BACT Issues – A Technical Perspective Presented to: American Public Power Association APPA New Generation Meeting: Anticipating New Permitting Issues, IGCC Technology Options, Atmospheric Modeling, and Anticipating the Public’s Reaction Presented by: Jennifer Sharp Seinfeld, P.E. Principal Zephyr Environmental Corporation © 2004 Zephyr Environmental Corporation June 28, 2006 Outline of Presentation •References for developing BACT analysis • Overall BACT considerations •Pollutant-specific issues/precedents for PC boilers •Mercury © 2004 Zephyr Environmental Corporation Finding Information • The good news… – A lot of useful relevant information is on the web • The bad news… – A lot of useful relevant information is on the web! © 2004 Zephyr Environmental Corporation Identifying Relevant Projects • RBLC Clearinghouse http://cfpub.epa.gov/rblc/cfm/basicsearch.cfm • National Coal-fired Utility Projects spreadsheet (updated 10/05) – verify accuracy (http://www.epa.gov/ttncatc1/products.html#misc) • DOE Summary of Coal-fired projects (03/06) ( http://www.netl.doe.gov/coal/refshelf/ncp.pdf • Clean Air Task Force - New Coal Plant Opposition Draft and Final Permits (http://www.catf.us/projects/power_sector/new_coal_plant_opposition/permits.php) • Networking • Summaries contained in recently submitted permit applications © 2004 Zephyr Environmental Corporation References for Emission Limits and BACT Discussions • RBLC Clearinghouse • Other permits (final, draft proposed) • Permit applications, related documents, hearing transcripts, written comments and other correspondence • Test/CEMS data from existing units • Acid Rain database for historical SO2 emissions http://www.epa.gov/airmarkets/emissions/prelimarp/index.html • EPA dockets (http://yosemite.epa.gov/oa/EAB_Web_Docket.nsf/) • State and regional databases © 2004 Zephyr Environmental Corporation Important BACT Considerations • Type of unit • Fuel type, sulfur content • Averaging times, different limits for different averaging times • Cost-effectiveness analyses • Startup, shutdown, malfunction emissions • Method of demonstrating ongoing compliance –CEMS –Test methods © 2004 Zephyr Environmental Corporation “Tuning” Periods/Feasibility Studies • The ‘middle ground’ in negotiations • Pros: – Progress toward permit issuance and start of project – Flexibility in not having to be in compliance with a challenging limit immediately • Cons: –Review/regulatory scrutiny continues © 2004 Zephyr Environmental Corporation Planned PC Boiler Installations Plant/Location Description (size, fuel) Status 800 MW; PRB coal Application filed 6/06 Duke Energy Cliffside Steam Station (# 5 and 6), NC 2 800 MW units;N. Appalachian and eastern bituminous coal Application submitted 5/06 Nets out of PSD for SO2 and HF TXU - Big Brown (#3), Monticello (#4), Martin Lake (#4), TX 3 800 MW units; PRB coal Application submitted 4/06 800 MW, PRB and other Permit issued 5/06 2 800 MW units; lignite Application submitted 1/05; contested hearing ended 6/06 750 MW, PRB coal Netted out of Fed PSD for NOx and SO2 Permit issued 12/05; construction started! 850 MW, subbituminous coal Permit issued 1/06 Construction to start in late '06; targeted to go into service '10 275 MW, subbituminous Permit issued 12/04. Funding approved 6/06! 116 MW, PRB Permit issued 1/06 construction began 03/06. 675 MW, PRB coal Permit issued 8/05; scheduled to begin operation in 2010 750 MW, subbituminous coal Permit issued 7/05; netted out of PSD for SO2 was under appeal, 6/06 District Court issued order upholding PSD permit NRG, Limestone #3, TX Sandy Creek Energy Station, TX TXU, Oak Grove (#1, #2), TX CPS of San Antonio, JK Spruce, TX Great Plains Energy, Kansas City P&L, Iatan (#2), MO City Utilities of Springfield Southwest, MO Rocky Mount Power, Hardin Generating Station, MT Big Cajun 2 (#4), LA Xcel Energy Comanche Station (#3), CO © 2004 Zephyr Environmental Corporation Planned PC Boiler Installations (continued) Plant/Location Newmont Nevada Energy, TS plant, NV Peabody Energy Corp Prairie State Generating Station, IL Omaha Public Power Nebraska City Station, NE Longview Power, WV Hastings Utilities, Whelan Energy Center #2, NE Wisconsin Public Service, Weston Plant, WI Intermountain Power Service Corp, UT Plum Point Energy, AR © 2004 Zephyr Environmental Corporation Description (size, fuel) Status 200 MW, PRB coal Permit issued 5/05 Under construction; proposed online date 6/08 2 750 MW, bituminous (can also use Illinois No. 5/6 coal) Permit issued 4/05 Construction not started as of 6/06 660 MW, PRB coal Permit issued 3/05 Construction started 10/05; expected online May '09 600 MW, bituminous Permit issued 3/04 Final settlement on air permit appeal 7/04 220 MW, PRB coal Permit issued 3/04 Construction started summer '05; anticipated online '09 500 MW, PRB coal Approval granted 10/04; appealed but permit upheld; permit finalized 2/06 Construction started 11/04; anticipated online in '08 ~900 MW, PRB coal Permit issued 10/04 (appeal denied due to standing); construction scheduled to begin spring, 2007 800 MW, PRB coal Permit issued 8/03 Construction began 4/06; commercial operation targeted for '10 Planned PC Boiler Installations (continued) Plant/Location MidAmerican Energy (#4),Council Bluffs, IA Bull Mountain Roundup, MT Thoroughbred, KY Louisville G&E, Trimble Station, KY Wisconsin Energy Elm Road, WI (Oak Creek) Peabody Mustang Energy, NM Santee Cooper (#3 & 4), SC © 2004 Zephyr Environmental Corporation Description (size, fuel) 790 MW, PRB coal Status Permit issued 6/03 construction started September 2003; plans to be in service summer '07 2 390 MW, subbituminous Permit issued '03; extension issued 11/05 to 12/06 with more stringent controls; no construction yet 2 750 MW, bituminous Permit issued 10/02; Permit revised 12/02 and 2/05; challenged by Sierra Club 12/05, permit remanded for BACT analysis 750 MW, eastern bituminous draft permit 7/05; (nets out of PSD for NOx and SO2) Approved 3/06; plans to begin construction 7/06 2 615 MW, bituminous Permit issued 1/04; construction began 7/05; proposed in service: first unit in 2009; second in 2010 300 MW, Clean Coal Initiative grant from DOE 2 660 MW, Bituminous 10/04 received DOE grant from DOE. 5/06 news article says project on hold. . Permit issued 2/04; construction underway. April '06 announcement to build another 600MW facility near Kingsburg SC Planned PC Boiler Installations (continued) Plant/Location Unisource Energy Tucson Electric, AZ Black Hills Wygen 2, WY Sand Sage Power, KS Description (size, fuel) Status 2 400 MW units Permit issued 4/02; (netted out of PSD for SO2) under construction; hopes to be online late '06 500 MW, subbituminous 660 MW, PRB Longleaf Energy Associates, GA 2 600 MW, PRB or Central Appalachian bituminous Cornbelt Energy, Prairie Energy Plant, IL 91 MW ; partially funded by DOE to test new coal reburn system for lower NOx emissions © 2004 Zephyr Environmental Corporation Permit issued 9/02 Construction began 8/05, expected finish by early '08 Permit issued 10/02; revised 6/05 Permit 11/04 Permit issued 12/02 SO2 PC BACT Emission Rates Plant/Location Fuel Emission Limit and Type of Scrubber Duke Energy Cliffside Steam Station (# 5 and 6), NC N. Appalachian and eastern bituminous coal TXU - Big Brown (#3), Monticello (#4), Martin Lake (#4), TX PRB subbituminous coal Sandy Creek Energy Station, TX PRB and other coal TXU, Oak Grove (#1, #2), TX Lignite 0.192 (30 day rolling) wet scrubber CPS of San Antonio, JK Spruce, TX PRB coal 0.10 (30 day rolling) 0.06 (12-month rolling) wet scrubber Great Plains Energy, Kansas City P&L, Iatan (#2), MO Subbituminous coal 0.09 (30-day rolling) wet scrubber City Utilities of Springfield Southwest, MO Subbituminous © 2004 Zephyr Environmental Corporation Unknown limits wet scrubber 0.10 (12 month rolling) dry scrubber Comments project nets out of PSD for SO2; no SO2 limits included in PSD application Proposed limit in application 0.10 (12 month rolling) 0.12 (30 day rolling) dry scrubber 0.095 (30-day rolling) dry scrubber Originally limit was 0.12, but was changed to 0.095 during BACT and visibility negotiations. SO2 PC BACT Emission Rates (continued) Plant/Location Rocky Mount Power, Hardin Generating Station, MT Big Cajun 2 (#4), LA Xcel Energy Comanche Station (#3), CO Newmont Nevada Energy, TS plant, NV Fuel PRB PRB coal Emission Limit and Type of Scrubber Comments 0.12 during 18 month optimization period; 0.11 (30-day rolling) thereafter dry scrubber Provides for optimization period 0.10 ( 30 day) wet or dry scrubber Subbituminous coal 0.10 (30 day rolling) dry scrubber PRB coal if S content >0.45%, 0.09 (24-hour rolling) 95% (30-day rolling) If S content <0.45%, 0.065 (24 hr rolling) 91% (30-day) dry scrubber Peabody Energy Corp Prairie State Generating Station, IL Bituminous Omaha Public Power Nebraska City Station, NE PRB coal © 2004 Zephyr Environmental Corporation 0.182 (30-day rolling) wet scrubber 98% control (12-month rolling), effective 18 months after start-up 0.095 (30-day) dry scrubber Permit provides for evaluating both wet and dry scrubbing systems Project netted out of PSD for SO2; limit not considered BACT Different requirements depending on S content; % removal; Not required to wash mine-mouth coal, but required to wash IL No. 5&6 coal SO2 PC BACT Emission Rates (continued) Plant/Location Fuel Emission Limit and Type of Scrubber 0.12 (24-hr rolling) 0.095 (calendar year) part of settlement agreement wet scrubber Longview Power, WV Bituminous Hastings Utilities, Whelan Energy Center #2, NE PRB coal 0.12 (30-day), 1.1 (3-hr rolling) dry scrubber Wisconsin Public Service, Weston Plant, WI PRB coal 0.10 (30-day rolling) 0.09 (12-month rolling) dry scrubber Intermountain Power Service Corp, UT PRB coal 0.09 (30-day) wet scrubber Plum Point Energy, AR PRB coal 0.16 dry scrubber MidAmerican Energy (#4),Council Bluffs, IA PRB coal 0.10 (30 day rolling) dry scrubber Bull Mountain Roundup, MT Subbituminous © 2004 Zephyr Environmental Corporation 0.12 dry scrubber Comments WVDEP stated that the 0.095 was not considered BACT Limits include SSM emissions; also mass limits on 3hr rolling averages Does not include SSM emissions SO2 PC BACT Emission Rates (continued) Plant/Location Fuel Emission Limit and Type of Scrubber Thoroughbred, KY Bituminous 0.167 wet scrubber, wet ESP Wisconsin Energy Elm Road, WI (Oak Creek) Bituminous 0.15 dry scrubber Santee Cooper (#3 & 4), SC Bituminous Black Hills Wygen 2, WY Subbituminous 0.10 (30-day) dry scrubber Sand Sage Power, KS Subbituminous 0.12 (30-day) dry scrubber Longleaf Energy Associates, GA PRB, subbituminous or central Appalachian bituminous 0.12 (30-day) dry scrubber Cornbelt Energy, Prairie Energy Plant, IL © 2004 Zephyr Environmental Corporation 0.13 (annual average) wet scrubber 0.15 wet scrubber Comments BACT being reevaluated PSD avoidance limits SO2 BACT Issues • The basics: – Some type of flue gas desulfurization system (FGD); – SO2 CEMS • For BACT analysis in application, typically expressed in units of lb/MMBtu • Common to have multiple emission limits for different averaging times – Short-term 1 or 3 hrs and/or 24 hrs – Long-term – 30-day and/or annual • Coal washing sometimes raised as an issue • Control efficiency as a permit limit © 2004 Zephyr Environmental Corporation SO2 BACT Issues – Wet vs. Dry Scrubber • Mix of wet and dry scrubbers in recent permits; majority are dry scrubbers • In general, wet scrubbers are more efficient, but dry scrubbers can still obtain approval • Cost-effectiveness arguments necessary? • Some with tuning periods © 2004 Zephyr Environmental Corporation BACT Arguments for Dry Scrubbers • • • • • Infrastructure Maintenance considerations Power and water requirements Market for wet scrubber byproducts Generally, higher ground level concentrations with wet scrubber • Better control of sulfuric acid mist, fine particulates, many HAP emissions from wet scrubber (?) © 2004 Zephyr Environmental Corporation Limits for Dry Scrubbers • Limits for dry are often contested, and have been ratcheted downward – Argument: unrealistic to base SO2 emissions on continuous use of highest sulfur fuel – Use of acid rain data base for typical sulfur content – Examples of recent dry scrubber limits: • City Utilities of Springfield – 0.12 to 0.095 lb/MMBtu (30 day rolling average) • Omaha Public Power Nebraska Cities – 0.10 to 0.095 lb/MMBtu (based on EPA comments) • WI Public Service, Weston 4 – 0.09 lb/MMBtu (12month average) (based on Sierra Club comments) • Newmont Nevada Energy – 0.09 lb/MMBtu, if fuel S content >0.45%; 0.065 lb/MMBtu, if fuel S content <0.45% S © 2004 Zephyr Environmental Corporation NOx PC BACT Emission Rates Plant/Location Fuel Duke Energy Cliffside Steam Station (# 5 and 6), NC N. Appalachian and eastern bituminous coal Emission Limit Comments 0.08 (30 day) application mentions consideration of burning "high NOx" coal TXU - Big Brown (#3), Monticello (#4), Martin Lake (#4), TX PRB subbituminous coal 0.05 (12-month rolling) Sandy Creek Energy Station, TX PRB and other coal 0.07 (30-day rolling) 0.05 (12-month rolling) TXU, Oak Grove (#1, #2), TX Lignite 0.08 (30-day rolling) Must specify 0.05 in proposals; 2-year demonstration period 0.069 (30 day rolling) 0.05 (12-month rolling) Option for optimization study for NOx, PM10, Hg, H2SO4 CPS of San Antonio, JK Spruce, TX PRB coal Great Plains Energy, Kansas City P&L, Iatan (#2), MO Subbituminous coal 0.08 (30 day) City Utilities of Springfield Southwest, MO Subbituminous 0.08 (30-day) Rocky Mount Power, Hardin Generating Station, MT PRB 0.09 (30-day) Big Cajun 2 (#4), LA PRB coal © 2004 Zephyr Environmental Corporation 0.07 (12 month) Provides for optimization period NOx PC BACT Emission Rates (continued) Plant/Location Xcel Energy Comanche Station (#3), CO Fuel Subbituminous coal Emission Limit Comments 0.08 (30 day) Project netted out of PSD for NOx, but limit considered comparable to BACT; includes SSM, except for cold start-ups Newmont Nevada Energy, TS plant, NV PRB coal 0.067 (24-hr rolling) Peabody Energy Corp Prairie State Generating Station, IL Bituminous 0.07 (30-day rolling) Omaha Public Power Nebraska City Station, NE PRB coal interim: 0.12 ; after 18 months, 0.07 Allows for optimization period 0.08 (24-hr) 0.07 (30-day) 0.065 (annual) WVDEP originally had 0.08 (24 hr rolling) as a permit limit; has stated that the 0.065/0.07 limits are not considered BACT PRB coal 0.08 (30-day); for first 18 months after startup, 0.12 (30-day) 18 month demonstration period Wisconsin Public Service, Weston Plant, WI PRB coal 0.07 (30-day rolling) 0.06 (12-month rolling) Limits reduced after appeal Intermountain Power Service Corp, UT PRB coal 0.07 (30-day) Longview Power, WV Bituminous Hastings Utilities, Whelan Energy Center #2, NE © 2004 Zephyr Environmental Corporation NOx PC BACT Emission Rates (continued) Plant/Location Fuel Plum Point Energy, AR PRB coal 0.07 (30-day rolling) MidAmerican Energy (#4),Council Bluffs, IA PRB coal 0.07 (30-day rolling) Bull Mountain Roundup, MT Subbituminous Thoroughbred, KY Bituminous Louisville G&E, Trimble Station, KY Eastern bituminous Wisconsin Energy Elm Road, WI (Oak Creek) Bituminous 0.15 dry scrubber Santee Cooper (#3 & 4), SC Bituminous 0.08 (annual) Black Hills Wygen 2, WY Subbituminous 0.07 (30-day) Sand Sage Power, KS Subbituminous 0.08 (30-day) Longleaf Energy Associates, GA PRB subbituminous or Central Appalachian bituminous 0.07 (30-day) Cornbelt Energy, Prairie Energy Plant, IL © 2004 Zephyr Environmental Corporation Emission Limit Comments 0.07 (24-hr) 0.08 (30-day) Nets out of PSD review for SO2 0.1 18-month tuning period allows for 24-month tuning period NOx BACT Issues • The basics: – Controls: SCR + “combustion controls” – CEMS • Averaging time is critical • Quantity of NOx generated depends on type of coal(?) • Ammonia slip – Approx 3 ppm, annual – Higher short-term - ~10 ppm, hourly • Several permits have optimization studies © 2004 Zephyr Environmental Corporation PM/PM10 PC BACT Emission Rates Plant/Location Duke Energy Cliffside Steam Station (# 5 and 6), NC TXU - Big Brown (#3), Monticello (#4), Martin Lake (#4) Sandy Creek Energy Station TXU Oak Grove (#1, #2), TX CPS of San Antonio, JK Spruce, TX Great Plains Energy, Kansas City P&L, Iatan (#2), MO City Utilities of Springfield Southwest, MO Fuel N. Appalachian and eastern bituminous coal Emission Limit and Type of Controls 0.015 (PM/PM10) for filterable only; no limit proposed for condensible portion or for PM2.5 PRB subbituminous coal 0.015 filterable 0.04 filterable + condensible baghouse PRB and other coal 0.015 filterable 0.04 filterable + condensible baghouse Lignite 0.015 filterable 0.04 filterable + condensible baghouse Comments Application states that little data is available from wet ESPs; and does not propose an emissions limit for PM2.5 or the condensible portion of PM10 750 MW, PRB coal 0.015 (filterable) 0.022 (filterable + condensible PM/PM10) baghouse Option for optimization study for NOx, PM10, Hg, H2SO4 Subbituminous coal 0.015 filterable PM (3-hr rolling) 0.014 filterable PM10 (3-hr rolling) 0.0236 total PM10 (30-day rolling) baghouse Required to have CEMS for PM Subbituminous © 2004 Zephyr Environmental Corporation 0.018 (3-hr) baghouse PM/PM10 PC BACT Emission Rates (continued) Plant/Location Rocky Mount Power, Hardin Generating Station, MT Big Cajun 2 (#4), LA Xcel Energy Comanche Station (#3), CO Newmont Nevada Energy, TS plant, NV Peabody Energy Corp Prairie State Generating Station, IL Omaha Public Power Nebraska City Station, NE Longview Power, WV Fuel PRB PRB coal Subbituminous coal PRB coal Bituminous PRB coal Bituminous © 2004 Zephyr Environmental Corporation Emission Limit and Type of Controls Comments 0.015 (filterable) during optimization period 0.012 (filterable) post optimization 0.024 (filterable and condensible) fabric filter Provides for optimization period 0.015 PM controls depend on which type of scrubber Appears to be only filterable; Method 5 is included in permit 0.013 (filterable PM) 0.012 filterable PM10 0.022 total PM 0.020 total PM10 baghouse 0.012 (24 hr rolling); filterable only Total PM10 (filterable and condensible) factors to be established during stack test 0.015 filterable PM/PM10 0.035 total PM10 ESP, Wet ESP Permit stipulates that total PM/PM10 limit subject to reduction based on stack test data 0.018 filterable and condensible PM/PM10 fabric filter 0.018 6 hr rolling (PM) 0.018 6 hr rolling (PM10, including filterable and condensible) wet scrubber PM/PM10 PC BACT Emission Rates (continued) Plant/Location Fuel Emission Limit and Type of Controls Hastings Utilities, Whelan Energy Center #2, NE PRB coal 0.018, filterable and condensible baghouse Wisconsin Public Service, Weston Plant, WI PRB coal 0.02 PM10 (includes filterable and condensible) Intermountain Power Service Corp, UT PRB coal 0.012 PM10 0.013 PM baghouse Plum Point Energy, AR PRB coal 0.018 baghouse MidAmerican Energy (#4),Council Bluffs, IA PRB coal 0.027 PM 0.025 PM10 (includes condensibles) baghouse Bull Mountain Roundup, MT Subbituminous © 2004 Zephyr Environmental Corporation 0.015 baghouse Comments PM/PM10 PC BACT Emission Rates (continued) Plant/Location Fuel Emission Limit and Type of Controls 0.018 PM (no condensibles) wet scrubber, wet ESP Thoroughbred, KY Bituminous Wisconsin Energy Elm Road, WI (Oak Creek) Bituminous 0.018 wet ESP Santee Cooper (#3 & 4), SC Bituminous 0.015 (PM) 0.018 (PM10) scrubber Unisource Energy Tucson Electric, AZ Type of coal Black Hills Wygen 2, WY Subbituminous 0.012 fabric filter Sand Sage Power, KS Subbituminous 0.015 Fabric filter Longleaf Energy Associates, GA PRB, subbituminous or Central Appalachian bituminous Cornbelt Energy, Prairie Energy Plant, IL © 2004 Zephyr Environmental Corporation 0.015 PM 0.055 PM10 0.033 fabric filter 0.02 (3-hr block) ESP Comments PM BACT Issues • Basic controls: – Dry FGD: • Baghouse – Wet FGD: • ESP or baghouse for primary filterable PM control • In some cases, wet (or polishing) ESPs downstream of the wet FGD are proposed (e.g., Thoroughbred, Duke Energy, Prairie Generating Station) © 2004 Zephyr Environmental Corporation PM BACT Issues • Inconsistency in various permit limits • Measurement method really defines particulate matter – Method 5 or 17– all sizes of PM, filterable – Method 201A – PM10, filterable – Method 202 –condensible or “fine PM” • Method 202 may overstate PM10 emissions, due to ammonia and sulfate compounds created in the sampling system © 2004 Zephyr Environmental Corporation PM BACT Issues • PM/PM10 compliance demonstration – PM CEMS • Performance specifications, PS-11 for PM CEMS • Only measures filterable PM – Typical requirements are periodic tests for PM10 and operational requirements for the PM control device © 2004 Zephyr Environmental Corporation CO/VOC BACT • Control technology - not an issue, but even these limits keep going down • “Good combustion practices”; trade-off with NOx control • CO CEMS; some permits use CO CEMS as a surrogate to estimate VOC emissions © 2004 Zephyr Environmental Corporation Mercury • Not subject to Federal PSD-BACT; no more case-by-case analysis • Subject to CAMR (70 FR 28606, revised 71 FR 33388) • CAMR highlights – – – – New coal-fired units – NSPS, Subpart Da New and existing units – cap and trade Monitoring requirements CEMS certified 90 operating days/180 calendar days after operation for new units © 2004 Zephyr Environmental Corporation Mercury • Some states have more stringent requirements and/or not opt-in to national trading program • Level of detail for application? © 2004 Zephyr Environmental Corporation Summary • Build a good library of information and continue to update it • Careful review of permit application – it will be scrutinized by many! • Careful negotiations with vendors for emission guarantees • Consider: – – – – SSM emissions Averaging periods Method of compliance Optimization periods © 2004 Zephyr Environmental Corporation Contact Information Jennifer Sharp Seinfeld, P.E. Zephyr Environmental Corporation 10420 Little Patuxent Parkway, Suite 320 Columbia, Maryland 21044 410-312-7915 jseinfeld@zephyrenv.com visit us at www.ZephyrEnv.com And www.HazMatAcademy © 2004 Zephyr Environmental Corporation