Reducing mercury emissions from the burning of coal

• US 7,955,577 B2
• Filed: 06/10/2010
• Issued: 06/07/2011
• Est. Priority Date: 03/17/2005
• Status: Active Grant

• Current Assignee: Nox Ii Ltd. (Arthur J Gallagher & Company)
• Original Assignee: Nox Ii Ltd. (Arthur J Gallagher & Company)
• Inventors: Comrie, Douglas C.
• Primary Examiner(s): Vanoy; Timothy C
• Application Number:
  US12/813,214
• Publication Number:
  US 20100251938A1
• Time in Patent Office: 362 Days
• Field of Search: 423/210, 423/244.01, 423/244.04, 423/244.07, 423/DIG.5, 431/2, 431/8, 110/186, 110/188, 110/203, 110/218, 110/342, 110/344, 110/345, 502/400, 502/407, 502/414, 106/705, 106/713, 106/718, 106/734, 422/108, 422/110, 422/111
• US Class Current: 423/210
• CPC Class Codes: B01D 53/508 by treating the gases with solids
• CPC Class Codes: B01D 53/64 Heavy metals or compounds thereof, e.g. mercury
• CPC Class Codes: C04B 18/065 Residues from coal gasification
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 20/023 Chemical treatment
• CPC Class Codes: C04B 2103/0088 Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 40/0039 Premixtures of ingredients
• CPC Class Codes: C04B 40/0608 Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
• CPC Class Codes: C10L 10/00 Use of additives to fuels or fires for particular purposes additives for liquid carbonaceous fuels characterised by their chemical nature C10L1/10; using binders for briquetting solid fuels C10L5/10; using additives to improve the combustion of solid fuels C10L9/10
• CPC Class Codes: C10L 10/02 for reducing smoke development
• CPC Class Codes: C10L 9/10 by using additives
• CPC Class Codes: F23J 15/003 for supplying chemicals to fumes, e.g. using injection devices
• CPC Class Codes: F23J 2215/60 Heavy metals; Compounds thereof
• CPC Class Codes: F23J 7/00 Arrangement of devices for supplying chemicals to fire
• CPC Class Codes: F23K 1/00 Preparation of lump or pulverulent fuel in readiness for delivery to combustion apparatus
• CPC Class Codes: F23K 2201/505 with additives
• CPC Class Codes: Y02E 20/32 Direct CO2 mitigation
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 423/05 Automatic, including computer, control

Abstract

Sorbent components containing calcium, alumina, and silica are used in combination during coal combustion to produce environmental benefits. Sorbents are added to the coal ahead of combustion and/or are added into the flame or downstream of the flame, preferably at minimum temperatures to assure complete formation of the refractory structures that result in various advantages of the methods. When used together, the components reduce emissions of elemental and oxidized mercury; increase the level of Hg, As, Pb, and/or Cl in the coal ash; decrease the levels of leachable heavy metals (such as Hg) in the ash, preferably to levels below the detectable limits; and make a highly cementitious ash product.

Claims

1. A method for reducing the amount of oxidized mercury in flue gases generated by combustion of a mercury-containing carbonaceous fuel in a furnace, the method comprising

adding an alkaline powder sorbent onto the fuel before combustion or directly into the furnace during combustion;

burning the fuel in the presence of the added alkaline powder sorbent;

measuring the level of mercury in the flue gases;

comparing the measured mercury level to a target level; and

if the measured value is above the target level, increasing the amount of powder sorbent added relative to the fuel,

wherein the powder sorbent comprises calcium, silica, and alumina.

2. A method according to claim 1, wherein the powder sorbent further comprises iron and magnesium.

3. A method according to claim 1, wherein the alumina content of the powder sorbent is higher than the alumina content of portland cement.

4. A method according to claim 1, wherein the alumina content of the powder sorbent is greater than 7% by weight.

5. A method according to claim 1, comprising injecting the powder sorbent into the furnace during the burning.

6. A method according to claim 1, wherein the fuel comprises coal and one or more components selected from the group consisting of biomass, polymer scrap, and rubber tires.

7. A method according to claim 1, wherein the powder sorbent comprises one or more materials selected from the group consisting of portland cement, calcium oxide, lime, limestone, sugar beet lime, cement kiln dust, and lime kiln dust, and further comprises an aluminosilicate material.

8. A method according to claim 7, wherein the powder sorbent comprises two or more of the materials and further comprises an aluminosilicate material.

9. A method according to claim 1, wherein the carbonaceous fuel comprises coal.

10. A method according to claim 9, wherein the coal comprises lignite coal.

11. A method according to claim 9, wherein the coal comprises bituminous coal.

12. A method according to claim 1, wherein the sorbent comprises 2-15 wt. % Al₂O₃, 30-75 wt. % CaO, 5-20 wt. % SiO₂, 1-10 wt. % Fe₂O₃, and 0.1-5 wt. % total alkali.

13. A method for reducing leaching of mercury and/or of other heavy metals from ash produced from the combustion of coal or other fuel in a coal burning system or in an incinerator, comprising:

introducing sorbent components containing silica and alumina into the incinerator or coal burning system during combustion at a rate of addition based on the amount of coal or other fuel being consumed by combustion;

measuring leaching of mercury and/or other heavy metals from the resulting ash; and

adjusting the addition rate according to the measured leaching of heavy metals.

14. A method according to claim 13, wherein the sorbent components are provided in an aluminosilicate material.

15. A method according to claim 14, wherein the aluminosilicate material comprises at least one material selected from the group consisting of calcium montmorillonite, sodium montmorillonite, and kaolin.

16. A method according to claim 13, comprising introducing one or more materials selected from the group consisting of portland cement, cement kiln dust, lime kiln dust, and sugar beet lime into the incinerator or coal burning system.

17. A method according to claim 13, comprising adding a sorbent composition onto coal before combustion in a coal burning furnace.

18. A method according to claim 13, comprising injecting a sorbent composition into the furnace during combustion.

19. A method according to claim 13, further comprising adding a sorbent composition comprising bromide onto coal upstream of the furnace, into the furnace during combustion, and/or into the flue gases downstream of the furnace.

20. A method of making coal ash with a targeted low level of leachable mercury, comprising burning the coal in the presence of added calcium, silica, and alumina, measuring the leaching of mercury from the resulting coal ash, and increasing the addition rate of silica and/or alumina if the measured leaching is below the targeted level.

21. A method according to claim 20, comprising adding calcium, silica, and alumina in the form of a sorbent composition comprising 2% to 50% by weight of an aluminosilicate material and 50% to 98% by weight of an alkaline powder comprising calcium.

22. A method according to claim 20, wherein the targeted level of leaching of the coal ash is characterized by a concentration of mercury in the extract of less than 0.2 ppm when tested using the TCLP Test Method 1311.

23. A method according to claim 20, comprising adding calcium, silica, and alumina in the form of a sorbent composition comprising 2-15 wt. % Al₂O₃, 30-75 wt. % CaO, 5-20 wt. % SiO₂, 1-10 wt. % Fe₂O₃, and 0.1-5 wt. % total alkali.