PDF 88504 22363
PDF 88504 22363
6 (2010), 1255-1262
Original Research
Absorption of NOx, SO2, and Mercury
in a Simulated Additive-Enhanced Wet Flue
Gas Desulphurization Scrubber
Abstract
Bench- and pilot-scale studies were conducted on the simultaneous removals of SO2, NOx, and mercury
(both Hg0 and Hg2+) from coal combustion flue gas using a limestone-based wet flue gas desulfurization (FGD)
scrubber. The wet scrubber performance for multi-pollutant control was significantly enhanced with the intro-
duction of an oxidizing additive – sodium chlorite (NaClO2). Parametric studies investigating the effects of
flue gas components (e.g., SO2, NO), temperature, and oxidant addition rate were completed with the bench-
and pilot-scale experimental facilities. Various process configurations were examined to optimize the addition
of sodium chlorite. Additional tests were also performed to better understand the chemistry of the oxidation
and subsequent capture of the pollutants of interest.
[3] and European Union directive [5]. The installation of The U.S. Argonne National Laboratory recently
post-combustion NOx control devices, such as selective cat- claimed that an integrated multi-pollutant approach through
alytic reduction (SCR), is one way to meet the stringent the wet FGD system can outperform current emission con-
emission standards. It is anticipated that deployment of trol strategies in the following ways:
SCR systems will continuously increase and ~50% of the (1) optimization of resource and energy,
coal-firing plants will have SCR installed by 2020 [6]. (2) lower capital and operating costs, and
Notwithstanding, the increasing price of ammonia (which (3) operational reliability [7].
is synthesized from natural gas) [32] might throw a road- In this approach, one multi-pollutant control technology
block to the wide deployment of SCR systems. can be realized by introducing additives to the wet scubber
Mercury is a component of coal and during the com- where NO and elemental Hg can be oxidized and scrubbed.
bustion process is released as Hg0 (elemental mercury) [33, This type of approach is also most attractive for small or
34]. Mercury reacts with different flue gas components and medium boilers. In addition, extending this application to
exists in three different forms in flue gases: elemental Hg0 the cement or waste treatement industry would be interest-
(elemental) and Hg2+ (oxidized form, e.g. HgCl2), and Hg in ing as well.
particulates (Hgp) [33, 34]. The elemental Hg0 does not dis- A lot of work has been performed in an effort to remove
solve in water and is not usually captured in air pollutant NO in the sodium chlorite solution by oxidation of NO to
control devices (APCD), while the Hg in particulates is NO2 or elevated states of oxides [11, 14-16, 26-28]. NO in
captured upstream of particulate control devices (e.g. elec- general has a low solubility and it is extremely difficult to
trostatic precipitator (ESP) or fabric filter (FF)). The oxi- achieve removal across a wet scrubber without it being con-
dized form dissolves in water and can be captured with verted into soluble matter, e.g. NO2 [25]. As such, the suc-
water spray or in a flue gas desulphurization (FGD) unit cess of NOx removal from flue gas when a wet scrubber is
[33, 34]. Wet-FGD scrubbers have the potential to provide utilized should involve oxidation of NO to NO2 and then
a high level of mercury control because of their substantial scrubbed in a liquid slurry. When oxidant is added to the
gas-liquid mass transfer and the high solubility of most oxi- wet scrubber, it also has the potential to oxidize elemental
dized mercury compounds (such as HgCl2). This co-benefit mercury, which is not water soluble. The efforts presented
control is only effective for flue gas streams containing oxi- in this paper are, therefore, to illustrate the role played by
dized forms of mercury, because the elemental form is not sodium chlorite in promoting NOx and Hg scrubbing across
soluble and tends to pass through the wet scrubber [33, 34]. a wet limestone scrubber system.
Mercury, well known for its toxic properties regarding
human health and the environment, should be removed Bench-Scale Demonstration
from flue gas [21]. A variety of technologies are being
developed to control mercury emissions from coal-fired The performance of NaClO2 in promoting multi-pollu-
power plants, including sorbent injection, catalyst oxida- tant control was first investigated with bench-scale tests.
tion, flue gas or coal additives, combustion modification, The bench-scale experimental apparatus, Fig. 1, made use
barrier discharges, and ultraviolet radiation [22-24]. Co- of a flow-through gas-liquid impinger to simulate a wet
benefit application of SCR in combination with wet scrub- FGD scrubber. The system included a gas blending system
ber without any additional capital investment is the most for the makeup of synthetic flue gas, a flow-through gas-
favorable solution [30]. However, challenges still exist due liquid impinger, and an online gas analysis system for mea-
to the potential deactivation of SCR catalysts by fly ash surement of the flue gas stream constituents. Slurry was
[31]. pumped through the impinger, being maintained at a con-
Worldwide research efforts have shed light on individ- stant slurry level through overflow mechanics. The scrub-
ual SO2, NOx, and mercury emission reductions [8-20, 27]. ber was operated at 55ºC by immersing the scrubber into a
Technological approaches for multipollutant control differ constant temperature water bath. Sodium chlorite (NaClO2)
dramatically, and some have gone beyond the co-benefit and calcium carbonate were mixed prior to being intro-
endeavor of current air pollutant control devices. For exam- duced to the scrubber through separate ports. The constant
ple, ReACT technology (ammonia and activated carbon) addition of NaClO2 was manipulated via weight losses in
and ECO (plasma) has achieved commercial application [8, the beaker. The alkali solution addition rate was monitored
9]. However, their application to the coal-fired power plant via the weight gain from the overflow of the scrubber.
commands additional equipment and investment. One con- Simulated flue gas was introduced to the experimental sys-
cept recently introduced is the multi-pollutant control tem from gas cylinders. The gas mix was comprised of 11%
where SO2, NOx, and other pollutants are simultaneously CO2, 8% O2, 1,500 ppmv SO2, 200 ppmv NO, 206 μg/m3
controlled in a single air pollutant control device. Hg0, and balanced with N2. The flow of the simulated flue
Apparently, the multipollutant control across wet FGD is an gas was maintained at 2 L/min (STP). Elemental mercury
option. Following the wide deployment of wet-FGD scrub- vapor was supplied from a VICI Metronics Dynacalibrator
bers in response to CAIR and the EU Directive, researching permeation oven, maintained at 100ºC and transported by
and developing a process where the wet scrubber is capable N2. The high level of mercury was necessary to meet the
of providing simultaneous multi-pollutant (SO2, NOx, and required sensitivity of the mercury analyzer. Prior to analy-
Hg) control is attractive. sis, the sampling gas passes through an ice cooler and a
Absorption of NOx, SO2, and Mercury in a Simulated... 1257
Table 1. Summary of Experimental Conditions in Bench-Scale Instrumentation, Inc.). The NOx species were measured
Experiments. using a continuous chemiluminescence NOx analyzer
Experimental (model 200AH, Advanced Pollution Instrumentation, Inc.).
Value Remark
conditions Slurry was feeding simultaneuosly with the oxidizer to
SO2 0-2,500 ppm SO2 in nitrogen the impinger until it started to overflow. A magnetic stirrer
was used to promote the mixing of slurry. The agitation was
NO 0-470 ppm NO in nitrogen maintained at a constant speed throughout all runs. Flue gas
CO2 11 vol % Compressed CO2 was then introduced to the impinger and the test was con-
tinued for 60 minutes. Fresh NaClO2/CaCO3 was added at
O2 8 vol % Compressed air (N2/O2)
a constant rate during the scrubbing period. The scrubber
N2 balance Compressed N2 effluent was collected every 10 minutes toward the end of
H0 permeation tube at the test. Collected samples were immediately weighed, and
Hg0 206 µg/m3 ice quenched to minimize potential oxidation reactions.
100ºC
Filtrate from samples was then analyzed as soon as practi-
Std conditions, 1 atm and
Total flue gas flow 2 L/min
20ºC
cally possible for chloride, chlorite, chlorate, sulfate,
nitrate, and nitrite concentrations with ion chromatography
Scrubber slurry Alkali and oxidant (IC) using EPA reference method 300.0.
10 wt %
solids wt % solutions combined
Oxidant Simultaneous Removal of SO2, NOx, and Hg
varied Sodium chlorite
concentration
Scrubber Simultaneous removal of SO2, NOx, and Hg was tested
55ºC Controlled by water bath
temperature at 55ºC by using SO2, NO, and Hg concentrations of 1,500
ppm, 200 ppm, and 206 μg/m3, respectively. NOx and Hg
removal efficiencies and resulting NO3¯, NO2̄ , and Hg2+ ion
Nafion dryer, where moisture is removed. Hg0 vapor was concentrations in the liquor are presented in Figs. 3 and 4.
measured using a continuous cold vapor atomic absorption SO2 removal efficiency was complete before the addition of
(CVAA) analyzer (BUCK model 400A). The interference NaClO2, This information is not presented in the figures for
of SO2 to mercury analyzer was determined and corrected clarity. Data show that NO was completely oxidized into
together with the downstream SO2 analyzer. The SO2 NO2 when NaClO2 concentration reached 5.0 mM. NO2
species were measured using a continuous SO2 fluores- scrubbing increased along with increasing NaClO2 addi-
cence analyzer (model 100AH, Advanced Pollution tion, ranging from 40% at 5.0 mM NaClO2 up to 60% at 25
NOx
Hg
Permeation
Oven
To Vent
Vent SO2
Rotameter
Gas
Filter
Hg
Outlet D.A.S.
Nafion
Dryer
Gas
Inlet
Oxidant
Scrubber
Balance
Overflow
Limestone
Slurry
Balance
Stirplate
Stirplate
Fig. 1. Bench-scale experimental schema.
1258 Krzyżynska R., et al.
and nitrate) in the slurry was consistent with the scrubbing 140%
mass balance from Hg in effluent
of the NO2 from the gas stream. The amount of Hg0
AmountRemoved
120%
Removal
removed as a function of chlorite concentration is shown in
100%
Fig. 4. Mercury was completely removed with the addition Hg (gas analysis)
of 3.0 mM NaClO2. The mass balance in some cases was 80%
Amount
not well closed, most likely due to analytical challenges in 60%
measuring low levels of Hg2+ concentration.
40%
0%
0.000 0.005 0.010 0.015 0.020 0.025 0.030
The effect of SO2 concentration on the simultaneous
-
removal of NOx, SO2, and Hg at 55ºC was performed at ini- [ClO 2 ] in Scrubber Slurry, Molar
tial NO of 200 ppm, Hg0 of 206 μg/m3, NaClO2 of 8.0 mM, Fig. 4. Amount of Hg0 removed as a function of chlorite con-
and CaCO3 of 10% (wt %) solid slurry. The SO2 concentra- centration in the CaCO3 slurry. The inlet concentration of NO
was 200 ppm. The initial SO2 concentration was 1,500 ppm.
tion varied from 0 to 2,500 ppm. These values represent the
extreme ranges of what might be seen in the flue gas of
coal-fired utilities.
120
Hg (gas analysis)
100
Amount Removed [%]
80
NO (gas analysis)
NOx (gas analysis)
60
40
20
0
0 500 1000 1500 2000 2500
SO2 Concentration into Scrubber, ppm
80% cury removal was observed. NO2 absorption was also low
NO X (gas analysis)
(~20%). This phenomenon is most likely related to the pH
60% of the medium, where high levels of pH are unfavorable for
Hg0 and NO oxidation. An addition of a low-SO2 concen-
40%
tration of 500 ppm to flue gas had rendered a 100%
N mass balance from (NO 3- and NO 2-) in
20% effluent removal of NO (oxidation) and mercury on the opposite
side of the spectrum due to the lack of SO2. The same level
0% of NO and Hg removal was continued in the presence of
0.000 0.005 0.010 0.015 0.020 0.025 0.030
[ClO SO2 and was consistent until it reached 2,500 ppm where
2̄ ] in
[ClO Scrubber
-] in ScrubberSlurry,
Slurry,Molar
Molar
2
NO removal decreased to ~75%. The NOx (as NO2) scrub-
Fig. 3. Amount of NO and NOx removed as a function of chlorite bing followed a similar pattern with lower scrubbing with
concentration in the CaCO3 slurry. The inlet concentration of NO no SO2 addition, an increase with SO2 addition, and then a
was 200 ppm. The initial SO2 concentration was 1,500 ppm. decline at the highest SO2 addition.
Absorption of NOx, SO2, and Mercury in a Simulated... 1259
Effect of NO Concentration natural gas at approximately 158,000 kJ/h. The fuel was
introduced at the top of the furnace and combusted with air
The effect of varying NO concentration on NOx, SO2, from axial and tangential directions. Since the natural gas-
and Hg removals at 55ºC was performed under the follow- derived flue gas contained no SO2 and only small amounts
ing conditions: SO2 =1,500 ppm, Hg0 = 206 μg/m3, NaClO2 of NO, these components were doped from gas cylinders to
= 8.0 mM, CaCO3 = 10% (wt %), and the range of NO achieve the desired flue gas concentrations. Similar to the
varying from 0 to 470 ppm. The results presented in Fig. 6 Hg generated for bench-scale tests, gaseous Hg0 was pro-
illustrate that the absence of NO in flue gas affects mercury duced in a permeation oven (VICI Metronics
oxidation to a certain degree. At 0 ppm NO, the Hg oxida- Dynacalibrator) and was transported by air into the duct
tion and removal was approximately 82% and approached before the scrubber.
100% with increasing NO concentrations. NO was com- The spray tower where SO2, NOx, and Hg are scrubbed
pletely oxidized when NO concentrations were present consists of three turbulent contact absorbers (10-cm in
from 100-300 ppm, and decreased to approximately 65% at diameter). Each absorber is 92-cm in length, and contains
470 ppm NO. The NOx (as NO2) scrubbing followed a sim- plastic hollow balls (2-cm in diameter) to promote intimate
ilar pattern as NO. contact between flue gas and scrubbing slurry. The effluent
slurry from the spray tower was not discharged to the
Effect of Temperature underlying slurry hold tank, but rather to a discrete forced
oxidation tower. A flow of ~45 L/min air was sparged to the
Increasing temperature accelerates the reaction rate, but bottom of the forced oxidation tower to oxidize SO32- into
decreases gas solubility in the liquid. Additional experi- SO42-. The slurry overflowed back to a small hold tank posi-
ments were conducted to identify the effects of varying tioned below the scrubbing tower. Slurry in the hold tank
temperature. The temperatures that were evaluated ranged was subsequently delivered back to the top of the spray
from room temperature to 65ºC. Test conditions also
included the following: 8.0 mM NaClO2, 10% (wt) solid
120
slurry, 200 ppm NO, 1,500 ppm SO2, and 206 μg/m3 Hg.
The oxidation and removal percentage for NO, and Hg 100
holds the same across the testing range of temperature (Fig.
8). Temperature in the range of 25-65ºC had a negligible 80
effect on pollutant removal efficiences in these experimen-
tal conditions. 60
40
Pilot-Scale Demonstration
20
Tests were also conducted utilizing a pilot-scale scrub-
ber system as shown in Fig. 2. The system was consistent- 0
ly operated in the forced oxidation mode. Simulated flue 0 50
100 150 200
gas was generated from a down-fired cylindrical furnace, Time, min.
known as the innovative furnace reactor (IFR). Although it Fig. 7. Effect of nominal 1.62 M NaClO2 injection at 5 mL/min.
is capable of burning coal, the IFR is typically fired with (hold tank slurry pH=6.4).
120
Hg (gas analysis)
100
Amount Removed [%]
Amount Removed [%]
NO (gas analysis)
80
40
20
0
0 100 200 300 400 500
Temperature [ºC]
NO
NOconcentration
Concentration in Scrubber,
Scrubber,ppm
ppm
Fig. 6. Amount of NO, NOx, and Hg removed as a function of Fig. 8. Amount of NO, NOx and Hg removed as a function of
varying concentration of NO in the entering gas. The entering temperature in the scrubber. The entering concentration of
concentration of NaClO2 added was 8 mM. SO2 concentration NaClO2 added was 8 mM. The inlet concentration of NO was
in entering gas was 1,500 ppm. 200 ppm. SO22 concentration – 1,500 ppm.
1260 Krzyżynska R., et al.
Table 2. Typical test conditions of the wet scrubber in the pilot- vs. time are plotted, flue gas Hg, NO, and NOx across the
scale experiments. scrubber rapidly declined following the NaClO2 injection.
Experimental Condition Parameter At steady state, ~65% of the Hg was removed from the flue
gas. Although NO and NOx across the scrubber declined as
Flue gas flow rate, L/min 850
well, these pollutants decreased at a diminishing rate. In
Inlet flue gas SO2 concentration, ppm 1,100±100 Fig. 7, ~32% of NO was oxidized into NOx, and only
Inlet flue gas NOx concentration, ppm 220±20 ~15% of total NOx was removal across the wet scrubber
system.
Flue gas O2 concentration, % 7-8
It appears that the multi-pollutant control across a wet
Flue gas CO2 concentration, % 6-7 scrubber system demands the addition of NaClO2, which
Hold tank slurry volume, L 10 is critical for initial Hg reduction. Efforts continued by
varying the NaClO2 addition concentration. The results
Hold tank pH 6.4 showed that the extent of scrubbed Hg increases with
Slurry recirculation rate to scrubber, L/min 2.2±0.2 increasing chlorite addition in the slurry, ranging from
~40% at 0.81 M NaClO2 up to ~70% at 1.62 M NaClO2.
Slurry recirculation rate to oxidation tower, L/min 30
However, the scrubbing for NO with pilot-scale wet
Hold tank slurry temperature, ºC 46±2 scrubber still ranged from 15 to 30% for selected NaClO2
Hg feed concentration, µg/Nm 3
17±2 injection rates. The addition rate of NaClO2 had little
effect on the scrubbing of NOx. It was observed that there
Hg2+ feed rate, µg/min 15±0.4 is a lower pollutant removal efficiency in pilot-scale test
NaClO2 addition concentration, M 1.62 than in the bench-scale. Further research will focus on
optimization of process conditions in order to increase
Air sparged to the forced oxidation tower, L/min 45
pollutants removal efficiencies in that type of multi-pollu-
Diameter of forced oxidation tower, cm 25.4 tant scrubber.
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