Sorb-Tec Case Study

Reducing Hydrated Lime Needed to Achieve SO3, ABS, and Blue Plume Reduction

Customer:

Cross Station

Project Objectives

  • Provide a performance comparison between standard lances, advanced lances, and Sorb-Tec injectors.
  • Identify possible reductions in the volume of sorbent injected to achieve minimum ABS formation temperature at the air heater inlet.

 

Set-Up

  • 640 MW coal-fired generating unit, using Illinois Basin coal.
  • Nol-Tec provided a temporary silo and injection equipment for the test.
  • Hydrated lime is injected for mitigation of SO3, ABS, and blue plume.
  • Sorbent was injected at the SCR outlet, with side A having six injection points and side B having two.
  • An SO3 monitoring probe was installed at the air heater inlet on both the A and B sides of the duct.
  • EPA Method 8A tests were performed at the air heater inlet on side A for select portions of testing.

 

Observed Performance

Conclusions

High performance achieved against operating baseline when compared to standard or advanced lances.

  • In SO3 removal, Sorb-Tec achieved same performance numbers using approximately 1,200 fewer lbs/hr of hydrated lime (when compared to advanced lances).
  • In ABS formation reduction, Sorb-Tec achieved same performance numbers using approximately 1,600 fewer lbs/hr of hydrated lime (when compared to standard lances).
  • All injectors tuned for different load operation, maximizing dispersion and mixing efficiency.
  • Sorb-Tec demonstrated a 63% performance improvement (reduction) in sorbent usage over other lance-based technology.
  • Estimated payback for technology purchase, based on sorbent reduction alone, is less than 1.5 years.
  • Estimated annual savings in sorbent usage alone > ~$400,000/unit annually.

 

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