This study presents the results of two field tests that aimed at evaluating two countermeasures (WESP and GGH) to avoid acid mist formation. A WESP is shown to be very efficient for the removal of nuclei from the flue gas (100% efficient) and thus can prevent aerosol formation inside an amine based absorber. This is however only valid in the absence of SO₂ in the flue gas entering the WESP. A decreasing WESP efficiency is noted in the presence of SO₂ with increasing voltages as a result of newly formed aerosols inside the WESP. This implies that no or very low levels of SO₂ should be present in the flue gas entering the WESP. Since most of the amine carbon capture installations have a pre-scrubber (usually using NaOH to remove residual SO₂ in the flue gas leaving the power plant's Flue Gas Desulphurisation) in front of their amine absorber, the WESP must be installed behind this pre-scrubber and not in front of it. Having a Gas-Gas Heater (or any type of flue gas cooling such as a Low Temperature Heat Exchanger) installed upstream of the wet scrubbing may prevent homogenous nucleation and thus prevent the conversion of H₂SO₄ into sulfuric acid aerosols and consequently mist formation issues in the amine based carbon capture installation. Which option to choose amongst the two countermeasures presented in this study will depend on whether a new built installation is being considered or whether a carbon capture is planned as a retrofit into an existing installation. Published by Elsevier Ltd.

This study is to our knowledge the first to describe the effect of a Gas-Gas Heater (GGH) of a coal fired power plant's has on (i) the H₂SO₄ concentration and (ii) the particle/aerosol number concentration and particle size distribution present in the flue gas. In the absence of a GGH, homogenous nucleation takes places inside the Wet Flue Gas Desulphurisation (WFGD) converting the gaseous H₂SO₄ into aerosol H₂SO₄. This leads to a high aerosol number concentration behind the WFGD with 80% of the aerosols being smaller than 0.02μm. This implies that an amine based carbon capture (CC) installation treating this flue gas can suffer from amine mist formation due to the high amount of available nuclei (i.e., H₂SO₄ aerosols) resulting in high amine emissions. In contrast, in the presence of a GGH not only 70% of the H₂SO₄ is removed from the flue gas (measured at the Nijmegen powerplant), but also homogenous nucleation in the WFGD is prevented resulting in low particle number concentrations. The flue gas leaving the GGH will not create any mist formation issues in an amine based CC installation due to the low amount of nuclei present in the flue gas. It is not the reduction in H₂SO₄ concentration by 70% inside the GGH as such that prevents mist formation but absence of H₂SO₄ in its aerosol form. These results are most likely quite widely transformable to other power plants that burn low sulfur coal i.e., around 0.7 weight%. This information will serve future pilot and demo CC installation around the world; in particular when retrofitted on power plants that have a GGH.

Recently, studies have appeared pointing out that aerosols can dominate the total amine emission from amine based PCCC pilot plant scale installations. For the design of countermeasure types (upstream or downstream of the PCCC installation), it is crucial to have an idea of the aerosol size distribution and numbers entering or leaving the absorber. This study is the first to present this kind of data and should serve future installations when designing aerosol emission countermeasures. H₂SO₄ aerosols entering the absorber are observed to be extremely small (i.e. <0.2μm) with number concentrations exceeding 1E8cm^-3. The aerosols grow in size as they travel through the absorber through the taking up of water and amine to sizes close to but staying below 1μm. However, despite the fact that most of the aerosols (expressed in number concentrations) are well below 1μm, most of the water (and thus amine) is found in the aerosol sizes between 0.5 and 2μm. Therefore, if one aims at designing efficient countermeasures, eliminating this size fraction is crucial. This amine emission stream is therefore very difficult to remove using water washes as aerosols are known to travel through water wash sections. Moreover, also classical demisters show very little efficiency for these small aerosol sizes and are therefore believed not to be suitable for the removal of aerosols. This information will therefore serve future installations when designing aerosol emission countermeasures.