Dry Sorbent Injection Dry Sorbent Injection of Trona for SO of Trona for SO x x Mitigation Mitigation John Maziuk Solvay Chemicals October 31, 2006 The 67th Conference on Glass Problems Presented at
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Dry Sorbent Injection of Dry Sorbent Injection of Trona for SOTrona for SOxx Mitigation Mitigation
John Maziuk
Solvay Chemicals
October 31, 2006
The 67th Conference on Glass Problems
Presented at
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
What is Trona?What is Trona?
Trona is a ore that is mined undergroundTrona is a ore that is mined undergroundTrona is naturally formed sodium Trona is naturally formed sodium
sesquicarbonatesesquicarbonateNaNa22COCO33 NaHCO NaHCO332H2H22OO
Green River formationGreen River formationNumerous beds of TronaNumerous beds of TronaContain billions of tons of TronaContain billions of tons of Trona
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Solvay Chemicals OperationsSolvay Chemicals Operations Solvay Chemicals, Solvay Chemicals,
Inc. Currently Mines Inc. Currently Mines Trona Ore Trona Ore
at an Approximate at an Approximate Depth of 1500’ Depth of 1500’
(457m)(457m) 12’ (3.67m) Thick and 12’ (3.67m) Thick and
of Very High Qualityof Very High Quality Provide Ore for Many Provide Ore for Many
YearsYears Use Both Longwall Use Both Longwall
Mining and Bore Mining and Bore MinersMiners
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Room and Pillar MiningRoom and Pillar Mining
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
The Surface PlantThe Surface Plant
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona Dry Sorbent Injection (DSI)Trona Dry Sorbent Injection (DSI)
“Popcorn Effect” ...5 to 20 times the original surface area
2(Na2CO3 NaHCO32H2O)
3Na2 CO3 + CO2 + 5H2O
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona SEM After CalcinationTrona SEM After Calcination
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona DSCTrona DSC
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona DSI ChemistryTrona DSI Chemistry
2(Na2(Na22COCO33 NaHCO NaHCO332H2H22O)O) +3SO+3SO33 3NaSO3NaSO44 +5H +5H22O + O +
4CO4CO2 2
2(Na2(Na22COCO33 NaHCO NaHCO33 2H2H22O) + 3SOO) + 3SO2 2 3Na 3Na22SOSO3 3 + +
44 COCO2 2 + 5H+ 5H22OO
3Na3Na22SOSO3 3 + 1.5O+ 1.5O22 3Na 3Na22SOSO44
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Parameters - Constraints Parameters - Constraints That Affect Sorbent Utilization:That Affect Sorbent Utilization:
Sorbent Injection RateSorbent Injection Rate NSR (Normalized Stoichiometric Ratio)NSR (Normalized Stoichiometric Ratio) Sorbent Particle SizeSorbent Particle Size Sorbent Residence Time In The Flue Gas StreamSorbent Residence Time In The Flue Gas Stream Sorbent Penetration And Mixing Within The Flue Sorbent Penetration And Mixing Within The Flue
Gas Gas Particulate Control Device UsedParticulate Control Device Used Other Acids Other Acids
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona DSI with BaghouseTrona DSI with Baghouse
SO2 Removal
0%20%40%60%80%
100%
0 0.5 1 1.5 2 2.5NSR
% R
emov
al
Trona Soda Ash
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Impact of Particle Size on TronaImpact of Particle Size on TronaPerformance @325Performance @325ooFF
Effect of Sorbent Size @ NSR 1Source: Solvay Chemicals
0
20
40
60
80
100
11 14 32 65 93
microns
%S
O2
Rem
ova
l
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona DSI @ Baghouse ConditionsTrona DSI @ Baghouse Conditions
PSD is very important to SO2 Removal Efficiency.
SO2 Removal
0
0.2
0.4
0.6
0.8
1
1 2 3 4 5 6 7 8 9 1
NSR
% S
O2 R
em
oval
T200
<38 micron
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Case Study at a Glass Furnace in CaliforniaCase Study at a Glass Furnace in California
A Glass Plant Was Having Operational Problems With A Dry Sorbent SOx Mitigation System
Sodium Bicarbonate Crystals Were Being Milled And Then Dry Injected Into The Duct From The Furnace Just Prior To The Hot Side ESP
The Perf Plates Would Plug Quickly Causing Frequent Shutdowns
After XRD And DSC Analyses They Lowered The Injection Temperature By Adding Outside Air.
The Lower Injection Temperature Delayed The Pluggage By Several Days But Did Not Solve The Problem
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
ESP Perf Plates Using Sodium Bicarbonate ESP Perf Plates Using Sodium Bicarbonate >700>700ooFF
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Perf Plates Using Sodium Bicarbonate at 550Perf Plates Using Sodium Bicarbonate at 550ooFF
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Sodium Sulphate IIISodium Sulphate III
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Case Study at a Glass Plant in California Case Study at a Glass Plant in California (continued)(continued)
The Glass Company Decided To Test TronaT200 Performed Much Better At The >700oF
Injection Temperature Range Higher SOx Removals
Higher Utilization Efficiency Air Cooling At The Injection Point Is Not Necessary Milling T200 Had Only A 5% Utilization Efficiency
Improvement Over Sodium Bicarbonate
No Plugging Occurred
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona DSI Trona DSI
SO2 Removal w/ Trona @ Glass Plant
50%
60%
70%
80%
90%
100%
NSR
SO2
Rem
oval
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona DSITrona DSI
SOx Removal w/ Trona @ Glass Plant
50%55%60%65%70%75%80%85%90%95%100%
530 550 700 700 710 710 720 725 750 750 750 805 805
oF
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Perf Plate Before Hot Side of ESP in Previous Perf Plate Before Hot Side of ESP in Previous Slide After Two Weeks of T200 DSI and still Slide After Two Weeks of T200 DSI and still
“clean as a whistle”“clean as a whistle”
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Test Data, continuedTest Data, continuedFigure 5:
Gavin Unit 2: SO3 Reduction
Lime and Trona Data: SCR Out of Service
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
Moles Sorbent : Moles SO3
% S
O3
Re
du
ctio
n M
ea
sure
d a
t ES
P
Ou
tlet
Trona - No ESP Conditioning
Trona ESP Conditioned
Lime
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Trona DSI BenefitsTrona DSI Benefits
High Removals With Low Cost Position Low Initial Capital Low Sorbent Cost High SOx Removal
Saved The Glass Plant $$$/Ton Of SOx Removal Costs Via SBC
Milling Improved T200 SOx Removal Efficiency By 5 - 10%
Spent Sorbent And Unused Sorbent Can Be Sent Back To Furnace
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Typical Trona DSI Loading/Storage SystemTypical Trona DSI Loading/Storage System
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
Dry Sorbent Injection (DSI)Dry Sorbent Injection (DSI)
Dry Sorbent Injection Of T200 Is A Very Cost Effective Way To Mitigate Acid Gas Emissions.
Low Capital Does Not Require Heating Of Tanks Or Lines Requires Few Mechanical Parts Compatible With ESPs, Baghouses And Most Wet Scrubbers
Will React With Acid Gases Over A Wide Temperature Range (2750F - 18000F)
Trona Sorbent Specifically Designed To Be Used For Neutralization Of Acid Gases That Can Be In Emissions From Boilers, Kilns, Combustors, Furnaces And Incinerators.
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
DSI of Trona DSI of Trona
Because Of The Positive Effect Sodium Has On The Resistivity Of Particles It Is Not Detrimental To The Operation Of An ESP And Can Actually Enhance It’s Operation
Trona Will Act As A Precoat On Baghouse Filter Media
Trona for DSI is A Fine (D50 30-35µ) Material That Can Be Easily Aerated For Pneumatic Transfer
Trona for DSI Can Be Used As Is Or Milled To A Smaller Size.
Copyright 2006, Solvay America, Inc.Solvay Chemicals, Inc.John Maziuk
The EndThe End