eneractive solutions - power plant solutions for naes conference
DESCRIPTION
VP of Eneractive's Power Plant Solutions Division, Bill Gretta, delivered a presentation on CO and SCR System Evaluation Tools to key stakeholders at the NAES Plant Managers' Conference in Bellevue, WA.TRANSCRIPT
CO and SCR System Evaluation Tools
For
2014 Plant Managers’ ConferenceSeptember 23, 2014
Bellevue, WA
Uncovering Value, Instilling Confidence
POWER PLANT SOLUTIONS
OUTLINE
Uncovering Value, Instilling Confidence
SCR System Basics
Catalyst
Flow Modeling
AIG Tuning
SCR Inspections
4NO + 4NH3 + O2 4N2 + 6H2O
Catalyst
2NO + NO2 + 2NH3 3N2 + 6H2O
SCR SYSTEM BASICS
Selective Catalytic Reduction (SCR) is the process of removing NOx (NO and NO2) out of the flue gas stream by injecting ammonia (NH3) into the flue gas as a reagent.
The flue gas passes over a fixed bed of catalyst installed in a reactor.
Ammonia reacts with nitrous oxides on the catalyst surface to form safe and clean nitrogen and water.
SIMPLE CYCLE SCR DESIGN - TYPICAL
Tempering Air
CO CATALYST – COMBINED & SIMPLE CYCLE
Designed to reduce CO from engine
Simple reaction (no reagent required):
O2 + 2CO 2CO2
Made from stainless steel substrate with precious metals added (platinum)
>90% Reduction typical
Deactivation over time can dramatically reduce performance
CO CATALYST SAMPLING
Should be tested when performance problems develop
Annual testing can identify problems before problems develop
CO CATALYST DEACTIVATION
The effect of catalyst aging results in degradation of performance
There are fewer active site and, typically, lightoff temperatures will increase, with a slower ramp-up.
Maximum conversions will also be lower.
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 100 200 300 400 500 600 700 800 900
% C
O O
xida
tion
Temperature, °F
CO Oxidation vs. Temperature (Lightoff Curves)
NEW AGED
SCR CATALYST – COMBINED & SIMPLE CYCLE
Designed to reduce NOx from engine
>90% Reduction typical
Ammonia Required
Deactivation over time can dramatically reduce performance
SCR CATALYST SAMPLING Should be tested when performance problems
develop
Annual testing will assure that goals are being met or when replacement is required
0.4
0.6
0.8
1
1.2
1.4
0 10000 20000 30000 40000 50000
Operating Time (h)
K/K
o (-
)
Unit-1 Unit-2 Initial Required Design
SCR CATALYST MANAGEMENT
“Cost effective planning for end of catalyst life”
Testing is a significant aid to optimal catalyst management
Sample testing
Performance testing
Operations
Options:
1. Replace catalyst with new
2. Rejuvinate used catalyst
3. Regenerate used catalyst
FLUID FLOW DESIGN CONSIDERATIONS
Poor flow distribution can have huge effect on system performance
Physical or CFD modeling is an effective economical means to identify AND fix flow problems
Poor flow, ammonia and temperature distribution can affect:
1. CO performance
2. SCR performance
1. NOx reduction
2. Ammonia Slip
3. Ammonia Usage
AIG TUNING
AIG should be designed with ability to tune as much as possible
Systems designed with no tuning capability have very limited flexibility
Adjustments to AIG can have significant benefit to performance
AIG DESIGN – THE NEED FOR GOOD AMMONIA DISTRIBUTION
High Aspect Ratio More Vertical Zones
Poor NH3/NOx distribution can significantly impact NH3 slip
As shown, the better (lower %RMS) the NH3/NOx distribution, the lower the overall ammonia slip (and ammonia usage)
AIG TUNING
Tuning performed by measuring NOx and O2 at the inlet and outlet of SCR catalyst
Can be done by manual traverse, but a permanent grid will provide much easier long-term testing and tuning
SCR INSPECTIONS – COMBINED & SIMPLE CYCLE
Inspections are a great method for identifying problems before performance issues develop Take catalyst samples (CO and SCR)
Check for Leaks - Gas Bypass is major contributor to performance problems
Seals between modules and along perimeter of reactor should be checked
Configuration Ammonia Slip,ppmvd @ 15% O2
Original Sealing System 6.8
With ENERActive Modified Sealing/Reinforcement System
2.0
SCR INSPECTIONS – COMBINED & SIMPLE CYCLE
Insulation Buildup can result in significant drop in performance
Pressure Drop
NOx and CO Reduction
Ammonia Slip
Source should be determined and corrected
ENERACTIVE OVERVIEW
Northeast Base with National Reach Asbury Park, New Jersey Clinton, New Jersey New York, New York Beltsville, Maryland (Washington DC)
Team Comprised of Field Engineers, Performance Engineers, Energy Engineers, Project/Construction Managers, and SMEs
Independent Technical Advisor for Component, System, and Plant Solutions
Projects Ranging From Simple Analyses to Multi-Million Dollar Implementation Efforts
#24 on Forbes List of Most Promising Companies
On NJBIZ’s List of 50 Fastest Growing Companies
POWER PLANT SOLUTIONS Services Include:
Complete Turnkey Projects
System Inspections Performance Testing Flow Modeling Performance Engineering AIG Tuning Catalyst Testing (CO and
SCR) Coal-Fired SCR
Optimization Combined Cycle/Simple
Cycle SCR System Optimization
CO Catalyst Systems for RICE
System Commissioning Control System Upgrades Specification
Development Feasibility Studies SCR Maintenance &
Catalyst Cleaning Catalyst Management
Energy Solutions… Efficient Results