Sulfur stack

Selection of pollution control methods is generally based on the need to control ambient air quaUty in order to achieve compliance with standards for critetia pollutants, or, in the case of nonregulated contaminants, to protect human health and vegetation. There are three elements to a pollution problem a source, a receptor affected by the pollutants, and the transport of pollutants from source to receptor. Modification or elimination of any one of these elements can change the nature of a pollution problem. For instance, tall stacks which disperse effluent modify the transport of pollutants and can thus reduce nearby SO2 deposition from sulfur-containing fossil fuel combustion. Although better dispersion aloft can solve a local problem, if done from numerous sources it can unfortunately cause a regional one, such as the acid rain now evident in the northeastern United States and Canada (see Atmospheric models). References 3—15 discuss atmospheric dilution as a control measure. The better approach, however, is to control emissions at the source. 

Other developing or potential appHcations for lime are neutralization of tail gas from sulfuric acid plants, neutralization of waste hydrochloric and hydrofluoric acids and of nitrogen oxide (NO ) gases, scmbbing of stack gases from incinerators (qv), and of course, from small industrial coal-fired boilers. 

L. B. Heia, A. B. Phillips, and R. D. Young, "Recovery of Sulfur Dioxide from Coal Combustion Stack Gases," ia F. S. MaHette, ed. Problems and Control of A.ir Pollution, Reioliold Publishing Corporation, New York, 1955, pp. 155—169. 

Re OPe from Flue Gases. Recovery of sulfur dioxide from flue gases has been described (25,93,227). The stack gas from smelting often contains sufficient sulfur dioxide (ca 6 wt %) for economic conversion to sulfuric acid the lower concentration ki power plant stack gases generally requkes some method for concentrating the sulfur dioxide. 

The Reich test is used to estimate sulfur dioxide content of a gas by measuring the volume of gas required to decolorize a standard iodine solution (274). Equipment has been developed commercially for continuous monitoring of stack gas by measuring the near-ultraviolet absorption bands of sulfur dioxide (275—277). The deterrnination of sulfur dioxide in food is conducted by distilling the sulfur dioxide from the acidulated sample into a solution of hydrogen peroxide, foUowed by acidimetric titration of the sulfuric acid thus produced (278). Analytical methods for sulfur dioxide have been reviewed (279). 

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

R. S. Saltzman, Challenges in Stack Sulfur Emissions Measurements, paper presented at 30th Annual Petroleum Mechanical Engineering Conference, Tulsa, OHa., Sept. 21-25,1975. 

In early years the contact process frequentiy employed only two or three catalyst stages (passes) to obtain overall SO2 conversions of approximately 95—96%. Later, four pass converters were used to obtain conversions of from 97% to slightiy better than 98%. For sulfur-burning plants, this typically resulted in sulfur dioxide stack emissions of 1500—2000 ppm. 

Small amounts of sulfuric acid mist or aerosol are always formed in sulfuric acid plants whenever gas streams are cooled, or SO and H2O react, below the sulfuric acid dew point. The dew point varies with gas composition and pressure but typically is 80—170°C. Higher and lower dew point temperatures are possible depending on the SO concentration and moisture content of the gas. Such mists are objectionable because of both corrosion in the process and stack emissions. 

More recentiy, sulfuric acid mists have been satisfactorily controlled by passing gas streams through equipment containing beds or mats of small-diameter glass or Teflon fibers. Such units are called mist eliminators (see Airpollution control methods). Use of this type of equipment has been a significant factor in making the double absorption process economical and in reducing stack emissions of acid mist to tolerably low levels. 

Process air in sulfur-burning plants is dried by contacting it with 93—98 wt % sulfuric acid in a countercurrent packed tower. Dry process air is used to minimise sulfuric acid mist formation in downstream equipment, thus reducing corrosion problems and stack mist emissions. 

Double-Absorption Plants. In the United States, newer sulfuric acid plants ate requited to limit SO2 stack emissions to 2 kg of SO2 per metric ton of 100% acid produced (4 Ib /short ton Ib = pounds mass). This is equivalent to a sulfur dioxide conversion efficiency of 99.7%. Acid plants used as pollution control devices, for example those associated with smelters, have different regulations. This high conversion efficiency is not economically achievable by single absorption plants using available catalysts, but it can be attained in double absorption plants when the catalyst is not seriously degraded. 

Exhaust emissions of CO, unbumed hydrocarbons, and nitrogen oxides reflect combustion conditions rather than fuel properties. The only fuel component that degrades exhaust is sulfur the SO2 concentrations ia emissions are directly proportional to the content of bound sulfur ia the fuel. Sulfur concentrations ia fuel are determined by cmde type and desulfurization processes. Specifications for aircraft fuels impose limits of 3000 —4000 ppm total sulfur but the average is half of these values. Sulfur content ia heavier fuels is determined by legal limits on stack emissions. 

A more obvious energy loss is the heat to the stack flue gases. The sensible heat losses can be minimized by reduced total air flow, ie, low excess air operation. Flue gas losses are also minimized by lowering the discharge temperature via increased heat recovery in economizers, air preheaters, etc. When fuels containing sulfur are burned, the final exit flue gas temperature is usually not permitted to go below about 100°C because of severe problems relating to sulfuric acid corrosion. Special economizers having Teflon-coated tubes permit lower temperatures but are not commonly used. 

Other problems that can be associated with the high dust plant can include alkaH deterioration from sodium or potassium in the stack gas deposition on the bed, calcium deposition, when calcium in the flue gas reacts with sulfur trioxide, or formation and deposition of ammonium bisulfate. In addition, plugging of the air preheater as weU as contamination of flyash and EGD wastewater discharges by ammonia are avoided if the SCR system is located after the FGD (23). 

Like M( F(7s, S()F(7s can integrate fuel reforming within the fuel cell stack, A prereformer converts a substantial amount of the natural gas using waste heat from the fuel cell, (iornpoiinds containing sulfur (e,g, thiophene, which is cornrnonlv added to natural gas as an odorant) must be removed before the reformer. Typically, a hvdrodesiilfii-rizer combined with a zinc oxide absorber is used. 

Tall stacks for SO2 dispersion have been used in the past but are no longer acceptable as the sole means of SO2 control. Acid plants have been installed at many smelters to convert the SO2 to sulfuric acid, even though it may not be desirable from an economic standpoint. 

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