Evaluation of low ash impact sorbent injection technologies for mercury control at a Texas lignite/PRB fired power plant

A sorbent injection test program was carried out at NRG Texas Power LLC's (NRG) Limestone Electric Generating Station (LMS). LMS fires a 30/70 blend of Powder River Basin (PRB) and Texas Lignite, and is equipped with a cold-side electrostatic precipitator (ESP) and wet scrubber. The plant markets its fly ash for beneficial use, so development of a low ash impact mercury control technology is important to the economics of implementing a mercury control system. In addition to standard activated carbon injection, two different low ash impact mercury control technologies were evaluated in parametric tests: low ash impact sorbents and Toxecon™ II. The parametric ACI test program conducted at LMS demonstrated that high (>90%) levels of mercury removal could be achieved with carbon sorbents. The Toxecon™ II design used at LMS did not provide for as high a mercury removal as injection upstream of the ESP, likely due to poor coverage of the cross-sectional area of the ESP. Limited concrete testing was performed with simulated ash/carbon mixtures. As expected, the amount of air-entraining additive required increased with increasing carbon content in the ash. However, it appeared that small amounts of non-passivated carbon may be acceptable in fly ash for concrete use.