Mcilvaine Insights

No. 118   September 4, 2019

WELCOME

Weekly selected highlights in flow control, treatment and combustion from the many McIlvaine publications.

·       Dry Scrubber Market will grow to $5 billion/yr.

·       Industrial and IIOT and Remote O&M Newsletter

·       Validating Lime Choices for Dry Scrubbing

Dry Scrubber Market will grow to $5 billion/yr.

Dry scrubbers are taking market share away from the wet scrubbing alternative in coal fired power, biomass combustion, cement, steel, waste to energy and other applications involving hot acid gases and particulate.

The advantages of dry scrubbers are the reduced need for water, the elimination of wastewater, and the capture of mercury, dioxins, and sulfuric acid mist. The negative aspect is the elimination of valuable byproducts.  If the acid gas ratio in the fuel is low dry scrubbing has the lowest total cost of ownership. The higher the acid content the less competitive dry scrubbing is to wet.

Dry scrubbing is the preferred choice in glass plants, waste to energy, and cement plants. In some other applications it has half the market share.  In coal fired power generation it has less than a 6 percent share.  A major change is taking place in India where coal fired power plants are expected to use dry scrubbing for one third of the requirements. As a result India will be a leading purchaser of dry scrubber hardware, lime and services in the future. It will spend just under $3 billion for dry scrubber hardware and construction over the seven year period ending in 2025.  It will be spending $650 million/yr for lime for dry scrubbing by 2025 and $325 million for service, repair and remote operation and maintenance.

Cement, waste to energy and furnace applications are sized based on CFM. Equivalent MW is provided as a convenience.

MW - CFM equivalent is 3000 CFM at 240F

U.S lime at $150/ton and 100 tons per equivalent MW

Lime in China, India, and ROW at $100/ton and 100 tons per equivalent MW

Hardware for new plants is $45,000/equivalent MW in India and China and $80,000/equivalent MW in U.S. and ROW.

Service, repair and remotely operate is $5000/ MW/yr

The world market for dry scrubbing hardware will average $710 million/yr over the period to 2025. Lime purchases will be just under $3 billion by 2025 while service, repair and remote O&M will rise to over $1.3 billion/yr.

Forecasts for both wet and dry scrubbing for each country are contained in two McIlvaine reports. One is focused on coal fired boilers and the other on the industrial market.  More information is available at

N027 FGD Market and Strategies

N008 Scrubber/Adsorber/Biofilter World Markets

Bob Mcilvaine can answer any questions at cell 847 226 2391 or rmcilvaine@mcilvainecompany.com

Industrial and IIOT and Remote O&M Newsletter August 2019
No. 478

This monthly newsletter is available for just $ 350/yr. and is also included in N031 Industrial IOT and Remote O&M

Table of Contents

• Coal-Fired Plant Decisions Provides Guide to Lowest Cost of Ownership
• Selling To the 500 Coal Plant Owners Who Make 99 Percent of the Purchases
• Would You Rather Share Sales Leads with Your Allies or With Your Competitors?
• Sales Program Based On the 500 Coal Plant Operators That Buy 99 Percent of the Combust, Flow and Treat Products
• Coal By-products Including Rare Earths Will Be A Game Changer

INDIA

• Mostly Combustion Modification for NOx Reduction at Delhi Area Plants
• Fortum Has Combustion Modification Order from Hindalco
• BHEL Has 13 Orders for Selective Catalytic Reduction (SCR) System to Reduce NOx
• BHEL Has Order for FGD Systems At the 4x250 MW Nabinagar Project of BRBCL
• Condensibles Become a Sematic Problem with FGD
• Indian FGD Status
• SEIL Floats Tender to Set Up Two FGD Units in Its Two Power Plants
• 63,000 MW of Precipitator Upgrades Planned
• ECOMAK Supplies Precipitator Upgrades and the Venturi Option Could Be Combined With FGD
• United Conveyor Has Dadri Order for DSI
• A Number of FGD and DeNOx Papers at Electric Power
• Envea Pursuing FGD CEMs Market in India
• Johnsen Chemicals Has A Combustion Catalyst That Lowers Pollutants
• Steam Equipments Supplied CEMS to Tata Power
• EPP Provides FRP Scrubber Vessels
• Uniphos Provides Particulate and Gas CEMS
• LeBracs Supplies Rubber Lining for Vessels and Ducts
• CSL - Chemtron Science Laboratories Provides Cannisters and Gas Handling Equipment
• Speakers at SOx-NOx 2019

ARTICLES IN THE INTELLIGENCE SYSTEM

• Acquire Control Supplies System for MBR at Landfill Site
• Automatic Control Systems for MBRs
• Innovative Treatment Products Has Control System to Adjust to Widely Varying MBR Flow
• Automatic Control for Koch AnMBR

INDUSTRY NEWS

• MHPS Establishes New Company In the Philippines Specialized In the Service Business
• Dry Scrubber Users Will Meet To “Work Smarter Not Harder”
• Dry Scrubber Silo Busting
• IEA Is an Important Resource
• Repeal of the Clean Power Plan; and Emission Guidelines for Greenhouse Gas Emissions From Existing Electric Utility Generating Units
• Keynote Speakers at Clean Coal 2019
• Flexible Coal Plants as Clean as Gas
• India Could Double Coal-fired Power Capacity
• Major Developments in CO₂ Capture and Use

Validating Lime Choices for Dry Scrubbing

Some people attending the September DSUA conference will be making lime purchasing decisions. Those attending SOx-NOx India have many questions about lime availability and use options.

Coal Fired Power Plant Decisions (CFPPD) is free of charge to plant operators. It can be used to facilitate decision making through access to the relevant information and ease with which operators can contact experts and conference attendees. The information in CFPPD can provide the evidence and interface at the conferences can facilitate the validation.

The DSUA/SOx-NOx India webinar analysis and recording is an example of the way periodic webinars can be spaced between conferences.  DSUA and SOx-NOx India can be a foundation for a whole program to validate Lowest Total Cost of Ownership (LTCOV) for lime. These two conferences can be the nucleus and the activity extended to PowerGen U.S. and PowerGen Europe and many other conferences.

It is useful to know which supplier personnel will be attending conferences and encourage operators to make arrangements for meetings in advance.  Here is an example of the database we are creating relative to conference participation by lime suppliers.

Personnel (Product - Lime)

The information in CFPPD will be used by subject matter experts who become subject matter ultra-experts (SMUEs) and provide input for data analytics software. The cycle than continues with new information in CFPPD analyzed by the SMUE and then integrated into the software.

This cycle was explained by Scott Affelt of XMPLR in the August 29 webinar.  Various lime company personnel should become subject matter ultra-experts in narrow niches e.g. Jerry Hunt of Lhoist gave a paper on SO3 capture with hydrated lime.  He can help add additional information on SO3 capture in the system and become an SMUE on this subject. Commercial subjects such as the quality and availability of lime in India should be addressed by one or more SMUEs. 

XMPLR, McIlvaine, and Tata Consultancy will be conducting a half-day session on Monday at PowerGen New Orleans.  The theme will be on how smaller companies can leverage their products and knowledge internationally.

This personnel database plus selected evidence from CFPPD will be displayed in CFPPD for the convenience of those focusing on lime.

LIME INSIGHTS IN COAL FIRED POWER PLANT DECISIONS

TABLE OF CONTENTS

Sept 2019 FGD Newsletter

·       Carmeuse exporting lime to India from Oman

·       Wet lime systems have a number of benefits compared to limestone systems

·       India needs additional high-quality hydrated lime production

·       Circulating Fluid Bed Scrubber could be the best choice for many Indian Power Plants

·       Sorbacal® SPS used in CDS and DSI systems

·       Lhoist announced possible price increases of 11% last December

·       Lhoist market share in Asia

·       United Conveyor has Dadri order for DSI 

·       Tata Power March 2019 bid request for 1 x 67.5 MW DSI FGD System

·       Bids close for DSI for 4 x 210 MW of DSI systems at Punjab State Power Roopnagar in September 2019 

August 2019 FGD Newsletter

·       Case for Dry Scrubbers for Indian Power Plants

·       India Will Be A Major Purchaser of Dry Scrubbers

·       NTPC March 2018 Tender for DSI for Dadri

April 2019 FGD Newsletter

·       Cement Kiln Dust for SO₂ removal

March 2019 Newsletter

·       Dry Scrubbing Discussions at the Cement Conference in St. Louis

November 2018 Newsletter

·       Dry Hydrate Users Group is another Resource

Articles in  Intelligence System

·       Mississippi Lime Presentation 2017: Targeted DSI Improvements

·       Costs for DSI

Lhoist Presentations in the Intelligence System

·       MACT Update Webinar - Hot Topic Hour - May 7, 2015

·       Flue Gas Treatment Specialist, by Marty Dillion, Lhoist - HTH 5-7-15

·       Dry Sorbent Injection Options and Issues Webinar Recording - Hot Topic Hour April 9, 2015

·       MATS Compliance Choices Webinar - Hot Topic Hour January 29, 2015

·       DSI for MATS and CSAPR by Jim Dickerman, Lhoist / Chemical Lime - Hot Topic Hour January 29, 2015

·       Lhoist Has Lots of Ceramic Filter Hot Gas Experience

·       Ceramic Filter with Embedded Catalyst and DSI Achieves High SOx, NOx and ROx Removal

·       Advances in Dry Sorbent Injection (DSI) Reagents by Mike Schantz, Lhoist - Hot Topic Hour July 11, 2013.

·       New Developments in Air Pollution Control Technology Webinar - Hot Topic Hour July 11, 2013

·       Overview of SO3 Emission Control with Hydrated Lime by Jim Dickerman, Lhoist. Hot Topic Hour March 8, 2012

·       SO3 Measurement and Control - Webinar - Hot Topic Hour March 8, 2012

·       Sorbacal Dry Sorbent Injection - a Low Capital Solution for HCl Control by Mike Schantz, Lhoist / Chemical Lime Co. - Hot Topic Hour November 18, 2010

·       Industrial MACT Webinar - Hot Topic Hour November 18, 2010 - Part 1

Lhoist Articles in Older FGD Newsletters

·       Dry Scrubbing Discussions at the Cement Conference in St. Louis- March 2019 

·       Lhoist Unveils Hydratex™ Proprietary Technology---Dec 2016

·       SO₃ removal with Sorbacal will solve the bag blinding problem at PacifiCorp August  2016

·       MACT Update Provided in Hot Topic Discussion May 7, 2015

·       MACT Compliance Options, by Pat Mongoven, Mississippi Lime, HTH 5-7-15

·       Flue Gas Treatment Specialist, by Marty Dillon, Lhoist - HTH 5-7-15

·       MACT Update Webinar - Hot Topic Hour - May 7, 2015

·       SO₃ removal with Sorbacal will solve the bag blinding problem at PacifiCorp

·       Lhoist North America Sorbacal Hydration Facility at Ste. Genevieve Plant-April 2013

·       SO₃ Measurement and Control” – Hot Topic Hour on March 8, 2012   (in the Monitoring Newsletter)

Carmeuse Newsletter Articles and Papers in the Intelligence System

·       Carmeuse is Positioned to Offer Lime and Provide Remote Operating Advice to Solid Fuel Combustion Operators Around the World - September 2017

ARTICLES AND LINKS

Sept 2019 FGD Newsletter

Carmeuse exporting Lime to India from Oman

Carmeuse Majan, a Salalah Free Zone company, operates a lime kiln at  full capacity of 400 tons per day (tpd). It is ready for growth depending upon availability of natural gas, which is crucial for any expansion.

Wael Abdalla, Carmeuse Majan’s General Manager, presented an ambitious picture.

“Development of four kilns is our current expansion plan. Of that, the second kiln investment preparations have already started and gas allocation to the second kiln at the soonest is an absolute necessity,” he said and added that in 10 to 15 years from now Carmeuse Majan would have eight kilns.

He, however, reiterated the urgent need of gas to meet the company’s target. “This will require gas allocation to support a third and fourth kiln within three to five years and to support fuel needs for four kilns in 8 to 15 years.”

Carmeuse lime, according to Abdalla, is in very good demand in India and other countries and called for seizing the opportunity of organic market growth and be ahead of competition from UAE, Malaysia, Vietnam, etc.

Commenting on some of the broad industry trends and developments taking place in his market, Abdalla termed India as the main target market at the current stage as the steel industry is the main consumer of quick lime in the Indian market.

“Lime demand in India is projected to grow from seven to 12 million tons by 2020 driven by the fast-growing steel industry. Reports suggest that India aims to achieve 300 million tons of annual steel production by 2025-30,” he said.

 The lime is ideal for a large variety of high demanding applications such as steel, paper, water and waste water, agri-food, construction, flue gas cleaning, chemical industry and others. The majority of the production is exported to India.

Wet lime systems have a number of benefits compared to limestone systems.

Carmeuse has made of process comparison high magnesium lime to limestone (Thiosorbic vs. Limestone Forced Oxidation (LSFO) • Lower Power Consumption § 1.4% versus 2.0% for LSFO for high-sulfur coal • Higher Reagent Utilization § 99.9% vs. up to 97% for LSFO • Better Gypsum Quality § 98-99% pure, bright white vs. 95%, brown or tan for lime

India needs additional high quality hydrated lime production

The present existing manufacturing capacity in India  for the manufacture of hydrated lime is not sufficient to meet the growing demand of its dependent chemical and other industries. Raw materials, process equipment’s, and the necessary know-how involved in the manufacture of hydrated lime are available indigenously but are not sufficient to produce quality Hydrated Lime using high reactive quicklime produced from modern twin shaft kilns.  It is most important to automatically control the feed rate of the water and quicklime to produce maximum high quality hydrated lime of A Grade, especially when we have to hydrate the high reactive lime coming from Twin Shaft Kilns. Further the design should take care of all the points mentioned above. The Indian designed plants are not very effective to handle the high reactive lime.

https://medium.com/limeglobalbrain/hydrated-lime-market-in-india-4bab4d0ba667

Circulating Fluid Bed Scrubber could be the best choice for many Indian Power Plants

Sumitomo SHI FW has made a detailed analysis comparing CFB scrubbers to wet limestone scrubbers without wallboard quality gypsum production. The  lower quality of limestone available, the expected 15-year life for the older plants to which the system may be applied, and the much lower capital cost of the CFB design are key aspects in the determination. Here are the factors and calculations for a 300 MWe  pulverized boiler contained in the linked paper.

This full paper will be posted to the Coal-Fired Boiler Intelligence System and further analyzed in the FGD & DeNOx Newsletter. It will be available for discussion in a pre-conference webinar taking place in late August and to attendees at DSUA in Kansas City, SOx-NOx India and registrants to the Power-Gen New Orleans emerging market tutorial. The creation of specific cost factors is very valuable as a foundation for discussions of various alternatives in India, the U.S. and other countries.

http://home.mcilvainecompany.com/images/Article_Show_me_the_Money_CFBS_vs_Wet_FGD_Aug19.pdf

Sorbacal® SPS used in CDS and DSI Systems

As an effective control strategy for all acid gas pollutants, Sorbacal® SPS can be used in the following applications: • DSI as the main SO2 control technology, even when moderate-to-high removals are needed • DSI as a boost to an existing flue gas treatment (FGT) system • Circulating dry scrubber (CDS) technology with demonstrated improved performance in specific conditions • Dry injection over a wide range of temperatures: from 120 to 2,000°F (50 to 1,100°C) • Both baghouse filter and ESP particulate control devices, with high effectiveness • Existing DSI systems without added expense • Existing sodium systems without the need for on-site milling

https://www.lhoist.com/sites/lhoist/files/brochure_sorbacalr_sps_-_en_8.pdf

Lhoist announced possible price increases of 11% last December

Lhoist Dec 2018 statement “As we head into 2019, we are faced with significant cost increases from the markets that supply critical inputs to our plants.  In  particular, we are facing :

Energy – Coal (up 15%), Oil (up 30%), Natural Gas (up 6%)

Steel products (up to 40% depending on product)

Employee wages and benefits

Regulatory requirements and the associated cost of compliance

The unprecedented headwinds facing the transportation industry, including regulatory pressures and a severe shortage of drivers that affects the cost of virtually everything we purchase as well as the products we ship via barge, rail, and truck.

As a result, we will adjust prices for lime, limestone, and clay products by up to 11% in most cases effective January 1, 2019 or as contracts allow so that we can continue to be a reliable supplier into the future.

While we continue to make a favorable impact with our Continuous Improvement focus, we are only able to partially offset the cost pressures we are facing.  As a result, we must increase prices in order to be able to remain a sustainable supplier to our customers in the long term”

https://www.lhoist.com/sites/lhoist/files/2019_lna_price_guidance_3.pdf

Lhoist Market Share in Asia

Lhoist Group is a global leader in lime, hydrated lime and derived products, established over 125 years ago in Belgium. The Lhoist Group is present in 25 countries with more than 90 facilities around the globe. Lhoist offers local solutions to Asia, by its regional headquarter in Kuala Lumpur, and production facilities in Malaysia. 

27% of Lhoist $ 2.4 billion revenue is environmental. Only 2% of revenue is in Asia.  53% is in Europe and 38% in North America 

https://www.slideshare.net/PnlopeFabre/lhoist-group-presentation-2018

Enhanced Hydrated Lime (EHLS) has a number of advantages

According to Lhoist, EHLSs provide the following benefits compared to standard hydrated lime:

1. Operating cost savings: EHLSs typically reduce sorbent usage by = 30% over standard hydrated lime sorbents. This results in a lower annual spend on sorbents.
2. Less impact on the ESP/BH filter: lower sorbent dosage rates will result in less dust loading to particulate capture equipment. Less dust to an ESP may directly impact particulate collection efficiency, and for a BH filter this could impact bag cleaning cycle frequency. Particle sizes play a critical role in ESP/BH operational efficiencies. Respective equipment manufacturers should be consulted on particle size guidelines.
3. Fuel and raw material flexibility: if a lower cost fuel or raw material becomes available but results in increased acid gas emissions, then an EHLS can provide additional flexibility. This is because it has the ability to achieve higher acid gas removal efficiencies than standard hydrated limes, without having to modify the existing DSI system.
4. Increased storage silo capacity: lower sorbent consumption using EHLSs results in more days of available storage in a fixed silo volume. Hence, reducing sorbent consumption by 50% equates to doubling the silo storage capacity.
5. One DSI system for acid gas and Hg control: EHLS blended with PAC is available and precludes the need for two separate systems.

These benefits are a result of the EHLS’s engineered and improved physical properties, which are designed to enhance acid gas reactivity.

https://www.worldcement.com/special-reports/06032019/optimising-dry-sorbent-injection/

United Conveyor has Dadri order for DSI 

United Conveyor Corp (UCC) is installing the dry injection systems at the 4 x 250 MW Dadri plant of NTPC.  Here are some of the  past FGD newsletter articles about UCC.  Rest of article deleted

August 2019 FGD Newsletter

Case for Dry Scrubbers for Indian Power Plant

Bob Giglio of SHI FW makes a case for CFB dry scrubbers for the 60,000 MW of coal-fired power plants in India, which are less than 500 MW and are older. SHI-FW has provided CFB dry scrubbers with a capacity of 300 MW both to China and the U.S. Advantages include the low water requirements.

https://www.shi-fw.com/wp-content/uploads/2019/03/CFB-scrubbers-make-a-Case-for-India-SHI-FW-TEI-Times-March-2019.pdf

Bids close for DSI for 4 x 210 MW of DSI systems at  Punjab State Power Roopnagar in September 2019 

The bid scope includes Design, Engineering, Manufacture, Shop Fabrication, Preassembly, Shop Testing/type Testing at Manufacturer’s Works, Packing, Transportation, Unloading, Handling and Conservation of Equipment at Site, Complete Services of Construction, including Erection, Supervision, Pre-commissioning, Commissioning and Performance Testing of Equipments Under Bidder’s Scope of Work of Dry Sorbent Injection (DSI) System using Sodium Bicarbonate as Reagent and its Associated Auxiliaries including all Associated Electrical, Control & Instrumentation, Civil, Structural and Architecture Works as detailed in Tender Specifications for Flue Gas Desulfurization (FGD) System Package At 4 x 210 MW Units (stage- Ii & Iii) of Ggsstp, Roopnagar

https://bidassist.com/punjab-tenders/punjab-state-power-corporation-limited/detail-74185446-f6bd-4800-839b-100a744c725b

Tata Power March 2019 bid request for 1 x 67.5 MW DSI FGD System

Design, engineering, manufacture, shop fabrication, assembly, shop testing, type testing at manufacturer's works, inspection, packing, supply, loading, unloading, transportation, proper preservation at site, storage & handling at site, erection/installation, construction, site testing and commissioning and performance testing of DSI-based Flue Gas Desulfurization (FGD) System for 100% of the flue gas flow rate for the 1 x 67.5 Unit No 1 of Jojobera Thermal power plant located at near Jamshedpur, East Singhbum District, Jharkhand State, India.

In order to limit the SO₂ emissions in the thermal power units, it is proposed to install Flue Gas Desulfurization (FGD) system at Jojobera for Unit 1 for treating 100% of flue gas coming out of this unit. The outlet SO₂ emissions shall be limited to 600 mg/Nm³ as per latest standards stipulated by MoEF&CC under Environment (Protection) Amendment Rules 2015 for thermal power plants. Bidder to offer a Sodium Bicarbonate-based dry sorbent injection system (DSI).

https://www.tatapower.com/TenderDocument/Tender_EOI_JOJO_FGD_Rev_R1_0bb5c34d9c.pdf 

India will be a Major Purchaser of Dry Scrubbers

India is predicted to purchase dry scrubbers to clean 180 million CFM over the next five years. This is the latest forecast in N027 FGD Market and Strategies. The bulk of the investment will be for coal-fired power plants. There will be some installations in waste-to-energy, cement, steel and other industrial applications.

India will join China and the U.S. as the leading three dry scrubber purchasers. Dry scrubbing includes semi dry scrubbers, circulating dry scrubbers and direct sorbent injection. United Conveyor Corp. has an order for 4 x 250-MW direct sorbent injection systems at the Dadri plant of  NTPC.

The market surge will be due to new rules that allow older smaller power plants to discharge higher levels of SO₂ than others. It is anticipated that 50,000 MW of Indian power plans will be fitted with dry scrubbers over the next three years.

Dry scrubbers are more economical than wet scrubbers when the emission rates are higher and the sulfur in the fuel is lower. Dry scrubbers use higher cost lime or sodium compounds whereas wet scrubbers utilize ground limestone. However, the capital cost of wet scrubbers is more than twice that of CDS and semi dry scrubbers. Direct sorbent injection is very low in capital cost but very high in reagent cost.

Direct sorbent injection can be used to supplement other systems. DSI can be used in conjunction with semi dry systems to maintain efficiency at higher sulfur levels. DSI can also be used ahead of the air heater to react with SO₃ and allow the air heater to be operated to extract more heat without corrosion.

For more information on this report click on N027 FGD Market and Strategies.

Bob McIlvaine can answer your questions at office 847-784-0013 cell 847-226-2391 or email him at rmcilvaine@mcilvainecompany.com.

NTPC March 2018 Tender for DSI for Dadri

The scope of Dry Sorbent Injection (DSI) System Package for NCTPP, Dadri, Stage-I (4x210 MW) for four units of 210 MW shall cover design, engineering, manufacture, shop fabrication, preassembly, shop testing/type testing at manufacturer’s works, packing, transportation, unloading handling and conservation of equipment at site, complete services of construction including erection, supervision, pre-commissioning, commissioning and performance testing of equipment under bidder’s scope of work of Dry Sorbent Injection (DSI) System and its associated auxiliaries including all associated Electrical, Control & Instrumentation, Civil, Structural and Architecture works. Dry Sorbent Injection System shall use Sodium Bicarbonate as reagent.

http://www.ntpctender.com/uploads/job_23882.html

April 2019 FGD Newsletter

Cement Kiln Dust for SO₂ removal

From 10 to 12 million tons of cement kiln dust accumulates annually at domestic cement plants. This finely divided dust is emitted from cement kilns to prevent the buildup of excessive salts in the cement product. If separated into its valuable components, waste cement kiln dust could become a significant source of potassium and a raw material for making cement. This article does not include the use of this dust for SO₂ removal from coal-fired boilers, but potassium is very reactive and would be a good reagent. One question is its use in direct sorbent injection or DSI.

There is widespread use of drinking water plant lime sludge as an FGD reagent. So other alternatives should also be explored. The use would be primarily where a small boiler is near a source or where multiple sources can be included so that enough reagent for a large application is available.

https://www.911metallurgist.com/portland-cement-kiln-dust-reprocessing/

March 2019 FGD Newsletter

Dry Scrubbing Discussions at the Cement Conference in St. Louis

The 61st Annual IEEE-IAS/PCA Cement Industry Technical Conference will be held in the St, Louis Convention Center, April 28-May 2, 2019. This is the largest conference in the cement industry and will include presentations of the latest technology covering a variety of topics important to the industry. There will also be Tutorials, Professional Training sessions, a state-of-the-industry-report and much more. There will be 150 exhibitors

McIlvaine has interviewed exhibitors in the past and posted this coverage plus other cement industry analyses and articles in a free site. These articles and interviews can be viewed at

http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/UnivDB/appl3.asp?ref1=806&ref2=0&ref3=0&ref4=0&ref5=0&ref6=0

There is lots of dry scrubbing activity in the cement industry. For applications where Hg control is either intermittent or low injection rates are needed, a blended hydrated lime (HL) and powdered activated carbon (PAC) sorbent allows for a single feed system to be used. For example, Lhoist North America’s blended HL-PAC product enables concurrent acid gas and Hg control, using a single sorbent injection system (instead of installing and maintaining two nearly identical systems), to inject the sorbents simultaneously as a pre-blended, homogeneous product. Lhoist North America produces customized enhanced hydrated lime blends (branded Sorbacal^® SP and SPS) with brominated PAC. These are produced either in bag or bulk, in 5 percent PAC (weight by weight) blend increments up to 30 percent.

Over the past twenty years, calcium-based sorbents have evolved, driven by the need to improve acid gas capture efficiencies. Realization of the importance of physical properties, such as particle size distribution, pore volume, and surface area, led to the development of enhanced hydrated lime sorbents (EHLSs) by engineering these properties to create more reactive hydrated lime sorbents. Sorbent physical properties directly impact material handling properties and acid gas removal performance, ultimately dictating annual operating expenditures.

Lhoist’s EHLS products are branded Sorbacal^®. The second generation product is Sorbacal^® SP and third generation is Sorbacal^® SPS. Sorbacal^® SPS is a chemically-activated formulation of Sorbacal^® SP, specifically designed to provide best-in-class acid gas capture performance. Surface area and pore volume are the key performance drivers for acid gas capture.

Sorbent particle size dictates material handling properties and removal efficiencies in electrostatic precipitators (ESPs) and BH filters. Empirical data from the field, as well as laboratory flow testing, has demonstrated that larger median particle diameters (i.e., D₅₀) are recommended for optimum handling. Specifically, a 32% improvement in flow properties was demonstrated between particles with D₅₀ = 2 µm and particles with D₅₀ = 11 µm.^7,8This is likely due to small particle-sized hydrated lime sorbents being more cohesive than larger particles; small particles can facilitate pluggage in the conveying system.

Additionally, fine particle-sized hydrated lime can become irreversibly lodged in BH filter bags and bin vents (this is called ‘blinding’) and can result in premature wear and poor bag cleaning efficiencies. Users should refer to their manufacturer’s design information regarding particle size and carefully weigh the impacts of introducing particles outside of the design range. Likewise, ESP particulate capture efficiencies decrease below approximately 6 µm and can result in increased particulate emissions.

November 2018 FGD Newsletter

Dry Hydrate Users Group is Another Resource

Hydrated lime is a proven sorbent for the removal of acid gases from flue gas. The Dry Hydrate Users Group (DHUG) is an organization focused on the exchange of current research and best practices for using pneumatic systems to inject hydrated lime into flue gas. Discussion areas include storage and material handling issues, injection practices and optimization of system performance. Members include plant operators, equipment vendors, engineering firms and lime producers. Originally formed to address power industry applications, discussions now also include other industrial boiler and kiln applications. 

The annual meeting in Nashville, TN, February 20-21, 2019 will provide discussions related to the latest developments in hydrated lime injection techniques. The meeting also provides an opportunity to develop contacts with others involved in this application.  The group is sponsored by four major lime producers – Carmeuse NA, Graymont Inc., Lhoist North America and Mississippi Lime

Articles in the Dry Scrubber Decisions Intelligence System

Here are some of the links in the Dry Scrubber Decisions Intelligence System. These are all recent postings but reflect a literature review from the past to capture older but relevant data.

Mississippi Lime Presentation 2017: Targeted DSI Improvements

Curt Biehn of Mississippi Lime made this presentation in 2017 which shows the following list of targeted DSI improvement: (1) Reduce scale and plugs, (2) Optimize distribution for O&M benefits, (3) Reduce minimum operating temperature requirement, (4) use prior to wet scrubbing for selenium and HCl removal (SO₃ was not listed but would be another in this category)

Revision Date:  2/25/2019

Tags: 221112 - Fossil Fuel ????, Mississippi Lime, Dry Sorbent Injection

Costs for DSI

This study by Sargent & Lundy provides methods to determine costs of DSI for acid gas removal. The sorbent requirement is a function of particle size, particulate control device, and other factors. 2016 cost factors are utilized. Based on commercial testing, removal efficiencies with DSI are limited by the particulate capture device employed. Trona, when captured in an ESP, typically removes 40 to 50 percent of SO₂ without an increase in particulate emissions, whereas hydrated lime may remove an even lower percentage of SO₂. A baghouse used with sodium-based sorbents generally achieves a higher SO₂ removal efficiency (70 to 90%) than that of an ESP. DSI technology, however, should not be applied to fuels with sulfur content greater than 2 lb SO₂/MMBtu.

Revision Date:  2/25/2019

Lhoist presentations in the intelligence system

MACT Update Webinar - Hot Topic Hour - May 7, 2015

There are unique site specific factors which are more important in MACT than in MATS. The reason is that in cement, brick and other industrial processes the material being processed may create more air toxics than the fuel. The special focus for this Hot Topic Hour was on dry sorbent injection. The use of hydrated lime was also discussed.

Flue Gas Treatment Specialist, by Marty Dillion, Lhoist - HTH 5-7-15

Sorbacal SPS is a lime hydrate which combines porosity and chemical treatment to provide much higher SO2 and HCl capture than alternatives. A number of trial and actual installations support the claim.

Revision Date:  5/7/2015

Tags:  221112 - Fossil Fuel ????, 327310 - Cement Manufacturing ????, Lhoist North America, Lime, MACT

Dry Sorbent Injection Options and Issues Webinar Recording - Hot Topic Hour April 9, 2015

DSI is an effective Route for SO3, SO2, and HCl reduction.

Revision Date:  4/10/2015

Tags:  221112 - Fossil Fuel ????, Mississippi Lime, Lhoist North America, AECOM, ClearChem Development LLC, Mobotec (USA), Sodium, Limestone, Sodium Bisulfate, Lime, HCl, SO2, SO3, CFD

Dry Sorbent Injection Options and Issues - Sorbacal HCl Removal by Marty Dillon, Lhoist North America - Hot Topic Hour April 9, 2015

Martin Dillon of Lhoist explained how a high surface area hydrated lime, Sorbacal® SP, is able to achieve HCl removal close to 80 percent.

Revision Date:  4/10/2015

Tags:  221112 - Fossil Fuel ????, Lhoist North America, Lime, HCl, SO2, SO3

MATS Compliance Choices Webinar - Hot Topic Hour January 29, 2015

Speakers at the Hot Topic Hour provided recent data which shows that improved activated carbon and absorbents will allow plants to meet MATS emission limits with lower amounts of consumables.

Revision Date:  1/29/2015

Tags:  221112 - Fossil Fuel ????, KC Cottrell, McIlvaine, Lhoist, Calgon Carbon, Precipitator, Fabric Filter, Dry Sorbent Injection, Activated Carbon, MATS, Mercury Removal, HCl, SO2, Particulate

DSI for MATS and CSAPR by Jim Dickerman, Lhoist / Chemical Lime - Hot Topic Hour January 29, 2015

Jim Dickerman provided recent data to show what a unique hydrate achieved.

Revision Date:  1/29/2015

Tags:  221112 - Fossil Fuel ????, Lhoist, Dry Sorbent Injection, MATS, SO2, HCl

Lhoist Has Lots of Ceramic Filter Hot Gas Experience

Lhoist was a presenter in the McIlvaine hot topic hour May 1, 2014 on hot gas filtration. The highly porous lime sorbent is achieving more than 95% SO2/HCl removal efficiency when used at 850F temperature preceding the ceramic filter. Product: lime, dry sorbent injection

Revision Date:  5/5/2014

Tags:  562213 - Solid Waste Combustors and Incinerators , Lhoist, Lime, Dry Sorbent Injection, Ceramic Filter, Fabric Filter

Ceramic Filter with Embedded Catalyst and DSI Achieves High SOx, NOx and ROx Removal

Richard Lydon of Clear Edge Filtration Group presented the case for using a ceramic media with an embedded catalyst. The result is high dust removal and high NOx reduction. DSI ahead of the filter allows acid gas removal as well. There are many thousands of these filter elements already in operation on various industrial operations. Recent installations in the U.S. show high efficiencies.

Revision Date:  4/24/2014

Tags:  Neuman, Lhoist, Clear Edge Filtration, Ceramic Filter, Fabric Filter

Advances in Dry Sorbent Injection (DSI) Reagents by Mike Schantz, Lhoist - Hot Topic Hour July 11, 2013.

New hydrated lime with more surface area and some chemical enhancement is performing better.

Revision Date:  7/11/2013

Tags:  221112 - Fossil Fuel ????, Lhoist, Hydrated Lime, MATS

New Developments in Air Pollution Control Technology Webinar - Hot Topic Hour July 11, 2013 

Revision Date:  7/11/2013

Tags:  221112 - Fossil Fuel ????, NeuCo, Lhoist, Novinda, ADA Carbon Solutions, Dry Sorbent Injection, Hydrated Lime, Optimization Software, Activated Carbon, MATS, PM2.5, Condensibles, NOx

New Developments in Power Plant Air Pollution Control Part 1 - Webinar July 11, 2013 - Presenter Bios

Revision Date:  7/11/2013

Tags:  221112 - Fossil Fuel ????, ADA Carbon Solutions, Novinda, Lhoist, NeuCo

Overview of SO3 Emission Control with Hydrated Lime by Jim Dickerman, Lhoist. Hot Topic Hour March 8, 2012

Jim presented an overview of SO3 emission control with hydrated lime.

Revision Date:  3/8/2012

Tags:  221112 - Fossil Fuel ????, Lhoist, Direct Injection System, Lime, Mercury, SO2, SO3, HCl

SO3 Measurement and Control - Webinar - Hot Topic Hour March 8, 2012

The effect of SO3 in the flue gas stream, emissions from the stack, particulate emissions and removal of mercury from the flue gas with ACI.

Revision Date:  3/8/2012

Tags:  221112 - Fossil Fuel ????, URS Corp., Industrial Monitor and Control Corp, Solvay Chemicals, Thermo Fisher Scientific, Lhoist, SO3 Monitoring, Sodium Bisulfate, Direct Injection System, Sodium Bicarbonate, Trona, SO3, HCl, Mercury, SO2, Monitoring

Sorbacal Dry Sorbent Injection - a Low Capital Solution for HCl Control by Mike Schantz, Lhoist / Chemical Lime Co. - Hot Topic Hour November 18, 2010

Mike Schantz, Director of New Business Development at Lhoist/Chemical Lime Company, explained that all hydrated lime is not the same. Sorbacal SP performs much better than typical hydrated lime on HCl. Sources using Sorbacal injection should be able to meet the 3 ppm HCl anticipated limit providing temperature, moisture, competing acid gases (SO3 and HF) and CO2 are within the normal range.

Revision Date:  11/18/2010

Tags:  221112 - Fossil Fuel ????, Lhoist / Chemical Lime, Hydrated Lime, MACT, Industrial Boiler

Industrial MACT Webinar - Hot Topic Hour November 18, 2010 - Part 1

Sodium Bicarbonate, Lime, CDS and Regulations were among the Topics covered on the First Day of the Industrial MACT Webinar. In 60 days or so we will know the specific changes for the final Industrial MACT. Correction -  we will know what is final until it is changed again. Unfortunately it will be three more years to find out if litigants are successful in causing changes. However, it will take three years to install the equipment and run it long enough to make sure of compliance. So it would seem there are two choices. Litigate and gamble you won’t have to shut down your plant or go ahead with the assumption that the rule will stand. Password: hth107

Revision Date:  11/18/2010

Tags:  Babcock & Wilcox Power Generation Group, Trinity Consultants, Lhoist / Chemical Lime, Troutman Sanders, Solvay Chemicals, Graymont, MACT, Industrial Boiler

 Lhoist Articles in Older FGD Newsletters

Dry Scrubbing Discussions at the Cement Conference in St. Louis- March 2019

The 61st Annual IEEE-IAS/PCA Cement Industry Technical Conference will be held in the St, Louis Convention Center, April 28-May 2, 2019. This is the largest conference in the cement industry and will include presentations of the latest technology covering a variety of topics important to the industry. There will also be Tutorials, Professional Training sessions, a state-of-the-industry-report and much more. There will be 150 exhibitors

McIlvaine has interviewed exhibitors in the past and posted this coverage plus other cement industry analyses and articles in a free site. These articles and interviews can be viewed at

http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/UnivDB/appl3.asp?ref1=806&ref2=0&ref3=0&ref4=0&ref5=0&ref6=0

There is lots of dry scrubbing activity in the cement industry. For applications where Hg control is either intermittent or low injection rates are needed, a blended hydrated lime (HL) and powdered activated carbon (PAC) sorbent allows for a single feed system to be used. For example, Lhoist North America’s blended HL-PAC product enables concurrent acid gas and Hg control, using a single sorbent injection system (instead of installing and maintaining two nearly identical systems), to inject the sorbents simultaneously as a pre-blended, homogeneous product. Lhoist North America produces customized enhanced hydrated lime blends (branded Sorbacal^® SP and SPS) with brominated PAC. These are produced either in bag or bulk, in 5 percent PAC (weight by weight) blend increments up to 30 percent.

Over the past twenty years, calcium-based sorbents have evolved, driven by the need to improve acid gas capture efficiencies. Realization of the importance of physical properties, such as particle size distribution, pore volume, and surface area, led to the development of enhanced hydrated lime sorbents (EHLSs) by engineering these properties to create more reactive hydrated lime sorbents. Sorbent physical properties directly impact material handling properties and acid gas removal performance, ultimately dictating annual operating expenditures.

Lhoist’s EHLS products are branded Sorbacal^®. The second generation product is Sorbacal^® SP and third generation is Sorbacal^® SPS. Sorbacal^® SPS is a chemically-activated formulation of Sorbacal^® SP, specifically designed to provide best-in-class acid gas capture performance. Surface area and pore volume are the key performance drivers for acid gas capture.

Sorbent particle size dictates material handling properties and removal efficiencies in electrostatic precipitators (ESPs) and BH filters. Empirical data from the field, as well as laboratory flow testing, has demonstrated that larger median particle diameters (i.e., D₅₀) are recommended for optimum handling. Specifically, a 32% improvement in flow properties was demonstrated between particles with D₅₀ = 2 µm and particles with D₅₀ = 11 µm.^7,8This is likely due to small particle-sized hydrated lime sorbents being more cohesive than larger particles; small particles can facilitate pluggage in the conveying system.

Additionally, fine particle-sized hydrated lime can become irreversibly lodged in BH filter bags and bin vents (this is called ‘blinding’) and can result in premature wear and poor bag cleaning efficiencies. Users should refer to their manufacturer’s design information regarding particle size and carefully weigh the impacts of introducing particles outside of the design range. Likewise, ESP particulate capture efficiencies decrease below approximately 6 µm and can result in increased particulate emissions.

Lhoist Unveils Hydratex™ Proprietary Technology - Dec 2016

The Lhoist Group continues to invest in the international development of Sorbacal^® for flue gas treatment applications. Over the years, Sorbacal^® SP has become one of the leading sorbents for the dry sorbent injection market worldwide. Sorbacal^® SP is currently used by industrial and utility customers across the five continents. Since 2012, Lhoist has commissioned three new Sorbacal^® SP plants in the USA and one in Asia. This expansion has enabled the Lhoist Group to build a unique and strong network of more than ten Lhoist Sorbacal^® SP production plants and to enter into licensing agreements with third parties. 

This unique worldwide exposure has built up a pool of dedicated experts with very specific know-how on flue gas treatment applications and sorbent manufacturing based on the diversity of operational and compliance-driven challenges they are facing every day. Lhoist has optimized plant operations for quality and throughput based on the initial patented Sorbacal^® SP technology. These innovative solutions and know-how have not only been developed for new plants but they have also recently been implemented in all existing plants producing Sorbacal^® SP products.

Lhoist has filed a number of international patents applications. They cover innovative Sorbacal^® SP technology, implementing a specific selection of new conditions. Sorbacal^® SP customers will benefit from the resulting improved consistency of product quality. These innovations establish the cornerstone of the newly branded Hydratex™ technology.

SO₃ removal with Sorbacal will solve the bag blinding problem at PacifiCorp August  2016

Gerald Hunt of Lhoist writes “Mitigating concern over blinding the bags should just be a matter of achieving sufficient SO₃ removal which can be driven by proper injection location (further upstream the better, not to mention taking advantage of the co-benefits of injecting upstream of air heater) and a well-designed injection grid system.  We have several DSI/SO₃ installations demonstrating the effectiveness of Sorbacal SP to provide very effective SO₃ capture which we can back up with references.  We are happy to work with PacifiCorp on providing technical expertise regarding injection location(s) and injection grid design if they desire.” 

McIlvaine is trying to arrange a recorded video interview with Lhoist and post it later this week. If you are interested in asking questions or making comments, we can include you as a participant.

MACT Update Provided in Hot Topic Discussion May 7, 2015

A MACT route map and summary was reviewed as a way to launch the MACT discussion on May 7, 2015. There are unique site specific factors which are even more important in MACT than in MATS. The reason is that in cement, brick and other industrial processes the material being processed may create more air toxics than the fuel.

The MACT route map cataloged the issues and options:

Issues 

• External
  • Regulatory
  • Economic

• Plant Specific

Options for

• Mercury
• Particulate
• Acid gases

The special focus is technology has risen to the top of the list in terms of relative importance. One reason is that it does not require much capital. Another is that the process is quickly implemented. Many industrial facilities have waited to make a MACT choice and therefore are now limited to those solutions which can meet the deadlines. The complete MACT route map and summary is found in “Power Plant Air Quality Decisions.”

There were two speakers on May 7. Both addressed the use of hydrated lime.

Pat Mongoven of Mississippi Lime compared several types of hydrated lime.

• DSI with hydrated lime can allow SO₂ and HCl reduction for both industrial boilers and cement manufacturers.
• Depending on the application and the facilities goals, a High Reactivity Hydrate may allow better removal or lower costs.
• In cement scrubber towers, DSI gave comparable removal rates to feeding a liquid slurry of hydrated lime directly to the scrubber tower.
  
  
  

MACT Compliance Options, by Pat Mongoven, Mississippi Lime, HTH 5-7-15

DSI with hydrated lime can allow SO₂ and HCl reduction for both industrial boilers and cement manufacturers. Depending on the application and the facilities goals, a High Reactivity Hydrate may allow better removal or lower costs. In cement scrubber towers, DSI gave comparable removal rates to feeding a liquid slurry of hydrated lime directly to the scrubber tower.

Revision Date:  5/7/2015  Tags:  221112 - Fossil Fuel ????, 327310 - Cement Manufacturing ????, Mississippi Lime, Lime, MACT

Marty Dillon of Lhoist enumerated advantages of a unique lime product.

Sorbacal SPS is a lime hydrate which combines porosity and chemical treatment to provide much higher SO₂ and HCl capture than alternatives. A number of trial and actual installations support the claim.

There was considerable discussion relative to balance of plant impacts. Marty cites information showing the at Sorbacal SPS results in lower pressure drop in baghouses and lower particulate emissions in precipitators than finely ground lime such as is provided by others. Curt Biehn of Mississippi Lime wanted more evidence. He cited papers showing that lime injection may enhance precipitator performance. He also pointed out that the lime reacts with acid gases to form larger particles.

Marty showed evidence that the Sorbacal greatly reduced the leachate potential of selenium and other air toxics, so there can be a positive benefit relative to landfill alternatives and cost.

Flue Gas Treatment Specialist, by Marty Dillon, Lhoist - HTH 5-7-15

Sorbacal SPS is a lime hydrate which combines porosity and chemical treatment to provide much higher SO₂ and HCl capture than alternatives. A number of trial and actual installations support the claim.

Revision Date:  5/7/2015  Tags:  221112 - Fossil Fuel ????, 327310 - Cement Manufacturing ????, Lhoist North America, Lime, MACT

The entire May 7 recording can be heard at MACT Update – 71 minutes

MACT Update Webinar - Hot Topic Hour - May 7, 2015

There are unique site specific factors which are more important in MACT than in MATS. The reason is that in cement, brick and other industrial processes the material being processed may create more air toxics than the fuel. The special focus for this Hot Topic Hour was on dry sorbent injection. The use of hydrated lime was also discussed.

Revision Date:  5/7/2015  Tags:  221112 - Fossil Fuel ????, 327310 - Cement Manufacturing ????, Lhoist North America, Mississippi Lime, Lime, MACT

SO₃ removal with Sorbacal will solve the bag blinding problem at PacifiCorp

Gerald Hunt of Lhoist writes “Mitigating concern over blinding the bags should just be a matter of achieving sufficient SO₃ removal which can be driven by proper injection location (further upstream the better, not to mention taking advantage of the co-benefits of injecting upstream of air heater) and a well-designed injection grid system.  We have several DSI/SO₃ installations demonstrating the effectiveness of Sorbacal SP to provide very effective SO₃ capture which we can back up with references. 

Lhoist North America Sorbacal Hydration Facility at Ste. Genevieve Plant - April 2013

Lhoist North America’s (LNA) new hydration facility at its Ste. Genevieve, MO plant is on schedule, and the facility was expected to begin production in March 2013. LNA’s Ste. Genevieve plant was selected as the optimal site to receive the first U.S. Sorbacal^® facility due to its proximity to the utility market.

This facility is being designed to produce Sorbacal^® SP, Lhoist’s proprietary emission control reagent that is the leading calcium hydroxide reagent for dry sorbent injection (DSI) in Europe and Japan. Sorbacal^® SP is a unique hydrated lime product with twice the surface area and three times the porosity of standard hydrated lime products. In addition, Sorbacal^® is ready to use in existing DSI systems without any special handling provisions or further processing.

SO₃ Measurement and Control” – Hot Topic Hour on March 8, 2012  (in the Monitoring Newsletter)

SO₃ in the flue gas stream from a fossil-fueled boiler has long been a concern for plant operators because of the potential for fouling and corrosion in the air heater and corrosion in ducts and equipment downstream caused by the sulfuric acid formed from the SO₃. Excessive SO₃ in emissions from the stack can also cause opacity (blue plume) and acid mist deposition problems. In addition, the presence of SO₃ adversely affects the removal of mercury from the flue gas with ACI. The effect of SO₃ aerosols on particulate emissions has also been a concern - more so in some plants than others.

But SO₃ in flue gas will soon be a much bigger concern for all. Because SO₃ contributes to the formation of condensable or fine particle emissions, the recent changes in the National Ambient Air Quality Standards (NAAQS) for particulates and ozone may force even greater control of SO₃ under local standards or under regulations dealing with particulates. The utility MATS with lower limits on mercury and SO₂ will further complicate the issue.

Control of SO₃ is a complex problem that can be highly dependent on the control technology utilized for NO_x, SO₂, mercury and particulates. In addition, measurement of SO₃ can be difficult which further complicates the control problem. In the March 8 Hot Topic Hour, five very knowledgeable speakers presented the current “state of the art” for SO₃ measurement and control.

James (Jim) C. Dickerman, Director of Flue Gas Treatment Applications at Lhoist North America (formerly Chemical Lime Company), presented an overview of SO₃emission control with hydrated lime. He discussed the development history of the technology as well as the key design parameters that need to be considered for successful operations. Initial problems (primarily plugging of lances) were resolved and the technology is fully commercialized now with installations at over 30 utility boilers. Future development is focused on the control of other acid gases such as HCl and SO_2.  He said they have demonstrated that hydrated lime can be injected downstream of the ESP (upstream of a scrubber) and not increase particulate emissions. Also, injecting hydrated lime at two locations is more effective than one location. Injection upstream of the air heater can reduce ABS formation with no downstream impacts.

James (Jim) B. Jarvis, Project Manager at URS Corp., stood in for Sterling Gray, Manager of SBS Injection Technology. He described the application of a liquid sodium based reagent (SBS) to reduce SO₃ and mercury emissions at power plants. He stated that since 2005 they have learned that injection of SBS upstream of the air preheater provides maximum benefits. Since 2005, they have had 24 boilers operating with upstream injection, some of which had downstream injectors relocated. They also have four installations ahead of the SCR that have been operating for three years. He stated that SBS injection can significantly reduce SO₃levels prior to the air heater and reduce stack emissions of SO₃ to less than 1ppm and 0.003 lbs/MMBtu SAM. He presented a number of graphs showing that mercury capture rates of 50 to 90 percent can be achieved with high-efficiency SO₃ control and with little to no carbon injection.

Curtis (Curt) Laush, Ph.D., Senior Scientist at Industrial Monitor and Control Corp. (IMACC), described the capabilities, operation and field-testing of a CEM-type analyzer based on a quantum cascade laser (QCL) absorption spectrometer for real time continuous monitoring of SO₃ and SO₂ across flue gas ducts. The in-situ design eliminates sample extraction issues allowing a truly representative measurement of SO₂, SO₃ and water vapor with fast response (less than 1 minute) and high resolution (500 ppb in a 5 meter duct).  In May IMACC will begin field-testing a second-generation instrument and expects to have it commercialized by the end of the year. Potential applications include tracking SO₂ oxidation in real time across catalysts and downstream, tracking potential SO₃ dew points when optimizing air heater operation and optimizing sorbent usage for SO₃ mitigation.

Dr. Yougen Kong, P.E., Technical Development Manager at Solvay Chemicals, Inc., discussed the interactions between SO₃, HCl, HBr, PM and Trona in flue gas. Trona injected before and after the air heater can be very effective at controlling acid gases as well as enhancing mercury removal. However, he emphasized that flue gas treatment at a coal-fired power plant has become a chemical processing plant and a solution for one plant may not fit another plant. Treating one component in the gas can affect the other components. Therefore to be successful, you must understand the chemistry of the gas, apply a systems approach and all suppliers of APC equipment and the design engineers must work closely together.

Jeff Socha, R & D Project Leader for the SO₃ CEMS at Thermo Fisher Scientific Air Quality Instruments described capabilities of and initial field test results for a dilution extractive SO₃ monitor being developed for real time monitoring of SO₃ in flue gas. The instrument uses a cascade laser and has an integrated SO₃ gas generator for daily calibrations and dynamic spiking to detect bias. The detection limit is 0.4 ppm. Two systems are currently undergoing beta evaluations at two power plants – one downstream of an FGD and one downstream of an ESP. An instrument with a 100-foot sample line has a response time of 19 minutes.

The entire March 8 recording can be heard at: SO3 Measurement & Control – 112 minutes – Password: hth881

The presentations are as follows:

?         SO3 Measurement and Control - Webinar - Hot Topic Hour March 8, 2012

?         Overview of SO3 Emission Control with Hydrated Lime by Jim Dickerman, Lhoist. Hot Topic Hour March 8, 2012

?         Effective SO3 and Mercury Control Using SBS Injection by Jim Jarvis, URS Corporation. Hot Topic Hour March 8, 2012.

?         Real Time Continuous Monitoring of SO3 and SO2 Across Flue Gas Ducts by Curtis Laush, Industrial Monitor and Control Corp (IMACC). Hot Topic Hour March 8, 2012

?         Real-Time Monitoring of SO3 in Flue Gas by Jeff Socha, ThermoFisher Scientific. Hot Topic Hour March 8, 2012

?         Interactions Between SO3, HCl, HBr, PM and Trona Injection in DSI by Yougen Kong, Solvay - Hot Topic Hour March 8, 2012

Carmeuse Newsletter Articles in the Intelligence System

Carmeuse is Positioned to Offer Lime and Provide Remote Operating Advice to Solid Fuel Combustion Operators Around the World - September 2017

The huge difference in lime consumption depending on the lime quality and operational skills makes it possible for an international lime company such as Carmeuse to compete for FGD business on a worldwide basis.  McIlvaine started reporting about the Dravo lime technologies in the mid-1970s.  the pilot plant operated by Dravo lime in Ohio was designed to demonstrate the ability of wet lime to compete favorably with limestone. This was due to compact size of a lime scrubber vs. a limestone scrubber and the lower use of reagent.  What made this option particularly attractive was the rod deck or venturi rod scrubber originally introduced in the 1960s by Environeering of which Bob McIlvaine was president. Dravo Lime was able to demonstrate favorable economics at the time using the rod deck scrubber design which could remove both particulate and SO_2.

Dravo Lime and then its new owner Carmeuse have pioneered in other FGD technologies. One uses magnesium enhanced lime.  It becomes a double alkali system with a clear mag oxide scrubbing loop and then production of magnesium oxide and calcium sulfate. The full potential of this design has not yet been reached.

The point is that here is a lime company with enough understanding of the processes to innovate several of its own competitive processes. With this process knowledge, it can contribute subject matter expertise to help FGD operators around the world achieve lowest total cost of ownership of their lime consumption.

Lime can be shipped by barge much more inexpensively than by land.  Carmeuse is taking advantage of this low cost of transport at its Oman plant. Carmeuse Majan, located in Oman’s Salalah Free Zone, is a joint venture operated by Carmeuse Group. It has direct access to some of the best limestone deposits in the Middle East and Asia. The proximity of the Salalah seaport allows it to compete for industrial customers in India, Oman, neighboring GCC countries and parts of Africa. The lime calcination plant has a daily production capacity of 800 tons.

Where Carmeuse does not have competitive facilities, it can form joint ventures. Carmeuse has signed an agreement with Handyman’s Lime and Astro Quarries shareholders for management of a. 200 kt/year modern Lime plant located in Ndola/Zambia. The plant and the quarry currently employ 111 people.

Carmeuse brings its geological and technical expertise as well as its market knowledge to manage Handyman’s Lime assets in the same sustainable way as if it was a Carmeuse owned plant. The actual takeover of the management was on July 1, 2017.

Carmeuse Overseas has been commercially active on the copper belt market since 2010 and now rises as an industrial player to better serve its clients, primarily the copper and cobalt mines of Zambia and Democratic Republic of Congo. Late last year Carmeuse, together with its partner GP Group, acquired a 45 percent stake in Golden Lime Public Company Limited Thailand’s leading lime company. The transaction triggered a tender offer to acquire the remaining publicly traded shares. The founding family will retain a minority interest in the company.

Thailand is one of the largest consumers of lime and lime derived products in South East Asia thanks to a large and diversified industrial and agricultural base. The country is among the largest producers of sugar in the world and continues to expand its capacity. It also targets major expansion of its core infrastructure to improve its appeal and competitiveness in the region.