Field Demonstration of Enhanced Sorbent Injection for Mercury Control

Alstom Power Inc. has conducted a DOE/NETL-sponsored program (under DOE Cooperative Agreement No. DE-FC26-04NT42306) to demonstrate Mer-Cure{trademark}, one of Alstom's mercury control technologies for coal-fired boilers. Mer-Cure{trademark} utilizes a small amount of Mer-Clean{trademark} sorbent that is injected into the flue gas stream for oxidation and adsorption of gaseous mercury. Mer-Clean{trademark} sorbents are carbon-based and prepared with chemical additives that promote oxidation and capture of mercury. Mer-Cure{trademark} is unique in that the sorbent is injected into an environment where the mercury capture kinetics is accelerated. This full-scale demonstration program was comprised of three seven-week long test campaigns at three host sites including PacifiCorp's 240-MW{sub e} Dave Johnston Unit No.3 burning a Powder River Basin (PRB) coal, Basin Electric's 220-MW{sub e} Leland Olds Unit No.1 burning a North Dakota lignite, and Reliant Energy's 170-MW{sub e} Portland Unit No.1 burning an Eastern bituminous coal. All three boilers are equipped with electrostatic precipitators. The goals for this Round 2 program, established by DOE/NETL under the original solicitation, were to reduce the uncontrolled mercury emissions by 50 to 70% at a cost 25 to 50% lower than the previous target of $60,000/lb mercury removed. The results for all three host sites indicated that Mer-Cure{trademark} technology could achieve mercury removal of 90%. The estimated mercury removal costs were 25-92% lower than the benchmark of $60,000/lb mercury removed. The estimated costs for control, at sorbent cost of $1.25 to $2.00/lb respectively, are as follows: (1) Dave Johnston Unit No.3--$2,650 to $4,328/lb Hg removed (92.8% less than $60k/lb); (2) Leland Olds Unit No.1--$8,680 to $13,860/lb Hg removed (76.7% less than $60k/lb); and (3) Portland Unit No.1--$28,540 to $45,065/lb Hg removed (24.9% less than $60k/lb). In summary, the results from demonstration testing at all three host sites show that the goals established by DOE/NETL were exceeded during this test program. Mercury removal performance4 of greater than 90% reduction was above the 50-70% reduction goal, and mercury removal cost of 25-92% lower than the benchmark was above the 25 to 50% cost reduction goal