2001 conference on cormetech scr and sncr madrid update 1st...1 cormetech 2001 conference on scr and...
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Cor
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ech 2001 Conference on
SCR and SNCRFirst Year's Operating Experience with
SCR on 600MW PRB Fired Boiler
May 17, 2001
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New Madrid SCR RetrofitProject Overview
◗ Unit 2 Base Award (6/98);Unit 1 Option Award (3/99)�Turnkey Project�Commercial Operation
Unit 2 - March 2000 Unit 1 - Fall 2001
◗ Joint Venture of Black & Veatchand J. S. Alberici Construction
◗ Catalyst Supplied byCormetech as Subvendor toBlack & Veatch
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1998 Economizer Outlet Temperatures
680
700
720
740
760
780
800
12/16/97 1/5/98 1/25/98 2/14/98 3/6/98 3/26/98 4/15/98 5/5/98 5/25/98 6/14/98 7/4/98
Series1Series2Series3Series4
New Madrid Units 1 and 2◗ Plant Overview:
� Owned and Operated by Associated Electric Cooperative, Inc.� 2 x 600 MW Cyclone Fired Boilers� Uncontrolled NOx = 1.50 lb/MBtu� 100% Powder River Basin Fuel (0.22% S; 4.5% Ash; 21.5% CaO)� Widely Varying Economizer Outlet Temperatures (680 to 800 F)� High Air Heater Gas Outlet Temperatures (350 to 360 F)
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New Madrid ProjectGuarantees
◗ NOx Removal - 93%◗ Ammonia Slip - Less Than 3 ppm (PRB Coal)◗ Catalyst Life and System Performance - 20,000 hrs◗ SO2 to SO3 Oxidation Rate - 3% Max (PRB Coal)◗ Pressure Drop - 2 in wg Reduction From Current
System Losses◗ Auxiliary Power Consumption◗ Air Heater Outlet Temperature - 280 F◗ Air Heater Leakage - 7%
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B&V/JSA Scope WasComprehensive
◗ SCR Reactor◗ Catalyst, Frames, and Seals◗ Catalyst Loading System◗ Ammonia Unloading & Storage◗ Ammonia Vaporization◗ Ammonia Injection Grid◗ Sootblowers (Catalyst and Air
Heater)◗ Double Louver Dampers & Seal
Air◗ New "SCR Ready"
Regenerative Air Heater◗ Air Preheat Coils◗ Modified FD Fan Casing
◗ Interconnecting Air & Gas Duct◗ Tubular Air Heater Demolition◗ Ash Hoppers◗ Insulation & Lagging◗ Expansion Joints◗ Controls◗ Gas Monitoring◗ Electrical Modifications◗ Structural Steel◗ Enclosures◗ Foundations◗ Engineering◗ Construction◗ Startup and Commissioning
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New Madrid Unit 2 Arrangement
NOT TO BE USEDFOR CONSTRUCTION12' 8' 4' 0 10' 20'
SCR Reactor
New “SCR Ready”Regenerative Air Heater
M46'-0" 32'-0" 46'-0"
Modified FD Fan Discharge
EL. 298'-0"
Preheat Coils
ELEVATION AT COL. ROW 20a
DAMPER
EL.404'-2"
EXPANSIONJOIN T
EXPANSION JOINTEXPANSION JOINT
EXPANSION JOINT
Dampers
DamperEXPANSION JOINT
EXPANSION JOINT
174'PLATF ORM EL 375'-0"
PLATF ORM EL 355'-0"
PLATF ORMEL 326'-0"
Knockout Baffle
ALL DIMENSIONS ARE APPROXIMATE
Catalyst StorageArea (1 Layer)
Inlet NOx Measurement (2 Sides)
SteamSootblowers (typ 4
x 6)
Control/Tuning Grid
EL 471'"
EconomizerOutlet
Windbox Inlet
FDD
EXPANSION JOINT
FD Fans (typ 3)
FlueGas toESP
Existing Tubular AirHeater Location
N P Q
100%Bypass
Future Catalyst
Catalyst (typ 180 x3)
Sootblower and CatalystHoistway Enclosure
AIG
Outlet NOx Measurement
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New Madrid Unit 2 SCRSystem Retrofit
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Initial Operation◗ 4 Day Tie-In Outage Completed February 6, 2000◗ SCR System Startup (February 7-10, 2000)
� Bypass Damper Closed� Ammonia System Started Up� Monitoring System Started Up� Catalyst Sootblowers Started Up
◗ Ammonia Injection GridTuned - March 3, 2000� Operating Up To
93% NOx Removal� Ammonia/NOx
Distribution <3%
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A 1A 3
A 5A 7
S1
S2S3
S40 100 200 300 400 500 600 700 800 900
1,000
NOx ppm
North BoilerSide
Inlet Concentration
Unit 2 NOx Inlet Distribution
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Initial MeasurementWithout AIG Adjustments
A 1A 2
A 3A 4
A 5A 6
A 7mp 7
mp 5
mp 3
mp 1100
150
200
250
300
NOx ppm
North Boiler
2/10/00 Unit 2 PreTuning Distribution
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Final Adjustment
A1 A
2 A3 A
4 A5 A
6 A7
mp 7
mp 5
mp 3
mp 10
50
100
150
200
NOx ppm
NorthBoiler
Unit 2 SCR Tuning Results (600 MW)
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ech Associated Electric Cooperative, Inc. - New Madrid Unit 2
Date 5/02/2000 Load: 5% Over PressureMeasuring time 6:15-8:20 pm
NO downstream of last catalyst layer NO [ppm] table 1 Inlet NOxA 1 A 2 A 3 A 4 A 5 A 6 A 7 Min. Max. Mean V. Port ppm
1 1030mp 7 68 80 91 94 92 90 64 64 94 83 2 1041mp 6 81 45 51 56 84 50 60 45 84 61 3 1066mp 5 45 35 50 64 57 48 55 35 64 51 4 1046mp 4 61 34 40 36 48 67 56 34 67 49 5 1051mp 3 82 76 80 24 33 30 58 24 82 55 6 1071mp 2 79 62 47 51 54 67 60 47 79 60 7 1087mp 1 79 54 50 22 80 95 84 22 95 66 8 1091
min. 45 34 40 22 33 30 55 22 Standard Deviation Avg Inlet 1060.4max. 82 80 91 94 92 95 84 95 19.28 Std Dev 21.99
mean v. 71 55 58 50 64 64 62 61 NOx Removal 94.3%
Test 1 = 94.3% NOx RemovalTest 2 = 93.8% NOx RemovalTest 3 = 94.4% NOx Removal
Std. Deviation is<2% of inlet NOx
Performance Test Results
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0
200
400
600
800
1000
1200
1:00 1:15 1:30 1:45 2:00 2:15Time
NO
x, F
uel,
and
Am
mon
ia
40
50
60
70
80
90
100
NO
x R
emov
al, %
Inlet NOx ppmOutlet NOx ppmNH3 Flow lb/hFuel Flow klb/hNOx Removal %
Outlet NOx, ppm Test Averages: Inlet NOx = 998 ppm Outlet NOx = 62.4 ppm NOx Removal = 93.8%
Inlet NOx, ppm
Unit 2 AIG Tuning TestMonitoring System Values (3/3/00)
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Controls Issues◗ Minimizing Ammonia Slip Requires Tight
Control of Injection Rate◗ Ideal Mode of Operation is Feed-Forward with
Trim on Outlet NOx�Control is Dependent on Quality of Input Signals
for NOx and Unit Load
◗ New Madrid Fuel Flow and NOxConcentration Swung Widely When BringingIndividual Cyclones Into/Out of Service
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Controls Solution◗ Feed-Forward Control Algorithm Designed for
Fail-Safe with Quick Recovery◗ Controls Performance Criteria:
�Avoid Over-Feeding Ammonia on Rapid LoadReduction
�Individual Hourly Average NOx Outlet Not to Varyby More than 10 ppm
◗ Load Inputs Consolidated to EnhanceResponse and Tracking
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Component New Madrid Experience
Dust gr/dscf
As, fuel ppm
Total Cao, %Free CaO, %
Na2O2, %
P2O5, %
K2O, %
1.0
1.5
18.0 - 26.3
11.9 - 17.4
0.9 - 2.7
0.6 - 2.6
0.2 - 0.8
0.7 - 10
1 - 25
2.4 - 12
0.9 - 8
0.05 - 1.6
0.06 - 1.3
0.1 - 4.0
New Madrid Catalyst andReactor Design
◗ Cormetech Honeycomb Catalyst� 9.2 mm Pitch� 16 Cell� Calcium Sulfate Masking Considered
in Sizing
◗ 3 + 1 Reactor Design Developed by B&V� 180 Catalyst Modules per Layer� 12 x 15 Module Arrangement
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Model Study VelocityDistribution Tests
◗ Model Study Performed byMitsubishi Heavy Industries inNagasaki Japan
◗ Ammonia Injection Grid� Velocity Distribution Met
Requirement� +/- 25% Over 90% of Area� +/- 30% Over 100% of Area
� Required Installation of FDD◗ Catalyst Inlet
� Velocity Distribution MetRequirement� +/- 10% Over 80% of Area� +/- 20% Over 20% of Area
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Model StudyVelocity Distribution Tests
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Catalyst Loading
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Behavior of PRB Ash
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Catalyst Reactor at 4242 Hours
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Catalyst Reactor at 4242 Hours
After Vacuuming
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Catalyst Reactor at 7966 Hours
Turning Vane
Ash Screen
Catalyst Bottom View
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Catalyst Reactor at 7966 Hours
After Vacuuming
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AIG After 7,966 Hours
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Catalyst Sampling◗ Catalyst Test Coupons
Included in Each Module◗ Activity Testing Conducted
at 850 and 4,242 Hours --No Significant Deactivation
◗ Sample Testing at 7,966Hours Underway
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Unit 1 in January 2001
Current Status◗ No Significant Catalyst
Deactivation◗ Unit 2 Performance
Tests Completed inMay 2000
◗ Unit 1 UnderConstruction