THE INDIGO AGGLOMERATOR
THE INDIGO AGGLOMERATOR
THE INDIGO AGGLOMERATOR
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<strong>THE</strong> <strong>INDIGO</strong><br />
<strong>AGGLOMERATOR</strong><br />
Reducing Particulate Emissions<br />
And Opacity<br />
APPA O&M Conference<br />
April 2005<br />
Wallis A. Harrison<br />
Particulate Control Technologies, Inc.
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<strong>THE</strong> ESP PROBLEM<br />
Electrostatic precipitator particle<br />
collection efficiency is particle size<br />
dependent with a minimum at<br />
about 0.5 - 2um
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How Does the Indigo Agglomerator Work?<br />
• Treats the dust prior to entering the Electrostatic Precipitator<br />
• Uses fluidic (FAP) and electrostatic (BEAP) forces to attach<br />
the fine particles to the larger, easily collected particles<br />
• The Bi-Polar Charger charges half the dust positively<br />
and the other half negatively<br />
• Fine negative particles are selectively mixed with the<br />
large positive particles and large negative particles<br />
with fine positive particles<br />
• When a fine particle comes close to an oppositely charged<br />
large particle, it is attracted and attaches to the large particle
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Agglomerator Is Like An ESP?<br />
• Grounded plates<br />
• Discharge electrodes<br />
• Alternating arrangement<br />
• High voltage energization<br />
• Low pressure drop
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Agglomerator Is Not Like An ESP!<br />
• No collection<br />
• No hoppers<br />
• No rappers<br />
• High velocity / small size<br />
• +/- high voltage<br />
• Low power consumption
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<strong>THE</strong> <strong>INDIGO</strong> <strong>AGGLOMERATOR</strong>
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KEY OPERATING FEATURES<br />
• No moving parts ensures high reliability<br />
and low maintenance<br />
• Low power consumption provides low<br />
operating cost (5kw/100MW generation)<br />
• High gas velocity ensures no dust<br />
build-up on electrodes or bottom of duct<br />
• Small size and pre-fabrication reduces<br />
outage time for installation to a few days<br />
• Low pressure loss (
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COMMERCIAL INSTALLATIONS<br />
• Delta Electric - Vales Point Station U5 - AUS<br />
– 1/4 of 660 MW unit – October 2002<br />
• Mississippi Power - Plant Watson U4 - US<br />
– 1/2 of 250 MW unit - March 2003<br />
• GA Power – Plant Hammond U3- US<br />
– 115 MW - October 2004<br />
• Tarong Power Station U1– AUS<br />
– 1/4 of 350 MW – December 2004
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VALES POINT POWER STATION
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VALES POINT <strong>AGGLOMERATOR</strong>
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VALES POINT DATA - 2002<br />
0.5<br />
100<br />
0.5<br />
100<br />
0.45<br />
80<br />
0.45<br />
80<br />
0.4<br />
60<br />
0.4<br />
60<br />
0.35<br />
40<br />
0.35<br />
40<br />
0.3<br />
20<br />
0.3<br />
20<br />
0.25<br />
0<br />
0.25<br />
0<br />
0.2<br />
-20<br />
0.2<br />
-20<br />
0.15<br />
-40<br />
0.15<br />
-40<br />
0.1<br />
-60<br />
0.1<br />
-60<br />
0.05<br />
-80<br />
0.05<br />
-80<br />
0<br />
-100<br />
0<br />
-100<br />
Days From July 25 Unt il August 25, 2002<br />
Days From January 23 Unt il February 28, 2003
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LOWERING INTO DUCT
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PLANT WATSON <strong>AGGLOMERATOR</strong>
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OPACITY TREND AT WATSON STATION
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WATSON ESP OUTLET TESTS<br />
WEST ELK COAL – APRIL 2003<br />
MEASUREMENT A PASS B PASS REDUCTION<br />
OPACITY % 15 4 73%<br />
PARTICULATE<br />
Grains/Act. Cubic Ft. 0.012 0.0066 45%<br />
Milligrams/Cubic Meter 27.5 15.1<br />
FLOW<br />
Actual Cubic Ft/Min 408 718 450 700<br />
Actual Cubic Meters/Min 11 573 12 762<br />
GAS TEMPERATURE<br />
Degrees F. 276 273<br />
Degrees C. 136 134
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WATSON ESP OUTLET TESTS<br />
EMERALD COAL – APRIL 2004<br />
MEASUREMENT A PASS B PASS REDUCTION<br />
OPACITY % 13.2 2.3 83%<br />
PARTICULATE<br />
Grains/Act. Cubic Ft. 0.0136 0.0082 40%<br />
Milligrams/Cubic Meter 31.3 18.8<br />
FLOW<br />
Actual Cubic Ft/Min 443 609 406 455<br />
Actual Cubic Meters/Min 12 563 11 511<br />
GAS TEMPERATURE<br />
Degrees F. 269 261<br />
Degrees C. 132 127
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PARTICLE SIZE SAMPLE POINTS
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WEST ELK COAL PARTICLE SIZE<br />
1000000<br />
B Side Precipitator Outlet<br />
100000<br />
A Side Airheater Outlet<br />
B Side Airheater Outlet<br />
Particle Concentration (#/c<br />
10000<br />
1000<br />
100<br />
A Side Precipitator Outlet<br />
10<br />
1<br />
0 1 2 3 4 5 6 7 8 9 10<br />
Patticle Diameter (microns)
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WEST ELK SLIP<br />
25%<br />
20%<br />
B Side Slip<br />
A Side Slip<br />
Emission Reduction<br />
100%<br />
90%<br />
80%<br />
% Slip<br />
15%<br />
10%<br />
5%<br />
70%<br />
60%<br />
50%<br />
40%<br />
30%<br />
20%<br />
% Emission Reduction with Indigo Agglo<br />
10%<br />
0%<br />
0%<br />
0 1 2 3 4 5 6 7 8 9 10<br />
Particle Diameter (microns)
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EMERALD COAL PARTICLE SIZE<br />
100000<br />
10000<br />
A Side Precipitator Outlet<br />
B Side Precipitator Outlet<br />
A Side Airheater Outlet<br />
B Side Airheater Outlet<br />
Particle Concentration (#/cm<br />
1000<br />
100<br />
10<br />
1<br />
0 1 2 3 4 5 6 7 8 9 10<br />
Particle Diameter (microns)
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EMERALD COAL SLIP<br />
25%<br />
100%<br />
B Side Slip<br />
A Side Slip<br />
90%<br />
Emission Reduction<br />
20%<br />
80%<br />
% Slip<br />
15%<br />
10%<br />
70%<br />
60%<br />
50%<br />
40%<br />
30%<br />
% Emission Reduction with Indigo Agglo<br />
5%<br />
20%<br />
10%<br />
0%<br />
0%<br />
0 1 2 3 4 5 6 7 8 9 10<br />
Particle Diameter (microns)
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DRUMMOND SUB-MICRON PARTICLE SIZE<br />
100000000<br />
10000000<br />
1000000<br />
A Precipitator Outlet<br />
B Precipitator Outlet<br />
A Air Heater Outlet<br />
B Air Heater Outlet<br />
100000<br />
10000<br />
1000<br />
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9<br />
Particle Diameter (um)
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DRUMMOND COAL SUB-MICRON SLIP<br />
100.0%<br />
90.0%<br />
A Pass Slip<br />
B Pass Slip Wit h Agglomerat or<br />
Emission Reduct ion<br />
80.0%<br />
70.0%<br />
60.0%<br />
%<br />
50.0%<br />
40.0%<br />
30.0%<br />
20.0%<br />
10.0%<br />
0.0%<br />
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9<br />
um
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INLET FIELD ELECTRICAL IMPROVEMENT<br />
A Precipitator<br />
B Precipitator<br />
Voltage<br />
(kV)<br />
Current<br />
(mA)<br />
Voltage<br />
(kV)<br />
Current<br />
(mA)<br />
Percentage<br />
Increase in<br />
Current<br />
Before<br />
Agglomerator<br />
52.4<br />
217<br />
52.6<br />
230<br />
5.8%<br />
After<br />
Agglomerator<br />
55.0<br />
230<br />
55.0<br />
330<br />
43.5%<br />
Percentage<br />
Increase<br />
5.0%<br />
6.0%<br />
4.6%<br />
43.8%
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OUTLET FIELD ELECTRICAL IMPROVEMENT<br />
A Precipitator<br />
B Precipitator<br />
Voltage<br />
(kV)<br />
Current<br />
(mA)<br />
Voltage<br />
(kV)<br />
Current<br />
(mA)<br />
Percentage<br />
Increase in<br />
Current<br />
Following Installation<br />
Agglomerator<br />
51.6<br />
1197<br />
52.8<br />
1106<br />
0.8%<br />
Before Shutdown<br />
Agglomerator<br />
48.8<br />
460<br />
54.8<br />
888<br />
93.0%<br />
Percentage Increase<br />
-5.4%<br />
-58.1%<br />
3.8%<br />
-19%
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WATSON 2 YEAR OPACITY TREND<br />
40<br />
35<br />
30<br />
A Opacity<br />
B Opacity<br />
Opacity<br />
25<br />
%<br />
20<br />
15<br />
10<br />
5<br />
0<br />
Mar-03 Jul-03 Nov-03 Mar-04 Jul-04 Nov-04 Mar-05<br />
Date
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HAMMOND STACK TESTS OCTOBER 2004<br />
MEASUREMENT UNIT 2 UNIT 3 REDUCTION<br />
PARTICULATE<br />
Grains/Act. Cubic Ft. 0.0038 0.0015 60%<br />
#/mmBtu 0.0124 0.0050 60%<br />
FLOW<br />
Actual Cubic Ft/Min 540,000 486,000<br />
GAS TEMPERATURE<br />
Degrees F. 261 253
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HAMMOND PARTICLE SIZE COMPARISON<br />
Average of Unit 2 and Unit 3 Slip and % change<br />
18.00<br />
16.00<br />
Unit 2<br />
Unit 3<br />
% Change<br />
900%<br />
800%<br />
14.00<br />
700%<br />
12.00<br />
600%<br />
10.00<br />
500%<br />
8.00<br />
400%<br />
6.00<br />
300%<br />
4.00<br />
200%<br />
2.00<br />
100%<br />
0.00<br />
0%<br />
0.2<br />
0.25<br />
0.3<br />
0.37<br />
0.46<br />
0.56<br />
0.69<br />
0.85<br />
1.05<br />
1.29<br />
1.59<br />
1.95<br />
2.4<br />
2.96<br />
3.64<br />
4.47<br />
5.5<br />
6.77<br />
8.33<br />
10.24<br />
12.6<br />
15.5<br />
19.07<br />
23.46<br />
28.85<br />
35.5<br />
43.67<br />
53.72<br />
66.08<br />
81.29<br />
Particle size<br />
Slip (%
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TARONG INSTALLATION
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SUMMARY<br />
• Four full scale Agglomerators in service<br />
• Two in service for over 2 years<br />
• 225 MW installation on PRB by May 05<br />
• Wide variety of Australian and US coals<br />
• Mass reductions of 30% to over 60%<br />
• Opacity reductions of 50% to over 80%<br />
• PM2.5 reductions of 70% to over 90%
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SUMMARY<br />
• Low capital cost ($8-10/kw installed)<br />
• Short outage duration required (1-6 weeks)<br />
• Short lead time (4-6 months)<br />
• Low operating and maintenance costs<br />
• Low pressure loss (less than 1 inch w.g.)<br />
• Low power consumption (5 kw per 100MW)<br />
equivalent installation
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