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 PacifiCorps 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
Settlement reached in Colstrip Environmental Litigation pending Court Approval
Restrictions of Emission Levels for Cheswick Coal-fired Power Plant in
Springdale Township, Allegheny County, PA
Environmentalists and Utilities eye Virginia Coal Ash Trial
Amec Foster Wheeler wins Coal Ash Treatment Project in Kentucky
COAL WORLD
China to add Coal Plants despite Pledge to lower Capacity
Bangladesh and India sign Rampal Power Plant construction Agreement
GE to supply Equipment for Turkish Coal-fired Power Plant modernization
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
9:00 am CDT
Markets Desalination
Thermal vs. Membrane; energy recovery, pump, valve, compressor and chemicals
options; power/desalination combinations.
Click here for more information
July 14, 2016
11:00 am CDT 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.
Click here for more information
July 19, 2016
11:00 am CDT 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.
Click here for more information
August 2, 2016
11:00 am CDT 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.
Click here for more information
August 25, 2016
10:00 am CDT
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
Monitoring
(9ABC) Gas
Turbine
Decisions
FGD and Acid Gas
June 16, 2016 Coal X X
Sewage X X
WTE X X
Cement X X
Steel X X
*Included in custom system
** Many of the decision guides also are displayed in the relevant market
reports. Power Plant Air Quality Decisions includes 1ABC, 3ABC, 4ABC, 9ABC
Sponsored Webinars allow suppliers to take advantage of all the valuable
information on their power point presentations. Click here for details
Hot Topic Hour Recordings
See and hear recordings of past Hot Topic Hours (Free for subscribers, $95.00
for non-subscribers)
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Bob McIlvaine
President
847-784-0012 ext. 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com