Comprehensive Report to Congress on the Clean Coal Technology Program Enhancing the Use of Coals by Gas Reburning and Sorbent Injection

DOE/FE-0087 CCTl87 PC 79796 Comprehensive Report Clean Coal Technology To Congress Program Enhancing the Use of Coals By Gas Reburning and Sorbent Injection A Project Proposed By Energy and Environmental Research Corporation May 1987 U.S. Department Office of Fossil Energy Washington, DC. 20545 of Energy TABLE OF CONTENTS Jl .O EXECUTIVE SUMMARY 2.0 INTRODUCTlONANDBACKGtiOUFiD 2.1 2.2 3.0 : : : : : :, : 12 Re uirementfor Report to Congress 1 Eva uatlon and Selection Process TECHNICAL FEATURES &)‘3.1 Project Description J3.1.1 Project Summaiy J3.1.2 Project Sponsorship and Coit : : : : 3.2 Gas Reburning-Sorbent Injection Process 3.2.1 Overview of Process Development 3.2.2 Process Descri tion : 3.2.3 Application o P Processe; in Propdsed Project 3.3 General Features 3.3.1 Evaluation of de&lo &en&l Risk : : : 3.3.1.1 Similarity of Preject to Other Demonstration/Commercial Efforts 3.3.1.2 Technical Fea$bility 3.3.1.3 Resource AvaIlability 3.3.2 Relationship Between Project Si;e and Prdjected Scale of Commercial Facility . 3.3.3 Role of the Pro’ect in Achieving commercial Feasibility oft h e Technolo 3.3.3.1 Applicabilit of the ?Y ata to be Genera Yed 3.3.3.2 Identification of Features that In&ease Potential for Commercialization. 3.3.3.3 Comparative Merits of Project and Projection of Future Commercial Economics and Market Acceptability. 37 :‘: 41 42 47 49 49 51 J4.0 J 5.0 ENVIRONMENTALCONSIDERATIONS PROJECT MANAGEMENT 5.1 5.2 5.3 5.4 5.5 Overview of Management Organization Identification of Respective Roles and Respdnsib’ilitie; Project lmplementation,and Control Procedures. Key Agreements lmpactrng Data Rights, Patent Waivkrs and InformatIon Reporting : Procedures for Commercialtzation of T&hnbiog$ J6.0 PROJECTCOST AND EVENT SCHEDULING 6.1 6.2 6.3 Project Baseline Costs Milestone Schedule Recoupment Plan . , :: 54 1.O EXECUTIVE SUMMARY The FY86 Appropriations $400 million demonstration Coal projects following to support facilities Act, P.L. 99-190, included the construction approximately of The Clean having the and operation using Clean Coal Technologies. spectrum of technologies cover a broad in common: things (1) all are intended acceptable to increase the and (2) all use of coal in an environmentally are ready to be proven manner; level. at the demonstration In response fifty-one to the resulting Program Opportunity Notice (PON), proposals were received in April 1986. After technologies, evaluation, were nine projects, selected representing seven different in July 1986 for funding under the Clean Coal Technology (CCT) Program. One of the nine projects Environmental demonstrate selected was the Energy and proposal Injection to process (GR-SI) combustion Research (EER) Corporation the Gas Reburning-Sorbent boilers representing on three different configurations. three different The CR-SI process has been developed coal combustion retained systems. The existing to interface burners with the existing are or comoustors Control when the GR-SI process is installed. by burning of nitrogen of coal in the coal oxides (NO,) is achieved boiler at a carefully a lesser amount controlled air to fuel ratio. The decreased input to the boiler which portion nitrogen combustion natural process. is injected is compensated downstream for by the use of natural zone. gas A to of the coal combustion by the coal combustion of the NO, formed by the reducing of natural is converted conditions caused by the partial downstream combustion of the gas. Air is then injected point to complete gas injection this staged The net effect 60% of this procedure is to reduce NOx emissions by approximately Sulfur oxides, or SOx, consist primarily Emission of this pollutant injecting a sorbent is reduced of sulfur dioxide, SO2. in the CR-9 process by part of the boiler The sorbent, or into the flue in into the upper of the boiler. gas duct downstream the fly ash, is removed precipitator ification, now contained electrostatic from the flue gas in an existing (ESP) or baghouse. which enhances The need for flue gas humidactivity for 502captureand basis. For both sorbent ESP performance, this project, and sorbent cyclone boiler will be determined on a site specific humidification injection will be used at two of the three sites at the into the flue gas duct will be tested this technology is capable site. While of reducing SO2 up to 80%, one of the objectives control at approximately a higher of this study will be to achieve burning a blend of the 50% level while percentage technology of sulfur coal containing provides The GR-SI process wet Flue Gas less physical space. an alternative to conventional requiring Desulfurization (FGD) processes, while 2 This project will use the following as host sites: A tangentially owned fired, 80 megawatt electric (MWe) boiler by Illinois Illinois. Power Company A tangentially and located fired boiler near has burners coal and Hennepin, mounted air toward at the corners and directs the burning of the boiler. points just off the center A wall fired 117 MWe boiler owned by Central Illinois Illinois. Light Company (CILCO) located has burners near Bartonville, which A wall fired boiler air/coal direct the burning which is are into the furnace in a direction perpendicular mounted. to the wall in which the burners A cyclone fired 40 MWe boiler and Power Company Illinois. which owned by City Water in Springfield, Light (CWLP) located A cyclone fired boiler is external to the boiler has a combustion system and the hot combustion is products complete. enter the boiler after the combustion The locations of these facilities boilers are shown in Figure 1. All three This units are commercial project viability is intended that are presently the technical with different operating. to demonstrate boilers and economic firing of GR-51 on three 3 / * Unit No. 1 Hennepin Station Illinois Power Hennepin. IL Tangentially Fired 80 MWe I Z2G kation Central Illinois Power Bartonville, IL Wall Fired 117 MWe I %%~‘Statl0n City Water Light 8 Power Co. Springfield, Illinois Cyclone Fired / *- FIGURE 1. EER GAS REBURNING-SORBENT INJECTION PROJECT LOCATIONS OF DEMONSTRATION PLANTS IN ILLINOIS. N0.113.941 configurations pre-NSPS boilers. fully tested performance which represent the majority and sorbent of all U.S. coal-fired, injection has been the Gas reburning on a pilot scale. This program of the integrated is expected technology will demonstrate on full scale commercial the same operating boiler systems, which to have about cost as wet FGD. However, on NOx. FGD captures only SO2 and has no effect This demonstration month period project will be performed over a fifty-four the design and at three test sites and includes testing, installation and reporting scheduled months of equipment, of results. data analysis, site restoration as originally proposed was This project months for forty-eight without with phase overlaps A fifty-four month or sixty project period and phase overlaps. has since been selected eliminate phase overlaps to accommodate plant outage periods at any one test site. The total project cost is $29,998,253. The co-funders ($10,000,000) are DOE and the ($14,998,253), the Gas Research Institute Testing State of Illinois ($5,000,000). is scheduled to begin at the and at CILCO site in early 1989, the Illinois the CWLP site in mid-1990. to occur in late 1991. Overall Power site in mid-1989 project completion is scheduled 2.0- INTRODUCTION AND BACKGROUND The domestic role in meeting coal resources current of the United energy States play an important needs. During the past and future effort 15 years, considerable improved provide has been directed conversion, energy to developing processes to coal combustion, efficient and utilization options. and economic permit These technology developments acceptability the attainment of environmental utilization of coal resources. as well as the efficient 2.1 Requirement for Report to Conqress In December Technology Making Agencies Other 1985, Congress (CCT) Program made funds available for a Clean Coal in Public Law No. 99-190, An Act of Interior and Related Appropriations for the Department September funds for the Fiscal Year Ending This Act provided 30, 1986, and for the purpose projects of Purposes. “...for conducting struction for future authorized cost-shared and operation commercial Clean Coal Technology of facilities applications for the con- to demonstrate the feasibility and of such technology...” Public Law available DOE to conduct the CCT program. to remain No. 99-190 provided expended, of which 5400 million”... 9100,000,000 until available; shall be immediately (2) an additional October available $150,000,000 shall be available beginning shall be 1, 1986; and (3) an additional beginning October 1, 1987.” $150,000,000 However, authority Section 325 of the by 0.6 percent so Act reduced each amount of budget 6 that these amounts $149.1 million, became $99.4 million, for a total 5149.1 million, and respectively, of $397.6 million. In addition, in the conference report accompanying a Public Law No. 99-190, the conferees comprehensive to be funded August Proposals report directed DOE to prepare received, on the proposals after the projects in on had been selected. The report was submitted Report 1986 and was titled Received “Comprehensive to Congress in Response to the Clean Coal Technology Notice,” DOE/FE-0070. Specifically, Pro- gram Opportunity outlines proposals the report the solicitation process implemented summarizes by DOE for receiving proposals that for CCT projects, provides the project were received, information on the technologies specific that were the focus of the CCT program, related to the solicitation. and reviews issues and topics Public Law No. 99-190 directed comprehensive award directive report DOE to prepare a full and to receive an of this to Congress on any project under the CCT program. and contains This report is in fulfillment a comprehensive description of the Energy and Environmental Project. Research Corporation GR-SI Demonstration 2.2 Evaluation and Selection Process DOE issued a Program February Opportunity Notice (PON) on cost- 17, 1986, to solicit proposals for conducting 7 shared CCT demonstrations. proposals were required identified Fifty-one proposals were received. All to meet preliminary evaluation was made to evaluation requirements determine requirements in the PON. An evaluation met those preliminary if each proposal and those proposals that did not were rejected. Of those proposals evaluations remaining in the competition, Technical separate Proposal, The PON greater and that were made for each offeror’s Proposal, Proposal Business and Management provided importance that the Technical and Cost Proposal. was of significantly Proposal than the Business and Management was minimal; however, the Cost Proposal everything else being equal, the Cost Proposal was very important. The Technical categories. projected different Evaluation Criteria were divided into two major addressed the The first, “Commercialization commercialization from the proposed Factors,” of the proposed demonstration involved technology. project This was itself and dealt with all of the other mercialization consideration socioeconomic economics proposed steps and factors The subcriteria in the comallowed for process. in this section health, of the projected impacts environmental, safety, and and the (EHSS); the potential marketability of the technology; technology and the plan to commercialize to the demonstration subsequent project. The second major category, recognized “Demonstration Project Factors,” project the fact that the proposed demonstration 8 represents operation project allowed adequacy the critical step between readiness, “pre-demonstration” scale of and commercial itself. Subcriteria and dealt with the proposed Project Factors” for scale- up; project; the and in “Demonstration of technical for consideration readiness and appropriateness of the demonstration aspects; EHSS and other site-related adequacy of the technical of Work. and the reasonableness and quality approach and completeness of the Statement The Business and Management Proposal was evaluated to deterof the under- mine the business and management offeror, standing Proposal appropriate the proposed performance potential the offeror’s and was used as an aid in determining of the technical was evaluated requirements to assess whether of the PON. The Cost the proposed cost was cost of was and reasonable, project and to determine the probable to the Government. The Cost Proposal approach to also used to assess the validity completing Statement the project, of the proposer’s in accordance with the proposed of the PON. of Work and the requirements Consideration factors: was also given to the following program policy a) The desirability projects of selecting for support a group of technical that represent a diversity of methods, approaches, or applications; 9 b) The desirability projects of selecting for support a group of of that would ensure that a broad base is utilized, cross section the U.S. coal resource future; and both now and in the c) The desirability projects expanding impacts. of selecting for support a group of that represent a balance between the goals of environmental the use of coal and minimizing An overall strategy for compliance consistent with NEPA was developed on Environmental for the CCT Program Quality with with the Council NEPA regulations and the DOE guidelines includes impact both for compliance and projectand NEPA. This strategy environmental programmatic during specific considerations, subsequent to the selection process. In light of the tight the confidentiality DOE established environmental decision-making Offerors specific proposal. schedule imposed by Public Law No. 99-190 and PON process, requirements alternative factors of the competitive procedures to ensure that and integrated into the were fully evaluated process to satisfy its NEPA responsibilities. to submit both programmatic and projectpart of their were required environmental data and analyses as a discrete IO This strategy preparation has three major elements. The first involves environmental and analysis impact of a comparative programmatic provided analysis, based on information supplemented by the offerors by DOE, as necessary. environmental programmatic This environmental consequences alternatives involves ensures that relevant Program of the CCT are evaluated preparation The third and reasonable process. in the selection of a preselection element documents the PON. provides The second element environmental project-specific for preparation review. by DOE of site-specific for financial assistance under for each project selected No funds from the CCT Program design, third construction, operation, will be provided and/or for detailed until the completed. dismantlement element of the NEPA process has been successfully each Cooperative Monitoring Agreement entered In addition, into will require siteand an Environmental Plan to ensure that significant data are collected and technology-specific disseminated. environmental After factors, considering the evaluation criteria, the program submitted policy by Energy was and the NEPA strategy, the proposal and Environmental one of the proposals Research Corporation, selected for award. Irvine, California, 11 3.0 TECHNICAL FEATURES 3.1 Project Description The EER project Injection will demonstrate that Gas Reburning and Sorbent (GR-SI), a control technology for retrofit for the acid rain precursors, applications. It will be the first technology that 50x and NOx, is suitable commercial is relevant scale demonstration to utility boilers of this particular States. in the United The demonstration sites each of which configuration: relatively will be conducted has a boiler with at three different a different firing utility test tangential, wall and cyclone. The boilers are all small commercial units sized at 80, 117, and 40 MW, represent most of the respectively. existing These design configurations utility boilers pre-NSPS coal-fired in the U.S. and successful for demonstrations retrofit on these units will make GR-SI attractive applications. The goal of this program feasibility is to prove the technical If successful, and economical it will achieve up of the GR-SI technology. to 60% NOx and 50% or more SO2 reduction as wet FGD processes which humidification enhance efficiency. capture at about the same cost only SO2. GR-51 will use will ESP in two of the three test sites. Humidification by the sorbent and aid in improving SO2 pick-up A summary of the three demonstration projects is shown in Table 1. 12 Table 1. Summary of Demonstrations by EER GENERAL Utility Station, Unit Location: State Capacity (MWe) BOILER Fi;Fg ConfiguraTangential Steam Capacity 103 Ib/hr) Jl anufacturer PRECIPITATOR Location Size (Sq. Ft.) Manufacturer FUEL Coal Type Sulfur (%) Gas Availability Illinois, 3.8 Yes BIT Blend of Illinois,BIT :.ytucky, Illinois, BIT 3.6 on site, within l/2 mile BIT Front Wall 850 Riley Cyclone 320 B&W Illinois Power Hennepin, 1 Illinois 80 CILCO Edwa,rds, 1 ‘/P CWLP Lakeside, P”” 7 :8E5 Side 42”:” Side :Y;d Standard Buell American Cold Side 333-1000 Smidth 4 miles from plant EMISSIONS CONTROL OACH NO, Approach Control (%) SO, Aooroach \I $s..e&urning Uoaer Furnace lnection minimum Humidification ~;:~e&urning Duct Control (9/o) ESP Enhancement sd Upper Furnace In ection minimum Humidification 503, Injection 5d 13 3.1.1 Project Summary Gas Reburning - Sorbent Injection Research Corporation Project Title: Proposer: Energy and Environmental (EEW Project Locations,: Bartonville, Illinois (Edwards Station) - Peoria County Hennepin, Putnam Illinois (Hennepin County Illinois County by gas reburning injection for NOx (Lakeside Station) Station) - Springfield, Sangamon Technology: Flue Gas Cleanup control and sorbent for SO2 control boilers Application: Retrofit of coal fired utility and industrial coals Types of Coal Used ‘. Illinois and Kentucky (1% to 3.8% sulfur) Product: Project Size: Project Start Date: Project End Date: Environmental Control bituminous Technology (three sites) 80 MWe, 117 MWe, 40 MWe July, 1987 December, 1991 3.1.2 Project Sponsorship and Cost Research Project Sponsor: Energy and Environmental Corporation Proposed Co-Funders: U.S. Department of Energy, State of Illinois, (GRI) and the Gas Research Institute Proposed Project Cost: $29,998,253 Participant Share (%) 50 Proposed Cost Distribution: DOE Share (%I 50 14 3.2 Gas Reburninq-Sorbent Injection Process 3.2.1 Overview of Process Development Sorbent injection Demonstrations Sorbent injection has been undergoing from development since the mid- 1970s under funding firms. EPA, DOE, EPRI and several commercial on identifying Work the process has focused on Most of the work has focused which optimize sulfur injection parameters the impacts performance impacts. capture. of the sorbent of a utility process on the overall for reducing scale reactivity tests that focus on reactivity effects; large pilot those tests; boiler and methods laboratory This work has included bench scale process design development time/temperature history and sorbent scale tests that focus on impacts mixing and combustion of firing system design and furnace programs. and additional directly A number efforts in model development of field evaluations are in progress. have been completed either EER has participated work. or indirectly most of this development In the last !O years, a number have been carried using a variety of test programs ranging from for sorbent injection out on boilers 15 to 600 MW and ‘were carried sorbent out in of coals. Most of these programs Europe and Canada and they all focused injection alone without regard involve to other gas firing on optimizing competing technologies. for NOx None of the programs or have potential 15 controi except by installation of low NOx burners. through This project the use of the offers the added feature natural gas reburning of NOx control process. Reburninq Demonstrations Compared to sorbent effort injectio.n, considerably less development on gas reburning and for NOx demonstration control. has been expended work The original was done in the United States in the early 1970s with subsequent commercial scale tests where work done in Japan, including NOx emission During reductions of greater than 50 percent were achieved. (mostly these tests coal and oil fuel was were fired simultaneously oil) and the reburning oil. Hence, the results are not representative boiler practice. of recent U.S. utility Since 1981, EER has continued United focused States under on defining support the development of reburning has in the from EPA and GRI. This work and included the key process variables IO million Btu/hr tests up to about to large pilot scale: 1 MWe. which corresponds These tests have demonstrated The EPA program that gas is the optimum has focused on gas reburning with fuel for reburning. only; the work for GRI includes sorbent injection. integration of gas reburning to co-fund of reburning and operation GRI and EPA have agreed This EPA/CR1 demonstration data on the design a reburning will of full scale demonstration. provide considerable gas reburning systems. However, this reburning demonstration sorbent will be technology injection specific in that it will not include for 502 control. 3.2.2 Process Description Gas Reburning-Sorbent combustion staging Injection is a two part process in which NOx while sorbent injection is used to control is used to control SO2. Gas Reburninq Nitrogen oxides, or NOx, are formed or when nitrogen when nitrogen included in the air is fuel oxidizes oxidized. nitrogen combustion contained in the combustion The formation content of NOx depends on flame temperature, for of the fuel, quantity of excess air available and residence time at high temperature. the greater is the tendency The greater to form NO,. any of these parameters, Reducing any of these parameters lower will reduce NOx formation. short residence time and Unfortunately oxygen other flame temperature, sufficient to greatly deprivation, problems reduce NO,, result in of carbon monoxide, soot, may such as high emissions organic effects. boiler contained and partially produce practices portion oxidized compounds, In addition, efficiency some of which adverse health result in loher of the energy these NOx avoidance waste a the and thereby Therefore, in the fuel. ?? problem has been to reduce side effects. NOx formation and emissions without are (GR), these undesirable required Special combustion techniques and one that has been developed is gas reburning part of the GR-SI process. combustors reburning, currently This process is applicable pulverized nitrogen to all types of used for firing coal. In gas (N2). NOx is reduced to molecular For NOx control, stages. reburning the combustion process is divided into three These are the primary, zone and the burnout fuel is natural fuel in earlier to the extent or main heat release zone, the zone. The primary fuel is coal and the reburning the reburning not decreased gas. Others experiments, achieved with have used oil or coal as however natural NOx levels were gas. Figure 2 depicts pertaining sorbent a boiler schematic which indicates the key areas A-E at which to gas reburning may be injected. and identifies the points The primary zone is the main heat release 80 to 85 percent with sufficient of the total air for its Sufficient reactions zone and accounts heat release. combustion. residence before for approximately In this zone, coal is burned Very little excess air is used in this zone. time is provided to complete the combustion the combustion products, including some NOx, enter the next zone. In the next zone, the reburning produce an oxygen deficient zone, natural condition. gas is injected to This converts zone to nitrogen. some of the The use of NOx which was formed in the primary 18 W d 0 ai a* E d i s? ;r z 3 z $j --.\ ~.ulcn ‘\ 0 ---. y-0 1 II G4 I n t-g, i: in, 19 natural gas instead of a coal or oil as the reburning fuel bound nitrogen cyanide fuel avoids introduction of additional into the process. (HCN) are also formed This mixture Some ammonia (NH3) and hydrogen in this zone as well as fragments then enters the next zone. of the fuel molecules. In the burnout fragments zone, additional air is injected water to burn the fuel dioxide. In and this produces vapor and carbon cyanide this zone the ammonia converted to molecular (NH3) and hydrogen nitrogen (HCN) are also NO. and to some residual The net effect reduction other of this combustion technique is up to a 60% of in NOx formation chemical without compounds no sulfur, increases in the emission or a waste of fuel. there is a reduction of gas fired. In undesirable addition, emissions since gas contains commensurate in SO2 with the fraction Sorbent Injection Sulfur oxides, predominantly of sulfur controlled, flue gas. compounds 502, are formed from the oxidation in the coal and its ash. The SO2, if not to the atmosphere with the balance of the is discharged One method of removing the SO2 is by dry sorbent injection as used in this and several other processes that are in approximately 20 the same state of development sorbent can be injected, as GR-9. Locations A-E, where the are shown in Figure 2. In the GR-SI process, sorbent conveyed to a storage (lime) is unloaded from trucks and to a feed silo. or silo and then transported is conveyed From the feed silo, the sorbent injection system to the point to a distribution that it is injected into the flue gas. It part of the boiler of the boiler is removed in an can be injected combustion (D, E). After with the burnout air, in the upper zone (A, B, C) or in the duct downstream absorbing the SO2, the spent sorbent to be inadequate ESP. If an existing ESP is considered for the job, it to may have to be upgraded enhance benefits, its performance. is accomplished the boiler or humidification Humidification, by the injection may be required which has several of a water spray into the and to and duct between humidification and the ESP. Moisture controlled additions will be carefully in these operations improvements meet the requirements SO2 capture. of particulate control For all three test sites, the nominal percent firing. of the heat input The sorbent test design basis is for 15 and 85 percent by coal to be by gas firing rate is projected utilization to be 25 percent, of bottom ash is Due to the lower reduced coal consumption, injection, the quantity the amount and due to sorbent of precipitator solid waste is increased. waste. The net impact is an Increase in solid 21 3.2.3 Application of Processes in Proposed Project The three specific sites involved the activities planned in this project and a description of for each site are as follows. Hennepin Station Unit No. 1 This unit is a tangentially at the corners. and air toward such a manner particles. fired boiler which has burners mounted coal in The burners points which at each corner direct the burning are just off the center of the boiler a swirling motion to the gas and coal as to impart The installation of the GR-SI system on the boiler and windbox the tangential modifications firing system. requires be that the furnace redesigned penetrations to accommodate Figure 3 is an overall installation. process flow diagram for a typical GR-SI The specific objectives are to: (1) reduce emissions particulate approach of the demonstration by 60 percent, at Hennepin Station NOx emissions (2) reduce SO2 or improve by 50 percent emissions to applying or more and (3) maintain operability. and general The preliminary station with is the use of upper furnace and GR-SI at the Hennepin integrated gas reburning sorbent in the upper furnace and humidification injection to improve SO2 removal ESP performance. 22 23 Edwards Station Unit No. 1 The Edwards unit is front air/coal wall fired. In a wall fired unit the burners with their direction the burners are mounted. objectives NOx direct the burning being perpendicular The front into the furnace to the wall in which wall is opposite the exit ductwork. Station The specific of the demonstration emissions equivalent at Edwards are to: (1) reduce levels by 60 percent, (2) maintain SO2 emission firing to those of a 1% sulfur coal while sulfur level, and (3) maintain a solid sorbent a coal blend emissions at with a higher current particulate is being levels even though used. The planned approach used to apply the GR-SI process to this unit is system in the upper furnace, injection of hydrated lime with integrate the to install the gas reburning the upper reburning performance furnace sorbent system and improve via humidification. electrostatic precipitator GR-SI will allow coal which percent a significant increase in the fraction of high sulfur can be fired. The fuel distribution on a heat input basis is as follows: Present, Baseline Heat Input ?/o GR-SI &eJ High Sulfur Coal Low Sulfur Coal Gas TOTAL 24 Natural gas is presently not available at Edwards Station. A new to supply through line will be run approximately this fuel. multiple four miles to the station into the upper furnace system will be added The water precipitator will be injected performance. The gas will be injected nozzles. A humidification downstream of the air heater. through Bench capture an array of nozzles to improve scale tests suggest considerably that this process may increase sulfur the sorbent requirement. thus reducing City Water Liqht & Power (CWLP) Lakeside Unit No. 7 This boiler combustor products uses a cyclone combustor is external to the boiler system. In this system the and the hot combustion is complete. The enter the boiler after combustion into which cyclone combustor of air are injected is a cylinder coal and a small amount from the end while the bulk of the combustion at a very high velocity. motion This imparts an air enters tangentially intense swirling or cyclonic to the coal and gases. The specific objectives of the demonstration Station: (1) reduce at Lakeside Station are the same as at Hennepin percent, NOx emissions by 60 (2) reduce SO2 emissions or improve However, an alternate and corrosion particulate by 50 percent emissions or more, and and general at this plant pass (3) maintain operability. requires erosion the cyclone firing sorbent injection configuration approach. Convective are serious problems for cyclone units that 25 may be worsened Consequently, downstream Gas reburning a commensurate this station the existing approaches, alternative by sorbent injection approach into the upper furnace. involves sorbent injection the planned of the air heater but upstream loading of the precipitator. and should result in r,educes the particulate reduction of erosion and corrosion. are required For SO2 control, The ESP at to maintain various is large and no enhancements particulate including sorbents, emission rates. the use of sorbent will be assessed. slurry systems and Due to the design of the air supply system to the cyclone combustors, the preheated it will be most convenient combustion to run a lateral duct from air duct around the side of the unit to This plant will require air injection Alternate the the space above the cyclone combustors. addition of a short gas supply line. Gas and overfire on the front wail are planned. into the upper furnace locations considered. on the rear wall and closer to the cyclone exit will also be 3.3 General Features of the Project 3.3.1 Evaluation of Developmental Risk As with any new technology, described sorbent earlier, injection. there is some risk. However as much prior work has been done in the area of amount of work has A lesser, but still significant 26 also been done with the reburning as the reburning obtained probability fuel. It is through technology, especially with oil the data and experience retains a high from this earlier work that this project of success. After reviewing the results of the developmental work at the 0.1 MW and 1.O MW levels for the GR-SI process and information supplied process. by EER, a low to moderate It will result in increased equipment. risk has been assigned solids loading, Upper furnace fouling affecting sorbent to this both the injection of ESP and ash handling may increase the potential boiler tubes. Duct injection for slagging, of sorbent and erosion may lead to a build may result in up of solids in the duct work and humidification condensation in the ESP and/or stack. These are considered to be and low or moderate controls Further, risks because there will be instrumentation and mitigate potential problems. that will identify the regular plant operating staff will be in full charge of the boilers that will be involved in this test program. 3.3.1.1 Similarity Commercial of the Project to Other Efforts Demonstration/ Gas reburning-sorbent aimed at reducing chemicals sorbent between injection emissions is a combination of processes of undesirable To capture acid rain precursor based zone or from combustors. is injected the boiler SO2, a calcium into the boiler above the reburning and the ESP. This process is similar to the Babcock the upper proceeding sorbent &Wilcox LIMB process, where zone. the sorbent is injected into part of the combustion to near term commercial Both processes are If the then the dry sorbent at Low scale demonstrations. of the boiler injection takes place downstream GR-51 process is similar to two other injection processes, Coolside (HALT). low temperature, Addition and Hydrate Temperature The distinguishing injection preheater characteristics (hydrated of the Coolside process are the of the air of a dry sorbent followed lime) downstream for SO;! capture. by lowering by humidification Humidification and thereby decreases improves flue gas volume temperature ESP efficiency. The Coolside process has been demonstrated at the 0.1 and 1 .O MW levels. In the Dravo HALT process, the flue gas stream humidification, capture then the hydrated lime sorbent is cooled is injected through to SO2. The HALT process is now undergoing demonstration at the 5 MW level. The gas reburning of converting technologies aspect of the GR-SI process is a unique to nitrogen. that permit Low NOx burner staged a portion combustion method control without NOx mainly use burners the later injection was formed of fuel to destroy of the NOx which to this point and in the burner. Work done on reburning with has been accomplished reburning fuel. largely oil as both a primary 28 3.3.1.2 Technical Feasibility The concept of reburning has been recognized that significant for over a decade. flue gas NOx that carboncan react Early research demonstrated reductions hydrogen with can be achieved (CH) fragments based on the principle of larger organic fuel molecules converted NO. When this happens, NOx is mainly to molecular nitrogen (Nz), and the CH fragments has recently been applied are oxidized at a foreign to CO2 and H20. commercial in the United This concept scale but it has not been demonstrated States. EER has conducted extensive commercially bench and pilot scale testing a scale-up domestic to characterize methodology fuels. the fundamental appropriate processes and develop burning for use in U.S. boilers The results of EER bench and pilot scale research have been recently now available. impact completed under funding programs which from EPA and GRI are the effecfor conditions. in a 25 kW to control burners pulverized fuels. In These studies were undertaken to quantify on reburning required industrial of fuel type and process parameters scale-up information under tiveness and to provide commercial applications of reburning Initial parametric refractory screening studies were conducted which allowed lined tunnel furnace profile. workers the time temperature Premixed and diffusion liquids, were used to study gaseous fuels, petroleum coals, and coal water slurries as primary and reburning 29 subsequent develop tests, a 3.0 MW, downfired The work furnace was used to on the the to scaling criteria. at both scales focused nitrogen species within importance reburning directly and fate of reacting zone. ‘The experimental conditions were designed simulate a practical boiler. There is, therefore, reburning a sound basis of data existing NOx emissions. for the concept has of as a way to reduce This technology been practiced capable on the commercial scale in Japan in installations States. This of coal firing experience and in pilot scale in the United provides background probability reduction the basis for believing achieving that a high a 60% of success exists for this technology in NOx emissions. The sorbent amount injection technology is based on an even greater to enhance its chances for success. for similar and of data and experience Demonstrations technologies Conoco. technology at the commercial developed scale are scheduled &Wilcox, by the EPA, Babcock A smaller scale (5 MW) demonstration by Dravo. laboratory on a similar are all is also planned of extensive These demonstrations and pilot work which the proper conditions the culmination enabled successful commercial been carried these companies operation. applications out. to establish for In addition, a significant injection number of foreign have of the sorbent technology 30 EER has participated injection in a number of field evaluations project of sorbent for process of EER and is scheduled of a sorbent to carry out another injection system.The optimization experience injection plus the wide spread interest indicate project that sorbent injection and work on sorbent is technically viable and that this reduction in SO2 will achieve its goal of a 50% or greater emissions. 3.3.1.3 Resource Availability Adequate present personnel resources members are available for this program. EER will use Additional of its staff to fill key positions. will be hired as needed. This project will not increase the host boilers’ will use approximately amount compared requirements for coal. The project which 45,000 tons of sorbent to the total U.S. annual for is a very minor production natural surpluses of 700 million tons of limestone. current supplies The requirement using available gas can be met from in the natural is expected gas market. The availability of these major raw materials stration to be adequate not only for the demonwhen this program but also to meet the demands technology has been commercialized. This program separate generating involves pre-NSPS boiler installations at three power sites, each being station, a fully operational facilities electrical with appropriate and scheduling 31 flexibility to accommodate this project. These three sites, selected an excellent all of the for the proposed opportunity situations demonstration of GR-SI, will provide in essentially to evaluate the technology that will likely be encountered All appropriate in the commercialization can be made available The installation, will be handled themselves. to cover by of the technology. resources to the site such as coal, natural construction personnel Adequate and restoration available funds gas, and sorbent. of GR-SI hardware at EER and at the utilities have been committed project by the co-funders costs. their share of the estimated These sites are likely to be required rain legislation is enacted. to lower their emissions if acid Two of the sites are burning of GR-SI will lower a lower sulfur region. medium SOx and NOx blend in sulfur coals for which emissions. application The Edwards unit is burning order to meet compliance in a non-attainment At this site the sulfur SOx NOx the use of CR-SI will be evaluated content emissions emissions. as a means whereby while of the blend can be increased at compliance The furnaces still maintaining levels and at the same time lowering are large enough to provide a full scale test of the technology. demonstrated Finally, the suitability of the process will be wall fired, and for ail for three distinct systems, tangential, cyclone fired units, which will prove the technology commonly used firing systems. 32 3.3.2 Relationship Commercial Between Facility Project Size and Projected Scale of As mentioned commercial multiple injection Therefore the number previously, units ranging all three test boilers from 40 to 117 MWe. are operating, However, small they use gas burners nozzles, and the test will require air injection the use of multiple injection ports and sorbent utility boilers nozzles. increasing scale up to larger of injection only involves points points and distribution representing will on many only the most minimal prove the applicability pre-NSPS boilers without risk. The net effect is that this project for retrofit of the CR-SI technology further demonstration. 3.3.3 Role of the Project in Achievinq the Technoloqy Commercial Feasibility of The combination medium of CR-SI has the potential coals under to enhance requiring the use of and high sulfur conditions compliance with environmental requires control. The commercialization data base enhancement needs and directly to and of the GR-SI technology demonstrating cost effectiveness means whereby industry. a comprehensive performance emission applied control, to meet specific industry the technology can be transferred 33 3.3.3.1 Applicability of the Data to be Generated In order to produce demonstrations collection accurate and reliable performance data, the data system wiil be fully instrumented A new computerized plant and use automated data acquisition techniques. will interface with the existing the following: instrumentation to gather data to monitor 0 0 0 0 0 0 0 0 0 0 0 0 0 Furnace absorptionicleanliness Convective surface cleanliness rates Slag deposition Sootblower effectiveness Gas temperatures Effectiveness of SOx and NOx reduction ESP performance Combustion efficiency Boiler performance Feed rates of coal, sorbent Humidification Gas velocities Heat rate deviations and gas The demonstrations will produce data to fully characterize of the both the boilers and the GR-SI process and for engineering commercial applications. applied The process performance to a large population sulfur coal. data obtained U.S. utility the cyclic can be directly stations of existing In addition, using high and medium 34 nature of the operation of these host site units will give a good varying load characterization conditions. of the GR-SI process under Analyses of the flue gas and coal will also be made. analytical reductions, results will provide ESP efficiency the basis for evaluating These SO2 and NOx Further, gas and process controllability. data for material and solids analyses will provide calculations reliability on sulfur evaluation. balance for data and sorbent species important Based on the SO2 removal economics proposed technical utility and operability results, process Since the will be determined demonstration and economic for the GR-SI process. is at a commercial scale, the resulting applicable to other analyses will be directly situations. 3.3.3.2 Identification of Features that Increase Potential for Commercialization The current expanded However, energy policy of the United States includes applications. the use of coal in utility and industrial concern acid rain is a recognized with and the increased use of coal is not to conflict development resulting environmental technology goals and thus requires to control the pollutants of cost-effective from coal combustion. 35 To achieve these environmental SO2 emissions objective from fossil fuel-fired goals the reduction boilers of NOx and has been a major of the DOE, the EPA and major boiler/burner for many years. efforts This is demonstrated by a number to manufacturers of concurrent develop that have been and are being conducted burners and improved combustion lower-NOx techniques. Once commercially economical minimal proven, the GR-SI process will provide control an means for simultaneous of SO2 and NOx. The cost of this process are especially space requirement features and competitive which also important applicable make this technology boilers. to the retrofit of existing This process consists of proven, such as nozzles, Some boiler reburn furnace pumps, blowers commercially and pneumatic available equipment systems. of the into the transport modifications are required air nozzles. for installation gas and burnout it can be injected If sorbent is injected with the burnout air. Since the sorbent of the boiler, can also be injected boiler performance into the ductwork downstream need not be impaired. natural Due to the replacement performance may be the tube gas of lo-20% enhanced of the coal with by the smaller gas, boiler quantities of ash passing through banks when duct injection has recently been falling is used. Since the price of natural and is approaching are expected the cost of coal in to be minor. some areas, fuel cost differences 36 In summary commercialization of this technology will be aided by: Simultaneously SO2 emissions Lowering Requiring Relatively reducing NOx emissions by up to 60% and by SO?/0or more cost space capital minimal easy retrofit of the boiler Little or no derating Flexibility Using commercially Having types. been proven available components popular boiler on three different Thus, success of this program effective, pollutants expected market. economical associated to significantly approach will establish to controlling that GR-SI is an the two major is with acid rain. penetrate As such, the technology the large pre-NSPS boiler 3.3.3.3 Comparative Commercial Merits of Project and Projection and Market Acceptability of Future Economics The GR-SI process, assuming technology, injection complete successful demonstration of the will be one of the most developed processes. burner It will also offer of the sorbent to a viable alternative replacement for NOx control. 37 One attractive demonstrated which operate feature of this project is that the technology will be all of on three different under varying size and types of boilers, This will provide different sorbent loads. a good and on into the of demonstration different of the process under conditions injection coals. It will also demonstrate boiler and in the downstream flexibility to potential duct, thus offering a high degree customers. Factors which include adequate disposal on-site contribute availability to minimizing of natural the cost of this project gas at two of the sites, of sorbent and waste ESP capacity, areas. and availability The GR-SI process is intended utilities which to provide technology from options existing for boiler desire to reduce SO2 emissions SO2 reduction technology units. Existing desulfurization technology includes wet flue gas The need for new and lime spray dryer processes. development arises from the fact that the existing cost, which certain makes their application which include boiler life and processes are high in capital particularly problems expensive presented under scenarios by regulations. Short remaining installation, technology lack of available of compliance GR-SI technology installation space for retrofit using the existing is characterized can increase the cost options. By contrast, by low capital cost and minor space requirements. 38 An economic comparison of wet limestone flue gas desulfurization and GR-SI technology was made at the 200 MWe, 300 MWe and cost for GR-SI is estimated at being less 400 MWe level. The capital than half that for wet flue gas desulfurization. The electric implement extensive utility generating companies are expected to outlays, technology plant that does not require or extreme into existing significant large capital modifications operational plants without difficulties. displacing CR-9 can be incorporated other equipment Operation operating or requiring new real estate. affected. The the of the plant will not be significantly costs for the GR-SI process are estimated captures only SOx, not both to be about same as FGD, which does GR-SI. NOx and SOx as The drive toward acceptance sorbent control, approach lower capital cost is evidenced by the rapid of spray dryer technology in Europe. to other in the U.S. and of boiler for a higher level of SO2 injection relative The potential low cost technologies makes this particularly desirable. 39 4.0 ENVIRONMENTAL CONSIDERATIONS The PON requires Participant information that, upon award to submit of financial assistance, the will be required as specified the environmental J of the PON. This detailed will be used as the basis for by DOE for the conof in Appendix information site- and project-specific site-specific selected sidered, NEPA documents to be prepared project. Such NEPA documents in full compliance shall be prepared, and published with the requirements decision 40 CFR 1500-I 508 and in advance beyond preliminary design. of a go/no-go to proceed Federal funds from the CCT Program design, construction, operation will not be provided and/or dismantlement for detailed until the NEPA process has been successfully completed. 30 5.0 PROJECT MANAGEMENT 5.1 Overview of Manaqement Orqanization The project the principal administration Manager responsible Officers technical will be managed contact with by EER’s Project Director. regarding He will be the DOE for matters of the agreement. In his absence, the EER Project The DOE Contracting Officer is will have this authority. for all contract matters and the DOE Contracting (COTR) is responsible for Technical Representative liaison and monitoring of the project. A Participants personnel from Committee will be formed and will be composed Department of EER, DOE, GRI and the State of Illinois Resources (ENR). This Committee of Energy and Natural as needed correcting will meet advice on to review the project, any deficiencies. assess plans and provide A Senior Review Committee senior representatives make up the Participants provide targeted pertinent (SRC) will be formed and will consist of whose personnel of the same organizations Committee. The Committee serves to a more encompassing to influence information view of the project, activities and hence, it is through supplying available. decision-making that may not have been otherwise In addition to DOE, the project co-funders are the State of Illinois and the Gas Research Institute. 41 5.2 Identification of Respective Roles and Responsibilities - DOE The DOE shall be responsible project, and for granting for monitoring all aspects of the required by this or denying all approvals Officer Agreement. representative Cooperative The DOE Contracting is the authorized related to the of the DOE for all matters Agreement. The DOE Contracting Technical Officer will appoint a Contracting Officer’s Representative (COTR) who is the authorized matters may: and has the authority to representative issue “Technical for all technical Advice” which 0 Suggest redirection a shifting of the Cooperative of work pursuit emphasis of certain Agreement between effort, work areas which recommend or tasks, and suggest assist in accomplishing lines of inquiry, of Work. the Statement 0 Approve information those technical required reports, plans, and technical to the to be delivered Agreement. by the Participant DOE under this Cooperative The DOE COTR does not have the authority advice which: to issue any technical 0 Constitutes Statement an assignment of Work. of additional work outside the 42 In any manner estimated Cooperative causes an increase or decrease in the total of the cost, or the time required Agreement. for performance Changes any of the terms, conditions, Agreement. or specifications of the Cooperative Interferes with the Participant’s of the Cooperative right to perform Agreement. the terms and conditions All technical advice shall be issued in writing by the DOE COTR. Participant The Participant performance Statement (EER) will be responsible under this Cooperative for all aspects of project as set forth in the Agreement of Work. The Participant’s for the technical performed under Project Director is the authorized performance Agreement. for all matters representative of all work to be He will be the between Project the and administrative this Cooperative point of contact single authorized Participant and DOE. In his absence the Participant’s 43 Manager with will be authorized to represent will interrelate sponsors the Participant between in contacts DOE. The Participant project the govern- ment and all other Management as shown in Figure 4, Project Structure. Industry Panel EER will establish industry, an Industry Panel to transfer the project results to to encourage commercialization and to receive comments in Phase 1 and the project. expected from the panel members. will meet periodically The panel will include to be directly sorbent involved This panel will be formed throughout (at least annually) representatives in the application possibly from organizations or use of gas reburningincluding: DOE, GRI, EPRI, sorbent Panel will to ensure injection technology, equipment EPA, electric suppliers, utilities vendors, fuel suppliers, The Industry guidance utilities and architect/engineers. and provide possible, review the status of the project that, to the maximum industry needs. extent the project will meet Participants Committee The Participants Committee will consist of representatives from but DOE, GRI, ENR, and EER. This Committee at least once each quarter, to review will meet as needed, assess future the project, 44 z I I[ I I I : ZZE-‘E.SE ma,E a=0 0 II3 I I zg XE ‘GE - % 0 fE 20” \ \ \ 45 plans, recommend correcting intended the project organization direct EER. shifts in emphasis and provide advice on is involved in any deficiencies. to be a working The Participants group of personnel Committee directly and will ensure that the objectives will be met. The Participants of each participating will not Committee Senior Review Committee The project Committee overview review organization will be the Senior Review for the administrative (SRC) that will be responsible of the project. The SRC will be composed members participants. the Committee representing of executive level individuals with DOE, the Participant, may change another and the co-funding its representative(s) on Each Participant by designating Senior Manager. The SRC of the will meet at least annually, Participant’s in nature Committee. or at the request The Committee management of any member will function authority. as advisory and has no specific 46 5.3 Summary of Project Implementation and Control Procedures All work to be performed divided under the Cooperative Agreement is into three Phases. Those phases are: o o o Phase I: Phase II: Phase IO: Design and Permitting Construction Operation, Disposition and Start-Up Data Collection, Reporting and As shown in Figure 5, there will be a one month overlap pause between Phases II and in Phases I and II and an eight month III. It should the overall be noted project, that although between there will be phase overlap there will be no phase overlap scheduled at any one site. for the month This plan will also accommodate installation project of equipment. was selected. test site outages It is for these reasons a fifty-four period Budget periods will be established with to coincide with the project sufficient period. with the phases. Consistent P.L. 99-190, DOE will obligate funds to cover its share of the cost for each budget Throughout technical, the course of this project, management, reports dealing cost and environmental will be prepared monitoring to aspects of the project DOE. by EER and provided 47 :?Is3? I 48 5.4 Key Aqreements Information lmpactinq Data Riqhts, Patent Waivers and Reportinq Since EER is a small business, during patent this demonstration patent project rights to discoveries will remain with made EER. Standard The and data clauses for a small business will apply. will have unlimited under this Cooperative rights in technical Agreement. government produced data first 5.5 Procedures for Commercialization of Technoloqy As part of the project, GR-SI technology. inventions EER will produce a design manual for the or In the event that know how is developed are made EER will attempt to other to sell the know how or with used licenses to use the inventions engineering and construction business concerned or the production of equipment in these technologies. EER’s interest in commercializing GR-SI is also in the license fees and consulting lations where this technology to the licensees at instalis can be used. Since the technology by EER, their experience will being developed also be valuable and demonstrated as consultants. The market enhanced emissions million for low cost retrofit by regulatory from changes SO2 control which stations. technology reductions can be in SO2 20 require non-NSPS utility Currently, from electric about tons per year of SO2 are emitted generating 49 stations which emit over 1.2 Ibs. of SO2 per million States, representing capacity. about BTU’s in the Eastern United fired electric reductions 175,000 MWe of coal SO2 emission share of generating would affect Any required the availability of a proportionate project is to this capacity. demonstrate utility The purpose the commercial of the proposed readiness of the GR-SI technology of those sitewill be the lowest for application, and to allow in which option. clear definition specific situations cost compliance these technologies The raw sorbent projected be required, adequate. availability is sufficient Additional to handle haulage current and CR-9 requirements. but existing of lime would to be in an exists in rail/truck capacity is expected The solid waste produced will increase resulting increase in the tonnage the U.S. a surplus even larger Therefore, of waste disposed. There currently in the available capacity supply of natural gas. There is an system. the unused feedstock in the natural gas delivery availability is not expected to restrain commercialization of this technology. for the proposed easily be performed industry. would nature technology, manufacturing of equipment within the that will due to the large overcapacity fabrication There are no unusual preclude requirements the use of existing components existing power manufacturing facilities. The of the individual with makes the GR-SI technology plant and environmental very compatible manufacturing methods. 50 6.0 PROJECT COST AND EVENT SCHEDULING 6.1 Project Baseline Costs The total estimated cost for this project is $29,998,253. The share in the Participants’ cash contribution and the Government costs of this project are as follows: Dollar Share (8) Percent Share (%) PHASE I Government Participants PHASE II Government Participants PHASE III Government Participants TOTAL PROJECT Government Participants 14,998,253 15,000,000 50 50 1,764,986 1,764,986 2: :?I :i Cash contributions will be made by the co-funders as follows: DOE: GRI: State of Illinois: TOTAL S14,998,253 1o,ooo,ooo 5,000,000 $29,998,253 51 At the beginning of each Phase, DOE will obligate sufficient funds to pay its share of the expenses for that phase. 6.2 Milestone Schedule The overall project will be completed in 54 months after award of the Cooperative Agreement. Phase 1 which involves permitting, preliminary after award and final design, and continue for will start for all sites immediately fifteen months. Upon completion in the project. of Phase 1, there will be a pause of the pause, Phase month. Each test the of one month Upon completion the thirty-third 2 will start and continue through site will have its own 8 month installations and checkouts period in order to complete for Phase 2. required Following is the anticipated Phase 3 schedule for each test site: Testing on the tangentially fired unit located at the Illinois month of the Power Site is scheduled project to start in the thirtieth months. and last for eighteen Testing on the wall fired unit located to start in the twenty-fifth in eighteen months. at the CILCO site is month and be scheduled completed 52 Testing on the cyclone fired unit located to start in the thirty-fourth months. at the CWLP site is and last for scheduled eighteen month The final months completion of the program will involve site restorations project. and of the final report for the overall 53 6.3 Recoupment Plan In response to the stated policy of the DOE to recover contribution to the project, in accordance an amount the Participant up to the Government’s has agreed to repay the Government Plan included with the Recoupment/Repayment Agreement. in the Cooperative 54