SHEAROFRCE LLC

NOX EMISSION THREATMENT

SYSTEMS

NOX Emissions

SYSTEMS

U2A Process

AOD Process

Anhydrous NH3 Process

Aqueous Nh3 Process

Flue Gas Conditioning

Heaters & Thermocouples

Hydrolysis verses Pyrolysis

Competitive Analysis

SHEAROFRCE LLC

NOX Emissions

• Fossil fuel combustion and industrial processes are responsible for

700,000 tones of nitrous oxide emissions per year.

• Nitrous oxide is a by-product of fuel combustion in mobile and stationary

sources resulting from the burning of any fossil fuel substance such as

burn coal, natural gas, fuel oil, biomass and waste.

• When any fossil fuel is burnt, part of the nitrogen that is in the fuel and

surrounding air gets oxidized creating nitrous oxide emissions.

SHEAROFRCE LLC

NOX Source

SHEAROFRCE LLC

NOX via Boilers• The Petroleum and Natural Gas power sources supply resources to the

Industrial, Commercial and Electric Power sectors in the forms of Gas

Turbines and Boilers.

• Many coal power plants are being replaced with highly efficient natural gas

turbines since natural gas prices are low as well as the ability to meet

stricter ambient emission regulations.

• Many Boilers are furnished as Industrial Boilers which can be categorized

into five segments.

Industry – Fuel Type No. of Boilers Size Size

NH3

Demand

HP Lb/hr Lbs./hr

1: Food - Gas 10,000 3930 - 7860 135-270 k 5-10

2: Pump & Paper - Black Liquor, Gas3,000 39,200 - 98,250

1,352-

3,400 k60 - 200

3: Chemical Manu. – Gas >10, 000 3930 135k 5

4: Refinery - Fuel Oil 1200 39,200 1,352k 60

5: Metal Plants - Coke & Gas 3,000 3930 135k 5

SHEAROFRCE LLC

NOX via Turbines

The number of Coal and Petroleum plants is decreasing as the number of Natural

Gas Plants is increasing.

There are 1,749 Power Plants with 803 Natural Gas Turbines being used by

Electric Utilities. These turbines fall in the Heavy Duty Gas Turbine market with

NH3 rates greater than 100 lbs./hr. which are well suited for the U2A.

The balances of 946 Natural Gas Turbines are being used by Industrial Companies

and the Oil and Gas Industry. These turbines are all suited for the AOD market.

SHEAROFRCE LLC

NOX via Turbines

Year Coal PetroleumNatural

Gas

Other

GasesNuclear

Hydro-

electric

Conven-

tional

Other

Renew-

ables

Hydro-

electric

Pumped

Storage

Other

Energy

Sources

Total (All Sectors)

2004 625 1,143 1,670 46 66 1,425 749 39 28

2014 491 1,082 1,749 43 62 1,441 2,674 41 94

Electric Utilities

2004 357 816 722 2 37 908 65 34 1

2014 286 780 803 1 32 889 272 35 20

Independent Power Producers, Non-Combined Heat and Power Plants

2004 100 173 355 1 29 457 478 5 2

2014 87 148 395 1 30 499 2,006 5 18

Independent Power Producers, Combined Heat and Power Plants

2004 48 15 180 3 -- -- 30 -- --

2014 30 9 145 2 -- -- 54 -- 7

Commercial Sector

2004 21 65 121 1 -- 9 46 -- --

2014 17 93 169 -- -- 10 178 1 6

Industrial Sector

2004 99 74 292 39 -- 51 130 -- 25

2014 71 52 237 39 -- 43 164 -- 43

SHEAROFRCE LLC

NOx Treatment Systems

Urea to Ammonia Aqueous AmmoniaAnhydrous Ammonia

Hydrolysis Pyrolysis

SCR SNCR

AIG

NOx Gas

SHEAROFRCE LLC

Ammonia SystemsItem Urea to Ammonia Hydrolysis Urea to Ammonia Pyrolysis Anhydrous Aqueous

Basic Pro/Con

Urea is safest but requires conversion

to Ammonia which is formed at 80 psig

and 300 F.

Again Urea is safest but conversion to

Ammonia to done at a much higher

temperatures of 700 F

100% Ammonia gas is

extremely toxic, potentially

fatal and difficult to store

Aqueous Ammonia must be

vaporized in order to use, it is

safer then Anhydrous

Ammonia,

Operating Concept

Chemical decomposition of bond of

Hydrogen & Oxygen Molecule of Water

using Urea Reagents, two molecules of

NH3 are formed

Pyrolysis is the decomposition of Urea

by extreme Heat in the absence of

oxygen, water, or any reagents, only

one molecule of Ammonia is formed

100 %Ammonia is directly

injected into system

Ammonia is diluted to 19% or

40% with water

Multiple Consumers

U2A & AOD are capable of feeding

Ammonia to multiple Consumers

Pyrolysis units are designed for a One

Unit to One Consumer basis.

100 %Ammonia systems are

designed for a is directly

injected into system

Ammonia is diluted to 19% or

40% with water

Operating Hazard

Very Safe, Ammonia is formed at 80

psig and 300 F.

Less Safe, Ammonia is formed at 700

F or higher

Very dangerous, requires

expensive handling

equipment. Not suitable for

highly populated areas

Dangerous, requires

expensive handling

equipment. Not suitable for

highly populated areas

Total decomposition

Urea is fully decomposed to NH3, CO2

& H2O for a complete reaction

Urea is not completely decomposed

resulting in an incomplete reaction of

NH3 & HNCO (isocyanuric acid)

NA NA

Decomposition to Gas not

Mist

The urea is decomposed to NH3 Gas

which is easily injected into the AIG.

Spay Nozzles are used to spray urea

mist which are prone to plugging

NA NA

SCR SNCR SCR SNCR SCR SNCR SCR SNCR

NOx Reduction 95 to 98% 50-70% 95 to 98% 50-70% 95 to 98% 50-70% 95 to 98% 50-70%

Operating Temp.

Operating Pressure

Energy Consumption

Feedstock Consumption

SHEAROFRCE LLC

Urea to Ammonia System

SHEAROFRCE LLC

Anhydrous Ammonia System

SHEAROFRCE LLC

Aqueous Ammonia System

SHEAROFRCE LLC

SO3 Flue Gas Conditioning

SHEAROFRCE LLC

Hydrolysis vs. Pyrolysis

HYDROLYSIS PYROLYSIS

One system can feed multiple Boilers, Turbines One system can only feed one Boiler, Turbine

Urea is heated under pressure of 70 psig and 302 F Urea is injected into a decomposition chamber at

600 to 700 F

Urea is fully decomposed to NH3, CO2 & H2O for a

complete reaction

Urea is not completely decomposed resulting in an

incomplete reaction of NH3 & HNCO (isocyanuric

acid)

Lower Operating Energy Consumption Higher Operating Energy Consumption

Lower Feedstock Consumption Higher Feed Stock Consumption

Urea Contaminants Removed by Blowdown Urea Contaminants may plug Catalyst

The urea is decomposed to NH3 Gas which is easily

injected into the AIG.

Spay Nozzles are used to spray urea mist which

are prone to plugging

Hydrolysis units are horizontal which is easily

shipped in containers and easily erected

Pyrolysis units are vertical and larger which are

costly to ship and harder to erect

Units are equipped with smaller air blower units Units required a significant amount of combustion

air at extremely high temperature

SHEAROFRCE LLC

Hydrolysis vs Pyrolysis Chemistry

Urea CO(NH2)2 heat Ammonium Cyanate NH4OCN heat Ammonia

NH3 + Iso--Cyanic Acid HNCO + Water H2O heat Ammonia NH3 +

Carbon Dioxide CO2 + Water H2O

+

Urea CO(NH2)2 Ammonia (g) NH3

Iso-Cyanic Acid HNCO

Water H2O

+Heat

Water H2O

Ammonium Cyanate

NH4NOCN

Heat Heat+ +

Ammonia (g) NH3

Carbon Dioxide CO2

Hydrolysis

Vs. Pyrolysis

+

Carbon Dioxide CO2Heat

+ +

2x Ammonia (g) NH3Water H2OUrea CO(NH2)2

2x Ammonia (g) NH3+ Water H2OUrea CO(NH2)2 heat + Carbon Dioxide CO2

SHEAROFRCE LLC

SCR vs. SNCR

Selective catalytic reduction (SCR) is a means of converting Nitrogen

Oxides (NOx) with the aid of a Catalyst into Diatomic Nitrogen (N2)

and Water (H2O) and Carbon Dioxide (CO2).

A gaseous reductant, typically Anhydrous Ammonia, Aqueous Ammonia,

or Urea, is added to a stream of Flue or Exhaust Gas and is

adsorbed onto a Catalyst.

Selective non-catalytic reduction (SNCR) is a method to LESSON

Nitrogen Oxides without a Catalyst into Diatomic Nitrogen (N2) and Water

(H2O) and Carbon Dioxide (CO2).

The process involves injecting either Ammonia or Urea into the into the

firebox of the boiler at a location where the flue gas is between 1,400 and

2,000 °F (760 and 1,090 °C) to react with the nitrogen oxides formed in

the combustion process.

The resulting product of the chemical redox reaction is molecular Diatomic

Nitrogen (N2), Carbon Dioxide (CO2), and water (H2O).

SHEAROFRCE LLC

• Ammonia Supply Systems – including patented

Urea to Ammonia (U2A®) Conversion systems

• AOD® – Urea Hydrolysis System

• Flue Gas Conditioning (FGC) Technologies- SO3 Systems for Fly Ash Resistivity

- NH3 Systems to Improve ESP Performance

• Fuel Control Valve Trains

• Custom Process Equipment

• Heaters and Thermocouples

• Aftermarket Service & Rentals

Systems

SHEAROFRCE LLC

U2A vs

AOD Key Operating Differences

Heat In

PCLC

NH3 Demand

Signal

Urea Supply

T

Variable Control Demand Increases

Pressure Fixed by PC Pressure Fixed

Temperature Floats with heat

input

Temp Rises with

reaction rate

Level Fixed by LC Level Fixed

Heat Input Based on Demand

Signal

Heat Increased

Variable Control Demand Increases

Pressure Fixed by PC Pressure Fixed

Temperature Fixed by bulk Temp Fixed

Level Variable by NH3

demand

Level Varies urea in

tubes and exposed

surface area

Heat Input Fixed bulk

temperature

Heat maintained

fixed

Steam In

Condensate

Out

PC

NH3 Product

GasLC

NH3 Demand

Signal

T

Urea Supply

SHEAROFRCE LLC

AOD® Process

SHEAROFRCE LLC

AOD®

SHEAROFRCE LLC

AOD®

Ammonia On Demand

Urea Hydrolysis System

SHEAROFRCE LLC

AOD®

Ammonia On Demand (AOD®)– Registered Trademark

Industrial Applications

Capacity: up to 25 lb/hr NH3

Small Footprint

All-in-One Design

SHEAROFRCE LLC

AOD®

SHEAROFRCE LLC

AOD®

SHEAROFRCE LLC

Product Overview:

Urea to Ammonia System

U2A® Process

SHEAROFRCE LLC

Process Description

Urea Hydrolysis

– 50% Urea Pumped to Reactor

– Heated to About 310°F (154°C)

– Pressure of 40 to 120 psig (2.76/8.3 barg)

– 50% Urea Solution Converts to:

37.5%Vol. Ammonia Gas

18.7%Vol. Carbon Dioxide

43.8%Vol. Water Vapor

SHEAROFRCE LLC

Operating Principles

Steam Modulated to Achieve Set Pressure

Urea Level in Hydrolyzer controlled to constant level

Ammonia Gas Mixture Controlled by Flow Control Valves at Each Metering Unit

Covered by (U.S. patents 6,077,491; 6,322,762; 6,436,359 and 6,506,350; European and Asian Patents Issued or Pending)

SHEAROFRCE LLC

Reactor Cross Section

Vapor space

Liquid Urea space

Heating/cooling tubes

Heat traced insulated piping

and Instrument/Control

devices

Insulated reactor vessel

SHEAROFRCE LLC

Hydrolyzer Skid

Steam

BOILER 1

SCR

Urea

Storage

TankUrea Feed Pumps

Backup

Hydrolyzer Condensate

U2A®

Hydrolysis

Process

2NH3

+

CO2

APH APHAPH APH

Metering

Unit

Metering

Unit

Metering

UnitMetering

Unit

BOILER 4

SCR

BOILER 2

SCR

BOILER 3

SCR

One System Supplies

Multiple Boilers

100% Redundant

Backup

Operating

Hydrolyzer

SHEAROFRCE LLC

U2A® Advantages

Low Energy Consumption and Cost – Uses

Low Energy Steam

Complete Conversion of Urea to Ammonia

Rapid Load Following

One Unit Can Supply Multiple Boilers

Equipment Redundancy

Urea Contaminants Removed by Blowdown

SHEAROFRCE LLC

Examples of U2A®

Equipment

SHEAROFRCE LLC

2 x 400 lb/hr Hydrolyzer Skids

SHEAROFRCE LLC

2,176 lb/hr Hydrolyzer Skid

SHEAROFRCE LLC

Level Sensors - Radar

SHEAROFRCE LLC

Urea Unloading Pump Skid

SHEAROFRCE LLC

Steam Saturator Skid

SHEAROFRCE LLC

AFCU Skid

SHEAROFRCE LLC

Formaldehyde-Free Urea

Fixed Price Supply Contracts

SHEAROFRCE LLC

DeNOx Direct

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DeNOx Direct

SHEAROFRCE LLC

Anhydrous Ammonia

SHEAROFRCE LLC

Anhydrous Ammonia

Anhydrous = Without Water (0.2-0.5%)

Pungent, Colorless Gas

Stored as Liquid Under Pressure

Explosive Limits 16 to 25% in Air

Energy to Vaporize ~ 540 btu / lb

Pressure Varies Greatly with Temperature

– e.g. 50º F ≈ 72 psig ; 90º F ≈ 160 psig

SHEAROFRCE LLC

Anhydrous Ammonia

0

50

100

150

200

250

300

350

-40 -20 0 20 40 60 80 100 120 140

Pre

ssu

re p

sig

Temperature Deg F

Vapor Pressure vs. Temperature

SHEAROFRCE LLC

Unloading Station

Liquid and Vapor Recovery Lines

Bulkhead Break-away

Purging and Venting options

All wetted parts stainless steel

SHEAROFRCE LLC

Transfer Pump Skid

Low NPSH pump

Entrained Vapor

Side Channel Type

Minimum flow bypass

Back Pressure control

SHEAROFRCE LLC

Transfer Pump Skid

Low NPSH pump

Regenerative Turbine Type

All wetted parts stainless steel

Overflow recirculation design

Back Pressure control

SHEAROFRCE LLC

Anhydrous NH3 Vaporizers

SHEAROFRCE LLC

Dilution Air Skid

SHEAROFRCE LLC

AFCU Skid

SHEAROFRCE LLC

Aqueous Ammonia

SHEAROFRCE LLC

Aqueous Ammonia Properties

Typical Dilution 19% & <29%

Pungent, Colorless Liquid

Specific Gravity = 0.92 ~ 0.89

Freezing Point

– 19% = -30 °F

– 29% = -100 °F

Boiling Point

– 19% = 140 °F

– 29% = 86 °F

SHEAROFRCE LLC

Aqueous Ammonia

0

5

10

15

20

25

30

35

40

30 40 50 60 70 80 90 100 110 120

psig

Temperature Deg F

29.4%

19%

SHEAROFRCE LLC

Unloading Station Aqua NH3

SHEAROFRCE LLC

In Line NH3 Vaporizer

SHEAROFRCE LLC

Flue Gas Conditioning

(FGC) Equipment

SHEAROFRCE LLC

SO3 FGC Background

Burning Low Sulfur Coal results in low levels

of Sulfur Trioxide (SO3) which prohibits the

formation of Sulfuric Acid (H2SO4)

FGC injects controlled quantities of Sulfur

Trioxide in the Flue Gas Stream to form the

Sulfuric Acid

Sulfuric Acid lowers the electrical resistance

of the Fly Ash which allows collection by

Electrostatic Precipitation

SHEAROFRCE LLC

SO3 FGC Theory

Controlled Injection of small quantities Sulfur

Trioxide into Flue Gas Stream

Reduces Resistivity of Fly Ash to permit

collection by Electrostatic Precipitators

(ESPs)

Small amount injected upstream of ESP

Commercialized by Wahlco in early 1970’s

Over 1,500 FGC Units Installed Worldwide

SHEAROFRCE LLC

SHEAROFRCE LLC

SHEAROFRCE LLC

SO3 Generator Skid

SHEAROFRCE LLC

Heaters and

Thermocouples

SHEAROFRCE LLC

Tubular Electric Heaters

Low watt density

duct heaters

and

Immersion heaters

for high temperature

use

SHEAROFRCE LLC

Duct Heaters

Heavy wall tubular

elements employ

Wahlco’s unique gas-

tight, non-sheath

attachment system

Terminal boxes are

separated from

flanges for reduced

temperatures

SHEAROFRCE LLC

Thermocouples

Custom

thermocouple arrays

Reliable, accurate

and fast temperature

sensing

Widely used in gas

turbines and extreme

environments

SHEAROFRCE LLC

Thermocouples

Fast response

temperate

measurement

For critical

applications

SHEAROFRCE LLC

Major U2A USERS

- AECOM / URS

- Alstom-GE

- Babcock & Wilcox

- Beijing Guodian Longyuan

- Black & Veatch

- Breen Energy

- Burns & McDonnell

SHEAROFRCE LLC

- CLP Power Hong Kong Ltd

- Doosan Heavy Industries

- Duke Energy

- Enel

- Hitachi (MHPSA)

- Hyundai Heavy Industries (HHI)

- IHI

- Kiewit

- Mitsubishi / MHI / MHPSA

SHEAROFRCE LLC

- Lummus Technology/CB&I

- Parsons/Progress Energy

- Petro-Chem

- Riley Power / Babcock Power

- Sargent & Lundy

- SNC Lavalin

- Tampa Electric

- UCLA

- Valmet