PacifiCorp looking for Ways to reduce a $700 Million NOx Control
Requirement
A webinar for PacifiCorp was the second in a series of three. In the 11:00 a.m.
Hot Topic Hour on July 14th, 60 participants viewed the Power Plant
Air Quality Decisions NOx control displays while Ian Andrews,
Director of Resource Development of PacifiCorp decried the regional haze ruling
which will require an expenditure of $700 million for SCR at four units at
Huntington and Hunter.
PacifiCorp would like to find a less expensive alternative. For compliance
purposes the alternative must need to achieve NOx emissions of less
than 0.07 lbs/MMBtus. The utility has two years to find a solution. It does have
some matching funds for R&D. The thinking is to reduce in-furnace emissions to
less than 0.22 lbs/MMBtu and then to achieve reductions to the final 0.07 lbs/MMBtu
in the back end.
Richard Himes of EPRI provided an overview of holistic NOx control
and indicated with proper in-furnace measurement and control it is possible to
achieve 0.08 lbs/MMBtu NOx at the furnace exit while burning PRB
coals. This level could not be achieved with western bituminous but the holistic
approach would provide significant reductions within the furnace. Jeff
Williams of Emerson indicated that their control systems had allowed many plants
to achieve in-furnace NOx of less than 0.1 lbs/MMBtu. Jeff promised
to provide specific case histories in the next session on July 19th.
There was discussion of the tunable diode laser measurement technology using the
Zolo instrumentation. Yokogawa TDLS were suggested as another equivalent.
Questions were asked about gas reburn. Richard mentioned successful lean reburn
success recently. Dale Pfaff of Fuel Tech provided details on their approach
which uses SNCR and induct catalyst. Blake Stapper of AECOM promised to provide
further details on LoTOx in the third session. LoTOx involves injecting ozone to
form NO2. This compound is then absorbed in the scrubber. It is
a good trim technology as is hydrogen peroxide.
Bob McIlvaine briefly reviewed other options which are covered in the PPAQD.
Replacing existing bags with catalytic filter elements (fiberglass with
impregnated catalyst) could be one answer. Air heater modifications to extract
more heat could have a beneficial effect on fan performance. The additional
pressure drop of in-dust catalyst could be offset by the reduced volume of the
gas reaching the ID fan.
In the second session on July 19, presentations were made by Jeff Williams of
Emerson, Peter “Spinney of GE, Bin Xu of Doosan and Don Hatch of Siemens
relative to controls. The options for optimization include both the
model-based as well as the neural network learning approach. Each of the
presenters referenced successful case studies and clear evidence that NOx
can be reduced by 4 to 20 percent.
We want opinions and recommendations from our readers on many questions. The
SootOpt GE approach cycles the soot blower operation based on results. How
important is it to have this kind of focus? The presenters referenced
laser and acoustic instrumentation to determine the distribution of oxygen and
CO. How important is the more precise measurement? What are the
advantages and disadvantages of each of the approaches? GE recently
purchased Neuco. So they must buy into the neural networks and learning based
operation of the soot blowers and other variables? Doosan is another
boiler supplier who weighed in. What do Babcock & Wilcox, Foster Wheeler
and MHPS utilize for retrofits and new boilers?
How does what we are learning about solving PacifiCorp’s problems apply to
boilers in the rest of the world? We have included a paper in the
intelligence system on the successful use of the Siemens optimizer at a large
Chinese supercritical plant. Is the ROW behind or ahead of the U.S. in
optimizing boiler operations? We have included a Yokogawa paper on their
successful application of the TDL. What is their experience in Europe and Asia?
The third session will focus on back-end solutions such as SNCR, ozone, hydrogen
peroxide and in-duct catalyst. One area for discussion will be the
adaptability of the optimization systems to performance on the back end.
The optimizer speakers addressed the degree to which their systems could cope
with changing conditions. One additional input will be the outlet NOx
after for example hydrogen peroxide addition. If the efficiency still needs to
be raised, do you add more hydrogen peroxide in the back end, urea in the front
end or is it your damper settings on the combustion air?
Dale Pfaff of Fuel Tech provided more details on the combined combustion
modification and SNCR approach. We have included a Doosan paper with some
information on European systems using SNCR reburn and other modifications.
We still need to hear from LP Amina who has a number of systems in China.
We would hope that the cloud problem solving that we have initiated results in
options that have not even been considered before. We have queried a number of
people and asked them to address the following potential option. The
amount of urea added in the boiler is limited by the considerations of ammonia
slip. How much can efficiency be improved if higher ammonia slip is acceptable?
Sterling Gray of AECOM has presented data showing that sodium bisulfite addition
ahead of the air preheater reduces the acid dewpoint and eliminates APH problems
related to ammonium sulfate build-up. The main purpose is to provide
conditions which allow the expansion of the air heater and improve boiler
efficiency. The question is what impact would this have on NOx?
The higher efficiency means lower Btu input per kWh and therefore lower NOx.
Bigger potential is to improve SNCR efficiency with more urea. Bin Xu of
Doosan responded to the query with this qualification. If sufficient urea
is already being added, then more urea just results in more ammonia slip.
But we must be missing something here in that the SNCR efficiency is low under
any circumstances. You would think there is room for improvement.
Relative to the buildup in the air preheater, would the addition of lime be a
positive or negative factor? Another concern is the blue haze potential.
But with the baghouse and scrubber downstream, this should not be a problem.
McIlvaine has reported on good reduction in the baghouse with additives but not
much success in the scrubber.
A fundamental question for PacifiCorp is the flexibility relative to the
guideline of measurement in lbs/MMBtu of fuel input. If you improve
efficiency, you need fewer BTUs of fuel to achieve the same electrical output.
Many more recent EPA regulations have been based on emissions per MWH output.
Is there flexibility to take into account NOx reduction by improving
efficiency? The EPA Federal Register document which is included in
the PPAQD shows the tons per year of NOx which will be reduced with
SNCR and SCR but did that take into account efficiency increases?
We would like to hear from you whether or not you have the benefit of accessing
the information. All the material which was displayed during the session and all
the responses to these queries will be or are included in Power Plant Air
Quality Decisions (PPAQD). As a subscriber to the Utility Tracking System,
this service-added cost is only $800 rather than the $1600 stand-alone price.
The service is free of charge to any power plant. All the presentations, the
list of participants and the recording are all included on the site.
The third session is slated for August 2, 2016.
Click here to Register for the Webinar
Market for Water used in Power Plants is Large and Fast Growing
Power plants extract and discharge more water than municipalities and industry
combined. Water shortages and environmental regulations are opening a large
market for many different technologies. The opportunities can be divided into
three segments:
·
Water delivery
·
Water discharge
·
Water avoidance
Water Delivery:
The need to utilize alternative water sources presents a several billion dollar
per year opportunity for:
·
Desalination: A number of Chinese and Indian power plants have already
incorporated desalinated water for cooling and boiler feedwater. Combined power
and desalination plants already provide both municipal drinking water and power
for many areas in the Middle East.
·
Use of treated municipal wastewater: Most power plants are within 100 miles of
municipal wastewater plants. With additional treatment this source is
ideal for power plant needs.
Water discharge:
Zero liquid discharge (ZLD) is mandated for new power plants in China and is
being evaluated for all new plants in water stressed regions. In some
areas, with plentiful water supply, ZLD has been chosen as a way to avoid delays
in obtaining water discharge permits.
Regulations are tightening for plants which are discharging wastewater. U.S.
power plants have to meet new Emission Limit Guidelines (ELG). The
retrofit of scrubbers in the U.S., China and elsewhere has created new
wastewater treatment challenges.
Water avoidance:
The steam plumes emanating from the stacks and cooling towers of plants are
not only testimony to water loss but to inefficiency. District heating is
an alternative which can nearly double power plant efficiency. More modest
efforts such as placement of the Blue Flint ethanol plant at one of the Great
Rivers Energy power plants need to be explored.
Recirculated water for cooling towers results in a big reduction in water
consumption versus once- through water. The problem is the net water loss
through evaporation. Dry cooling eliminates the water loss but requires
considerable energy. It is not practical in warm climates.
Initiatives to improve power plant efficiency have a direct effect on water
consumption per unit of energy produced. McIlvaine is conducting webinars
on greater heat recovery from flue gas with more efficient air preheaters and
the use of high temperature particulate removal to allow for the use of more
efficient heat exchangers.
These opportunities need to be addressed on a plant by plant basis. A
number of Indian power plants have immediate needs. Adani Power has shut down
five units of 660 MW capacity at the Tiroda plant in Maharashtra due to an acute
water shortage. The 2100 MW coal-fired Farakka power station in West Bengal shut
down its six turbines due to lack of water. The 1720 MW Raichur Thermal Power
Station in Karnataka state has been hit by lack of water also. Since March 15,
it has had to shut down several of its units indefinitely. The 1130 MW Parli
power station in Maharashtra state has been shut down since July 2015 due to
lack of water. NTPC's Solapur power plant is facing commissioning delays due in
part to uncertainty over water supplies. In Karnataka's Krishna Basin, NTPC's
Kudgi power plant and KPCL's Raichur power plant were affected by lack of water
this summer.
Individual coal-fired power plant opportunities are tracked in two services:
42EI
Utility Tracking System
tracks all projects worldwide except China where projects are tracked in
42EIC
Chinese Utility Plans.
Gas turbine projects are tracked in59EI
Gas Turbine and Combined Cycle Supplier Program. Biomass,
hydro and geothermal projects are tracked in
N042
Renewable Energy World Markets. The market opportunity is
also addressed in a number of multi client market research reports Markets.
End
users are aided by the following services 44I
Power Plant Air Quality Decisions, Gas
Turbine and Combined Cycle Decisions,
Decision Guides.
Utility E-Alert Tracks Billions of Dollars of New Coal-fired Power Plants on a
Weekly Basis
Here are some headlines from the Utility E-Alert.
UTILITY E-ALERT
#1281 – July 15, 2016
Table of Contents
COAL – US
COAL
– WORLD
The
41F
Utility E-Alert
is issued weekly and covers the coal-fired projects, regulations and other
information important to the suppliers. It is $950/yr. but is included in the
$3020
42EI
Utility Tracking System
which has data on every plant and project plus networking directories and
many other features.
HOT
TOPIC HOUR (HTH) SCHEDULE
DATE |
HOT TOPIC HOUR
AND DECISION
GUIDE SCHEDULE
The opportunity
to interact on
important issues |
July 14, 2016 |
Desalination
Thermal vs. Membrane; energy
recovery, pump, valve,
compressor and chemicals
options; power/desalination
combinations. |
July 14, 2016 |
NOx Control for
PacifiCorp: Overview and Summary
of Low NOx Options
Discussion of options for
PacifiCorp to comply with new NOx
removal requirements for four
350 MW coal-fired generators
operating in Utah. The first
webinar will consider the range
of both in-furnace and back end
options. |
July 19, 2016 |
NOx Control for
PacifiCorp: Combustion
Modifications and Neural
Networks
Discussion of options for
PacifiCorp to comply with new NOx
removal requirements for four
350 MW coal-fired generators
operating in Utah. This second
webinar will consider the range
of both in-furnace options to
reduce NOx to between
0.15- 0.22 lbs./MMBtu. |
August 2, 2016 |
NOx Control for PacifiCorp: Back
end NOx Control
Discussion of options for
PacifiCorp to comply with new NOx
removal requirements for four
350 MW coal-fired generators
operating in Utah. This third
webinar will consider the range
of options such as peroxide,
ozone, and catalysis to reduce
emissions to 0.06 lbs./MMBtu. |
August 25, 2016
Markets |
Oil, Gas, Refining
-
Supply and demand; impact on
flow control and treatment
products; regional impacts
e.g. subsea in North Atlantic
vs. shale in the US vs. Oil
Sands in Canada. |
TBA
Markets |
Food
- Analysis
of 12 separate
applications within food and
beverage with analysis of valve,
pump, compressor, filter,
analyzer and chemical options;
impact of new technologies such
as forward osmosis. |
TBA
Markets |
Municipal Wastewater
-
Quality of pumps, valves,
filters, and analyzers in
Chinese and Asian plants; new
pollutant challenges; water
purification for reuse. |
TBA
Markets |
Mobile Emissions
-
Reduction in CO, VOCs, and
particulate in fuels, oils, and
air used in on and off road
vehicles; impact of RDE and
failure of NOx traps
and the crisis in Europe created
by the focus on clean diesel. |
Click here to Register for the Webinars
Details on Webinars
McIlvaine conducts periodic webinars which are in a discussion format and are
free of charge to all participants. The displayed material and recordings are
free to purchasers of the products and services and by subscription to others.
Format: 50-90-minute recorded discussion using McIlvaine display material.
The session will be free of charge to all participants but registration is
required.
Approach: There are two types of webinars. One is focused on Markets and
directed to suppliers. The other is focused on aiding purchasers make the best
Decisions relative to purchases of flow control and treatment equipment and
services.
Markets HTH
General overviews of the market including size and major variables will be
discussed with heavy emphasis on technology and regulatory drivers. The
presentation will be based on the latest information appearing in McIlvaine
multi-client reports. Questions and views from both subscribers and
non-subscribers are encouraged.
Decisions HTH
McIlvaine has been publishing information systems on pollution control since
1974. Each subject is organized by the pollutant control technology e.g. fabric
filter, scrubber etc. There are search capabilities to retrieve information on
any application. The newest addition has been slide deck systems displaying the
issues and options relative to specific applications. Coal-fired power, cement,
steel, and waste combustion decision slide decks are continually updated.
The continually updated slide decks are displayed on the applicable Decision
System. It is recommended that participants view the slide deck in advance
of the session and be prepared with questions and views.
Value to purchasers and specifiers: Your questions and interests will be
prioritized in the discussion. You will get a monthly newsletter and have
continuing access to the system and multiple ways to interface in the future
along with a networking directory of suppliers.
Value to Suppliers: You have the opportunity to provide data to be
considered at no charge. If you are also a subscriber you will see the summaries
in advance and be able to shed light on issues and options not properly covered
in the slide deck. If you are a subscriber you will receive the monthly
newsletter and continuing yearly access to the system including networking
directories.
44I Power
Plant Air Quality Decisions
includes 1ABC, 3ABC, 4ABC, 9ABC decision services but not 2ABC. So those with
multiple technologies and at least partial focus on power will find this
combination most cost effective.
Applicable Services for Hot
Topic Hours** |
|||||||
Pollutant |
Industry |
Fabric Filter
(1ABC) |
Scrubber
(2ABC) |
Precipitator
(4ABC) |
FGD & DeNOx
(3ABC) |
Air Pollution
(9ABC) |
Gas |
FGD and Acid Gas |
Coal |
|
|
|
X |
X |
|
Sewage |
|
X |
|
|
X |
|
|
WTE |
|
X |
|
|
X |
|
|
Cement |
|
X |
|
|
X |
|
|
Steel |
|
X |
|
|
X |
|
*Included in custom system |
Sponsored Webinars
allow suppliers to take
advantage of all the valuable
information on their power point
presentations. Click
here for details |
Free Sponsored Webinars
·
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·
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You can register for our free McIlvaine Newsletters at:
http://home.mcilvainecompany.com/index.php?option=com_rsform&formId=5.
Bob McIlvaine
President
847-784-0012 ext. 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com