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“Enhanced Plant Performance via Effective SO 3 Control” Sterling Gray, URS Corporation Mick Harpenau, Duke Energy EUEC Conference Phoenix, AZ February 3, 2010. SO 3 Adversely Impacts …. Equipment Corrosion. Air Heater Reliability. Mercury Capture. NOx Removal. Heat Rate. - PowerPoint PPT Presentation
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“Enhanced Plant Performance via
Effective SO3 Control”
Sterling Gray, URS CorporationMick Harpenau, Duke Energy
EUEC ConferencePhoenix, AZ
February 3, 2010
2
SO3 Adversely Impacts …
Heat Rate
Air Heater
Reliability
NOx Removal
Mercury Capture
CO2 Emissions
Equipment
Corrosion
3
Impact on Corrosion Potential
220
230
240
250
260
270
280
290
300
310
320
0 10 20 30 40 50 60
SO3 Concentration (ppmv)
Su
lfu
ric
Aci
d D
ewp
oin
t (D
eg F
)
14% H20
12% H20
10% H20
8% H20
6% H20
4
Air Heater Fouling
Ash
Sulfuric Acid
Ammonium Bisulfate
Source: Alstom Airpreheater Company
5
Impact on Heat Rate
$0.7
$1.4
$0.0
$0.2
$0.4
$0.6
$0.8
$1.0
$1.2
$1.4
$1.6
An
nu
al F
uel
Sav
ing
s (
$M/Y
r)
340 305 270
APH Exit Temperature (F)
500 MW Gross9500 Btu/kW-hr85% Cap Factor$2.00/MMBtu
6
Impact on CO2 Emissions
$0.2
$0.8
$0.4
$1.6
$0.0
$0.2
$0.4
$0.6
$0.8
$1.0
$1.2
$1.4
$1.6
$1.8
An
nu
al C
O2 C
red
it V
alu
e ($
M/Y
r)
340 305 270
APH Exit Temperature (F)
$5/ton CO2$20/ton CO2
500 MW Gross9500 Btu/kW-hr85% Cap Factor
7
Impact on NOx Control
• Increase SCR NOx Removal– limit ABS formation via SO3 reduction
– permit operation at elevated NH3 slip
• Extend Useful Life of Catalyst– elevated slip permits lower reactor potential
• Extend Low-Load Operation of SCR– reduce SO3 level at SCR inlet
– lower Min Op Temp (min load)
• Strategy can be Applied to SNCR
8
Impact on NOx Removal
$0.9
$1.8
$2.7
$0.0
$0.5
$1.0
$1.5
$2.0
$2.5
$3.0
An
nu
al N
Ox
Cre
dit
Val
ue
($M
/Yr)
84 88 92 96
SCR NOx Removal (%)
500 MW Gross9500 Btu/kW-hr85% Cap Factor0.5 lb/MMBtu NOx$2500/ton Nox Credit
9
Impact of SO3 on ACI Performance
Injection Concentration (lb/MMacf)0
100
90
80
70
60
50
40
30
20
10
02 4 6 8 10 12 14 16 18 20
Vap
or
Hg
Re
mo
val
Acr
oss
PM
Co
ntr
ol (
%)
WC, FF or TOXECONWC, ESP, brominated carbon
LSEB, ESP
HSEB, ESP
WC = Western Coal
LS = Low Sulfur
HS = High Sulfur
EB = Eastern BituminousSource: EPRI
10
Impact on Hg Capture in Ash
0
2
4
6
8
10
12
14
0 5 10 15 20 25 30 35 40 45
Measured or Estimated SO3 Conc at ESP Outlet (ppm)
Mer
cury
Fra
ctio
n in
Ash
LO
I (u
g/g
)
Plant A
Plant B
Plant C
Plant D
Plant E
Plant D (Downstream) 2009
Plant D (Pre-SCR) 2009
Power (Plant B)
Power (Plant C)
Power (Plant A)
Power (Plant D)
Power (Plant E)
Power (Plant D (Pre-SCR)2009)Power (Plant D (Downstream)2009)
11
Impact on Hg Removal with ACI
0
10
20
30
40
50
60
70
80
90
100
0 lb/Macf 2 lb/Macf 5 lb/Macf 10 lb/Macf
Activated Carbon Injection Rate
To
tal H
g R
emo
val (
%)
No SO3 Removal
With SO3 Removal
Source: EPRI, Mercury Research Center, March 2007
12
Comparison of SO3 Controls
SBS Injection
Mag Hydroxide
Hydrated Lime
Trona Ammonia
Typical Injection Location
Boiler √Before SCR √Before AH √Before ESP √ √ √Before FGD √
Typical SO3 Removal 90 - 98% 80 - 90% 50 - 80% 70 - 90% 80 - 95%
Typical Injection NSR 1 - 1.5 3 - 4 3 - 5 2 - 3 1 - 2
13
SBS Injection™ Technology
Features• Patented Technology• Simple Solution Injection• Sodium-Based Reagent• Dual-Fluid Atomization• Selective Reactions
• High SO3 Removal
• Low Injection Rate• Product Collected with Ash
Benefits• Opacity Elimination• Corrosion Reduction• ESP Enhancement• HCl and Se Removal • Potential Heat Recovery• SCR/SNCR Flexibility• Hg Capture Enhancement
• CO2 Reduction
Maximum Benefits with “Upstream” InjectionMaximum Benefits with “Upstream” InjectionMaximum Benefits with “Upstream” InjectionMaximum Benefits with “Upstream” Injection
14
Simplified SBS Flow Diagram
FE FE
REAGENTSOLUTION STORAGE
TANK
INJECTION FEED PUMP
HOPPER TRUCK
INJECTION AIR:PLANT AIR OR COMPRESSOR
INJECTION LANCES
FLUE GAS
FILTER
DILUTION WATER PUMP
SBS DILUTION WATER
DUPLEXSTRAINER
(SOFTENED)
DILUTION WATERTANK
DE
SOLIDSWETTING
PUMP
15
SBS Injection Locations
SCR Outlet
Air Heater Outlet
SCR Inlet
16
SBS Injection Installations
12,500 MW Installed on 20 Boilers12,500 MW Installed on 20 Boilers12,500 MW Installed on 20 Boilers12,500 MW Installed on 20 Boilers
Utility Plant Location MWDesign
SO3Injection Location
ReagentStartup
Date
FirstEnergy Mansfield 1-3 Shippingport, PA 3 x 860 80 Air Heater Inlet Sodium Sulfite March 2003
TVA Widows Creek 7 Stevenson, AL 550 54 Air Heater Inlet Sodium Sulfite April 2003
NIPSCO Bailly 8 Porter, IN 365 59 Air Heater Outlet Sodium Carbonate April 2004
Vectren Culley 3 Newburgh, IN 287 48 SCR Outlet Byproduct SBS July 2004
PPL Montour 1-2 Washingtonville, PA 2 x 765 42 Air Heater Outlet Sodium Carbonate Aug 2004
Duke Energy Gibson 1-5 E. Mt. Carmel, IN 5 x 650 110SCR Inlet /
Air Heater OutletSodium Carbonate May 2005
DP&L Killen 2 Manchester, OH 635 34 / 36Econ Outlet /
SCR OutletSodium Carbonate Oct 2007
IP&L Harding St 7 Indianapolis, IN 465 58 SCR Outlet Sodium Carbonate Nov 2007
NIPSCO Bailly 7 Porter, IN 180 59 SCR Outlet Sodium Carbonate April 2008
DP&L Stuart 1-4 Aberdeen, OH 4 x 620 90 Econ Outlet Sodium Carbonate Sept 2008
17
SCR First Catalyst Layer
SBS Injection Lances (Par Mixers removed)
Ammonia Injection Grid
Economizer Outlet
TurboMixers
Gibson “Pre-SCR” Injection
18
19
Gibson SO3 Test Results
0
5
10
15
20
25
30
35
40
45
50
Econ Out SCR In AH In ESP Out
Mea
sure
d S
O3, p
pmvd
@ 3
% O
xyge
n
1717 17
< 0.5Avg 0.3
46
38
1.0
< 5.0Avg 2.3
Baseline
SBS Injection
20
520
540
560
580
600
620
640
0 5 10 15 20 25 30 35
SO3 Concentration, ppm
Min
imu
m O
per
atin
g T
emp
erat
ure
, °F
SCR Min Op Temp vs SO3
Δ MOT ~ 80°FΔ MOT ~ 80°F
Baseline – 615°F
With SBS – 635°F
Composite Range of MOT Information Provided by
Catalyst Suppliers
21
Summary
• SO3 Adversely Impacts Plant Performance– Corrosion– AH Fouling– Heat Rate– CO2 Emissions– NOx Removal – Mercury Capture
• SO3 Removal can Generate Millions $ in Benefits– Avoided Forced Outages– Fuel Savings– Lower Environmental Compliance Costs
• SBS Injection Offers Cost-Effective SO3 Control– Treats upstream of SCR / AH– Very high SO3 removal (~98%)– Proven - 20 units - 12,500 MW – 7 yrs
SOSO33 Removal: Removal: It’s not just for It’s not just for
““Blue Plume” anymoreBlue Plume” anymore
SOSO33 Removal: Removal: It’s not just for It’s not just for
““Blue Plume” anymoreBlue Plume” anymore
22
Questions?