Powdered Activated Carbon (PAC)

Selection, Handling and Safety

Presentation C.2.2 at EUEC
San Diego, CA

Robert Huston
February 3, 2016

Expertise. Reliability. Compliance.

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THE INFORMATION CONTAINED IN THIS PRESENTATION IS FOR GENERAL
INFORMATIONAL PURPOSES ONLY, AND IS NOT INTENDED AS LEGAL
ADVICE. YOU SHOULD CONSULT AN ATTORNEY OR OTHER APPROPRIATE
PROFESSIONAL FOR ADVICE REGARDING YOUR INDIVIDUAL SITUATION.

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Science of Efficient Mercury Capture

Three Critical Mechanisms

Conversion
of elemental mercury
(Hg0) to an oxidized
state (Hg+ or Hg++) to
enhance mercury’s
receptivity to the
Contact capture media
of mercury, which is in
Capture
very dilute of the mercury in the
concentrations in the capture media’s
flue gas, with the structure for removal
capture media from the system

• All three mechanisms must occur in seconds or less to achieve compliance.

• Must integrate the APC System to Maximize Native and Co-benefit Hg Capture

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What is the “best” PAC for me?
 Maximizes effective mercury capture
1. Is adaptable to fuel switching and variability
2. Takes advantage of my existing emission
train’s Hg capture co-benefits
3. Optimizes Contact, Conversion and Capture
mechanisms
4. Provides “active” engineering controls on
demand
5. Capture Hg as far forward in your emission
train as possible...downstream capture
must contend with multiple phases,
complex uncontrolled & competing
chemistries, dilute Hg concentrations with
lower capture driving force, etc.
 Minimizes adverse Balance-of-Plant impacts
1. Considers all aspects of my existing
emissions train design
2. Is tailored to have minimal impact on the
primary function of emission equipment
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 Is Reliable in performance
1. Has demonstrated performance in many full-
scale EGU tests
2. Has consistency in quality of manufacturer and
Hg capture performance
 Is Reliable in supply
1. Is supported by a dedicated, state-of-the-art
manufacturing facility and supply chain for
reliable supply and delivery
2. Has demonstrated, experienced after-sale
technical support with a customer service
representative assigned to my account
 Continues to innovate and improve
1. Has next-generation performance features
quickly following
2. Is backed by a technology team that applies
basic science and works collaboratively with
EGUs partners and industry groups such as EPRI
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Key PAC Advancements & Collaboration Opportunities
• Wet Scrubber PAC
o Removal of oxidized mercury without impact on bulk chemistry (no ORP effect)
o Low PAC consumption; successful separation from gypsum
• High mercury removal in the presence of SO3 (5-25 ppm)
o Many chemistries and formulations tested and scaled up using our science-based
approach and DMI – pilot – full scale pathway
o Successful formulations are customized, prototyped, and commercialized quickly
o Effectiveness in high-SO3 flue gases has been demonstrated
• DSI compatibility
o Can be a benefit or detriment to PAC performance
 Detriment in halogen scavenging and NO2 interference with Gen 1 PACs
 Benefit in removal of SO3
o Problems can be solved in either case through advanced formulations and physical
equipment configuration
• Balance of Plant (BOP) management
o Ash compatibility has been addressed effectively
o Bromine impacts mitigated through design using low-volatility salt and alternative
technologies to enhance oxidation
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Generation 4 SO3 Tolerant PAC Performance:
EGU 4 - High Sulfur Fuel Blend (18-24 ppm SO3)
EGU 4 & Pilot Scale Testing - Comparative Hg Removal Across ESP

F Gen 4 - Enhanced Oxidation/SO3 Tolerance

E Catalytic Oxidation/SO3 Tolerance

Stepwise
PAC Formulation

D Enhanced Oxidation/SO3 Tolerance

mechanistic
formulation
C Catalytic Oxidation
enhancements
B SO3 Tolerance

A Baseline PAC

0% 10% 20% 30% 40% 50% 60% 70% 80% 90%

% Hg Removal Relative

New Gen 4 PACs have enhanced Hg removal at high SO3 flue gas levels

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Focus on: Safe Material Handling
The Good News…
PAC has been safely handled at industrial sites for decades in water
treatment and in the past 20 years for flue gas injection.

To many utilities however, it is a new material. It is distinct from coal because our
manufacturing process drives off volatiles and moisture, making it less susceptible
to fire and explosion risk than pulverized coal. With knowledge of the proper
handling it can continue to be a safe part of the industrial work environment.

Some of the startup guidelines described are connected to material handling

safety. Education on the Safety Data Sheet (SDS) of the material, Personnel
Protective Equipment (PPE) required, housekeeping/cleanup, measurements
available is recommended. For more details on safe PAC handling, refer to our
handouts, product information and technical experts.

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 Safety Data Sheets (SDSs)
• SDS – Safety data sheet
• Provides workers/employees and
emergency personnel with
information and procedures for
safe handling and work practices
for a specific substance.
• Includes:
• Physical and Chemical Properties
• Toxicity
• First Aid Measures
• Handling and Storage
• Disposal Considerations
• Transport Information
• Regulatory Information
• Others…

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Coal and PAC Analyses

Moisture Volatiles Ash Fixed

Carbon
wt% wt% wt% wt%

Lignite Coal 37% 26% 9% 28%

ADA FastPAC
Premium PAC 6% 6% 27% 61%

Coal and PAC share some common aspects, but are vastly
different in many respects.

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 Volatiles

• Class II, Div. 2 Group F is a • NFPA 654

– Prevention of Fire and Dust
National Electrical Code
Explosions from the
(NEC) designation. Manufacturing, Processing,
and Handling of Combustible
• Less than 6 wt% volatiles Particulate Solids
• Primarily CO2, CO and O2 • NFPA 68
– Standard on Explosion
• VOC content typically Protection by Deflagration
Venting
< 100 ppm
• OSHA
http://www.osha.gov/
Publications/3371combustible-
dust.pdf
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Overview of Dust Explosion Potential

• Combustible dusts are a small portion of the particulate solids.

Combustible dusts are further defined by Occupational Safety and
Health Administration (OSHA) by the following properties:
o A particle size less than 420 microns (in comparison, table salt
has an average particle size of 100 microns and Human hair is
40-70 microns); and
o Present a fire or explosion hazard when dispersed and ignited
in air.

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Overview of Dust Explosion Potential
• For a dust explosion to occur; the three • The minimum ignition energy (MIE) is
required components for a fire must be greater than 10 joules
present: (1) Fuel, (2) Oxygen, (3) Ignition • Auto ignition occurs at temperatures
(Heat)
greater than 400oC
• Along with two additional required
components: (4) Dispersion of dust particles Dust Kst (bar.m/s) Characteristic Typical
Explosion Material
in sufficient quantity and concentration; and Class
(5) Confinement of the dust cloud
St 0 0 No Explosion Silica

St 1 0 and Weak Powdered

≤ 200 Explosion Milk,
Charcoal,
Sugar, Coal

St 2 200 and Strong Cellulose,

≤ 300 Explosion Wood Flour

St 3 > 300 Very Strong Aluminum,

Explosion Magnesium

Sources: OSHA (CPL 03-00-008, Combustible Dust National Emphasis Program);

NFPA 68 (Standard on Explosion Prevention by Deflagration Venting).

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Oxygen Pick-up - Warning

Wet or dry activated carbon depletes oxygen from the air,

creating oxygen-deficient atmospheres in confined spaces.

• If powdered activated carbon is in a confined or closed space,

it may deplete the oxygen levels from the air. The oxygen
content of the air in the “confined space” should be
determined before workers are allowed to enter such a space.
All applicable low-oxygen work rules and procedure should be
followed.

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Oxygen Pick-up & Bed Heat-up

• All activated carbons have a tendency to chemisorb oxygen

when exposed to air to achieve an equilibrium oxygen level on
its surfaces and pores.
• This chemisorption process is exothermic and can produce
carbon monoxide as a byproduct.
• Activated carbon is a highly insulative material.
• If the exothermic heat of the chemisorption is not dissipated
effectively, then heat can be trapped potentially raising the
temperature of the carbon to the point of self-combustion,
particularly in the surface layer exposed to oxygen.

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Bed Heat-up
• One such instance is when the activated carbon is significantly
wetted and then subsequently rapidly dried.
• The wetting displaces the equilibrium level of oxygen with
moisture, making the carbon surface oxygen deprived.
• Upon displacement of the water by rapid drying, the oxygen will
re-adsorb onto the carbon surface, giving off heat.
• Once again, if the heat is not dissipated effectively, the carbon
bed could overheat and begin to smolder.
• Thus, carbon should be stored under relatively dry conditions
and significant wetting/drying exposure should be avoided.

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 Respiratory- Warning

• Avoid excessive inhalation of activated carbon dust.

Appropriate protective equipment should be worn
when working with activated carbon, including
eyewear and respiratory protection.

Pictures curtsey of http://www.compliancesigns.com/CustomLabelWorkSafetyPPESymbols.shtml

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Housekeeping
• Avoid spills and accumulations of dust, or generation of airborne dust. If a spill
does happen use a broom or HEPA filter vacuum for cleanup (if area of spill is
classified as explosion area than vacuum should be explosion proof).
• Operators should be aware of the ignition sensitivity and explosion severity of all
the material in their plant – available on SDS (MSDS)
• Do not enter places where bulk PAC is used or stored until adequately ventilated
to prevent asphyxiation.
• Avoid inhalation and eye contact.
• Ground all transfer, blending and dust collecting equipment to prevent static
discharge.
• Remove all ignition sources from material handling, transfer, and processing areas
where dust may be present.
• If activated carbon is contained, hoppers should be emptied frequently and
particular care should be exercised when hopper heaters are in use.
• Cutting or welding operations should not be used near this material.
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Questions?

ADA Carbon Solutions, LLC

1460 W. Canal Court
Littleton, CO 80120-5632

Robert Huston
David Park
robert.huston@ada-cs.com
david.park@ada-cs.com
720-480-5819
720-279-7226
Senior Director of Technical
Senior R&D Engineer
Services

Joe Wong
joe.wong@ada-cs.com
720-431-9640
Chief Technology Officer

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