Documente Academic
Documente Profesional
Documente Cultură
.1
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.2
B&W is technically, financially
and strategically positioned to support you
through our nations energy transformation
Headquarters: Charlotte, NC
Incorporation: Delaware
Company CEO: E. James (Jim) Ferland
Profile 12,700 plus 10,400
Employees:
joint venture employees
Ticker Symbol: NYSE: BWC
A leader in clean energy technology and services, primarily for the fossil,
nuclear and renewable power markets, as well as premier advance technology
and mission critical defense contractor.
.3
A Global Business
.5
B&W Power Generation Group (B&W PGG)
Business Footprint Product Line Portfolio
Utility and industrial boilers
Firing fossil fuels
Environmental products
Control regulated emissions
Construction
Install all B&W supplied scope
O&M services
.6
Environmental Products and Services
.7
A Complete Environmental Technology Portfolio
Mercury Acid Gas CO2 SCR / Low Emissions Aftermarket Construction Ash
Control Dry Sorbent Control NOX Monitoring Services Management
Injection Burner
.8
Extensive Environmental Field Service Capabilities
150 Environmental
Field Specialists Support and train / retrain O&M
personnel; Inspections and troubleshooting
Field Service
Organization Equipment Remote Consulting Support for troubleshooting,
O&M, process performance, over the phone
.9
Babcock & Wilcox Research Center
Modern laboratories for
basic research on clean
fuel utilization
Pilot plants for combustion,
oxy-firing, emissions
control, and post-
combustion CO2 capture
Collaborations with
universities, national labs,
and industry
Research focused by
business vision and
technology roadmaps
.10
Clean Energy Technology
.11
B&Ws SCR Qualifications
Oldest domestic SCR technology supplier
.12
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.13
What is Selective Catalytic Reduction (SCR)?
A process for the control of
nitrogen oxide emissions from
stationary sources
Catalyst is defined as a
substance that causes or
accelerates a chemical reaction
without itself being affected
4 NO + 4 NH3 + O2 = 4 N2 + 6 H2O
.15
Typical Coal Fired SCR System
Catalyst
Ammonia injection grid (AIG)
Static mixers
Flow distribution devices
Flow straightener
Catalyst cleaning equipment
Catalyst loading equipment
.16
General System Design Parameters
Operating temperature
Min ~585 F
Max 780 F
Velocity in SCR fluework
50 to 60 ft/sec
Velocity through reactor
< 18 ft/sec
NOX performance (coal)
Up to ~90+% reduction or ~0.05 lbs/MBtu
NOX whichever is first achieved
Ammonia slip (coal)
2 - 5 ppm (dependent on fuel)
SO2 to SO3 Conversion
0.25% to 0.5% per layer
Pressure drop
As necessary for requisite
system equipment
.17
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.18
Minimum Ammonia Injection Temperature
.19
Options to Raise SCR Inlet Temperature
.20
Maximum Temperature Control
Upper temperature limit set to avoid impacts to:
Catalyst
Support structure
Other affected materials
Controlling temperature to achieve 780 can be achieved via:
Boiler cleaning equipment modifications / revised protocol
Economizer or other surface (superheater) modifications
Addition of external heat trap
.21
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.22
Ash Management
.23
Ash Types
Fly ash
Small, light particles that remain entrained in flue gas
May result in catalyst erosion
May form layer on top of catalyst typically managed with sonic horns,
sootblowers or both
Bottom ash
.24
Ash Management Design Options
Solution Function Application
Units w/ compatible
LPA baffle Redirect LPA
economize outlet
LPA screen w/ rappers Capture LPA Any unit
Greater than 20% PRB
Eliminate ash build up
Scalloped vane slots and other high ash
on vanes
coals
Greater than 20% PRB
Boxed catalyst support
Prevent ash collection and other high ash
beams
coals
Greater than 20% PRB
Allow ash to flow freely
Large pitch catalyst and other high ash
through bed
coals
Sootblowers/sonic Avoid ash piling; move All coal-fired
horns/air cannons ash through bed applications
.25
Aerodynamic Approach to LPA Management
Install baffle and/or adjust economizer outlet geometry such that
large ash particles are aerodynamically captured in hoppers
Dependent upon accurate measurement of the ash particles
aerodynamic properties
Density
Drag
Restitution
Friction
Designed using CFD modeling
.26
.27
Physical Barrier for LPA Management
.29
Large Particle Ash Screens
Considerations:
Pitch
Screen types
Perforated plate
Wedge wire
Screen materials
Carbon steel
Stainless steel
Conforma Clad coating
UTEx TM 1-120LPA
Cleaning methods
Sootblowing
Rapping
.31
Large Particle Ash Screen Cleaning Devices
Sootblowers
Rappers
.32
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.33
Universal SCR Reactor
A reactor designed to
accommodate catalysts
from multiple suppliers for
the NOx reduction required.
Outliers may be excluded
from consideration.
Catalyst support system based
on heaviest catalyst module
Reactor height based on tallest
catalyst module
Access and provisions for
catalyst loading based on
largest catalyst volume
Equipment to handle each type
of catalyst
.34
Catalyst
Corrugated
Active ingredients:
V, Ti, W
Catalyst sizing based on:
Inlet NOx concentration Honeycomb
NOx reduction level
NH3 slip required
Fuel constituents
Gas flow
Plate
Operating temperature
SO2 to SO3 conversion
Required life
.35
Catalyst Selection
Fuel and ash characteristics
Fuel type
Bituminous
Sub-bituminous
Lignite
Ash type
Flow characteristics
Hygroscopic
Catalyst type and pitch
Corrugated, honeycomb or plate
Pitch
.36
Major Catalyst Suppliers
Plate Type
Ceram
Hitachi
Johnson Matthey
Corrugated Type
Haldor Topsoe
Honeycomb Type
Ceram
Cormetech
Johnson Matthey
.37
Catalytic DeNOX Reaction
Active sites constantly being
regenerated in a cycle
Active site available
Adsorb ammonia
Reaction of NOX with NH3
Regenerate site with O2
Sites busy with NOX reduction
(ammonia) not available
for oxidation
Poisons prevent active sites
from being regenerated in
the cycle
.38
Catalyst Deterioration Issues
Operating temperatures
Sintering unacceptably above design
Sintering > 800 to 850F
Alkaline metals
Masking
Ash
Arsenic
Poisoning Phosphorus
Other ash constituents
.39
Typical Catalyst Management Plan
1.2
0.8
0.6
0.4
0.2
0.0
0 1 2 3 4 5 6 7 8 9 10
Operating Time (Years)
.45
SO2 to SO3 Conversion
N2
NOX H2SO4 Acid Plume
Boiler SCR NH3 Slip
Outlet Catalyst H2O
SO2
SO3
.46
Mercury Oxidation
.47
Catalyst Cleaning
Sonic Horns Purpose is to prevent ash from accumulating at all
Uses small amounts of compressed air
Cannot remove deposits that form due to improper operation
Inexpensive system to install, operate, and maintain
Sootblowers Purpose is to remove ash that has accumulated over 1 shift or 1 day
Rake-type (multi-element) used
Air or steam acceptable
Steam must be superheated to prevent condensate
on catalyst
Can possibly remove deposits that form due to improper operation
Expensive system to install, operate, and maintain
.50
Catalyst Cleaning Equipment - Sonic Horns
Arrangement
Spacing
Single & multiple walls
Flush or inset
Level or sloped
Insulation
Operation (PRB firing)
Begin with 10 sec on / 10 sec off
Pairing (1&2, 3&4)
Sequencing (1&2, 2&3)
.51
Catalyst Cleaning Equipment - Sootblowers
Media may be either
Air
Clean, dry & oil-free
65-110 ft/sec
ISO 8573-1
Particulate (1 0.1 , 0.1 mg/m3)
Moisture dew point (3 -20C, -4F)
Oil content (2 0.1 mg/m3)
Steam
Superheated (dry)
65-110 ft/sec
Thermal drain
.54
Catalyst Cleaning Equipment Air Cannons
.55
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.56
Ammonia Systems
System Pros Cons
Easy to transport
Shipping traffic
Aqueous Ammonia Not classified as hazardous material
Safety issues (19% vs 29%)
(19% or 29%) if less than 20%
Vaporization costs
Safer than anhydrous
.57
Manifold Valve Station
.63
Ammonia Injection and Mixing
B&W customizes injection zones and hybrid vane
vortex mixers to enable
Zone-by-zone control
Straightforward initial tuning
Infrequent future tuning
Flexibility to accommodate
unit operation changes
Acceptable NH3/NOX and
temperature distributions
without unnecessary
ash collectors
.64
Ammonia Injection and Mixing Equipment
Mixing Devices
Vortex Blending from counter rotating downstream vortices
and general turbulence
Benefits: minimal equipment with low weight
Drawbacks: requires turbulent flow and significant
downstream flue length, P
.65
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.66
Flow Modeling
Use both physical and Computational Fluid Dynamic (CFD) modeling
.67
CFD Modeling of Flue Gas Velocity
.68
CFD Modeling of NH3 / NOX Ratio
.69
Physical & CFD Modeling of Ash
.70
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.71
SCR Reactor Design Options
An array of design options enables selecting an approach
that best fits the plant and its site.
Flat panel delivery for
restricted delivery access,
arrangement and erection
challenges
Truck-shippable modules when
there is adequate space for
laydown and cranes; adequate
access for placement
Barge-shippable modules
when there is water access with
unloading capability; open area
for placement with large cranes
.72
Reactor Modularization
Design goals:
Reduced cost
Enhanced quality
Enhanced safety
Reduced schedule risk
Reduced impact to plant operations
.73
Completed Reactor
.107
Flue Arrangement
.112
Do's & Don'ts of Flue Arrangements
Flue gas velocity in general Gas Speed Ft/Min)
.113
Arrangement Tips
FLOW
ASH BUILD
FLOW
UP AREA
FLOW
.114
Arrangement Tips
FLOW
FLOW
GOOD FLUE ARRANGEMENT
SAME CROSS SECTIONAL AREA MAINTAINED
ASH BUILD
UP AREA
EQUIPMENT INLET
OR OUTLET FLUE
.118
Catalyst Lifting Rig
Quick Disconnect
.119
Hinged & Bolted Catalyst Loading Door
.121
Catalyst Gas Seals - Ash Shields
.122
Structural Support Steel
.125
Mirant Morgantown SCR Feb. 3, 2005.
Structural Steel
Structural steel is the backbone of the project
Significant cost, both material and erection labor
Major project schedule impacts
Coupled with the flues and the reactor, defines the
complexity of the project
Independent steel structure generally more cost-effective
Required reinforcement of existing steel less favorable
.126
Mirant Morgantown SCR Feb. 3, 2005.
B&W Structural Steel Experience
.129
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.130
Retrofit SCR/Boiler Relationship
The SCR is not simply an add on
The SCR system must be designed to work efficiently
with the boiler, other AQCS equipment and peripherals
Boiler and boiler peripherals modifications may be
necessary as part of SCR installation to achieve the
optimum solution
The SCR system must be integrated with boiler
operation to achieve least-cost NOX compliance
.131
SCR Design Information
Detailed and accurate information enables realistic project
planning and precludes (or minimizes) false starts
Boiler and peripherals design and performance
data including
Gas flow
Economizer exit gas temperature
NOX in flue gas
Ash carryover information
Drawings site plans, general arrangements, major
equipment drawings
Fuel analyses for fuel(s) that will be fired with SCR in place
Performance goals
Site constraints
Future plans
.132
Integrated Design Process
The Steps:
1. Define scope explicitly
2. Define arrangement - in concert with existing structures
and equipment
3. Define construction approach early
4. Perform joint project management, engineering and
construction reviews
5. Iterate through 2 - 4 above to advance / evolve the design
.133
Agenda
Company Overview
Technology Review
Project Execution
Experience List
.140
B&W SCR System Case Histories
.141
B&W SCR Case History, Bruce Mansfield 1 - 3
Bruce Mansfield 1 - Boiler OEM: Foster Wheeler
3
Boiler MW: 3 x 856
Sammis 6, 7
Boiler Fuel: Bituminous coal / pet coke
.142
B&W SCR Case History, Sammis 6, 7
Bruce Mansfield 1 - Boiler OEM: B&W
3
Boiler MW: 2 x 680
Sammis 6, 7
Boiler Fuel: Bituminous coal / PRB
.143
B&W SCR Case History, Cheswick 1
Bruce Mansfield 1 - Boiler OEM: CE (Alstom)
3
Boiler MW: 580; corner-fired
Sammis 6, 7
Boiler Fuel: Eastern bituminous
Sandow 4
.144
B&W SCR Case History, Karn 1, 2
Bruce Mansfield 1 - Boiler OEM: CE / B&W
3
Boiler MW: 2 x 265
Sammis 6, 7
Boiler Fuel: PRB blend
Cheswick 1 Inlet NOX: 0.45 lb/106 Btu (Unit 1), 0.38 lb/106 Btu (Unit 2)
.145
B&W SCR Case History, Campbell 3
Bruce Mansfield 1 - Boiler OEM: Foster Wheeler
3
Boiler MW: 871
Sammis 6, 7
Boiler Fuel: PRB
Sandow 4
.146
B&W SCR Case History, Southwest 1
Bruce Mansfield 1 - Boiler OEM: Riley Stoker
3
Boiler MW: 1 x 195
Sammis 6, 7
Boiler Fuel: PRB
.147
B&W SCR Case History, J.T. Deely 2
Bruce Mansfield 1 - Boiler OEM: CE (Alstom)
3
Boiler MW: 1 x 446
Sammis 6, 7
Boiler Fuel: PRB
.148
B&W SCR Case History, Sandow 4
Bruce Mansfield 1 - Boiler OEM: CE (Alstom)
3
Boiler MW: 1 x 591
Sammis 6, 7
Boiler Fuel: Texas Lignite
.149
Take-Aways
Complete portfolio of air quality control systems to achieve
fully integrated solutions
.150
Thank you.
Questions?
.151