Survey on Methods for Analysis and Conservation of Hydrated Lime

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A Survey on Methods for Analysis and Conservation of Hydrated Lime Particles Sampled in Flue Gas Cleaning Systems Martin Koehler, Andrea Ohle, Daniel Bernhardt, Kathrin Gebauer, Michael Beckmann, Marie Kaiser, and Wolfgang Spiegel Ind. Eng. Chem. Res., Just Accepted Manuscript • DOI: 10.1021/acs.iecr.8b03794 • Publication Date (Web): 10 Oct 2018 Downloaded from http://pubs.acs.org on October 14, 2018

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Industrial & Engineering Chemistry Research

A Survey on Methods for Analysis and Conservation of Hydrated Lime Particles Sampled in Flue Gas Cleaning Systems Martin Köhler,∗,† Dr.-Ing. Andrea Ohle,† Dr.-Ing. Daniel Bernhardt,† Dr. rer. nat. Kathrin Gebauer,† Prof. Dr.-Ing. Michael Beckmann,† Marie Kaiser,‡ and Dr. rer. nat. Wolfgang Spiegel‡ †Technische Universität Dresden, Chair for Energy Process Engineering, 01062 Dresden, Germany ‡CheMin GmbH, Am Mittleren Moos 46A, 86167 Augsburg, Germany E-mail: [email protected]

Abstract In terms of analyzing and modeling conditioned dry absorption an unbiased view on the injected hydrated lime particles is needed. Multiple investigations on the reaction mechanisms are reported in the literature. Nevertheless, outstanding issues are still existing as a necessary conservation in the time between the particle sampling and analysis as well as the suitability of the analyzing methods itself has been regarded only roughly yet. Thus, in this work TGA, XRD and SEM-EDS were used for analyzing Ca(OH)2-CaCl2 · 2 H2O-mixtures. TGA turned out to be inappropriate as the composition of the mixture changes during analysis. A cooling of the particle samples down to 277.15 K under air exclusion proved to be a sufficient conservation method for the time span between sampling and analysis.

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Introduction Conditioned dry absorption (CDAS) is one of the most applied flue gas cleaning processes, particularly at waste incineration plants and biomass fired power plants in Germany. The basic principle of CDAS is the injection of hydrated lime into the flue gas. The hydrated lime absorbs the sour gas components (HCl, SOX, HF) and is deposited at the bag house filters. Usually a partial recirculation of the hydrated lime follows to increase the additives yield. By adjusting the flue gas temperature and humidity the absorption rates can be influenced. In the past decades, this process has been investigated intensively, in particular for SOX-cleaning 1–3 . Furthermore, process optimization models have been developed to predict the conversion of Ca(OH)2 as a function of time 4–8 . Due to instable reaction products a verification of these models by analyzing particles sampled from the flue gas is limited. Accumulating methods, e.g. particle impactor or filter cartridges, underlie not quantifiable uncertainties. Even with sampling methods characterized by a very short sampling time, e.g. the particle-wire-mesh method 9 , further reactions can take place between sampling and analysis. Although the conditioned dry absorption process has been studied for years, a consistent reaction mechanism for the component HCl is not documented. The following reactions turned out to be most significantly 5,10–17 : Ca(OH)2 + 2HCl ←−→ CaCl2 + 2H2 O

(R 1)

Ca(OH)2 + 2HCl ←−→ CaCl2 · 2H2 O

(R 2)

Ca(OH)2 + HCl ←−→ CaClOH

(R 3)

Calcium chloride is strongly hygroscopic. Even a low moisture content in the surrounding gas phase leads to an increase of its degree of hydration: CaCl2 · nH2 O + 2H2 O ←−→ CaCl2 · (2 + n)H2 O 2


n=0,2,4

(R 4)

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Partially reacted hydrated lime undergoes further reactions with the formed products. These internal transformation reactions are: Ca(OH)2 + CaCl2 · nH2 O ←−→ 2CaClOH + nH2 O

n=0,2,4,6

(R 5)

Besides these, reactions with other flue gas components occur in industrial applications. Moreover hydrated lime with industrial purity contains calcium carbonate as well as magnesia species, which may have an impact on the reactions above. Particularly the internal transformation reactions have a significant influence when analyzing particle samples containing the mentioned calcium chloride species as they change the composition of the sample. The aim of this work is foremost the evaluation of the Thermogravimetric Analysis (TGA), X-ray Diffraction (XRD), and Energy Dispersive X-ray Spectrometry (EDS) for the analysis of these particle systems. Based on that, the effect of conservation methods is outlined, thereby realizing a sufficient time span between sampling and analysis of particles from flue gas cleaning systems.

Analyzing Methods Thermogravimetric Analysis Thermogravimetric Analysis (TGA) is based on the weight change of a sample due to reactions, drying, degassing etc., when increasing or decreasing its temperature. TGA was used among others by Allal et al. 12 to predict the formation enthalpy of CaClOH. Therefore Allal et al. mixed Ca(OH)2 and CaCl2 · 2 H2O and analyzed this mixture after at least one day in the thermobalance. They concluded that the first occurrent weight loss represents the dehydration of CaClOH · 2 H2O and the second loss represents the dehydroxilation of Ca(OH)2. The third weight loss is characteristic for the dehydration of CaClOH and the 3



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forth weight loss for the decarbonation of CaCO3. Using the pure substances Ca(OH)2 (provided by Honeywell with a purity of 96 %) and CaCl2 · 2 H2O (provided by Grüssing with a purity of 99 %) Thermogravimetric Analysis results into Figure 1. Three characteristic weight losses can be detected in the defined temperature range. In contrast to Allal et al. 12 it is not indicated, that the first weight loss exclusively represents the dehydration of CaClOH · 2 H2O. The weight loss is more likely to be caused by the dehydration of CaCl2 · 2 H2O, as both pure CaCl2 · 2 H2O as well as a Ca(OH)2 - CaCl2 · 2 H2O - mixture show the same behavior: CaCl2 + nH2O↑

CaCl2 · nH2O

(R 6)

The second weight loss is caused by the dehydroxilation of Ca(OH)2 as it was stated by Allal et al.: CaO + H2O↑

Ca(OH)2

(R 7)

We found the third weight loss to be representing the decomposition of CaClOH: 2 CaClOH

CaO + CaCl2 + H2O↑

(R 8)

Figure 2 shows that the first weight loss disappears after a residence time of one hour in the atmosphere. This is in contradiction to the results of Allal et al. 12 , who found a weight loss at these temperatures in every mixture. With regard on the molar fraction of calcium hydroxide in this mixture calcium chloride dihydrate should be totally converted after long residence time if reaction R 5 occurs. Therefore, the absent first weight loss between 323.15 K to 423.15 K after three hours might be reasonable. At the same time, this indicates that calcium chloride hydroxide does not exist in hydrated manner or more time is needed to form hydrates. It is obvious that Thermogravimetric Analysis is not suitable for analyzing these mixtures, as

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Weight loss in %

100

Heat flux in W g−1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60


Dehydration 90 Dehydroxylation 80

CaClOH-Decomposition

0 −1 −2 −3 350

400

450

500

550 600 650 Temperature in K

CaCl2 · 2 H2O

Ca(OH)2

700

750

800

850

Mixture

Figure 1: Thermogravimetric Analysis of pure Ca(OH)2 and CaCl2 · 2 H2O as well as of a 50 Ma.-%-50 Ma.-%-mixture (Mettler-Toledo TGA/DSC I HT GC200, method: Tmin =308.15 K, Tmax =853.15 K, ∆T=10 K min−1 , 40 µl Al-crucible, 50 ml min−1 nitrogen flushing gas)

5



Weight loss in %

100

Heat flux in W g−1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

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90

80

0 −1 −2

350

400

450

500

550 600 650 Temperature in K

0h

1h

700

750

800

850

3h

Figure 2: Thermogravimetric Analysis of an mixture of 50 Ma.-% Ca(OH)2 and 50 Ma.-% CaCl2 · 2 H2O for different residence times on the atmosphere (Mettler-Toledo TGA/DSC I HT GC200, method: Tmin =308.15 K, Tmax =853.15 K, ∆T=10 K min−1 , 40 µl Al-crucible, 50 ml min−1 nitrogen flushing gas)

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the third CaClOH characterizing weight loss occurs although there was a minimum residence time at the atmosphere by the mixture marked with 0 h in Figure 2. This residence time might be overcome by a preparation in a glove-box. However, occurring reactions during the heating phase in the first few minutes of the analysis process are unavoidable.

X-ray diffraction The measuring principle of X-ray diffraction is the deflection of X-rays on lattice planes of crystals. It is a common method to differentiate between multiple crystalline species within a solid sample 18 . Figure 3 shows the results of X-ray diffraction analysis of pure calcium hydroxide, calcium chloride dihydrate and a 50 Ma.-% to 50 Ma.-% mixture of both, which was forced to react by increasing its temperature to 343.15 K for 30 min. The elevation of the base line at 2θ between 15° to 25° is caused by the use of a sample holder with air protection cap. The relevant calcium-chlorine-species can be distinguished. The differentiation of these species is needed for evaluating the success of the conservation method later. Nevertheless some peaks are not clearly related to calcium-chlorine-species, e.g. at approximately 11°. These peaks may occur as a result of impurities like aluminum iron hydroxides, which are also indicated by EDS-analysis in next section. However, the necessary use of the air protection cap does not allow a quantitative analysis of the spectra. The use of XRD is therefore strongly limited.

Scanning Electron Microscopy with Energy Dispersive X-ray Spectrometry (SEM-EDS) The use of short time sampling methods, e.g. the particle-wire-mesh method, requires the analysis of the collected particles with SEM-EDS. The result of SEM-EDS-analysis is the weight fraction of selected elements at a specific location. Therefore a parameter has to be found, which characterizes the different calcium-chlorine species. The EDS analysis provides

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CaCl2 · 2 H2O

CPS in s−1

80 60 40 20 0

Ca(OH)2

CPS in s−1

80 60 40 20 0 (b) (a)

80 CPS in s−1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

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(b,c) (a)(b) (c)

Mixture

(b,c) (b)

(a)(b)

60 40 20 0 10

15

20

25

30

35 40 2θ in °

45

50

55

60

65

Figure 3: X-ray diffraction analysis of calcium chloride dihydrate, calcium hydroxide and a 50 Ma.-% to 50 Ma.-% reacted mixture of both with (a) calcium chloride dihydrate, (b) calcium hydroxide and (c) calcium chloride hydroxide (Bruker D8 Eco, method: 2θmin =10°, 2θmax =65°, ∆θ=0.02°, tθ =1.5 s, sample holder with air protection cap)

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Figure 4: SEM picture of a cross section of embedded pure calcium chloride dihydrate

Table 1: Weight fraction of selected elements of pure calcium chloride dihydrate analyzed with EDS in Figure 4 Mark residual 1 2 3 4 5

19.8 26.7 24.6 21.0 22.4

Na

Mg

Al

Si

P

Cl

K

Ca

0.1 -

-

0.2 0.2 0.1 0.2 0.2

0.2 0.4 0.4 0.3 0.3

-

52.0 45.4 47.6 50.1 49.5

-

27.3 - 0.3 - 0.52 26.2 0.3 0.8 0.1 0.58 27.1 - 0.57 27.1 0.3 0.8 0.1 0.54 26.9 0.2 0.5 - 0.54

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Cr

Fe

Ni

ζ


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Figure 5: SEM picture of a cross section of an embedded 50 Ma.-% calcium hydroxide to 50 Ma.-% calcium chloride dihydrate mixture, which was heated to 434.15 K for 30 min

Table 2: Weight fraction of selected elements of a 50 Ma.-% calcium hydroxide to 50 Ma.-% calcium chloride dihydrate mixture, which was heated to 434.15 K for 30 min, analyzed with EDS in Figure 5 Mark residual 1 2 3 4 5

28.7 34.8 30.8 52.4 32.2

Na

Mg

Al

Si

P

0.1 -

0.2 0.1 0.2 0.3 0.1

0.1 -

0.3 - 31.8 0.3 - 26.3 0.5 - 27.8 0.4 0.2 2.70 0.4 - 32.0

10

Cl

K

Ca

Cr

Fe

-

38.4 36.6 39.0 43.2 34.3

0.2 0.4 0.4 0.2 0.2

0.4 - 1.21 1.2 0.1 1.39 1.1 - 1.40 0.6 - 16.0 0.6 - 1.07


Ni

ζ

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reasonable results only for elements with an atomic number of eleven or higher 19 . Hydrogen and oxygen are not detected. Consequently, we found the calcium-chlorine weight ratio ζi to be appropriate for the differentiation of the species. For calcium chloride dihydrate this ratio is ζCaCl2 · 2 H2O = 0.56, whereas it is for calcium chloride hydroxide ζCaClOH = 1.13. For unreacted calcium hydroxide the calcium-chlorine weight ratio goes to infinity. We embedded pure CaCl2 · 2 H2O in epoxy resin on a sample holder, made a cross section and analyzed it with SEM-EDS. The results in Figure 4 and Table 1 show the specified calcium-chlorine weight ratio in every measuring point. To analyze this ratio also for CaClOH, again a mixture of 50 Ma.-% Ca(OH)2 and 50 Ma.-% CaCl2 · 2 H2O was heated to 434.15 K for 30 min to force the reaction to CaClOH (see R 5) and prepared in the mentioned manner afterwards. Figure 5 and Table 2 indicate the calcium-chlorine weight ratio for calcium chloride hydroxide in the measuring points 1, 2, 3 and 5. On the other hand measuring point 4 shows unreacted calcium hydroxide. The high resolution detail of Figure 5 in Figure 6 in combination with the results of EDS analysis in Table 3 shows that it is possible to detect a progressive reaction front in the hydrated lime particles, thereby enabling the validation of process models. It has to be mentioned, that even in case of very high resolution it is not able to measure single molecules with SEM-EDS. Thus, parallel present unreacted calcium hydroxide and calcium chloride dihydrate appear to be calcium chloride hydroxide with a view on the calciumchloride weight ratio. For an unambiguous allocation the measuring points have to be set away from the border between the unreacted core and the shell containing reaction products. Furthermore, the presented results arise out of considerations on the calcium-chlorine-species. In samples out of flue gas cleaning systems, particularly at waste incineration plants, a bulk of elements is mixed in the samples. SEM-EDS as well as XRD have to proof their suitability in further investigations.

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Figure 6: High resolution detail of Figure 5

Table 3: Weight fraction of selected elements analyzed with EDS according to Figure 6 Mark residual Na Mg Al 1 2

47.7 25.5

-

0.3 0.3

-

Si

P

Cl

0.4 0.1 4.20 0.5 0.1 30.6

12

K

Ca

-

46.3 0.2 0.8 41.9 0.2 0.8


Cr

Fe

Ni

ζ

-

11.0 1.37

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Conservation of Particle Samples A sample conservation is needed, because of the change in composition due to the internal transformation reactions, which occur in the time between sampling and analysis. Moreover the samples show a strongly hygroscopic behavior. In general, there are three possible approaches by • lowering the temperature to decrease reaction kinetics, • inerting the surrounding gas phase to prevent interactions with it, and • embedding the sample in epoxy resin for the latter reason. To interrupt the transformation reactions temperatures far below 273.15 K are necessary, where the inter-crystalline water is forced to freeze. Indeed this changes the particles morphology - an appropriate parameter to differentiate between additive and fly ash particles by SEM. Furthermore, the vapor pressure of ice is high enough to realize a significant drying effect in e.g. a nitrogen atmosphere. During the embedding in epoxy resin heat is released when the hardening begins. That is why we decided to lower the temperature to 277.15 K and combined it with the exclusion of air by using either an air protection cap for XRD or a varnish coating for SEM-EDS. XRD analysis was taken to prove a conservation. A mixture of 50 Ma.-% Ca(OH)2 and 50 Ma.-% CaCl2 · 2 H2O conserved by the above mentioned procedure was analyzed after various residence times. In Figure 7, the XRD analysis after zero days, three days and 26 days are plotted. Furthermore, we subtracted the zero-daysspectrum from the remaining ones. In case of ideal conservation this subtraction leads to a zero line regarding the counts per second. A few peaks are visible. In comparison to the not conserved sample after twelve hours (also plotted in Figure 7 as subtracted spectrum), they are significantly less pronounced. The time span between the sampling of the particles and their analysis is typically less than three days. The results indicate, that this time span can be realized with the described procedure without a significant change in the sample composition. 13


0

20

−20

40

3 d-0 d

20 0

20

CPS in s−1

3d

−20

0 26 d

40

26 d-0 d

20 0

20

CPS in s−1

CPS in s−1

20 CPS in s−1

0 h-12 h (not conserved)

0d

40

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0

CPS in s−1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

CPS in s−1


−20

0 10

20

30

40 2θ in °

50

60

10

20

30

40 2θ in °

50

60

Figure 7: XRD analysis of a conserved mixture of 50 Ma.-% Ca(OH)2 and 50 Ma.-% CaCl2 · 2 H2O (Bruker D8 Eco, method: 2θmin =10°, 2θmax =65°, ∆θ=0.02°, tθ =1.5 s, sample holder with air protection cap)

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Outlook Short-time conservation of particles sampled directly from the flue gas cleaning system is feasible by cooling them down to 277.15 K under the exclusion of air. This enables the use of the particle-wire-mesh method for the validation of kinetic models considering the reaction of hydrated lime with sour gases components. In the upcoming part of the current research project we will analyze different flue gas cleaning systems to set up guidelines for further process optimization regarding the absorption of HCl and thereby increasing the utilization of the additives.

Symbols & Abbreviations T

temperature

K

ζ

weight fraction

g g−1 , Ma.-%

CDAS

Conditioned dry absorption

CPS

Counts per second

EDS

Energy dispersive X-ray spectrometry

SEM

Scanning electron microscopy

TGA

Thermogravimetric analysis

XRD

X-ray diffraction

Acknowledgement The authors thank the Deutsche Bundesstiftung Umwelt for financing the research as part of the project "Untersuchung von Möglichkeiten der Weiterentwicklung der PartikelGitterNetzSonde (PGNS) für den Einsatz im niedrigen Temperaturbereich bei Abgasreinigungsanlagen" 15



(AZ: 33004/01) and Ms. Theresa Beerbaum for her energetic support during the experimental investigations.

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(11) Jozewicz, W.; Gullett, B. K. Reaction mechanism of dry Ca-based sorbents with gaseous HCl. Ind. Eng. Chem. Res. 1995, 34, 607–612. (12) Allal, K. M.; Dolignier, J.-C.; Martin, G. Reaction mechanism of calcium hydroxide with gaseous hydrogen chloride. Rev. Inst. Fr. Pet. 1998, 53 . (13) Fonseca, A. M.; Órfao, J. J.; Salcedo, R. L. Kinetic Modeling of the Reaction of HCl and Solid Lime at Low Temperatures. Ind. Eng. Chem. Res. 1998, 37, 4570–4576. (14) Bodénan, F.; Deniard, P. Characterization of flue gas cleaning residues from European solid waste incinerators: assessment of various Ca-based sorbent processes. Chemosphere 2003, 51, 335–347. (15) Yan, R.; Chin, T.; Liang, D. L.; Laursen, K.; Ong, W. Y.; Yao, K.; Tay, J. H. Kinetic Study of Hydrated Lime Reaction with HCl. Environ. Sci. Technol. 2003, 37, 2556– 2562. (16) Bausach, M.; Krammer, G.; Cunill, F. Reaction of Ca(OH)2 with HCl in the presence of water vapour at low temperatures. Thermochim. Acta 2004, 421, 217–223. (17) Chin, T.; Yan, R.; Liang, D. T. Study of the Reaction of Lime with HCl under Simulated Flue Gas Conditions Using X-ray Diffraction Characterization and Thermodynamic Prediction. Ind. Eng. Chem. Res. 2005, 44, 8730–8738. (18) Dinnebier, R. E.; Billinge, S. J. L. Powder Diffraction; The Royal Society of Chemistry, 2008. (19) Gilfrich, J. V. Advances in X-ray Analysis; Plenum Press, 1995; Vol. 39; pp 29 – 39.

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Graphical TOC Entry 1. Introduction 2. Analyzing Methods 3. Conservation of Particle Samples 4. Outlook

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Survey on Methods for Analysis and Conservation of Hydrated Lime

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