Professional Documents
Culture Documents
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2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
SCR Flow Model
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Multiple Injection Points
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
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SCR Dust
Model
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Catalyst Cleaning
Steam Sootblowers
Requires controlled steam quality, dry steam
Rake type sootblower
Required for high ash concentration (> 20 g/Nm
3
)
Sonic Horns
Compressed air requirements typical of service air
Low air quantities required
Continuous operation
U.S. application and popularity increasing
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Anhydrous Ammonia
Hazardous chemical
governed by codes
Aqueous Ammonia
Concentration based
codes, maybe changed in
future
Urea Based Ammonia
Safe storage, more
equipment and complex
Ammonia Systems
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Safety Codes &
Standards
3 Levels of alarm and detection
35 ppm (Lights): Threshold Limit Value Short Term
Exposure Limit (TLV-STEL) by the American
Congress of Governmental Industrial Hygienists
(ACGIH)
50 ppm (Lights & Horns): OSHA 8 hour exposure limit
300 ppm (Lights, Horns, & E-Stop): Immediately
Dangerous to Life or Health (IDLH) limit from the
National Institute for Occupational Safety and Health
(NIOSH) and OSHA
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia Injection
Anhydrous
Vaporizers
Direct injection
Dilution air, 5% by volume
Aqueous
Vaporizers
Direct injection
Urea
Direct injection
Dilution air, 5% by volume
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Anhydrous
99.5% NH
3
, 0.5% H
2
O
Method of vaporization
Flooded vaporizer with storage tank
Level controlled vaporizer
Direct injection
Dilution air
5% ammonia by volume (lower explosive limit 15%)
Typically 175 to 300F at duct injection location
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Anhydrous Codes
OSHA 29 CFR 1910.111, Storage and Handling of
Anhydrous Ammonia
ANSI/CGA K61.1, Safety Requirements for the
Storage and Handling of Anhydrous Ammonia
ASME B31.3, Process Piping
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Direct Injection Anhydrous
Ammonia System
Hot Water Coils
(Redundant)
Flow Control Valves
(Redundant)
Ammonia Pump
Dilution Air Header
Delta Wings
TM
3
-
5
%
N
H3
300F
Minimizes Tuning and Adjustment Requirements
Dilution Air Fans
(Redundant)
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Anhydrous
Equipment Selection
Storage Tanks
-28F to site maximum design temperature
250 psig design pressure minimum
Code ASME Section VIII vessel
Excess flow valves on all nozzles
Two methods of level indication
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Anhydrous
Equipment Selection
Transfer pumps
Seal-less pump design
Magnetic drive
Canned pump
Suction pipe design
Recirculation vs. injection rate
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Anhydrous
Equipment Selection
Piping / Valves
No copper, brass, or galvanized steel
Conforming to ASME B31.3, Process Piping
Minimum number of threaded connections
Hydrostatic relief required on all isolatable sections
Leak / pressure tests of system prior to service
All instrumentation suitable for anhydrous ammonia
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Anhydrous
Equipment Selection
Truck / Railcar Unloading
Snappy Joes and breakaways to protect ammonia
equipment
DOT Regulations to be followed
Railroad unloading procedures per ammonia / railroad
supplier
Truck unloading procedures per ammonia / truck
supplier
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Aqueous
3 Common concentrations
9% Ammonia
19% Ammonia
29% Ammonia
No definitive codes or standards
Sound engineering practices need to be applied
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Aqueous
Equipment Selection
Storage tanks
ASME Section VIII
API 610
Pumps same as anhydrous
Pipes and valves
No definitive codes or standards
Typical ASME B31.1 acceptable
Unloading by truck only
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Dual Fluid Nozzle Injector
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Ammonia System Urea
Multiple conversion technologies available
Typically delivered in dry or liquid form
Best stored on site as liquid
No definitive codes or standards
Good engineering practices need to be applied
Heat tracing critical
Urea quality issues
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Urea Systems (Others)
FuelTech
Thermal breakdown of urea by gas
combustion
High gas use if ambient air is used
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Catalyst in Place
Catalyst Staged
Catalyst Doors
Reactor Layer Detail
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Domestic Shipment of Catalyst
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Overseas Shipment Containers
(Honeycomb Catalyst)
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Lifting Catalyst on Hoist
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Catalyst in Position for Loading
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Catalyst Module Being Pushed into
Reactor
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Installation of Catalyst Module Seals
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Requirements of NOx Measurement
Instrumentation for SCR Control
Provide inlet and outlet NO
x
measurement in ppm for the forward
feed with back trim ammonia injection control loop
Respond quickly to changes in the NO
x
values to reduce the risk of
over/under feeding ammonia to the process
The ability to service the instrument, including probe in flue gas duct
without removing boiler or SCR from service
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Types of Available NOx Measurement
Instrumentation
Extractive, extractive systems draw flue gas at temperature from the
system in a heated sample line to the analyzer
Dilution Extractive, dilution extractive system draw flue gas from the
system and dilution the gas with air to lower the concentrations of
SO
3
, H
2
O, etc to eliminate the need for heated sample lines to
the analyzer
In Situ, in situ system place the measuring device directly in the flue
gas path
One SourceMany SolutionsOne Purpose
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
SCR Performance
11/
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Units 1&2 Background
642 MW
G
CE balanced draft boilers
Eastern bituminous coal
High sulfur (3%)
Fuel oil burned at startup
U2A reagent
Routinely operate at minimum load of
33% MCR
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Design Requirements
High NO
x
removal
92.5% NO
x
removal
0.045 lb/MBtu outlet
LPA Mitigation
LPA screen
Baffle and deflector plates
Minimum load of 33% MCR with 0.045 lb/MBtu outlet
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Guarantees
Guarantees Values
Outlet NO
x
0.045 lb/MBtu
Ammonia slip 2 ppmvd
Pressure drop 8.4 iwg
SO
2
oxidation rate 0.50%
Ammonia consumption 1260 lb/h
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
SCR Design Parameters
Parameter Maximum Load Minimum Load
Boiler heat input, MBtu/h 5,800 2,400
Flue gas flow rate, lb/h 5,885,000 3,076,438
Inlet NO
x
, lb/MBtu
0.6 0.45
Outlet NO
x
, lb/MBtu
0.045 0.045
Economizer exit gas temperature,
o
F
700 495
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
SCR Design Features
Two four layer reactors per unit
Three initially installed layer and one future layer of catalyst
Inlet and outlet NO
x
analyzers
SCR inlet temperature control (per reactor)
Two double louver economizer bypass dampers
One single louver backpressure damper
Delta Wing
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=
AVE OUTLET AVE INLET
POINT OUTLET AVE INLET
X
NOx NOx
NOx NOx
NO
NH
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
System Optimization Influence Testing
Insight into ammonia distribution
Aids in injector tuning
Influences can be simulated in the flow model for
comparison
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
System Optimization Influence Testing
5 10 15 20 25 30 35 40 45 50
5
10
15
20
25
30
35
40
45
304
299
305
304
268
321
333
339
312
305
346
371
399
390
373
449
424
422
460
480
518
518
496
508
510
540
531
521
515
514
545
532
527
520
520
557
548
544
539
537
#1 #2 #3 #4 #5 #6
100% 0% 0% 0% 0% 0%
5 10 15 20 25 30 35 40 45 50
5
10
15
20
25
30
35
40
45
310
298
308
308
271
329
332
341
307
312
356
366
394
383
377
446
417
425
450
475
516
504
502
499
513
539
526
502
519
522
549
530
531
526
525
563
547
547
547
547
#1 #2 #3 #4 #5 #6
420
422
424
426
428
430
432
434
436
438
440
442
444
446
448
450
452
454
456
458
460
462
464
466
468
470
0% 100% 0% 0% 0% 0%
Valve 1
Valve 2
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Optimization Technique
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2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Optimized Distribution Tuning
Simulated in flow model
Has been used to manually tune SCR
Patent pending on automated tuning
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Retrofit Low Load Operation
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Operational Issues
610 MW unit
Daily operation down to <350 MW
Minimum catalyst operating temperature 570
o
F
Turning off ammonia flow at 440 MW
Non-compliance to 30 day rolling average
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Initial Findings
Significant temperature stratification in catalyst inlet face
Lack of mixing between economizer outlet and bypass flow
Insufficient economizer bypass flow to achieve desired catalyst
operating temperature
Possible solutions
Better mixing of economizer and economizer bypass flows
Increased bypass flow
Backpressure damper
Raising feedwater temperature
2008 SCR Users Group Conference
Copyright 2008 Babcock Power Inc. All rights reserved.
www.babcockpower.com
Thank You