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

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

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

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

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

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

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

Pleasant Prairie PRB Testing completed Nov. 2001.

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

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

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

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

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

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

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

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

Brayton Point Bit. Testing completed Aug. 2002.

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

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

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

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

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

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

Salem Harbor Bit. Testing completed Nov. 2002.

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

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

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

  The NOx SNCR system had no effect on mercury capture.

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

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

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

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

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

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

which averaged 87% during reagent injection.

% Hg Removal Species Baseline Reagent Total 45% 51%

Oxidized 90% 87%

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

Endicott uses a limestone wet FGD.)

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

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

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

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

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

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

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

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

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

mercury removal with the Teflon glass bag, but only 70

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

oxidized mercury at the baghouse inlet.

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

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

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

However, additional evaluation is necessary.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

( average 48%) without SCR operation.

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

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

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

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

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

The first phase of the project, scheduled for 2002

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

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

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

Results from the pilot scale testing are:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

after bag cleaning.

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

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

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

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

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

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

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

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

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

Salt B  40%, and Salt C  50%.

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

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

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

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

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

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

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

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

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

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

interpretation of data was difficult due to a boiler upset.

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

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

The chloride salts were added directly to the coal.

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

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

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

  Salt A did not increase mercury removal across the WPS.

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

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

  Salt injection increased stack opacity.

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

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

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

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

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

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

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

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

  Gold might be effective oxidation catalyst in lignite coal application.

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

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

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

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

  Gold might be effective oxidation catalyst in PRB coal application.

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

foot long gold coated plate with various plate

toplate spacing and coating thickness.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

  Results To Date None available.

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

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

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

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

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

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

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

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

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

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

The Valley Plant test results are not yet available.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

  Schedule On going in house research and development project.

  Cost Annual in house allocation.

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

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

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

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

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

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

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

  Schedule Complete. Tool base.

  Cost Exploratory funding as needed.

  Status Complete.

  Results To Date See publication.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

  Results To Date None available.

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

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

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

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

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

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

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

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

  Results To Date None available.

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

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

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

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

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

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

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

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

  Results To Date None available.

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

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

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

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

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

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

  Status Testing completed in October 2002.

  Results To Date None available.

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

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

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

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

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

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

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

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

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

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

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

  Sponsors The project is being funded by NETL and UNDEERC.

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

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

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

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

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

  Results To Date None available.

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