Overview of SCR Technology and Retrofitting of SCR’s · Increased Catalyst Loading Reactor Area for Added Catalyst, ... Information courtesy of Cormetech reduced fuel costs

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Mitsubishi Hitachi Power Systems Americas, Inc.

SCAQMD AWMA Annual Regional Meeting

Overview of SCR Technology and Retrofitting of SCR’s

to Comply with Upcoming NOx BARCT Standards for

Electric Power Generating Units (EGUs)

Robert McGinty

Senior Product Manager

Gas Turbine & Industrial SCR Systems

1


Corporate Qualification

Innovative & Improved Technical Advances

(System Design, Catalyst, Modeling)

Validation of Innovation

(Reference Plants - Historical Performance)

Presentation Overview


Advanced Hot SCR Systems For Frame Simple Cycle Gas Turbines

US Reference Validating “LAER” SCR Systems for Large Frame Class Turbines

Expertise’ built over 40 years with >1000 SCR systems worldwide

(Original Pioneer of SCR Technology)

Leader in Gas Turbine & SCR Technology

Ultra Low NOx Demonstrating All BACT & LAER Requirements

Time Tested Frame SCGT Hot SCRs Spanning 25 Years

Demonstrated High Temperature SCR Systems for SC Frame GT’s

Patented Tempered Air Systems for SC Frame Turbines

OEM - Producing Both Gas Turbine and SCR Systems

Largest US Peaking Plant with Hot SCR Systems

Numerous 1st in Class Innovative Technologies

Most Advanced Class SCR System for Frame SC Gas Turbines

Reference Plant for FERC, Validating High Temp Hot SCR Systems

NRG Marsh Landing SCRs for Large Frame Simple Cycle GTs


MHPS ONLY Experienced OEM who can wrap both the Gas Turbine and the SCR

for Simple Cycle Applications to meet Current and Future Environmental Regulations

Leader In Gas Turbine and SCR Technology

MHPS - Tomorrow’s Power Plant, Today

Multiple Models

J/G/H/FT

w/ Hot SCR BACT LAER*

9 ppm ≤2 ppm 2-25 ppm <2.5 ppm

15 or 25 ppm ≤2 ppm

Advanced Class Gas Turbines Hi Temp Hot SCR

NO

x

*Requirement in

Nonattainment

Regions

(and growing)


Key Components of Conventional Hot SCR Systems

Ammonia Injection

Grid

Stack

SCR Catalyst

Ammonia Vaporizing Skid

Ammonia Pump Skid

Ammonia Storage Tank

CO Catalyst

Tempering Air Injection


CONVENTIONAL SCR & CO/VOC CATALYST MODULES

WIDE ARRAY OF CATALYST SELECTION ENSURES BEST FIT APPLICATION


Large operating temperature range (350 - >1100oF)

70%

80%

90%

100%

500 600 700 800 900 1000 1100

Temperature [oF]

NO

x R

emov

al E

ffic

ienc

y

Zero V2O5

Low V2O5

High V2O5

NO = 50 ppmvd

NH3/NO = 1.25

O2 = 15.0%

H2O = 7.0%

Zero V2O5

Low V2O5

High V2O5

At higher temps, reduce V:W ratio

Stronger NH3 adsorption

Lower NH3 decomp rate

Higher DeNOx rate

Lower sintering rate

• High temp catalyst:

900F ~ >1,100F

• Medium-high temp catalyst:

800F ~ 900F

• Medium (Standard) catalyst:

450F ~ 800F

Extruded catalyst

consistently demonstrates

uniform cell sizing and

pressure drop prediction


• Platinum or other PGM promotes

CO to CO2 oxidation. May be

temperature sensitive to PGM type

• Substrate may be brazed joint

corrugated metallic foils, stacked

corrugated foil or ceramic cells.

• Typically high density CPSI

substrate employed to provide high

surface area per cu.ft. of catalyst

• Oxidation occurs on “surface” of

catalyst at active sites

• Pressure drop is directly dependent

on catalyst depth and compactness

Conventional CO & VOC Catalyst


KEY CONSIDERATIONS FOR FUTURE BARCT (EXISTING UNITS)

Existing vs. Future NOx Levels Increased Catalyst Performance

Flue Gas and Ammonia Distribution CFD Modeling for Reduced

Deviation of Velocity & Distribution

Increased Catalyst Loading Reactor Area for Added Catalyst,

Sealing System to Prevent Bypass

Catalyst Configuration Consideration Application Dual Purpose Catalyst

Advanced Catalyst Geometry

Increased Ammonia Flow High Density Ammonia Injection

Increased Balancing Valve Array

Increased Ammonia Vaporization Retrofit or Replace – AFCU

Retrofit or Replace Ammonia FPS

BEST AVAILABLE RETROFIT CONTROL TECHNOLOGY (BARCT)


Example of Advanced Catalyst Configuration, Geometry, Performance

Step-change reduction in pressure drop: 60–75% Lower!

Vastly improved emission control solution capability for NOx, CO, NH3 slip

Innovative seal to prevent need for maintenance

+ +

Pleated Module Advanced Catalyst Potential

60% Higher

Integrated Seal

Result:

0

0.5

1

1.5

2

Legacy New

Potential / Volume

Combines three new tools

Patent Pending

Information courtesy of Cormetech

Platform


Single Zone Catalyst Reactor for Combined or Simple Cycle

AIG METEOR™

Homogeneously extruded honeycomb catalyst (1 layer)

SCR functionality

V2O5-WO3/TiO2

Oxidation functionality

PGM (Pd and/or Pt)

Simplicity of one catalyst layer vs. two

Smaller footprint in HRSG

Lower pressure drop

Lower capital and O&M costs

Flexibility

applicable to new units, retrofits, and

replacements

Lower SO2 oxidation rate

Potential for reduced backend fouling

Highly resistant to sulfur, compounds in

the flue gas

Broader load flexibility from reduced

sensitivity to sulfur fouling agents when

operating at low temperature

Lower Pressure Drop

improved power output

reduced fuel costs Information courtesy of Cormetech


Catalyst Poisoning & Degradation Mechanisms

Degradation Source Mechanism

High Temperature Decreases available surface area by thermal sintering of ceramic or

washcoat material

Fine particulate Reduces available surface area by masking surface and preventing

diffusion into pre structure

Ammonia-sulfur compounds Plugs pores and prevents diffusion

Alkaline metals, Na, K Ion exchange with active sites

Alkaline earth metals, Ca, Mg Typically in form of sulfates, bond with acid sites reducing the ability of

catalyst to absorb NH3 I.e. formation of CaSO4

Halogen May react with and volatilize active metal sites

Arsenic Gaseous arsenic diffuses into catalyst and covers active sites,

preventing further reaction

V, Pt, Cr and Family Deposit onto catalyst, increasing NH3 to NO and/or SO2 to SO3


MHPS Flow Modeling – Validates Design – Minimizes Risk

13

1) Develop flow distribution devices and injection ports to;

a) Achieve acceptable velocity distributions through CO and SCR catalyst:

b) Achieve acceptable ammonia distribution at the inlet to the SCR catalyst:

c) Achieve acceptable temperature distributions at the catalyst inlets:

2) To determine from model measurements the system pressure loss for the final configuration

• Typical Boundaries: Turbine Diffuser or Process Equipment Exhaust Outlet through Stack Outlet.

• CFD and CFM results, validates ammonia injection design, ammonia mixing devices, tempering air

distribution through injection ports, turning vanes, perforated plates and flow straightening devices.


Tempering Air & Ammonia Mixing Challenges

- Major Design Concern;

a) Short Distance Available to Mix the Air

b) Conflicting requirement at the inlet duct

Mix the air into flue gas (Turbulence)

versus

Uniform gas flow necessary at CO catalyst face.

versus

Homogeneous ammonia mix in flue gas at SCR catalyst face

(Flow Straightening & Velocity Normalizing at Catalyst)

Challenging Turbine Exhaust Conditions – Typical

Flue gas exiting turbine diffuser up to ~140 FPS

Tempering air ~ 30% total flue gas volume

High exhaust gas temperature ~ 1200 def.

Contrasting optimum catalyst temperature profiles CT

SCR cata

CO cata


VAPORIZED NH3

EXHAUST

DUCT

LANCE PANELS

BALANCING

MANIFOLD

• Double reactor side entry balancing valve manifold to fine tune AIG

• Lance panels allows expedient optimization

• High density drilling, dense ammonia injection pattern

• Orifice flow measurements validate ammonia panel flow field balance

• Allows for future optimizing as catalyst ages or turbine performance degrades

Represents most responsive balancing

approach, easy to adjust and fastest

response, does require additional

piping, valves and manifolds

Multi-Zone

A Core Technical Attribute Facilitating Less Than 2PPM NOx & Low Ammonia Slip


Catalyst Sealing Mechanism – Good & Bad Comparison


Engineered Modules Reduce Installation Cost Minimize Flue Gas Bypass

MHPS Designed Catalyst Super-modules

Structurally engineered, up to 6” growth,

improves reliability, shortens outage time


Installations Worldwide – An Original Pioneer Of SCR Technology

MHPSA – Global Solutions for SCR Systems

MHPSA Japan, Asia, North &

South America

Boiler

Coal 173

Oil 103

Gas 52

Gas Turbine 423

Diesel Engine 224

FCC & Refinery Heater 48

Total Units Installed 1023

Over 40 years of first hand experience

Numerous SCRs Installed in Refinery, Power and

Petrochemical for boilers, heaters, FCC, Gas Turbines


Project K-Point SMUD

McClellan

TEPCO

Yokosuka

Carson

IceGen

NRG

Marsh

Landing

Calpine

Mickleton

Calpine

Carll’s

Corner

PNM

La Luz

CT M701F GE 7EA M701DA LM 6000 SGT6

5000F W501AC

P&W

FT 4

TwinPac

LM6000

Gas Temp

Deg. F 1112 1020 986 875 1146 900 900 <900

Minimum

DeNOx Eff. 86% 90% 60% 90% 87% 75% 76% >94%

Start of

Operation

Jul.

1992

Apr.

2004

Aug.

1992 June 1995

Apr.

2013

May

2015

May

2015 Nov. 2015

Turbine Type Frame Frame Frame Aero Frame Frame Aero Aero

Tempering Air

Fan YES NO NO NO YES NO NO Yes

Wide Range of Gas Turbine Models and Temperature Variations


‘Knowledge’ and ‘Expertise’ built over the past 40 years

(Developer of honeycomb catalyst, plate catalyst, ammonia grid and ammonia vaporizing system technology)

Successfully completed the most difficult and challenging projects for Frame & Aero GT’s, Refinery

FCCs, Process Heaters, Thermal and Power Boilers

Ultra Low NOx & Slip (< NOx 2ppm/NH3 2ppm)

Zero-Slip ammonia systems

High temperature SCR systems SCGT’s

Tempered air systems for SC Frame Turbines

More than 1000 SCR systems world wide

Proven track record. (translates to Low Risk)

Have always met or exceeded performance guarantees

Only OEM supplier of SCR catalyst and SCR systems

We do not walk away

Competitive offerings, high reliability systems

Experienced teams in the USA, Japan R&D Centers

Financial stability

MHPS – A World Leader of Intelligent Engineered SCR Systems


Thank You

21

Robert McGinty

Mitsubishi Hitachi Power Systems

Senior Product Manager

Gas Turbine and Industrial SCR Systems

Office: 949-856-8419 Mobile: 949-633-8614

[email protected]

mailto:[email protected]

© 2017 Mitsubishi Hitachi Power Systems Americas, Inc. All Rights Reserved. 22

Documents

Overview of SCR Technology and Retrofitting of SCR’s · Increased Catalyst Loading Reactor Area for Added Catalyst, ... Information courtesy of Cormetech reduced fuel costs