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Abstract
The legacy of mining coal in Pennsylvania spans over a 100 year period starting at the beginning of the 20th century.
Coal mined in Pennsylvania helped fuel the industrial revolution, established the mass production of steel, and
served to propel the United States to victory in two World Wars. During the industrial boom period, few people
recognized the environmental consequences that would follow in the years ahead. Large waste coal piles continued
to grow as the coal mining industry increased production year after year. The resulting environmental damage,
caused by elemental sulfur in the waste coal, is known today as Acid Mine Drainage (AMD). The acidification of
groundwater and streams is considered to be the greatest environmental problem in Pennsylvania.
Until recently, the solution to the Acid Mine Drainage problem was nearly hopeless since costs associated with
traditional methods of remediation are simply prohibitive. The importation of the Circulating Fluidized Bed
Combustion (CFBC) boiler technology from Europe, in the early 1980s, changed that. The CFB boiler design
offers the first glimmer of hope due to its ability to burn large amounts of waste coal, thereby, eliminating the waste
coal from the environment. In addition to providing useful electricity and steam from waste coal, the resulting ash
product was determined to have beneficial value in reclaiming waste coal contaminated land due to its alkaline
properties. Simply removing the waste coal from the environment would not completely solve the problem because
the acidity in the surrounding soil and residual sulfur bearing waste coal would remain unabated. Mixing the
alkaline ash product with underlying soil and residual waste coal serves to neutralize the remaining acidity in the
vicinity of the waste coal piles, thus returning the area to its pre-mining condition.
The Circulating Fluidized Bed power plant serves the dual purpose of producing valuable electricity and steam
while simultaneously reclaiming the land occupied by environmentally damaging waste coal. This reclamation is
accomplished at no cost to the tax payers of Pennsylvania and has a remarkable record of success.
circulation. The primary air fan supplies most of its air to the under-bed grid nozzles. The floor of the combustor
consists of thousands of air nozzles that act to suspend the bed material in a fluidized state throughout the
combustor. The bed material consists of waste coal, ash, limestone, unburned carbon, and products of the limestone
reaction. This hot circulating bed provides the heat required to generate steam in the boiler water wall tubes which
comprise the sides of the boiler for its entire height. Interestingly, a significant amount of the heat transfer is
accomplished via conduction as the hot bed material slides down the walls of the water wall tubes. The suspension
of the bed material in the combustor also provides a well mixed environment for the combustion and limestone
reactions. As expected, the bed density is greatest at the bottom of the combustor and decreases as the bed rises to
the top and approaches the cross-over duct to the cyclones.
Limestone is used to remove sulfur dioxide that forms from the elemental sulfur that is present in the waste coal.
The limestone is introduced with the fuel at the four fuel feed locations and is no small amount. For every pound of
fuel fed to the combustor, approximately 0.20 pounds of limestone is required for SO2 control. Typical sulfur values
in waste coal range from 2% 4 % by weight. The limestone product used in this particular unit contains 83%
CaCO3 by weight.
Calcium carbonate does not react with SO2 directly. Sulfur capture is accomplished by CaO (lime) that forms when
limestone is introduced to the combustor at 1,650 F. The limestone and sulfur capture reactions are described as
follows:
CaCO3 CaO + CO2
CaO + SO2 + 1/2O2 CaSO4
From the reactions we can see that SO2 reacts with CaO to form CaSO4. The calcium sulfate is a solid that makes
up a portion of the bed inventory. The environmental air permit requires that 92% of the SO2 be removed from the
flue gas. The CFB design allows these units to operate with much lower SO2 emissions when compared with typical
coal fired boilers operating without flue gas desulfurization.
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The fly ash is carried through the heat recovery components or convection section of the boiler with the flue gas.
The fly ash and flue gas are cooled in the convection section prior to entering the baghouse portion of the boiler.
The baghouse consists of ten compartments, each equipped with 240 filter bags. Mechanical filtration is used to
separate the fly ash from the flue gas. Fly ash is collected in the compartment fly ash hopper and conveyed
pneumatically to a silo for storage. The fly ash is mixed with water to allow conveyance via a belt conveyor.
Although the bottom and fly ash products are initially treated separately, they are ultimately recombined on the same
transfer belt for eventual use as a soil amendment at the active waste coal excavation site.
Waste coal combustion ash is often referred to as fly ash when, in fact, the ash product is a mixture of both bottom
and fly ash. In a typical CFBC boiler, the fly ash/bottom ash split is commonly 60% fly ash and 40% bottom ash by
weight. The Cambria facility is somewhat unusual given that the split is 40% fly ash and 60% bottom ash on a mass
basis.
of surface and ground water. Sulfurous acid is formed from the sulfur and sulfur oxides that make up the waste coal.
The ash product that is removed from the CFBC boiler is the unburned rock that enters with the waste coal. The
CFBC ash product also contains byproducts from the limestone reactions that occur in the combustor, primarily
calcium sulfate. A more detailed elemental analysis of the waste coal indicates the presence of various metals.
These metals are also found in native soils. A discussion of the fate of these metals is provided in more detail in
subsequent sections of this paper. The metals in the waste coal are environmentally problematic because they are
particularly mobile. The acidic conditions of the existing waste coal produce a situation that allows the various
metals to leach into the ground and surface water.
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Limestone
Total: 135,001 tons
Fuel
Total: 465,691 tons
Ash: 209,561 tons
Carbon 45%
Ash 45%
Other 10%
CFB Boiler
Ash
Total: 418,263 tons
Moisture: 83,653 tons
Ash: 334,610 tons
vicinity of the waste coal permit area to compare the ash sample results with surface soils from the wooded areas
surrounding the Borough. Additional studies of the CFBC ash have shown that trace elements and acidity in waste
coal samples exceed those in the ash product. This result was similarly demonstrated by Rose, Sheetz, et al., in
additional studies that provide the physical mechanism for this result. In qualitative terms, the ash demonstrates a
superior ability to bind the metals in a more stable matrix relative to that exhibited by the waste coal. As a result,
the levels of trace elements in the CFB ash product are comparable to those found in native soils, and in some cases,
are actually lower than native soils.
The results from the 1998 Synthetic Precipitation Leaching Procedure test are given in Table 1 and Figures 3 6.
The graphs were prepared to provide a visual comparison for each element that was analyzed. In addition, the
Pennsylvania Department of Environmental Protection (PADEP) Standard was added to provide a comparison of the
test results with the State upper concentration limits. The graphs also use a logarithmic scale on the Y-axis since the
PADEP standard is often orders of magnitude higher than the test results for many of the elements. In some cases,
the PADEP does not have an upper limit for some of the elements such as aluminum, cobalt, molybdenum, and
potassium. The results of the leachate tests show another interesting result. In many cases, the concentrations of the
samples are the same for each of the various elements analyzed. For example, the test results for cadmium show
concentrations of 0.04 mg/l for each sample. The PADEP standard is 0.125 mg/l. This result is likely due to the
sample concentrations being at or below the detectable limit of the analyzer or test for that particular element.
The overall result of the leachate test shows that the elemental analysis for the Cambria CFB ash is well within the
range of concentration typically found in native soils. None of the element concentrations of the ash exceed the
PADEP standard. Interestingly, some of the elements found in native soils exceed the PADEP standard. This result
is observed for iron and manganese.
Table 1. Comparison of Leachate Results for CFBC Ash versus Native Soils
Metal
Aluminum
Antimony
Arsenic
Barium
Boron
Cadmium
Chromium
Cobalt
Copper
Iron
Lead
Manganese
Mercury
Molybdenum
Nickel
Potassium
Selenium
Silver
Zinc
Cambria
CoGen CFB
Ash
(mg/l)
0.32
0.041
0.004
1.25
0.119
0.04
0.071
0.15
0.053
0.21
0.2
0.038
0.0008
0.15
0.125
6.87
0.022
0.04
0.04
Ernest
Drilling
Tailings
(mg/l)
0.62
0.003
0.003
0.2
0.1
0.04
0.04
0.1
0.04
0.27
0.2
0.1
0.0004
0.01
0.04
1.9
0.002
0.04
0.04
Ernest Area
Corn Field
(mg/l)
PaDEP
Ernest Area Top
Standard
Soil (mg/l)
(mg/l)
36.3
0.003
0.008
0.2
0.1
0.04
0.06
0.1
0.07
30.5
0.12
0.8
0.0004
0.01
0.04
11.3
0.002
0.04
0.16
13.1
0.003
0.006
0.2
0.1
0.04
0.04
0.1
0.04
14.3
0.12
0.42
0.0004
0.01
0.04
3.6
0.002
0.04
0.09
53
NA
0.15
1.25
50
78
0.125
2.5
NA
32.5
7.5
0.375
0.05
0.1
NA
5
NA
1.25
1.25
1.25
10
CFB Ash
Drilling Tailings
Corn Field
Top Soil
PaDEP Stds
0.1
0.01
0.001
Aluminum
Antimony
Arsenic
Barium
Boron
Metals
Figure 3. Soluble Metal Concentrations for CFB Ash versus Native Soils
CFB Ash and Ernest Soils Soluble Metal Comparison
100
10
CFB Ash
Drilling Tailings
Corn Field
Top Soil
PaDEP Stds
0.1
0.01
0.001
Cadmium
Chromium
Cobalt
Copper
Metals
Figure 4. Soluble Metal Concentrations for CFB Ash versus Native Soils
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Iron
10
1
CFB Ash
Drilling Tailings
0.1
Corn Field
Top Soil
PaDEP Stds
0.01
0.001
0.0001
Lead
Manganese
Mercury
Molybdenum
Nickel
Metals
Figure 5. Soluble Metal Concentrations for CFB Ash versus Native Soils
CFB Ash and Ernest Soils Soluble Metal Comparison
100
10
CFB Ash
Drilling Tailings
Corn Field
Top Soil
PaDEP Stds
0.1
0.01
0.001
Potassium
Selenium
Silver
Metals
Figure 6. Soluble Metal Concentrations for CFB Ash versus Native Soils
55
Zinc
Summary
The greatest environmental problem facing the State of Pennsylvania is Acid Mine Drainage and discharges.
Decades of active coal mining resulted in the generation of millions of tons of acid bearing coal waste. Current
estimates indicate approximately 250,000 acres of abandoned mine lands covering 43 of the 67 counties and
adversely affecting over 2,400 miles of streams. The CFBC boiler technology has been successfully used by
independent power producers to produce valuable electricity and steam while simultaneously removing the
mountains of hazardous waste coal scattered throughout the state. In addition to removing the waste coal, the sites
are reclaimed beneficially by using alkaline ash to neutralize the residual acidity of the waste coal surface areas.
The ability of CFBC ash to bind the metals contained in the waste coal results in decreased mobility of these metals
into the environment. Reclamation is completed by using topsoil as a cover and planting with native vegetation to
restore the areas to a condition similar to premining conditions. The environmental remediation and site reclamation
are conducted with tremendous savings to the citizens of Pennsylvania. The environmental improvements
accomplished by Pennsylvanias waste coal plants are well documented and should be embraced by both Federal
and State regulatory agencies.
Stephen N. Skidd is Plant Manager of the Cambria Cogeneration Facility in Ebensburg, PA. He has been in this
position since February 1996. The Cambria CoGen Facility is a net 88 MW facility that sells electric power to
Penelec and up to 20,000 lbs/hr of steam to a local nursing home. The facility burns waste bituminous coal obtained
from company owned property in Indiana County, PA. Prior to his position at Cambria CoGen, he worked for Air
Products and Chemicals, Inc. as Plant Manager of the Hopkinton Liquified Natural Gas facility in Hopkinton
Massachusetts and Plant Manager of an Air Separation Facility in Glenmont, NY. He has 22 years of experience as
a Manager, Engineer, and Project Manager in power generation and the chemical process industry. He received his
B.S. degree in Chemical Engineering from the University of Connecticut in 1981. In addition, he is a registered
Professional Engineer in the States of New Jersey and Pennsylvania.
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