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2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and...

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1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17, 2001 DOE 010517-2 Cormetech New Madrid SCR Retrofit Project 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 & Veatch and J. S. Alberici Construction Catalyst Supplied by Cormetech as Subvendor to Black & Veatch
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Page 1: 2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17,

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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

Page 2: 2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17,

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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

Page 4: 2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17,

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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%

Page 5: 2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17,

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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

Page 6: 2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17,

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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

Page 8: 2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17,

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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

Page 10: 2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17,

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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

Page 14: 2001 Conference on Cormetech SCR and SNCR Madrid Update 1st...1 Cormetech 2001 Conference on SCR and SNCR First Year's Operating Experience with SCR on 600MW PRB Fired Boiler May 17,

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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


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