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.
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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
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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
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