errica - tftei cost methodology tool the apatity ...€¦ · efficiency : 80% to more than 92% for...

ERRICa - TFTEI Cost Methodology Tool The Apatity combustion plant

TFTEI technical secretariat

Carmen Mayer (KIT), Nadine Allemand (CITEPA)

Workshop to Promote the Understanding and Implementation of Best Available Techniques (BAT) across the Entire UNECE Region with Focus on Countries in the

EECCA Region 20 – 22 April 2016 - Berlin

Agenda Characteristics of ERICCa_LCP

Main capacities of ERICCa_LCP

Implementation and documentation

Application to the Apatity combustion plant

Berlin Workshop : 21 April 2016

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ERRICa_LCP- capacities

Development started in 2013 Since then the tool has continuously been improved and updated in close collaboration with the subgroup on LCP

It can be downloaded from the TFTEI website http://tftei.citepa.org Work in progress => Costs of reduction techniques for LCP

History

Availability

ERICCa: Emission Reduction Investment and Cost Calculation Name

ERICCa_LCP: Large Combustion Plants (> 50MW) (other ERICCa-Tools are currently under development) Application

ERICCa_LCP at a glance


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http://tftei.citepa.org/

Technologies

ERICCa_LCP at a glance

Coal, oil, gas, solid biomass (wood) in co-combustion with coal

Detailed and general approach

Fuels

Fuel approach

Boilers (> 50 MWth) Plants

NOx, SO2, PM Pollutants

NOx: LNB (Low NOX Burner), SCR (selective catalytic reduction), SNCR (selective non-catalytic reduction)

SO2: Wet flue gas desulphurization (FGD), lime spray dryer, dry process

PM: Fabric filter (FF), electrostatic precipitator (ESP)

ERRICa_LCP- capacities Berlin Workshop : 20 April 2016

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Plant and fuel data input

Calculation of boiler outlet emission loads

Setting stack emission goals

Choice of potential abatement technologies

Economic assessment

General structure of the cost estimation in ERICCa_LCP

0

5,000

10,000

15,000

20,000

25,000

100% 80% 60% 40% 20%

Spec

. NO

x re

duct

ion

cost

s [€

/t ab

ated

]

Annual Capacity Factor

Type of results obtained


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guidance with technology and fuel specific „typical“ NOx values from literature

Economic assessment of deNOX processes

Introduction

Challenge

Approach

mass balancing is not possible!

NOx Boiler outlet emissions according to technology [mg/Nm³] Hard Coal / Bituminous Coal Lignite

Wall-Fired Tangentially-Fired Wall-Fired Tangentially-Fired

1st Gen. LNB 600-800 500-600 300-400 300-400 2nd Gen. LNB 500-600 400-500 200-300 200-300 3rd Gen. LNB 400-500 350-400 150-200 150-200


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upgrade of existing LNB to newest generation

few data from literature, old EGTEI values

Option

Investment

no quantification of costs could be obtained => Cop,var = 0 Variable Costs

Boiler Size 1,000 MWth Ccap 500,000 €/year Flue gas flow 1E+09 Mio. Nm³/year Cop,fix 100,000 €/year LoadNOx,dry,O2-ref 800 mg/Nm³ Ctot = Ccap + Cop 600,000 €/year New LoadNOx,dry,O2-ref 400 mg/Nm³ NOx mass abated 400 t/year Spec. Investment 5 €/kWth Cost per ton NOx 1,500 €/t NOx Total Investment 5,000,000 €

Illustrative example: 10% p. a. of total investment 2% p. a. of total investment

ERRICa_LCP deNOx


Low-NOX-Burner (LNB)


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SCR or SNCR? Decision

Reference Box - SNCR Efficiency Maximum Achievable SNCR Reduction Rates

Plant Size Max. Reduction < 100 MWth 60%

100 - 300 MWth 55% 300 - 500 MWth 47,5% 500 - 700 MWth 40%

> 700 MWth 35% Sources: - Air Pollution Control Cost Manual, US EPA - SNCR Guidelines, EPRI - Emission Control at Stationary Sources in Germany, KIT - EGTEI Questionnaires 2012

SCR Efficiency: 70-90%


Secondary Abatement Techniques

ERRICa_LCP deNOx Berlin Workshop : 21 April 2016

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Logic Tree Upgrade 1°?

Derive new 2° inlet emissions

Determine required 2° efficiency

Econonmic Analysis SNCR

Econonmic Analysis SCR

Details SNCR Details SCR

current emissions

Is SNCR feasible? Yes No




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Example analysis: Effect of SCR operation (left) and plant operation (right)

on spec. NOx reduction cost of an SCR

1,000 MWth | 80 €/kWth SCR investment | 2% fixed O&M costs | 9% CRF | 6,000 h/a full load hours | SCR inlet emission load: 400 mg/Nm³

2,000

2,400

2,800

3,200

3,600

4,000

200180160140120100

spec

. NO

x re

duct

ion

cost

s [€

/t ab

ated

]

NOx emission load at stack (mg/Nm³]

0

5,000

10,000

15,000

20,000

25,000

100% 80% 60% 40% 20%

Spec

. NO

x re

duct

ion

cost

s [€

/t ab

ated

] (8

0% re

duct

ion

(400

- 12

0 m

g/N

m³)

)

Annual Capacity Factor

80% reduction (400 to 120 mg/Nm³)




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Method for ESP equipment cost

ERRICa_LCP- FF and ESP Berlin Workshop : 21 April 2016

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Adapted from US EPA methodology Bottom up approach with input data depending on the choice made by the user

Method for Fabric Filter equipment cost

ERRICa_LCP- FF and ESP Berlin Workshop : 21 April 2016

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Adapted from US EPA methodology Only pulse jet systems considered Bottom up approach with input data depending on the choice made by the user

SO2 abatement techniques considered

ERRICa_LCP- desulphurisation techniques

Use of low sulphur fuel Wet flue gas desulphurisation (Investments based on US EPA studies of 2010 and literature) Use of lime or limestone slurry, forced oxidation and production of gypsum Adapted for large combustion plant > 300 MWth Efficiency : 92% to more than 99% for Ca/S between 1.01 to 1.1 For plants > 300 MWth Lime spray dry adsorber (Investments based on US EPA studies of 2010 and literature) Use of a slurry of lime, production of waste in a solid form Efficiency : 80% to more than 92% for Ca/S between 1.1 to 2 For plants < 1500 MWth Dry process: duct sorbent adsorption (based on manufacturer interview and literature) Use of lime or sodium bicarbonate, production of waste in a solid form Efficiency : 50% to 80% for Ca/S between 2 to 4, 70% to 90% with Na/S between 1.4 to 2% For plants < 300 MWth


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SO2 abatement techniques considered Examples of results

ERRICa_LCP- desulphurisation techniques

0

20

40

60

80

100

120

0 1000 2000 3000 4000 5000 6000

Uni

t co

st €

/kW

th

Thermal power MWth

Unit cost €/kWth

0200400600800

10001200140016001800

0 1000 2000 3000 4000 5000 6000

€/t s

o2 a

bate

d

Thermal power MWth

€/t SO2 removed


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Total operating hours and the load dependent capacity factor are calculated from the part load input values.

The following parameters are calculated for both, full load and annual average operation:

Fuel consumption Flue gas volume NOx emissions

For design parameters, full load operation is taken into account, for consumption parameters (except electricity) annual average values (considering part load) are used.


Latest developments in ERICCa_LCP


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Implementation of Part Load Calculation


Full load column Part load

level Operating

hours

NOx emission adoption

Gross electric

efficiency

Resulting full load

hours

Latest developments in ERICCa_LCP


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Implementation of Part Load Calculation




Application to the Apatity plant


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ERRICa_LCP - implementation Berlin Workshop : 21 April 2016

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Exemplary working sheet

ERRICa_LCP - implementation Berlin Workshop : 21 April 2016

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Exemplary working sheet

The user manual is providing general information about ERICCa_LCP and the use of the VBA applications

Due to the facilitations caused by the VBA programming, it is rather shorter and not very complicated, as it is focusing on the technical aspects rather than the content of the tool

More details about the calculations in ERICCa_LCP are provided in the technical document

User Manual

ERRICa_LCP - documentation Berlin Workshop : 21 April 2016

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The technical document is providing detailed information about the calculations, references and other contents of ERICCa-LCP.

This is especially relevant for advanced users or if individual adaptions are necessary.

Both, the user manual and the technical document are publicly available on the TFTEI website. (http://tftei.citepa.org)

Technical Document

ERRICa_LCP - documentation Berlin Workshop : 21 April 2016

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http://tftei.citepa.org/






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ERRICa_LCP - Apatity Plant 24

Apatity combustion plant

Apatity: located in the center of the Kola Peninsula, between "Imandra“ lake, the largest lake in the Murmansk region, and the Khibiny mountains. Apatity : the second largest city in the Murmansk region, more than 70,000 inhabitants. Abundant natural resources : apatite, raw mineral used in the production of phosphorous mineral fertilizers. Source: wikipedia.org

Apatity, Murmansk oblast


Apatity combustion plant: 10 boilers and 8 steam turbines for heat and electricity generation – 1700 hours full load

Boiler sizes : rated thermal input of 153 MWth

Total rated thermal input of the plant: 1 530 MWth Bituminous and sub bituminous coals used of Russian origin

Type of fuels consumed Net calorific

value

Ash content in operating conditions

Fuel consumption

2010 GJ/t % w/w kt

Intinskiy (Sub bituminous) 22.8 27.4 62 Vorkutinskiy (Sub bituminous) 22.6 21.4 167 Kuznetskiy (Bituminous) 17.8 16.8 171 Fuel oil 39.9 0.65

ERRICa_LCP - Apatity Plant



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Total emissions 2008 2010

kt kt Dust before venturi scrubbers (unabated emissions) 91.3 84.6

Dust after venturi scrubbers (abated emissions) 6.5 6.0

NOx 2.4 2.3 SO2 (based on a sulphur content in coals of 1.5 %) 13.1 12.1

Apatity combustion plant: equipped with venturi scrubbers to limit TSP emissions




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Unabated average concentrations

observed

ELVs of annexes IV, V and X of the Gothenburg Protocol

mg/m3 STP and 6 % O2

Dust 30 500 20

NOx 815 200

SO2 4 370 200

Abatement efficiency required for the Apatity power plant: TSP : 99.9 % ; NOx : 75.5 % and SO2 : 95.4 %


Apatity combustion plant: ELVs applied


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DeNOx:

Primary measures: not sufficient for the reduction efficiency required

Selective Non Catalytic Reduction: not sufficient for the reduction efficiency required

Selective Catalytic Reduction (SCR): adapted to the situation if installed in high dust configuration for temperature requirement

DeSOx (FGD: Flue Gas Desuphurisation):

Coals with very low sulphur content (less than 0.1 %) do not exist

LSFO: limestone with forced oxidation for gypsum production: largely used in the world


Apatity combustion plant: available reduction techniques


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Dedusting:

Venturi scrubbers in place are not sufficiently efficient

Both Electrostatic Precipitators (ESP) and Fabric Filters (FF) could be use.


Apatity combustion plant: available reduction techniques


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Apatity combustion plant: available reduction techniques A chain of SCR (Selective Catalytic Reduction) to remove NOx, ESP (Electrostatic Precipitator) to remove dust and wet FGD (Flue Gas desulphurisation with forced oxidation )is taken into account Due to too low outlet temperatures, venturi scrubbers (less than 70 °C) are not kept in operation to avoid reheating of flue gases for the SCR Cost assessment carried out for the following chain: Each boiler equipped with its own small SCR unit, followed by an ESP

After the ESPs, waste gases are collected and convoyed towards a unique FGD unit. FGD with forced oxidation. Gypsum recovered

ERRICa_LCP - Apatity Plant Berlin Workshop : 21 April 2016

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Prices used for definition of variable operating costs (country specific): The prices of utilities, wages, and reagents are taken into account as follows: Electricity: 0.1 €/kWh Wages: 6 k€/person/year Waste disposal: 8.3 €/t Limestone: 20 €/t CaCO3. NH3: 400 €/t NH3. Cost assumed to be similar to costs in the EU SCR catalyst : 20 000 €/m3


Apatity combustion plant: country specific costs


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SO2 NOx TSP Investments - M€ 2010 63.6 62.9 30.7 Operating costs - M€ 2010 / year 5.0 2.9 2.1 Total annual costs - M€ 2010/year 10.7 9.7 4.9

Initial annual average emissions tons/year 12 612 2 352 87 961

Emissions abated tons/year

12 034 1 764 87 903

Pollutants emitted after treatment tons/year 578 588 58

Cost € 2010/t pollutant abated

892 5 509 56


Apatity combustion plant: reduction costs


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The TFTEI methodology for estimating costs in LCP was successfully applied to estimate costs in an LCP in Russia

Experience is replicable to other sectors/plants Provide useful information for estimating the economic impact of a regulation

Site specific engineering cost study would be necessary to define the costs more accurately. For example, the complexity of the retrofit is not known for the Apatity plant. Costs might thus be underestimated.


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Conclusions

Thank you very much for your attention!

Questions? TFTEI Technical Secretariat

errica - tftei cost methodology tool the apatity ...€¦ · efficiency : 80% to more than 92% for...

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