Advanced Air Quality Control

Solutions for WTE Combustors

Joseph Riley
JoAnn Pacinelli
BoldEco Environment, Inc.
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions
Address So
X
, Hcl, No
X
, Hg, Pm
10
And Pm
2.5
Individually Or Comprehensively
Fully Retrot and Add-On Technologies
Small Footprint - Require Little Space for Installation
High Performance - Require Shorter Residence Times
Cut Into Existing Ductwork; Short Tie-In Time
Leverage Inherent Process Chemistries to Achieve Minimal Operating Cost
Low Capital and Operating Costs
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions
Scrubbing (Multi-Phase Reaction) Optimization Solutions
- Acid Gas Scrubbing and Neutralization

Sorbent Efciency and Utilization

- Elemental Hg Conversion and Adsorption

Oxidation and Particulate Formation

Particulate Control Solutions
- Pm Capture Optimization For Esps

Resistivity and Humidity Control

- Condensables And Ionic Hg Capture

Nucleation by Gas Cooling

Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions
Acid Gas Scrubbing Optimization
- DSI Enhancement

Spray Cooling
- SNCR Enhancement

Vaporized SNCR
- SCR Enhancement

Hybrid SNCR/SCR
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions
Hg and Particulate Control Enhancement
- FF Enhancement

Reverse Gas Duct Standing Shockwave Generator

- ESP Enhancement

Spray Cooling
- Condensables Enhancement

Spray Cooling
- ACI Enhancement

Spray Cooling
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Family of Technical Solutions
Eco|SprayTech Systems
- Gas cooling and reaction chambers, patented injection systems for gas
cooling, humidication, emergency dilution and chemical reactions
Eco|SorbTech Systems
- Low-cost BACT and MACT level acid gas and combined PM removal
Eco|PulseTech Systems
- Low-cost MACT level high efciency Fabric Filters for PM removal, controls
and add-on systems for FF optimization
Eco|SelecTech Systems
- Low-cost MACT level, low temperature SCR and SNCR NO
X
removal, hybrid
SNCR/SCR systems, innovative, low-cost soot blowing systems
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions


Particulate Control
Solutions
Reinhold PCUG 2012 - Baltimore, MD
Low-Cost RAFF Enhancement
Tsunami Standing Shockwave Generator
- Works with Existing RAFF Systems
- Installs on the RAFF Reverse Gas Ducting System
- Works by Generating a Standing Shockwave in the RA Duct to Improve
Cleaning and Pressure Drop
Solution Element -
RAFF Standing Shockwave Generator
Reverse Air Fan Tsunami Impulse Booster Gas In
tuO saG
Compartment 1 Compartment 2 Compartment 3 Compartment 4
Poppet Valve
Solution
Element -
RAFF Standing
Shockwave
Generator
!Generates a standing
shockwave in the
reverse gas duct that
vibrates the bags clean
!Simple in-duct
installation
!May be red multiple
times as needed to
clean lter media
Reverse
Air
Fan
Tsunami Impulse Booster
Gas In
t
u
O

s
a
G
Compartment
1
Compartment
2
Compartment
3
Compartment
4
Poppet
Valve
Reinhold PCUG 2012 - Baltimore, MD
Low-Cost RAFF Enhancement
Reinhold PCUG 2012 - Baltimore, MD
Low-Cost ESP Enhancements
ID-side - Evaporative Gas Cooling Tower
FD-side - Fan Inlet Cooling
Solution Element -
EGC Spray Cooling Tower
Solution
Element -
EGC Spray
Cooling Tower
!Downow EGC Tower
in installed after APH
where nely atomized
water is evaporated to
cool gases to lower
resistivity
!EGC tower eliminates
danger of build-up in
ductwork and provides
engineered
evaporation times
to Dust Collector
Spray Lances
From APH
Reinhold PCUG 2012 - Baltimore, MD
Flyash Resistivity
Optimum
Resistivity
Range for Good
ESP Operation
Reinhold PCUG 2012 - Baltimore, MD
Air Preheater Outlet Temperature Prole

Reinhold PCUG 2012 - Baltimore, MD
Zone Cooling Approach
Spray Cooling
Target
Reinhold PCUG 2012 - Baltimore, MD
Zone Cooling Implementation with EGC
Duct Temperature Prole
Upstream of EGC
Duct Temperature Prole
Downstream of EGC
ESP Inlet Temperature Prole
280-300F Average
Reinhold PCUG 2012 - Baltimore, MD
Additional Benets of Cooling Technology
Enhancement of DSI
Enhancement of ACI
Enhanced Collection of Condensable Fraction
More Stable ESP Electrical Operation
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions


NO
X
Control Solutions
Reinhold PCUG 2012 - Baltimore, MD
Low-Cost NO
X
Solutions
SNCR with Catalytic Urea Conversion
Hybrid SNCR/SCR with Single-layer Catalyst Bed
Oxidizer with Activator Optimization
Two-step SNCR/Oxidizer
Solution
Element -
Catalytic Urea
Conversion
SNCR System
!Patented urea
conversion process
!High-temperature,
vaporized injection of
catalyzed urea
!Full-scale results show
greater than 85% NO
X

reduction
!Reduces urea
consumption by >50%
Injection
Location
Reinhold PCUG 2012 - Baltimore, MD
Enhanced SNCR Test Results
Page 7
Customer: Cement Plant
Proposal: 120515-1 Rev 0
Date: May, 2012

No part of this proposal may be reproduced, copied, disclosed or used by any party without the written permission of
EcoSpray Srl. 2011
Prova 5 5 Aprile 2012

!"##
#
"##
%##
&##
'##
(###
("##
(%##
(&##
('##
()*(& ()*+( ()*%, ('*## ('*(% ('*"' ('*%+
!
"
#
$
%
& !
"
%
&"
(
&#
& )
!
*
+
*
%
*
#
*
,
*
-
+
"

.*/0$
-./0-1 02" 345 (# 6 2" 17-489
-./8-1 :2 345 (# 6 2"
;3<7 %,6 <=7>937?93< @AB
;3<7 %,6 17-<37 @AB


Nella prova 5, sono stati riportati i valori di NOx, portata di Urea iniettata all evaporatore, il valore di CO al
camino, e il valore di Urea iniettata in camera. I valori sono corretti al 10% di ossigeno.
Obiettivo di questa prova stata quella di trovare il valore di NOx minimo utilizzando 400 LPH di urea all
evaporatore e 1000 lph di urea in camera come viene normalmente fatto in cementeria.
Vengono definiti anche i seguenti valori rilevati per il calcolo delle performance:
- Portata gas al camino: 29200 Nm3/h, dry
- Ossigeno al camino: 11.9% dry
- NOx in ingresso: 1320 mg/Nm3
- Urea iniettata (evaporatore): 400 LPH
- Urea iniettata (in camera): 1000 LPH

La sovrapposizione degli effetti della normale iniezione in camera (1000 LPH) e di 400 LPH di urea all
evaporatore ha consentito di raggiungere (con gli usuali ritardi tipici della iniezione in camera) 50-60 mg/Nm3.
Virtualmente tutti gli NOX sono rimossi.
Reinhold PCUG 2012 - Baltimore, MD
Enhanced SNCR Test Results Page 5
Customer: Cement Plant
Proposal: 120515-1 Rev 0
Date: May, 2012

No part of this proposal may be reproduced, copied, disclosed or used by any party without the written permission of
EcoSpray Srl. 2011
EFFICIENZA SISTEMA DI INIEZIONE

!"
$!"
%!"
&!"
'!"
(!"
)!"
*!"
+!"
,!"
$!!"
!-' !-( !-) !-* !-+ !-, $ $-$ $-% $-& $-'
!
"
#
$
%
&
'
(

"
*
*
&
$
&
"
(
$
+

#
,
*
-

#
(
.

(
'
/

!
"
.
,
$
%
&
'
(

-

(0! 1&(2"$%". 3'4"0 1(5676 $' 8 3'4"0 ('6 9#0"4&("7
./0 123"
456
789:;<: =./0 123">
789:;<: =456>


In base ai dati riportati alle prove 1,2,3 sono stati calcolati i punti di efficienza sulla base del N.S.R.

Con bassi dosaggi di Urea (NSR=0.8) si ottengono ovviamente livelli di rimozione dei NOx inferiori (circa 50%)
ma si ha anche un alta efficienza di utilizzo dell Urea (AUF=65-68%).
Con dosaggi di Urea maggiori (NSR= 1.2-1.4) si ottengono elevati rendimenti di rimozione dei NOx (75%) ma
una minore efficienza di utilizzo dell Urea iniettata (AUF=50-55% circa).

Il sistema attualmente installato con iniezione di Urea liquida in camera in grado di diminuire i NOx sino a 700-
800 mg/Nm3 con portata iniettate di 1000 LPH.

Il sistema con gassificazione dell Urea si invece dimostrato in grado di ridurre i NOx a livelli simili con
un consumo di soli 400 LPH (solo il 40% di quello attuale).

Con consumi superiori a 400 LPH si sono ottenuti valori di NOx nel range 350-400 mg/Nm3.

Non si sono potuti testare consumi di Urea superiori ai 600 LPH in quanto il calore necessario per tale
evaporazione era superiore a quello generabile dal bruciatore installato. Dato che poi il livello di temperatura
ottimale a valle della torre evaporativa risultato di 350 oC e dato che questa temperatura non era raggiungibile
con 600 LPH, molto probabile l AUF con NSR=1.3-1.4 potr essere migliorato ulteriormente utilizzando
temperature di reazione ottimizzate.
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions


Acid Gas Control Solutions
Reinhold PCUG 2012 - Baltimore, MD
Low-Cost Acid Gas Solutions
DSI Enhancement
- Evaporative Gas Cooling Tower (EGC) Temperature Control

Enhances Acid Gas Removal by Approach to Saturation

Enhances HCl, H
2
SO
4
and SO
2
Capture
- EGC Combined with Turbulent Fluid Bed Reactor

Increases Utilization of Sorbent

EGC establishes Optimum Temperature to Optimize Reaction

Provides Increased Turbulence

Increases Gas Contact Time

Eliminates Sorbent Build-up

Solution Element -
TFB Reaction Chamber
Solution
Element -
TFB Reaction
Chamber
!Upow reactor close-
coupled to an EGC
Tower
!Sorbent is injected
downstream of pre-
cooled gases to
maximize reaction
!Upow reactor greatly
increases turbulence,
mixing and residence
time
to Dust Collector
Spray Lances
From APH
Spray Lances
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions


Hg Control Solutions
Reinhold PCUG 2012 - Baltimore, MD
Low-Cost Hg Control Solutions
ACI Enhancement
- Installation of EGC

Decreases Gas Temperature for enhanced elemental Hg adsorption

Oxidizer Injection
- Installation of Oxidizer System

Converts elemental Hg to ionic Hg upstream of dust collector

Captured in dust collector as a particulate

Solution
Element -
Hg Oxidizer
System
!Oxidizer alone or in
conjunction with
activator
!Can be engineered to
provide >50% NO
X

reduction
!Can be used in
conjunction with SNCR
to provide higher NO
X

reduction
Injection
Location
Solution Element -
EGC Spray Tower for Improved ACI Performance
Solution
Element -
EGC for Hg
Control
!Cooling gases has
been proven to
improve ACI
performance on
elemental Hg
to Dust Collector
Spray Lances
From APH
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Low-Cost Solutions


Multi-Pollutant Control
Solutions
Reinhold PCUG 2012 - Baltimore, MD
BoldEco Technology Benets
Single Reactor Units Can Be Installed in Parallel
MuLtiple Reactor Units Consist of Identical Subsystems in Parallel
Can Be Started-Up and Shut-Down Independently of Plant Processes
Subsystems Can Be Individually Operated or Turned Down to:
- Accommodate Different Operating Modes
- Low Load Conditions at the Lowest Possible Operating Cost
- Allow for Off-Line Cleaning Mode for Maximum Performance
Designed to Be Phased in with Compliance Deadlines
Solution
Element -
VersaMAPS
Multi-pollutant
Control
!Address So
X
, Hcl, No
X
,
Hg, Pm
10
And Pm
2.5

!Small Footprint
!Designed To Have
Single Or Multiple
Reactor Arrangement
!High Sorbent
Utilization