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Novacon Energy Systems Technology Presentation


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Novacon Energy Systems at: has developed a process for reducing the air pollutants produced by the burning of coal, waste materials, petroleum and other fuels used in power plants, industrial boilers and many other commercial applications.

The process reduces the production of Sulfur Dioxide, Oxidized Mercury, Sulfur Trioxide, and Unburned Carbon released to the atmosphere.
It can also assist in improving combustion efficiency and the plant’s production capacity, adding to overall plant profits.

The Novacon TAMs process involves the introduction of a unique Calcium-based sorbent directly into the combustion zone of the furnace through simple pneumatic injectors.

Novacon Energy Systems development of the use of our patented TAMs sorbent demonstrates to the industry our ability to revolutionize in-furnace sorbent technology. The uniqueness of the process lies in its ability to reduce emissions to a higher degree at lower cost than other technologies now in use.

TAMs are capable of being used at very high combustion temperatures without sintering or losing efficiency and therefore can be used in a wide variety of combustion systems operating at temperatures from 1,600f to 2,600f. It is scalable for use in any size or type furnace, including Circulating Fluidized Bed, Pulverized Coal, Stoker Grate, Rotary Kilns, and industrial process combustors.

We are capable of reducing Sulfur Dioxide by over Ninety Five percent in CFBs at very low Calcium to Sulfur ratios, while simultaneously reducing carbon in ash by at least 30% and oxidized Mercury by over 75%.

We can reduce Sulfur Dioxide by 70 to 80 percent in PCBs at a Ca/S ratio of 2. Higher reductions may be attained, by simply feeding more sorbent to the boiler.

Low Capital, operating, maintenance, and labor costs, equals higher profits.

The Novacon TAMs Multi-Pollutant Control System provides that elusive combination of high performance, low cost, and flexibility that the industry has sought for decades.

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Novacon Energy Systems Technology Presentation

  1. 1. Novacon Energy Systems, Inc. The TAMS Flue Gas Multi-Pollutant Control System For conventional utility boilers, TAMS holds the promise of extending the useful life of the plant while simultaneously reducing emissions and meeting higher future demand for electric power at competitive prices. For smaller utility boilers it would allows for substantial emissions Reductions without the high capital, labor, maintenance, and Operating costs associated with scrubbers. For Circulating Fluidized Bed combustors it would significantly reduce costs, increase efficiency, increase plant output, and provide for very high emissions reductions without additional capital investment. TAMS very low capital cost significantly reduces the financial risks of facilities planning and pollution control cost containment strategies. It may be used in any type of combustor and is applicable to Waste to Energy plants, Paper manufacturing, and many other industrial applications.
  2. 2. THE NOVACON SORBENT INJECTION PROCESS Thermally Active Marble (TAM (c) ) WHAT IS IT ? A specially selected and prepared form of Calcium Carbonate exhibiting greatly increased performance as compared to conventional Limestone,Hydrated lime, Sodium Bicarbonate, and other sorbents
  3. 3. TAMs Dynamics Why does it outperform other in-furnace or in-duct sorbents? <ul><li>DECREPITATES CONTINUOUSLY AT A PREDICTABLE RATE, EXPOSING FRESH SURFACE AREA THAT INCREASES SULFUR CAPTURE (SURFACE AREA IS KEY TO CAPTURE EFFICIENCY AS THIS IS A SELF-EXTINGUISHING REACTION) </li></ul><ul><li>Reactions- SO2 + Ca CO3 = CaSO3 + CO2 [Small amount converted to CaSo4.2H2O+CO2 (Gypsum)]. All CaSO3 may be converted into Gypsum by forced oxidation. </li></ul><ul><li>CAUSES MICRO-TURBULENCE IN THE COMBUSTOR </li></ul><ul><li>INCREASES MIXING OF FUEL AND SORBENT INCREASING EFFICIENCY </li></ul><ul><li>INCREASES CARBON BURNOUT </li></ul><ul><li>SIMULTANEOUSELY REDUCES SO3 AND OXIDIZED MERCURY AS WELL AS SO2 </li></ul>
  4. 4. TAMs Injection into CFB or PCB TAMS can be used in any type of combustor through a simple system consisting of a silo, a metering valve, and pneumatic injectors. Drawing shows schematic for the majority of installed boiler types Works well in Stoker-Grate, Rotary Kiln and Mixed-with-Coal- Systems
  5. 5. Novacon Process Schematic for P.C.B. boilers For C.F.B.s no equipment needed since they are already equipped for limestone injection Feed Stone Supply Grinding & Processing Equipment Grinding & Processing Equipment Two production lines for increased reliability TAMs Silo Variable speed Feeder Boiler Combustor Injectors * * Closed-Loop Control System Feed rates would be automatically controlled by CEMS stack sensor data vs. Emissions Set-Point
  6. 6. THE ADVANTAGES OF THE NOVACON TAMs FLUE GAS DESULFURIZATION SYSTEM FOR PULVERIZED COAL BOILERS (PCB) <ul><li>Can reduce SO2 emissions by 73-78% @ a Ca/S ratio of 2 ( higher at increased feed rates) </li></ul><ul><li>Can be installed quickly and easily with less than one day plant down time </li></ul><ul><li>It is extremely inexpensive to install. In a typical 500 megawatt PCB, the total capital cost (in U.S) would be 5 to 7 million dollars (much less for smaller plants) </li></ul><ul><li>Significant economies of scale in multi boiler facilities where material preparation equipment can be scaled to great economic advantage </li></ul><ul><li>Inexpensive to operate and maintain (minimal labor cost) </li></ul><ul><li>Material has proven to be substantially less fouling on boiler surfaces </li></ul><ul><li>The process can remove at least 75% of oxidized Hg emissions </li></ul><ul><li>Resultant ash streams have lower acidity (more environmentally friendly) </li></ul><ul><li>Reduces corrosion throughout the system and provides an ash that is more readily saleable </li></ul><ul><li>The process is compatible with all known NO2 and Carbon control systems </li></ul><ul><li>Equipment has very small real estate footprint </li></ul><ul><li>Process can be used with many fuels of varying sulfur content </li></ul><ul><li>Process can be successfully utilized in all combustor types </li></ul><ul><li>Older power plants can be operated economically while greatly reducing emissions, without having to install expensive scrubbers </li></ul>
  7. 7. Comparison of TAMs to Limestone in Pulverized Coal Boiler Demonstrations Firing 2.48% Sulfur Bituminous Coal % SO 2 Capture at Ca/S of 2 Test performed under the sponsorship of the U.S. Dept. of Energy and The Illinois Clean Coal Institute at EERC (General Electric). Over 500 limestones tested in this program. Showed 78% reductions @ 2 CA/S at Penn State firing same coal.
  8. 8. THE ADVANTAGES OF TAMs IN CIRCULATING FLUIDIZED BED (CFB) COMBUSTORS IN PLACE OF LIMESTONE <ul><li>No capital costs involved </li></ul><ul><li>When used in CFBs, sorbent use is reduced by 30 to 50% for equivalent reductions in SO2 </li></ul><ul><li>Much coarser grind required - saving energy </li></ul><ul><li>Lowering of the Ca to S ratio allows the process to be effective where +95% removal rates are required </li></ul><ul><li>Carbon-in-ash streams are reduced by 30% or more </li></ul><ul><li>Fuel costs can be reduced by approximately 3% </li></ul><ul><li>Reduction in the throughput of inert materials reduces plant maintenance and labor </li></ul><ul><li>Will increase plant production capacity by reducing sorbent consumption- Less inert material, more fuel per hour </li></ul><ul><li>Due to the lower L.O.I.- the final ash streams are more saleable and easier to re-purpose or dispose of (also less toxic) </li></ul>
  9. 9. CFB Pilot Scale Test Please note: SO2 reductions with TAMS higher by 1.8% Difference in feed rates would have been higher at same reduction rate Results of Demonstrations in CFB Power Plants Ca/S ratios required to meet SO2 reduction targets. Over 1 year in use at Foster Wheeler, AES, Tampella,
  10. 10. Superior Performance allows the option of using less expensive higher-sulfur fuels in CFBs while still meeting very stringent emission standards <ul><li>Sorbent consumption declines by up to 50% and the system can reduce SOx emissions by over 95% (this plant required only 90% reduction) </li></ul><ul><li>Unburned carbon-in-ash can be reduced by over 30% which will increase overall plant efficiency and reduce fuel costs by up to 3% </li></ul><ul><li>The emission of oxidized mercury will decrease by over 75% </li></ul><ul><li>TAMs will eliminate the production of Arsenic and SO 3 which fouls NOx control systems (SCR & NSCR catalysts) </li></ul>
  11. 11. TAMs Compared to Other Sorbents Higher temperature tolerance without sintering and flatter curve This allows it to be injected closer to the flame which increases residence time and assures higher mixing efficiencies of SO2, coal, and sorbent Temperature conversion- 2200 F = 1204 C 2300 F = 1260 C 2400 F = 1316 C 2500 F = 1370 C
  12. 12. Tests run at EERC Key Operating Results Firing 2.5% Sulfur Illinois Coal (EERC is a subsidiary of General Electric) 2450 F = 1343 C Flue gas V = 2.15 m/s
  13. 13. Cost/Benefit Issues and Implications <ul><li>More than half of a power plant’s operating expenses are fuel costs </li></ul><ul><li>Fuel transportation cost can be as much as half of total cost </li></ul><ul><li>Local higher-sulfur coals can be used in place of low sulfur coals that may have to be shipped from thousands of miles away from the plant </li></ul><ul><li>Blending coals to achieve emissions standards is expensive, both from a capital equipment and labor viewpoint </li></ul><ul><li>Low sulfur fuel is available at higher cost, as compared to the TAMS process used with higher sulfur fuel </li></ul><ul><li>In many cases it would reduce the need for importing low sulfur coal or shipping fuel long distances, preserving coal mining jobs, while creating new ones in limestone mining, transportation and processing. </li></ul>
  14. 14. TAMs (c) Can be used at Coal and Oil Burning Power Plants as the Transformation Technology to a Cleaner, Greener Environment