The Effects of Oxy-firing Conditions on Gas-phase Mercury Oxidation by Chlorine and Bromine Topical Report Reporting Period Start Date: April 2009 Report Period End Date: June 2010 Principal Authors: Paula A. Buitrago and Geoffrey D. Silcox Issue date: October 2010 DOE Award Number: DE-NT0005015 Project Officer: David Lang University of Utah Department of Chemical Engineering 50 S. Central Campus Drive, MEB 3290 Salt Lake City, Utah i DISCLAIMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. ii ABSTRACT Bench-scale experiments were conducted in a quartz-lined, natural gas-fired reactor with the combustion air replaced with a blend of 27 mole percent oxygen, with the balance carbon dioxide. Quench rates of 210 and 440 K/s were tested. In the absence of sulfur dioxide, the oxy-firing environment caused a remarkable increase in oxidation of mercury by chlorine. At 400 ppm chlorine (as HCl equivalent), air-firing results in roughly 5 percent oxidation. At the same conditions with oxy-firing, oxidation levels are roughly 80 percent. Oxidation levels with bromine at 25 and 50 ppm (as HBr equivalent) ranged from 80 to 95 percent and were roughly the same for oxy- and air-firing conditions. Kinetic calculations of levels of oxidation at air- and oxy-conditions captured the essential features of the experimental results but have not revealed a mechanistic basis for the oxidative benefits of oxy-firing conditions. Mixtures of 25 ppm bromine and 100 and 400 ppm chlorine gave more than 90 percent oxidation. At all conditions, the effects of quench rate were not significant. The presence of 500 ppm SO2 caused a dramatic decline in the levels of oxidation at all oxy-fired conditions examined. This effect suggests that SO2 may be preventing oxidation in the gas phase or preventing oxidation in the wetconditioning system that was used in quantifying oxidized and elemental mercury concentrations. Similar effects of SO2 have been noted with air-firing. The addition of sodium thiosulfate to the hydroxide impingers that are part of wet conditioning systems may prevent liquid-phase oxidation from occurring. iii TABLE OF CONTENTS DISCLAIMER .................................................................................................................... ii ABSTRACT ....................................................................................................................... iii LIST OF FIGURES ............................................................................................................ v LIST OF ABBREVIATIONS ............................................................................................ vi EXECUTIVE SUMMARY .............................................................................................. vii INTRODUCTION .............................................................................................................. 1 METHODS ......................................................................................................................... 1 RESULTS AND DISCUSSION ......................................................................................... 5 Effects of Oxy-firing on Gas-phase Mercury Oxidation by Chlorine and Bromine....... 6 Effects of SO2 ............................................................................................................... 10 CONCLUSIONS............................................................................................................... 11 REFERENCES ................................................................................................................. 13 iv LIST OF FIGURES Figure 1. Sketch of the homogeneous mercury reactor (Fry et al., 2006). Figure 2. Temperature profiles in the homogeneous mercury reactor. Figure 3. Mercury analysis system (Fry et al., 2006). Figure 4. Extents of oxidation by bromine and chlorine with air-firing and no SO2. Figure 5. Extents of oxidation with oxy-firing, chlorine, and no SO2. Figure 6. Kinetic calculations showing predicted effects of oxy-firing with chlorine in the absence of SO2. Chlorine concentrations are as ppm HCl equivalent. Figure 7. Oxidation of elemental mercury with oxy-firing, bromine, and no SO2. Figure 8. Mercury oxidation with oxy-firing, mixtures of bromine and chlorine, and no SO2. Figure 9. Mercury oxidation by chlorine and bromine with oxy-firing in the presence of SO2. v LIST OF ABBREVIATIONS Br Bromine Cl Chlorine ESP Electrostatic precipitators HCl Hydrochloric acid Hgp Particle-bound mercury Hg++ Oxidized mercury Hgo Elemental mercury HgCl2 Mercuric chloride NO Nitric oxide NO2 Nitrogen dioxide SCR Selective catalytic reduction SLPM Standard liters per minute SO2 Sulfur dioxide vi EXECUTIVE SUMMARY The fate and speciation of mercury in oxy-coal combustion processes is of particular interest because trace amounts of mercury lead to the embrittlement and cracking of aluminum heat exchangers that are used in the cryogenic separation and compression of carbon dioxide. Mercury exists in three forms in coal-derived flue gas: particle-bound (Hgp), oxidized (Hg++), and elemental (Hgo). The oxidized form is desirable because it is more readily removed by adsorption on solids and is more readily captured by absorption in wet flue gas desulfurization scrubbers. The adsorbed, particle-bound mercury is removed by electrostatic precipitators (ESPs) or fabric filters. Oxidized mercury is primarily mercuric chloride (HgCl2) and its formation depends on the halogen content of the coal and the existence of catalytic surfaces that enable oxidation. The latter include unburned carbon and SCR reactors. This report focuses on the homogeneous, gas-phase oxidation of mercury by bromine and chlorine under oxyfiring conditions. There is a dearth of oxy-fired, mercury-oxidation results for gas-phase and heterogeneous conditions. Oxy-coal experiments conducted in a 1.5 MW facility (Imada et al., 2010) showed 75 % mercury removal across the ESP with oxy-firing and 63 % with air-firing. The temperature of the ESP and the sulfur content of the coal were key factors affecting removal. Lower temperature and lower sulfur content led to higher removal. The recycle of flue gas in oxy-coal systems led to higher mercury concentrations at the inlet to the ESP. Bench-scale experiments were conducted at the University of Utah in a quartz-lined, natural gas-fired reactor with the combustion air replaced with a blend of 27 mole percent oxygen, balance carbon dioxide. Quench rates of 210 and 440 K/s were tested. In the absence of sulfur dioxide, the oxy-firing environment caused an increase in oxidation of mercury by chlorine. At 400 ppm chlorine (as HCl equivalent), air-firing results in roughly 5 percent oxidation. At the same conditions with oxy-firing, oxidation levels are roughly 80 percent. Oxidation levels with bromine at 25 and 50 ppm (as HBr equivalent) ranged from 80 to 95 percent and were roughly the same for oxy- and air-firing conditions. Kinetic calculations of levels of oxidation at air- and oxy-conditions captured the essential features of the experimental results but have not revealed a mechanistic basis for the oxidative benefits of oxy-firing conditions. Mixtures of 25 ppm bromine and 100 and 400 ppm chlorine gave more than 90 percent oxidation. At all conditions, the effects of quench rate were not significant. The presence of 500 ppm SO2 caused a dramatic decline in the levels of oxidation at all oxy-fired conditions examined. This effect suggests that SO2 may be preventing oxidation in the gas phase or preventing oxidation in the wet-conditioning system that was used to quantify elemental and oxidized mercury concentrations. Similar effects of vii SO2 have been noted with air-firing. The addition of sodium thiosulfate to the hydroxide impingers that are part of wet conditioning systems may prevent liquid-phase oxidation from occurring. An evaluation of several potential pathways that gave rise to the positive effects of oxyfiring on oxidation did not reveal an understanding of the mechanism. It is possible that the replacement of N2 by CO2 results in higher collision efficiencies in the key, ratecontrolling reaction for oxidation: Hg + Cl + M = HgCl + M (1) In other words, CO2 is more effective at removing energy from the HgCl transition state complex than N2. It is also possible that the decreased levels of NO and NO2 that occur with oxy-firing remove a reaction that is consuming Cl atoms (Bozzelli, 2010), e.g., NO + Cl = NOCl (2) The kinetic calculations do not consider the identity of the third body, M, in Reaction 1 and hence this explanation cannot be supported by the calculations. Calculations in which Reaction 2 is removed do not increase the level of oxidation at air-firing conditions. Additional possible reactions involving NO, Cl, and HgCl include (Bozzelli, 2010) NO + HgCl = NOCl + Hg HCl + NO = NOCl + H Cl + NOCl = Cl2 + NO The decreased levels of NO at oxy-firing conditions would diminish the importance of these reactions in removing Cl radicals from the mercury oxidation process and prevent the destruction of the vital intermediate, HgCl. A fundamental understanding of the experimental and theoretical observations in this study is still incomplete. viii INTRODUCTION The fate and speciation of mercury in oxy-coal combustion processes is of particular interest because trace amounts of mercury lead to the embrittlement and cracking of aluminum heat exchangers that are used in the cryogenic separation and compression of carbon dioxide. Mercury exists in three forms in coal-derived flue gas: particle-bound (Hgp), oxidized (Hg++), and elemental (Hgo). The oxidized form is desirable because it is more readily removed by adsorption on solids and is more readily captured by absorption in wet flue gas desulfurization scrubbers. The adsorbed, particle-bound mercury is removed by ESP’s or fabric filters. Oxidized mercury is primarily mercuric chloride (HgCl2) and its formation depends on the halogen content of the coal and the existence of catalytic surfaces that enable oxidation. The latter include unburned carbon and SCR reactors. This report focuses on the homogeneous, gas-phase oxidation of mercury by bromine and chlorine under oxyfiring conditions. There is a dearth of oxy-fired, mercury-oxidation results for gas-phase and heterogeneous conditions. Oxy-coal experiments conducted in a 1.5 MW facility (Imada et al., 2010) showed 75 % mercury removal across the ESP with oxy-firing and 63 % with air-firing. The temperature of the ESP and the sulfur content of the coal were key factors affecting removal. Lower temperature and lower sulfur content led to higher removal. The recycle of flue gas in oxy-coal systems led to higher mercury concentrations at the inlet to the ESP. METHODS The homogeneous mercury reactor is shown schematically in Figure 1 along with associated equipment. The reactor consists of a 50-mm OD x 47-mm ID quartz tube (132 cm in length) located along the center of a high-temperature Thermcraft heater. The tube extends 79 cm below the heater, is temperature controlled, and has a quartz sampling section attached at the bottom with a capped end. The peak gas temperature in the electrically heated zone was about 1080C. The reactor was operated with two temperature or quench profiles: 210 and 440 K/s. The former will be referred to as low quench (LQ) and the latter as high quench (HQ). The air-fired profiles are given in Figure 2 and were obtained by adjusting the current supplied to the heaters surrounding the bottom 79 cm of the quartz tube. The effect of oxy-firing on temperatures and temperature profiles was not determined although temperatures should be modestly lower because of the higher heat capacity of CO2 (37.3 J/mol-K at 300 K) relative to that of N2 (29.1 J/mol-K at 300K). A 300-W, methane-fired, premixed burner made of quartz glass supplied realistic combustion gasses to the reactor. All reactants were introduced through the burner and 1 passed through the flame to create a radical pool representative of real combustion systems. The burner provided 3.7 SLPM of combustion gases. To study the effects of flue gas components such as SO2, NO, NO2, HCl, and HBr, different concentrations of these or related species were introduced through the burner. A Tekran 2537A Mercury Analyzer, coupled with a wet sample conditioning system designed by Southern Research Institute (SRI), provided measurement of total and elemental mercury in the exhaust gas and is shown in Figure 3. Sample gas was pulled in two streams from the last section of the quartz-lined reactor into a set of conditioning impingers. In the standard configuration of the conditioning system, one stream was bubbled through a solution of stannous chloride to reduce the oxidized mercury to elemental form, followed by a solution of sodium hydroxide to remove acid gases. This stream was analyzed to give the total mercury concentration in the sample. The second stream was treated with a solution of potassium chloride to remove oxidized mercury species, followed by a solution of sodium hydroxide for acid gas removal. Sodium thiosulfate was added to the KCl impinger (Cauch et al., 2008) to prevent the liquidphase oxidation of elemental mercury by Cl2 and Br2. The KCl-washed stream was analyzed to give the elemental mercury concentration in the sample. Oxidized species were calculated by the difference between total and elemental mercury concentrations. A chiller removed water from the sample gas and each stream was intermittently sent to the analyzer. The experiments were performed with different dopants added through the burner. Before adding these, the baseline mercury level at the furnace outlet was checked using a material balance. Because of limited time and materials, the experiments were performed only once. Table 1 gives the baseline, air-fired flue gas composition for the experiments on a dry basis. The gas composition was not intended to duplicate the flue gas in coal-fired power plants; the intent of this work was to study reactions of mercury and common flue gas species in a well-controlled system. All species that were added to the reactor (SO2, Cl2, Hg0, and Br2) passed through the flame. Their subsequent speciation depended on flame chemistry as well as on the temperature profile in the reactor. The effects of oxy-firing on flue-gas composition were not independently measured with gas analyzers as they were for the air-fired results in Table 1. For the oxy-fired experiments, the air was replaced with a mixture of 27 percent oxygen and 73 percent CO2, and the amount added was calculated to give the same oxygen level, 1.0 percent, as in the air-fired tests. This mixture composition, 27 percent O2 and 73 percent CO2, was chosen to match typical industrial conditions. At the oxy-fired conditions, nitrogen still entered the system through the bottled Cl2, Br2, and SO2 gases that were added through the burner. The bromine bottle was 3000 ppm Br2 in air and the chlorine bottle was 6000 Cl2 in air. Sulfur dioxide was also 6000 ppm in air. The concentration of NOx was not measured and NO and NO2 were not added to the reactor because their effects on mercury oxidation in parallel, air-fired tests were 2 negligible. Under oxy-firing conditions, the temperature profiles and gas compositions in the reactor were not measured and probably differ somewhat from those shown in Figure 2. Compressed Air Filters Pressure Regulator Flashback Arrestor PS Analytical Mercury Cal Gas Generator Solenoid Valve Support Tee & Blowoff Nozzle Mass Flow Controllers Cl2/ Air Cal Gas SO2/ Air Cal Gas Purge Nozzle Thermcraft Heater Rotameter CH4 UV Detector NO Inswool O2 Analyzer Data Acquisition Temperature Controllers Heat Tape 2 NO Analyzer CO Analyzer Heat Tape 1 Heat Tape 3 Mercury Analysis System Heat Tape 4 CO2 Analyzer Figure 1. Sketch of the homogeneous mercury reactor (Fry et al., 2006). 3 1200 Temperature, oC 1000 Low Quench ~210 K/s 800 600 High Quench ~440 K/s 400 200 0 0 1 2 3 4 5 6 7 8 Time, sec Figure 2. Temperature profiles in the homogeneous mercury reactor. PS Analytical Mercury Cal Gas Generator Mercury Reactor HgT Tekran 2537A Mercury Analyzer Hg0 SnCl2 KCl Intermittent Hg0 and HgT Chiller NaOH 4 Port Sampler NaOH Peristaltic Pump NaOH SnCl2 KCl NaOH Fresh Reagents To NOx, CO2, CO and O2 Analyzers Hg0 Vacuum Pump Waste Reagents NaOH SnCl2 KCl NaOH HgT Figure 3. Mercury analysis system (Fry et al., 2006). 4 Table 1. Air-fired flue gas compositions (dry basis). Species O2 H2O CO2 NO SO2 HCl* HBr** Hg0 Concentration 0.8 vol% 16.5 vol% 7.7 vol% 30, 500 ppmv 0-500 ppmv 0-500 ppmv 0-50 ppmv 25 µg/Nm3 (1 atm and 0C) *Assuming all chlorine added as HCl **Assuming all bromine added as HBr The differential equations describing the gas-phase chemical kinetics of mercury oxidation were integrated using CHEMKIN and compared with results from a stiff integrator, REKS, developed by Reaction Engineering International. The two sets of calculations agree, but only those from REKS are shown below because the University of Utah had more experience with REKS and CHEMKIN provided somewhat inconsistent results. CHEMKIN and REKS include modules for the simulation of plug-flow (PFR) and completely stirred tank (CSTR) reactors. The calculations performed in this study used a CSTR to represent the burner and a PFR to represent the heat and quench sections of the University of Utah facility. The temperature profiles shown in Figure 2 were used as input and the feed streams to the CSTR were chosen to match the experimental conditions. RESULTS AND DISCUSSION Typical U of U, air-fired, gas-phase oxidation results with the high quench profile and a baseline mercury concentration of 25 µg/m3 are shown in Figure 4. Bromine is clearly a superior oxidant at these conditions with oxidation levels ranging from 30 to 80 percent at bromine concentration from 20 to 50 ppm bromine (as HBr equivalent). The extent of oxidation by chlorine ranges from 2 to 7 percent at 100 to 500 ppm chlorine (as HCl equivalent). The results in Figure 4 were obtained in the absence of SO2. 5 Figure 4. Extents of oxidation by bromine and chlorine with air-firing and no SO2. Effects of Oxy-firing on Gas-phase Mercury Oxidation by Chlorine and Bromine Replacement of the air with a mixture of 27 % oxygen, balance carbon dioxide, has a dramatic effect on the ability of chlorine to oxidize mercury. Figure 5 shows gas-phase oxidation levels with oxy-firing of 70 to 80 % at 100 and 400 ppm chlorine (as HCl equivalent). Oxidation levels with bromine at 25 and 50 ppm (as HBr equivalent) range from 70 to 100 %. The results in Figure 5 were obtained in the absence of SO2. 6 Figure 5. Extents of oxidation with oxy-firing, chlorine, and no SO2. The surprisingly high levels of oxidation by chlorine are compared to kinetic calculations in Figure 6. The two air-firing curves are for the high and low quench rates and show levels of oxidation that are similar to those in Figure 4. The two oxy-firing curves show predicted levels of oxidation ranging from 60 to almost 100 percent. After investigating several potential pathways that give rise to the positive effects of oxyfiring on oxidation, the kinetics are still not understood. It is possible that the replacement of N2 by CO2 results in higher collision efficiencies in the key, rate controlling reaction for oxidation: Hg + Cl + M = HgCl + M (1) In other words, CO2 is more effective at removing energy from the HgCl transition state complex than N2. The kinetic calculations do not consider the identity of the third body, M, in Reaction 1 and hence an explanation in terms of the efficiency of third-body collisions cannot be supported by the calculations. It is also possible that the decreased levels of NO that occur with oxy-firing diminish the significance of a reaction that is consuming Cl atoms (Bozzelli, 2010), e.g., NO + Cl = NOCl (2) Calculations in which Reaction 2 is removed do not increase the level of oxidation at airfiring conditions. 7 Additional possible reactions involving NO, Cl, and HgCl include (Bozzelli, 2010) NO + HgCl = NOCl + Hg HCl + NO = NOCl + H Cl + NOCl = Cl2 + NO The decreased levels of NO at oxy-firing conditions would diminish the importance of these reactions in removing Cl radicals from the mercury oxidation process and prevent the destruction of the vital intermediate, HgCl. A fundamental understanding of the experimental and theoretical results in Figures 5 and 6 is still not available. Oxy-firing, high quench Oxy-firing, low quench Air-firing, high quench Air-firing, low quench Figure 6. Kinetic calculations showing predicted effects of oxy-firing with chlorine in the absence of SO2. Chlorine concentrations are as ppm HCl equivalent. Figure 7 shows gas-phase oxidation levels with oxy-firing and bromine as a function of quench rate and bromine concentrations. The levels of oxidation are insensitive to quench rate and range from 75 to 100 percent as bromine concentration is increased from 25 to 50 ppm (as HBr equivalent). 8 Figure 7. Oxidation of elemental mercury with oxy-firing, bromine, and no SO2. The effects of mixtures of bromine and chlorine with oxy-firing on oxidation are shown in Figure 8. The presence of 25 ppm bromine (as HBr equivalent) and chlorine concentrations from 100 to 400 ppm (as HCl equivalent) resulted in higher levels of oxidation that when just bromine or chlorine was present. Changing the chlorine concentration from100 to 400 ppm had no effect on the levels of oxidation. 9 Figure 8. Mercury oxidation with oxy-firing, mixtures of bromine and chlorine, and no SO2. Effects of SO2 The results in Figures 4 to 8 were obtained in the absence of SO2. At 500 ppm SO2, the encouraging oxy-fired results in Figures 4 to 8 are replaced with the results in Figure 9. The ability of chlorine and bromine to oxidize mercury drops dramatically. A mechanistic explanation of these results may involve gas-phase reactions between the halogen atoms and SO2. A second explanation involves aqueous-phase reactions that are interfering with the conditioning system and the analysis of mercury by the atomic fluorescent analyzer used in this study (Tekran 2537A Mercury Analyzer). It is believed that the aqueous reactions can be controlled by adding reducing agents such as sodium thiosulfate to the sodium hydroxide impinger solutions. The results in Figure 4 to 8 may be due to oxidation of elemental mercury in the hydroxide impingers. The KCl impinger solution is already treated with sodium thiosulate (Cauch et al., 2008) to prevent halogens from oxidizing mercury. Sulfur dioxide also acts as a reducing agent; hence, the hypothesis that the results in Figure 9 are an artifact of the wet conditioning system. 10 Figure 9. Mercury oxidation by chlorine and bromine with oxy-firing in the presence of SO2. CONCLUSIONS Bench-scale experiments were conducted in the University of Utah’s quartz-lined, natural gas-fired reactor with the combustion air replaced with a blend of 27 mole percent oxygen and 73 percent carbon dioxide. In the absence of sulfur dioxide, the oxy-firing environment caused an increase in oxidation of mercury by chlorine. At 400 ppm chlorine (as HCl equivalent), air-firing results in roughly 5 percent oxidation. At the same conditions with oxy-firing, oxidation levels are roughly 80 percent. Oxidation levels with bromine at 25 and 50 ppm (as HBr equivalent) ranged from 80 to 95 percent and were roughly the same for oxy- and air-firing conditions. Kinetic calculations of levels of oxidation at air- and oxy-conditions captured the essential features of the experimental results but have not revealed a mechanistic basis for the oxidative benefits of oxy-firing conditions. Mixtures of 25 ppm bromine and 100 and 400 ppm chlorine gave more than 90 percent oxidation. At all conditions, the effects of quench rate were not significant. The presence of 500 ppm SO2 caused a dramatic decline in the levels of oxidation at all oxy-fired conditions examined. This effect suggests that SO2 may be preventing oxidation in the gas phase or preventing oxidation in the wet-conditioning system that was used in quantifying oxidized and elemental mercury concentrations. Similar effects of SO2 have been noted with air-firing. The addition of sodium thiosulfate to the hydroxide impingers that are part of wet conditioning systems may prevent liquid-phase oxidation from occurring. 11 These results imply that oxy-firing conditions may greatly enhance the gas-phase oxidation of mercury by chlorine and emphasize the importance of preventing liquidphase oxidation of elemental mercury in wet conditioning systems. It is recommended that sodium thiosulfate be added to the hydroxide impingers that are typically part of wet conditioning systems. Additional bench-scale testing is needed to verify the positive effects of oxy-firing on gas-phase mercury oxidation and the negative effects of SO2. Small, pilot-scale testing with pulverized coal is needed to explore the importance of surface effects and catalysis by unburned char. 12 REFERENCES 1 Bozzelli, J. W. Department of Chemistry and Environmental Science, New Jersey Institute of Technology. Private communication. 2010. 2 Cauch, B.; Silcox, G.; Lighty, J.; Wendt, J.; Fry, A.; Senior, C. Confounding Effects of Aqueous-Phase Impinger Chemistry on Apparent Oxidation of Mercury in Flue Gases. Environ. Sci. Technol. 2008, 42(7), 2594–2599. 3 Fry, A.; Cauch, B.; Lighty, J. S.; Silcox, G. D.; Senior, C. L. Experimental Evaluation of the Effects of Quench Rate and Quartz Surface Area on Homogeneous Mercury Oxidation. Thirty-First Symposium (International) on Combustion. The Combustion Institute: Pittsburgh, PA, 2006. 4 Imada, N., H. Kikkawa, K. Kobayashi, N. Oda, “Study of Mercury Behavior in Flue Gas of Oxy-fuel Combustion,“ The 35th International Technical Conference on Clean Coal & Fuel Systems, Clearwater, Florida, June 6 to 10, 2010. 13