Optimizing Scrubber Performance

Stewart Nicholson Primex Process Specialists, Inc. Introduction Coal fired power generating facilities in the U.S. currently spend over $200 million per year on lime for flue gas treatment[1]. This expenditure is expected to increase by more than $100 million per year by 2020, as more stringent emission regulations take effect and 31,000 megawatts of new coal-fired generating 2 capacity are added[ ]. At facilities equipped with dry scrubbers, recent research and practical experience shows that lime consumption can be substantially reduced by optimization of the reagent preparation process. In addition to reducing lime consumption, other financial and operational benefits may include reduced corrosion in downstream components, greater safety and improved dependability.
CLEAN FLUE GAS LIM E SLURRY
PROCESS WATER PROCESS ORWATER RECYCLE ASH SLURRY

Corey Linville Sunflower Electric Power Corp..

SO 2

BOILER FLUE GAS

A SPRAY D RYER REACTOR ABSORBER B

SO 2

T EM P

BA GHOUSE C

STACK STACK

FLYASH

FIGURE 1. Typical Dry Scrubber FGT Process

Sunflower Electrics Holcomb Station is typical of many coal fired facilities using dry scrubber technology for flue gas treatment. This paper describes a general model applicable to dry scrubber processes and successful application of that model and related principles to reduce lime consumption at Holcomb Station. Dry Scrubber Operation A typical dry scrubber type flue gas treatment (FGT) process is shown in Fig. 1. Boiler flue gas enters the spray drier absorber (SDA) at point A where reagent slurry is sprayed into the gas stream. At coal-fired facilities, gas temperature at this point is approximately equal to air preheater temperature, typically ranging from 250F to 350F. The reagent slurry typically consists of a mixture of solid hydrated lime (calcium hydroxide) suspended in water which may also include recycled flyash solids. Evaporation of the liquid water begins immediately at point A and continues until the drying process is complete at point B where gas temperature is typically 150F 190F. Gas temperature at this point is controlled by varying the water (or recycle ash slurry) flowrate to the SDA while SO2 removal is controlled by varying reagent flowrate.

The Gas Temperature Effect and Scrubber Process Model Common practical experience shows that gas temperature at the SDA outlet (point B) significantly affects SO2 removal and lime consumption. This effect is substantial; measurements at operating facilities show that a five degree reduction in SDA outlet temperature can reduce lime consumption by 10-30%. The effect of SDA outlet temperature on performance can be modeled by assuming a relationship between SO2 absorption rate, drying time and temperature. Referring to Figures 1 and 2 together, reagent enters the gas stream at point A as a slurry of solid calcium hydroxide particles suspended in liquid water. During the evaporation phase (between points A and B), the presence of liquid water enables the solid lime to dissolve and react rapidly with the gaseous sulfur dioxide. This rapid absorption process continues until the liquid water is fully evaporated at point B. After evaporation is complete, the remaining dry solids continue absorbing acid gas between points B and C, however the reaction rate in this dry solid phase is substantially reduced.

The model illustrated in Fig. 2 shows that decreasing SDA outlet temperature will prolong the rapid reaction phase (shifting point B to the right), thereby increasing total SO2 absorption. Conversely, increasing outlet gas temperature shortens the rapid reaction phase and reduces total absorption. Hence, for a given SO2 removal target, this model predicts that lime consumption will be affected significantly by SDA outlet temperature. The Lime Slurry Reactivity Effect

LIQUID SLURRY PHASE

DRY SOLID PHASE

B SO2 ABSORBED

DIMINISHED REACTION RATE

A TIME

In addition to gas temperature effects, recent experience at facilities such as Holcomb Station shows that lime consumption can be significantly affected by changes to the lime slaking process. This effect is believed to be related to reagent properties (such as hydrated lime solids surface area) that affect the dissolution and absorption rates. The same principles discussed above predict this effect; as shown in Figure 3, accelerating the absorption rate (at a fixed SDA outlet temperature) should increase SO2 absorption and thereby decrease lime consumption. While gas temperature is readily measured and controlled in dry scrubbers, SO2 absorption rate and the factors affecting it are not practically measurable in operating systems. However, a method for measuring lime slurry reactivity (defined herein as the rate at which a particular lime slurry absorbs sulfuric acid in the liquid phase) has been developed[3]. Reactivity measurements using this method show a significant correlation to scrubber performance. This correlation suggests that reactivity is valid as a key indicator of absorption rate and that the absorption rate model presented in Fig. 3 is also valid.

FIGURE 2. Effect of Evaporation on SO2 Absorption

Figure 3 suggests another important possibility. With the accelerated absorption afforded by a more reactive reagent, the slope of the absorption curve is flatter at the evaporation point (C); therefore, absorption should be less sensitive to gas temperature changes. While this effect is yet to be verified experimentally, it suggests that increasing the absorption rate may not only reduce lime consumption but may also enable higher operating temperatures, thereby reducing corrosion and solids buildup.
DRY SOLID PHASE

LIQUID SLURRY PHASE

REMOVAL EFFICIENCY GAINED

SO2 ABSORBED

ACCELERATED REACTION RATE

NORMAL REACTION RATE

A TIME

FIGURE 3. Effect of Increasing Absorption Rate

Factors Affecting Lime Slurry Reactivity At most dry scrubber facilities, reagent is produced by onsite slaking of quicklime (calcium oxide) to produce a slurry of solid hydrated lime (calcium hydroxide) particles. The factors affecting the lime slaking process and their effect on lime slurry properties have been well documented4. These factors include: Reactant Chemical and Physical Properties Slaking Water Temperature Water to Quicklime Ratio Slaker Residence Time Slaking Process Stability Recent research indicates that these same factors affect lime slurry reactivity and that they can be optimized to improve reactivity considerably. Holcomb Station A Case Study Summary Located near Garden City, Kansas, Holcomb Station is a 360 megawatt coal-fired power generating station owned by Sunflower Electric Power (SEP) Corporation. The station became operational in 1983 and is equipped with a dry scrubber type FGT system consisting of three SDA modules and fabric filter baghouse, similar to the configuration shown above in Fig. 1. Reagent is prepared by slaking quicklime to produce hydrated lime slurry as shown in Fig. 4. The lime slurry is then mixed with recycled (baghouse) flyash slurry and fed to the SDA modules through rotary atomizers.

Test Methodology Scrubber performance was evaluated by measuring specific lime consumption (the mass ratio of quicklime consumed to SO2 removed). The test plan included two basic steps to quantify the effect of lime slurry reactivity on specific lime consumption at Holcomb Station. The first step was to establish baseline performance with the existing reagent preparation processes. The second step was to modify the reagent preparation process and, to the extent practical, hold all other variables constant (as compared to the baseline tests) while measuring specific lime consumption. Lime slurry reactivity was measured during each of the test steps. Quicklime used during conveyed as usual into This material handling pulverization of the Quicklime used during the baseline test was received, one of the two lime day bins. process resulted in significant quicklime prior to slaking. the modified process test was
TO ATOMIZER FEED TANK

LIME DAY BIN WATER HEATER

GRIT SCREEN

PROCESS WATER

WEIGHBELT FEEDER

BALL MILL LIME SLAKER

LIME SLURRY TANK LIME SLURRY SUMP

An evaluation of scrubber performance at Holcomb Station in March 2003 FIGURE 4. revealed low slurry reactivity. The evaluation report concluded that optimization of the reagent preparation processes could substantially improve scrubber performance. Actions to improve slurry reactivity were identified and implemented during a series of reagent preparation and scrubber performance tests in August and October 2003. Test results yielded two significant conclusions. First, that lime slurry reactivity could be approximately doubled by changes to reagent handling and preparation processes; and second, that lime consumption at full load was 22% lower with the more reactive slurry.

Holcomb Station Lime Slurry Preparation System

conveyed pneumatically by self unloading bulk delivery trucks directly into the other lime day bin, thus bypassing the storage silo and two-step pneumatic conveying process. In addition, during the modified process test, slurry was prepared with slaking process conditions chosen to maximize lime slurry reactivity. Comparing the modified slaking process to the baseline process, the principal changes were: Use of pebble quicklime (modified test) vs. pulverized quicklime (baseline test).

Slaking water temperature was increased and controlled to enable higher slaking temperatures during the modified test. Slaking water flowrate and quicklime feedrate were controlled to stabilize slaking temperature at the maximum safe temperature during the modified test. Lime slurries produced during the baseline and modified slaking processes were stored in separate holding tanks. These slurries were then fed to the scrubber during two separate 24 hour periods, during which SDA outlet temperature was set to 175F and all other operating parameters recorded. Observations and Results Scrubber operating parameters and performance indicators are presented in Table 1 below. Lime slurry reactivity results are shown in Fig. 5. As expected, the multiple storage and conveying steps caused substantial pulverization of quicklime used during the baseline test, with approximately 65% passing #40 mesh measured at the slaker inlet. Quicklime for the modified test was mostly pebbled material with only 6% passing #40 mesh. However as slaking progressed the quantity of fines increased to 52% passing #40 mesh. The existing electric circulation heater used for slaking water had been refurbished to enable optimum slaking process control. The piping configuration is such that slaking water is supplied to both ball mills through this heater, hence the B mill water was heated whenever the A mill was operating[5]. Reliable slaking water temperature indication was not available, however measurements taken during the flushing cycles indicated that the heater was yielding a temperature increase of approximately 15F with normal slaking water flow for one operating mill. During slaker operation slaking temperatures were 145-162F in the B (baseline) mill and 195-200F in the A mill. Temperature in the A mill was not reliably indicated with the plant instrumentation due to the cooling effect of the trommel screen spray water. This temperature was measured manually for the duration of the modified slaking process and controlled by manual adjustment of lime feedrate and slaking water flowrate. Lime slurry produced during modified slaking in mill A appeared to be substantially more viscous than slurry produced in the B mill6. Additional dilution water was therefore required to maintain sufficient agitation in the A mill sump. This additional water resulted in a reduction in solids concentration (after dilution) to approximately 15% in the modified slurry as compared to 21% in the baseline slurry. While lime slurry flowrate to

the scrubber was proportionately higher, the solids difference is not believed to have affected scrubber performance significantly. Other factors that may influence specific lime consumption were comparable for the duration of the test periods as shown in Table 1 below. Inlet SO2 (and therefore SO2 removed) was higher during the modified slaking test than the baseline test, however previous data at Holcomb suggests this difference should not significantly affect specific lime consumption. Conclusions and Recommendations Analysis of scrubber performance data from the two tests yielded the following principal conclusions: Lime consumption over 24 hours averaged 14% lower with the modified slaking as compared to baseline consumption. Lime consumption over the 16 hour full load (365 mW) period averaged 22% lower with the modified slaking as compared to baseline performance. Laboratory analysis of lime slurry samples as shown in Figure 5 indicates that lime slurry produced during the modified slaking process was approximately twice as reactive (acid absorbed vs. time) than the baseline slurry. Following analysis of test results and conclusions, Primex offered the following recommendations 1. Stabilize and Optimize Quicklime Properties a. Modify or bypass the existing quicklime unloading, storage and conveying system to minimize quicklime particle size reduction. b. Review quicklime supplier options, change supplier and/or supply specifications as required to maximize as delivered quicklime quality and value. c. Test quicklime properties (temperature rise, available CaO and particle size) on an ongoing basis to ensure compliance with supply specifications. 2. Reconfigure Lime Slaking Process Equipment, Instrumentation and Controls to Maximize Lime Slurry Reactivity a. Relocate dilution water flow transmitter or trommel screen spray water takeoff branch to enable accurate dilution water flow indication.

b. c. d.

e.

Relocate thermowell for accurate indication of slaking temperature Add slaking water inlet temperature instrumentation to indicate inlet water temperature locally and remotely. Modify 120 kW heater controls as required to maintain water temperature within specified limits and to prevent excessive or uncontrolled heat addition. Reconfigure slaking system automatic controls to enable safe and stable slaker operation at 195200F operating temperature.

f.

Reconfigure slaking system automatic controls to enable continuous (demand paced) slaker operation.

3. Education and Training for Operations and Maintenance Personnel a. Initial training for all scrubber operations and maintenance personnel in dry scrubber theory and practice, lime slaking concepts, reagent key performance indicators, measurement and performance optimization techniques. b. Recurrent (annual) training as required for existing personnel, new hires and transfers.

Table 1. Holcomb Station Scrubber Test Results 24 Hr. Average Values

Pr oce ss Va r ia ble Coal Flow Rate (tons/ hr) Inlet SO2 (lbs/ m m btu) Outlet SO2 (lbs/ m m btu) SO2 Rem oved (lbs/ hr) SDA Inlet Tem p Avg. SDA Outlet Tem p Avg. Lim e Slurry Density (% Solids) Lim e Slurry Flow Rate (gpm ) Quicklim e Consum ed (lbs/ hr) Reactor Slurry Flow Rate Total (gpm ) Additive Tank Dilution Water Flow Rate (gpm ) Ash Flow Rate (100 lbs/ hr) SO2 Rem oval Rate % Specific Lim e Consum ption (quicklim e/ SO2) 2 4 h r Pe r iod V a r ia ble Loa d Ba se line M odifie d Sla k in g 189 188 0.74 0.84 0.17 0.18 1853 2154 290 292 175 176 20.7 15.5 30 41 2679 2686 291 298 183 180 928 947 77% 78% 1.46 1.26 1 6 hr s St e a dy St a t e Full Loa d Ba se lin e M odifie d Sla k ing 201 201 0.73 0.87 0.19 0.20 1908 2376 295 297 175 175 20.5 15.2 33 45 2930 2860 320 331 201 203 1018 1057 74% 78% 1.57 1.20

120%

PrimeX
PROCESS SPECIALISTS

100%

% Acid Absor be d

80%
(From pH 1.8 to pH 11.0)

60%

40%

Baseline 10/ 7/ 03, 02:00 Modified 10/ 8/ 03, 20:00

20%

Opt im ized Ball Mill Slaker

0% 00:00 00:10 00:20 00:30

TI M E ( m in :se c)

Figure 5. Lime Slurry Reactivity Results Baseline vs. Modified Slaking Processes

For More Information For more information, contact Corey Linville Sunflower Electric Power Corporation 2440 Holcomb Lane PO Box 430 Holcomb, KS 67851 Tel 620 277 4517 email: linville@sunflower.net www.sunflower.net Stewart Nicholson Primex Process Specialists, Inc. PO Box 571, Doylestown, PA 18901. Tel (215) 340 3648 Email: stewart@primexprocess.com www.primexprocess.com

NOTES AND REFERENCES [1] USGS Mineral Survey 2003 Lime Use Statistics [2] Department of Energy, Energy Information Adminstration (EIA) available at www.eia.doe.gov. [3] Using test methods based on ASTM C400 Standard Test Methods for Quicklime and Hydrated Lime for Neutralization of Waste Acid, ASTM Philadelphia, PA (1995) [4] Miller, T.C. A Study of the Reaction Between Calcium Oxide and Water, National Lime Association, Washington D.C. (1960) [5] Slurry reactivity results indicate this inadvertent heating of the B mill slaking water did not significantly affect baseline scrubber performance. [6] Slurry viscosity changes are usually attributable to inconsistent quicklime properties. These changes are unlikely to persist, however dilution water controls can and should be configured to compensate for viscosity effects.