The Integrated Flue Gas Treatment (IFGT) system is a new concept whereby a Teflon covered ® condensing heat exchanger is adapted to remove certain flue gas constituents, both particulate and gaseous, while recovering low level heat. The pollutant removal performance and durability of this device is the subject of a USDOE sponsored program to develop this technology. The program was conducted under contract to the United States Department of Energy's Fossil Energy Technology Center (DOE-FETC) and was supported by the Ohio Coal Development Office (OCDO) within the Ohio Department of Development, the Electric Power Research Institute's Environmental Control Technology Center (EPRI-ECTC) and Babcock and Wilcox -a McDermott Company (B&W).This report covers the results of the first phase of this program. This Phase I project has been a two year effort. Phase I includes two experimental tasks. One task dealt principally with the pollutant removal capabilities of the IFGT at a scale of about 1.2MW . The other task studied the t durability of the Teflon covering to withstand the rigors of abrasive wear by fly ash emitted as a ® result of coal combustion.The pollutant removal characteristics of the IFGT system were measured over a wide range of operating conditions. The coals tested included high, medium and low-sulfur coals. The flue gas pollutants studied included ammonia, hydrogen chloride, hydrogen fluoride, particulate, sulfur dioxide, gas phase and particle phase mercury and gas phase and particle phase trace elements. The particulate removal efficiency and size distribution was investigated. These test results demonstrated that the IFGT system is an effective device for both acid gas absorption and fine particulate collection. Although soda ash was shown to be the most effective reagent for acid gas absorption, comparative cost analyses suggested that magnesium enhanced lime was the most promising avenue for future study.The durability of the Teflon covered heat exchanger tubes was studied on a pilot-scale single-® stage condensing heat exchanger (CHX ). This device was operated under typical coal-fired ® flue gas conditions on a continuous basis for a period of approximately 10 months. Data from the test indicate that virtually no decrease in Teflon thickness was observed for the coating on the ® first two rows of heat exchanger tubes, even at high inlet particulate loadings. Evidence of wear was present only at the microscopic level, and even then was very minor in severity. Final Technical Report for Phase I -Revision 0 Contract DE-AC22-95PC95255ii of xv iii of xv This contract includes two phases with the second phase to be proposed after completing the first phase. Phase I testing was completed at a scale of about 1.3 MW . By comparison, the Phase II t work will be proposed at a scale of about 10 MW . The purpose of this report is to present the t results of the Phase I tests.The purpose of Phase I of this contract was to determine the pollutant removal performance and the anticipated wear life of...

McDermott Technology, lnc. assumes no liability with respect to the use of, or for damages resulting from the use of, or makes any warranty or representation regarding any information, apparatus, method, or process disclosed in this report.McDermott Technology, Inc. expressly excludes any and all warranties either expressed or implied, which might arise under law or custom or trade, including without limitation, warranties of merchantability and of fitness for specified or intended purpose.. warranties of merchantability and of fitness for specified or intended purpose.. 11-14-96Customer Feedback QuestionnairePlease help us do a better job for you. RC-447Report This report covers the results of the first phase of this program. This Phase I project has been a two year effort. Phase I includes two experimental tasks. One task dealt principally with the pollutant removal capabilities of the lFGT at a scale of about 1.2MWt. The other task studied the durability of the Teflon@ covering to withstand the rigors of abrasive wear by fly ash emitted as a result of coal combustion.The pollutant removal characteristics of the IFGT system were measured over a wide range of operating conditions. The coals tested included high, medium and low-sulfur coals. The flue gas pollutants studied included ammonia, hydrogen chloride, hydrogen fluoride, particulate, sulfur dioxide, gas phase and particle phase mercury and gas phase and particle phase trace elements. The particulate removal efficiency and size distribution was investigated. These test results demonstrated that the IFGT system is an effective device for both acid gas absorption and fine particulate collection. Although soda ash was shown to be the most effective reagent for acid gas absorption, comparative cost analyses suggested that magnesium enhanced lime was the most promising avenue for future study.The durability of the Teflon@ covered heat exchanger tubes was studied on a pilot-scale singlestage condensing heat exchanger (CHX@). This device was operated under typical coal-fired flue gas conditions on a continuous basis for a period of approximately 10 months. Data from the test indicate that virtually no decrease in Teflon@ thickness was observed for the coating on the first two rows of heat exchanger tubes, even at high inlet particulate loadings. Evidence of wear was present only at the microscopic level, and even then was very minor in severity.i of xv

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FAX: 330-829-7283 McDermott Technology, Inc. assumes no liability with respect to the use of, or for damages resulting from the use of, or makes any warranty or representation regarding any information, apparatus, method, or process disclosed in this report.McDermott Technology, Inc. expressly excludes any and all warranties either expressed or implied, which might arise under law or custom or trade, including without limitation, warranties of .merchantability and of fitness for specified or intended purpose. Integrated Flue Gas Treatment (IFGT) uses two Condensing Heat Exchangers (CHX' so) in series to recover waste heat from the flue gas and remove a variety of pollutants from the flue gas. The Teflon@-covered internals of the condensing heat exchanger permit heat recovery at temperatures below the acid dew-point of the flue gas. Prior to this work, only limited data existed on the pollutant removal efficiency of the IFGT process. MULTIPLE POLLUTANT REMOVAL USINGThe pollutant removal characteristics of the IFGT system were measured over a wide range of operating conditions in a pilot Integrated Hue Gas Treatment System rated at 1.2 MW, (4 million Btukr) using a wide range of coals. The coals tested included a high-sulfur coal, a medium-sulfur coal and a low-sulfur coal. The flue gas pollutants investigated included ammonia, hydrogen chloride, hydrogen fluoride, particulate, sulfur dioxide, gas phase and particle phase mercury and gas phase and particle phase trace elements. The.particulate removal efficiency and size distribution was also investigated. Pollutant removal efficiencies were determined by simultaneous measurements of concentrations at the inlet and outlet of the IFGT system as a function of the coal type, scrubbing liquid, liquid-to-gas ratio and pH, flue gas flow rate and flue gas outlet temperature, and fly-ash concentration in the flue gas. So,da ash, lime and magnesium-lime scrubbing reagents were investigated.The test results show that the IFGT system can remove greater than 95% removal of acid gases with a liquid-to-gas ratio less than. 1.34 l/m3 (10 gaY1000 it3), and that lime reagents show promise as a substitute for soda ash. Particulate and ammonia gas removal was also very high.Ionic mercury removal averaged 80%, while elemental mercury removal wasvery low. Trace metaIs were found to be concentrated in the fine particulate with removal efficiencies in the range of 50% to 80%. performance of an IFGT system for both utility and industrial applications.