ES StationaryDe-Nox TECHNOLOGY

NOx REDUCTION IN UTILITY & NOx REDUCTION IN UTILITY &

INDUSTRIAL BOILERS

By Mr. Prem Talreja(Head - Stationary India &Managing Director)

Content

S. No

DescriptionS

No.Description

1 Yara at a Glance 8 SNCR Technology

2 Our Portfolio / Offering 9 Proven Technology

3 NOx, its implications 10 Challenges in Power Plant

4 De-NOx technologies 11 Challenges in Monitoring

2

5 Notification of India &

Implementation status

12 Avoid dilution

6 Global Norms of NOx control 13 Conclusion

7 SCR technology 14 Our Future…

Revenues and other income (2017)

US $ 11

Number of employees

15.527

Located in more than

50 countries

27,2 million tons Fertilizers

7,12 million tons

Key numbers

(Appx.)billion

50 countries

Sales to more than

150 countries

Industrial products

2,03 million tons Ammonia trade

3

Yara delivers sustainable solutions for agriculture and the environment

Agricultural Industrial Environmental products products solutions

4

3

We serve a wide range of customers through an extensive offering

Services

• Dispensing bulk

equipment

• Telemetry

• Training

• SCR

Technology

• SNCR

Automotive

• Optimization of

operations,

emissions

Off-road vehicles

Cars

Trucks

• NOxCare:

high-quality

urea solution

End users Yara value proposition Yara competitive edge

Reagent Technology

• AdBlue:

High-quality

urea

solution

Power plants

• Global reach

• Strong market

infrastructure

• Reliable supply

Stationary

Marine

• SCR

Technology

• SOx

scrubbers

• Design and

engineering

• SNCR

Technology

• Hybrid-

systems

• NOxCare40:

High purity

urea solution

emissions

reduction, safety

and performance

improvement

• Commissioning

• Operational

training

• Safety training

• Maintenance

• Spare-parts

Cruise and ferries

Coast-nearvessels

Deep sea vessels

urea solution

and

ammonia

solution

Cement factories

Waste Incinerators

• Proximity to customers

• High-quality products

• Proven technology

• Strong Yara brand

5

Nox reacts with hemoglobin affecting body tissues causing tachycardia, high blood pressure, and arrhythmia

> 15 µg/m3, irritation of the eyes

Nox and its impacts of environment & health

NOx is a generic term for mono-nitrogen oxides, namely NO and NO2. NOx is formed during combustion at high temperatures (above 1350 deg. C).

> 25 µg/m3 dyspnea, asthma crisis

> 150 – 200 µg/m3 pulmonary edema

6

One Study indicates that every coal-based power plant in India is

responsible for around 650 deaths every year: approximately 500 deaths are associated with SO2, 120 with NOx and 30 with PM 2.5.

Emission Standards Notified in India in 2015

7

Implementation-??

Implementation Norms – Current Status

� Environment ministry notifies standards for oxides of nitrogen emissions (NOx)

in 2015. Deadline for implementation: 2017.

� In 2017 further extended to 2022 for Power

� 80% cement sector already implemented the technologies to reduce the NOx

� In 2019, MoP and Power Industry still deliberating norms, limits, technology etc

after 4 years

� Above time scale indicates communication gap between regulator and industry.

� Proactive approach from the industry needs to be exhibited since it involves

health and sustainability of development for future generations.

8

GLOBAL SCENARIO OF EMISSION STANDARDS

Country Time

Period

NOx ,mg/Nm3

existing new

China hourly 100 50

Indonesia (*) 850 200-300

Japan 410 200

USA daily 135 95.3

EU Cont. 200 150

(*) Proposed, implemented from 2020

Eye Opener : Even Spain having type of Coal which is close to the Indian Coal is

Implementing the EU emission Norms

9

DeNOx Technologies

� SNCR

– Boilers / Cogeneration

– Industrial applications

� SCR

– Boilers / Cogeneration

– Industrial applications

� HYBRID

– Boilers / Cogeneration

– Industrial applications

Marin

De-NOx Technology available as secondary measures:

DeNOx Reducing Agents

� Available Reagents:

– Anhydrous ammonia

– Aqueous ammonia

– Solid urea

– Urea solution

NH3 + NOx N2 + H2O

NH3 slip

– Marine

Reasons to Opt for Secondary Measures with Primary measures :

1) In combination of Primary Measure with Secondary Measures , we can go less than100 mg/Nm3.

2) SNCR is a low cost solution with which we can achieve 300 mg/Nm3 as per MoEF notification.

3) Short time of installation with min time of Boiler shut down

10

SCR technology

• New block with SCR system

• RETROFIT - high dust DeNOx

The SCR is the best developed and most widely used method for removing NOx from flue gases.

It consists in the reduction of NO and NO2 to N2 under the influence of ammonia on the catalyst layer.

• in a second draft

• external reactor

• RETROFIT – low dust DeNOx

• tail end solution

11

SCR System – main components

• Ammonia Storage

• Ammonia Vaporizer

• Ammonia Injection Grid

• Catalyst

• SCR Reactor

12

PROJECT DESCRIPTION:

Design and erection of SCR DENOX plants for 4 coal fired boilers type OP-650k (K7, K8 and

optionally K5, K6) inclusive NH4OH-storage, modernization of rotary air preheater and ID-fans.

MAIN QUANTITIES:

Flue gas flow rate/boiler: 780.000 Nm³/h

NOx reduction (400 mg/Nm³): <100 mg/Nm³, dry 6% O2

NH3 Slip: <4 mg/Nm³, 6% O2

SCR Retrofit Rybnik

Customer: EDF Polska

Commissioning:

March-April 2015 (K7 & K8)

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NOxCare SNCR system

PU reagent injectionStorageTank

CMM

Combustionchamber /

Boiler

Process control

Reagent mixing & distribution

14

PMR PMW

PMR = Pump module for reagentPMW = Pump module for waterUnloading

pump

ADVANCED TECHNOLOGY FOR POWER BOILER

The Yara SNCR system is designed for high degree of NOx reduction with low NH3 slip and high efficiency of reduction agent

Various Techologies :

� ACL (air cooled lance) – the new injection technology

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� UDL (urea decomposition lance) –injection of urea betweensuperheaters with no corrosion risk

� CFD model of the boiler / injection of reagent

� Acustic pyrometer or equivalenttechnologies for temperature control in the boiler

UDL

ACL

CASE STUDY (SNCR): COAL FIRED UTILITY BOILER 500 MWel – PILOT PLANTMain information

• Capacity: 500 Mwel

• Maximum continuous rating: 1,675 t/h steam

• Pressure of superheated steam: 178 kg/cm2

• Temp. Superheated steam: 540°C

• Fuel: Coal

• SNCR reagent: urea solution

• NOx baseline: 500 mg/Nm3, @ 6 % O2

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• Target NOx with SNCR: 30% reduction

• 018

CASE STUDY : COAL FIRED UTILITY BOILER 500 MWel– PILOT PLANT ( NOZZLE’S PLACEMNTS)formation

Vertical urea decompositionlances UDL

17

Horizontal air cooled lances ACL

Globally Prooven Technologyinformation

S.No. Plant Country Units Fuel Eff. of De-NOx system

1 Jiangyin

Ligang Power

China 600 MW Coal- T

fired Boiler

> 30% (SNCR)

2 Martin Lake USA 850 MW Coal

Lignite

> 30% (SNCR)

3 Vindyachal

(Pilot Test)

India 500 MW Coal > 30% (SNCR)

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(Pilot Test)

4 Rihand

(Pilot Test)

India 500 MW Coal > 30% (SNCR)

Note : *) With Combination of Primary Measures and SCR this reduction can go up-to 90% and we can achieve the MoEfNotification.#) Above references is from different companies (Not only from Yara) to proove the stand that De-NOx is globallyprooven technology

De-NOx – India Power sector

� In Pilot Test, NTPC has limited vendors to only use existing ports and hence there by not able exploit the

complete potential of pilot plant. Nevertheless Yara has been able to achieve an efficiency of approx 30%,

we are however confident that the efficiency can be improved to about 40% if there is flexibity to increase

and decide the ports and their

� SCR pilot plant is an extremely small compared to the full plant hence the actual results of pilot plant may

not be fully representative of the actual results and efficiency that can be achieved, Nevertheless, Yara

has been able to achieve efficiency of approx 90%.

� Tests should be carried out with different reagents i.e Aqua ammonia , Ammonia to be able to ascertain

the most appropriate reagent suitable for Indian

� Flow distribution of high dust gas in pilot set up is more difficult than in full scale plant set-up

� The isokinetic gas sample obtained at the economiser outlet was not provided always the desired

conditions for the SCR reactor. The desired conditions and system control will be more feasible to

achieve for a full scale plant.

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Nox release at different limits

Typical data for 500 MW Plant

Implication of changing norm from 300 mg/Nm3 to 450 mg/Nm3

Additional NOX in Air per annum 2193 t

Implication of changing norm from 100 mg/Nm3 to 450 mg/Nm3

Additional NOX in Air per annum 3066 t

NOx emissions in India are currently at 9.5 million tons/year. Out of which 55 % is estimated from

total coal firing in electricity generation, heavy and light industry

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Conclusions

� Globally Proven technologies are available to achieve the emission

norms of <100 mg/Nm3.

� Need better understanding between agencies and Industry for

implementation of the Norms

� Proactive of Power industry , similar to Cement, to implement the

Norms

� Pilot plants should have been built with vendor / industry participation,

involvement and commitment would have been better.

21

� A time bound approach from the regulator will reduce the uncertainity

for all the stake holders.

We are not very far

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