Innovation to the Next Generation Coal Combustion - …arinah.com/resources/EESEnzergy.pdfInnovation to the Next Generation Coal Combustion ... Boiler efficiency GCV AR(ASME PTC 4.1

Innovation to the Next Generation Coal Combustion


➢ Enzergy ™ is a form of protein (enzyme, CxHyOz), that is produced by microscopic organism

➢ For the commercialization/transportation application, the microscopic organism is completely separated from the protein – Enzergy™

➢ Enzymes are naturally occurring biocatalysts which can accelerate and sustain the necessary biochemical reaction with shelf life of ~12 months


➢ Food & Beverage - For years, enzymes have been used to turn starch into sugar for brewing beers, wine, vinegar and making bread, cheese, sweeteners.

➢ Pulp & Paper- Enzymes (Esterases) cut the stickies into smaller, more water soluble compounds, facilitating their removal from pulp.

➢ Detergent, Textiles, Leather, Biodegradable Plastics & Bio-ethanol


Enzergy™ (enzyme, CxHyOz), is an naturally occurring, environmental friendly enzymes which is non-harmful and non-toxic. It is specially formulated to treat the respective fossil fuel of coal, oil, gasoline and diesel

➢ TOXICITY TEST: LD50 > 15,000 (NON-TOXIC)

➢ CORROSION TEST: ASTM D130 – 1A (NON-CORROSIVE)

➢ LEAD (PB) TEST: CNS 12221 – NOT DETECTABLE

➢ DENSITY (15OC): CNS 12017 – 0.842 G/ML

➢ ASH CONTENT: CNS 3576 – 0.01%


Oil-fired Boiler Tubes Inspection – Pre Enzergy™ Application

Oil-fired Boiler Tubes Inspection – Post Enzergy™ Application – 6 months


➢ It initiates several Bio-catalytic reactions and depolymerizes/de-composites coal’s long aromatic molecular chains - Depolymerization

Without Enzyme

With Enzyme

➢ Weakens and breaks down hydrogen-carbon bonds to free hydrogen atoms to bond with oxygen atoms. This increase the fuel oxygen content, thus requiring less excess air/oxygen for combustion - Oxygenation

➢ Catalyzes the reaction of sulfur and nitrogen into sulfate and nitrate salts that remain in the fly/bottom ash - Enhanced Oxidization


➢ This CHP plant has 3 PC boilers (steam capacity 130, 210, 330 tons/hr) ≈ 204 MW

➢ Burns 1,500 tons coal/day, 500,000 tons/year, all treated w/ Enzergy™ for only one incentive to reduce coal consumption /cost


➢ The coal that this CHP is burring is similar to a blend of bituminous and subbituminous in the U.S.

➢ A 3-month trial was performed before the source committed into a 3-year contract to continuously apply Enzergy™ , this process is still on-going

Week No. Coal Moisture as

Heating Value as dry

Volatile Matte

Ash as dry Sulphur as dry

Unit % Btu/lb % % %1 12.71 11,978 32.25 13.32 0.592 11.84 12,530 37.20 13.30 0.573 12.70 12,130 37.20 15.60 0.57


➢ During combustion, moisture content is reduced by 7% more at the similar temperature level ~410°C

➢ Complete combustion happens Approximately 24°C faster


➢ ~204 MW, 100% bituminous, ESP + MgO Scrubber

Plant Combustion Performance

Optimization with Plant PI data

ESP

APH

MgO FGD

StackEnzergy ™

Treatment

Plant NOx/SO2/CO2 CEMs


➢ Every3 liters of diluted Enzergy™ to treat 1 ton of coal – add 0.3% Moisture to coal

➢ Enzergy™ sprayed on coal three times: 1) when trucks arrive, 2) during unloading, and 3) on its way to the silo. - There is no mixing mechanism

➢ Not the ideal configuration: coal is sprayed but not mixed, and the solution soaks for only 8 hours – Contact/reaction Time???


Enzergy™ improves thermal efficiency which lower flue gas temperature. (420°C - pre Enzergy™ vs. 395°C – Post Enzergy™ )


Without Enzergy™ , the normal soot-blowing was 5-6 times a day at ~420°C


With Enzergy™ , the improved soot-blowing was 2-3 times a day at ~395°C


2011 Boiler Tubes Inspection – Pre Enzergy™ Application

2012 Boiler Tubes Inspection – Post Enzergy™ Application


2011 ESP Inspection – Pre Enzergy™ Application

2012 ESP Inspection – Post Enzergy™ Application


The Enzergy™ application improves about 22.4% in NOX emission reduction. Forsome PRB or lignite fired applications, 20% -25% is about the best performance for SNCR without creating huge NH3 slip.


➢ Based on the SO2 CEMs reading at the MgO scrubber inlet, the 3 month averaged SO2 reduction is ~ 27.6%

➢ Due to the coal change, MgO consumption is also taken into considerations

Date Coal Type SGS Reported Sulfur Content(%)

Calculated SO2 in flue gas (ppm)

Actual SO2 Reading at MgO inlet

SO2 Reduction (%)

Status

7/06-7/14 Chinese Coal 0.97% 689 655 Baseline

7/15-7/19 Australian coal

0.33% 322 386 Baseline

7/20-8/11 Chinese Coal 0.93% 700 595 Baseline


0.50% 488 334 31.56% Enzergy™ Treated

8/30-9/04 Blended 0.50%-0.93%

N/A 473 Baseline + Enzergy™


0.65% 634 413 34.86% Enzergy™ Treated

9/14-9/21 Chinese Coal 0.92% 700 589 15.86% Enzergy™ Treated


0.65% 634 385 39.27% Enzergy™ Treated


0.52% 507 352 30.57% Enzergy™ Treated


0.33% 322 285 11.49% Enzergy™ Treated


0.52% 507 356 29.78% Enzergy™ Treated


➢ This CHP has a Magnesium Oxide (MgO) Injection facility to reduce SO2 emission ➢ The 6 months average of coal treated by one ton of MgO without Enzergy™ is about 93.3

(tones of coal) comparing to 122.0 (tons of coal) on 3 months average with Enzergy™ ➢ The SO2 emission reduction is determined at 30.8% ➢ Enzergy™ did not impact the MgO performance on SO2 control

Month MgO Consumption Coal Consumption Coal/MgO(tons) (tons) (tons/tons)

Jan-11 525 45,882.10 87.4Feb-11 OverhaulMar-11 411 42,669.80 103.8Apr-11 484 44,189.90 91.3May-11 398 46,917.30 117.9Jun-11 557 42,220.20 75.8Jul-11 521 43,639.30 83.8Aug-11 437 45,485.20 104.1Sep-11 451 43,655.00 96.8Oct-11 265 43,743.20 165.1


➢ During this 3 month trial, the bottom ash increases by 9.05%, on average which can be Calcium sulfite or Calcium sulfate.

➢ The Calcium sulfite or Calcium sulfate are formed by the reaction of CaO and the SO4(2-)

➢ The CaO in the CHP ash: ~4% ;

Period Ash/Coal % Bottom % Fly %

Baseline 13 Months

16.15% 13.28% 86.72%

Enzergy Treated 3 Months

15.20% 14.48% 85.52%

Change -0.94% 1.20% -1.20%% -5.85% +9.05% -1.38%


Coal Saving:

➢ Boiler evaporation ratio was determine to increase by 5.62% ➢ Boiler efficiency GCVAR(ASME PTC 4.1 Input-Output Method) was

determine to increase by 5.79% ➢ Boiler efficiency GCVAR(ASME PTC 4.1 heat Loss Method) was

determine to increase by 4.18% Emissions Reduction:

➢ Sulfur Dioxides (SO2) reduction 30.8% (MgO Consumption reduction )

➢ Sulfur Dioxides (SO2) reduction 27.6% (Lbs/MMBtu) – SO2 CEMs ➢ Nitrogen Oxides (NOX) reduction 22.4% (Lbs/MMBtu)


➢ 500 MW, 100% PRB, ESP only

DSI across the

APH

APH

ESPSTACK


30.0%

30.2% 20.0%

10.0%

0.0% 0 2000 4000 6000 8000 10000 12000 14000

Trona Injection (lb/hr) ➢ SO2 Reduced by 30% at Trona Injection rate of 8000#/hr, $5.6 per tone coal

40.0%

60.0%

$9,000,000/yr 50.0%

St ac k S O 2 R e m o va l Ef fi ci e n cy

( % )

$6,000,000/yr

$7,500,000/yr

42.1%

49.7%


For a 200 MW unit (700,000 ton coal/year), Coal Saving at 5 %: ➢ PRB at $25/ton, 5% saving: $1.25/ton coal ➢ Bituminous at $50/ton, 5% saving: $2.5/ton coal

Emissions Reduction:

➢ With a scrubber, SO2 reduction at 30 %: the saving on the scrubber consumables (~$600,000/year) at $0.85/ton coal

➢ Without a scrubber (DSI), SO2 reduction at 30 %: the saving on the DSI consumables (~$1,300,000/year) at $1.85/ton

➢ Nitrogen Oxides (NOX) reduction 20 %: the saving on the SCR consumables (~$300,000/year) at $0.43/ton coal

➢ According to the proposed 111d, CO2 reduction requirement with the option of co- firing natural gas for 5 % CO2 reduction: $6.33/ton coal

For a 200 MW, total estimated saving with a Enzergy™ application

➢ A PRB -fired unit: $9.86/ton coal ➢ A Bituminous -fired unit: $10.11/ton coal


ESP Stack

Enzergy™ Treatment

Plant NOx/SO2/C O2

CEMs

Plant Combustion Performance

Optimization with Plant PI data



➢ During combustion, moisture content is reduced by 3% more at the similar temperature level ~150°C

➢ Complete combustion happens Approximately 25°C faster

Baseline Enzergy™ Application


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Innovation to the Next Generation Coal Combustion - …arinah.com/resources/EESEnzergy.pdfInnovation to the Next Generation Coal Combustion ... Boiler efficiency GCV AR(ASME PTC 4.1

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