Environmental Control Solutions At the forefront of Technology Fabio Dinale
Environmental Control SolutionsAt the forefront of Technology
Fabio Dinale
What are our customers asking for?
Leading Efficiency, Lower Emissions, Better Economics
EMISSIONS COMPLIANCE
PROFITABLE GROWTH
GREATERRELIABILITY
BETTER
PERFORMANCE
Smarter. Cleaner. Steam Power.
50%efficiency
Steam Power Systems has accelerated the development of leading efficiency, lower emission technologies to deliver more value to customers.
Technology Advancements
1½ % points more efficient & 3% lower emissions
compared to today’s best
DigitalCapabilities
Delivers up to 1 ½% more power over
the life of a plant
Environmental Controls
Able to lower emissions by 70% more than the world’s most
stringent emission standards
Driving towards
Environmental Controls
LOWER ENVIRONMENTAL FOOTPRINT
500 GW eq. & 5000 industry systems
REDUCED COMPLIANCE COST More than 90 years of experience
FLEXIBILITY & RELIABILITY
Innovation, flexibility & robustness
SOx
>98% NOx
≥95%Particulates
99.9%
TECHNOLOGY READY TO RESPOND TO INCREASING ENVIRONMENTAL STANDARDS
POLLUTANT REMOVAL RATES
GE SIR for ESPs
Up to 60% decrease on ESP dust emissions
Compact size, no cabinet required
Smaller sized cables
Installation & comm. in ½ day vs. several days for conventional T/R
Efficiency >95%
Modular design & standardized spare parts –minimal downtimes
Switched Integrated RectifierHigh voltage power supply combining a transformer/HV rectifier (T/R) and control system for energizing and controlling electrostatic precipitators (ESPs)
Key Reference: 32 SIRs 70 kV / 800 mA
-300k$/y OPEX on energy savings
SO3 conditioning system removed: • additional savings in operation & maintenance• Possibility to comply to future Mercure limitations
11% stack opacity reduced to 1.6% Weight Input ph. Pw. factor Ripple Arc shtdwn
Conventional
technology T/R set
1,200-3,000 kg
(cabinet incl.)
1-phase cos φ =
0,63
30% 10 ms Thyristor
50 Hz
High frequency
technology SIR unit
240-500 kg 3-phase cos φ =
0,92
<1% 10 μs Transistor
25-50 KHz
GE Mega-FF Technology
Up to 10% savings on CAPEX vs designs using shorter bags
Lower emission guarantees
Reduced footprint
Reduced bag wear on bag top
Enhanced ash transport to hoppers during cleaning
Improved gas distribution and gravimetric flow in bag nests
Optipulse® & Optipow®Optimized valves and pulsing technology allowing uniform pressure along the bags resulting in more effective cleaning and longer bag life
Gravimetric flow & nozzle designUnique gas distribution arrangement in each compartment, with flow covering the full cross section area and following larger radius on turns
Manjung 4, 1000 Mwe ultra-supercritical, Malaysia
24 000 PPS/PPS w. PTFE treatment bags, 10 m long. Stack PM emission 1.6 mg/Nm3 dg at guarant. test.
Lomellina Energia WtE Plant, Italy
1600 PI-PTFE/PTFE w. intrinsic PTFE coating bags, 9 m long. Stack PM emission always < 1 mg/Nm3 dg.
Key References
GE ADIS & IsoSwirlTM for SCR
CAPEX reduction from 2% to 3% of total EPC cost
OPEX energy saving ~ € 110,000/y (ref. 210 MWe Unit)
No external heat required for the evaporation
Reduced maintenance
Smaller footprint requirements
Global Mixer(if necessary)
CatalystRectifierGlobal Mixer
ADIS NH3 injection
NH3 Flow control
Compressed air flow control
Barrier air
Ammonia Direct Injection SystemInjects aqueous ammonia via spray nozzles directly into the hot flue gas in the flue gas ducts without any external conditioning (evaporation, dilutions)
IsoSwirlTM
Global mixing system guarantying a good mixing of gas velocity, temperature, NOx concentration and ammonia/NOx ratio distributions at the catalyst inlet
Key Reference: Plomin 2 SCR
Boiler Outlet
ADIS
IsoSwirlTM
SCR
Total Savings
-200k€ CAPEX
-2% EPC costs
-170k€/y OPEX @0.15€/kW
DFGD: GE LLD for NID
Reduction/elimination of flue gas recirculation
Extended operating envelope for the NID
Improved operation stability at low load
OPEX energy savings from booster/ recirculation fan
Device for low load operationRobust design of disperser plate and mixer water lances:
Movable disperser plate controlling duct opening area for sufficient gas velocity at low gas flow
Dual-fluid deflector nozzles maintaining spray distribution at a wider water flow range
Zilina, Slovakia
Bygdoczsz, Poland
Key References
DFGD: GE Hydrator for NID
Mixer
Distribution stage
Hydration stage
1 of 4 installation arrangements
2-stage axial flow hydratorPlug-flow design for high-performance hydration
Improved lime-feed control
New release, available for tendering.
Key References
OPEX savings
Higher quality of hydrated lime
Up to 5% reduction on lime consumption
Improved availability and accessibility
Reduced maintenance
WFGD: 3G OST Design
95% to 99+% SOx removal
CAPEX reduction from 5 to 10% compared to 2nd Generation (2G)
OPEX energy savings from 10 to 20% vs. 2G
Reduced maintenance costs due to fewer mechanical equipment
Particulate emission reduced inside the absorber
Spray zone advanced designDual flow nozzles increasing SO2 removal rate
High nozzle density improving SO2 removal & particulates emission levels
PEP (wall rings) reducing SO2 emissions > 40% at the same L/G
Improved mist eliminators for higher gas velocities (up to 4.5 m/s)
Key References
Gas Flow
Nozzle Location
Sneakage areasGas Velocity Profile
Craiova, Romania
Rybnik, Poland
Opole, Poland
WFGD: SulfiTrac™
Up to ~ 50% OPEX energy saving
Compact size
Shorter installation & comm. time
High corrosion resistance
Simplified operation
Minimal maintenance
GE Sulfite AnalyzerRobust design: stainless steel casing, heavy duty HDPE outer vessel with conical bottom, inner sample container using overflow bucket concept in different sizes, and wetted electrode/ring with rotating cleaning block.
Key References
Size Weight Control box Probe Op. Tª Pw. Supply Signal
Ø0.3m L1m ~20kg NEMA 4
rated
Platinum
surface
-10⁰C to
+70⁰C
24 VDC
~25 W
4-20 mA
output, RTD
Craiova, Romania
Rybnik, Poland
Opole, Poland
Digital CapabilitiesDIGITAL ENVIRONMENTAL CONTROLS
Delivering better performance, greater efficiency & improved reliability over the life of the plant
Automated reporting/trends for each equipment & at fleet level
Feedback to NPI
Advanced warning of downward trend
Monitoring & alerts if KPI goes red
Insights / actions to get «back to green»
Push parameter changes to optimize ECS equipment based on other asset behavior
Collect data to improve knowledge base
Temperature reasoner for NID
Mechanical failure detection for ESPs
Examples of applications
The winning equation
13
EFFICIENCY +leading
EMISSIONS =lower
ECONOMICSbetter
1% point efficiency improvement
22MW Power Output$30 Million NPV Over Asset Life67,000 Tons Coal Consumption120,000 Tons CO2 Emissions
Per year figures for a 1000 MW plant, ~3,000,000 tons coal consumption
Full plant optimization
Lower lifecycle cost
Profitable growth
Improved delivery time
Access to financing
Environmental Compliance
Reduced CO2 Emissions
Better Air Quality
Local Project Support
DELIVERING MORE VALUE FOR OUR CUSTOMERS