limestone injection for protection of scr catalyst€¦ · riley power inc. conclusions • optimum...
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MEGA Symposium May 19 – May 22, 2003, Washington, D.C.
LIMESTONE INJECTION FOR PROTECTION OF SCR CATALYST
Terence Ake, Clayton Erickson, William MedeirosRiley Power Inc., a Subsidiary of Babcock Power Inc.Linton HutchesonDuke EnergyMark Barger, Scott RutherfordCormetech, Inc.
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MEGA Symposium, Washington, D.C. 2Riley Power Inc.
Introduction & Background
• Gaseous Arsenic Poisoning Predominant Deactivation Mechanism
• CaO Potential Poison at High Percentages• Gaseous As Controllable with CaO from
– Naturally in Coal– Limestone Addition to Fuel– Fuel Blending
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MEGA Symposium, Washington, D.C. 3Riley Power Inc.
Arsenic Control Through Limestone Addition
• Gaseous Arsenic (AsO3) as Catalyst Poison
• Addition of Limestone (CaCO3) to Coal form solid Non-Poisoning Form ((Ca3(AsO4)2)
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MEGA Symposium, Washington, D.C. 4Riley Power Inc.
European And Japanese Experience
• Japanese Experience Good, Low As Coals -Dry Bottom Units
• European Experience Good, Low As Coals -Dry Bottom Units
• Bad European Experience, Low As Coals -Wet Bottom Ash Recirculation
• Recirculation Revaporized As to Gaseous Phase
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MEGA Symposium, Washington, D.C. 5Riley Power Inc.
United States Coals
• USGS Coal Database - 22 ppm As Average• Coal Cleaning Reduces As by 35 to 83%• Utilities Need for Fuel Flexibility
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MEGA Symposium, Washington, D.C. 6Riley Power Inc.
Arsenic Variation in Coals
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MEGA Symposium, Washington, D.C. 7Riley Power Inc.
First US Limestone Addition• Large Variation in As Concentration with
Low CaO• Arsenic Levels as High as 24 ppm • Unit Had Past History of Slagging• Approach
– Temporary Limestone Feed System– Measure Gaseous Arsenic (AsO3)– Observe Boiler Performance
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MEGA Symposium, Washington, D.C. 8Riley Power Inc.
Effect of Limestone Addition
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MEGA Symposium, Washington, D.C. 9Riley Power Inc.
Limestone Addition Experience
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MEGA Symposium, Washington, D.C. 10Riley Power Inc.
Limestone Addition Experience
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MEGA Symposium, Washington, D.C. 11Riley Power Inc.
Duke Energy Cliffside Unit 5
• 50% of Fuels Did Not Require Limestone• Two Fuels Cannot Achieve Continuous
Operation With Limestone Addition• Using Limestone Addition System and Fuel
Knowledge Two Initial Catalyst Layers• Cormetech FIELD Guide Developed for
Fuel Range
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MEGA Symposium, Washington, D.C. 12Riley Power Inc.
Duke Energy Cliffside Unit 5
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MEGA Symposium, Washington, D.C. 13Riley Power Inc.
Mark Barger
SCR Catalyst Supplier for Cliffside 5 Project
Project Manager – Cliffside 5
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MEGA Symposium, Washington, D.C. 14Riley Power Inc.
FIELD Guide
• Fuel Impact and Evaluation of Life Determination
• Unit Design Specific• Assumes Constant Fuel Sulfur Level• For Arsenic poisoning SCR applications
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MEGA Symposium, Washington, D.C. 15Riley Power Inc.
FIELD Guide
20K+hours
16-20Khours
12-16Khours
0-12Khours
CaO%
As (ppm)
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MEGA Symposium, Washington, D.C. 16Riley Power Inc.
Cliffside 5 with 2002 fuels plotted
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MEGA Symposium, Washington, D.C. 17Riley Power Inc.
Cliffside 5 with 2003 fuels plotted
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MEGA Symposium, Washington, D.C. 18Riley Power Inc.
Linton Hutcheson
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MEGA Symposium, Washington, D.C. 19Riley Power Inc.
Cliffside Unit 5 SCR Management
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MEGA Symposium, Washington, D.C. 20Riley Power Inc.
Limestone Injection
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MEGA Symposium, Washington, D.C. 21Riley Power Inc.
FIELD GUIDE
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MEGA Symposium, Washington, D.C. 22Riley Power Inc.
Cliffside Unit 5 SCR Management
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MEGA Symposium, Washington, D.C. 23Riley Power Inc.
Coal Data Information
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MEGA Symposium, Washington, D.C. 24Riley Power Inc.
Cliffside Unit 5 SCR Management
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MEGA Symposium, Washington, D.C. 25Riley Power Inc.
Fly-ash Data Information
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MEGA Symposium, Washington, D.C. 26Riley Power Inc.
Cliffside Unit 5 SCR Management
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MEGA Symposium, Washington, D.C. 27Riley Power Inc.
CS5’s SCR PI Performance Data
More than 100 Additional SCR Data Points Stored
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MEGA Symposium, Washington, D.C. 28Riley Power Inc.
Cliffside Unit 5 SCR Management
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MEGA Symposium, Washington, D.C. 29Riley Power Inc.
Viewing Short Version of PI Data
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MEGA Symposium, Washington, D.C. 30Riley Power Inc.
Viewing Short Version of PI Data
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MEGA Symposium, Washington, D.C. 31Riley Power Inc.
Cliffside Unit 5 SCR Management
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MEGA Symposium, Washington, D.C. 32Riley Power Inc.
Time Passing Across the Catalyst
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MEGA Symposium, Washington, D.C. 33Riley Power Inc.
Conclusions• Optimum Catalyst Designs are Achievable
With Current and Future Fuel Knowledge• Limestone Addition Reduces Gaseous As• Limestone Addition Protects• Limestone Adds to Fuel Flexibility• Limestone System is Part of an Integrated
SCR Reactor Design, Fuel Purchase, Catalyst Management, and Plant Operation Approach