Proof of concept testing of an integrated dry injection system for SO{sub 2}/NO{sub x} control. Final report

The integrated Dry Injection Process (IDIP) consists of combustion modification using low NO{sub x} burners to reduce NO{sub x} emissions, dry injection of hydrated line at economizer temperatures for primary capture of SO{sub 2}, dry injection of a commercial grade sodium bicarbonate at the air heater exit for additional SO{sub 2} and NO{sub x} removal, and humidification for precipitator conditioning. IDIP offers the potential for simultaneously achieving 90% SO{sub 2} removal, and 65% NO{sub x} removal from a high sulfur flue gas. The process is well suited for new or retrofit applications since it can be incorporated within existing economizer and downstream ductwork. Subscale tests were performed in order to identify the best calcium and sodium sorbents. These tests involved the injection of calcium hydroxide and sodium sorbents at various points of the flue gas system downstream of a 0.25 MM BTU/hr. coal fired combustor, and the gas residence times, cooling rates and temperatures were comparable to those found for full-scale utility boilers. These tests verified that a high surface area hydrated lime provides maximum sorbent utilization and identified an alcohol-water hydrated lime as yielding the highest surface area and the best SO{sub 2} removal capability. The tests also identified sodium bicarbonate to be somewhat more effective than sodium sesquicarbonate for SO{sub 2} removal. The proof of concept demonstration was conducted on the large combustor at the Riley Stoker Research Facility in Worcester, MA. When economically compared to conventional limestone slurry scrubbing on a 300 MW plant, the dry injection process shows lower capital cost but higher operating cost. Hydrated lime injection can be less costly than limestone scrubbing when two or more of the following conditions exist: plant is small (less than 100MW); yearly operating hours are small (less than 3000); and the remaining plant lifetime is small (less than 10 years)