Economics of an Integrated Approach to Control SO2, NOx, HCl, and Particulate Emissions from Power Plants

Abstract An integrated approach for the simultaneous reduction of major combustion-generated pollutants from power plants is presented along with a simplified economic analysis. With this technology, the synergistic effects of high-temperature sorbent/coal or sorbent/natural gas injection and high-temperature flue gas filtration are exploited. Calcium-based (or Na-based, etc.) sorbents are sprayed in the post-flame zone of a furnace, where they react with S- and Cl-containing gases to form stable salts of Ca (or Na, etc.). The partially reacted sorbent is then collected in a high-temperature ceramic filter, which is placed downstream of the sorbent injection point, where it further reacts for a prolonged period of time. With this technique, both the likelihood of contact and the length of time of contact between the solid sorbent particles and the gaseous pollutants increase, because reaction takes place both in the furnace upstream of the filter and inside the filter itself. Hence, the sorbent utilization increases significantly. Several pollutants, such as SO2, H2S, HCl, and particulate (soot, ash, and tar), may be partially removed from the effluent. The organic content of the sorbents (or blends) also pyrolyzes and reduces NOx. Unburned carbon in the ash may be completely oxidized in the filter. The filter is cleaned periodically with aerodynamic regeneration (back pulsing) without interrupting furnace operation. The effectiveness of this technique has been shown in laboratory-scale experiments using either rather costly carboxylic salts of Ca or low- to moderate-cost blends of limestone, lime, or sodium bicarbonate with coal fines. Injection occurred in the furnace at 1150 °C, while the filter was maintained at 600 °C. Results showed that 65 or 40% SO2 removal was obtained with calcium formate or a limestone/coal blend, respectively, at an entering calcium-to-sulfur molar ratio of 2. A sodium bicarbonate/coal blend resulted in 78% SO2 removal at a sodium-to-sulfur molar ratio of 2. HCl removal efficiencies have been shown to be higher than those for SO2. NOx reductions of 40% have been observed with a fuel (coal)-to-air equivalence ratio, π, around 2. The filter has been shown to be 97–99% efficient in removing PM2.5 particulates. Calculations herein show that this integrated sorbent/filter method is costeffective, in comparison with current technologies, on both capital cost ($/kW) and levelized cost ($/ton pollutant removed) bases, if a limestone/coal mixture is used as the sorbent for fossil fuel plants. Capital costs for the filter/sorbent combination are estimated to be in the range of $61–$105/kW for a new plant. Because current technologies are designed for removing one pollutant at a time, both their cost and space requirements are higher than those of this integrated technique. At the minimum projected removal efficiencies for HCl/SO2/NOx of about 40%, the levelized costs are projected to be $203–$261/ton of combined pollutant SO2/HCl/NOx and particulates removed from coalfired power plants.