Engineering Conferences International
ECI Digital Archives
CO2 Summit II: Technologies and Opportunities
Proceedings
Spring 4-12-2016
Mist injection causes high CO2 capture in
wastewater stream
Sanjev Jolly
Environ Ambient Corporation
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Part of the Environmental Engineering Commons
Recommended Citation
Sanjev Jolly, "Mist injection causes high CO2 capture in wastewater stream" in "CO2 Summit II: Technologies and Opportunities",
Holly Krutka, Tri-State Generation & Transmission Association Inc. Frank Zhu, UOP/Honeywell Eds, ECI Symposium Series,
(2016). http://dc.engconfintl.org/co2_summit2/22
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[email protected].
Mist Injection Causes High CO2 Removal in
Wastewater Stream
Sanjeev Jolly, P. E.
Enviro Ambient Corporation
ECI CO2 Summit
April 12, 2016
CONFIDENTIAL – Enviro Ambient ©2016
1
Overview
Enviro Ambient is dedicated to the ongoing development of advanced, clean energy
technologies
Company
Proven Technology
Strong Value
Proposition
2
• Privately Held - Headquartered in Boston, Massachusetts
• Original Equipment Manufacturer (OEM) of patented air quality control system
(AQCS) technology
• Engineering operations in Louisville, KY
• R&D Operations at Queen’s University in Kingston, Ontario Canada
Multi-pollutant Unit (MPU)
• Advanced ‘all-in-one’ Multi-Pollutant Emission Control Reactor Module
• Multi-pollutant removal rates of greater than 95% (NOx, SOx, acid gases, heavy
metals including Hg, Residual PM2.5, PM10)
• 50% CO2 capture, higher capture rates with C3 module
• Exceeds all current U.S. EPA Air Quality Regulation compliance levels for MATS,
CAIR, Boiler MACT and NAAQS rules.
• Operated both a coal unit and natural gas unit up to 2.5 MW Equivalent - June 2010
to Jan. 2014
• Performance & economics evaluated by multiple 3rd parties including EPRI and URS
CO2 Capture Unit (C3)
• CO2 capture unit can be sized for add-on to MPU to increase CO2 to 80% level
• Stand alone unit available removing only CO2 up to 80% level
• Lowest levelized cost solution on the market today for
widest spectrum of pollutants removed
• Smaller footprint, shop-assembled modules, and
shortest cycle time from engineering to operation
• Applicable to all fossil fuels
• Ideal for retrofit and new build applications
• Potential expansion of primary fuel options for owner
• Downstream byproduct revenue stream
CONFIDENTIAL – Enviro Ambient ©2016
GLOBAL REGULATORY LANDSCAPE
Global environmental regulations continue to spur market demand for emission control solutions
Air Pollutant Emission Standard for Coal-Fired Power Plants (mg/m3)
Pollutant
SO2
NOx
PM
Mercury
Generation
New
Existing
New
Existing
New
Existing
New
Existing
US
160
1
160/640
117
2
117/160/640
22.5
22.5
0.001
0.002
EU
200
400
3
500/200
3
500/200
50
50
0
0
1) 160 for plants built 1997-2005; 640 for plants built1978-1996
2) 117 for plants built after 2005; 160 for plants built 1997-2005; 640 for plants built 1978-1996
3) 500 until end 2015; 200 as from 2016
4) 400 for four provinces with high-sulfur coal
5) 100 for plants built 2004-2011; 200 for plants built before 2004
Source: WRI 2012
3
CONFIDENTIAL – Enviro Ambient ©2016
China
100
4
200/400
100
5
100/200
30
30
0.03
0.03
Product Integration – Cold End
Reactor Module fully integrates into current plant operations downstream of
primary particulate collection device
4
CONFIDENTIAL – Enviro Ambient ©2016
Process Schematic
The process is simple, cost effective, and patented.
5
CONFIDENTIAL – Enviro Ambient ©2016
Summary of Process Chemistry
Acid Gases - Halogens (HF, HCl, HBr) Removal
NOx Removal
NOx (95% NO / 5% NO2 ) NO2 is water soluble; NO is not
NO is converted to NO2 by adding ozone:
Flue gas has both HCl and chlorine. Water injected through
foggers convert any remaining chlorine to HCl
NO + O3 → NO2 + O2
2Cl2 + 2H2O → 4HCl + O2
O3 injected in the flue gas stream
Water injected in the first stage converts NO2 to nitric acid mist (HNO3)
HNO3 mist is condensed out of flue gas stream at the acid dew point and
treated outside duct.
HCl is condensed in the Reactor Module when cooled to dew point
temperatures
SOx (SO2 & SO3) Removal
Filterable Residual Particulate Matter –Removal
SOx (99% SO2 / 1% SO3 )
Hydrogen peroxide (H2O2 )/ water injected in the first fogging stage to
convert SO2 to sulfuric acid mist
New or Reconstructed Units = 0.007 lb/MWh
Existing Units = 0.3 lb/MWh or 0.03 lb/MMBtu
SO2 + H2O → H2SO3; H2SO3 + H2O2 → H2SO4 + H2O
Condensation process removes any particulate not captured by
upstream ESP/baghouse, etc.
SO3 + H2O → H2SO4
Sulfuric acid mist is condensed out of flue gas stream at the acid dew
point and treated outside duct
Carbon Dioxide (CO2) Removal
Mercury (Hg) & Heavy Metals (Cd, CR, Ni, Be, As) Removal
Most CO2 captured on a transitory basis in waste water, degases with minimal agitation
Mercury - Elemental (insoluble in water) & Oxide (water soluble)
Formation of acid gases (halogens) oxidize mercury in the first fogging
stage. Additionally, hydrogen peroxide (H2O2) oxidizes the elemental
mercury
Very small amount of CO2 captured as carbonic acid
CO2 + H2O → H2CO3
Mercury oxide is condensed out of flue gas stream in the wastewater
stream and treated outside duct. Other heavy metals removed – arsenic,
cadmium, chromium, selenium, barium, lead, silver
6
CONFIDENTIAL – Enviro Ambient ©2016
Waste Water Process Schematic
Condensation primarily consists of strong acids (low
pH) and relatively weaker acids
Quantity of wastewater varies depending on
temperature of flue gas entering the units.
The wastewater streams can be combined or separated
for acid resale.
Byproduct is salt and water.
7
CONFIDENTIAL – Enviro Ambient ©2016
Reactor Module – Unit Layout Diagram
Straightforward and functional design allows for ease of operation and maintenance
of units
5
4
3
2
1
1
8
1
First & Second Stage fogging arrays
2
Inconel 686 Alloy Lining
3
CPVC Media Section
4
Inconel 625 Demister
5
Granulated Activated Carbon Filter
CONFIDENTIAL – Enviro Ambient ©2016
Reactor Module – Design Basis
Utility grade design for reliability, durability, redundancy and safety.
•
•
Carbon steel exterior and construction
•
Fogging nozzle arrays - Inconel 686 or equivalent material.
Fogging nozzles - 316 SS.
•
•
•
•
Packing media – CPVC geometric shapes
•
Auxiliary power consumption 3-8% of gross plant output. Less
than 1% if there is an existing SCR at the plant.
•
Operating temperature 225 to 375°F / 105 to 190°C (Inlet)
120 to 130°F/ 50 to 55°C (Outlet)
Built-in system redundancy (fogging, reagents)
•
•
Reactor Module
Interior liner - Inconel 686 or equivalent material to protect
against acid corrosion
Mist eliminator - Inconel 625 wire mesh
Outlet duct & stack lining downstream of Reactor Module – FRP
Gas side system pressure drop 6” – 8” wg (152 mm – 203 mm
of water column) (1.5 kPa – 2.0 kPa)
Routine visual inspections during planned plant outage.
9
25 MW
(60,000 SCFM/28.3 N m3/sec)
•
•
•
•
Designed for 25 year life
Fabricated weight ≈ 110,000 lbs. (≈ 50 MT)
Total weight ≈ 180,000 lbs. (≈ 82 MT)
Total operating weight ≈ 190,000 to 200,000 lbs. (86 to 91
MT)
CONFIDENTIAL – Enviro Ambient ©2016
Technology Center – Coal & Natural Gas
State-of-the-art facility opened in June 2010 to demonstrate the advanced multi-pollutant
emission control capabilities of the Reactor Module
• Began Operation – June, 2010
• Coal Fired – Designed for 5 MW equivalent volume
• Natural Gas Units – Designed for 5 MW equivalent
volume
• Design Volume - 15,000 SCFM (7.1 N m3/sec)
Design
•
Measurement
& Verification
•
•
•
•
•
•
•
Sub-systems
Eastern Bituminous Coal (2.2% Sulfur), PRB & Lignite
Flue Gas Analysis
Real time Emission Monitoring
Sorbent Trap testing for Hg removal
Proprietary Systems
Ozone Generator
Hydrogen Peroxide
Waste Water Treatment
• Third party engineering validates technical
performance and life-cycle market readiness
• Component testing validates the design and
confirms no mechanical degradation
• EPRI confirmation of commercial readiness*
Validation
50%
* EPRI neither endorses products or services, nor allows the data or other results of EPRI work to be used as an endorsement.
Unsurpassed multi-pollutant removal efficiencies
Sustaining fossil fuel generating assets requires disruptive technology to reduce multiple pollutants
Demonstrated performance for 3+ years
10
CONFIDENTIAL – Enviro Ambient ©2016
Proven, Repeatable Performance: Coal Fired
Demonstrated at Technology Center Firing Eastern Bituminous Coal
100
100
80
80
60
60
40
40
20
20
0
0
Operating Conditions (8/14/2012)
Inlet (ppm)
Outlet (ppm)
Carbon
Hydrogen
4.70%
Gas Temp
257⁰F (125⁰C)
89⁰F (32⁰C)
Oxygen
6.40%
NOx
43.36 (ppm)
0.44 (ppm)
Nitrogen
1.20%
Sulfur
2.20%
SO2
CO2
216.58 (ppm)
0.00 (ppm)
Ash
13,865 (ppm)
3,352 (ppm)
Heating Value 12,644 Btu/lb
SO2 Removal
CO2 Out
25,000
100
80
20,000
80
15,000
60
10,000
40
5,000
20
40
20
0
0
0
1:30 PM
1:36 PM
1:42 PM
1:48 PM
1:54 PM
2:00 PM
2:06 PM
2:12 PM
2:18 PM
2:24 PM
60
*Results verified by Midlothian & Associates
11
CO2 Removal
100
CO2 ppm
350
300
250
200
150
100
50
0
CO2 In
Removal %
SO2 Out
1:30 PM
1:35 PM
1:41 PM
1:46 PM
1:51 PM
1:57 PM
2:02 PM
2:08 PM
2:13 PM
2:19 PM
2:24 PM
SOx ppm
SO2 In
Eastern Bituminous Coal
Ultimate Analysis
CONFIDENTIAL – Enviro Ambient ©2016
Removal %
NOx Removal
Removal %
NOx Out
1:30 PM
1:35 PM
1:41 PM
1:46 PM
1:51 PM
1:57 PM
2:02 PM
2:08 PM
2:13 PM
2:19 PM
2:24 PM
NOx ppm
NOx In
Moisture
69.90%
13.20%
2.40%
Proven Performance: Natural Gas Fired
Demonstrated at Enviro Ambient Technology Center Gas Fired Burner
Operating Conditions (3/28/2012)
400⁰F (204⁰C)
90⁰F (32⁰C)
NOx
CO2
6.95 ppm
0.35 ppm
10,035 ppm
8,915 ppm
CO2 Out
CO2 Removal
12,000
100
90
80
70
60
50
40
30
20
10
0
10,000
8,000
6,000
4,000
2,000
0
11:30:00 AM
11:34:15 AM
11:38:33 AM
11:42:48 AM
11:47:07 AM
11:51:22 AM
11:55:48 AM
12:00:03 PM
12:04:22 PM
12:08:37 PM
12:12:57 PM
12:17:12 PM
12:21:33 PM
12:25:48 PM
100
90
80
70
60
50
40
30
20
10
0
*As demonstrated March 28, 2012 - Gas
12
Gas Temp
CO2 In
CO2 Concentration (ppmv)
20
18
16
14
12
10
8
6
4
2
0
Outlet (ppm)
CONFIDENTIAL – Enviro Ambient ©2016
Percent Removal (%)
NOx Removal
Percent Removal (%)
NOx Out
11:30:00 AM
11:33:30 AM
11:37:03 AM
11:40:33 AM
11:44:03 AM
11:47:37 AM
11:51:07 AM
11:54:48 AM
11:58:18 AM
12:01:52 PM
12:05:22 PM
12:08:52 PM
12:12:27 PM
12:15:57 PM
12:19:33 PM
12:23:03 PM
12:26:35 PM
NOx Concentration (ppmv)
NOx In
Inlet (ppm)
Carbon Capture Process Description
•
With standard reactor module arrangement, 50% CO2 capture is expected depending
upon the application.
•
Higher CO2 capture rates require addition of C3 module – it could be a stand-alone
system or downstream of reactor module or other traditional pollution abatement
devices.
•
High capture rates require a combination of slowing of flue gases and higher water
spray rates than those required for multi-pollutant reduction such as SO2, NOx, etc.
The C3 module is designed to achieve these conditions.
•
The flue gases from the exhaust gas stream are split and then diverted to multiple
vessels where they are sprayed with water utilizing an arrays of fogging nozzles
arranged in a grid across the vessel cross-section.
•
One to two stages of nozzle arrays depending upon the application and capture rates
required.
•
Mist eliminators placed in the outlet branch of the vessel to remove water droplets from
the exiting treated flue gases.
•
The flue gases are then routed to the common ductwork and then to the stack.
13
CONFIDENTIAL – Enviro Ambient ©2016
Carbon Capture Wastewater Treatment
•
Since most of the pollutants are captured upstream, the C3 module wastewater stream
primarily consists of condensed CO2 either as carbonic acid or dissolved in water.
•
This wastewater is routed to a settling tank and then to a aggravator tank where the
separation of CO2 is facilitated by an agitator.
•
The pure CO2 can then be compressed and used for EOR application or other suitable
industrial application.
•
The wastewater can be recycled. About 65% of the water sprayed is recovered.
•
An RO system or filtration system is required.
•
Treated water taken to water supply storage tank where it is mixed with city water for
spraying in the vessel.
14
CONFIDENTIAL – Enviro Ambient ©2015
Carbon Capture Process Schematic
15
CONFIDENTIAL – Enviro Ambient ©2016
Carbon Capture Process Schematic
P&ID for Coal Fired Unit, 250 MW - Bituminous
16
CONFIDENTIAL – Enviro Ambient ©2016
CO2 Mass Balance for Various Coals
CO2 Capture Capabilities 250 MW Coal-Fired Boiler (Bituminous Coal)
Coal Flow Rates
Units
Btu Input Rate to
MMBtu/hr
Boiler
Coal Input Rate to
tons/hr
Boiler
Coal Input Rate to
lbs/MMBtu
Boiler
MMBtu/Hr Out of
MMBtu/hr
Boiler
Flue Gas Downstream of Air Heater
PRB
BIT
LIG
2,400
2,400
2,400
144
92
172
120.0
76.7
143.3
2,019
2,117
1,981
O2
lbs/MMBtu
66.15
64.35
66.83
CO2
lbs/MMBtu
210.22
200.1
212.81
N2
lbs/MMBtu
788.08
783.62
790.02
NOx
lbs/MMBtu
0.255
0.433
0.279
HCl
lbs/MMBtu
0.037
0.095
0.059
SO2
lbs/MMBtu
1.15
3.95
2.848
SO3
lbs/MMBtu
0.001
0.039
0.016
Hg (Total)
H2O
lbs/TBtu
10.8
7.66
24.35
lbs/MMBtu
86.275
50.74
99.167
Gas Dry
lbs/MMBtu
1065.9
1052.587
1072.869
Gas Wet
lbs/MMBtu
1152.176
1103.327
1172.036
wt%
7.49
4.6
8.46
% H2O
3
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
Before (C Module)
PRB
BIT
LIG
158,760
154,440
160,392
504,528
480,240
510,744
1,891,392
1,880,688 1,896,048
612
1,039
670
88.8
228.0
141.6
2,760
9,480
6,835
2.40
93.60
38.40
0.0259
0.0184
0.0584
207,060
121,776
238,001
2,558,160
2,526,209 2,574,886
2,765,222
2,647,985 2,812,886
7.49%
4.60%
8.46%
CO2 Removal
17
CONFIDENTIAL – Enviro Ambient ©2016
3
After (C Module)
PRB
BIT
LIG
158,760 154,440 160,392
100,906 96,048 102,149
1,891,392 1,880,688 1,896,048
551
935
603
0.9
2.3
1.4
2,484
8,532
6,152
0.12
4.68
1.92
0.020736 0.014707 0.046752
207,060 121,776 238,001
2,154,093 2,140,650 2,165,347
2,361,153 2,262,426 2,403,347
8.77%
5.38%
9.90%
80%
80%
80%
CO2 Capture
CO2 Capture Capabilities 250 MW Coal-Fired Boiler (Bituminous Coal)
Coal-Fired Unit
Flue Gas:
Flow
CO2 Concentration
Total CO2 in Flue Gas
CO2 Removed
CO2 Removed
250
2,647,985
1,921
480,250
384,200
1,346,237
MW
Capacity Factor
80%
lb/hr
Temp
230 ⁰F
lb/MWhr
CO2 Wt.
18.14 %
lb/hr
(% CO2 Removal) 80%
lb/hr
CO2 Removed
192.10 Short Tons/hr
Short Tons/yr
•
CO2 captured can be compressed and directly used for EOR application or other
industrial application.
•
Increasingly, new solutions that convert CO2 into commercial products are being
developed.
•
CO2 can be captured from coal, gas or any fossil burning power plant. The above
example is for 250 MW coal-fired unit with 80% capacity factor.
18
CONFIDENTIAL – Enviro Ambient ©2016
CO2 Enhanced Oil Recovery Application
CO2 Capture Capabilities Coal Fired Unit
Unit Cost
O&M Only
Capital
Transportation
Total
CO2 Revenue:
Sell Price
Cost
Net Revenue
$7.08
$6.15
$8.75
$21.98
per ton of CO2 Removed
per ton of CO2 Removed
per ton of CO2 Removed
per ton of CO2 Removed
40
per ton
21.98
per ton
$24,258,995 per year
$53,849,472
$29,590,477
per year
per year
•
Water cost = $1.00 per 1000 gal.; Electric Rate = $0.05 per kWhr.
•
Design Life = 20 years; Interest Rate = 6%.
•
Auxiliary Load = 7.9% of plant output.
•
Plant output = 250 MW.
•
The above data is for C3 module only. No multi-pollutant cost included in the above
estimate.
19
CONFIDENTIAL – Enviro Ambient ©2016
International Clean Tech Accelerator
http://www.enviroambient.com
/news-publications/index.shtml
20
http://www.enviroinnovate.co
m/news-events/index.shtml
CONFIDENTIAL – Enviro Ambient ©2016
Enviro Ambient CO2 Modeling Project
21
CONFIDENTIAL – Enviro Ambient ©2016
Enviro Ambient CO2 Modeling Project
Dr. Kim McAuley, Professor of Chemical
Engineering
at
Queen’s
University
and
Associate Dean of Graduate Studies. Has
served on the Board of Directors for MITACS
and the Fields Institute for Research in
Mathematical Science. Editor for Chemical
Engineering
Journal
International
and
Advisory
serves
on
Boards
the
for
Macromolecular Theory & Simulations and
Macromolecular Reaction Engineering.
McAuley received
Dr.
a Queen Elizabeth II
Diamond Jubilee Medal for her modeling
research.
22
CONFIDENTIAL – Enviro Ambient ©2016
Enviro Ambient CO2 Modeling Project
Project Overview
Dr. Kim McCauley, her team and our Vice President of Engineering, Sanjeev Jolly, have
been charged with the modeling of our existing CO2 transient absorption process and our
increase in CO2 capture.
Project Description
A series of mathematical models are being developed to gain improved understanding of the
carbon dioxide capture behaviour of our process.
Project Deliverables & Milestones
•
Complicated model estimated delivery dates: September 1, 2016; January 30, 2017; and
April 30, 2017
•
Draft report estimated delivery date: June 1, 2017
•
Final report estimated delivery date: September 10, 2017
23
CONFIDENTIAL – Enviro Ambient ©2016
Enviro Ambient CO2 Modeling Project
Project Status
Initial research and computational models are already starting to move in a direction
consistent with our pre-project analysis and hypothesis regarding the carbon dioxide capture
behaviour of our process. This information is being shared with our committed engineering
and sales pipeline constituency.
Project Utilization
Preliminary and final versions of this research report, and the modeling of our existing
CO2 transient absorption process, will be utilized by Enviro Ambient for the purpose of
driving existing generation sales and marketing, as well as the increase in CO2 reduction in
support of our next generation product lines, and the additional commercial utilization of
transiently absorbed CO2.
24
CONFIDENTIAL – Enviro Ambient ©2016
World Class Management Team
Over 75 combined years experience serving the power generation industry
Tom Thompson
President & Chief Executive Officer
Christine Frieze
Chief Financial Officer
•
•
•
•
20+ years executive experience in the power and
financial industries
Successful history of expanding the markets of
established businesses across the glove
Held various executive and senior leadership
positions at Capital Business Management Group,
Canada Trust, The Royal Bank of Canada, and
City First Trust Company
•
25+ year veteran with successful financial
management experience in corporate finance, tax
credit equity financing and project financing
Held various leadership positions with Meridian
Companies, Schoenfeld Associates, BOTEC and
Dober Lidsky Craig and Associates
Sanjeev Jolly, P.E.
Vice President, Engineering (Contract)
Paul Scott, CPA
Vice President, Finance
•
•
•
25 years experience in senior engineering roles in
design, sales and project execution of boilers,
emission reduction systems for combined cycle,
coal and wood-fired power plants
Senior engineering positions with Vogt Power and
Caldwell Energy and is an active member of
PowerGen and ASME
25
•
•
10+ years of experience in the clean-tech industry
with significant experience in power industry
15+ years of corporate finance and mergers and
acquisition experience as partner in leading
Canadian mid-market investment bank
10+ years of start-up and turnaround experience
in software industry
CONFIDENTIAL – Enviro Ambient ©2016
Mist Injection Causes High CO2 Removal in
Wastewater Stream
Sanjeev Jolly, P. E.
Enviro Ambient Corporation
ECI CO2 Summit
April 12, 2016
CONFIDENTIAL – Enviro Ambient ©2016
26