using
the
spray
cooling
system.

 
The
PAC
injection
rendered
the
fly
ash
unacceptable
for
marketing
as
a
concrete
additive.
This
could
dramatically
affect
the
cost
of
removal
as
well
as
create
a
new
waste
stream.

 
Representativeness:
The
CSESP
at
existing
coal
plants
has
a
median
SCA
of
300.
The
SCA
for
the
demonstration
is
about
50%
larger
than
is
typically
observed
for
existing
plants.

Brayton
Point
Bit.
Testing
completed
Aug.
2002.

The
PAC
injection
was
located
between
the
first
and
second
coldside
ESPs.
Average
mercury
concentration
at
the
inlet
to
the
first
ESP
was
approx.
6
ug/
dncm
of
which
85%
was
particulate­
bound.

During
baseline
testing
the
average
mercury
removal
ranged
from
30
to
90%
across
both
ESPs
and
0
to
10%
across
the
second
ESP.

During
the
parametric
testing
of
Norit's
Darco
FGD
activated
carbon
at
feed
rates
of
3,
7,
10,
15,
and
20
lb./
MMacf
the
mercury
capture
averaged
approx.
25%,
40%,
70%,
75%,
and
90%

respectively
across
the
second
ESP.
 
The
carbon
injection
did
not
deteriorate
ESP
performance.

However,
the
second
ESP
is
relatively
large
(
400
SCA).

 
Representativeness:
The
demonstrated
ESP
configuration
is
unusual
and
could
affect
mercury
removal.
Oxidized
fraction
of
mercury
is
higher
than
typically
observed.

Salem
Harbor
Bit.
Testing
completed
Nov.
2002.

Average
mercury
concentration
at
the
inlet
to
the
ESP
was
approx.

10
ug/
dncm
of
which
95%
was
particulate­
bound.
During
baseline
testing
without
PAC
injection,
average
mercury
capture
was
approximately
90%.
The
high
baseline
mercury
removal
is
attributed
to
high
levels
of
unburned
carbon
(
LOI
was
25
to
30%)

and
low
flue
gas
temperature
(
approx.
270
°
F).
Baseline
mercury
removal
decreased
from
approx.
90%
to
20%
while
increasing
flue
gas
temperature
from
270
to
350
°
F.
 
Increasing
flue
gas
temperature
decreases
mercury
capture.

 
The
NOx
SNCR
system
had
no
effect
on
mercury
capture.

 
Representativeness:
particulate
fraction
of
mercury
is
extremely
high
and
is
well
beyond
normally
observed
levels.
Loss
on
ignition
was
typically
25%
to
30%
and
is
an
order
of
magnitude
higher
than
typical
levels.

Oxidation
reagent
ull­
scale
field
testing
of
a
proprietary
liquid
reagent
to
enhance
mercury
capture
in
two
coalfired
power
plants
equipped
with
wet
FGD
systems.
Endicott
Bit.
Testing
completed
in
2001.

Testing
demonstrated
the
reagent
was
able
to
suppress
mercury
reduction
across
the
wet
FGD
system.
There
was
no
increase
in
elemental
mercury
emissions
during
reagent
usage
compared
to
the
baseline
increase
of
over
40%.
As
a
result,
total
mercury
removal
averaged
76%
during
the
two­
week
verification
testing
compared
to
the
baseline
removal
of
approximately
60%.
There
was
no
significant
change
in
the
level
of
oxidized
mercury
removal
which
averaged
over
90%
both
with
and
without
reagent
usage.
%
Hg
Removal
Species
Baseline
Reagent
Total
60%
76%
 
FGD
mercury
capture
can
be
enhanced
with
the
B&
W/
MTI
proprietary
reagent,
but
not
necessarily
in
all
applications.

 
The
testing
at
Endicott
and
Zimmer
also
included
an
evaluation
of
the
mercury
concentration
in
the
various
byproduct
streams.
One
of
the
most
significant
findings
from
the
test
program
was
that
the
mercury
in
the
wet
FGD
waste
slurry
from
both
plants
was
associated
primarily
with
the
fines
and
not
bound
to
the
gypsum
particles.
Therefore,
it
may
be
possible
to
use
particle
separation
techniques
to
minimize
potential
mercury
contamination
of
the
gypsum.

 
Representativeness:
The
demonstration
configuration
is
typical
of
existing
wet
scrubber
systems.
wet
FGD
system
during
reagent
usage.
Elemental
mercury
increased
by
41%
across
the
wet
FGD
system
during
reagent
usage
compared
to
the
baseline
increase
of
approximately
20%.

There
was
no
significant
effect
on
total
mercury
removal,
which
averaged
51%
during
the
two­
week
verification
testing
compared
to
a
baseline
removal
of
approximately
45%.
The
reagent
had
no
significant
impact
on
the
level
of
oxidized
mercury
removal,

which
averaged
87%
during
reagent
injection.

%
Hg
Removal
Species
Baseline
Reagent
Total
45%
51%

Oxidized
90%
87%

Elemental
(
20%)
(
41%)
which
may
have
impeded
the
reagent
performance.
(
Note:

Endicott
uses
a
limestone
wet
FGD.)

 
The
FGD
scrubber
configuration
for
this
demonstration
is
not
typically
observed
at
existing
plants
equipped
with
wet
FGDs.
Less
than
5%
of
existing
wet
FGD
systems
use
this
configuration.

ow
temperature
operation
ilot­
scale
testing
to
evaluate
the
effect
of
flue
gas
temperature
on
mercury
capture
in
plants
equipped
with
ESPs.

The
pilot
plant
consists
of
an
air
preheater
to
lower
flue
gas
temperature,
a
water­
spray
cooling
system
as
an
optional
method
to
lower
flue
gas
temperature,
an
ESP
to
collect
the
mercury
along
with
the
fly
ash,
and
an
alkaline
sorbent
(
magnesium
hydroxide)
injection
system
to
control
sulfuric
acid
condensation.
Mitchell
Bit.
No
results
available.
Testing
to
begin
May
2003.
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.
The
pilotscale
demonstration
addresses
a
sub­
population
of
power
plant
configurations
having
low
to
medium
high
rank
coal
feed
systems
capable
of
adapting
to
a
lower
flue
gas
operating
temperature.
Full­
scale
demonstration
at
Pleasant
Prairie
indicates
that
this
technology
may
not
provide
significant
improvement
of
mercury
capture
for
low
rank
coals.

Alternative
sorbents
This
project
will
assess
the
mercury
capture
performance
of
several
low­
cost
novel
mercury
sorbents
using
an
actual
flue
gas
slipstream
in
a
small­
scale
pilot
plant
equipped
with
an
ESP
and
baghouse.
The
sorbents
being
tested
include
activated
carbon
samples
from
coal,
biomass,
and
tires;
char
sorbents
made
from
coal;
fly
ashderived
sorbents;
and
zeolite
sorbents.
Powerton
PRB
The
Powerton
slipstream
pilot
testing
included
experimental
sorbents
produced
from
corn
(
CFA),
oil
soot
(
CS80),
waste
tires
(
TDAC),
flyash
(
STI­
B),
a
commercially
available
carbon
made
from
lignite
coal
(
HOK),
and
an
iodine­
impregnated
sorbent
(

CBIAC
Norit's
Darco
FGD
activated
carbon
was
also
tested
as
a
benchmark.
Major
results
from
the
Powerton
pilot
testing
are
as
follows:

o
Initial
screening
tests
were
conducted
at
1.5
lb/
MMacf
and
300
°
F
using
the
COHPAC
configuration.
Similar
mercury
removal
of
approximately
80%
was
achieved
by
the
FGD,

CFA,
CS80,
and
HOK
sorbents.
Mercury
removal
for
the
TDAC
and
STI­
B
were
approximately
60%
and
35%

respectively.
The
CB­
IAC
mercury
removal
was
72%
at
a
lower
injection
rate
of
0.6
lb/
MMacf.
The
CFA
and
HOK
sorbents
were
selected
for
additional
parametric
testing
in
the
COHPAC
configuration
based
on
their
lower
estimated
delivered
cost.

o
The
parametric
and
long­
term
COHPAC
testing
again
showed
similar
performance
of
the
CFA,
HOK,
and
FGD
sorbents.
However,
mercury
removal
was
different
for
the
two
types
of
filter
bag
materials
that
were
tested.
At
2
lb/
MMacf
the
three
sorbents
achieved
approximately
90%

mercury
removal
with
the
Teflon
glass
bag,
but
only
70
­

80%
mercury
removal
with
the
Torcon
bag.
However,
the
difference
in
mercury
removal
may
have
been
a
result
of
the
bag
cleaning
frequency
used
during
the
testing.
Mercury
removal
was
also
similar
for
the
three
sorbents
at
both
300
°
and
350
°
F.

o
Based
on
results
of
the
COHPAC
screening
tests,
the
CFA
and
CS80
were
selected
for
testing
in
the
residence
chamber
(
ESP)
configuration.
The
FGD
and
IAC
sorbents
were
also
included
as
benchmarks.
The
CFA,
CS80,
and
FGD
mercury
removal
was
less
than
50%
for
injection
rates
between
2.5
and
15
lb/
MMacf
at
both
two
and
four
second
residence
times.
The
IAC
sorbent
achieved
approximately
60%

mercury
removal
at
four
seconds
and
45%
at
two
seconds
at
2.5
lb/
MMacf.

o
Preliminary
cost
estimates
for
the
alternative
sorbents
indicate
production
costs
could
be
approximately
50%
less
 
Lower
cost
alternative
sorbents
could
be
capable
of
similar
mercury
removal
performance
compared
to
commercially
available
activated
carbons
in
PRB
coal
applications.

 
Representativeness:
Technique
may
be
sensitive
to
flue
gas
chemistry
and
flue
gas
control
equipment
configuration.
control
performance
of
sorbent
injection
used
in
conjunction
with
the
AHPC.
AHPC
is
a
combination
ESP
and
fabric
filter
designed
to
optimize
fine
particulate
collection.
acf
compared
to
a
baseline
(
no
sorbent)
mercury
collection
efficiency
of
49%.
The
relatively
high
mercury
removal
rates
may
have
occurred
because
the
average
inlet
mercury
speciation
during
the
testing
was
55.4%
particulate,
38.1%

oxidized,
and
only
6.4%
elemental.
This
is
not
considered
typical
for
PRB
coal,
which
normally
have
much
higher
levels
of
elemental
mercury.
Subsequent
analysis
showed
that
the
high
proportion
of
particulate
and
oxidized
mercury
may
have
been
related
to
unexpectedly
high
levels
of
chlorine
in
the
flue
gas,
which
may
have
resulted
from
co­
combustion
of
tirederived
fuel
(
TDF)
during
the
November
2001
test
period.

 
A
second
AHPC
2.5
MW
pilot­
plant
test
was
conducted
at
Big
Stone
in
August
2002
using
a
Belle
Ayr
PRB
coal.
Mercury
speciation
was
17%
particulate,
32%
oxidized,
and
51%

elemental.
Baseline
mercury
removal
ranged
from
0%
to
10%.

Mercury
removal
was
63%
during
activated
carbon
injection
at
1.5
lb/
MMacf
and
without
any
TDF
co­
firing.
There
was
no
adverse
effect
on
AHPC
particulate
collection
performance
during
the
activated
carbon
injection
testing.

 
A
third
AHPC
2.5
MW
pilot­
plant
test
was
conducted
at
Big
Stone
in
November
2002.
Mercury
removal
ranged
from
65%

to
over
90%
during
activated
carbon
injection
at
1.5
lb/
MMacf
and
without
any
TDF
co­
firing.
A
possible
reason
for
the
improved
mercury
removal
in
November
compared
to
the
August
2002
test
is
lower
flue
gas
temperature
of
250
°
F
compared
to
270
°
­
290
°
F.
Supplemental
injection
of
HCl
had
little
or
no
effect
on
mercury
removal.

 
A
small
AHPC
200
acfm
pilot­
scale
test
was
conducted
in
late
2002
using
a
Springfield
high­
sulfur
bituminous
coal.
The
NORIT
Darco
FGD
activated
carbon
was
ineffective
with
average
mercury
removal
at
less
than
15%
for
various
combinations
of
flue
gas
temperature
(
275
°
­
320
°
F)
and
injection
rates.
A
possible
reason
for
the
poor
mercury
removal
was
the
relatively
high
level
of
SO3
(
over
30
ppm)

concentration
in
the
flue
gas.
However,
activated
carbon
injection
in
conjunction
with
the
AHPC
may
be
ineffective
in
high­
sulfur
bituminous
coalfired
applications.

 
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.

Mercury
Control
with
Spray
Dryer
Scrubber
Combined
with
AHPC
or
Baghouse
Using
Elemental
Mercury
Oxidation
Additives
onduct
small
pilot­
scale
testing
to
evaluate
the
effect
of
elemental
mercury
oxidation
additives
to
enhance
mercury
capture
for
North
Dakota
lignitefired
plants
using
a
lime
spray
dryer
combined
with
either
an
AHPC
or
fabric
filter
baghouse.

Oxidation
additives
to
be
tested
include
sodium
chloride,
hydrogen
chloride,
copper
chloride,
and
potassium
chloride.

(
Note:
This
task
was
issued
in
April
2003
as
an
addendum
to
the
Statement
of
Work
for
the
UND/
EERC
AHPC
project.)
Laboratory
pilot
test
Lignite
 
Results
not
available
­
Pilot­
scale
testing
to
be
conducted
third
quarter
2003
and
a
final
report
will
be
issued
by
December
2004.
 
Testing
will
determine
potential
for
chloride
additives
to
enhance
mercury
capture
for
lignite­
fired
power
plants
 
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.

Field
Testing
of
W.
L.
Gore
Filter
Bag
Mercury
Adsorbent
Technology
Conduct
small
pilot­
scale
and
large
pilot­
scale
field
testing
to
evaluate
the
mercury
control
performance
on
North
Dakota
lignite
coal
of
a
new
technology
that
utilizes
an
adsorbent
filter
bag
installed
within
an
existing
baghouse.
The
adsorbent
filter
bag
was
developed
by
W.
L.
Gore
&
Associates
with
funding
by
U.
S.
EPA.
The
technology
is
unique
because
it
does
not
rely
on
continuous
sorbent
injection.
TBD
Lignite
 
Results
not
available
­
Field
slip­
stream
pilot­
plant
testing
to
be
conducted
third
quarter
2003
and
a
final
report
will
be
issued
by
December
2004.
 
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.
ECO
is
a
non­
thermal,
plasma­
based
multipollutant
control
concept
designed
for
the
simultaneous
removal
of
SO2,
NOx,
and
fine
particulate
emissions.
The
process
includes
a
dielectric
barrier
discharge
(
DBD)
reactor
to
oxidize
SO2,
NOx,
and
mercury
for
subsequent
removal
in
an
ammonia­
based
reagent
wet
FGD
system,
which
produces
ammonium
sulfate/
nitrate
fertilizer
as
a
by­
product.
Fine
particulate
and
aerosols
are
captured
in
a
wet
ESP.
2002
resulted
in
an
average
mercury
removal
of
88%
across
the
ECO
pilot
plant.

 
Normal
inlet
flue
gas
elemental
mercury
concentration
is
extremely
low
at
the
Burger
Plant
and
artificial
injection
of
elemental
mercury
into
the
pilot
plant
is
being
tested
to
demonstrate
ECO
capability
to
capture
elemental
mercury.

 
Mercury
captured
in
the
ECO
ammonia
scrubber
liquid
is
removed
using
a
sulfur­
impregnated
activated
carbon
filter
(
Mersorb).
Mercury
levels
in
the
scrubber
liquid
have
been
reduced
from
200
ppb
to
less
than
the
limit
of
detection
(
approx.
20
ppb).
95%,
there
was
some
apparent
reduction
of
oxidized
mercury
to
elemental
mercury
within
the
wet
FGD
system.

 
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.

Alternative
sorbents
onduct
bench­
scale
and
pilot­
scale
testing
to
assess
the
mercury
capture
performance
of
calcium­
based
sorbents
and
oxidizing
agents
as
an
alternative
to
commercially
available
activated
carbons.
ARCADIS
has
developed
two
proprietary
calciumbased
sorbents
that
could
provide
for
the
simultaneous
removal
of
both
mercury
and
SO2
from
coal­
fired
power
plants.
One
sorbent
consists
of
a
hydrated
lime,
Ca(
OH)
2,
with
an
oxidant
and
the
other
sorbent
consists
of
a
silica­
modified
calcium,
CaSiO3,
with
an
oxidant.
The
oxidant
is
intended
to
enhance
overall
sorbent
mercury
capture
by
oxidizing
gas­
phase
elemental
mercury.

Other
calcium­
based
sorbents
such
as
lime
will
be
used
with
alternative
oxidants
such
as
injected
chlorine
compounds,
sodium
tetra­
sulfide,
or
high
iron
oxide
fly
ash
from
the
bituminuous
coal.

These
oxidants
will
be
tested
with
a
lime
sorbent
on
a
subbituminous
Powder
River
Basin
coal
that
characteristically
has
a
high
fraction
of
elemental
mercury.
laboratory
pilot
test
various
o
The
initial
pilot­
plant
testing
of
two
proprietary
calcium­
based
sorbents
with
an
oxidant
additive
and
a
bituminous
coal
showed
both
to
be
ineffective
in
enhancing
the
oxidation
and
capture
of
elemental
mercury
and
achieved
overall
mercury
removal
of
only
25
to
50%.
Follow­
up
testing
with
an
ordinary
hydrated
lime
sorbent
without
the
oxidant
was
able
to
remove
80
to
90%

of
the
mercury
which
occurred
primarily
across
the
sorbent
dust
cake
collecting
on
the
baghouse
filter
bags.
Approximately
30
to
35%
mercury
capture
occurred
"
in­
flight"
prior
to
the
baghouse.

o
SRI
and
PS
Analytical
developed
a
"
spike
and
recovery"

system
to
reduce
mercury
S­
CEM
measurement
uncertainty.
A
known
concentration
mercury
"
spike"
is
introduced
in
the
sampling
probe
in
order
to
increase
the
concentration
of
mercury
in
the
sampled
flue
gas.

o
Pilot­
scale
testing
with
a
kaolinite
(
Al2O3.2SiO2.
H2O)
adsorbent
and
a
Choctaw
bituminous
coal
was
ineffective
for
mercury
capture
at
injection
temperatures
that
ranged
from
1100
°
to
2100
°
F.

o
SRI
conducted
pilot­
scale
testing
of
chlorine
gas
(
Cl2)
injection
in
order
to
evaluate
the
ability
of
HCl
to
promote
mercury
oxidation
and
adsorption
with
PRB
coal
ash.
Chlorine
injection
through
the
burner
was
effective
in
increasing
the
oxidized
mercury
from
less
than
20%
to
over
50%
and
increasing
mercury
adsorption
on
the
PRB
coal
ash
from
less
than
5%
to
over
30%.
However,
chlorine
injection
upstream
of
the
air
heater
was
ineffective.

o
SRI
conducted
pilot­
scale
testing
to
condition
PRB
coal
with
a
high­
iron,
low­
chlorine
bituminous
coal.
As
a
result,
PRB
coal
ash
composition
was
found
to
be
more
important
than
flue
gas
chlorine
content
relative
to
mercury
oxidation
and
capture.

With
PRB
coal
only,
there
was
less
than
15%
oxidized
mercury
at
the
baghouse
inlet.
However,
a
coal
blend
with
10%

bituminous
and
90%
PRB
coal
resulted
in
greater
than
50%

oxidized
mercury
at
the
baghouse
inlet.

o
SRI
also
conducted
tests
to
condition
the
PRB
coal
ash
with
injection
of
high­
iron
bituminous
coal
ash
and
hydrated
lime
at
the
baghouse
inlet.
The
rate
of
ash/
lime
injection
was
approximately
equivalent
to
the
PRB
ash
loading.
Three
ash/
lime
injection
ratios
were
tested:
100%
ash;
50%
ash/
50%

lime;
and
20%
ash/
80%
lime.
The
mercury
oxidation
across
the
baghouse
increased
from
a
baseline
of
approximately
60%
to
80%
with
100%
high­
iron
bituminous
ash
injection.
The
increase
in
mercury
oxidation
was
less
with
the
ash/
lime
blends.

o
Increasing
the
baghouse
inlet
flue
gas
temperature
from
260
°
to
300
°
F
increased
oxidized
mercury
while
burning
100%
PRB
coal.
The
oxidized
mercury
increased
less
than
10
percentage
points
at
the
baghouse
inlet,
but
increased
approximately
30
percentage
points
at
the
baghouse
outlet.
However,
this
temperature
effect
was
not
significant
with
the
bituminous/
PRB
coal
blend.
o
The
mercury
capture
effectiveness
for
PRB
coals
might
be
enhanced
using
either
a
chlorine­
based
additive
to
the
furnace,
or
fuel
blending
with
high­
iron
bituminous
coal.

However,
additional
evaluation
is
necessary.

o
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.
oxidation
of
elemental
mercury
in
the
combustion
flue
gas.
Increasing
gas­
phase
oxidized
mercury
would
enhance
overall
mercury
capture
in
plants
equipped
with
wet
FGD
systems.

The
four
catalysts
being
tested
are
1)
Pd
#
1,
a
commercial
palladium
catalyst;
2)
SCR,
a
Siemens
commercial
NOx
catalyst
using
titaniumvanadium
3)
Carbon
#
6,
a
tire­
derived
activated
carbon;
and
4)
SBA
#
5,
an
active
fly
ash.
elemental
mercury
across
the
SCR
catalyst
dropped
from
67%

to
28%
after
62
days
in
service.
Subsequent
inspection
of
the
two
catalysts
indicated
that
a
buildup
of
fly
ash
in
the
pilot
test
chamber
likely
caused
the
drop
in
oxidation
rather
than
a
loss
of
catalyst
activity
since
mercury
oxidation
was
restored
after
cleaning
in
January
2003.

o
A
sonic
horn
is
being
tested
to
prevent
the
buildup
of
fly
ash
in
the
Pd
#
1
chamber
and
will
be
installed
on
the
remaining
chambers
if
effective.

o
Testing
of
the
SBA
#
5
catalyst
began
in
December
2002
and
oxidation
of
elemental
mercury
was
75%
when
first
measured
in
late
January
2003.

o
The
Carbon
#
6
catalyst
testing
is
being
postponed
until
the
fly
ash
buildup
problem
is
corrected.

o
There
was
some
concern
that
the
catalysts
might
also
lead
to
oxidation
of
SO2
and
NO
which
could
produce
undesirable
balance­
of­
plant
effects.
However,
there
is
no
apparent
oxidation
of
SO2
to
SO3
and
approximately
7%
oxidation
of
NO
to
NO2.

o
Pilot
testing
should
be
completed
by
December
2003.
FGD
system.
However,
further
evaluation
is
required.

o
Representativeness:
Technique
may
be
sensitive
to
flue
gas
chemistry
and
flue
gas
control
equipment
configuration.

J.
K.
Spruce
PRB
Results
not
available.
Testing
at
CPS
J.
K.
Spruce
Plant
is
scheduled
to
begin
in
the
third
quarter
2003.
 
Representativeness:
Technique
may
be
sensitive
to
flue
gas
chemistry
and
flue
gas
control
equipment
configuration.

Characterization
Field
test
program
will
determine
the
effect
NOx
SCR
and
SNCR
controls
have
on
the
speciation
of
mercury
in
the
combustion
flue
gas
and
resultant
enhancement
of
mercury
captured
in
downstream
pollution
control
equipment.
2001
­
6
plants
2002
­
4
plants
PRB
and
Bit.
The
2001
field­
testing
was
conducted
at
six
coal­
fired
power
plants.
Four
of
the
plants
are
equipped
with
SCR
controls,
one
plant
uses
SNCR
control,
and
one
plant
uses
ammonia
and
sulfur
trioxide
for
ash
conditioning
to
improve
particulate
control.

Field­
testing
was
conducted
in
2002
at
two
of
the
2001
SCR
equipped
plants
and
two
additional
plants
with
SCRs.
Overall
test
results
are
as
follows:

 
SNCR
and
NH3/
SO3
flue
gas
conditioning
did
not
affect
mercury
oxidation.

 
For
the
bituminous
plants,
the
increase
in
oxidized
mercury
across
the
SCR
varied
significantly
from
11
to
70
percentage
points.
The
oxidized
mercury
at
the
downstream
pollution
control
device
(
PCD)
inlet,
increased
from
­
1
to
37
percentage
points
with
an
average
of
17%.
However,
for
the
two
sites
with
minimal
SCR
oxidation,
the
non­
elemental
mercury
was
greater
than
90%
both
with
and
without
the
SCR.

 
SCR
catalyst
did
not
significantly
promote
the
oxidation
of
mercury
for
the
one
PRB
test
site.
The
oxidized
mercury
increased
20
percentage
points
across
the
SCR,
but
was
unchanged
at
the
PCD
inlet.

 
SCR
catalysts
promote
mercury
capture
in
wet
FGD
systems
and
possibly
reduce
the
re­
emission
of
elemental
mercury.
For
the
three
plants
with
SCR
and
wet
FGD,
mercury
removal
was
84
­
92%
(
average
89%)
with
SCR
operation
and
43
­
51%

(
average
48%)
without
SCR
operation.

 
SCR
size,
as
measured
by
space
velocity,
appeared
to
have
a
minimal
affect
on
mercury
oxidation
across
the
SCR.
There
was
no
significant
difference
in
non­
elemental
mercury
at
the
SCR
outlet
or
PCD
inlet
for
the
five
bituminous
plants.

 
Based
on
results
from
the
two
plants
tested
in
2001
and
2002,
it
is
uncertain
whether
SCR
catalyst
aging
affects
mercury
oxidation.
The
increase
in
oxidized
mercury
across
the
SCR
at
site
S2
decreased
from
43
percentage
points
in
2001
to
33
percentage
points
in
2002.
However,
there
was
no
change
in
oxidized
mercury
at
the
PCD
inlet
which
remained
approx.

97%.
The
increase
in
oxidized
mercury
across
the
SCR
at
site
S4
decreased
from
70
percentage
points
in
2001
to
29
percentage
points
in
2002.
Again
however,
there
was
no
change
in
oxidized
mercury
at
the
PCD
inlet
which
was
93%
in
2001
and
95%
in
2002.
 
The
results
from
the
2001and
2002
field­
testing
are
mixed
and
demonstrate
that,
while
oxidation
of
mercury
across
SCR
systems
can
occur,
the
oxidation
is
a
complex
process
that
may
be
dependent
on
several
variables
such
as
coal
properties,
furnace
combustion
conditions,
and
SCR
catalyst
factors
including
type,
sizing,
and
age.

 
Representativeness:
The
elemental
mercury
fraction
of
total
mercury
was
typically
higher
than
ICR
elemental
mercury
fractions
for
similar
configurations
without
SCR
turned
on.

Only
one
demonstration
site
for
low
rank
coal
power
plant
equipped
with
an
SCR.
technologies
for
utilities
that
burn
lignite
coal.

The
first
phase
of
the
project,
scheduled
for
2002­

2003,
is
to
conduct
bench­
scale
and
pilot­
scale
evaluation
for
screening
of
potential
sorbents.
The
second
phase
of
the
project,
scheduled
for
2003­

2004,
is
to
conduct
full­
scale
field
tests
of
the
selected
sorbents
at
a
lignite­
fired
power
plant
(
Saskatchewan
Power's
Poplar
River
Power
Station).
Bench­
scale
testing
using
a
simulated
lignite
coal
flue
gas
was
conducted
using
several
carbon
sorbents
prepared
from
three
lignite
coals,
a
calcium
silicate,
and
NORIT's
DARCO
FGD
activated
carbon.
Pilot­
scale
testing
using
two
lignite
coals
(
Poplar
River
and
Freedom
coal
mines)
was
conducted
with
EERC's
550,000
Btu/
hr
combustor
and
four
particulate
control
configurations:
1)
ESP,
2)
FF,
3)
combined
ESP
&

FF,
and
4)
Advanced
Hybrid.
significantly
better
than
the
same
carbon
sorbents
activated
at
750oC.
The
DARCO
FGD
and
800oC
activated
Luscar
charderived
sorbents
were
selected
for
further
pilot­
scale
testing.

Results
from
the
pilot­
scale
testing
are:

 
The
Poplar
River
coal
had
a
higher
mercury
concentration
than
the
Freedom
coal,
but
both
coals
resulted
in
similar
speciation
with
85%
elemental
and
15%
oxidized
mercury.

 
Lignite
coal
requires
a
higher
sorbent
feed
rate
for
similar
mercury
removal
compared
to
full­
scale
data
for
bituminous
coal.
To
achieve
70%
mercury
removal,
the
best
Luscar
sorbent
injection
rates
were
17.1,
7.8,
and
2.92
lb/
MMacf
for
the
ESP,
FF,
and
combined
ESP­
FF
configurations
respectively.

 
Mercury
removal
was
approx.
10
­
15
percentage
points
higher
for
the
Freedom
coal
compared
to
the
Poplar
River
coal
for
the
ESP­
only
configuration.

 
Mercury
removal
was
approx.
10
­
15
percentage
points
lower
for
both
the
Freedom
and
Poplar
River
coals
when
the
flue
gas
temperature
was
increased
from
300
°
to
400
°
F
for
all
particulate
control
configurations.
importance
of
hydrogen
chloride
in
the
flue
gas,
which
apparently
conditions
the
sorbents.
Further
evaluation
is
required.

 
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.

ElectroCore
The
ElectroCore
is
an
electrically
enhanced
mechanical
separator
designed
to
be
retrofitted
downstream
of
an
existing
ESP
to
optimize
fine
particulate
collection.
The
ElectroCore
process
first
pre­
charges
the
ash
particles
and
then
uses
combined
electrical
and
centrifugal
forces
to
separate
the
flue
gas
into
"
dirty"
and
"
clean"
gas
streams.
The
dirty
gas
stream
can
either
be
recirculated
to
the
inlet
of
the
upstream
ESP
or
diverted
to
a
polishing
ESP
or
FF.
Gaston
Bit.
The
pilot­
scale
testing
was
conducted
from
November
2001
through
February
2002.
Preliminary
test
results
indicate
the
ElectroCore
process
captures
approximately
90%
of
the
total
mercury
at
a
PAC
injection
rate
of
7
lb/
MMacf.
A
final
report
on
the
mercury
testing
phase
of
the
project
is
not
yet
available.
 
Insufficient
test
data
available
to
evaluate
the
mercury
capture
effectiveness
of
the
ElectroCore
technology.
Further
evaluation
is
required.

 
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.

THIEF
The
THIEF
process
(
U.
S.
Patent
No.
6,521,021)

removes
mercury
from
coal
combustion
flue
gas
by
adsorption/
absorption
onto
thermally
activated
sorbent
produced
in­
situ.
The
sorbent
consists
of
semi­
combusted
coal,
which
is
extracted
from
the
furnace
and
then
injected
into
the
flue
gas
downstream
of
the
air
preheater.
The
thermally
activated
sorbent
reacts
with
the
mercury
and
is
removed
from
the
flue
gas
by
the
downstream
particulate
control
device.
laboratory
pilot
test
Bit.
&

PRB
The
in­
situ
produced
sorbent
is
not
as
reactive
as
commercially
available
activated
carbon,
but
pilot­
scale
testing
indicates
that
mercury
removal
efficiencies
of
up
to
70%
are
achievable.
 
Further
evaluation
is
required.

 
Representativeness:
Scale­
up
of
the
results
from
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.

GP­
254
he
GP­
254
process
(
U.
S.
patent
pending)
uses
253.7­
nm
ultraviolet
radiation
to
induce
components
of
flue
gas
to
react
with
elemental
mercury
and
subsequently
cause
an
increase
in
the
fraction
of
oxidized
mercury.
The
oxidized
mercury
species
can
then
be
captured
near
the
radiation
zone
or
in
downstream
particulate
control
or
wet
FGD
pollution
control
equipment.
laboratory
bench­
scale
Small­
scale
laboratory
testing
using
simulated
flue
gases
have
been
used
to
demonstrate
the
process.
 
Representativeness:
Scale­
up
of
the
results
from
laboratory
demonstration
must
be
reconciled
based
on
past
experience
with
flue
gas
control
technology
of
trace
species.

Activated
carbon
injection
onduct
a
one­
year
long­
term
performance
evaluation
of
the
impact
of
powdered
activated
carbon
injection
on
the
COHPAC
fabric
filter
particulate
collection
system
at
Alabama
Power's
E.
C.
Gaston
Plant.
The
long­
term
testing
will
include
six­
month
PAC
injection
with
the
existing
COHPAC
filter
bags
and
six­
month
PAC
injection
with
new
high­
permeation
filter
bags.
Gaston
Bit.
Preliminary
baseline
test
results
include:
1)
higher
COHPAC
cleaning
frequency
compared
to
April
2001
Phase
I
tests,
2)
large
variation
(
0
to
90%)
in
baseline
mercury
removal,
and
3)
higher
carbon
content
in
COHPAC
hopper
ash
compared
to
Phase
I
tests.

Based
on
results
of
optimization
testing,
the
PAC
injection
rate
was
lowered
from
1.5
to
0.3
lb/
MMacf.
Average
mercury
removal
varied
from
70
to
95%
at
0.3
lbs/
MMacf
PAC
injection
rate
during
May
2003
optimization
testing.
 
Of
particular
concern
during
PAC
injection
is
the
increased
cleaning
frequency
of
the
COHPAC
which
could
adversely
affect
filter
bag
life.

 
Representativeness:
This
demonstration
should
provide
Combustion
modification
RD
Green
Bit.
Results
not
available.
both
SCR
and
FGD
systems.
The
objective
of
the
study
is
to
measure
the
level
of
mercury
oxidation
across
the
SCR
and
subsequent
removal
in
the
downstream
FGD
system.
The
27­
month
long
program
will
include
testing
at
five
plants
equipped
with
an
SCR
and
wet
limestone
FGD,

three
plants
with
an
SCR
and
wet
lime
FGD,
and
two
plants
with
an
SCR
and
dry
lime
FGD.

Characterization
Characterize
the
speciation
of
mercury
in
the
stack
plume
of
a
coal­
fired
power
plant.
The
test
will
include
simultaneous
mercury
measurements
in
the
stack
and
stack
plume
using
aircraft
instruments.

The
in­
stack
and
stack
plume
measurements
will
be
compared
to
determine
whether
the
speciation
of
mercury
changes
as
it
is
transported
downwind
in
the
plume.
In
addition,
a
plume
dilution
sampling
device
is
being
used
in
an
attempt
to
simulate
the
cooling
and
dilution
processes
that
occur
in
the
stack
plume.
If
results
of
the
plume
dilution
sampling
device
are
comparable
to
the
stack
plume
measurements
it
could
be
used
to
estimate
the
mercury
speciation
changes
for
other
plants.
Pleasant
Prairie
PRB
Results
not
available.
 
If
oxidized
mercury
is
reduced
to
elemental
mercury
within
the
stack
plume,
there
should
be
less
concern
with
local
"
hot
spots"
of
mercury
deposition
and
perhaps
less
environmental
objections
to
a
mercury
emissions
trading
program.

Characterization
Characterize
the
speciation
of
mercury
in
the
stack
plume
of
a
coal­
fired
power
plant.
Bowen
Bit.
Results
not
available.
 
See
above
comment.

Characterization
onduct
a
six­
month­
long
pilot­
scale
mercury
speciation
test
for
five
commercially­
available
NOx
SCR
catalysts
using
a
flue
gas
slipstream.

Parametric
testing
will
evaluate
the
effect
of
space
velocity
(
residence
time)
and
ammonia
feed
rate
on
mercury
oxidation
across
the
SCR
catalysts.
Rockport
PRB
Preliminary
results
from
the
initial
mercury
speciation
testing
are
under
review.
Some
general
observations
from
the
S­
CEM
measurements
are:
1)
mercury
oxidation
ranged
from
approx.
0%

to
50%
across
the
five
catalysts
at
a
space
velocity
of
5,700
hr­
1,
2)

mercury
oxidation
increased
to
60%
to
80%
without
ammonia
feed,
3)
an
unexplained
10%
to
40%
reduction
of
total
mercury
was
measured
across
the
catalysts,
4)
mercury
oxidation
decreases
as
space
velocity
increases.
 
Mercury
oxidation
can
vary
significantly
across
NOx
SCR
catalysts
in
PRB
coal
applications.
Further
evaluation
is
required.

Characterization
valuation
of
the
potential
release
of
mercury
and
other
air
toxic
elements
associated
with
the
disposal
and
commercial
use
of
coal
utilization
byproducts
Laboratory
and
field­
testing
will
be
conducted
on
various
ash
and
FGD
CUBs
from
conventional
and
advanced
pollution
control
systems.
The
potential
release
mechanisms
to
be
evaluated
include
leaching,
vaporization
at
ambient
and
elevated
temperature,
and
biologically
induced
releases.
Various
Bit.
PRB
Lignite
The
three­
year
project
will
be
completed
by
December
2005.

Results
not
available.
 
Results
from
this
testing
will
be
critical
in
determination
of
the
cost
of
disposal
for
CUBs
associated
with
mercury
control
technologies.
Rank
Activated
carbon
injection
Conduct
full­
scale
parametric
testing
with
four
activated
carbons,
including
one
that
was
iodine
impregnated.
Testing
conducted
at
Great
River
Energy's
60
MW
Stanton
Unit
10
which
burns
North
Dakota
lignite
fuel
and
uses
a
lime
spray
dryer
and
baghouse
for
SO2
and
particulate
control.

Reference:
Sjostrom,
S.,
et.
al.;
"
Full­
Scale
Evaluation
of
Mercury
Control
at
Great
River
Energy's
Stanton
Generating
Station
Using
Injected
Sorbents
and
a
Spray
Dryer/
Baghouse"

Presented
at
Air
Quality
III
Conference
in
Arlington,
VA,
September
9­
12,
2002
Stanton
Lignite
Testing
conducted
in
April
2002
 
SD
inlet
mercury
concentration
ranged
from
5.5
to
9.5
ug/
Nm3
and
was
primarily
elemental
mercury.
No
measurable
baseline
mercury
removal.

 
Average
mercury
removal
with
the
three
untreated
sorbents
at
an
injection
rate
of
6.1
lb/
MMacf
was
81%.
The
three
untreated
sorbents
were
similar
in
performance.

 
Average
mercury
removal
with
iodine
impregnated
carbon
(
IAC)
injection
at
0.7
lb/
MMacf
was
96%.
(
Note:
The
IAC
costs
$
7/
lb
versus
$
0.5/
lb
for
regular
PAC.)

 
Mercury
removal
varies
across
the
BH
during
the
cleaning
cycle.
For
example,
at
a
PAC
injection
rate
of
6.4
lb/
MMacf
mercury
removal
was
90%
before
bag
cleaning
and
only
70%

after
bag
cleaning.

 
There
was
no
effect
on
baghouse
cleaning
frequency
or
pressure
drop
during
PAC
injection.

 
Sodium
chloride
(
NaCl)
injected
in
the
boiler
increased
oxidized
mercury
from
less
than
10%
to
18%
which
increased
mercury
removal
from
between
69
and
77%
to
over
90%
during
regular
PAC
injection.
 
Lime
spray
dryers
restrict
the
mercury
removal
performance
with
untreated
PAC
injection
in
lignite
coal
applications
due
possibly
to
the
SD
removal
of
HCl
from
the
flue
gas.

 
The
mercury
removal
performance
of
PAC
injection
can
be
enhanced
in
lignite
coal
applications
with
the
use
of
iodine
impregnated
PACs,
or
the
addition
of
chlorides
to
the
flue
gas.

Chloride
salt
injection
Conduct
full­
scale
testing
of
chloride
salt
injection
into
a
North
Dakota
lignite­
fired
boiler
in
order
to
increase
the
oxidized
mercury
content
of
the
flue
gas
and
enhance
mercury
removal
across
a
lime
spray
dryer
and
baghouse.
Three
chloride
salts
were
tested.
The
chloride
salt
solutions
were
injected
into
the
boiler
above
the
burners.
Testing
conducted
at
Great
River
Energy's
60
MW
Stanton
Unit
10.
Reference:

EPRI
"
The
Evaluation
of
Chemical
Additives
for
Mercury
Emissions
Control
at
Great
River
Energy's
Stanton
Station.
Final
Report
January
2003.
Richardson,
C.,
et.
al.;
"
Chemical
Addition
for
Mercury
Control
in
Flue
Gas
Derived
from
Western
Coals".
Presented
at
Mega
Symposium
in
Washington,
DC,
May
19­
22,
2003.
Stanton
Lignite
Testing
conducted
in
April
2002
 
Baseline
SD
inlet
mercury
concentration
ranged
from
5.4
to
7.2
ug/
Nm3
and
was
less
than
10%
oxidized
mercury
with
3­
14%

mercury
removal
across
the
SD­
BH.
Flue
gas
HCl
was
approximately
1
ppm
at
the
SD
inlet
and
undetectable
at
the
BH
inlet.

 
Salt
feed
rate
at
0.2%
chloride
relative
to
lignite
burn
rate.
HCl
ranged
from
80
to
110
ppm
at
the
SD
inlet
and
approximately
95%
was
removed
across
the
SD.

 
At
the
same
80
ppm
HCl
concentration,
mercury
oxidation
with
the
four
salts
varied:
Salt
A
­
40%,
Salt
B
­
47%,
Salt
C
­
57%.

 
Mercury
removal
across
the
SD­
BH
also
varied:
Salt
A
­
none,

Salt
B
­
40%,
and
Salt
C
­
50%.

 
Salt
injection
increased
cleaning
frequency
of
the
BH
due
to
increased
pressure
drop.

 
Salt
injection
apparently
led
to
some
air
heater
pluggage
based
on
increased
pressure
drop
across
the
air
heater.

 
Long­
term
impact
on
boiler
slagging
and
corrosion
are
unknown.
 
Chloride
salt
injection
can
increase
mercury
oxidation
and
enhance
mercury
removal
across
the
SD­
BH
in
lignite­
fired
applications.
However,
mercury
oxidation
and
removal
varied
among
the
three
chloride
salts
tested.
Despite
increased
mercury
oxidation,
one
of
three
salts
tested
did
not
improve
mercury
removal
across
the
SD­
BH.
Further
evaluation
is
required.

 
Balance­
of­
plant
impacts
resulting
from
chloride
salt
injection
need
further
evaluation.

Activated
carbon
injection
Conduct
full­
scale
parametric
testing
with
four
activated
carbons,
including
one
that
was
iodine
impregnated.
(
Note:
Same
sorbents
as
tested
at
GRE
Stanton
Unit
10.)
Testing
conducted
at
Minnesota
Power's
55
MW
Laskin
Energy
Center
Unit
2
which
burns
PRB
coal
and
uses
a
wet
particulate
scrubber
(
WPS)
for
control
of
particulate
and
SO2.

Reference:
Sjostrom,
S.,
et.
al.;
"
Full­
Scale
Evaluation
of
Mercury
Control
Across
A
Wet
Particulate
Scrubber".
Presented
at
Mega
Symposium
in
Washington,
DC,
May
19­
22,
2003.
Laskin
PRB
Testing
conducted
in
August
2002
 
Baseline
mercury
removal
across
the
WPS
ranged
from
10
to
40%.
The
WPS
inlet
mercury
was
70%
elemental.

 
The
three
untreated
sorbents
achieved
less
than
15%
additional
mercury
removal
across
the
WPS
at
an
injection
rate
of
up
to
12
lb/
MMacf.
(
Note:
In­
flight
mercury
capture
prior
to
the
WPS
was
measured
at
20
to
25%
indicating
that
some
of
the
captured
mercury
may
be
released
in
the
WPS.)

 
The
iodine
impregnated
sorbent
achieved
54%
mercury
removal
across
the
WPS
at
an
injection
rate
of
11
lb/
MMacf.
(
Note:

Inflight
capture
prior
to
the
WPS
accounted
for
most
of
the
mercury
removal
and
there
was
no
apparent
release
in
the
WPS.)

 
A
brief
PAC
injection
test
was
also
conducted
with
a
blended
coal
burn
(
33%
bituminous,
66%
PRB).
However,

interpretation
of
data
was
difficult
due
to
a
boiler
upset.

Elemental
mercury
ranged
from
0
to
49%
and
mercury
removal
ranged
from
0
to
61%.
 
The
wet
particulate
scrubber
restricts
the
mercury
removal
performance
with
untreated
PAC
injection
in
PRB
coal
applications.

 
The
mercury
removal
performance
of
PAC
injection
can
be
enhanced
in
PRB
coal
applications
with
the
use
of
iodine
impregnated
PAC.
oxidized
mercury
content
of
the
flue
gas
and
enhance
mercury
removal
across
a
wet
particulate
scrubber
(
WPS).
Two
chloride
salts
were
tested.

The
chloride
salts
were
added
directly
to
the
coal.

(
Note:
At
the
Stanton
Plant
a
salt
solution
was
injected
into
the
boiler
above
the
burners.)
Testing
conducted
at
Minnesota
Power's
55
MW
Laskin
Energy
Center
Unit
2.

Reference:
Richardson,
C.,
et.
al.;
"
Chemical
Addition
for
Mercury
Control
in
Flue
Gas
Derived
from
Western
Coals".
Presented
at
Mega
Symposium
in
Washington,
DC,
May
19­
22,
2003.
0.10%
chlorine.
At
the
0.20%
feed
rate
with
Salt
A,
the
HCl
in
the
flue
gas
was
over
70
ppm.

 
At
the
0.20%
feed
rate
with
Salt
A,
mercury
oxidation
was
over
80%.
Salt
D
resulted
in
slightly
better
oxidation
than
Salt
A
at
similar
HCl
concentrations.

 
Salt
A
did
not
increase
mercury
removal
across
the
WPS.

(
Similar
to
Stanton
results
with
the
Salt
A
solution.)

 
Salt
D
achieved
30%
mercury
removal
across
the
WPS
at
an
HCl
concentration
of
36
ppm
and
50%
mercury
oxidation.

 
Salt
injection
increased
stack
opacity.

 
Salt
injection
resulted
in
excessive
solid
deposition
on
boiler
tubes.
varied
among
the
two
chloride
salts
tested.
Despite
increased
mercury
oxidation,
one
of
two
salts
tested
did
not
improve
mercury
removal
across
the
WPS.
Further
evaluation
is
required.

 
Balance­
of­
plant
impacts
resulting
from
chloride
salt
injection
need
further
evaluation.

Stanton
Lignite
Testing
began
in
October
2001
 
Tested
10­
foot
long
gold­
coated
plate
(
Type
1
substrate)
with
½
"
spacing
located
downstream
of
spray
dryer
and
baghouse.

Gas
velocities
ranged
from
16
to
40
ft/
sec.
Initial
mercury
removal
was
89%.
After
4582
hours
exposure
the
mercury
removal
was
39%.

 
Three
types
of
stainless
steel
substrates
(
Types
1,
2,
&
3)
were
also
evaluated
and
results
indicated
significant
differences
in
mercury
capture
between
the
substrates.

 
MerCAP
testing
located
upstream
of
the
spray
dryer
and
baghouse
resulted
in
insignificant
mercury
removal.
 
MerCAP
mercury
removal
might
be
effective
in
scrubbed
gas
applications
but
appears
to
be
ineffective
in
unscrubbed
applications.

Coal
Creek
Lignite
Testing
began
in
December
2002
 
Tested
10­
foot
long
gold­
coated
plate
(
Type
2
substrate)
with
1'

spacing
located
downstream
of
ESP.
Mercury
removal
was
only
10%
at
a
velocity
of
43
ft/
sec.
However,
the
percentage
of
oxidized
mercury
increased
from
the
probe
inlet
to
the
probe
outlet.
 
MerCAP
mercury
removal
might
be
ineffective
in
unscrubbed
applications.

 
Gold
might
be
effective
oxidation
catalyst
in
lignite
coal
application.

Pleasant
Prairie
PRB
Testing
began
in
February
2002
 
Tested
10­
foot
long
gold­
coated
plate
(
Type
1
substrate)
with
½
'
spacing
located
downstream
of
ESP.
Mercury
removal
was
initially
low
and
ranged
between
0
and
20%
over
5000
hours
exposure.

 
Tested
10­
foot
long
gold­
coated
plate
(
Type
3
substrate)
with
1'

spacing
located
downstream
of
ESP.
Mercury
removal
was
only
24%
at
a
velocity
of
40
ft/
sec.
However,
the
percentage
of
oxidized
mercury
increased
from
35%
at
the
probe
inlet
to
78%

at
the
probe
outlet.
 
MerCAP
mercury
removal
might
be
ineffective
in
unscrubbed
applications.

 
Gold
might
be
effective
oxidation
catalyst
in
PRB
coal
application.

MerCAP
EPRI
is
conducting
slipstream
tests
at
four
power
plants
of
a
new
mercury
control
technology
known
as
MerCAP
(
Mercury
Control
Adsorption
Processes).
The
MerCAP
process
uses
a
sorbentcoated
plate
or
tube
structure
which
can
be
retrofitted
into
existing
ductwork
downstream
of
the
air
heater.
Sorbents
tested
have
been
both
activated
carbon
and
gold.
The
sorbent
structure
would
be
periodically
regenerated
to
recover
the
captured
mercury.
The
slipstream
tests
used
a
10­

foot
long
gold­
coated
plate
with
various
plate­

toplate
spacing
and
coating
thickness.

Reference:
Sjostrom,
S.,
et.
al.;
"
Development
and
Demonstration
of
Mercury
Control
by
Adsorption
Process
(
MerCAPTM)"
Presented
at
Mega
Symposium
in
Washington,
DC,
May
19­
22,
2003.
Laskin
PRB
Testing
began
in
August
2002
 
Tested
10­
foot
long
gold­
coated
plate
(
Type
2
substrate)
with
1'

spacing
located
upstream
of
wet
particulate
scrubber.
Mercury
removal
was
only
20%
at
a
velocity
of
34
ft/
sec.
The
MerCAP
probe
became
partially
plugged
with
fly
ash
after
1120
hours
operation
and
mercury
removal
was
only
9%.
The
percentage
of
oxidized
mercury
only
increased
from
11%
at
the
probe
inlet
to
26%
at
the
probe
outlet.
 
MerCAP
mercury
removal
might
be
ineffective
in
unscrubbed
applications.

 
Gold
was
not
as
effective
as
oxidation
catalyst
in
this
PRB
coal
application.
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Full­
Scale
Testing
of
Mercury
Control
Via
Sorbent
Injection
(
DE­
FC26­
00NT41005)

 
Objective
Conduct
full­
scale
field
demonstration
testing
of
sorbent
injection
technology
for
the
control
of
mercury
emissions
from
coal­
fired
power
plants.
The
full­
scale
testing
will
provide
design,
performance,
and
cost
information
which
can
be
used
for
future
full­
scale
commercial
applications
of
the
technology.

 
Sponsors
The
project
is
funded
by
NETL
and
a
partnership
team
headed
by
ADA
Environmental
Solutions.
The
partnership
team
includes
EPRI,
Alabama
Power
Company,
PG&
E
National
Energy
Group,
and
Wisconsin
Energy
along
with
several
others.

 
Background
Previous
laboratory,
bench,
and
pilot­
scale
studies
have
shown
that
powdered
activated
carbon
(
PAC)
injection
could
be
an
effective
technology
for
the
control
of
mercury
emissions
from
coal­
fired
power
plants.
Full­
scale
testing
of
PAC
injection
is
necessary
to
demonstrate
cost
and
performance
for
various
coal
rank
and
particulate
control
device
combinations.

 
Project
Description
The
full­
scale
demonstration
testing
is
being
conducted
at
the
following
four
power
plants:
Alabama
Power's
270
MW
E.
C.
Gaston
Unit
3
which
burns
low
sulfur
bituminous
coal
and
uses
a
hot­
side
ESP
and
Compact
Hybrid
Particulate
Collector
(
COHPAC)
fabric
filter
for
particulate
control;
Wisconsin
Energy's
600
MW
Pleasant
Prairie
Unit
2
which
burns
a
Powder
River
Basin
subbituminous
coal
and
uses
a
cold­
side
ESP;
PG&
E
NEG's
Brayton
Point
Station
which
burns
low
sulfur
bituminous
coal
and
uses
two
cold­
side
ESPs
inseries
and
PG&
E
NEG's
Salem
Harbor
Station
which
burns
low
sulfur
bituminous
coal,
uses
a
cold­
side
ESP
and
also
a
SNCR
system
for
NOx
control.
The
PAC
injection
system
used
for
the
tests
consists
of
a
bulk
storage
silo
and
dual
pneumatic
conveying
equipment
rated
at
750
lb/
hr.
An
Apogee
Scientific
mercury
CEM
is
used
for
semi­
continuous
speciated
mercury
measurements
during
the
testing.
The
testing
at
each
plant
includes
parametric
tests
using
several
commercially
available
PAC
products
at
various
feed
rates
and
operating
conditions
followed
by
a
one
to
two
week
long­
term
test
with
a
PAC
selected
from
the
parametric
testing.

 
Schedule
Project
started
September
2000
and
is
to
be
completed
in
September
2003.
Testing
at
the
four
sites
was
completed
as
follows:
Gaston
in
April
2001;
Pleasant
Prairie
in
November
2001;
Brayton
Point
in
August
2002;
and
Salem
Harbor
in
November
2002.
The
final
project
report
is
scheduled
for
completion
in
August
2003.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
6.8
million.
(
DOE
funding
$
4,542,563)

 
Status
The
field
demonstration
testing
has
been
completed
at
all
four
sites.

 
Results
To
Date
The
following
is
a
brief
summary
of
the
results
from
the
field
tests:

o
E.
C.
Gaston:
There
was
no
measurable
performance
difference
between
the
different
PACs
used
during
the
parametric
testing.
Norit's
Darco
FGD
activated
carbon
was
used
for
the
nine
day
long­
term
testing.
Mercury
capture
averaged
from
87
to
90%
with
a
carbon
injection
rate
of
1.5
lbs/
MMacf
based
on
three
short­
term
Ontario
Hydro
test
results.
However,
the
long­
term
mercury
CEM
data
indicated
an
average
capture
of
78%
that
varied
from
36%
to
90%.
Average
COHPAC
inlet
mercury
concentration
was
approx.
11
ug/
dncm
of
which
40%
was
elemental.
The
carbon
injection
significantly
increased
the
required
cleaning
frequency
of
the
COHPAC
baghouse.
There
was
no
improvement
in
mercury
capture
using
the
spray
cooling
system.
o
Pleasant
Prairie:
Norit's
Darco
FGD
activated
carbon
was
used
during
the
three
5
day
long­
term
tests
at
feed
rates
of
1.6,
3.7,
and
11.3
lb./
MMacf.
Mercury
capture
averaged
approx.
46%,
57%,
73%
respectively.
Average
ESP
inlet
mercury
concentration
was
approx.
17
ug/
dncm
of
which
85%
was
elemental.
The
carbon
injection
did
not
deteriorate
ESP
performance.
However,
the
ESP
is
relatively
large
(
468
SCA)
and
additional
testing
needs
to
be
conducted
on
units
with
smaller
ESPs.
There
was
no
improvement
in
mercury
capture
using
the
spray
cooling
system.
o
Brayton
Point:
The
PAC
injection
was
located
between
the
first
and
second
cold­
side
ESPs.
Average
mercury
concentration
at
the
inlet
to
the
first
ESP
was
approx.
6
ug/
dncm
of
which
85%
was
particulatebound
During
baseline
testing
the
average
mercury
removal
ranged
from
30
to
90%
across
both
ESPs
and
0
to
10%
across
the
second
ESP.
During
the
parametric
testing
of
Norit's
Darco
FGD
activated
carbon
at
feed
rates
of
3,
7,
10,
15,
and
20
lb./
MMacf
the
mercury
capture
averaged
approx.
25%,
40%,
70%,
75%,
and
90%
respectively
across
the
second
ESP.
The
carbon
injection
did
not
deteriorate
ESP
performance.
However,
the
second
ESP
is
relatively
large
(
400
SCA)
and
additional
testing
needs
to
be
conducted
on
units
with
smaller
ESPs.
o
Salem
Harbor:
Average
mercury
concentration
at
the
inlet
to
the
ESP
was
approx.
10
ug/
dncm
of
which
95%
was
particulate­
bound.
During
baseline
testing
without
PAC
injection,
average
mercury
capture
was
approximately
90%.
The
high
baseline
mercury
removal
is
attributed
to
high
levels
of
unburned
carbon
(
LOI
was
25
to
30%)
and
low
flue
gas
temperature
(
approx.
270
°
F).
Baseline
mercury
removal
decreased
from
approx.
90%
to
20%
while
increasing
flue
gas
temperature
from
270
to
350
°
F.
The
NOx
SNCR
system
had
no
effect
on
mercury
capture.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Scott
Renninger,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
Bustard,
C.
Jean;
Durham,
Michael;
Lindsey,
Charles;
Starns,
Travis;
Baldrey,
Ken;
Martin,
Cameron;
Schlager,
Richard;
Sjostrom,
Sharon;
Slye,
Rick;
Monroe,
Larry;
Miller,
Richard;
Chang,
Ramsey
Full­
Scale
Evaluation
of
Mercury
Control
with
Sorbent
Injection
and
COHPAC
at
Alabama
Power
E.
C.
Gaston.
Presented
at
the
A&
WMA
Specialty
Conference
on
Mercury
Emissions:
Fate,
Effects,
and
Control
and
the
US
EPA/
DOE/
EPRI
Combined
Power
Plant
Air
Pollutant
Control
Symposium:
Mega
Symposium,
Chicago,
IL,
August
2001.
o
Bustard,
Jean;
Durham,
Mike;
Starns,
Travis;
Lindsey,
Charles;
Martin,
Cameron;
Schlager,
Richard;
Baldrey,
Ken
Full­
Scale
Evaluation
of
Sorbent
Injection
for
Mercury
Control
on
Coal­
Fired
Power
Plants.
In
Proceedings
of
Air
Quality
III:
Mercury,
Trace
Elements,
and
Particulate
Matter
Conference;
Arlington,
VA,
September
9­
12,
2002.
o
Bustard,
C.
Jean,
et.
al.;
Results
of
Activated
Carbon
Injection
Upstream
of
Electrostatic
Precipitators
for
Mercury
Control.
Presented
at
the
A&
WMA/
US
EPA/
DOE/
EPRI
Combined
Power
Plant
Air
Pollutant
Control
Mega
Symposium,
Washington,
DC,
May
19­
22,
2003.
o
Bustard,
C.
Jean,
et.
al.;
Results
of
Activated
Carbon
Injection
for
Mercury
Control
Upstream
of
a
COHPAC
Fabric
Filter.
Presented
at
the
A&
WMA/
US
EPA/
DOE/
EPRI
Combined
Power
Plant
Air
Pollutant
Control
Mega
Symposium,
Washington,
DC,
May
19­
22,
2003.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
B&
W
Full­
Scale
Testing
of
Enhanced
Mercury
Control
in
Wet
FGD
(
DE­
FC26­
00NT41006)

 
Objective
Conduct
full­
scale
demonstration
testing
of
a
proprietary
liquid
reagent
developed
by
Babcock
&
Wilcox
and
McDermott
Technology,
Inc.
(
B&
W/
MTI)
to
enhance
the
capture
of
mercury
in
coal­
fired
power
plants
equipped
with
wet
flue
gas
desulfurization
(
FGD)
systems.
Previous
pilot
plant
testing
with
the
reagent
resulted
in
an
increase
in
mercury
capture
across
the
FGD
system
from
a
baseline
of
71%
to
approximately
85%.
The
full­
scale
demonstration
testing
will
provide
design
and
performance
information
which
can
be
used
for
future
full­
scale
commercial
applications
of
the
technology.

 
Sponsors
The
project
is
funded
by
NETL,
the
Ohio
Coal
Development
Office,
and
Babcock
&
Wilcox.
Host
sites
and
associated
support
is
provided
by
Michigan
South
Central
Power
Agency
(
MSCPA)
and
Cinergy.

 
Background
The
mercury
in
coal­
fired
power
plant
combustion
flue
gas
exists
primarily
as
either
elemental
or
oxidized
mercury
species.
Previous
testing
has
shown
that
although
elemental
mercury
is
not
readily
captured,
oxidized
mercury
can
be
effectively
captured
in
coal­
fired
power
plants
equipped
with
wet
FGD
systems.
However,
there
is
also
evidence
that
a
portion
of
the
oxidized
mercury
is
reduced
back
to
elemental
mercury
within
the
wet
FGD
system
and
discharged
out
the
stack.
Therefore,
a
method
to
prevent
the
reduction
of
oxidized
mercury
back
to
elemental
mercury
would
enhance
the
overall
mercury
capture
across
the
wet
FGD
system.
Previous
B&
W/
MTI
pilot
plant
testing
evaluated
a
proprietary
reagent
that,
when
added
to
the
wet
FGD
system
scrubbing
liquor,
was
able
to
prevent
the
reduction
of
oxidized
mercury.
This
full­
scale
demonstration
project
is
necessary
to
evaluate
the
long
term
effectiveness
of
the
reagent
for
cost­
effective
use
in
future
wet
FGD
commercial
applications.

 
Project
Description
The
full­
scale
demonstration
testing
is
being
conducted
at
two
power
plants,
MSCPA's
60
MW
Endicott
Station
in
Litchfield,
Michigan
and
Cinergy's
1300
MW
Zimmer
Station
in
Moscow,
Ohio.
Both
plants
burn
Ohio
high
sulfur
bituminous
coal
and
use
cold­
side
ESPs
for
particulate
control.
The
Endicott
Station
utilizes
a
limestone
wet
FGD
system
with
in­
situ
forced
oxidation;
while
the
Zimmer
Station
utilizes
a
magnesium
enhanced
lime
wet
FGD
system
with
ex­
situ
forced
oxidation.
The
reagent
feed
equipment
consists
of
a
tanker
truck
for
storage
and
a
skid­
mounted
feed
system
with
two
metering
pumps
and
associated
controls.
The
field
demonstration
at
both
power
plants
was
to
include
short­
term
parametric
tests
followed
by
four
months
of
longterm
testing.
(
The
actual
testing
at
Zimmer
was
limited
to
only
two
weeks.)

 
Schedule
Project
started
September
2000
and
was
completed
in
September
2002.
Testing
at
the
Endicott
Station
was
completed
in
October
2001.
Testing
at
the
Zimmer
Station
was
completed
in
November
2001.
A
final
report
was
issued
in
August
2002.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
2.0
million.
(
DOE
funding
$
1,305,374)

 
Status
The
testing
is
complete
at
both
power
stations.
A
final
report
was
issued
in
August
2002.

 
Results
To
Date
Test
results
were
mixed
and
indicate
a
need
for
further
study
and
evaluation
prior
to
commercialization
of
the
process.
The
testing
at
Endicott
was
successful
since
there
was
no
appreciable
increase
in
elemental
mercury
across
the
wet
FGD
system
during
reagent
usage
and
total
mercury
removal
averaged
77%
(
including
95%
removal
of
the
inlet
oxidized
mercury)
compared
to
a
baseline
removal
of
approximately
60%.
However,
the
testing
at
Zimmer
was
not
successful
since
there
continued
to
be
an
increase
in
elemental
mercury
across
the
wet
FGD
system
during
reagent
usage
and
there
was
no
significant
effect
on
total
mercury
removal
which
averaged
52%
(
including
87%
removal
of
the
inlet
oxidized
mercury)
compared
to
a
baseline
removal
of
approximately
45%.
Possible
explanations
for
the
poor
results
at
Zimmer
include
the
much
higher
sulfite
concentration
and
lower
liquid­
to­
gas
ratio
in
the
magnesium
enhanced
lime
wet
FGD
system
which
may
impede
the
reagent
performance.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Scott
Renninger
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html.
 
Publications
o
Nolan,
Paul;
et.
al.
Mercury
Emissions
Control
in
Wet
FGD
Systems.
In
Proceedings
of
Air
Quality
III:
Mercury,
Trace
Elements,
and
Particulate
Matter
Conference;
Arlington,
VA,
September
9­
12,
2002.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Pilot
Plant
Study
of
Low
Temperature
Mercury
Capture
with
an
ESP
(
DE­
FC26­
01NT41181)

 
Objective
Conduct
pilot
testing
at
a
coal­
fired
power
plant
to
evaluate
the
performance
of
lowering
the
combustion
flue
gas
temperature
in
order
to
enhance
overall
mercury
capture
in
plants
equipped
only
with
existing
electrostatic
precipitators
(
ESP).
Based
on
previous
laboratory
testing
80
to
90%
mercury
removal
was
achieved
at
a
temperature
of
200
degrees
F.
The
pilot
testing
will
provide
engineering
design
and
performance
information
which
can
be
used
for
future
full­
scale
commercial
applications
of
the
technology.

 
Sponsors
The
project
is
being
funded
by
NETL,
CONSOL
Energy,
and
Allegheny
Energy.
Other
participants
are
Alstom
Power
Inc.,
Environmental
Elements
Corp.,
and
Carmeuse
North
America.

 
Background
Based
on
results
of
the
EPA's
1999
mercury
data
information
collection
request
(
ICR)
for
coalfired
power
plants,
it
was
found
that
existing
ESP's
are
capable
of
capturing
some
portion
of
the
mercury
in
the
combustion
flue
gases.
However,
the
mercury
capture
efficiency
of
ESP's
varies
widely
from
plant­
to­
plant
and
is
likely
not
sufficient
to
meet
future
EPA
regulatory
control
requirements.
Previous
research
conducted
by
CONSOL
Energy
demonstrated
that
the
fly
ash
particles
in
power
plant
combustion
flue
gas
can
absorb
a
significant
portion
of
the
mercury
if
the
gas
is
cooled
below
typical
exhaust
temperatures,
e.
g.,
from
300
to
200
degrees
F.
However,
operating
at
reduced
flue
gas
temperatures
also
results
in
the
condensation
of
SO3
which
can
lead
to
serious
equipment
and
duct
corrosion
problems
downstream
of
the
air
preheater.
In
order
to
address
the
corrosion
problem,
CONSOL
Energy
has
conducted
research
of
an
alkaline
sorbent
injection
system
to
reduce
the
flue
gas
SO3
concentration
by
approximately
80%
to
allow
for
plant
operation
at
the
lower
flue
gas
temperatures.
The
pilot
plant
project
is
necessary
to
demonstrate
the
long
term
effectiveness
of
this
control
strategy.

 
Project
Description
The
pilot
testing
is
being
conducted
at
Allegheny
Energy's
288
MW
Mitchell
Power
Station,
Unit
No.
3,
which
burns
a
medium
sulfur,
eastern
bituminous
coal.
The
pilot
plant
consists
of
an
air
preheater
to
lower
flue
gas
temperature,
a
water
spray
cooling
system
as
an
optional
method
to
lower
flue
gas
temperature,
an
ESP
to
collect
the
mercury
along
with
the
fly
ash,
and
an
alkaline
sorbent
(
magnesium
hydroxide)
injection
system
to
control
sulfuric
acid
condensation.
The
pilot
plant
is
supplied
with
approximately
a
16,500
lb/
hr
flue
gas
slipstream
taken
upstream
of
the
plant's
air
preheater.
Mercury
capture
across
the
ESP
will
be
measured
with
varying
air
preheater
outlet
flue
gas
temperatures
between
220
to
320
degrees
F.

 
Schedule
Project
started
August
2001
and
is
to
be
completed
in
September
2004.
The
pilot
testing
is
scheduled
to
begin
in
January
2003
and
will
be
completed
in
March
2004.
A
final
report
will
be
issued
in
September
2004.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
2.4
million.
(
DOE
funding
$
1,826,539)

 
Status
The
pilot
plant
equipment
is
in
operation
and
baseline
testing
is
to
begin
in
May
2003.

 
Results
To
Date
None
available.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Lynn
A.
Brickett
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html.

 
Publications
Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Assessment
of
Low
Cost
Novel
Mercury
Sorbents
(
DE­
FC26­
01NT41180)

 
Objective
Conduct
pilot
testing
at
two
coal­
fired
power
plants
to
assess
the
mercury
capture
performance
of
novel
sorbents
which
could
be
used
as
an
alternative
to
commercially
available
activated
carbons
in
order
to
enhance
performance
and
reduce
operating
costs
for
carbon
injection
mercury
control
systems.

 
Sponsors
The
project
is
being
funded
by
NETL,
EPRI,
and
Apogee
Scientific.
Other
project
participants
include
URS,
Illinois
State
Geological
Survey,
ADA
Environmental
Solutions,
Physical
Sciences
Inc.,
Wisconsin
Electric
Power,
and
Midwest
Generation.

 
Background
Activated
carbon
injection
systems
are
currently
under
development
for
the
control
of
mercury
emissions
from
coal­
fired
power
plants.
However,
the
commercially
available
activated
carbons
currently
being
used
in
full­
scale
field
demonstrations
of
the
control
technology
are
relatively
expensive.
Therefore,
the
development
of
alternative
lower
cost
sorbents
could
significantly
reduce
the
cost
of
mercury
control.
This
project
is
necessary
to
assess
the
mercury
capture
performance
of
several
low
cost
novel
mercury
sorbents
using
an
actual
flue
gas
slipstream
in
a
small­
scale
pilot
plant
equipped
with
an
ESP
and
baghouse.

 
Project
Description
The
pilot
testing
is
being
conducted
at
two
power
plants,
Wisconsin
Electric
Power's
Valley
Plant
in
Milwaukee,
WI
which
uses
a
low
sulfur
bituminous
coal
and
Midwest
Generation's
Powerton
Generating
Station
in
Pekin,
IL
which
uses
a
Powder
River
Basin
sub­
bituminous
coal.
The
sorbents
being
tested
include
activated
carbon
samples
from
coal,
biomass,
and
tires;
char
sorbents
made
from
coal;
fly
ash
derived
sorbents;
and
zeolite
sorbents.
Initially,
bench­
scale
laboratory
tests
were
conducted
on
46
different
sorbents
using
simulated
bituminous
coal
flue
gas
and
29
sorbents
using
simulated
PRB
coal
flue
gas.
Based
on
results
from
the
bench­
scale
testing
17
sorbents
for
bituminous
applications
and
8
sorbents
for
PRB
applications
were
selected
for
additional
fixed­
bed
testing
using
actual
flue
gas
slipstreams
at
the
two
plants.
The
fixed­
bed
testing
at
the
plants
led
to
the
final
selection
of
sorbents
for
testing
in
a
small­
scale
(
10
to
50
acfm)
slipstream
pilot
plant
equipped
with
a
residence
chamber
to
simulate
an
ESP
and
a
baghouse
to
simulate
a
COHPAC
configuration.

 
Schedule
Project
started
August
2001
and
is
to
be
completed
in
August
2003.
The
field
pilot
testing
of
the
sorbents
is
scheduled
for
completion
by
February
2003.
A
final
report
is
scheduled
for
completion
by
August
2003.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
0.8
million.
(
DOE
funding
$
550,654)

 
Status
Seven
sorbents
were
selected
for
testing
in
the
small­
scale
pilot
at
Powerton
which
was
completed
in
July
2002.
The
small­
scale
pilot
testing
at
the
Valley
Plant
started
in
December
2002
and
should
be
completed
by
February
2003.

 
Results
To
Date
The
Powerton
slipstream
pilot
testing
included
experimental
sorbents
produced
from
corn
(
CFA),
oil
soot
(
CS80),
waste
tires
(
TDAC),
flyash
(
STI­
B),
a
commercially
available
carbon
made
from
lignite
coal
(
HOK),
and
an
iodine­
impregnated
sorbent
(
CB­
IAC).
Norit's
Darco
FGD
activated
carbon
was
also
tested
as
a
benchmark.
Major
results
from
the
Powerton
pilot
testing
are
as
follows:
o
Initial
screening
tests
were
conducted
at
1.5
lb/
MMacf
and
300
°
F
using
the
COHPAC
configuration.
Similar
mercury
removal
of
approximately
80%
was
achieved
by
the
FGD,
CFA,
CS80,
and
HOK
sorbents.
Mercury
removal
for
the
TDAC
and
STI­
B
were
approximately
60%
and
35%
respectively.
The
CB­
IAC
mercury
removal
was
72%
at
a
lower
injection
rate
of
0.6
lb/
MMacf.
The
CFA
and
HOK
sorbents
were
selected
for
additional
parametric
testing
in
the
COHPAC
configuration
based
on
their
lower
estimated
delivered
cost.
o
The
parametric
and
long­
term
COHPAC
testing
again
showed
similar
performance
of
the
CFA,
HOK,
and
FGD
sorbents.
However,
mercury
removal
was
different
for
the
two
types
of
filter
bag
materials
that
were
tested.
At
2
lb/
MMacf
the
three
sorbents
achieved
approximately
90%
mercury
removal
with
the
Teflon
glass
bag,
but
only
70
­
80%
mercury
removal
with
the
Torcon
bag.
However,
the
difference
in
mercury
removal
may
have
been
a
result
of
the
bag
cleaning
frequency
used
during
the
testing.
Mercury
removal
was
also
similar
for
the
three
sorbents
at
both
300
°
and
350
°
F.
o
Based
on
results
of
the
COHPAC
screening
tests,
the
CFA
and
CS80
were
selected
for
testing
in
the
residence
chamber
(
ESP)
configuration.
The
FGD
and
IAC
sorbents
were
also
included
as
benchmarks.
The
CFA,
CS80,
and
FGD
mercury
removal
was
less
than
50%
for
injection
rates
between
2.5
and
15
lb/
MMacf
at
both
two
and
four
second
residence
times.
The
IAC
sorbent
achieved
approximately
60%
mercury
removal
at
four
seconds
and
45%
at
two
seconds
at
2.5
lb/
MMacf.
o
Preliminary
cost
estimates
for
the
alternative
sorbents
indicate
production
costs
could
be
approximately
50%
less
than
commercially
available
activated
carbons.

The
Valley
Plant
test
results
are
not
yet
available.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Bob
Patton,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Mercury
Control
with
the
Advanced
Hybrid
Particulate
Collector
(
DE­
FC26­
01NT41184)

 
Objective
Conduct
bench­
scale
testing,
small
pilot­
scale
testing,
and
large
pilot­
scale
field
demonstration
testing
to
evaluate
the
mercury
control
performance
of
sorbent
injection
used
in
conjunction
with
the
Advanced
Hybrid
Particulate
Collector
(
AHPC).
The
pilot­
scale
field
demonstration
testing
will
provide
engineering
design
and
performance
information
which
can
be
used
for
future
full­
scale
commercial
applications
of
the
technology.

 
Sponsors
The
project
is
being
funded
by
NETL
and
the
University
of
North
Dakota
Energy
and
Environmental
Research
Center
(
EERC).
Other
participants
are
W.
L.
Gore
&
Associates
and
Otter
Tail
Power
Company.

 
Background
NETL
has
previously
supported
the
RD&
D
of
the
AHPC
which
is
a
combination
electrostatic
precipitator
(
ESP)
and
fabric
filter
baghouse
(
FF)
system
designed
to
optimize
fine
particulate
collection.
While
sorbent
injection
used
in
conjunction
with
conventional
ESPs
and
FFs
is
being
demonstrated
to
be
effective
for
mercury
capture,
the
AHPC
may
be
capable
of
equivalent
or
better
performance
at
lower
sorbent
feed
rates
which
is
to
be
demonstrated
under
this
project.

 
Project
Description
Bench­
scale
and
small
pilot­
scale
testing
is
being
conducted
at
EERC.
Field
demonstration
pilot
plant
testing
is
being
conducted
at
Otter
Tail
Power
Company's
450
MW
Big
Stone
Plant
located
in
Big
Stone
City,
South
Dakota,
which
burns
Powder
River
Basin
sub­
bituminous
coal.
The
bench­
scale
testing
is
being
conducted
to
evaluate
mercury
capture
effectiveness
of
activated
carbon
sorbents
under
varying
SO2
and
NOx
flue
gas
concentrations
using
both
simulated
and
real
flue
gas.
The
small
pilot­
scale
testing
will
use
the
200
acfm
EERC
particulate
test
combustor
(
PTC)
and
is
being
conducted
to
compare
the
mercury
capture
effectiveness
of
a
pulse­
jet
baghouse
and
the
AHPC
both
with
and
without
sorbent
addition
for
both
an
eastern
bituminous
and
western
sub­
bituminous
coal.
The
field
demonstration
pilot
plant
testing
will
use
the
9,000
acfm
(
2.5
MW)
AHPC
pilot
plant
previously
installed
at
the
Big
Stone
Plant
to
demonstrate
the
AHPC
technology
for
particulate
control.
A
pilot­
scale
sorbent
injection
system
is
being
added
to
the
AHPC
pilot
plant
for
the
mercury
control
testing.
NORIT
Darco
FGD
activated
carbon
was
used
for
both
the
200
acfm
and
2.5
MW
pilot­
scale
testing.

 
Schedule
Project
started
June
2001
and
is
to
be
completed
in
December
2004.
The
long­
term
field
demonstration
pilot
plant
testing
is
scheduled
to
be
completed
by
the
spring
of
2003.
A
final
report
is
expected
to
be
available
by
September
2003.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
1.5
million.
(
DOE
funding
$
2,641,120)

 
Status
The
initial
short­
term
field
demonstration
baseline
pilot
plant
testing
was
conducted
in
November
2001.
The
bench­
scale
and
small
pilot­
scale
testing
were
completed
in
March
and
June
2002
respectively.
The
long­
term
field
demonstration
pilot­
plant
testing
is
scheduled
to
be
completed
by
the
spring
of
2003.

 
Results
To
Date
 
Results
from
the
small
pilot­
scale
testing
burning
a
Belle
Ayr
PRB
coal
indicated
approximately
70%
of
the
mercury
was
elemental
and
there
was
very
little
baseline
mercury
capture
from
both
the
AHPC
and
pulse­
jet
baghouse.
Mercury
removal
with
the
AHPC
ranged
from
50%
to
71%
at
a
carbon­
to­
mercury
mass
ratio
of
3000:
1
and
from
65%
to
87%
at
a
mass
ratio
of
6000:
1.
 
Results
from
the
November
2001
short­
term
AHPC
2.5
MW
pilot­
plant
test
at
Big
Stone
indicated
91
to
97%
total
mercury
collection
efficiency
with
a
sorbent
feed
rate
of
1.5
lb/
million
acf
compared
to
a
baseline
(
no
sorbent)
mercury
collection
efficiency
of
49%.
The
relatively
high
mercury
removal
rates
may
have
occurred
because
the
average
inlet
mercury
speciation
during
the
testing
was
55.4%
particulate,
38.1%
oxidized,
and
only
6.4%
elemental.
This
is
not
considered
typical
for
PRB
coals,
which
normally
have
much
higher
levels
of
elemental
mercury.
Subsequent
analysis
showed
that
the
high
proportion
of
particulate
and
oxidized
mercury
may
have
been
related
to
unexpectedly
high
levels
of
chlorine
in
the
flue
gas,
which
may
have
resulted
from
co­
combustion
of
tire­
derived
fuel
(
TDF)
in
the
Big
Stone
boiler
during
the
November
2001
test
period.
 
A
second
AHPC
2.5
MW
pilot­
plant
test
was
conducted
at
Big
Stone
in
August
2002
using
a
Belle
Ayr
PRB
coal.
Mercury
speciation
was
17%
particulate,
32%
oxidized,
and
51%
elemental.
Baseline
mercury
removal
ranged
from
0%
to
10%.
Mercury
removal
was
63%
during
activated
carbon
injection
at
1.5
lb/
MMacf
and
without
any
TDF
co­
firing.
There
was
no
adverse
effect
on
AHPC
particulate
collection
performance
during
the
activated
carbon
injection
testing.
 
A
third
AHPC
2.5
MW
pilot­
plant
test
was
conducted
at
Big
Stone
in
November
2002.
Mercury
removal
ranged
from
65%
to
over
90%
during
activated
carbon
injection
at
1.5
lb/
MMacf
and
without
any
TDF
cofiring
A
possible
reason
for
the
improved
mercury
removal
in
November
compared
to
the
August
2002
test
is
lower
flue
gas
temperature
of
250
°
F
compared
to
270
°
­
290
°
F.
Supplemental
injection
of
HCl
had
little
or
no
effect
on
mercury
removal.
 
A
small
AHPC
200
acfm
pilot­
scale
test
was
conducted
in
late
2002
using
a
Springfield
high­
sulfur
bituminous
coal.
The
NORIT
Darco
FGD
activated
carbon
was
ineffective
with
average
mercury
removal
at
less
than
15%
for
various
combinations
of
flue
gas
temperature
(
275
°
­
320
°
F)
and
injection
rates.
A
possible
reason
for
the
poor
mercury
removal
was
the
relatively
high
level
of
SO3
(
over
30
ppm)
concentration
in
the
flue
gas.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Bill
Aljoe
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
Miller,
Stanley;
Zhuang,
Ye;
Rinschler,
Craig;
Gebert,
Rich;
Davis,
Dwight;
Swanson,
William
Mercury
Control
with
the
Advanced
Hybrid.
In
Proceedings
of
Air
Quality
III:
Mercury,
Trace
Elements,
and
Particulate
Matter
Conference;
Arlington,
VA,
September
9­
12,
2002.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Mercury
Removal
in
a
Non­
Thermal,
Plasma­
Based
Multi­
Pollutant
Control
Technology
for
Utility
Boilers
(
DE­
FC26­
01NT41182)

 
Objective
Conduct
pilot­
scale
field
demonstration
testing
to
optimize
the
mercury
control
performance
of
Powerspan's
Electro
Catalytic
Oxidation
(
ECO)
multi­
pollutant
control
technology
process
while
maintaining
high
removal
levels
of
SO2,
NOx,
and
fine
particulate
matter.
The
pilot­
scale
testing
will
provide
engineering
design
and
performance
information
which
can
be
used
for
future
full­
scale
commercial
applications
of
the
technology.

 
Sponsors
The
project
is
being
funded
by
NETL
and
Powerspan
Corp.
Other
participants
include
FirstEnergy
Corporation.

 
Background
Powerspan
has
developed
a
non­
thermal,
plasma
­
based
multi­
pollutant
control
technology
known
as
the
Electro
Catalytic
Oxidation
(
ECO)
process
that
was
designed
for
the
simultaneous
removal
of
SO2,
NOx,
and
fine
particulate
emissions
from
the
combustion
flue
gas
of
coal­
fired
boilers.
Based
on
previous
pilot­
plant
testing
it
was
determined
that
the
ECO
process
has
the
potential
for
significant
mercury
removal.
The
ECO
process
includes
a
dielectric
barrier
discharge
(
DBD)
which
converts
the
elemental
mercury
to
mercuric
oxide
which
can
be
efficiently
captured
along
with
any
previously
oxidized
mercury
in
a
downstream
ammonia
reagentbased
wet
FGD
absorber
and
wet
ESP.

 
Project
Description
The
pilot­
scale
field
demonstration
testing
is
being
conducted
at
First
Energy's
R.
E.
Burger
Plant
located
in
Shadyside,
Ohio,
which
burns
eastern
bituminous
coal.
The
testing
will
use
a
3,000
scfm
flue
gas
slip­
stream
pilot­
scale
ECO
system
previously
installed
for
a
field
demonstration
of
the
process.
(
Note:
A
large
full­
scale
50
MW
commercial
ECO
system
is
under
construction
at
the
R.
E.
Burger
Plant
and
is
expected
to
be
ready
for
operation
during
the
2nd
quarter
2003.)
The
ECO
pilot
plant
is
being
equipped
with
a
PS
Analytical
mercury
CEMs
system
to
provide
continuous
mercury
speciation
measurements
across
the
various
ECO
process
components
during
the
testing.
In
addition,
an
activated
carbon
filtration
system
is
being
developed
and
installed
for
removal
of
the
captured
mercury
from
the
wet
FGD
discharge
liquid
product
stream
prior
to
crystallization
of
the
ammonium
sulfate
and
nitrate
byproducts.

 
Schedule
Project
started
September
2001
and
is
to
be
completed
in
March
2004.
The
pilot­
scale
field
demonstration
testing
is
scheduled
to
be
complete
by
September
2003
and
a
final
report
will
be
issued
by
March
2004.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
2.8
million.
(
DOE
funding
$
2,248,002)

 
Status
Initial
baseline
mercury
speciation
measurements
were
obtained
across
the
pilot
plant
dry
ESP
during
the
3rd
quarter
2002.
Bench­
scale
testing
of
the
activated
carbon
filtration
system
has
also
been
initiated.

 
Results
To
Date
Preliminary
Ontario
Hydro
method
test
measurements
in
May
2002
resulted
in
an
average
mercury
removal
of
88%
across
the
ECO
pilot
plant.
While
particulate
and
oxidized
mercury
removal
exceeded
95%,
there
was
some
apparent
conversion
of
oxidized
mercury
to
elemental
mercury
which
reduced
the
overall
removal.
Normal
inlet
flue
gas
elemental
mercury
concentration
is
extremely
low
at
the
Burger
Plant
and
artificial
injection
of
elemental
mercury
into
the
pilot
plant
is
being
tested
to
demonstrate
ECO
capability
to
capture
elemental
mercury.
Mercury
captured
in
the
ECO
ammonia
scrubber
liquid
is
removed
using
a
sulfur­
impregnated
activated
carbon
filter
(
Mersorb).
Mercury
levels
in
the
scrubber
liquid
have
been
reduced
from
200
ppb
to
less
than
the
limit
of
detection
(
approx.
20
ppb).

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Scott
Renninger,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
McLarnon,
Christopher
Mercury
Removal
in
a
Multi­
Pollutant
Control
Technology
for
Utility
Boilers.
In
Proceedings
of
Air
Quality
III:
Mercury,
Trace
Elements,
and
Particulate
Matter
Conference;
Arlington,
VA,
September
9­
12,
2002.
o
McLarnon,
C.
and
Steen,
D.;
Combined
SO2,
NOx,
PM,
and
Hg
Removal
from
Coal­
Fired
Boilers.
Presented
at
the
A&
WMA/
US
EPA/
DOE/
EPRI
Combined
Power
Plant
Air
Pollutant
Control
Mega
Symposium,
Washington,
DC,
May
19­
22,
2003.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Testing
of
Mercury
Control
with
Calcium­
Based
Sorbents
and
Oxidizing
Agents
(
DE­
FC26­
01NT41183)
 
Objective
Conduct
bench­
scale
and
pilot­
scale
testing
to
assess
the
mercury
capture
performance
of
calciumbased
sorbents
and
oxidizing
agents
which
could
be
used
as
an
alternative
to
commercially
available
activated
carbons
in
order
to
enhance
performance
and
reduce
operating
costs
for
carbon
injection
mercury
control
systems
used
at
coal­
fired
power
plants.

 
Sponsors
This
project
is
being
funded
by
NETL
and
the
Southern
Research
Institute
(
SRI).
Other
project
participants
include
ARCADIS
G&
M,
Inc.

 
Background
Activated
carbon
injection
systems
are
currently
under
development
for
the
control
of
mercury
emissions
from
coal­
fired
power
plants.
However,
the
commercially
available
activated
carbons
currently
being
used
in
full­
scale
field
demonstrations
of
the
control
technology
are
relatively
expensive.
Therefore,
the
development
of
alternative
lower
cost
sorbents
could
significantly
reduce
the
cost
of
mercury
control.
Working
with
the
EPA,
ARCADIS
has
developed
two
proprietary
calcium­
based
sorbents
which
could
provide
for
the
simultaneous
removal
of
both
mercury
and
sulfur
dioxide
from
coal­
fired
power
plants.
The
two
sorbents
consist
of
a
hydrated
lime,
Ca(
OH)
2,
with
an
oxidant
and
a
silica­
modified
calcium,
CaSiO3,
with
an
oxidant.
The
oxidant
is
intended
to
oxidize
the
elemental
mercury
in
order
to
enhance
overall
mercury
capture
by
the
sorbent.
This
project
is
necessary
to
assess
the
mercury
capture
performance
of
these
and
other
calcium­
based
sorbents
using
flue
gas
from
a
pilot­
scale
coal
combustor.
Other
calcium­
based
sorbents
such
as
lime
will
be
used
with
alternative
oxidants
such
as
injected
chlorine
compounds,
sodium
tetra­
sulfide,
or
high
iron
oxide
fly
ash
from
the
bituminuous
coal.
These
oxidants
will
be
tested
with
a
lime
sorbent
on
a
subbituminous
Powder
River
Basin
coal
that
characteristically
has
a
high
fraction
of
elemental
mercury.

 
Project
Description
SRI
is
testing
the
calcium­
based
sorbents
at
its
Combustion
Research
Facility
located
in
Birmingham,
AL
using
a
1
MW
(
1150
SCFM)
pilot
plant.
The
calcium­
based
sorbents
are
being
tested
on
a
variety
of
coal
types
and
flue
gas
conditions.
The
pilot
plant
sorbent
injection
system
includes
a
downstream
water
injection
cooling
system
followed
by
a
fabric
filter
baghouse
for
particulate
and
mercury
capture.
A
PS
Analytical
mercury
CEMs
system
is
being
used
for
speciated
mercury
measurements
across
the
pilot
plant
during
the
sorbent
injection
testing.

 
Schedule
Project
started
September
2001
and
is
to
be
completed
in
September
2004.
The
test
program
is
to
consist
of
numerous
pilot
plant
runs
over
a
three­
year
project
period.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
1.4
million.
(
DOE
funding
$
1,109,719)

 
Status
Initial
pilot­
plant
testing
of
the
two
proprietary
calcium­
based
sorbents
and
an
ordinary
hydrated
lime
sorbent
was
completed
in
the
spring
2002.

 
Results
To
Date
o
The
initial
pilot­
plant
testing
of
the
two
proprietary
calcium­
based
sorbents
with
an
oxidant
additive
and
bituminous
coal
showed
both
to
be
ineffective
in
enhancing
the
oxidation
and
capture
of
elemental
mercury
and
achieved
overall
mercury
removal
of
only
25
to
50%.
Follow­
up
testing
with
an
ordinary
hydrated
lime
sorbent
without
the
oxidant
was
able
to
remove
80
to
90%
of
the
mercury
which
occurred
primarily
across
the
sorbent
dust
cake
collecting
on
the
baghouse
filter
bags.
Approximately
30
to
35%
mercury
capture
occurred
"
in­
flight"
prior
to
the
baghouse.
o
SRI
and
PS
Analytical
developed
a
"
spike
and
recovery"
system
to
reduce
mercury
S­
CEM
measurement
uncertainty.
A
known
concentration
mercury
"
spike"
is
introduced
in
the
sampling
probe
in
order
to
increase
the
concentration
of
mercury
in
the
sampled
flue
gas.
o
Pilot­
scale
testing
with
a
kaolinite
(
Al2O3.2SiO2.
H2O)
adsorbent
and
a
Choctaw
bituminous
coal
was
ineffective
for
mercury
capture
at
injection
temperatures
that
ranged
from
1100
°
to
2100
°
F.
o
SRI
conducted
pilot­
scale
testing
of
chlorine
gas
(
Cl2)
injection
in
order
to
evaluate
the
ability
of
HCl
to
promote
mercury
oxidation
and
adsorption
with
PRB
coal
ash.
Chlorine
injection
through
the
burner
was
effective
in
increasing
the
oxidized
mercury
from
less
than
20%
to
over
50%
and
increasing
mercury
adsorption
on
the
PRB
coal
ash
from
less
than
5%
to
over
30%.
However,
chlorine
injection
upstream
of
the
air
heater
was
ineffective.
o
SRI
conducted
pilot­
scale
testing
to
condition
PRB
coal
with
a
high­
iron,
low­
chlorine
bituminous
coal.
As
a
result,
PRB
coal
ash
composition
was
found
to
be
more
important
than
flue
gas
chlorine
content
relative
to
mercury
oxidation
and
capture.
With
PRB
coal
only,
there
was
less
than
15%
oxidized
mercury
at
the
baghouse
inlet.
However,
a
coal
blend
with
10%
bituminous
and
90%
PRB
coal
resulted
in
greater
than
50%
oxidized
mercury
at
the
baghouse
inlet.
o
SRI
also
conducted
tests
to
condition
the
PRB
coal
ash
with
injection
of
high­
iron
bituminous
coal
ash
and
hydrated
lime
at
the
baghouse
inlet.
The
rate
of
ash/
lime
injection
was
approximately
equivalent
to
the
PRB
ash
loading.
Three
ash/
lime
injection
ratios
were
tested:
100%
ash;
50%
ash/
50%
lime;
and
20%
ash/
80%
lime.
The
mercury
oxidation
across
the
baghouse
increased
from
a
baseline
of
approximately
60%
to
80%
with
100%
high­
iron
bituminous
ash
injection.
The
increase
in
mercury
oxidation
was
less
with
the
ash/
lime
blends.
o
Increasing
the
baghouse
inlet
flue
gas
temperature
from
260
°
to
300
°
F
increased
oxidized
mercury
while
burning
100%
PRB
coal.
The
oxidized
mercury
increased
less
than
10
percentage
points
at
the
baghouse
inlet,
but
increased
approximately
30
percentage
points
at
the
baghouse
outlet.
However,
this
temperature
effect
was
not
significant
with
the
bituminous/
PRB
coal
blend.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Barbara
Carney,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
Gale,
Thomas
K.
et
al.;
Mercury
Speciation
as
a
Function
of
Flue
Gas
Chlorine
Content
and
Composition
in
a
1
MW
Semi­
Industrial
Scale
Coal­
Fired
Facility.
Presented
at
the
A&
WMA/
US
EPA/
DOE/
EPRI
Combined
Power
Plant
Air
Pollutant
Control
Mega
Symposium,
Washington,
DC,
May
19­
22,
2003.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Pilot
Testing
of
Mercury
Oxidation
Catalysts
(
DE­
FC26­
01NT41185)

 
Objective
Conduct
pilot
testing
at
two
coal­
fired
power
plants
to
evaluate
the
performance
of
several
catalyst
materials
that
would
be
used
to
promote
the
oxidation
of
elemental
mercury
in
the
flue
gas
in
order
to
enhance
overall
mercury
capture
in
plants
equipped
with
existing
wet
flue
gas
desulfurization
(
FGD)
systems.
Based
on
laboratory
testing
a
minimum
90%
mercury
oxidation
rate
is
expected
from
the
pilot
testing.
The
pilot
testing
will
provide
engineering
design
and
performance
information
which
can
be
used
for
future
full­
scale
commercial
applications
of
the
technology.

 
Sponsors
The
project
is
being
funded
by
NETL,
EPRI,
Great
River
Energy
(
GRE),
City
Public
Service
(
CPS)
of
San
Antonio,
and
the
North
Dakota
Industrial
Council.
URS
Corporation
is
the
prime
contractor.

 
Background
The
mercury
in
coal­
fired
power
plant
combustion
flue
gas
exists
primarily
as
either
elemental
or
oxidized
mercury
species.
The
degree
of
mercury
speciation
can
vary
significantly
from
plant
to
plant,
but
in
general
plants
burning
sub­
bituminous
or
lignite
coal
have
a
higher
percentage
of
elemental
mercury
compared
to
bituminous
coal.
Previous
testing
has
shown
that
although
elemental
mercury
is
not
readily
captured,
oxidized
mercury
can
be
effectively
captured
in
coal­
fired
power
plants
equipped
with
wet
FGD
systems.
Therefore,
a
method
to
convert
the
elemental
mercury
to
oxidized
mercury
in
the
flue
gas
would
enhance
the
overall
mercury
capture.
A
previous
NETL/
EPRI
project
evaluated
several
catalyst
materials
in
small,
fixed
sand­
bed
reactors
that
were
effective
in
the
oxidation
of
elemental
mercury.
This
pilot
project
is
necessary
to
demonstrate
the
long
term
effectiveness
of
these
catalysts
on
honeycomb
substrates
that
could
be
used
in
full­
scale
commercial
applications.

 
Project
Description
The
pilot
testing
is
being
conducted
at
two
power
plants,
the
GRE
Coal
Creek
Station
which
uses
a
North
Dakota
lignite
fuel
and
the
CPS
J.
K.
Spruce
Plant
which
uses
a
Powder
River
Basin
(
PRB)
subbituminous
fuel.
The
four
catalysts
being
tested
are:
1)
Pd
#
1,
a
commercial
palladium
catalyst;
2)
SCR,
a
Siemens
commercial
NOx
catalyst
using
titanium­
vanadium;
3)
Carbon
#
6,
an
activated
tire­
derived
carbon;
and
4)
SBA
#
5,
an
active
fly
ash.
Each
of
the
four
catalysts,
are
contained
on
honeycomb
design
alumina
substrates
and
mounted
in
separate
40"
cube
test
chambers
that
are
supplied
with
approximately
a
2,000
acfm
flue
gas
slipstream
taken
downstream
of
the
plant's
particulate
control
device.

 
Schedule
Project
started
August
2001
and
is
to
be
completed
in
August
2004.
The
GRE
Coal
Creek
Station
pilot
testing
was
scheduled
to
begin
in
October
2002
and
the
CPS
J.
K.
Spruce
Plant
was
scheduled
to
begin
in
March
2003.
The
testing
at
each
plant
is
scheduled
for
14
months.
A
final
report
will
be
issued
by
August
2004.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
1.2
million.
(
DOE
funding
$
897,616)

 
Status
The
pilot
unit
at
the
Coal
Creek
Station
began
initial
operation
in
October
2002
and
should
be
completed
by
December
2003.
Testing
at
J.
K.
Spruce
Plant
is
scheduled
to
begin
in
the
third
quarter
2003.

 
Results
To
Date
Coal
Creek
Station:
o
Pilot
testing
for
the
Pd
#
1
and
SCR
catalysts
began
in
October
2002.
Oxidation
of
elemental
mercury
across
Pd
#
1
dropped
from
93%
to
53%
after
62
days
in
service.
Oxidation
of
elemental
mercury
across
the
SCR
catalyst
dropped
from
67%
to
28%
after
62
days
in
service.
Subsequent
inspection
of
the
two
catalysts
indicated
that
a
buildup
of
fly
ash
in
the
pilot
test
chamber
likely
caused
the
drop
in
oxidation
rather
than
a
loss
of
catalyst
activity
since
mercury
oxidation
was
restored
after
cleaning
in
January
2003.
o
A
sonic
horn
is
being
tested
to
prevent
the
buildup
of
fly
ash
in
the
Pd
#
1
chamber
and
will
be
installed
on
the
remaining
chambers
if
effective.
o
Testing
of
the
SBA
#
5
catalyst
began
in
December
2002
and
oxidation
of
elemental
mercury
was
75%
when
first
measured
in
late
January
2003.
o
The
Carbon
#
6
catalyst
testing
is
being
postponed
until
the
fly
ash
buildup
problem
is
corrected.
o
There
was
some
concern
that
the
catalysts
might
also
lead
to
oxidation
of
SO2
and
NO
which
could
produce
undesirable
balance­
of­
plant
effects.
However,
there
is
no
apparent
oxidation
of
SO2
to
SO3
and
approximately
7%
oxidation
of
NO
to
NO2.
 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Bruce
Lani
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html.

 
Publications
o
Blythe,
Gary;
Richardson,
Carl;
Rhudy,
Richard
Pilot
Evaluation
of
the
Catalytic
Oxidation
of
Mercury
for
Enhanced
Removal
in
Wet
FGD
Systems.
In
Proceedings
of
Air
Quality
III:
Mercury,
Trace
Elements,
and
Particulate
Matter
Conference;
Arlington,
VA,
September
9­
12,
2002.
o
Blythe,
Gary
et.
al.;
Pilot
Testing
of
Oxidation
Catalysts
for
Enhanced
Mercury
Control
by
Wet
FGD.
Presented
at
the
A&
WMA/
US
EPA/
DOE/
EPRI
Combined
Power
Plant
Air
Pollutant
Control
Mega
Symposium,
Washington,
DC,
May
19­
22,
2003.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Evaluation
of
Mercury
Speciation
at
Power
Plants
Using
SCR
and
SNCR
NOx
Control
Technologies
(
DE­
FC26­
98FT40321­
36)

 
Objective
Conduct
field
testing
at
numerous
coal­
fired
power
plants
equipped
with
selective
catalytic
reduction
(
SCR)
or
selective
non­
catalytic
reduction
(
SNCR)
NOx
control
technologies
to
determine
their
effect
on
the
speciation
of
mercury
in
the
combustion
flue
gas
and
resultant
enhancement
of
mercury
emissions
capture
in
downstream
pollution
control
equipment.

 
Sponsors
The
project
is
being
funded
by
NETL,
the
University
of
North
Dakota
Energy
and
Environmental
Research
Center
(
EERC),
the
Electric
Power
Research
Institute
(
EPRI),
and
the
Environmental
Protection
Agency
(
EPA).
Other
participants
include
numerous
electric
utility
companies
that
provided
host
sites
for
the
testing.

 
Background
The
mercury
in
coal­
fired
power
plant
combustion
flue
gas
exists
as
either
elemental,
oxidized,
or
particulate­
bound
species,
and
the
degree
of
mercury
speciation
can
vary
significantly
from
plant
to
plant
depending
on
coal
type
and
combustion
conditions.
Although
elemental
mercury
is
not
readily
captured,
oxidized
and
particulate
mercury
can
be
effectively
captured
in
a
plant's
conventional
pollution
control
equipment
such
as
an
ESP,
baghouse,
or
FGD
system.
Previous
pilot­
scale
testing
indicated
that
the
catalyst
and/
or
ammonia
reagent
associated
with
SCR
and
SNCR
NOx
control
technologies
might
further
convert
some
of
the
elemental
mercury
to
oxidized
mercury
in
the
flue
gas
and
therefore
enhance
overall
mercury
capture.
This
field
testing
project
is
necessary
to
demonstrate
the
effectiveness
of
SCR
and
SNCR
NOx
control
technologies
to
promote
the
oxidation
of
elemental
mercury
in
full­
scale
commercial
applications.

 
Project
Description
The
initial
2001
field
testing
was
conducted
at
six
coal­
fired
power
plants.
Four
of
the
plants
are
equipped
with
SCR
NOx
controls,
one
plant
uses
SNCR
NOx
control,
and
one
plant
uses
ammonia
and
sulfur
trioxide
for
ash
conditioning
to
improve
particulate
control.
Field
testing
was
also
conducted
in
2002
at
two
of
the
2001
SCR
equipped
plants
and
two
additional
plants
with
SCRs.
Additional
plants
may
be
selected
for
testing
in
2003.
The
field
testing
included
the
use
of
both
the
manual
Ontario
Hydro
method
and
semi­
continuous
emission
monitors
(
SCEM's)
to
measure
the
speciated
mercury
concentrations
at
the
inlet
and
outlet
of
the
SCRs
to
determine
changes
in
the
level
of
oxidized
mercury.

 
Schedule
Project
started
April
2001
and
is
to
be
completed
in
October
2003.
Field
testing
was
scheduled
for
2001,
2002,
and
2003
at
various
plants.
A
final
report
for
the
2001
testing
was
issued
in
October
2002.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
1.25
million.
(
DOE
funding
$
445,000)

 
Status
The
2002
field
testing
has
been
completed
and
a
draft
final
report
is
under
review.
Two
additional
plants
are
being
tested
in
2003.

 
Results
The
2001
field­
testing
was
conducted
at
six
coal­
fired
power
plants.
Four
of
the
plants
are
equipped
with
SCR
controls,
one
plant
uses
SNCR
control,
and
one
plant
uses
ammonia
and
sulfur
trioxide
for
ash
conditioning
to
improve
particulate
control.
Field­
testing
was
conducted
in
2002
at
two
of
the
2001
SCR
equipped
plants
and
two
additional
plants
with
SCRs.
Overall
test
results
are
as
follows:
o
SNCR
and
NH3/
SO3
flue
gas
conditioning
did
not
affect
mercury
oxidation.
o
For
the
bituminous
plants,
the
increase
in
oxidized
mercury
across
the
SCR
varied
significantly
from
11
to
70
percentage
points.
The
oxidized
mercury
at
the
downstream
pollution
control
device
(
PCD)
inlet,
increased
from
­
1
to
37
percentage
points
with
an
average
of
17%.
However,
for
the
two
sites
with
minimal
SCR
oxidation,
the
non­
elemental
mercury
was
greater
than
90%
both
with
and
without
the
SCR.
o
SCR
catalyst
did
not
significantly
promote
the
oxidation
of
mercury
for
the
one
PRB
test
site.
The
oxidized
mercury
increased
20
percentage
points
across
the
SCR,
but
was
unchanged
at
the
PCD
inlet.
o
SCR
catalysts
promote
mercury
capture
in
wet
FGD
systems
and
possibly
reduce
the
re­
emission
of
elemental
mercury.
For
the
three
plants
with
SCR
and
wet
FGD,
mercury
removal
was
84
­
92%
(
average
89%)
with
SCR
operation
and
43
­
51%
(
average
48%)
without
SCR
operation.
o
SCR
size,
as
measured
by
space
velocity,
appeared
to
have
a
minimal
affect
on
mercury
oxidation
across
the
SCR.
There
was
no
significant
difference
in
non­
elemental
mercury
at
the
SCR
outlet
or
PCD
inlet
for
the
five
bituminous
plants.
o
Based
on
results
from
the
two
plants
tested
in
2001
and
2002,
it
is
uncertain
whether
SCR
catalyst
aging
affects
mercury
oxidation.
The
increase
in
oxidized
mercury
across
the
SCR
at
site
S2
decreased
from
43
percentage
points
in
2001
to
33
percentage
points
in
2002.
However,
there
was
no
change
in
oxidized
mercury
at
the
PCD
inlet
which
remained
approx.
97%.
The
increase
in
oxidized
mercury
across
the
SCR
at
site
S4
decreased
from
70
percentage
points
in
2001
to
29
percentage
points
in
2002.
Again
however,
there
was
no
change
in
oxidized
mercury
at
the
PCD
inlet
which
was
93%
in
2001
and
95%
in
2002.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Lynn
Brickett,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
EPRI.
Power
Plant
Evaluation
of
the
Effect
of
Selective
Catalytic
Reduction
in
Mercury;
EPRI
Report
No.
1005400;
December
2002.
o
Results
from
2001
field
testing
were
published
in
February
2003
edition
of
AWMA's
EM
Magazine.
o
L.
Brickett,
et.
al.;
Impact
of
SCR
on
Mercury
Speciation
for
Coal­
Fired
Boilers.
Presented
at
the
A&
WMA/
US
EPA/
DOE/
EPRI
Combined
Power
Plant
Air
Pollutant
Control
Mega
Symposium,
Washington,
DC,
May
19­
22,
2003.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Evaluation
of
Mercury
Control
Technologies
for
Utilities
Burning
Lignite
Coal
(
DE­
FC26­
98FT40321­
45)

 
Objective
Conduct
a
three­
year,
two­
phase
project
to
develop
and
test
sorbent
injection
mercury
control
technologies
for
utilities
that
burn
lignite
coal.
The
first
phase
of
the
project,
scheduled
for
2002­
2003,
is
to
conduct
bench­
scale
and
pilot­
scale
evaluation
for
screening
of
potential
sorbents.
The
second
phase
of
the
project,
scheduled
for
2003­
2004,
is
to
conduct
full­
scale
field
tests
of
the
selected
sorbents
at
a
lignite­
fired
power
plant.

 
Sponsors
The
project
is
being
funded
by
NETL
and
UNDEERC.
Other
participants
include
EPRI
and
several
electric
utilities
that
operate
lignite­
fired
plants.

 
Background
The
combustion
flue
gas
of
lignite­
fired
power
plants
primarily
contains
elemental
mercury
and
therefore
results
in
minimal
mercury
capture
across
the
existing
air
pollution
control
equipment.
Therefore,
potential
sorbents
must
be
evaluated
to
develop
a
cost­
effective
sorbent
injection
control
technology
applicable
to
lignite­
fired
plants.

 
Project
Description
The
bench­
and
pilot­
scale
testing
is
being
conducted
at
UNDEERC.
Initial
bench­
scale
laboratory
tests
were
conducted
on
11
different
sorbents
using
a
fixed­
bed
reactor
and
simulated
lignite
coal
combustion
flue
gas.
In
addition
to
commercially
available
activated
carbons,
several
high­
sodium
lignite
coals
were
used
to
produce
activated
carbons.
An
ARCADIS
calcium
silicate
sorbent
was
also
included
in
the
benchscale
testing.
The
pilot­
scale
testing
uses
the
200
acfm
UNDEERC
particulate
test
combustor
and
is
being
conducted
to
compare
the
sorbent
mercury
capture
effectiveness
of
an
ESP,
fabric
filter,
and
the
UNDEERC
advanced
hybrid
particulate
collector
(
AHPC).
The
pilot­
scale
testing
is
being
conducted
using
two
different
lignite
coals
(
Luscar
and
Freedom).

 
Schedule
Project
started
February
2002
and
is
to
be
completed
by
__________.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$__
million.
(
DOE
funding
$_____)

 
Status
The
Phase
I
bench­
and
pilot­
scale
testing
was
completed
in
November
2002.
A
Phase
I
draft
final
report
has
been
submitted
for
review.

 
Results
To
Date
Bench­
scale
tests
results
indicated
that
the
inactivated
lignite­
based
carbon
sorbents
and
calcium
silicate
were
not
effective.
The
lignite­
based
carbon
sorbents
activated
at
800oC
performed
significantly
better
than
the
same
carbon
sorbents
activated
at
750oC.
The
bench­
scale
testing
also
demonstrated
the
importance
of
hydrogen
chloride
in
the
flue
gas,
which
apparently
conditions
the
sorbents.
The
DARCO
FGD
and
800oC
activated
Luscar
char­
derived
sorbents
were
selected
for
further
pilot­
scale
testing.
Results
from
the
pilot­
scale
testing
are:
 
The
Poplar
River
coal
had
a
higher
mercury
concentration
than
the
Freedom
coal,
but
both
coals
resulted
in
similar
speciation
with
85%
elemental
and
15%
oxidized
mercury.
 
Lignite
coal
requires
a
higher
sorbent
feed
rate
for
similar
mercury
removal
compared
to
full­
scale
data
for
bituminous
coal.
To
achieve
70%
mercury
removal,
the
best
Luscar
sorbent
injection
rates
were
17.1,
7.8,
and
2.92
lb/
MMacf
for
the
ESP,
FF,
and
combined
ESP­
FF
configurations
respectively.
 
Mercury
removal
was
approximately
10
­
15
percentage
points
higher
for
the
Freedom
coal
compared
to
the
Poplar
River
coal
for
the
ESP­
only
configuration.
 
Mercury
removal
was
approx.
10
­
15
percentage
points
lower
for
both
the
Freedom
and
Poplar
River
coals
when
the
flue
gas
temperature
was
increased
from
300
°
to
400
°
F
for
all
particulate
control
configurations.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Lynn
Brickett,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
Pavlish,
J.;
Pilot­
Scale
Investigation
of
Mercury
Control
Technologies
for
Utilities
Burning
Lignite
Coal.
Presented
at
the
A&
WMA/
US
EPA/
DOE/
EPRI
Combined
Power
Plant
Air
Pollutant
Control
Mega
Symposium,
Washington,
DC,
May
19­
22,
2003.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Integrated
System
to
Control
Primary
PM2.5
from
Electric
Power
Plants
(
Mercury
Control
with
the
Advanced
ElectroCore
Particulate
Collector)
(
DC­
FC26­
00NT­
40757)

 
Objective
Under
its
particulate
control
program
DOE/
NETL
is
sponsoring
the
pilot­
scale
development
of
LSR
Technologies'
particulate
control
technology
known
as
ElectroCore.
In
addition
to
particulate
removal,
the
mercury
removal
performance
of
the
ElectroCore
process
was
evaluated
in
conjunction
with
powdered
activated
carbon
(
PAC)
injection.

 
Sponsors
The
project
is
being
funded
by
NETL
and
LSR
Technologies.
Other
participants
include
EPRI,
EPA,
and
Alabama
Power
Company
(
Southern
Company
Services).

 
Background
The
ElectroCore
is
an
electrically
enhanced
mechanical
separator
designed
to
be
retrofitted
downstream
of
an
existing
ESP
to
optimize
fine
particulate
collection.
The
ElectroCore
process
first
pre­
charges
the
ash
particles
and
then
uses
combined
electrical
and
centrifugal
forces
to
separate
the
flue
gas
into
"
dirty"
and
"
clean"
gas
streams.
The
centrifugal
particulate
separation
is
achieved
using
cylindrical
separators
with
a
tangential
inlet,
a
tangential
dirty
gas
outlet,
and
a
dual
axial
clean
gas
outlet.
The
centrifugal
separation
is
enhanced
by
a
centrally
located
electrode
within
the
separator.
The
electrode
is
charged
with
the
same
polarity
as
the
ash
particles
thereby
further
driving
the
particles
to
the
dirty
gas
outlet.
The
dirty
gas
stream
can
either
be
recirculated
to
the
inlet
of
the
upstream
ESP
or
diverted
to
a
polishing
ESP
or
FF.

 
Project
Description
The
pilot­
scale
testing
was
conducted
at
Alabama
Power
Company's
E.
C.
Gaston
Unit
No.
4
located
in
Wilsonville,
Alabama.
The
plant
burns
a
Powder
River
Basin
subbituminous
coal.
The
5,000
acfm
pilot
plant
consists
of
a
dry
scrubber,
water­
cooled
pre­
charger
and
advanced
ElectroCore
module.
In
addition
to
particulate
removal,
the
mercury
removal
performance
of
the
ElectroCore
process
was
evaluated
in
conjunction
with
PAC
injection.

 
Schedule
Project
started
February
2000
and
was
to
be
completed
in
June
2002.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
1.6
million.
(
DOE
funding
$
1,191,267)

 
Status
The
pilot­
scale
testing
was
conducted
from
November
2001
through
February
2002.
A
final
report
for
the
ElectroCore
particulate
collection
test
results
was
issued
in
February
2003.
A
final
report
on
the
mercury
testing
phase
of
the
project
is
not
yet
available.

 
Results
To
Date
Preliminary
test
results
indicate
the
ElectroCore
process
captures
approximately
90%
of
the
total
mercury
at
a
PAC
injection
rate
of
7
lb/
MMacf.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Peter
Botros,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
Altman,
Ralph;
Easom,
Bruce;
Harrison,
Wallace
Results
of
ElectroCore
Pilot
Testing
at
E.
C.
Gaston
Steam
Plant.
In
Proceedings
of
Air
Quality
III:
Mercury,
Trace
Elements,
and
Particulate
Matter
Conference;
Arlington,
VA,
September
9­
12,
2002.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
In­
Situ
Sorbent
Removal
of
Mercury:
The
THIEF
Process
(
NETL
In­
house
project)

 
Objective
Conduct
pilot­
scale
testing
at
NETL
to
develop
an
alternative
mercury
control
technology
using
an
activated
carbon
sorbent
produced
in­
situ
at
the
power
plant.

 
Sponsors
NETL
In­
house
R&
D
 
Background
The
THIEF
process
(
U.
S.
Patent
No.
6,521,021)
removes
mercury
from
coal
combustion
flue
gas
by
adsorption/
absorption
onto
thermally
activated
sorbent
produced
in­
situ.
The
sorbent
consists
of
semicombusted
coal,
which
is
extracted
from
the
furnace
and
then
injected
into
the
flue
gas
downstream
of
the
air
preheater.
The
thermally
activated
sorbent
reacts
with
the
mercury
and
is
removed
from
the
flue
gas
by
the
downstream
particulate
control
device.

 
Project
Description
Pilot­
scale
testing
of
the
THIEF
process
was
conducted
using
the
NETL
500
pound­
perhour
pulverized
coal­
fired
combustion
system
that
includes
a
furnace,
air
pre­
heater,
spray
dryer,
ductwork,
and
a
pulse­
jet
fabric
filter.

 
Schedule
On­
going
in­
house
research
and
development
project.

 
Cost
Annual
in­
house
allocation.

 
Status
Continued
testing
of
the
THIEF
process
will
be
carried
out
in
the
500­
lb/
hr
combustor
while
burning
different
coals
(
i.
e.
PRB
coal).

 
Results
To
Date
The
in­
situ
produced
sorbent
is
not
as
reactive
as
commercially
available
activated
carbon,
but
pilot­
scale
testing
indicates
that
mercury
removal
efficiencies
of
up
to
70%
are
achievable.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Bill
O'Dowd,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
Pennline,
H.
W.;
Granite,
E.
J.;
Freeman,
R.
A.;
Hargis,
R.
A.;
O'Dowd,
W.
J.
A
Technique
to
Control
Mercury
From
Flue
Gas.
Presented
at
the
AIChE
Annual
Meeting,
Indianapolis,
IN,
November
2002.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Photochemical
Removal
of
Mercury:
The
GP­
254
Process
(
NETL
In­
house
project)

 
Objective
Conduct
bench­
scale
testing
at
NETL
to
develop
an
alternative
mercury
control
technology.

 
Sponsors
NETL
in­
house
R&
D
 
Background
The
GP­
254
process
(
U.
S.
patent
pending)
uses
253.7­
nm
ultraviolet
radiation
to
induce
components
of
flue
gas
to
react
with
elemental
mercury
and
subsequently
cause
an
increase
in
the
fraction
of
oxidized
mercury.
The
oxidized
mercury
species
can
then
be
captured
near
the
radiation
zone
or
in
downstream
particulate
control
or
wet
FGD
pollution
control
equipment.

 
Project
Description
Small­
scale
laboratory
testing
using
simulated
flue
gases
have
been
used
to
demonstrate
the
process.

 
Schedule
Complete.
Tool
base.

 
Cost
Exploratory
funding
as
needed.

 
Status
Complete.

 
Results
To
Date
See
publication.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Evan
Granite,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
o
Granite,
Evan;
Pennline,
Henry
Photochemical
Removal
of
Mercury
from
Flue
Gas.
Industrial
&
Engineering
Chemistry
Research,
October
2002.

Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Long­
Term
Operation
of
a
COHPAC
System
for
Removing
Mercury
from
Coal­
Fired
Flue
Gas
(
DE­
FC26­
02NT­
41591)

 
Objective
Conduct
a
one­
year
long­
term
performance
evaluation
of
the
impact
of
powdered
activated
carbon
injection
on
the
COHPAC
fabric
filter
particulate
collection
system
at
Alabama
Power's
E.
C.
Gaston
Plant.
Longterm
testing
will
determine
whether
PAC
injection
with
COHPAC
is
a
viable,
long­
term
approach
for
mercury
control.
The
testing
will
also
determine
design
criteria
and
costs
for
new
retrofit
COHPAC
systems
as
well
as
balance­
of­
plant
impacts.

 
Sponsors
The
project
is
being
funded
by
NETL
and
ADA
Environmental
Solutions.
Other
participants
include
Southern
Company,
Reaction
Engineering,
Southern
Research
Institute,
Grubb
Filtration
Testing
Services,
Hamon
Research­
Cottrell,
EPRI,
and
several
utility
company
sponsors.

 
Background
ADA­
ES
conducted
a
successful
two­
week
demonstration
of
PAC
injection
at
Gaston
in
April
2001.
The
objective
of
this
project
is
to
evaluate
the
long­
term
effects
of
PAC
injection
on
mercury
capture
and
COHPAC
performance.
Of
particular
concern
during
PAC
injection
is
the
increased
cleaning
frequency
of
the
COHPAC
which
could
adversely
affect
filter
bag
life.

 
Project
Description
The
full­
scale
demonstration
testing
is
being
conducted
at
Alabama
Power's
270
MW
E.
C.
Gaston
Unit
3
which
burns
low
sulfur
bituminous
coal
and
uses
a
hot­
side
ESP
and
COHPAC
fabric
filter
for
particulate
control.
The
long­
term
testing
will
include
six­
month
PAC
injection
with
the
existing
COHPAC
filter
bags
and
six­
month
PAC
injection
with
new
high­
permeation
filter
bags.
Demonstration
will
also
include
testing
of
alternate
sorbents.

 
Schedule
Project
started
September
2002
and
is
to
be
completed
in
October
2005.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
2.4
million.
(
DOE
funding
$
1,356,976)

 
Status
Baseline
testing
completed
in
April
2003.
PAC
injection
optimization
testing
conducted
in
May
2003.

 
Results
To
Date
Preliminary
baseline
test
results
include:
1)
higher
COHPAC
cleaning
frequency
compared
to
April
2001
Phase
I
tests;
2)
large
variation
(
0
to
90%)
in
baseline
mercury
removal;
and
3)
higher
carbon
content
in
COHPAC
hopper
ash
compared
to
Phase
I
tests.
Based
on
results
of
optimization
testing,
the
PAC
injection
rate
was
lowered
from
1.5
to
0.3
lb/
MMacf.
Average
mercury
removal
varied
from
70
to
95%
at
0.3
lbs/
MMacf
PAC
injection
rate
during
early
May
optimization
testing.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Scott
Renninger,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Preliminary
Field
Evaluation
of
Mercury
Using
Combustion
Modifications
(
DE­
FC26­
03NT­
41725)

 
Objective
Conduct
a
two­
year
field
evaluation
using
a
combination
of
overfire
air
(
OFA)
and
coal
reburn
to
achieve
multi­
pollutant
control
of
both
NOx
and
mercury.
Combustion
modifications
will
be
used
to
increase
the
reactivity
of
fly
ash
to
enhance
mercury
adsorption
and
resultant
capture
in
a
downstream
ESP
or
FF.

 
Sponsors
The
project
is
being
funded
by
NETL
and
General
Electric
Energy
and
Environmental
Research
Corporation
(
GE
EER).
Other
participants
include
Western
Kentucky
Energy.

 
Background
GE
EER
has
been
developing
the
use
of
OFA
and
coal
reburn
as
a
NOx
control
technology.
Coal
reburn
pilot­
scale
testing
demonstrated
that
fly
ash
with
unburned
carbon
formed
"
in
situ"
can
adsorb
mercury
under
certain
operating
conditions.

 
Project
Description
The
field­
testing
will
be
conducted
at
Western
Kentucky
Energy's
RD
Green
Power
Station,
which
burns
a
blend
of
Illinois
bituminous
coal
and
petroleum
coke.
Field
measurements
of
fly
ash
properties
and
mercury
removal
across
the
ESP
will
be
taken
on
Unit
No.
1
after
installation
of
an
OFA
and
coal
reburn
system
for
NOx
control.
Data
from
the
Unit
No.
1
field
testing
will
be
used
to
optimize
the
design
of
the
NOx
control
system
for
mercury
removal
using
a
300
KW
pilot­
scale
combustor
at
GE
EER's
test
facility.
Results
from
the
pilot­
scale
testing
will
be
used
for
the
design
of
the
OFA
and
coal
reburn
system
to
be
installed
on
RD
Green
Unit
No.
2.
Mercury
removal
performance
will
then
be
tested
on
Unit
No.
2
after
installation
of
the
optimized
NOx
control
system.

 
Schedule
Project
started
January
2003
and
is
to
be
completed
in
July
2004.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
0.8
million.
(
DOE
funding
$
489,600)

 
Status
Baseline
mercury
emission
testing
to
be
conducted
in
May
2003.

 
Results
To
Date
None
available.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Peter
Botros,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Evaluation
of
Mercury
Emissions
from
Coal­
Fired
Facilities
with
SCR­
FGD
Systems
(
DE­
FC26­
02NT­
41589)

 
Objective
Conduct
field
testing
at
ten
bituminous
coal­
fired
power
plants
equipped
with
selective
catalytic
reduction
(
SCR)
control
technologies
to
determine
their
effect
on
the
speciation
of
mercury
in
the
combustion
flue
gas
and
resultant
enhancement
of
mercury
emissions
capture
in
downstream
flue
gas
desulfurization
(
FGD)
control
equipment.

 
Sponsors
The
project
is
being
funded
by
NETL
and
CONSOL.
Other
participants
include
numerous
electric
utility
companies
that
are
providing
host
sites
for
the
testing.

 
Background
Previous
field
testing
indicated
that
NOx
SCR
catalyst
converts
some
of
the
elemental
mercury
to
oxidized
mercury
in
the
flue
gas
and
therefore
can
enhance
overall
mercury
capture
in
downstream
pollution
control
equipment.
However,
the
amount
of
SCR
mercury
oxidation
has
been
quite
variable
from
plant­
to­
plant.
Previous
field
testing
has
also
indicated
some
inconsistencies
in
the
mercury
capture
performance
of
wet
FGD
systems
due
to
possible
evolution
of
elemental
mercury.
This
field
testing
project
is
necessary
to
evaluate
the
effectiveness
of
SCR
to
promote
the
oxidation
and
subsequent
capture
of
elemental
mercury
in
full­
scale
commercial
FGD
applications.

 
Project
Description
Conduct
mercury
speciation
field­
testing
at
ten
bituminous
coal­
fired
power
plants
to
measure
the
level
of
mercury
oxidation
across
the
SCR
and
subsequent
removal
in
the
downstream
FGD
system.
The
27­
month
long
program
will
include
testing
at
five
plants
equipped
with
an
SCR
and
wet
limestone
FGD,
three
plants
with
an
SCR
and
wet
lime
FGD,
and
two
plants
with
an
SCR
and
dry
lime
FGD.

 
Schedule
Project
started
September
2002
and
is
to
be
completed
in
September
2005.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
0.7
million.
(
DOE
funding
$
584,419)

 
Status
Two
plants
had
been
tested
as
of
5/
30/
03.

 
Results
To
Date
None
available.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Peter
Botros,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Direct
Measurement
of
Mercury
Reactions
in
Coal
Power
Plant
Plumes
(
DE­
FC26­
03NT­
41724)

 
Objective
Conduct
field
testing
to
characterize
the
speciation
of
mercury
in
the
stack
plume
of
a
coal­
fired
power
plant.

 
Sponsors
The
project
is
being
funded
by
NETL
and
EPRI.
Other
participants
include
UNDEERC,
Frontier
Geosciences
and
We
Energies.

 
Background
The
proportions
of
elemental
and
oxidized
species
of
mercury
emissions
from
coal­
fired
power
plants
may
influence
the
relative
location
of
their
potential
environmental
impact.
Gaseous
elemental
mercury
is
relatively
unreactive
and
can
persist
in
the
atmosphere
for
periods
of
months
to
years
before
returning
to
the
surface
environment.
However,
gaseous
oxidized
mercury
is
more
reactive
and
likely
to
return
to
the
surface
environment
locally
or
regionally
via
wet
or
dry
deposition.
However,
atmospheric
reactions
might
occur
after
release
from
the
stack
that
alters
the
proportion
of
elemental
and
oxidized
mercury
species.
Previous
analysis
of
mercury
concentrations
measured
at
an
ambient
monitor
located
about
15
km
south
of
Southern
Company's
Bowen
Plant
suggested
that
a
significant
portion
of
Bowen's
oxidized
mercury
stack
emissions
may
have
been
reduced
to
elemental
mercury
while
being
transported
to
the
monitoring
site.

 
Project
Description
Conduct
field
testing
to
characterize
the
speciation
of
mercury
in
the
stack
plume
of
We
Energies'
Pleasant
Prairie
Plant.
The
tests
include
simultaneous
mercury
measurements
in
the
stack
and
stack
plume
using
aircraft­
borne
instruments.
The
in­
stack
and
stack
plume
measurements
will
be
compared
to
determine
whether
the
speciation
of
mercury
changes
as
it
is
transported
downwind
in
the
plume.
In
addition
to
the
in­
stack
and
stack
plume
mercury
measurements,
a
plume
dilution
sampling
device
is
being
used
in
an
attempt
to
simulate
the
cooling
and
dilution
processes
that
occur
in
the
stack
plume.
If
results
of
the
plume
dilution
sampling
device
are
comparable
to
the
stack
plume
measurements
it
could
be
used
to
estimate
the
mercury
speciation
changes
for
other
plants.

 
Schedule
Project
started
March
2003
and
is
to
be
completed
in
September
2004.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
0.8
million.
(
DOE
funding
$
648,154)

 
Status
Stack
plume
measurements
scheduled
to
be
conducted
in
July
2003.

 
Results
To
Date
None
available.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Bill
Aljoe,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Evaluation
of
Mercury
Speciation
in
a
Power
Plant
Plume
(
DE­
FC26­
98FT40321­
54)

 
Objective
Conduct
field
testing
to
characterize
the
speciation
of
mercury
in
the
stack
plume
of
a
coal­
fired
power
plant.

 
Sponsors
The
project
is
being
funded
by
NETL
and
UNDEERC.
Other
participants
include
EPRI,
Frontier
Geosciences,
TVA
and
Southern
Company.

 
Background
The
proportions
of
elemental
and
oxidized
species
of
mercury
emissions
from
coal­
fired
power
plants
may
influence
the
relative
location
of
their
potential
environmental
impact.
Gaseous
elemental
mercury
is
relatively
unreactive
and
can
persist
in
the
atmosphere
for
periods
of
months
to
years
before
returning
to
the
surface
environment.
However,
gaseous
oxidized
mercury
is
more
reactive
and
likely
to
return
to
the
surface
environment
locally
or
regionally
via
wet
or
dry
deposition.
However,
atmospheric
reactions
might
occur
after
release
from
the
stack
that
alters
the
proportion
of
elemental
and
oxidized
mercury
species.
Previous
analysis
of
mercury
concentrations
measured
at
an
ambient
monitor
located
about
15
km
south
of
Southern
Company's
Bowen
Plant
suggested
that
a
significant
portion
of
Bowen's
oxidized
mercury
stack
emissions
may
have
been
reduced
to
elemental
mercury
while
being
transported
to
the
monitoring
site.

 
Project
Description
Conduct
field
testing
to
characterize
the
speciation
of
mercury
in
the
stack
plume
of
Southern's
Bowen
Plant.
The
tests
include
simultaneous
mercury
measurements
in
the
stack
and
stack
plume
using
aircraft­
borne
instruments.
The
in­
stack
and
stack
plume
measurements
will
be
compared
to
determine
whether
the
speciation
of
mercury
changes
as
it
is
transported
downwind
in
the
plume.
In
addition
to
the
in­
stack
and
stack
plume
mercury
measurements,
a
plume
dilution
sampling
device
is
being
used
in
an
attempt
to
simulate
the
cooling
and
dilution
processes
that
occur
in
the
stack
plume.
 
Schedule
Project
started
October
2002
and
was
completed
in
March
2003.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
68,000.
(
DOE
funding
$
27,324)

 
Status
Testing
completed
in
October
2002.

 
Results
To
Date
None
available.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Bill
Aljoe,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Oxidation
of
Mercury
Across
SCR
Catalysts
in
Coal­
Fired
Power
Plants
Burning
Low­
Rank
Coals
(
DE­
FC26­
02NT­
41728)

 
Objective
Conduct
pilot­
plant
testing
to
determine
the
effect
of
various
NOx
SCR
catalysts
on
mercury
speciation
for
plants
that
burn
subbituminous
Powder
River
Basin
coal.

 
Sponsors
The
project
is
being
funded
by
NETL
and
Reaction
Engineering.
Other
participants
include
EPRI,
Ceramics
GmbH,
and
American
Electric
Power
(
AEP).

 
Background
Previous
field
testing
indicated
that
NOx
SCR
catalyst
converts
some
of
the
elemental
mercury
to
oxidized
mercury
in
the
flue
gas
and
therefore
can
enhance
overall
mercury
capture
in
downstream
pollution
control
equipment.
However,
the
amount
of
SCR
mercury
oxidation
has
been
quite
variable
from
plant­
to­
plant
and
there
is
limited
test
data
available
for
PRB
coal
applications.
This
pilot­
plant
testing
is
necessary
to
evaluate
the
effectiveness
of
various
SCR
catalysts
to
promote
the
oxidation
of
elemental
mercury
in
PRB
coal
applications.

 
Project
Description
Conduct
a
six­
month­
long
pilot­
scale
mercury
speciation
test
for
five
commercially
available
NOx
SCR
catalysts
using
a
flue
gas
slipstream
at
AEP's
1300
MW
Rockport
Power
Plant
Unit
1,
which
burns
a
subbituminous
Powder
River
Basin
coal.
Parametric
testing
will
evaluate
the
effect
of
space
velocity
(
residence
time)
and
ammonia
feed
rate
on
mercury
oxidation
across
the
SCR
catalysts.

 
Schedule
Project
started
February
2003
and
is
to
be
completed
in
August
2003.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
120,000.
(
DOE
funding
$
69,698)

 
Status
The
initial
mercury
speciation
testing
was
completed
in
April
2003.

 
Results
To
Date
Preliminary
results
from
the
initial
mercury
speciation
testing
are
under
review.
Some
general
observations
from
the
S­
CEM
measurements
are:
1)
mercury
oxidation
ranged
from
approx.
0%
to
50%
across
the
five
catalysts
at
a
space
velocity
of
5,700
hr­
1,
2)
mercury
oxidation
increased
to
60%
to
80%
without
ammonia
feed,
3)
an
unexplained
10%
to
40%
reduction
of
total
mercury
was
measured
across
the
catalysts,
4)
mercury
oxidation
decreases
as
space
velocity
increases.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Jose
Figueroa,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
Return
to
Project
Summary
Table
DOE/
NETL
Environmental
&
Water
Resources
Mercury
Control
Technology
Project
Fact
Sheet
Mercury
and
Air
Toxics
Element
Impacts
of
Coal
Combustion
Byproduct
Disposal
and
Utilization
(
DE­
FC26­
03NT­
41727)

 
Objective
Conduct
laboratory
and
field­
testing
to
evaluate
the
potential
release
of
mercury
and
other
air
toxic
elements
associated
with
the
disposal
and
commercial
use
of
various
ash
and
FGD
coal
utilization
by­
products
from
conventional
and
advanced
pollution
control
systems.

 
Sponsors
The
project
is
being
funded
by
NETL
and
UNDEERC.

 
Background
There
is
limited
data
available
on
the
environmental
acceptability
of
CUBs
produced
at
plants
with
various
conventional
and
advanced
emission
control
systems.

 
Project
Description
CUBs
from
bituminous,
subbituminous,
and
lignite
fuels
will
be
included
in
the
evaluation.
The
project
includes
a
literature
search,
selection
of
analytical
methods,
selection
of
CUB
samples,
chemical
and
physical
characterization
of
samples,
laboratory
testing
of
release
mechanisms,
and
field
investigations.
The
potential
release
mechanisms
to
be
evaluated
include
leaching,
vaporization
at
ambient
and
elevated
temperature,
and
biologically
induced
releases.

 
Schedule
Project
started
January
2003
and
is
to
be
completed
in
January
2006.

 
Cost
The
total
budget
cost
for
the
project
is
approximately
$
1.5
million.
(
DOE
funding
$
1,200,000)

 
Status
A
project
kick­
off
meeting
was
conducted
in
April
2003.

 
Results
To
Date
None
available.

 
Contacts
For
further
information
on
this
project,
contact
NETL
Project
Manager,
Nam
Lee,
or
visit
the
NETL
website
at
http://
www.
netl.
doe.
gov/
coalpower/
environment/
index.
html
 
Publications
Return
to
Project
Summary
Table
