United States Environmental Protection Agency Air and Energy Engineering Research Laboratory Research Triangle Park NC 27711 Research and Development EPA/600/S8-88/065 Apr. 1988 Project Summary Industrial Boiler Furnace Sorbent Injection Algorithm Development Julie Maddox The Industrial Combustion Emissions (ICE) Model is one of four stationary source emission and control cost forecasting models developed by EPA for tne National Acid Precipitation Assessment Program (NAPAP). The ICE Model projects air pollution emis- sions (sulfur dioxide, sulfates, nitrogen oxides, and particulate matter), cost, and fuel mix for industrial fossil-fuel- fired (natural gas, distillate and residual fuel oil, and coal) boilers by state and year (1980 baseline, 1990, 1995, 2000, 2010, 2020, and 2030). The report describes the develop- ment of a performance and control cost algorithm for the ICE Model. This algorithm enables the ICE Model to consider, on an economic basis, the use of hydrated lime injection for S02 control when a S02 emission reduction strategy is implemented. The algo- rithms described in this report have been incorporated into ICE Model Version 6.0. This Project Summary was devel- oped by EPA's Air and Energy Engi- neering Research Laboratory. Research Triangle Park. NC. to announce key findings of the research project that is fully documented in a separate report of the same title (see Project Report ordering information at back). Introduction The full report documents the devel- opment of the furnace sorbent (hydrated lime) injection cost algorithm for coal- fired industrial boilers. This document describes the methods used to develop capital, operating, and annualized costs. The boiler size range examined covers units with capacities from 100 million to 1300 million BtuVhr input. All costs are in June 1985 dollars. Design Bases The furnace injection scheme involves pneumatic injection of the sorbent into the flue gas (in the upper furnace) with subsequent collection of particulate matter (PM) downstream. The injected sorbent reacts with the S02 in the flue gas to form solid products. The reaction product and the unreacted sorbent are then collected downstream with the fly ash in a baghouse or electrostatic precipitator (ESP). For this cost analysis, hydrated lime is the sorbent. By purchasing hydrated lime, the industrial boiler operator eliminates the need for limestone pul- verizers, crushers, and bulky storage piles. Also, lime has exhibited higher SO2 capture than limestone. Furnace sorbent injection alters the quantity and chemical characteristics of PM emitted from the boiler. This results in modifications of the PM control system, which are based on: • It is assumed that all existing boilers with heat inputs greater than or equal to 250 million Btu/hr have an existing ESP. This assumption is based on the requirement that all boilers with heat inputs greater than or equal to 250 million Btu/hr meet a 0.1 Ib** PM/ million Btu*** emission limit. • In order to control the additional PM loading in an ESP, additional collec- tion area is required. Also, an S03flue *1 million But/hr = 0 29 MW. "1 lb = 0.45kg. ***1 million Btu = 1.05 GJ. ------- gas conditioning system must be installed in order to adjust the resis- tivity into a range which optimizes the ESP collection efficiency. • All existing units with heat inputs of less than 250 million Btu/hr will need to retrofit a fabric filter. • It is assumed that all units employing fabric filters to control PM will incur a sorbent savings of 10% due to the additional SOZ removal across the bag filters. • Due to the sorbent savings, all new units will install fabric filters to control PM. Algorithm Development The costs of the sorbent injection system are based on data gathered from manufacturers and literature sources. The major capital cost components include the storage silo, feed bins, gravimetric feeders, and pneumatic conveyors. Most of the capital costs depend on the sorbent feed rate into the boiler. The cost equations for fabric filters and ESPs are based on algorithms developed for industrial boilers. These cost equa- tions were developed as part of the Industrial Boiler New Source Perfor- mance Standard. For fabric filters, the capital costs depend on the flue gas flow rate. Since sorbent injection has little effect on the flue gas flow rate, the capital costs are unaffected. The increased PM loading due to sorbent injection increases the fabric filter operating costs. The injection of sorbent into the flue gas stream causes a large increase in the PM loading. The total collection plate area needed in the ESP depends on the PM loading of the flue gas. The additional collection area needed is calculated based on the percent increase in PM loading due to sorbent injection. Sorbent injection also increases the resistivity of PM in the flue gas to levels which significantly reduce ESP collection efficiency. | Case Studies Tables 1 and 2 present the results of several case studies examined in this report. Capital, operating, and annualized costs are calculated for new and retrofit units ranging in size from 100 to 400 million Btu/hr. The algorithms further break down the costs into direct furnace sorbent injection system costs and PM control costs. Appendices A, B, and C of the report list Lotus spreadsheets used to estimate the costs. Table 1. Furnace Sorbent Injection Costs for New Boilers Capital Costs ($) Furnace Paniculate Total Injection Matter Capital Boiler Type/Size (million Btu/hr) System Control Cost Annual Operating Costs ($/yr) Furnace Paniculate Total Injection Matter Operating System Control Cost Annualized Costs ($/yr) Furnace Paniculate Total Injection Matter Annualized System Control Cost Spreader Stoker Boiler 100-50% Removal 100-7 5% Removal 250-50% Removal 250-75% Removal Pulverized Coal Boiler 250-50% Removal 250-75% Removal 400-50% Removal 400-75% Removal 384.393 462,304 594. J 65 768,316 594,165 768,316 795.688 1.061,250 1.138.313 1.144.649 2.279.192 2,295,031 2,218.192 2.234,081 3.157.157 3,182.499 1.522,908 1.606.953 2.873.357 3.063,347 2.812.357 3,002,347 3.952,845 4.243,749 231.460 380,149 442,118 813,418 442,118 813,418 652.607 1.246.413 1 72.344 197,686 373,021 436,376 367,328 430,683 570,479 671.847 1 1 1 1 403,804 577.835 815,139 ,249.794 809.446 .244.101 .223.086 ,918,260 298,758 453.119 536.603 981.140 536.603 981,140 777.903 1.406,648 364,957 390,983 758,137 823,076 742.072 807.011 1.103.072 1,206.974 1 1 1 1 1 2 658,715 844,052 ,294,740 .754.216 ,278,675 .738.151 .880.975 .613,622 Table 2. Furnace Sorbent Injection Costs for Retrofit Boilers Capital Costs ($) Furnace Paniculate Total Injection Matter Capital Boiler Type/Size (million Btu/hr) System Control Cost Annual Operating Costs ($/yr) Annualized Costs ($/yr) Furnace Paniculate Total Furnace Paniculate Total Injection Matter Operating Injection Matter Annualizei System Control Cost System Control Cost Spreader Stoker Boiler 100-50% Removal 100-75% Removal 250-50% Removal 250-75% Removal Pulverized Coal Boiler 250-50% Removal 250-75% Removal 400-50% Removal 400-75% Removal 519.382 589,467 817,709 973.242 800.409 945.056 1.074.967 1.293.178 1.470.635 1.476,032 2.943,186 2,956,677 5.171,169 6,376,607 6.277.127 7.823,546 1.990.O17 2,065,499 3,760,895 3.929.919 5.971,578 7.321.663 7.352.094 9.116,724 287,093 406.235 581.029 878,567 577,663 873,136 869,365 1,341,907 179,424 201.009 390.719 444,681 214,057 310,599 330,931 483.185 1 1 1 1 466,517 607,244 971,748 ,323,248 791,720 .183,735 ,200,296 .825.092 419.351 552.632 782,906 1,110,356 792.795 1.117,168 1.153.079 1.667.855 579.734 601.859 1.190.356 1,245.667 1.774,464 2.232.371 2.221.439 2.835.830 1 1 2 2 999.085 ,154,491 ,973,262 ,356,023 ,567,259 3,349,539 3 4 ,374,518 ,503.685 ------- Julie Maddox is with Radian Corporation, Research Triangle Park, NC 27709. Larry G. Jones is the EPA Project Officer (see below). The complete report, entitled "Industrial Boiler Furnace Sorbent Injection Algorithm Development," (Order No. PB 88-184 890/AS; Cost: $14.95, subject to change) will be available only from: National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Telephone: 703-487-4650 The EPA Project Officer can be contacted at: Air and Energy Engineering Research Laboratory U.S. Environmental Protection Agency Research Triangle Park, NC27711 United States Environmental Protection Agency Center for Environmental Research Information Cincinnati OH 45268 :'r ''-;:\ r.vrv I lj.i.[>0l'!/tb MY.c'liS ! '";,:_ ! Official Business Penalty for Private Use $300 EPA/600/S8-88/065 0000329 PS M •frU.S. GOVERNMENT PRINTING OFFICE: 1988—548-013/8 ------- |