Control of Sulfur Dioxide Emissions

A number of processes are being used to remove sulfur and sulfur oxides from fuel before combustion and from stack gas after combustion. Most of these efforts concentrate on coal, since it is the major source of sulfur oxides pollution. Physical separation techniques can be used to remove discrete particles of pyritic sulfur from coal. Chemical methods can also be employed for removal of sulfur from coal. 

Fluidized bed combustion of coal can be used to eliminate SO2 emissions at the point of combustion. The process consists of burning granular coal in a bed of finely divided limestone or dolomite maintained in a fluidlike condition by air injection. Heat calcines the limestone to produce CaO, which absorbs SO2 as shown by the following two reactions  

Many processes have been proposed or studied for the removal of sulfur dioxide from stack gas. Several of these are in widespread use. They include throwaway and recovery systems as well as 

Slurries of either lime (Ca(OH)2) or limestone can be injected into stack gas scrubbers downstream from the boilers. With lime, the reaction is 

Ca(OH)2 -F SO2 CaSOj (CaS04)-F H2O and with limestone, the reaction is as follows  

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Control of sulfur dioxide emissions from stationary sources (such as power plants) usually takes one of three forms fuel cleaning, also known as fuel beneficiation removal of sulfur during combustion or flue gas processing. 

While the development of flue gas clean-up processes has been progressing for many years, a satisfactory process is not yet available. Lime/limestone wet flue gas desulfurization (FGD) scrubber is the most widely used process in the utility industry at present, owing to the fact that it is the most technically developed and generally the most economically attractive. In spite of this, it is expensive and accounts for about 25-35% of the capital and operating costs of a power plant. Techniques for the post combustion control of nitrogen oxides emissions have not been developed as extensively as those for control of sulfur dioxide emissions. Several approaches have been proposed. Among these, ammonia-based selective catalytic reduction (SCR) has received the most attention. But, SCR may not be suitable for U.S. coal-fired power plants because of reliability concerns and other unresolved technical issues (1). These include uncertain catalyst life, water disposal requirements, and the effects of ammonia by-products on plant components downstream from the reactor. The sensitivity of SCR processes to the cost of NH3 is also the subject of some concern. 

U.S. Department of Energy, Clean Coal Technology Topical Reports. (1999). Technologies for the Combined Control of Sulfur Dioxide and Nitrogen Oxides Emissions from Coal-Fired Boilers. Report No. 13 (May). Washington, DC U.S. Government Printing Office. 

Since this estimated share pattern was derived mainly from projection of trends (particularly long term trends), it seems appropriate to focus on oil and speculate as to how possible future events might alter its forecast future role. Events related to pollution control tend to indicate increases in petroleum demand. The use of lead free gasoline, for instance, requires additional refinery processing, which in turn consumes more petroleum fuel. Increasingly tighter controls on sulfur dioxide emissions from thermal-electric plants will cause a shift from coal to low sulfur fuel oil if there is no economic flue-gas desulfurization to cope with coals sulfur content. 

The control measures are connected with implementations of different strategies of sulfur dioxide emission abatement. 

Air Pollution. Particulates and sulfur dioxide emissions from commercial oil shale operations would require proper control technology. Compliance monitoring carried out at the Unocal Parachute Creek Project for respirable particulates, oxides of nitrogen, and sulfur dioxide from 1986 to 1990 indicate a +99% reduction in sulfur emissions at the retort and shale oil upgrading faciUties. No violations for unauthorized air emissions were issued by the U.S. Environmental Protection Agency during this time (62). 

Emissions control systems play an important role at most coal-fired power plants. For example, PC-fired plants sited in the United States require some type of sulfur dioxide control system to meet the regulations set forth in the Clean Air Act Amendments of 1990, unless the boiler bums low sulfur coal or benefits from offsets from other highly controlled boilers within a given utiUty system. Flue-gas desulfurization (FGD) is most commonly accomphshed by the appHcation of either dry- or wet-limestone systems. Wet FGD systems, also referred to as wet scmbbers, are the most effective solution for large faciUties. Modem scmbbers can typically produce a saleable waUboard-quaUty gypsum as a by-product of the SO2 control process (see SULFURREMOVAL AND RECOVERY). 

Sulfur Dioxide Emissions and Control. A substantial part of the sulfur dioxide in the atmosphere is the result of burning sulfur-containing fuel, notably coal, and smelting sulfide ores. Methods for controlling sulfur dioxide emissions have been reviewed (312—314) (see also Air POLLUTION CONTROL PffiTHODS COAL CONVERSION PROCESSES, CLEANING AND DESULFURIZATION EXHAUST CONTROL, INDUSTRIAL SULFURREMOVAL AND RECOVERY). 

The new Clean Air Act will result in a permanent 10 million ton reduction in sulfur dioxide (SOj) emissions from 1980 levels. To achieve this, EPA will allocate allowances of one ton of sulfur dioxide in two phases, The first phase, effective January 1, 1995, requires 110 powerplants to reduce their emissions to a level equivalent to the product of an emissions rate = (2,5 lbs of S02/mm Btu) x (the average mm Btu of their 1985-1987 fuel use). Plants that use certain control technologies to meet their Phase 1 reduction requirements may receive a two year extension of compliance until 1997. The new law also allows for a special allocation of 200,000 annual allowances per year each of the 5 years of Phase 1 to powerplants in Illinois, Indiana and Ohio. 

Today s major emissions control methods are sorbent injection and flue gas desulfurization. Sorbent injection involves adding an alkali compound to the coal combustion gases for reaction with the sulfur dioxide. Typical calcium sorbents include lime and variants of lime. Sodium-based compounds are also used. Sorbent injection processes remove 30 to 60% of sulfur oxide emissions. 

Implementation of cleaner production processes and pollution prevention measures can yield both economic and environmental benefits. The following production-related targets can be achieved by measures such as those described above. The numbers relate to the production processes before the addition of pollution control measures. In sulfuric acid plants that use the double-contact, double absorption process, emissions levels of 2 to 4 kilograms of sulfur dioxide... 

Pollution prevention is always preferred to the use of end-of-pipe pollution control facilities. Therefore, every attempt should be made to incorporate cleaner production processes and facilities to limit, at source, the quantity of pollutants generated. The choice of flash smelting over older technologies is the most significant means of reducing pollution at source. Sulfur dioxide emissions can be controlled by ... 

Use of some biomass feedstocks can increase potential environmental risks. Municipal solid waste can contain toxic materials that can produce dioxins and other poisons in the flue gas, and these should not be burned without special emission controls. Demolition wood can contain lead from paint, other heavy metals, creosote, and halides used in presen a-tive treatments. Sewage sludge has a high amount of sulfur, and sulfur dioxide emission can increase if sewage sludge is used as a feedstock. 

Public concerns about air quality led to the passage of the Clean Air Act in 1970 to amendments to that act in 1977 and 1990. The 1990 amendments contained seven separate titles covering different regula-toiy programs and include requirements to install more advanced pollution control equipment and make other changes in industrial operations to reduce emissions of air pollutants. The 1990 amendments address sulfur dioxide emissions and acid rain deposition, nitrous oxide emissions, ground-level ozone, carbon monoxide emissions, particulate emissions, tail pipe emissions, evaporative emissions, reformulated gasoline, clean-fueled vehicles and fleets, hazardous air pollutants, solid waste incineration, and accidental chemical releases. 

In magnesium casting, sulfur dioxide is employed as an inert blanketing gas. Another foundry application is as a rapid curing catalyst for fiirfuryl resins in cores. Surprisingly, in view of the many efforts to remove sulfur dioxide from flue gases, there are situations where sulfur dioxide is deliberately introduced. In power plants burning low sulfur coal and where particulate stack emissions are a problem, a controlled amount of sulfur dioxide injection improves particulate removal. 

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