Mercury Removal
from flue gas streams
FLUEPAC® POWDERED ACTIVATED CARBONS
pure water
clean air
better world
Research and Development
Calgon Carbon has 20 years of experience in the removal of
mercury from flue gas, and we have supplied Fluepac to coal-fired
utilities for over six years. When testing Fluepac, we routinely secure
the services of the best third-party mercury test crews in the industry
to ensure that both we and our customers receive the most accurate
data on the performance of our products at their sites.
We have invested over 12 million dollars in research and development
of the Fluepac product line. Thanks to this effort, Calgon Carbon
developed a first generation of advanced carbon products that typically
require less than half usage rate when compared to a standard
carbon. More recently, a second and third generation of advanced
products has allowed further use rate reductions of up to an additional
40%, all while significantly reducing the amount of bromine in the
About
Calgon Carbon
products. Looking forward, R&D efforts will continue in the areas of
mercury capture performance, concrete friendliness, SO3 tolerance,
cost savings, and the use of less bromine.
Fluepac Powdered Activated Carbons
Calgon Carbon Mercury Removal Products
Choosing Calgon Carbon will reduce injection rate
and treatment costs, grant you peace of mind
regarding compliance, and ensure your access
to the most advanced powdered activated carbons
available today.
Mercury emissions created by coal-fired boilers in power plants are a critical
environmental concern. New regulations now require companies to address this
issue. Calgon Carbon’s evolving line of standard and advanced activated carbon
products—plant-tested and proven to remove more than 90% of mercury—
gives you the flexibility you need for any plant size, configuration, and coal type
to achieve compliance.
Category
Product
Benefit
Standard
MC
Standard Brominated
MC P
Benefit
MC Maxx
Benefit
SPR Maxx
Reduce injection rate by
50–70% over standard
non-brominated carbons
SL
Designed for injection into
wet FGD units for the control
of mercury re-emission
Advanced Brominated/Sulfur Tolerant
Category
Product
LMC+
Halogenated versions of Fluepac
MC that promote the oxidation
of mercury without the need for
front-end boiler additives
Advanced
Category
Product
MC+
Compared to other industry
standard carbon products,
will meet or exceed
performance expectations
ST
STF
S3
SF3
For challenging flue gas environments or any situation
where bromine is required. Reduce injection rate
by 50–90% over standard brominated carbons
Nobody knows carbon
better than Calgon
Carbon. As one of
the largest producers
of activated carbon,
we manufacture it in
granular, powdered,
pelletized, catalytic,
and impregnated forms
for vapor and liquid
purification solutions
that make water and
air safer and cleaner.
ADVANCED PRODUCTS
ADVANCED PRODUCTS
NON-BROMINATED
BROMINATED/SULFUR TOLERANT
Increased mercury capture, lower carbon consumption, lower treatment costs.
Formulated to enhance mercury capture in challenging treatment applications,
such as flue gas streams with elevated levels of sulfur trioxide (SO3 ).
• When compared to the industry benchmark standard carbon, 50–70% reduced injection rates
mean fewer carbon deliveries, less wear and tear on equipment, reduced particulate load,
and a lower impact on fly ash.
• When compared to the industry benchmark brominated PAC, 50–90% reduced injection rates
mean fewer carbon deliveries, less bromine in your system, and a lower impact on fly ash.
• Ideal for PRB-fired units.
• Performance is impacted far less than other carbons by the presence of SO3.
• Extremely effective in situations where an oxidizing agent is not required on the carbon.
• Unique formulation allows for improved performance at drastically reduced injection rates in
any situation where a brominated PAC is needed.
100
600 MW PRB-fired unit with an ESP
Standard
Br-PAC
Percent Hg Removal
90
Fluepac MC
Maxx, post-APH,
20 gph CaBr2
80
Fluepac MC
Maxx, pre-APH,
8 gph CaBr2
70
60
50
40
1
2
3
4
5
2ND GENERATION, FLUEPAC ST AND STF
An advanced performance PAC product for
utilities using calcium bromide addition.
At 6 ppm SO3, ST easily met the targeted removal while it is unclear if the
competitive industry benchmark PAC will ever reach compliance in this
situation. Compliance is even more challenging to reach at 9 ppm SO3.
• Helps preserve fly ash sales through lower
feed rates and inherent concrete friendliness.
6
FLUEPAC SPR MAXX
0.45
80
70
0.4
60
0.35
50
0.3
40
0.25
0.2
30
0.15
20
0.1
10
0.05
0
0
Fluepac MC
with CaBr2
(standard PAC)
Fluepac MC Maxx
with CaBr2
(advanced PAC)
Advanced Br-PAC
Fluepac SPR Maxx with
CaBr2 (2nd generation
advanced PAC)
A second generation advanced PAC capable
of significant reductions of injection rates over
other commercial standard and advanced
products on the market. Provides the ability
to remove more than 95% of mercury.
• Most useful when mercury is oxidized
naturally or by the use of boiler additives.
• Delivers a reduction in both the boiler
additive used on the coal and the amount
of activated carbon injected when
compared to standard products.
• Extremely effective when used in units that
collect particulate matter in a baghouse.
• Suited for preserving fly ash sales to the
Portland cement market.
Benchmark
BR-PAC,
6 ppm S03
0.04
Fluepac ST,
6 ppm S03
Fluepac ST,
9 ppm S03
0.03
GWh Illinois
Target (0.008 lbs)
0.02
0.01
0.00
0
1
2
3
4
5
6
Carbon Feed Rate (lbs/MMacf)
Fluepac SF3 performance on 200 MW PRB-fired unit
8
Stack Mercury Emissions (lb/TBtu)
Unit 2, 700 MW, post-APH injection
Carbon Injection Rate (lbs/hr)
Carbon Injection Rate (lbs/MMacf)
0.5
Unit 1, 665 MW, pre-APH injection
0.05
Even a few parts per million of SO3
will have a dramatic impact on the
performance of standard activated
carbons. Considering this issue,
Calgon Carbon has developed a line
of advanced PAC products that are
impacted far less by the presence
of SO3 than are standard mercury
capture carbons.
Carbon Feed Rate (lbs/MMacf)
ACI feed rates to reach 1.2 lbs Hg/TBtu on a PRB-fired unit with baghouse
PRB coal, ESP with 6 and 9 ppm SO3 injection
Sulfur Tolerance
• Delivers a reduction in both the boiler
additive used on the coal and the amount
of activated carbon injected when
compared to standard products.
• Particularly effective with low-sulfur/
low-chlorine coals like PRB.
30
0
FLUEPAC MC MAXX
Hg Emissions (lbs/GWh)
Fluepac MC Maxx: Increased performance with ACI + CaBr2
Fluepac SF3
Cold Side,
June 2014
7
Fluepac SF3
Hot Side,
June 2014
6
5
Industry
Benchmark
Br-PAC,
Cold Side, 2010
4
3
Utility MATS
Limit,
1.2 lb/TBtu
2
1
0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
PAC Injection Rate (lb/MMacf)
8.0
9.0
10.0
3RD GENERATION
FLUEPAC S3 AND SF3
On this unit with cold-side injection, SF3
reached compliance at 75–80% reduced
injection rate when compared to the
competitive benchmark brominated carbon.
Results are even more favorable on the
hot side.
Compatibility
For DSI and Wet FGD Configurations
Fluepac products are compatible with a variety
of different plant configurations.
Concrete Friendliness
FLUEPAC WITH DRY SORBENT INJECTION (DSI)
All advanced and standard Fluepac carbons are inherently concrete
friendly due to the nature of our raw materials and manufacturing
method. Our process limits the larger pores best suited for adsorbing
air entrainment additives, which reduces the negative impact on
concrete production and provides you with more micropores to
remove the mercury you want to capture.
1. Our base materials yield an inherently concrete-friendly activated carbon.
2. The reduced injection rate from our advanced products means less
carbon ends up in your fly ash.
Built-in concrete friendliness
40
Lignite-based
Br-PAC
35
Lignite based carbons readily
adsorb air entrainment additives
Foam Index
30
25
Mix of
Lignite PAC
and Fluepac
MC Maxx
Calgon Carbon bituminous-based carbons
are inherently concrete friendly
20
Mix of Fluepac
MC Maxx and
Fluepac ST
10
Fluepac ST
5
0
0.5
1
1.5
Percent Carbon in Ash
6.0
Sorbent A
with Trona
5.0
Fluepac ST
with Trona
4.0
Fluepac ST
without Trona
Nearly no impact of trona
on Hg removal performance.
3.0
Sorbent C
with Trona
2.0
Sorbent D
with Trona
Sorbent E
with Trona
1.0
0.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
Activated Carbon Injection Concentration (lbs/MMacf)
Fluepac
MC Maxx
15
0
The addition of trona at injection
rates of 500–6,000 lbs/hr shows
no significant impact on the
performance of Fluepac ST.
Notice that Fluepac ST (purple
circles with trona, light blue
circles without trona) remains
below the targeted compliance
line at injection rates under
2 lb/MMacf both with and
without trona.
Fluepac with dry sorbent injection on 140 MW PRB-fired unit using an ESP
and trona injection for SO2 control
Outlet Mercury Emmissions (lb/TBtu)
You can rest assured knowing that whichever Fluepac product you choose,
the quality of your fly ash will be minimally impacted. Calgon Carbon’s Fluepac
products maintain fly ash quality in two ways:
DSI with sodium-based sorbents like trona is known to negatively
impact the performance of PAC in flue gas, often making it
necessary to increase the carbon injection rate to maintain the
same level of mercury removal. Our advanced Fluepac products
are impacted far less by DSI than are other carbon products.
2
2.5
FLUEPAC AS A WET SCRUBBER ADDITIVE
FLUEPAC SL
Fluepac SL is an advanced PAC designed to be injected directly into
wet flue gas desulphurization units. Fluepac SL is used to control
mercury re-emission, and has demonstrated a 50% reduction in
activated carbon injection over standard grade carbon products.
Contact us for additional information on Fluepac SL.
GLOBAL LOCATIONS
FACILITY
SERVICE
SALES
REACTIVATION
HEADQUARTERS
FELUY
PITTSBURGH
SINGAPORE
+1 800 422 7266 calgoncarbon .com
Corporate Headquarters
Calgon Carbon Corporation
3000 GSK Drive
Moon Township, PA 15108 USA
Phone: +1.412.787.6700
1.800.422.7266
European Operations
Chemviron Carbon
Zoning Industriel C de Feluy
B-7181 Feluy, Belgium
Phone: +32 (0) 64 51 1811
Fax: +32 (0) 64 54 1591
Calgon Carbon Asia Pte Ltd.
9 Temasek Boulevard
#26-02 Suntec Tower Two
Singapore 038989
Phone: +65 6221 3500
Fax: +65 6221 3554
© 2015 Calgon Carbon Corporation. All rights reserved.
BRO-MR15-ZTN-E1