New Webinars for PacifiCorp On Front End Optimization and Back End NOx Reduction Are Slated for The End of the Month
The next article summarizes the conclusions at the end of the PacifiCorp webinar on August 2. Since that time there have been further discussions and the tentative conclusion that raising the air heater exit temperature and adding Sorbacal ahead of the baghouse will result in an installation to cost effectively remove NOx. The other requirement is initial NOx reduction in the furnace through optimization and SNCR. Two more webinars will be held on the project. On September 1, there will be a discussion of the back end options. On September 8, the front end options will be discussed. In each case, participants will be advised to view new information added to Power Plant Air Quality Decisions (PPAQD).
There is the belief that NOx leaving the furnace can be reduced to as low as 0.l lb./MMBtu. On the other hand, maybe the exit quantity would be 0.22 lbs./MMBtu. Since .07 lbs./MMBtu is the exhaust limit, the removal efficiency for the catalytic filter will have to be 30-70 percent. Doosan, Siemens, Emersion and GE have all made presentations relative to reducing NOx leaving the boiler to as low as 0.1 lbs./MMBtu. In order to further determine the likelihood of this reduction, we have asked for case histories and white papers. We have already posted additional sever papers from Emerson and one from GE. Siemens is supplying several papers. We may make some phone calls to find out the current status of these installations. We are soliciting names of people and locations so we can make these calls. Results of the calls will be posted. In some cases, where confidentiality is desired, we will just provide a generic plant name such as a “large plant in the Midwest.”
Relative to the back end and urea/ammonia/H202 injection we need recommendations on where and which chemical should be injected. If both SNCR and catalytic filters are used, there will be ammonia slip from the SNCR. Where should the additional reagent be injected? Where should the Sorbacal be injected? Is there any reason to consider SBS instead of hydrated lime? Bob Crynack believes the addition of H202 along with the urea will increase removal efficiency. This needs to be further pursued. More information on the projected temperature vs. efficiency on the catalytic filters will be provided by FLS.
There may be other options that have been missed in the three previous webinars. If you believe there are other technologies which should be considered, please send your information to Bob McIlvaine at rmcilvaine@mcilvainecompany.com.
Lots of Options but No Clear Winner for PacifiCorp NOx Control Program
Catalytic Filters – Last Thursday most of the attendees including McIlvaine heard information which was being released for the first time relative to the performance of catalytic filters on NOx removal. Some insights on use of H202 as a reducing agent were also new to almost all the listeners.
The previous sessions had established that optimization along with SNCR, combustion modifications and possibly reburn would achieve front end emissions of 0.22 to 0.15 lbs/MMBtu. McIlvaine was optimistic that this session would demonstrate that all that would be required on the back end would be to insert catalytic bags to replace the existing sets. F.L. Smidth, W.L Gore and others raised a serious obstacle when we found out that the maximum temperature at the baghouse entrance would be 275°F. This raises maintenance as well as efficiency concerns.
The maintenance concern is that at 275°F, there will be formation of ammonium bisulfate and plugging of the bags. Unfortunately, URS sodium bisulfite proponents were not on the call but presentations at previous webinars have shown that bag plugging can be reduced with the injection of SBS at the inlet to the air heater. The primary role is keeping the air heater clean but the injection seemed to reduce downstream bag plugging.
This brings up a point relative to alternatives. SNCR is likely to play a key role under any combination of technologies. This means that the bags will be subjected to ABS under any scheme. Would it be worse when the catalytic bags are used as compared to the FLS bags already in place. Ken Johnson of Pentair was on the call and indicated his willingness to pursue these issues. Bag cleaning will be a challenge under all the scenarios. Pentair has solved problems with their pulsing systems at other plants, so their input will be welcome.
Lime injection ahead of the bag filters would also very likely solve the problem. Lhoist, Mississippi Lime and others can provide insights on this. A radical option would be to remove both NOx and acid gases in the bag filter and eliminate the downstream lime scrubbers. But then the question of solid waste disposal would have to be addressed.
The second concern is efficiency. At 275°F, a three layer FLS bag might only have a 50 percent NOx removal efficiency or maybe even lower. Nadia Jorgensen, sales manager for catalytic filters for FLS, promised to review the efficiency curves and respond with some predictions for removal at 275°F. An alternative would be to raise the gas temperature. The plants which have opted for tail-end SCR have justified a very large increase in gas temperature. Here the need may be only for a 275°F rise. PacifiCorp indicated this would not be easy but would be doable.
One thing to check is air heater leakage. Is the 275°F a function of 10 percent air in leakage into the air heater? If so, then the temperature can be raised with air heater modifications. Air volume to the baghouse would be reduced and the catalytic filter would be a great choice. We will check with Arvos and Howden for their opinions on the air heater in leakage. Both were in a previous PacifiCorp webinar. We will also check with Howden on fan implications (volume is a function of temperature).
It would all be a matter of economics. Raising the gas temperature entering the baghouse means less transfer of heat in the air pre heater and a fractional percent decrease in plant efficiency. On the other hand, an SCR would add 8-10 in. pressure drop to the system and also reduce plant efficiency. The capital cost of the SCR would be far greater than the catalytic bag filter replacement and some minor air heater modifications. If the solution is reducing air heater leakage, then the economics for the catalytic filter are even more attractive.
H202 and Ozone - Bob Crynack cited his considerable experience with FMC to conclude that H202 to oxidize the NOx to a soluble NO2 and downstream capture in the lime scrubbers was not very promising, but that injection in the furnace along with urea would substantially enhance SNCR. He believes this could be a cost effective route for PacifiCorp. FMC has sold the division involved in this. We will contact the new owners and gather more information.
DuPont indicated that their Lotox system which adds ozone ahead of the scrubbers would likely be a good solution. They make this observation based on a number of refinery and industrial installations, so we will seek more information from them and also from Linde who is the licensor.
In-Duct SCR - Fuel Tech submitted additional slides to validate the performance of a small layer of catalyst. Combined with SNCR this approach should yield sufficiently high NOx removal. More input on this approach will be sought.
In-furnace Reduction - The Castle Light presentation focused on replacing the burners with entrained gasifiers. The NOx reduction is substantial. The negative would be a significant capital investment. One question we will pursue with Keith Moore is whether the use of calcium sulfite as a catalyst for NOx reduction in the burners can be implemented without the whole entrained gasifier installation.
Where do we go from here?
McIlvaine will continue to pursue the in-furnace and back-end options. Future webinars are planned. Coordination with PacifiCorp will be pursued. Smaller groups to pursue individual options will be encouraged. Optimization is an example.
Siemens, Doosan, Emerson, and GE all recommended in furnace approaches. Each has a different approach. The next step will be to understand the differences. On a broad basis there seems to be a difference in whether to rely on changing parameters to affect the results or changing the results empirically, which in turn changes the parameters. With neural networks which can learn from various damper settings, the settings can be optimized. This has the same result of centering the fire ball which is alternatively done with tunable diode laser measuring tools and then burner air damper adjustments.
How do each of the suppliers characterize their reliance on actual on line instrumentation, OFA, EGR, reburn, models, and learning systems. This first step can be followed by more insights on actual experience in similar boiler designs with similar coals.
The recording of this session and the power point presentations are available in 44I Power Plant Air Quality Decisions (Power Plant Decisions Orchard). This is free of charge to utilities. Since you are receiving this Alert you are undoubtedly a subscriber to the 42EI Utility Upgrade Tracking System. If so, the 44I is only $800/yr plus $80/yr for additional users.
COAL – US
Coal-fired Power Plants Must Make Many Tough Decisions
Old coal-fired power plants in Europe and the U.S. must invest in technology to meet new emission standards, but must do so with a modest investment. New coal-fired power plants being built in Asia and certain other countries are tasked with obtaining high conversion efficiencies which are achieved with operation at high temperatures and pressures. The result is that coal-fired power plants, whether they are new or old, have difficult decisions to make. 44I Power Plant Air Quality Decisions (PPAQD) which includes information on all coal-fired power plant products and services provides power plants and their suppliers with Decision Guides to include the latest developments presented in a format so that the benefits of each option are compared.
PPAQD provides a powerful new tool both for the plant operators and suppliers. For example, in the last three weeks there has been a specific analysis of NOx control options for a utility which is facing a $700 million investment to comply with regional haze rules. The major options are to install SCR or to initiate a series of projects which in combination will achieve the needed NOx reduction. The combination options include:
A: In Furnace:
• Catalytic burners
• Combustion optimization systems
• Reburn
• SNCR
B: Back End:
• Catalytic filters
• Ozone injection
• Hydrogen peroxide
• Catalytic baskets in the air preheater
• In-duct SCR
These options have been reviewed in webinars with a large number of utility people in attendance to hear presentations by GE, Siemens, Emerson, Fuel Tech, FLS, AECOM and others.
For more information on 44I Power Plant Air Quality Decisions (Power Plant Decisions Orchard), click on: http://home.mcilvainecompany.com/index.php/other/2-uncategorised/86-44i
Xcel Energy reduces NOx with Neuco system
Sherco Unit 1 is a 750 MW unit with overfired air and low NOx burners. A NOx control program was initiated in 2014. The goal was to reduce and maintain NOx emissions from a shared stack to below 0.15 lb/MMBtu over a 30 day rolling average starting January, 2015. At the start of the project, the goal was not being met. The penalty is that if the NOx is not maintained below the 0.15 lb/MMBtu average, the units must be derated to achieve the goal. Emissions are measured in a shared stack from two 730 MW T-fired units with no SCRs. CO constraint is that CO emissions must be maintained below 400 ppm.
Some of the problems centered around poor coal fineness and distribution. All seven mills were retrofitted with Loesche dynamic classifiers with the goal of achieving 75 percent through 200 mesh and 99.9 percent through 50 mesh. The company also installed a Neuco Combustion Opt system which provides closed loop optimization of fuel and air biases in the boiler as frequently as very minute. The result was a 10 percent NOx reduction and achievement of the goals.
Improving the Right-to-Win Ability for High Performance Flow Control and Treatment Products
The right-to-win for high performance flow control and treatment products can be enhanced by leveling the playing field and changing the scoring method. Right-to-win is the ability to engage in any competitive market with a better-than-even chance of success. Four strategies have been used to improve the right-to-win ability. They are position, execution, adaptation and concentration.
In flow control and treatment there are two types of products and services: high performance and general performance. The right-to-win strategies for them differ significantly.
The challenge of large U.S. and European based suppliers of high performance flow control and treatment products is to not only improve the right-to-win ability in the existing market, but to be pro-active in changing the rules of the game to level the playing field and even the scoring method in developing countries. Most of these large companies have not achieved the sales and profits in the fast growing developing market. McIlvaine, therefore, proposes that “creation” be considered a fifth right-to-win strategy. The importance of each strategy has been ranked from very important to irrelevant.

Right-to-Win Strategies for High Performance
and General Performance Products
(5 is very important and 1 is irrelevant)
Right-to-Win Strategy High Performance General Performance
Position 3 5
Execution 3 5
Adaptation 5 3
Concentration 3 4
Creation 5 2
The creation strategy changes the playing field by making it easier for purchasers to buy the best rather than the lowest cost product. This entails finding an easier way to determine the lowest total cost of ownership (LTCO). Arcelor Mittal is doing this by global sourcing and then providing LTCO analyses for its 200 plants around the world. McIlvaine is accomplishing this in certain industries with free Decision Guides for end users.
Changing the scoring method is another game changer. Most flow control and treatment products contribute to increased life quality today at some penalty to future generations (e.g. greenhouse gases or resource depletion). The perspective is quite different for a wealthy individual who wants to set up annuities for his grandchildren and the starving parent who cannot even ensure the survival of his children. McIlvaine has created a metric to help developing countries make the best choice for their citizens.
For more information on right-to-win strategies in flow control and treatment contact Bob McIlvaine 847-784-0012 ext. 112 rmcilvaine@mcilvainecompany.com.
For more information on the markets see N064 Air/Gas/Water/Fluid Treatment and Control: World Market.
Here are some Headlines from the Utility E-Alert – August 5, 2016
UTILITY E-ALERT
#1284 – August 5, 2016
COAL – US

• 7,000 Utility Coal-fired Power Plants Are Continuing to Upgrade and Replace Controls
and Equipment
• Coal-fired Power Plants Must Make Many Tough Decisions
• OriginClear’s PWT completes another Power Utility Boiler Feedwater Upgrade
• Xcel Energy reduces NOx with Neuco System
• Longview now Operating Well
• TVA to reduce Toxic Metals in Wastewater
COAL – WORLD

• First FGD System in the West Balkans supplied for Ugljevik Thermal Power Plant in Bosnia and Herzegovina
• Turkey imposes Selected Import Duty on Coal and Power Generation
• Russians to build 1.4 GW Coal Plant in Iran
• Changxing ZLD with FO is Successful
• EnBW RDK 8 uses GE (Alstom) Technology to achieve 47.5 Percent Efficiency
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.
7,000 Utility Coal-fired Power Plants are Continuing to Upgrade and Replace Controls and Equipment
The market to upgrade and replace components in the existing 7,000 coal-fired power plants is larger than the new equipment market for wind, solar, or gas turbines. The upgrades and replacements are tracked in the Utility Tracking System published by the McIlvaine Company.
Many of the power plants in the U.S. are more than 40 years old but are expected to operate another 20 years. Optimization systems can improve efficiency, reduce greenhouse gases and save fuel. The payback is often measured in months and not years or decades. So, even if the expected remaining life is 10 years or less, investment is warranted.
In many instances, the remaining life is determined by the upgrade investment costs. McIlvaine has been conducting three webinars for a large utility to determine whether optimization systems can reduce NOx sufficiently to meet new regional haze requirements. The alternative is expensive selective catalytic reduction (SCR) systems. Siemens, GE and Emerson have made presentations showing how substantial NOx reductions can be maintained by combining predictive models, advanced instrumentation and results based tuning.
The Utility Tracking System also tracks upgrades of utility water systems. Power plants in the U.S. must make adjustments to limit harm to aquatic life at water intakes. These same power plants must also now meet new wastewater emission standards. Many power plants around the world are opting for zero liquid discharge (ZLD) systems. This requires major investments in evaporators, crystallizers, membrane separators and mechanical vapor recompression.
The drought in India and water shortages in many countries are resulting in the use of treated municipal wastewater. Most power plants are within 70 miles of a municipal wastewater plant. The treatment costs to make this water usable by the utility are modest. So, if water is valued, the investment can be justified.
The average power plant is only 40 percent efficient. The steam plume visible from the stack and cooling tower are testimony to the large quantity of wasted heat. Sorbent injection and air preheater extension investment can be justified with payback within a year or two.
Air pollution regulations are not static. There is a new round of regulations at least once a decade. New pollutants such as mercury now have to be reduced as well as the traditional acid gases and particulate. The Utility Tracking System tracks all the upgrades in a database with details on each plant. A weekly 10 to 20-page alert covers new developments. For more information, click on 42EI Utility Tracking System.

Bob McIlvaine
President
847-784-0012 ext. 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com