Advanced in-duct sorbent injection for SO{sub 2} control. Topical report No. 6, Task 5: Conceptual commercial process design and economic evaluation

The objective of this research project is the development of a second generation in-duct sorbent injection technology as a cost-effective compliance option for the 1990 Clean Air Act Amendments. Research focused on the Advanced Coolside Process, which has shown the potential of exceeding the performance targets of 90% SO{sub 2} removal and 60% sorbent utilization. In Task 5, Conceptual Process Design and Economic Evaluation, the economics of the CONSOL Advanced Coolside Process as a Clean Air Act compliance option were evaluated. A conceptual process design for full-scale, coal-fired applications is described. Advanced Coolside is compared to conventional Limestone Forced Oxidation (LSFO) wet FGD technology. The process economics for coal sulfur levels ranging from 1.0% to 3.5% (as-received) and plant sizes ranging from 160 to 512 gross MW were investigated, In addition, the economics of on-site versus off-site lime hydration and the cost sensitivity to delivered pebble lime and hydrate prices are investigated, Advanced in-duct sorbent injection enjoys a capital and levelized cost advantage relative to LSFO in all cases examined in this study. As a result of this study and others made during this contract, the following conclusions can be made: (1) The capital cost of Advanced Coolside is 55% to 60% less than that of LSFO and varies slightly depending on coal sulfur content and plant size. (2) The total levelized SO{sub 2} control cost advantage relative to LSFO varies from 15% to 35% over the range of coal sulfur contents and plant sizes evaluated. This cost advantage is sensitive to sorbent transportation charges. As a result, the economics are site-specific. (3) The experimental optimizations based on interim economic analyses were the key to capital and levelized cost reductions.