CA2856974A1 - Method of removing sulfur trioxide from a flue gas stream - Google Patents

Method of removing sulfur trioxide from a flue gas stream Download PDF

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Publication number
CA2856974A1
CA2856974A1 CA2856974A CA2856974A CA2856974A1 CA 2856974 A1 CA2856974 A1 CA 2856974A1 CA 2856974 A CA2856974 A CA 2856974A CA 2856974 A CA2856974 A CA 2856974A CA 2856974 A1 CA2856974 A1 CA 2856974A1
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Prior art keywords
flue gas
trona
gas stream
temperature
ppm
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CA2856974A
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French (fr)
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CA2856974C (en
Inventor
John Maziuk Jr.
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Solvay Chemicals Inc
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Solvay Chemicals Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/46—Removing components of defined structure
    • B01D53/48—Sulfur compounds
    • B01D53/50—Sulfur oxides
    • B01D53/508—Sulfur oxides by treating the gases with solids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/46—Removing components of defined structure
    • B01D53/48—Sulfur compounds
    • B01D53/50—Sulfur oxides
    • B01D53/501—Sulfur oxides by treating the gases with a solution or a suspension of an alkali or earth-alkali or ammonium compound
    • B01D53/505—Sulfur oxides by treating the gases with a solution or a suspension of an alkali or earth-alkali or ammonium compound in a spray drying process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/30—Sulfur compounds
    • B01D2257/302—Sulfur oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/40—Nitrogen compounds
    • B01D2257/404—Nitrogen oxides other than dinitrogen oxide
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S423/00—Chemistry of inorganic compounds
    • Y10S423/05—Automatic, including computer, control
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S423/00—Chemistry of inorganic compounds
    • Y10S423/08—Corrosion or deposition inhibiting

Abstract

A method of removing SO3 from a flue gas stream includes providing a reaction compound selected from the group consisting of sodium carbonate, sodium bicarbonate, sodium sesquicarbonate, and mixtures thereof. The reaction compound is injected into the flue gas stream. The temperature of the flue gas is between about 500°F and about 850°F. The reaction compound is maintained in contact with the flue gas for a time sufficient to react a portion of the reaction compound with a portion of the SO3 to reduce the concentration of the SO3 in the flue gas stream.

Description

=

METHOD OF REMOVING SULFUR TRIOXIDE FROM A FLUE GAS STREAM
This application is a division of Canadian patent application No 2,622,064 corresponding to international laid-open application No WO 2007/031551.
The present invention relates to the purification of gases, and more particularly to a method of purifying flue gases which contain noxious gases such as S03.
S03 is a noxious gas that is produced from the combustion of sulfur-containing fuel. When present in flue gas, the S03 can form an acid mist that condenses in electrostatic precipitators, ducts or bag houses, causing corrosion.
S03 at concentrations as low as 5-10 ppm in exhaust gas can also result in white, blue, purple, or black plumes from the cooling of the hot stack gas in the cooler air in the atmosphere.
The effort to reduce NO emissions from coal-fired power plants via selective catalytic reactors (SCRs) has resulted in the unintended consequence of oxidizing SO2 to S03 and thereby increasing total 803 emissions. SCRs employ a catalyst (typically vanadium pentoxide) to convert NO to N2 and H20 with the addition of NH3, but there is also an unintended oxidation of the SO2 to S03. Although the higher stack S03 concentrations are still relatively low, the emissions can sometimes produce a highly visible secondary plume, which, although unregulated, is nonetheless perceived by many to be problematic. Efforts to reduce the S03 levels to a point where no secondary S03 plume is visible can impede particulate collection for stations that employ electrostatic precipitators (ESPs). S03 in the flue gas absorbs onto the fly ash particles and lowers fly ash resistivity, thereby enabling the ESP to capture the particle by electrostatic means. Some plants actually inject S03 to lower fly ash resistivity when ash resistivity is too high.
S03 reacts with water vapor in the flue gas ducts of the coal power plant and forms vaporous H2SO4. A portion of this condenses out in the air heater baskets.
Another portion of the sulfuric acid vapor can condense in the duct if the duct =
temperature is too low, thereby corroding the duct. The remaining acid vapor condenses either when the plume is quenched when it contacts the relatively cold atmosphere or when wet scrubbers are employed for flue gas desulfurization (FGD), in the scrubber's quench zone. The rapid quenching of the acid vapor in the FGD tower results in a fine acid mist. The droplets are often too fine to be absorbed in the FGD tower or to be captured in the mist eliminator. Thus, there is only limited S03 removal by the FGD towers. If the sulfuric acid levels emitted from the stack are high enough, a secondary plume appears.
Dry sorbent injection (DS!) has been used with a variety of sorbents to remove S03 and other gases from flue gas. However, DSI has typically been done in the past at temperatures lower than around 370 F because equipment material, such as baghouse media, cannot withstand higher temperatures. Additionally, many sorbent materials sinter or melt at temperatures greater than around 400 F, which makes them less effective at removing gases. The reaction products of many sorbent materials also adhere to equipment and ducts, which requires frequent cleaning of the process equipment.
In one aspect, a method of removing S03 from a flue gas stream including S03 is provided. The method includes providing a reaction compound selected from the group consisting of sodium carbonate, sodium bicarbonate, sodium sesquicarbonate, and mixtures thereof. The reaction compound is injected into the flue gas stream. The temperature of the flue gas is between about 500 F and about 850 F. The reaction compound is maintained in contact with the flue gas for a time sufficient to react a portion of the reaction compound with a portion of the S03 to reduce the concentration of the S03 in the flue gas stream.
In another aspect, a method of removing S03 from a flue gas stream including at least about 3 ppm S03 includes providing a source of trona having a mean particle size between about 10 micron and about 40 micron. The trona is injected as a dry granular material into the flue gas stream. The temperature of the flue gas is between about 275 F and about 365 F. The trona is maintained in ..=
..
2a contact with the flue gas for a time sufficient to react a portion of the sodium sorbent with a portion of the S03 to reduce the concentration of the S03 in the flue gas stream. The reaction product comprises Na2SO4.
The invention as claimed is however more specifically directed to a method of removing S03 from a flue gas stream, comprising:
= providing a source of trona;
= injecting the trona as a dry granular material into the flue gas stream, wherein the temperature of the flue gas is between about 500 F and about 850 F and wherein the flue gas stream comprises at least about 3 ppm S03;
and = maintaining the trona in contact with the flue gas for a time sufficient to react a portion of the trona with a portion of the S03 to reduce the concentration of the S03 in the flue gas stream.
The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims.
The presently preferred embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.
FIG. 1 is a phase diagram showing the reaction products of trona with S03 as a function of flue gas temperature and S03 concentration.
FIG. 2 is a schematic of one embodiment of a flue gas desulfurization system.
The invention is described with reference to the drawings in which like elements are referred to by like numerals. The relationship and functioning of the various elements of this invention are better understood by the following detailed description. However, the embodiments of this invention as described below are by way of example only, and the invention is not limited to the embodiments illustrated in the drawings.
Dry sorbent injection (DSI) has been used as a low cost alternative to a spray dry or wet scrubbing system for the removal of S03. In the DSI process, the sorbent is stored and injected dry into the flue duct where it reacts with the acid gas. Under certain processing conditions, the reaction product of the sorbent and the acid gas is a sticky ash. The sticky ash tends to stick to the process equipment and ducts, thus requiring frequent cleaning. Thus, it would be beneficial to have a process that minimizes the amount of sticky ash reaction product.
The present invention provides a method of removing S03 from a flue gas stream comprising S03 by injecting a reaction compound such as sodium sesquicarbonate, sodium bicarbonate, or soda ash into a flue gas stream to react with S03. Sodium sesquicarbonate is preferably provided from trona. Trona is a mineral that contains about 85-95% sodium sesquicarbonate (Na2CO3=NaHCO3-2H20). A vast deposit of mineral trona is found in southwestern Wyoming near Green River. As used herein, the term "trona"
includes other sources of sodium sesquicarbonate. The term "flue gas" includes the exhaust gas from any sort of combustion process (including coal, oil, natural gas, etc.). Flue gas typically includes acid gases such as S02, HC1, S03, and NO.
When heated at or above 275 F, sodium sesquicarbonate undergoes rapid calcination of contained sodium bicarbonate to sodium carbonate, as shown in the following reaction:
2 [ Na2CO3 = NaHCO3 = 2H2O] 3Na2CO3 + 5H20 + CO2 Sodium bicarbonate undergoes a similar reaction at elevated temperatures:
2 NaHCO3 3Na2CO3 + H20 + CO2 A preferred chemical reaction of the reaction compound with the S03 is represented below:
Na2CO3 + S03 --*Na7SO4 + CO2 However, under certain conditions, undesirable rcactions may occur which produce sodium bisulfate. If the sodium sesquicarbonate or sodium bicarbonate is not completely calcined before reaction with S03, the following reaction occurs:
NaHCO3 + S03 NaHSO4 + S03 Under certain conditions, another undesirable reaction produces sodium bisulfate as represented below:
Na2CO3 + 2S03 + H2O¨+ 2NaHSO4 + CO2 Sodium bisulfate is an acid salt with a low melt temperature and is unstable at high temperatures, decomposing as indicated in the following reaction:
2NaHSO4 Na2S207 The type of reaction product of the Na2CO3 and the S03 depends on the S03 concentration and the temperature of the flue gas. FIG. 1 is a phase diagram showing the typical reaction products of trona with S03 as a function of flue gas temperature and S03 concentration. In particular, above a certain S03 concentration, the reaction product can be solid NaHSO4, liquid NaHSO4, Na2SO4, or Na2S207, depending on the flue gas temperature. The boundary between the liquid NaHSO4 and the solid Na2SO4 at a temperature above 370 F
may be represented by the equation log[S03]=0.009135T-2.456, where [S03] is the log base 10 of the S03 concentration in ppm and T is the flue gas temperature in OF. Liquid NaHSO4 is particularly undesirable because it is "sticky" and tends to adhere to the process equipment, and cause other particulates, such as fly ash, to also stick to the equipment. Thus, it is desirable to operate the process under conditions where the amount of liquid NaHSO4 reaction product is minimized.
Thus, the process may be operated at a temperature below about 370 F, above about 525 F, or at a temperature and S03 concentration where 1 og[S03]<0.009 1 35T-2.456.
The temperature of the flue gas varies with the location in the injection system and may also vary somewhat with time during operation. As the temperature of the flue gas increases, the reaction product of the sodium compound and the S03 ranges from solid NaHSO4, to liquid NaHSO4, to solid Na2SO4 or Na2S207. Therefore, to avoid the formation of sticky ash, the process is preferably operated in a suitable temperature range. In one embodiment, the temperature of the flue gas where the trona is injected is between about 500 F
and about 850 F. The trona is maintained in contact with the flue gas for a time sufficient to react a portion of the trona with a portion of the S03 to reduce the concentration of the S03 in the flue gas streain. The temperature of the flue gas is preferably greater than about 500 F. The temperature of the flue gas is preferably less than about 800 F, and most preferably less than about 750 F.

The temperature of the flue gas is most preferably between about 525 F and about 750 F. In another embodiment, the temperature of the flue gas is between about 275 F and about 365 F. This temperature rangc is below the temperature for formation of the sticky NaHSO4.
The S03 concentration of the flue gas stream to be treated is generally at least about 3 ppm, and commonly between about 10 ppm and about 200 ppm. In order to avoid the adhesion of waste material on the process equipment, when operated at flue gas temperatures greater than about 500 F the non-gaseous reaction product is preferably less than about 5% NaHSO4, and most preferably less than about 1% NaHSO4. The desired outlet S03 concentration of the gas stack is preferably less than about 50 ppm, more preferably less than about 20 ppm, even more preferably less than about 10 ppm, and most preferably less than about 5 ppm. The byproduct of the reaction is collected with fly ash.
Trona, like most alkali reagents, will tend to react more rapidly with the stronger acids in the gas stream first, and thcn after some residence timc it will react with the weaker acids. Such gas constituents as HC1 and S03 are strong acids and trona will react much more rapidly with these acids than it will with a weak acid such as S02. Thus, the injected reaction compound can be used to selectively remove S03 without substantially decreasing the amount of SO2 in the flue gas stream.
A schematic of one embodiment of the process is shown in FIG. 2. The furnace or combustor 10 is fed with a fuel source 12, such as coal, and with air 14 to bum the fuel source 12. From the combustor 10, the combustion gases are conducted to a heat exchanger or air heater 30. Ambient air 32 may be injected to lower the flue gas temperature. A selective catalytic reduction (SCR) device 20 may be used to remove NO gases. A bypass damper 22 can be opened to bypass the flue gas from the SCR. The outlet of the heat cxchanger or air heater is connected to a particulate collection device 50. The particulate collection 30 device 50 removes particles made during the combustion process, such as fly ash, from the flue gas before it is conducted to an optional wet scrubber vessel 54 and then to the gas stack 60 for venting. The particulate collection device 50 may be an electrostatic precipitator (ESP). Other types of particulate collection devices, such as a baghouse, may also be used for solids removal. The baghouse contains filters for separating particles made during the combustion process from the flue gas.
The S03 removal system includes a source of reaction compound 40. The reaction compound is selected from sodium sesquicarbonate, sodium bicarbonate, and soda ash. The reaction compound is preferably provided as particles with a mean particle size between about 10 micron and about 40 micron, most preferably between about 24 micron and about 28 micron. The reaction compound is preferably in a dry granular fortn.
The reaction compound is preferably sodium sesquicarbonate in the form of trona. A suitable trona source is T-200 trona, which is a mechanically refined trona ore product available from Solvay Chemicals. T-2000 trona contains about 97.5% sodium sesquicarbonate and has a mean particle size of about 24-28 micron. The S03 removal system may also include a ball mill pulverizer, or other type of mill, for decreasing and/or otherwise controlling the particle size of the trona or other reaction compound.
The reaction compound is conveyed from the reaction compound source 40 to the injector 42. The reaction compound may be conveyed pneumatically or by any othcr suitable method. Apparatus for injecting the reaction compound is schematically illustrated in FIG. 2. The injection apparatus 42 introduces the reaction compound into flue gas duct section 44, which is preferably disposed at a position upstream of the air heater 30. The injection system is preferably designed to maximize contact of the reaction compound with the S03 in the flue gas stream. Any type of injection apparatus known in the art may be used to introduce the reaction compound into the gas duct. For example, injection can be accomplished directly by a compressed air-driven eductor. Ambient air 32 may be injected to lower the flue gas temperature before the injection point 42.
The process requires no slurry equipment or reactor vessel if the reaction compound is stored and injected dry into the flue duct 44 where it reacts with the acid gas. However, the process may also be used with humidification of the flue gas or wet injection of the reaction compound. Additionally, the particulates can be collected wet through an existing wet scrubber vessel 54 should the process be used for trim scrubbing of acid mist. In particular, the flue gas desulfurization system may be operated so that the S03 removal is accomplished by injecting the reaction compound with the S03, while the majority of the SO2 is removed by the wet scrubber 54.
The process may also be varied to control the flue gas temperature. For example, the flue gas temperature upstream of the trona may be adjusted to obtain the desired flue gas temperature where the reaction compound is injected.

=
. ' Additionally, ambient air 32 may be introduced into the flue gas stream to lower the flue gas temperature and the flue gas temperature monitored where the reaction compound is injected. Other possible methods of controlling the flue gas temperature include using heat exchanges and/or air coolers. The process may also vary the trona injection location or include multiple locations for reaction compound injection.
For the achievement of desulfurization, the reaction compound is preferably injected at a rate with respect to the flow rate of the S03 to provide a normalized stoichiometric ratio (NSR) of sodium to sulfur of about 1.0 or greater. The NSR is a measure of the amount of reagent injected relative to the amount theoretically required. The NSR expresses the stoichiometric amount of sorbent required to react with all of the acid gas. For example, an NSR of 1.0 would mean that enough material was injected to theoretically yield 100 percent removal of the S03 in the inlet flue gas; an NSR of 0.5 would theoretically yield 50 percent S03 removal. The reaction of SO3 with the sodium carbonate is very fast and efficient, so that a NSR of only one is generally required for S03 removal. The reaction compound preferentially reacts with S03 over S02, so S03 will bc removed even if large amounts of SO, are present. Preferably, an NSR of less than 2.0 or more preferably less than 1.5 is used such that there is no substantial reduction of the SO, concentration in the flue gas caused by reaction with excess sorbent.
In one embodiment, the flue gas stream further comprises S02, and sufficient reaction compound is added to also remove some of the S02. The reaction compound is maintained in contact with the flue gas for a time sufficient to react a portion of the reaction compound with a portion of the S02 to reduce the concentration of the SO2 in the flue gas stream. This may be particularly useful in small plants, where it is more economical to have a single system for removing both SO2 and S03 rather than adding a wet scrubber to remove the S02.
Because NO removal systems tend to oxidize existing SO2 into S03, the injection system may also be combined with an NO removal system. The trona injection system may also be combined with other SOõ removal systems, such as sodium bicarbonate, lime, limestone, etc. in order to enhance performance or remove additional hazardous gases such as HC1, NO, and the like.
Surprisingly, it has been observed that when the temperature of the flue gaz is between about 500 F and about 850 F (preferably between about 550 F and =.
about 750 F), or between about 275 F and about 365 F, the reaction product is not sticky. Solid build ups in the filter arc avoided, in particular when it is a ESP. This effect is particularly pronounced in the upper temperature range.
Consequently, he invention concerns also the usc of the method of removing S03 from a flue gaz according to the invention and its preferred embodiments to avoid the formation of sticky reaction products.
EXAMPLES
Studies were conducted in an electric generation plant in Ohio using a hot side electrostatic precipitator (ESP) and no baghouse. The plant used a catalyst for NO, removal, which caused elevated S03 levels in the flue gas. The S03 concentration in the flue gas was between about 100 ppm and about 125 ppm.
The trona used was T-200 from Solvay Chemicals.

T-200 trona was injected into the flue gas at a flue gas temperature of 367 F. A perforated plate of an ESP in the plant had significant solids buildup after operation of the S03 removal system for about two weeks.

The operation of Exatnple 1 was repeated with the change that the trona was injected at a flue gas temperature below 365 F. In comparison to the perforated plate of Example 1, a perforated plate of an ESP in the plant had significantly less solids buildup after operation of the S03 removal system for two weeks than.

The operation of Example 1 is repeated with the change that the trona is injected into flue gas at a temperature of about 500 F. A perforated plate of an ESP in the plant is relatively free of solids buildup after operation of the removal system for two weeks using T-200 trona.
Of course, the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims (10)

1. A method of removing SO3 from a flue gas stream, comprising:
.cndot. providing a source of trona;
.cndot. injecting the trona as a dry granular material into the flue gas stream, wherein the temperature of the flue gas is between about 500°F and about 850°F and wherein the flue gas stream comprises at least about 3 ppm SO3;
and .cndot. maintaining the trona in contact with the flue gas for a time sufficient to react a portion of the trona with a portion of the SO3 to reduce the concentration of the SO3 in the flue gas stream.
2. The method of claim 1, wherein the flue gas stream comprises between about 10 ppm and about 200 ppm SO3 upstream of the location where the trona is injected.
3. The method of claim 1 or 2, wherein the trona is provided in the form of particles with a mean particle size of between about 10 micron and about 40 micron.
4. The method of any one of claims 1 to 3, wherein the temperature of the flue gas is between about 500°F and about 750°F.
5. The method of any one of claims 1 to 4, wherein the reaction product of the reaction compound and the SO3 is selected from the group consisting of Na2SO4, Na2S2O7, and mixtures thereof.
6. The method of any one of claims 1 to 5, further comprising adjusting the flue gas temperature upstream of the trona to obtain the desired flue gas temperature where the trona is injected.
7. The method of claim 6, wherein the adjusting further comprises introducing ambient air into the flue gas stream and monitoring the flue gas temperature where the trona is injected.
8. The method of claim 6, wherein the adjusting further comprises controlling the flow of a material through a heat exchanger in communication with the flue gas.
9. A method of removing SO3 from a flue gas stream comprising at least about 3 ppm SO3, comprising:
.cndot. providing a source of trona having a mean particle size between about 10 micron and about 40 micron;
.cndot. introducing ambient air in the flue gas stream to reduce the temperature of the flue gas to less than about 365°F;
.cndot. injecting the trona as a dry granular material into the flue gas stream, wherein the temperature of the flue gas is between about 275°F and about 365°F; and .cndot. maintaining the trona in contact with the flue gas for a time sufficient to react a portion of the sodium sorbent with a portion of the SO3 to reduce the concentration of the SO3 in the flue gas stream, wherein the reaction product is selected from solid phase Na2SO4, solid phase NaHSO4, and mixtures thereof.
10. The method of claim 9, wherein the flue gas stream comprises between about 10 ppm and about 200 ppm SO3 upstream of the location where the trona is injected.
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US11/229,011 US7481987B2 (en) 2005-09-15 2005-09-15 Method of removing sulfur trioxide from a flue gas stream
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