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Title: Multiple pollutant removal using the condensing heat exchanger

Abstract

The Integrated Flue Gas Treatment (IFGT) system is a new concept whereby a Teflon ® covered condensing heat exchanger is adapted to remove certain flue gas constituents, both particulate and gaseous, while recovering low level heat. The pollutant removal performance and durability of this device is the subject of a USDOE sponsored program to develop this technology. The program was conducted under contract to the United States Department of Energy's Fossil Energy Technology Center (DOE-FETC) and was supported by the Ohio Coal Development Office (OCDO) within the Ohio Department of Development, the Electric Power Research Institute's Environmental Control Technology Center (EPRI-ECTC) and Babcock and Wilcox - a McDermott Company (B&W). This report covers the results of the first phase of this program. This Phase I project has been a two year effort. Phase I includes two experimental tasks. One task dealt principally with the pollutant removal capabilities of the IFGT at a scale of about 1.2MW t. The other task studied the durability of the Teflon ® covering to withstand the rigors of abrasive wear by fly ash emitted as a result of coal combustion. The pollutant removal characteristics of the IFGT system were measured over a wide range ofmore » operating conditions. The coals tested included high, medium and low-sulfur coals. The flue gas pollutants studied included ammonia, hydrogen chloride, hydrogen fluoride, particulate, sulfur dioxide, gas phase and particle phase mercury and gas phase and particle phase trace elements. The particulate removal efficiency and size distribution was investigated. These test results demonstrated that the IFGT system is an effective device for both acid gas absorption and fine particulate collection. Although soda ash was shown to be the most effective reagent for acid gas absorption, comparative cost analyses suggested that magnesium enhanced lime was the most promising avenue for future study. The durability of the Teflon ® covered heat exchanger tubes was studied on a pilot-scale single- stage condensing heat exchanger (CHX ® ). This device was operated under typical coal-fired flue gas conditions on a continuous basis for a period of approximately 10 months. Data from the test indicate that virtually no decrease in Teflon ® thickness was observed for the coating on the first two rows of heat exchanger tubes, even at high inlet particulate loadings. Evidence of wear was present only at the microscopic level, and even then was very minor in severity.« less

Authors:
 [1];  [1];  [1]
+ Show Author Affiliations
  1. McDermott Technology Inc., Alliance, OH (United States)
Publication Date:
Research Org.:
Federal Energy Technology Center (FETC), Morgantown, WV, and Pittsburgh, PA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
7506
Report Number(s):
DE-AC22-95PC95255-06
ON: DE00007506
DOE Contract Number:
AC22-95PC95255
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; 20 FOSSIL-FUELED POWER PLANTS; Heat Exchangers; Flue Gas; Pollutants; Removal

Citation Formats

Jankura, B. J., Kudlac, G. A., and Bailey, R. T.. Multiple pollutant removal using the condensing heat exchanger. United States: N. p., 1998. Web. doi:10.2172/7506.
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Jankura, B. J., Kudlac, G. A., & Bailey, R. T.. Multiple pollutant removal using the condensing heat exchanger. United States. doi:10.2172/7506.
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Jankura, B. J., Kudlac, G. A., and Bailey, R. T.. Mon . "Multiple pollutant removal using the condensing heat exchanger". United States. doi:10.2172/7506. https://www.osti.gov/servlets/purl/7506.
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@article{osti_7506,
title = {Multiple pollutant removal using the condensing heat exchanger},
author = {Jankura, B. J. and Kudlac, G. A. and Bailey, R. T.},
abstractNote = {The Integrated Flue Gas Treatment (IFGT) system is a new concept whereby a Teflon ® covered condensing heat exchanger is adapted to remove certain flue gas constituents, both particulate and gaseous, while recovering low level heat. The pollutant removal performance and durability of this device is the subject of a USDOE sponsored program to develop this technology. The program was conducted under contract to the United States Department of Energy's Fossil Energy Technology Center (DOE-FETC) and was supported by the Ohio Coal Development Office (OCDO) within the Ohio Department of Development, the Electric Power Research Institute's Environmental Control Technology Center (EPRI-ECTC) and Babcock and Wilcox - a McDermott Company (B&W). This report covers the results of the first phase of this program. This Phase I project has been a two year effort. Phase I includes two experimental tasks. One task dealt principally with the pollutant removal capabilities of the IFGT at a scale of about 1.2MWt. The other task studied the durability of the Teflon ® covering to withstand the rigors of abrasive wear by fly ash emitted as a result of coal combustion. The pollutant removal characteristics of the IFGT system were measured over a wide range of operating conditions. The coals tested included high, medium and low-sulfur coals. The flue gas pollutants studied included ammonia, hydrogen chloride, hydrogen fluoride, particulate, sulfur dioxide, gas phase and particle phase mercury and gas phase and particle phase trace elements. The particulate removal efficiency and size distribution was investigated. These test results demonstrated that the IFGT system is an effective device for both acid gas absorption and fine particulate collection. Although soda ash was shown to be the most effective reagent for acid gas absorption, comparative cost analyses suggested that magnesium enhanced lime was the most promising avenue for future study. The durability of the Teflon ® covered heat exchanger tubes was studied on a pilot-scale single- stage condensing heat exchanger (CHX ® ). This device was operated under typical coal-fired flue gas conditions on a continuous basis for a period of approximately 10 months. Data from the test indicate that virtually no decrease in Teflon ® thickness was observed for the coating on the first two rows of heat exchanger tubes, even at high inlet particulate loadings. Evidence of wear was present only at the microscopic level, and even then was very minor in severity.},
doi = {10.2172/7506},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Mon Jun 01 00:00:00 EDT 1998},
month = {Mon Jun 01 00:00:00 EDT 1998}
}
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DOI:  10.2172/7506
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  • ;
    Integrated Flue Gas Treatment (IFGT) uses two Condensing Heat Exchangers (CHXs{reg_sign}) in series to recover waste heat from the flue gas and remove a variety of pollutants from the flue gas. The Teflon{reg_sign}-covered internals of the condensing heat exchanger permit heat recovery at temperatures below the acid dew-point of the flue gas. The pollutant removal characteristics of the IFGT system were measured over a wide range of operating conditions in a pilot Integrated Flue Gas Treatment System rated at 1.2 MW{sub t} (4 million Btu/hr) using a wide range of coals. The coals tested included a high-sulfur coal, a medium-sulfurmore » coal and a low-sulfur coal. The flue gas pollutants investigated included ammonia, hydrogen chloride, hydrogen fluoride, particulate, sulfur dioxide, gas phase and particle phase mercury and gas phase and particle phase trace elements. The particulate removal efficiency and size distribution was also investigated. Soda ash, lime and magnesium-lime scrubbing reagents were investigated. The test results show that the IFGT system can remove greater than 95% removal of acid gases with a liquid-to-gas ratio less than 1.34 l/m{sup 3} (10 gal/1,000 ft{sup 3}), and that lime reagents show promise as a substitute for soda ash. Particulate and ammonia gas removal was also very high. Ionic mercury removal averaged 80%, while elemental mercury removal was very low. Trace metals were found to be concentrated in the fine particulate with removal efficiencies in the range of 50% to 80%. The data measured in this task provides the basis for predictions of the performance of an IFGT system for both utility and industrial applications.« less

  • The purpose of Task 2 (IFGT Pilot-Scale Tests at the B&W Alliance Research Center) is to evaluate the emission reduction performance of the Integrated Flue Gas Treatment (IFGT) process for coal-fired applications. The IFGT system is a two-stage condensing heat exchanger that captures multiple pollutants -- while recovering waste heat. The IFGT technology offers the potential of addressing the emission of S0{sub 2} and particulate from electric utilities currently regulated under the Phase 1 and Phase 2 requirements defined in Title IV, and many of the air pollutants that will soon be regulated under Title III of the Clean Airmore » Act. The performance data will be obtained at pilot-scale conditions similar to full-scale operating systems. The Task 2 IFGT tests have been designed to investigate several aspects of IFGT process conditions at a broader range of variables than would be feasible at a larger scale facility. The data from these tests greatly expands the IFGT performance database for coals and is needed for the technology to progress from the component engineering phase to system integration and commercialization. The performance parameters that will be investigated are as follows: SO{sub 2} removal; particulate removal; removal of mercury and other heavy metals; NO{sub x} removal; HF and HCl removal; NH{sub 3} removal; ammonia-sulfur compounds generation; and steam injection for particle removal. For all of the pollutant removal tests, removal efficiency will be based on measurements at the inlet and outlet of the IFGT facility. Heat recovery measurements will also be made during these tests to demonstrate the heat recovery provided by the IFGT technology. This report provides a preliminary test plan for all of the Task 2 pilot-scale IFGT tests.« less

  • The objective of this task is to demonstrate long term operation of a condensing heat exchanger for coal-fired conditions. A small condensing heat exchanger will be installed at the Environmental Control Technology Center in Barker, New York. It will be installed downstream of the flue gas particulate removal system. The test will determine the amount of wear, if any, on the Teflon{trademark} covered internals of the heat exchanger. Visual inspection and measurements will be obtained for the Teflon{trademark} covered tubes during the test. The material wear study will conducted over a one year calendar period, and the CHX equipment willmore » be operated to the fullest extent allowable.« less

  • The purpose of Task 2 (IFGT Pilot-Scale Tests at the B&W Alliance Research Center) is to evaluate the emission reduction performance of the Integrated flue Gas Treatment (IFGT) process for coal-fired applications. The IFGT system is a two-stage condensing heat exchanger that captures multiple pollutants - while recovering waste heat. The IFGT technology offers the potential of a addressing the emission of SO{sub 2} and particulate from electric utilities currently regulated under the Phase I and Phase II requirements defined in Title IV, and many of the air pollutants that will soon be regulated under Title III of the Cleanmore » Air Act. The performance data will be obtained at pilot-scale conditions similar to full-scale operating systems. The task 2 IFGT tests have been designed to investigate several aspects of IFGT process conditions at a broader range of variable than would be feasible at a larger scale facility. The performance parameters that will be investigated are as follows: SO{sub 2} removal; particulate removal; removal of mercury and other heavy metals; NO{sub x} removal; HF and HCl removal; NH{sub 3} removal; ammonia-sulfur compounds generation; and steam injection for particle removal. For all of the pollutant removal tests, removal efficiency will be based on measurements at the inlet and outlet of the IFGT facility. Heat recovery measurements will also be made during these tests to demonstrate the heat recovery provided by the IFGT technology. This report provides the Final Test Plan for the first coal tested in the Task 2 pilot-scale IFGT tests.« less

  • ; ;
    The Integrated Flue Gas Treatment (IFGT) system is a new concept whereby a Teflon{reg_sign} covered condensing heat exchanger is adapted to remove certain flue gas constitutents, both particulate and gaseous, while recovering low level heat. Phase 1 includes two experimental tasks. One task dealt principally with the pollutant removal capabilities of the IFGT at a scale of about 1.2MW{sub t}. The other task studied the durability of the Teflon{reg_sign} covering to withstand the rigors of abrasive wear by fly ash emitted as a result of coal combustion. The pollutant removal characteristics of the IFGT system were measured over a widemore » range of operating conditions. The coals tested included high, medium and low-sulfur coals. The flue gas pollutants studied included ammonia, hydrogen chloride, hydrogen fluoride, particulate, sulfur dioxide, gas phase and particle phase mercury and gas phase and particle phase trace elements. The particulate removal efficiency and size distribution was investigated. These test results demonstrated that the IFGT system is an effective device for both acid gas absorption and fine particulate collection. The durability of the Teflon{reg_sign} covered heat exchanger tubes was studied on a pilot-scale single-stage condensing heat exchanger (CHX{reg_sign}). Data from the test indicate that virtually no decrease in Teflon{reg_sign} thickness was observed for the coating on the first two rows of heat exchanger tubes, even at high inlet particulate loadings. Evidence of wear was present only at the microscopic level, and even then was very minor in severity.« less