Berkshire Hathaway Energy
Alert #4, November 1, 2016
Linkedin Discussion Groups
McIlvaine is setting up a number of Linkedin
decision groups covering the range of products
and services utilized by BHE. These
decision groups are open to any power plant
operator and to McIlvaine subscribers.
Many of the subjects are ones which are
currently of high importance to BHE. The purpose
of the groups is to complement the information
appearing in the Alerts, newsletters, webinars
and databases. The groups provide you with
an easy way to ask questions and to receive
specific answers. There will be dozens of
groups launched in the coming months. Here are
the ones which are active now:
Flue gas
desulfurization
Coal-fired power
plant instrumentation and controls
Coal combustion
residues and wastewater emissions
Dry Scrubbing
HRSG Valve
Decisions
NOx Scrubbing
To join any group go to google and type in
Linkedin then the subject and then group e.g.
Linkedin Nox Scrubbing Group.
Information about the Hunter and Huntington Nox
options appear in a number of the groups.
There is even a NOx scrubbing group.
The Flue gas desulfurization group includes a
discussion of the impact of ozone on SO2
removal. The dry scrubbing group will evaluate
filter media issues with H202/urea injection in
the boiler.
Linkedin NOx Scrubbing
Group
This group consists of NOx
generators, McIlvaine subscribers and selected
experts or contributors. It covers coal-fired
power, incineration, chemical, refining and
other industries generating NOx.
Should coal-fired boiler scrubbers remove NOx?
SCR and SNCR are proven
methods for NOx removal but there are
situations where a relatively small amount of NOx
needs to be removed and there are existing
scrubbers. Ozone can be used for oxidizing NOx
to NO2 and then N205. Refineries are using ozone
ahead of scrubbers. Why shouldn't the power
industry consider its utilities in Utah, Alabama
and Mississippi that have suddenly been required
to remove more NOx. A detailed
analysis of this option is being pursued on a
special website set up for BHE. Insights from
this Linkedin group will be conveyed to the BHE
subscribers.
One major question is whether to use peroxide
instead of just ozone ahead of the scrubbers.
Robert McIlvaine -
Refineries are using ozone instead of SCR. There
is the assumption that Ozone scrubbing is too
expensive. If so why are refineries using it? Is
it a question of the quantity of NOx
to be removed? If so then those power plants
which only need to remove another 0.06 lbs/mm
btu are more likely candidates than those who
need to remove 0.2 lbs/mm btu or more.
Where is NO2
being absorbed in plate or packed towers?
Robert McIlvaine -
Conversion of NO to NO2 - (Envitec) One tray is
used in the case there is a sufficiently high
concentration of NO in the inlet gas stream or
sufficiently low outlet concentration limit for
NO. NO is essentially insoluble in water, but it
can be quickly oxidized to NO2 by chlorine
dioxide (ClO2) or ozone (O3). This can be done
using a packed bed, but the reaction of NO
actually occurs in the gas phase. The packed bed
functions as a ClO2 generator and static mixer,
or as a static mixer for ozone injected in the
form of an aqueous solution. ClO2 can be
generated by the reaction of sodium chlorite
(NaClO2) with a strong acid. Sulfuric acid
(H2SO4) is commonly used, but if the air being
scrubbed contains enough nitric acid fumes, it
may not be necessary to add much H2SO4. Most NOx
scrubbers don't have an oxidation stage. When NOx
is generated by the reaction of nitric acid with
metals, it usually consists mainly of NO2. NO is
invisible, and it is much less toxic than NO2.
Robert McIlvaine –
The Mt. Vernon, IN plant of
GE Plastics has installed a NOx
scrubber. When such GE Plastics products as
Ultem resins are produced, nitric acid is used,
and emissions from this step are tightly
controlled. But to address upset conditions, the
company opted to install an emergency scrubber
that can treat up to
66,000 ft3/min of air containing 9,600 ppm
nitric acid vapor and 1,100 ppm of NO2 for 1h. To
meet this need, Tri-Mer Corp. has successfully
adapted the design of its continuous-duty NOx
The Tri-Mer system used at Mt. Vernon comprises
two horizontal scrubbing stages, with each stage
having its own circulation system. A proprietary
combination of caustic, sodium hypochorite and a reducing
agent is used.
The Kanto Denka process (1) employs a scrubbing
solution containing 0.2% hydrogen peroxide and
10% nitric acid while the Nikon process uses a
10% sodium hydroxide solution containing 3.5%
hydrogen peroxide. A fourth process, the Ozawa
process, scrubs NOx by spraying a
hydrogen peroxide solution into the exhaust gas
stream. The liquid is then separated from the
gas stream, and the nitric acid formed is
neutralized with potassium hydroxide. The excess
potassium nitrate is crystallized out, and the
solution reused after recharging with hydrogen.
Member coordination between
component and system suppliers
Belco and Xylem are
participating. Let’s discuss potential beyond
refineries to other applications but also ozone
in conjunction with other technologies. Any
comments on both subjects?
Robert McIlvaine -
Belco Lotox : Marathon conducted a review of
several options to reduce nitrogen oxides (NOx)
from its 52,000 barrels per day FCCU. The LoTOx
technology was identified as a potential NOx
control technology. Unfortunately, the LoTOx
technology had never been used on an FCCU.
Marathon needed more assurance that applying it
to an FCCU would result in similar performance
to that experienced in the other application. To
that end, Marathon, BOC and Belco conducted a
demonstration of Belco’s EDV wet scrubbing
system with LoTOx technology. The
demonstration was conducted October through
November 2002. Following review of the results,
Belco finalized its proposal to Marathon for the
system and eventually concluded negotiations for
the design and supply of the system for the
Texas City refinery. This commercial system
successfully started operating in February 2007,
achieving all established goals and confirming
the results of the demonstration
Linkedin Flue Gas
Desulfurization Group
Flue gas desulfurization
Power plants
generate SO2 which can be captured
and converted to disposable products or usable
byproducts such as gypsum, sulfuric acid, or
ammonium sulfate fertilizer. The choice for an
individual plant is affected by many factors.
There are 1000s of components in these systems.
The corrosive and abrasive environment dictates
careful selection of components as well as
special operation and maintenance practices.
Discussions of all of this are encouraged.
What are the impacts on the scrubber when ozone is injected ahead
of the scrubber for purposes of NOx
capture
Robert McIlvaine -
Ozone injection creates NO2 and N205. The N205
is more readily absorbed in the scrubber. NO2 is
also absorbed but at lower efficiency rates.
Shiaw Tseng of Graymont believes that there are
concerns about some of the reactions which can
take place. We are asking Shiaw to elaborate on
this.
Is DSI -catalytic filtration ready for prime time
Direct sorbent injection
followed by catalytic filtration is being
successfully used in hundreds of glass,
incineration, and other plants. It has yet to be
installed on a large coal-fired boiler. Because
of the big reduction in capital cost by reducing
three vessels to just one it is time for serious
consideration of this option. What are the
imitations and how do we move forward?
Robert McIlvaine -
One of the problems is the fact that the ceramic
catalytic filter elements are only 3 meters
long. The FLS catalytic filter element with
fiberglass media can be supplied with 10 meter
long bags. A large installation is now
successfully operating on a cement kiln in
Europe. How about more details?
Robert
McIlvaine -
Lhoist has launched a worldwide program to
provide an improved hydrated lime which has
expanded surface area and the high reactivity
needed for DSI. The cost of the lime will be a
critical factor in deciding whether to invest
more capital or use a higher operating cost
approach. We need some Lhoist examples comparing
the capital cost saving to the increased
operational cost.
The HRSG valve group is discussing the important
reduction in total cost of ownership. This
should be interesting to BHE procurement for
global specifying and TCO analyses.
Review selection and repair of valves used in
the heat recovery steam generation systems
associated with gas turbine combined cycle power
plants. This group is for any HRSG operator,
McIlvaine Subscribers, and selected
contributors. The group will be providing
analysis for McIlvaine Power Plant Valve
Decisions,
this includes
the ultrapure water, steam cycle, and
condensate. It addresses the problems associated
with frequent cycling including both performance
and maintenance. The emphasis is on determining
the lowest total cost of ownership (TCO)
approach. In a number of severe service
applications a more expensive repairable valve
may provide the lowest TCO.
What are the most significant
HRSG valve problems?
Robert McIlvaine -
McIlvaine conducted a 90 minute webinar on GTCC
valve decisions and options. A large number of
issues and some solutions are provided.
Additional comments are encouraged. The
recording and the power points are found in GTRE
Decisions. The 80 slide power point presentation
is also posted in the free Global Decisions
Orchard
http://www.mcilvainecompany.com/Decision_Tree/2015%20WEBINARS/June%202015/GTCC%20Valves%20Decision%20Guide%20by%20Bob%20McIlvaine.pdf
What are the challenges when you bypass steam around the turbine at
startup?
During initial operation of
the HRSG, valves are needed to bypass steam
(HP/HRH/LP) around the steam turbine to ensure
that the unit doesn't come up to temperature too
quickly. The large pressure differential across
the valve can cause high noise levels that need
to be attenuated. Other challenges are high
temperature, valve leakage and need for fast
operation. What is the solution?
Emerson provides Sky Vent engineered systems
with proper valve and controller selection. To
reduce the noise potential, the pressure drop is
split between the valve and a downstream
diffuser or silencer. The pressure split also
serves to optimize the size of each component.
The details on the Sky Vent are included in the
GTRE Decisions Intelligence system but are also
included in the Free McIlvaine Global Decisions
Orchard
http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/DescriptionTextLinks/Fisher%20bypass%20valve%20system.pdf
Is stellite delamination still a
problem?
NV Energy Higgins station any other HRSG owners
are experiencing stellite liberation from
high-pressure (HP) and hot reheat (HRH) valves
serving in F-class combined cycles. Tight
shutoff of parallel-slide gate and non-return
globe valves has been compromised in some cases.
This is an industry-wide problem and something
NV Energy is dealing with at Higgins and other
plants. EPRI has established a committee on
“Cracking and Disbonding of Hardfacing Alloys in
Combined-Cycle Plant Valves. 4 NV Energy people
participated in discussions on this at a user
group meeting. We will contact them for updates.
GTRE Decisions has lots of details on BHE
pipelines and compressor stations
Very detailed information on turbines and
engines used in existing and pending pipelines
is included in the GTRE Decisions. If you
click on Title you see all entries
chronologically starting with the most recent.
You can also search by key words. The
excerpts below include the key words which were
used.
Natural Gas
Pipeline Technology Overview
The pipeline transmission system — the
“interstate highway” for natural gas — consists
of 180,000 miles of high-strength steel pipe
varying in diameter, normally between 30 and 36
inches in diameter. The primary function of the
transmission pipeline company is to move huge
amounts of natural gas thousands of miles from
producing regions to local natural gas utility
delivery points. These delivery points, called
“city gate stations,” are usually owned by
distribution companies, although some are owned
by transmission companies. Compressor stations
at required distances boost the pressure that is
lost through friction as the gas moves through
the steel pipes (EPA 2000).
Revision Date:
10/25/2016
Tags:
211111 - Crude Petroleum and Natural Gas
Extraction
原油和天然气开采, Argonne National Laboratory, Compressor
Stations, Pipeline, Steel Pipe, Compression,
Transmission, Pipeline, USA.
Northern
Lights, Owatonna Compressor Station, Air
Emissions Permit
The Owatonna Compressor Station is used to
pressurize natural gas in order to facilitate
its transmission through a pipeline system. The
facility consists of a 16,000 BHP natural
gas-fired turbine and one emergency generator.
The facility is subject to a New Source
Performance Standard for the turbine, and
therefore requires a permit.
Revision Date:
10/21/2016
Tags:
211111 - Crude Petroleum and Natural Gas
Extraction
原油和天然气开采, Northern Natural Gas Co, Generator, Gas
Turbine, Pipeline, Compressor Stations,
Pipeline, Compression, Permitting, Gas-fired,
USA
Northern
Lights, North Branch Compressor Station, Air
Emissions Permit
Northern Natural Gas Company operates a
compressor station in North Branch to pressurize
natural gas in order to facilitate its
transmission through the pipeline system. The
facility was built in 1966. The North Branch
facility consists of four (4) natural gas-fired
reciprocating engines to drive the pipeline
natural gas compressors (all four are
Worthington ML-7 2-stroke lean burn engines
rated at 2,000 horsepower), a diesel-fired
emergency generator (a Kohler D300 engine rated
at 462 horsepower), and a natural gas fired
boiler rated at 3.35 MMBtu/hr. The compressors
pressurize the natural gas in the pipeline
causing it to flow to the next compressor
station. The primary emissions are nitrogen
oxides (NOx) and greenhouse gasses
(CO2e) from the reciprocating engines. Emissions
are not controlled. The facility also has
equipment that qualifies as insignificant
activities under Minn. R. 7007.1300,
subparagraphs 3 and 4. This permit is a
reissuance of the Title V operating permit. In
this permit, EU 005 (the natural gas-fired
auxiliary generator engine) has been removed
from the list of permitted facilities. Federal
NESHAP requirements for the emergency generator
and the boiler have been added.
Revision Date:
10/21/2016
Tags:
211111 - Crude Petroleum and Natural Gas
Extraction
原油和天然气开采, Northern Natural Gas Co, Compressor
Stations, Engine, Generator, Gas Turbine,
Permitting, Compression, Pipeline, Gas-fired,
USA.
Northern Lights, Hugo Compressor Station, Air
Emissions Permit
The facility will use a 7229 hp natural
gas-fired turbine to compress natural gas in a
pipeline. The facility will operate an emergency
generator as a backup for electrical power.
Uncontrolled emissions from the facility are
less than the thresholds for all criteria
pollutants. However, the natural gas-fired
turbine is subject to 40 CFR pt. 60, subp. GG
and the Permittee will therefore receive a state
operating permit.
Revision Date:
10/21/2016
Tags:
211111 - Crude Petroleum and Natural Gas
Extraction
原油和天然气开采, Northern Natural Gas Co, Compressor
Stations, Gas Turbine, Pipeline, Generator,
Pipeline, Permitting, Gas-fired, Compression,
USA.
Northern
Lights, Albert Lea Compressor Station, Air
Emissions Permit
Northern Natural Gas -Albert Lea is a natural
gas compressor station. The facility operates a
119 MM Btu (15,596 hp) natural gas fired turbine
(EU 001), used to compress natural gas in a
pipeline. The turbine is subject to 40 CFR pt.
60, subpart KKKK. The facility also has a 4.37
MM Btu (619 hp) diesel emergency generator (EU
002) to power the turbine during power outages.
The generator is subject to 40 CFR pt. 60,
subpart 1111. The engine is a 2007 model year or
later with a displacement less than 10 liters
per cylinder.
Revision Date:
10/21/2016
Tags:
211111 - Crude Petroleum and Natural Gas
Extraction
原油和天然气开采, Northern Natural Gas Co, Compressor
Stations, Gas Turbine, Generator, Pipeline,
Gas-fired, Pipeline, Compression, Permitting,
USA.
Northern
Lights, Farmington Compressor Station, Air
Emissions Permit
The Farmington Compressor Station is used to
pressurize natural gas for transport through the
pipeline system. The facility is composed of a
compressor building which houses five natural
gas-fired reciprocating compressor engines and a
natural gas-fired turbine that provide power to
the pipeline compressor. There is also a
diesel-fired electric generator for emergency
power.
Revision Date:
10/20/2016
Tags:
211111 - Crude Petroleum and Natural Gas
Extraction
原油和天然气开采, Gas Turbine, Engine, Generator, Compressor
Stations, Pipeline, Gas-fired, Permitting,
Pipeline, Compression, USA.
Northern
Lights, Faribault Compressor Station, Air
Emissions Permit
The Faribault Compressor Station consists of one
16,000 braking horsepower (BHP) natural gas
turbine and one emergency generator. The turbine
is subject to 40 CFR pt. 60, subp. GG. The
facility is considered not considered to be a
major source under any air quality permitting
regulations. The modification authorized by this
amendment is to remove the 10,600 BHP limit on
the natural gas turbine to allow operation of
the turbine at full capacity of 16,000 BHP.
Revision Date:
10/20/2016
Tags:
211111 - Crude Petroleum and Natural Gas
Extraction
原油和天然气开采, Northern Natural Gas Co, Compressor,
Pipeline, Engine, Gas Turbine, Generator,
Modification, Construction, Gas-fired,
Permitting, Pipeline, Compression, USA.
Apex Expansion
Project, Final Environmental Impact Statement
The purpose of the Apex Expansion Project is to
transport an additional 266 million cubic feet
per day (MMcf/d) of natural gas on Kern River’s
existing pipeline system from southwestern
Wyoming to Nevada. Dependent upon Commission
approval, Kern River proposes to begin
construction in the fall 2010 and place the
facilities into operation in November 2011. Kern
River proposes to construct and operate: •
approximately 27.6 miles of 36 – inch – diameter
natural gas transmission pipeline loop extending
southwest in Utah from Morgan County through
Davis County to Salt Lake County • one new
30,000 horsepower compressor station (known as
Milford Compressor Station) in Beaver County,
Utah; • modifications to four existing
compressor stations to add additional compressor
(the Coyote creek Compressor Station located in
Uinta County, Wyoming; the Elberta Compressor
Station located in Utah County; and the Dry Lake
Compressor Station located in Clark County,
Nevada); six mainline valves (four new and two
existing that require modifications;) and
three pig launcher and two pig receiver
facilities.
Revision Date:
10/19/2016
Tags:
211111 - Crude Petroleum and Natural Gas
Extraction
原油和天然气开采, Kern River Gas Transmission Co, Valves,
Pipeline, Compressor Stations, Gas Turbine,
Pipeline, Modification, Compression, Permitting,
USA.
