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July 2013 • www.power-eng.com

NUCLEAR OPPORTUNITY A Q&A WITH AREVA CEO MIKE RENCHECK

COAL ROUNDTABLE EXECUTIVES DISCUSS THE FUTURE OF COAL

COAL DUST HOW TO CONTROL IT

the magazine of power generation

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www.power-eng.com 1

OPINION

Last month, President Barack

Obama officially announced

plans to use his executive pow-

ers to establish greenhouse gas limits

for new and existing power plants in the

U.S. The long-awaited announcement

contained few details, but it marked the

beginning of what will surely be intense

negotiations between regulators, envi-

ronmental groups and utilities.

There will be lawsuits, bi-partisan

wrangling and a lot of pontificating.

Already, the pow-

er generation indus-

try has announced

plans to retire more

than 60 GW of coal-

fired generation by

2020. That’s about

19 percent of the

nation’s coal-fired

capacity. Some of

these closures stem

from the benefits

of low-priced natu-

ral gas. But a sig-

nificant number of

these closures stem

from a bevy of new

rules and standards

for mercury emissions, coal ash stor-

age, wastewater treatment and cooling

water technology. Establishing the first-

ever limits on CO2 for new and existing

plants will inflate the number of shut-

tered coal plants in the U.S.

But the actual impact of Obama’s cli-

mate-change plan is almost impossible

to measure at this point. It depends on

the standard the Environmental Protec-

tion Agency (EPA) sets and how the plan

is rolled out, said Mac McFarland, chief

executive officer of Luminant, Texas’

largest power provider.

“The devil is in the details and those

details will need to be practical and

actionable,” McFarland told the Dallas

Morning News. “It’s not just the number,

but how the reductions over time are

achieved.”

If the CO2 standards for coal plants

are based on proven and available

technology and the industry is given

enough time and flexibility to com-

ply, the vast major-

ity of U.S. coal-fired

generation can re-

main online under

Obama’s climate-

change plan.

The Obama-run

EPA is expected to

release final CO2

limits for new power

plants by Sept. 20.

A proposal to limit

CO2 from existing

plants is expected

to be issued in June

2014 and finalized

by June 2015.

The Clean Air Act

allows the EPA to set separate stan-

dards for each fuel type – coal, oil and

natural gas. What’s more, the law al-

lows a separate standard based on the

best emission reduction technology

for each fuel type. Right now, the pro-

posed GHG rule for new plants would

establish one standard – 1,000 pounds

per MWh – for gas and coal plants.

But this standard can only be met by

using one type of fuel – natural gas –

and one type of generating technology

The Devil Could be in the DetailsBY RUSSELL RAY, MANAGING EDITOR

– combined cycle.

“It was written more for a gas plant

than a coal plant,” said Tim Curran,

president of Alstom Power. “We be-

lieve they’re working on correcting the

rule. Something has to change there in

order to keep coal in the mix.”

The rule, in its current form, would

likely be tossed out by an appeals court

because it fails to provide the flexibil-

ity proffered under the Clean Air Act.

The EPA is rewriting the rule so it can

withstand a legal challenge from coal-

fired power producers. By law, the EPA

cannot finalize CO2 standards for ex-

isting plants until it finalizes the pro-

posed standard for new plants. One is

inextricably tied to the other under the

Clean Air Act.

A coal plant would not be able to

meet the proposed standard without

installing a carbon capture and stor-

age (CCS) system, a risky undertaking

due to the cost, liability and questions

about CCS technology.

“The proposed rule seemed to pro-

hibit new coal without any kind of

CCS technology. That’s concerning,”

said Jim Heilbron, senior vice presi-

dent of Alabama Power. “We were

happy to participate in those 2 million

or so comments that were received. We

would suggest that you separate out

standards for gas and for coal. That

only seems to be appropriate.”

Obama’s climate-change plan will

be widely discussed at COAL-GEN

2013, Aug. 14-16, in Charlotte, N.C.

To register online, visit www.coal-gen.

com. If you have a question or a com-

ment, please contact me at russellr@

pennwell.com.

1307PE_1 1 6/27/13 4:56 PM

Power Engineering is the flagship media sponsor for

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DEPARTMENTS

1 Opinion

4 Clearing the Air

6 View on Renewables

8 Nuclear Reactions

10 Demand Response

76 Products

81 Generating Buzz

117VOLUME

28 Coal Dust Control

42 Opportunity in Nuclear: A Conversation with Mike Rencheck, President and CEO, AREVA Inc.

60 Entergy Blends a Dedication to Energy with a Dedication to Customers

68 Plant Management: Don’t Lose Focus on FAC Issues

34 Boiler Upgrades & Conversions

No. 7, July 2013FEATURES

2

42 O

3

12 Chemical Looping for Nearly Zero-Pollution Coal Power Researchers at Ohio State University provide Power

Engineering an exclusive look into technology that

produces power from coal without creating any

greenhouse gas emissions.

20 Special Report: Coal Executive Roundtable

48 Emissions Control: Handling NOx and SOx Emissions

54 Pre-engineered Strategies Maximize Knowledge Base to Ensure Efficiency and Reduce Downtime

1307PE_2 2 6/27/13 4:57 PM

Bechtel is among the most respected engineering,

project management, and construction companies in

the world. Bechtel operates through five global

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Since its founding in 1898, Bechtel has worked on

more than 22,000 projects in 140 countries on all

seven continents. Today, our 53,000 employees team

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www.power-eng.com4

CLEARING THE AIR

wastewater, concentrated brine is created.

This concentrated brine, around five

percent of the initial blowdown flow, can

be mixed with plant fly ash and landfilled

as a solid waste still meeting zero “liquid”

discharge. Partial ZLD avoids operational

difficulties that may occur during the

crystallization process. This is especially

beneficial when softening is avoided

leaving predominantly CaCl2 salts in the

concentrated brine.

BIOLOGICAL

SYSTEMS SOLUTIONS

For those who don’t go the ZLD

route, there are other options. Due to

the NPDES permitting process and

the numeric criteria implemented at

Merrimack Station, some believe the EPA

is leaning towards regulations based on

the performance of chemical precipitation

followed by biological treatment.

Biological systems operate by creat-

ing a reducing atmosphere and convert-

ing nitrates to nitrogen gas, followed by

conversion of selenium compounds to

insoluble elemental selenium. Although

these systems offer significant cost sav-

ings over ZLD systems, potential issues

can occur as a result of f luctuating FGD

wastewater chemistry. Close monitor-

ing of wastewater will ensure minimal

upsets to the biological system and en-

able suitable living conditions for the

reducing bacteria.

Whatever solution a utility considers,

understanding the interactions between

the wastewater technology and the

upstream process, using that information

to plan viable options, and providing

accurate design specifications will help

ensure the best available option is selected

for each plant.

With the U.S. Environmen-

tal Protection Agency’s

(EPA) April 2013 release of

the effluent limitation guidelines (ELG)

proposed rule regulating wastewater dis-

charges from the steam electric industry,

plant owners should investigate their op-

tions for compliance prior to the expected

release of the final rule in May 2014.

The proposed rule will be implemented

on a rolling schedule through National

Pollutant Discharge Elimination System

(NPDES) permits up for renewal and

would set limits on the levels of pollutants

in wastewater discharge from flue gas

desulfurization (FGD) wastewater,

discharges from fly ash and bottom ash

systems, combustion residual leachate and

gasification wastewater. Utilities, however,

may want to pay particular attention to the

selection of FGD wastewater treatment

and the associated interactions with

upstream equipment due to the large

investment likely needed to comply with

the FGD regulations.

ZERO LIQUID DISCHARGE

One strong reason to consider going with

a Zero Liquid Discharge (ZLD) option is

to avoid potential issues with achieving

and maintaining the specified numeric

criteria and to avoid additional equipment

installations for more stringent future

regulations. However, implementation of a

ZLD system comes with higher capital and

operating costs than some other options.

Some facilities may find that the trade-off

between the higher capital expenditure

and the uncertainty involved with other

systems favors ZLD.

In the proposed rule, the EPA included a

voluntary incentive program to encourage

selection of ZLD systems. Plants electing

ZLD for all of their wastewater streams,

with the exception of cooling tower

blowdown, could be granted up to five

additional years for compliance. This could

be an attractive way to postpone the large

capital investment of a ZLD system.

ZLD system options include evapora-

tion ponds, deep well injection of waste-

water, closed loop FGD operation (in

which chloride levels are increased and

chlorides are purged through gypsum

that is landfilled), spray dry evaporation

in flue gas and evaporation via mechanical

vapor compression (MVC). Since evapora-

tion ponds are limited to deserts and deep

well injection requires suitable geologic

formations, few plants will be able to se-

lect these technologies as a ZLD solution.

In addition, if the chlorine content of the

coal being burned is high, the closed loop

FGD operation may lead to unacceptable

chloride concentrations and corrosion

concerns . This leaves MVC and spray dry

evaporation as the leading candidates for

ZLD systems.

If a completely closed loop system

is beyond the capability of the FGD

system due to chloride levels, a smaller

increase in chloride level can be achieved

by decreasing, instead of removing, the

blowdown stream. This offers cost savings

for both an MVC system and a spray

dryer due to the reduced flow of water

to evaporate. This increase in chloride

concentration may increase the scaling

potential of the absorber tower and/or

reduce SO2 removal.

PARTIAL ZLD SOLUTION

MVC systems also have the ability

to go to a “partial” ZLD system. For a

partial ZLD system, instead of completely

crystallizing the dissolved solids in the

Planning for the ELGBY MICHAEL G. KLIDAS, RESEARCH ENGINEER, BABCOCK & WILCOX POWER GENERATION GROUP

1307PE_4 4 6/27/13 4:57 PM

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www.power-eng.com6

VIEW ON RENEWABLES

Future is Bright as Wind Becomes Mainstream American EnergyBY MICHAEL GOGGIN, AWEA SENIOR INDUSTRY ANALYST

•  Xcel Energy plans to add approxi-

mately 550 MW of new wind gen-

eration in Colorado between now 

and 2016. A company spokesman 

said,  “These  projects  meet  our 

customers’ interest in a clean, reli-

able and diverse energy supply … 

at prices  that would make  sense 

for  our  customers  regardless  of 

any environmental regulations.” 

•  Portland  General  Electric  said  it 

will buy a 267 MW wind farm in 

Washington  state  that  is  under 

construction and operate  it after 

it’s completed in 2015.

SOME HIGHLIGHTS

FROM WINDPOWER 2013:

Incoming  AWEA  Board  Chair 

Gabriel  Alonso,  of  EDP  Renew-

ables, outlined his vision of a strat-

egy  for  the  industry  to  achieve  the 

stability and sustainability it needs. 

That  strategy,  he  said,  includes 

strengthening AWEA and the indus-

try’s  brand  and mobilizing  compa-

nies  and  their  employees  to  carry 

the  industry’s  message  to  policy 

makers.

Incoming  AWEA  CEO  Tom  Kier-

nan  was  officially  introduced  to  his 

new  industry.  Kiernan  said  his  pas-

sion  for  wind  energy  is  personal: 

“Wind power is clean, affordable, and 

homegrown. The country needs us to 

succeed.  The  natural  world  needs  us 

to  succeed. And  frankly, my children 

and your children need us to succeed.” 

At  another  session,  representatives of 

AWEA,  the National Wildlife  Federa-

tion,  American  Wind  Wildlife  Insti-

tute,  and  National  Audubon  Society 

joined Jose Zayas, director of the Wind 

As nearly 10,000 wind energy 

professionals  gathered  last 

month  for  the WINDPOW-

ER 2013 Conference & Exhibition in 

Chicago,  there  were  signs  of  opti-

mism. Most industry participants ex-

pect a significant drop in wind farm 

installations this year, but a solid re-

covery in 2014.

That  forecast  follows  a  very  late 

extension of the federal wind energy 

production  tax  credit  (PTC).  Con-

gress allowed the incentive to expire 

December 31, 2012, before renewing 

it the next day. The result: 2012 was 

a record year with 13,131 MW of new 

installations as developers rushed to 

meet  the deadline—wind power  ac-

counted  for  42  percent  of  new U.S. 

generating capacity, topping all other 

energy  sources  for  the  first  time. At 

the same time, the industry’s supply 

chain  experienced  severe  whiplash 

as orders  for 2013 shrank to zero at 

many companies. 

With  the  PTC  restored,  the  indus-

try is reviving. Utilities are seizing the 

opportunity to purchase wind power, 

which offers both  low-cost electricity 

at long-term fixed rates and portfolio 

diversification.  Since  WINDPOWER, 

utility plans for wind totaling roughly 

$3.5 billion  in  investment have been 

announced:

•  MidAmerican Energy Co., owned 

by  billionaire  investor  Warren 

Buffett,  said  it  will  add  up  to 

1,050 megawatts  (MW)  of wind 

generation in Iowa by the end of 

2015.  The  new  development,  it 

said, will be built at no net cost to 

its customers and will help stabi-

lize electric rates. 

and  Water  Power  Technologies  Of-

fice at the U.S. Department of Energy 

(DOE), to launch discussion of a new 

vision  for  the  wind  industry’s  future 

to  succeed  the  “20  Percent  by  2030” 

technical report produced by DOE in 

2008.

According  to  Lawrence  Berkeley 

National  Laboratory,  wind  energy 

costs  have  fallen  by  one-third  over 

the  last  several  years,  due  primar-

ily  to  technological  advances  yield-

ing  larger  and  taller  wind  turbines 

with  greater  energy  production. 

Utilities are taking advantage of these 

reduced costs, with a total of 74 buy-

ing or owning wind power in 2012, up 

from 42 in 2011.

Utilities and grid operators are also 

successfully  integrating  increasing 

quantities  of  wind  energy.  In  2011, 

wind  energy  provided  around  20 

percent of  the electricity  in  Iowa and 

South  Dakota,  and  recently  broke  a 

new record on the main power system 

in Texas, providing more than 35 per-

cent of  the electricity at one point  in 

early 2013.

Across Texas, the Midwest and parts 

of  the  West,  new  transmission  lines 

that will enable dozens of gigawatts of 

new  wind  energy  development  have 

been  approved  and  are  expected  to 

be placed in service over the next five 

years. 

These are exciting times for the wind 

industry, and times of great challenge 

as  well.  Our  country’s  energy  sector 

must shape a new paradigm for meet-

ing  America’s  energy  needs  and  ad-

dressing the threat of climate change. 

The best days for American wind pow-

er are still ahead.

Author

Michael Goggin

joined AWEA in

February 2008.

As Senior Electric

Industry Analyst,

Michael works to

promote transmis-

sion investment and

advance changes in

transmission rules

and operations to

better accommo-

date wind energy on

the power system

while maintaining

system reliabil-

ity. Prior to joining

AWEA, he worked for

two environmental

advocacy groups

and a consulting

frm supporting the

U.S. Department of

Energy’s renewable

energy programs.

Michael holds an un-

dergraduate degree

with honors from

Harvard University.

1307PE_6 6 6/27/13 4:57 PM

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NUCLEAR REACTIONS

than fossil fuel costs. Natural gas,

and coal to a lesser extent, experi-

ence more short-term volatility than

nuclear fuel costs.

• Nuclear power plant fuel costs are

much lower than coal and natural

gas fuel costs. In 2011, for example,

the coal and gas costs averaged $25/

MWh and $36/MWh, respectively,

compared to $6/MWh for nuclear.

Given the same wholesale electricity

price, therefore, nuclear power plants

produce more net revenue.

What does the narrowing of the quark

spread mean for nuclear plant owners?

In some cases, it may impact investment

decisions related to major capital expen-

ditures or even decisions such as prema-

ture shutdown. Nuclear plants owned by

vertically integrated utilities may be in a

better position to recover capital invest-

ments by passing them through to rate-

payers; in contrast, merchant plants are

more directly reliant on the wholesale

It’s getting tougher and tougher to

be a successful nuclear plant these

days. Beyond the challenges posed

by aging equipment, Fukushima-related

upgrades, and the threats posed by re-

newables and natural gas, nuclear plant

profitability is now threatened in some

cases by a market metric with a funny

name: the quark spread. And while the

quark spread is not a causal factor in the

travails of nuclear power, it’s definitely a

symptom.

The quark spread is the difference

between the wholesale price of electric-

ity generated by nuclear power and the

price of the fuel (uranium) used to gener-

ate that electricity, measured in $/MWh.

In effect, quark spread is a proxy for the

profitability of a nuclear plant. It is anal-

ogous to its more well-known cousins

– the dark spread and the spark spread –

which capture the theoretical profitabil-

ity of coal and natural gas plants, respec-

tively. Dark and spark spreads are terms

that have become more familiar in the

past decade because coal and gas units

have historically been much more likely

to be operating on the dispatch margin in

wholesale electricity markets.

That market condition is now chang-

ing. With ample natural gas supplies and

low natural gas prices, wholesale elec-

tricity prices have fallen, taking quark

spreads down with them. As shown in

the accompanying graph from the Energy

Information Administration (EIA), quark

spreads in the Midwest and Mid-Atlantic

regions – which house a number of nu-

clear units – are getting thinner.

There are two main differences be-

tween quark spreads and spark and

dark spreads, according to the April

EIA analysis:

• Nuclear fuel costs are more stable

market to recover these costs, and much

more exposed to the quark spread.

In other cases, the thinning quark

may mean considering the pros and

cons of operating at least some of the

time in a cycling fashion to take advan-

tage of (or respond to) market condi-

tions. These market opportunities may

not just be the filling of load valleys

caused by varying electricity demand. It

also may mean providing ancillary ser-

vices such as spinning reserve to back

up intermittent renewable energy.

Taking such actions is not something

a nuclear plant would necessarily like to

do, but it’s not something outside the

technological envelope, either. Despite

their baseload history and reliable base-

load performance for decades, many

nuclear plants were designed with at

least some capacity to cycle. So don’t

be surprised to see nuclear plant own-

ers dusting off their original design and

performance specifications and explor-

ing non-baseload operation.

Dark, Spark, and QuarkBY BRIAN SCHIMMOLLER, CONTRIBUTING EDITOR

#Average Monthly Quark Spreads by Region

90

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Jan. 2006 - Mar. 2013

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DEMAND RESPONSE

by the 97 percent of demand side re-

sources that are responding to zonal

capacity prices as opposed to granular

energy prices.

There is currently a significant op-

portunity gap for Economic Load Re-

sponse since participation in the pro-

gram is coming primarily from a few

large participants responding mostly

as a result of convenience to their

own operations. We should focus on

enabling more diverse participation

through the use of new methods and

technologies. This may be utilization

of advanced building management

systems, facility optimization plat-

forms, two-way communication devic-

es or real time price feeds. It may also

include practices such as auto DR and

optimized market bidding strategies.

Furthermore, we need a variety of end-

users at specific LMPs that engage in

strategies for participation in a larger

quantity of more lucrative hours in

order to fully capitalize on Economic

Load Response.

PJM’s implementation of FERC 745

has created greater participation in

Economic Load Response. With mar-

ket barriers removed, we can now fo-

cus on tapping into more value on the

demand side. By relieving congestion

in ways that other types of participants

are incapable of, demand side resourc-

es have the capability of reaping high

revenues at specific times and specific

LMPs, which is precisely what Eco-

nomic Load Response rewards. With

optimization of the participation pro-

file, Economic Load Response has the

potential to create value that no other

market mechanism can.

Recently, PJM released an anal-

ysis, entitled ‘2012 Economic

Demand Response Perfor-

mance Report’, of its implementation

of FERC Order 745. Order 745 directed

Independent System Operators to cre-

ate a mechanism for paying a demand

response resource the Locational Mar-

ginal Price (LMP) at its location for cur-

tailed load whenever the hourly price

is above a “Net Benefits” threshold. In

only five months after PJM implement-

ed the order in April 2012, the volume

of energy that was curtailed for this

program was about equal to the vol-

ume that had been curtailed over the

previous three and a half years. While

this is certainly an achievement, there

are still many opportunities to create

increased flexibility in PJM’s demand

side.

Since its post-745 rejuvenation, the

report shows that Economic Load Re-

sponse has had more than 42 percent

of its participation come from the

Dominion zone that stretches from

Northern Virginia to North Carolina.

The large volume of participation in

the zone stems from neither high pric-

es nor populous geography but from

the fact that 97 percent of these energy

market participants are larger than

5MW. As PJM notes, most participa-

tion is coming from “a small number

of very large customers.” Thus, this up-

tick we’ve seen in Economic Load Re-

sponse since last April has been from

a couple large industrial customers in

remote, uncongested areas of the PJM

grid.

Additionally, most participation

is coming from facilities that are

responding less to the market and

more to the convenience of curtailing,

resulting in hours of resource partici-

pation with only slight correlation to

peak prices. Participants are not taking

advantage of the long tail at the high

end of the market’s price distribution.

In fact, the average of the top 1500

hours — significantly more hours than

participants participated in — during

the relevant time period in Dominion

is still significantly higher than the av-

erage price participants made per hour

there.

It is also worth noting that eco-

nomic participation is only a small

part of demand response in PJM. The

report notes that enrollment in Eco-

nomic Load Response is only 3 per-

cent of the enrollment in Emergency

Load Response, a mechanism that al-

lows end-users to bid into the capac-

ity market. The disadvantage to a de-

mand response market dominated by

zonal capacity pricing without a robust

LMP-based energy market has begun

making itself prominent. PJM recently

elicited a strong response from several

Curtailment Service Providers (CSPs),

all of which will now essentially have

to fix where their loads are located

before bidding into the Base Residual

Auction. PJM instituted this because,

as they noted in a statement, the cur-

rent demand response requirements

“do not provide enough information

for PJM to adequately understand the

quantity and location of demand re-

sponse to include in reliability plan-

ning.” PJM’s desire for more locational

information about its resources is

undoubtedly caused, at least partly,

The Opportunity Gap in Economic Load ResponseBY RICHARD FUSCO, REGULATORY AND RESEARCH MANAGER, JOULE ASSETS INC.

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1307PE_11 11 6/27/13 4:57 PM

www.power-eng.com12

At a research-scale combustion unit at Ohio State University, engineers are testing a clean coal technology that harnesses the energy of coal chemically, without burning it. Here, doctoral student Elena Chung (left) and master’s student Samuel Bayham (right) display chunks of coal along with pulverized coal (bottle, center) and the iron oxide beads (bottle, right) that enable the chemical reaction. Photo by Jo McCulty, courtesy of Ohio State University.

1307PE_12 12 6/27/13 4:58 PM

www.power-eng.com 13

Chemical Looping for Nearly ZERO-Pollution Coal Power

chemical engineering fundamentals in

particle technology, gas-solid fluidiza-

tion and reactor design to develop new

chemical process technologies that can

address energy and environmental issues.

Throughout his career, Fan has con-

tinuously researched engineering tech-

nologies for pollution control of fossil

fuel combustion. Specifically, our group

has studied methods for sulfur dioxide

(SO2), nitric oxides (NOx) and toxic

metal (arsenic, selenium and mercury)

removal from coal-fired power plants. In

the early 2000s, we successfully demon-

strated clean coal technologies such as

the Ohio State Carbonation Ash Reac-

tivation (OSCAR) process for flue gas

desulfurization and toxic heavy metal

removal and the CARBONOX process

for NOx removal from the flue gas using

activated coal char.

With increasing environmental con-

cern about greenhouse gas emissions

from coal-fired power plants, CO2 cap-

ture research was a natural evolution for

our research, starting in 1998. We be-

gan developing technologies for carbon

capture, utilization and sequestration

(CCUS). This first resulted in the devel-

opment of the carbonation-calcination

reaction (CCR) process for carbon diox-

ide removal.

Coal Power

Chemical Looping for Nearly ZERO-Pollution Coal Power

BY LIANG-SHIH FAN AND ELENA CHUNG, OHIO STATE UNIVERSITY

Coal plays a big role in

America’s energy present

and future. According to

the U.S. Energy Infor-

mation Administration

(EIA), coal comprises 20 percent of the

primary U.S. energy fuel consumption

and provides 42 percent of our country’s

electricity generation.1 The EIA projects

that coal’s share of U.S. electricity gen-

eration will fall by 2040, but still remain

the leader at 35% percent.2 Thus, coal will

continue to be important in satisfying

growing U.S. energy demands, but how

exactly that future plays out will depend

a great deal on the development of tech-

nologies that eliminate coal emissions.

Here in Ohio, coal is used to generate

about 78 percent of electricity, according

to the Ohio Public Utilities Commis-

sion.3 With such a high dependence on

coal, Ohio has a long history of push-

ing innovative technologies that use do-

mestic energy sources while protecting

health and the environment.

Our lab at Ohio State University is led

by Liang-Shih Fan, professor of chemi-

cal and biomolecular engineering, who

has committed his research career to de-

veloping cleaner and more environmen-

tally-friendly fossil fuel conversion solu-

tions. In particular, we focus on applying

1307PE_13 13 6/27/13 4:58 PM

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IF YOU NEED TO UNLOAD COAL (OR OTHER PRODUCTS)

OUT OF YOUR RAIL CARS,

WE HAVE YOUR SOLUTION.

Since 1992

source comes from a metal oxide particle

rather than air. Among possible carbon

capture technologies listed on the U.S.

Department of Energy (DOE)’s Carbon

Emission Control Technology Road-

map, DOE projects chemical looping to

be one of the most economical.4

One crucial advantage of chemical

looping is the flexibility in terms of fuel

source and products. Chemical looping

systems have been demonstrated around

the world with both gaseous fuels such

as synthesis gas (syngas) and natural gas,

or solid fuels such as coal, biomass and

waste. The heat generated from such sys-

tems can be used for electricity produc-

tion. This technological process can also

be designed to produce hydrogen, syn-

gas, chemicals and liquid fuels. Chemi-

cal looping reactors can be redesigned to

handle many different types of fuel and

to produce a variety of products.

In Ohio State’s Clean Energy Research

More recently, our chemical looping

processes were developed out of Fan’s

lifelong passion of cleaning the environ-

ment, protecting public health and pro-

viding efficient, affordable energy. We

want to continue to push the forefront

of clean coal innovations with research

in order to secure reliable, domestic en-

ergy that has a reduced environmental

impact.

CHEMICAL LOOPING

Chemical Looping is an innovative

chemical process that converts carbon-

based fuels such as coal, biomass, syngas

and natural gas to electricity, liquid fuels

and/or hydrogen with low to negative

net carbon emissions. The process is a

series of reduction-oxidation reactions

where initially a carbon-based fuel is re-

acted with metal oxide at high tempera-

tures. The carbon reacts with the oxygen

from the metal oxides to form carbon

dioxide and steam. By producing only

carbon dioxide and steam gases, the car-

bon dioxide can be easily separated and

captured by condensing the steam. Then

using air, the reduced metal particles are

re-oxidized back to metal oxides that

can be circulated and used again in the

chemical looping process.

Though today’s application of chemi-

cal looping is novel, the fundamental

concept of the technology started with

the steam-iron process in which iron

was used to produce hydrogen in the

1900s. Then a similar circulating reac-

tion scheme was used in the 1950s to

produce pure carbon dioxide for the bev-

erage industry. The environmental appli-

cations of such chemical looping tech-

nology were first reported by the Tokyo

Institute of Technology in the 1980s.

Chemical looping is a type of pre-

combustion and oxy-combustion carbon

capture technology where the oxygen

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www.power-eng.com16

Chemical Looping

Source: Ohio State University

1

1

2

3

4

5

6

6

Pulverized coal is conveyed into the reducer reactor to be reacted with the iron oxide-based particles.

Pulverized coal and the iron oxides are reacted at high temperatures, where the coal is combusted to ash and the iron oxides are reduced to iron.

A pure stream of carbon dioxide is formed that can be captured. Steam is also formed and removed from the reducer reactor.

The reduced iron and ash are transferred to the combustor reactor. Air and/or steam is added to re-oxidize the iron to iron oxides. This oxidation produces heat and/or hydrogen.

Ash is removed from the system with a cyclone. Heat and/or hydrogen can be utilized for electricity generation and/or chemical/fuel production.

The re-oxidized iron oxide particles are transferred back to the reducer reactor to be re-used and continue the chemical looping process.

Water and/or Air

Water

Carbon Dioxide

Coal

Iron

Re-oxidizediron oxides

Ash

Heat and/orHydrogen

2 4

5

3

in collaboration with Babcock and Wil-

cox Power Generation Group (B&W

PGG), CONSOL Energy, Inc., Particu-

late Solid Research, Inc. (PSRI), Clear

Skies Consulting LLC (Clear Skies)

and Air Products and Chemicals, Inc.

(Air Products). This SCL pilot scale is

sponsored by the Ohio Department of

Development (ODOD) and the U.S.

Laboratory, we feel that the simplicity of

the chemical looping design is critical;

The beauty of the process is the stream-

lined and flexible design. In place of a

conventional pulverized coal-fired boil-

er, our chemical looping combustion

process uses separate reactors to avoid

mixing air and fuel, which eliminates the

need for costly, energy-intensive gas sep-

aration systems. In comparison to other

carbon capture technologies, the chemi-

cal looping reaction lends itself to higher

efficiencies in capturing carbon dioxide.

Our patented chemical looping tech-

nique is the result of more than 10 years

of extensive research from Fan and more

than 60 undergraduate students, gradu-

ate students and post-doctorates. The lab

explores both calcium- and iron-based

chemical looping, where the looping me-

dia used is calcium oxide and iron oxide,

respectively. Two of these processes—the

Syngas Chemical Looping (SCL) system

and the Coal-Direct Chemical Looping

(CDCL) system—have been progressing

closer to commercial scale.

SYNGAS CHEMICAL LOOPING (SCL)

The SCL process utilizes the gaseous

fuel-based chemical looping process that

converts syngas to hydrogen and heat.

As compared to other chemical looping

technologies, the SCL system is unique

in that it uses three reactors that can

allow for co-production of electricity

and pure hydrogen. This hydrogen can

be utilized economically by the petro-

chemical and chemical industries. Un-

like other chemical looping gasification

technologies, our chemical looping sys-

tems use a unique counter-current mov-

ing bed reducer reactor and fluidized

bed combustor reactor.

We’ve laboratory tested the SCL pro-

cess for over 100 hours, exhibiting a

product stream of pure hydrogen with

complete CO2 capture at bench scale

(around 2.5-kWth). With this success,

we pressed on with a larger scale 25

kWth sub-pilot unit in Columbus, OH.

Over 300 demonstration hours, the SCL

sub-pilot unit exhibited above 99 per-

cent purity for CO2 with over 99 percent

syngas conversion and 93-99 percent hy-

drogen purity.

With the success at smaller scales,

we are now preparing to scale up the

technology to a 250 kWth pilot plant

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1307PE_17 17 6/27/13 4:58 PM

www.power-eng.com18

NOx and SO2 concentrations that are

comparable to quantities produced

from a conventional pulverized coal

combustion boiler equipped with a low

NOx burner. The NOx concentrations

are also typically lower because of the

lower reaction temperatures. These NOx

and SO2 pollutants can be removed using

traditional selective catalytic reduction

units and flue gas desulfurization units,

respectively.

With these successful CDCL

demonstrations, Ohio State plans to

further scale up with a CDCL pilot scale

demonstration unit in the near future

with B&W PGG.

FUTURE PLANS AND APPLICATIONS

With the upcoming demonstration at

NCCC of the SCL pilot unit, we hope to

lead the commercialization of chemical

looping technologies. Future testing

would require integrating the carbon

capture technology with partners for

carbon utilization or sequestration.

On a commercial scale, the SCL

and the CDCL technologies can be

implemented as a part of a greenfield

plant or as a repowering of the aging

fleet of coal-fired boilers in a traditional

pulverized coal power plant.

DOE’s Advanced Research Programs

Agency-Energy (ARPA-E)—the agency

that specifically helps advance high risk,

potentially breakthrough technologies

to commercial scale.

At the U.S. DOE’s National Carbon

Capture Center (NCCC), operated by

Southern Co. in Wilsonville, Alabama,

Ohio State’s SCL pilot demonstration

project will be the largest pressurized

scale-up of chemical looping technology

for hydrogen generation from coal and

biomass. Using a slipstream of syngas

from Southern’s transport gasifier, the

fully integrated 250 kWth pressurized

unit will begin commissioning in the

third quarter of 2013. This demonstra-

tion unit will be used to verify the oper-

ability and feasibility of advanced chemi-

cal looping technologies.

Based on independent economic anal-

yses, both the commercial-scales of the

SCL and CDCL technologies are pro-

jected to meet the U.S. DOE’s goal of

less than 35 percent increase in cost of

electricity for the production of a new

power plant. Further, we anticipate that

the commercial scale chemical looping

processes can be used for repowering ex-

isting coal power plants or for integrat-

ing into newly constructed coal power

plants.

COAL-DIRECT CHEMICAL LOOPING (CDCL)

Following a similar advancement

pathway of the SCL unit, the CDCL

sister project—the solid fuel-based

chemical looping combustion system—

was funded by the U.S. DOE and

ODOD. In the CDCL process, finely

powdered coal directly reacts with iron

oxide beads. Similar to the SCL process,

in the first reactor, coal reacts with the

oxygen from the iron oxides to form

carbon dioxide and steam, which are

removed from the system. In the CDCL

process, the solid iron and coal ash are

left behind. One inherent benefit of the

CDCL design is that the iron beads can

be easily separated from the coal ash

because of the size difference. The coal

ash is easily removed from the entire

system with a cyclone and without the

need for any additional fine removal

device. Then in the second reactor, the

iron beads are re-oxidized to be recycled

and reacted with fresh coal powder in

the first reactor.

Recently, in Columbus and in

collaboration with B&W PGG, Clear

Skies, and Air Products, we demonstrated

the fully integrated chemical looping

combustion 25 kWth unit. From more

than 600 hours of testing, Ohio State

has operated the CDCL sub-pilot system

with nearly full conversions of different

types of coals while producing over

99 percent pure carbon dioxide. Most

recently, the CDCL system completed

a milestone by successfully testing a

continuous 200 hours test with sub-

bituminous and lignite coals and

metallurgical coke.

During the CDCL sub-pilot

demonstrations, the system produced

other pollutants that have been

demonstrated to be easily manageable.

For example, the process produced

The Coal-Direct Chemical Looping sub-pilot demonstration

unit at Ohio State University in Columbus, Ohio.

1307PE_18 18 6/27/13 4:58 PM

www.power-eng.com 19

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References:

1. U.S. Energy Information Administration,

What is the Role of Coal in the United

States?: http://www.eia.gov/energy_

in_brief/article/role_coal_us.cfm

2. U.S. Energy Information Administration,

Annual Energy Outlook, DOE/EIA-

0383(2013), May 2013.

3. Public Utilities Commission of Ohio,

Where Does Ohio’s Electricity Come

From?: http://www.puco.ohio.

gov/puc o / index .c fm /c onsumer-

information/consumer-topics/where-

does-ohioe28099s-electricity-come-

from/

4. Figueroa, J.D., Fout, T., Plasynski, S.,

McIlvried, H., Srivastava, R.D. “Advances

in CO2 Capture Technology—The

U.S. Department Energy’s Carbon

Sequestration Program”, International

Journal of Greenhouse Gas Control

2008, 2, 9-20.

With the fuel source and product

flexibilities of chemical looping tech-

nologies, the possibilities for chemical

looping are abundant. Currently, we

are also exploring  a concentrated so-

lar-power-related thermal energy gen-

eration technology. As a part of DOE’s

National Renewable Energy Labora-

tory’s SunShot initiative,  Utah State

University, B&W PGG and Ohio State

are developing a solid-particle solar re-

ceiver that can be integrated into a solar

chemical looping process. 

The recent shale gas boom has also

pushed efforts for natural gas conver-

sion technologies. We have demonstrat-

ed the viability of using natural gas for

carbon capture and chemical synthesis.

Ohio State has tested methane at both

the bench scale and sub-pilot scale for

nearly full natural gas conversion with

100 percent carbon capture. With the

fuel f lexibility of the SCL pilot unit at

NCCC, we plan to test methane during

its operation at in early 2014. Addition-

ally, the chemical looping process can

be used to produce various chemicals

and liquid fuels. At Ohio State, bench

scale tests have also validated the con-

version of methane to syngas using the

chemical looping technology. We are

also researching the application of coal

or natural gas chemical looping for gas-

to-liquids, coal-to-liquids and chemical

production. The potentials of chemical

looping technologies are extensive, as

such conversion processes could be used

to generate electricity, to fuel vehicles

and to produce useful chemicals with

minimal greenhouse gas emissions. We

believe that, ultimately, chemical loop-

ing is a potentially game-changing tech-

nology that can truly make a difference

in our energy landscape.

1307PE_19 19 6/27/13 4:58 PM

www.power-eng.com20

several fronts.

The future of coal-fired generation is

still unclear as government regulators

work to finalize new rules on green-

house gas emissions, wastewater stan-

dards, and coal ash management. But

most agree that coal, which has long

been the dominant fuel for power gen-

eration in the U.S., will serve a diminish-

ing role in U.S. power production.

I recently moderated a roundtable dis-

cussion with executives from Alabama

Power, the Electric Power Research In-

stitute (EPRI), and Alstom. The discus-

sion centered on the future of coal-fired

generation, the sustainability of today’s

low gas prices and the challenges of

complying with a collection of new rules

from the Environmental Protection

Agency (EPA) .

The participants were: Tim Curran,

president of Alstom Power; Tom Alley,

vice president of Generation, Electric

Power Research Institute; and Jim Hei-

lbron, senior vice president and senior

production officer, Alabama Power.

What follows is a transcript of that dis-

cussion.

Power Engineering: Together, low

natural gas prices and stricter en-

vironmental rules are expected to

prompt the retirement of more than

60 GW of coal-fired generation in

the U.S. by 2020. As a result, plans to

build new coal-fired capacity have

largely been postponed. Is there

enough incentive to pursue projects

and initiatives that demonstrate and

validate the use of clean coal tech-

nologies? How would you describe

the progress in clean coal research

and development?

Tim Curran: I would describe it as

stalled. We know that there is substantial

work taking place globally on coal. We

are on our ninth project of supercritical

boilers in India. We recently contracted

two 1,000-MW coal-fired units in Ma-

laysia. We’re also working on projects

in development in Indonesia and Viet-

nam. It’s fortunate that we can keep our

competency in this technology working

around the world while we hope for a re-

turn to the use of coal in the U.S. When

we look at the retirements, it seems like,

overall, that new gas plants are not mov-

ing forward as fast as they had been

projected. In terms of new coal and new

technology development, we’re pursuing

many options to serve the markets out-

side the U.S.

Tom Alley: I would agree with Tim.

I think the pace of any kind of activity

around clean coal has certainly slowed

significantly. I think the Department of

Energy (DOE) is actively funding some

Coal-fired power produc-

ers are facing a myriad

of new rules establish-

ing strict limits on air

and water emissions.

What’s more, forecasts of abundant gas

reserves and low gas prices continue to

push the industry further away from

coal.

As a result, utilities are conceiving cal-

culated strategies that call for a massive

retirement of coal-fired generation, hefty

investments in new control technologies

and a changeover to generation fueled by

cleaner-burning gas. Clean coal research

and development has slowed, but it has

not stopped. Progress is being made on

Difficult Decisions

BY RUSSELL RAY, MANAGING EDITOR

SPECIAL REPORT:

Executives Discuss the Future

of Coal-Fired Power

1307PE_20 20 6/27/13 4:58 PM

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www.power-eng.com22

scale. We will certainly be paying atten-

tion to those and learn as much as we

can. You have to think about the eco-

nomic viability of these projects and

how you are going to make them feasible

from a customer perspective.

When you think about it from a plan-

ning perspective, we really need regu-

latory certainty. Without that, I think

CCS development at a commercial scale

is challenged because you don’t have a

regulatory driver moving you down that

path.

Power Engineering: Power pro-

ducers have until April 2015 to com-

ply with the Mercury and Air Toxics

Standard. Many options are avail-

able and several new clean-air rules

are still looming. The decisions utili-

ties make now could increase the

cost of complying with new limits for

other air pollutants down the road.

How does a utility avoid choosing

the wrong solution?

Tom Alley: Every plant is unique. It’s

an integration of the plant design, the

type of coal that’s used, access to water.

A number of variables go into the perfor-

mance of the plant and the emissions a

plant has. Solutions for emissions con-

trol is really a combination of a number

of different technologies that are trained

together to handle these pollutants. It’s

not just one technology. It’s hard for

me to believe that a utility is going to

get it wrong. The research and develop-

ment here is around creating a number

of options that utilities have to address

the specifics of their plant. All of these

things have to be put together in a con-

solidated form to manage pollutants. So

it’s very unlikely they get it wrong. It’s a

great role for research and development

to work on these individually. That gives

the utilities a chance to pick and choose

which options make the best sense for

them.

Jim Heilbron: We have some cer-

tainty. We have MATS. We know when

initiatives around advanced technology

on CO2. There are smaller efforts that

the industry is pursuing – technologies

that really manage traditional pollut-

ants. As we do more research on tradi-

tional pollutants, we have to continue to

look at water. We realize that the tech-

nologies we’ve developed around re-

moving traditional pollutants from flue

gas have put those things in some other

waste stream. That waste stream ends

up being something else the site has to

manage. We’re trying to stay ahead of the

curve in the development of technology

around wastewater.

Many decisions have already been

made. We read announcements every

day that plants are being closed. But

there are still a number of people out

there that are still anguishing over deci-

sions around a particular asset. Do they

want to upgrade that asset to include

emission controls to comply with cur-

rent regulations, or is it better to close

that asset?

Jim Heilbron: As a former wholesale

guy, I have to touch on something that

Tim talked about, which is the slow-

down in the build. I think the economy

is a really big player in that. It continues

to be sideways, at best, in many markets.

Whether it is coal, gas or whatever, it is

just slow right now.

From a research perspective, there is

a lot of advancement in what we would

consider a pilot and demonstration scale

type of project (at Plant Barry near Mo-

bile, Ala.). We see valuable information

coming out of that, which will hopefully

lend itself to commercial deployment

at some point. We’re definitely getting

some good information from that proj-

ect. We’re thinking hard about how you

reduce the energy-intensive needs of

getting CO2 out of the flue gas stream

and how to build it cheaper. Those are

the two major obstacles that face a CCS

retrofit on any existing asset. There are

other projects across the country that are

in construction phase at the commercial

Jim Heilbron

Tim Curran

Tom Alley

1307PE_22 22 6/27/13 4:58 PM

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be the development of a multi-pollutant

device that we call NID, a semi-dry flue

gas desulphurisation system. It enables

the customers to meet the requirements

of MATS and CAIR with a single device

in a most cost-effective way. We devel-

oped that device about five years ago,

and we’ve actually demonstrated it in the

U.S. Our challenge is to be able to ramp

up to support our customers’ needs with

this short time frame to comply. It’s

tough when you plan for a market and

decide you’re going to ramp up, but then

a scenario changes, which cancels the

contract. So we’re being whipped around

as a supplier, but this is our business and

we’re doing all we can to support our

customers.

Power Engineering: The carbon

capture and storage market in

North America has suffered several

setbacks. Several companies have

backed away from plans to add

expensive CCS systems to coal-fired

plants due to poor economics. Still,

a few coal-fired projects under de-

velopment in North America plan

to use CCS technologies. Alabama

Power’s Plant Barry started captur-

ing CO2 in June 2011 and sequester-

ing the CO2 underground in August

2012 in a successful demonstration

project. SaskPower’s Boundary Dam

project is expected to be complet-

ed early in 2014. Mississippi Power’s

Kemper County coal gasification/

CCS project is expected to be up

and running in 2014. In addition,

Summit Power’s 400-MW coal gasifi-

cation/CCS plant known as the Tex-

as Clean Energy Project is expected

to begin commercial operation late

next year. Where is the market for

CCS heading? Will the projects at

Plant Barry, Boundary Dam, Kemper

County and Texas open the door to

more CCS projects in North Ameri-

ca?

Jim Heilbron: We want to keep coal

in the mix. We want to have a diverse

best for the customer. We do all that

with one goal in mind. How do we com-

ply with the law and how do we deliver

the lowest cost, reliable electricity for our

customers.

Tim Curran: We believe we’ve got the

best portfolio of products to assist our

customers. One case and point would

that will occur. We have to think about

each unit, consider all of the numerous

business drivers for that asset, and then

decide whether it’s better to retire or con-

trol or retire and replace. We’ll do that

with sensitivity analyses and scenario

planning. At the end of the day, you have

to go with the lowest cost option that’s

1307PE_24 24 6/27/13 4:58 PM

www.power-eng.comFor info. http://powereng.hotims.com RS# 13

portfolio that can hedge our custom-

ers’ risk to price volatility. By keeping

all of these fuels alive, we’re able to

achieve that. As a result, we can deliver

the lowest cost option to our customer

at any given time despite what the mar-

ket might be doing in any given com-

modity. CCS is really the only technol-

ogy solution to address the challenge of

large-scale CO2 emissions from fossil

fuel plants. It is definitely technically

feasible. We’re proving that in our fleet,

and others are too.

From a commercial-scale deployment

perspective, we need some regulatory

certainty to give us direction. You have

to be ready to deal with the risk profile of

these projects, especially when you start

talking about injecting CO2 deep into

the earth. More work needs to be done

to give us more

certainty around

these projects. I

would tout Mis-

sissippi Power’s

Kemper County

coal gasification/

CCS project be-

cause it will have

a much smaller

carbon footprint. It will serve the cus-

tomers of Mississippi Power for many

years. It’s close to 80 percent completion

and is scheduled to begin operation in

May 2014. There’s proof there that there

are CCS options where they are commer-

cially deployable.

Tim Curran: The fundamental need

is regulatory certainty. We had a dem-

onstration project, AEP Mountaineer,

that sequestered a similar amount of

CO2 as Plant Barry’s project. However,

that was stopped because the ratepayers

in the areas that plant served would not

pay to continue the project. So with no

regulation, AEP pulled the plug because

the ratepayers said no. We also see that

DOE funding is going down, with the

pressures on government spending. We

expect a 30 percent reduction in DOE

funding. We believe the only way to

further the technology and continue the

use of coal is to have regulatory certainty.

We are still doing CCS projects. Three

years ago, we had 10 projects. Now we’re

down to half and all outside the U.S. But

we’re still developing the carbon capture

technologies. We are working with the

government in the U.K. on a 500-MW

oxy-combustion demonstration project.

It is slow going, but we’re hopeful that

project will get funded. We’re confident

the technology will work.

Tom Alley: The Mountaineer project

and now Plant Barry certainly demon-

strate the feasibility of using solvents to

capture CO2. Barry extends that dem-

onstration to look at compression, trans-

port and injection. They’re beginning to

answer the question about our ability

to sequester CO2 safely in deep under-

ground forma-

tions. These are

very important

projects. They’ve

gone very well.

They show the

technical feasibil-

ity of doing some

of these things.

But the market for

CO2 becomes very site specific. There’s

plenty of capability for EOR (enhanced

oil recovery), but it’s very regional. Now

you’re focusing on other beneficial uses

of CO2. That’s going to be a very chal-

lenging issue to resolve.

I have a lot of difficulty looking at the

current projects underway right now

and feel that they are opening the door

for more projects. I think they’ve given

us a great amount of education. They’ve

accomplished many goals and educated

us with regard to parasitic loads and

some of the difficulties associated with

these projects. But I don’t think they’ve

opened the door for additional projects.

Now it will be interesting to watch Kem-

per County and Edwardsport to get un-

derway and watch this technology ma-

ture. Beyond the projects we see on the

books right now, I don’t see a whole lot

CCS is really the only technology solution to address the challenge of large-scale CO2 emissions from fossil fuel plants.- Jim Heilbron, Alabama Power

1307PE_25 25 6/27/13 4:59 PM

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Tim Curran: It certainly appeared, as

the rule was written, that it would kill

new coal. We along with other industry

groups commented on the rule in point-

ing out that CCS is not currently techni-

cally available. It was written more for a

gas plant than a coal plant. We believe

they’re working on correcting the rule.

Something has to change there in order

to keep coal in the mix.

Jim Heilbron: They haven’t stated

a reason for the delay. But hopefully

they went out for comments for a rea-

son. Hopefully there’s some more rea-

sonability. I agree with what Tim ob-

served, which was that the proposed

rule seemed to prohibit new coal with-

out any kind of CCS technology. That’s

concerning. We were happy to partici-

pate in those 2 million or so comments

that were received. We would suggest

that you separate out standards for gas

and for coal. That only seems to be ap-

propriate.

Power Engineering: The future of

new coal-fired generation depends

largely on the price of natural gas.

Are today’s low gas prices sustain-

able? Do you have questions or

concerns about reserves or pipe-

line capacity?

Tim Curran: We see that supplies are

ample, but we also know that gas prices

will always be volatile. What’s interest-

ing is the difference in the price of gas

here in the U.S. versus Europe. When we

look at the global picture, the largest in-

crease in fuel consumption for genera-

tion in the last 12 months is coal.

We are actively participating in the

gas market and are developing the next

generation of gas turbines to take ad-

vantage of the increasing supply of gas.

We are also continuing to develop lower

cost CO2 capture technologies for coal

combustion, to be ready when the mar-

ket comes back to being favorable to

coal. In general, we don’t believe (the

price of gas) will stay as low as it is.

Tom Alley: There’s a preponderance

of opinions. We see the forecasts for $4

to $6 per million Btu for the next five to

six years.

There seems to be a fair amount of

confidence in that. I’m fairly confident

with what I see on the supply side. The

supply picture gets brighter every day.

But I’m a little concerned about the de-

mand side.

Jim Heilbron: There’s no doubt coal-

fired generation has a lot of pressure on

it. One of them is low gas prices. I can’t

predict it.

I look at the same curves. We put

them up on overheads and they con-

verge around $4 to $6. We don’t see gas

as a panacea. We see it as one of the piec-

es of the puzzle to hedging price volatil-

ity on behalf of our customers.

more occurring here in the U.S. I think

the market of CO2 is going to be pretty

restricted.

Power Engineering: The U.S. En-

vironmental Protection Agency

has delayed the release of its New

Source Performance Standard for

power plants. In its current form, the

rule would establish one CO2 stan-

dard – 1,000 pounds per MWh – for

new plants. Under this standard, it

would be almost impossible to build

a new coal plant without equip-

ping it with a carbon capture and

storage system, a questionable

and costly technology. What is the

motivation for the delay? Do you

think the EPA will rewrite the rule to

provide the industry separate CO2

standards for gas and coal plants?

1307PE_26 26 6/27/13 4:59 PM

For info. http://powereng.hotims.com RS# 15

1307PE_27 27 6/27/13 4:59 PM

www.power-eng.com28

year, according to the Energy Informa-

tion Administration, the statistical arm

of the U.S. Department of Energy.

For power plants handling millions

of tons of coal a year, minimizing coal

dust is a high priority. A wide range of

techniques are used to manage, control

and prevent coal dust in and around coal-

fired power plants.

Controlling coal dust is vital to worker

safety because of the risk of coal dust ex-

plosions. In addition to creating safety

and environmental hazards, coal dust in-

creases the cost of maintaining material

handling equipment.

Many coal-fired plants are turning

to high-tech dust suppression systems

to control fine airborne coal particles

known as fugitive coal dust. From high-

powered fans that emit a fine mist of wa-

ter over large areas to programs that use

a combination of anti-oxidants, binders

and foaming agents, the technologies

vary in scale and cost.

A gust of wind can create swirling black

clouds of coal dust as coal shipments are

loaded and unloaded. These “blow-outs”

may not exceed air-quality standards,

but they do create a nuisance for neigh-

boring businesses and homeowners. The

suppliers and operators of coal handling

equipment are under pressure to provide

technologies and develop best practices

Where there is

coal, there is

coal dust, one

of the biggest

nuisances for

coal-fired power plants.

The U.S. produces more than 1 billion

tons of coal each year, and more than

90 percent is used to generate electric-

ity at U.S. power plants. Altogether, the

nation’s 1,400 coal-fired units consume

more than 900 million tons of coal each

COAL Dust Control BY RUSSELL RAY, MANAGING EDITOR

1307PE_28 28 6/27/13 5:00 PM

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to reduce the nuisance of fugitive coal dust.

Coal sealants offer coal-fired plants a way to protect large

stockpiles of coal against moisture, oxidation and other forms

of deterioration. Left unsealed, coal piles will suffer a loss of

Btu value and burn less efficiently. What’s more, it will result

in an actual loss of coal.

GE TECHNOLOGY FOR

COAL DUST CONTROL

General Electric has developed a new line of products

designed to mitigate fuel degradation brought about by ox-

idation and prevent coal dust emissions. At POWER-GEN

International 2012, the company unveiled a portfolio of

products known as PowerTreat.

GE’s PowerTreat technologies allow power plants to con-

trol fugitive coal dust without adding excessive amounts

of water. In addition, PowerTreat products can help reduce

dusting from unloading of coal, by barge or railcar, by up

to 90 percent, the company said. PowerTreat also offers ef-

fective dust suppression with low moisture addition to the

coal, which reduces calorific value penalties and decreases

1307PE_30 30 6/27/13 5:00 PM

www.power-eng.com 31

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•  Dust control binders applied to coal 

sent to short term or long-term stor-

age.

GE’s  CoalPlus  technology  retards 

the  oxidation  and  weathering  of  low 

rank  coals,  which  reduces  hot  spots, 

smokers and spontaneous combustion 

coal  flow  problems  that  result  from 

wet coal conditions.

“As  coal  plants  face  challenges  to 

meet  or  exceed  environmental  con-

siderations,  GE’s  PowerTreat  program 

gives utilities more  fuel  consumption 

flexibility and the ability to burn chal-

lenging coal. This new line of products 

improves  the  quality  of  coal,  while 

reducing  dust  and  minimizing  haz-

ardous  conditions  such  as  spontane-

ous  combustion  and  hot  spots,”  said 

John  Schumann,  general  manager  of 

Chemical and Monitoring Solutions—

Water and Process Technologies for GE 

Power & Water.

PowerTreat  products,  which  are  a 

part  of  GE’s  CoalPlus  portfolio,  in-

clude: 

•  Foaming  agents  used  to  provide 

high expansion ratio foam for sup-

pressing dust at transfer points while 

minimizing  moisture  addition  to 

the coal. 

•  Anti-oxidants and dust control bind-

ers applied to coal that is directed to 

short  term  storage  piles  to  inhibit 

oxidation  of  coal while  controlling 

dust through agglomeration of fines. 

For power plants handling millions of tons of coal a year,

minimizing coal dust is a high priority. A wide range of

techniques are used to manage, control and prevent

coal dust in and around coal-fired power plants.

1307PE_31 31 6/27/13 5:00 PM

www.power-eng.com32

The DustBoss DB-60 is an oscillat-

ing, 25 horse-power fan that can cover

21,000 square feet with a blanket of

fine mist – atomized water droplets

designed specifically for capturing and

containing coal dust.

The DB-60 is developed by Illinois-

based Dust Control Technology.

“We atomize the water to 50-200

microns, which gives us the maximum

attraction and avoids a slipstream

effect,” said DCT President Edwin

Peterson. The DB-60 features 30

brass nozzles designed specifically to

atomize droplets to the optimum size

for dust capture.

The dust suppression system is used

at a coal-fired plant in Oahu, Hawaii.

The owner, AES Hawaii, was using

sprinklers and hoses to control the

dust and was looking for a more ef-

ficient system. The company rented

a DB-60 unit and consequently pur-

chased the machine from DCT, accord-

ing to DCT’s website.

out with the rest of the swept debris. A

majority of the fugitive dust falls into

the hopper with only a small amount of

dust getting to the filter.

The Eagle is equipped with a pat-

ented system to pick

up PM 10 and PM

2.5 particles. Dry

sweeping provides a

number of environ-

mental benefits, in-

cluding a reduction

in your water foot-

print and less silt, a

byproduct of water-based dust control

sweepers.

REDUCING AIRBORNE

DUST AT UNLOADING

Other coal dust control technologies

mitigate dust the same way firefight-

ers put out a fire. They use a powerful

water spray to smother clouds of dust

erupting from a pile of coal as it is un-

loaded in the coal yard.

at generating stations. In addition, less

weathering reduces Btu losses during

outside storage at coal yards and ter-

minals.

“The CoalPlus portfolio of dust con-

trol binders and antioxidants enhanc-

es coal quality, reduces dust emissions

and minimizes spontaneous combus-

tion, addressing operator safety and

environmental compliance, two of the

main challenges faced by mines and

utilities,” said Homero Endara, chemi-

cal and monitoring solutions (CMS)

senior global product manager—water

and process technologies for GE Power

& Water.

WATERLESS

DUST CONTROL

Elgin provides coal-fired power plants

a waterless dust control system designed

to collect fine dust particles without the

use of water. Elgin

supplies two types of

waterless sweepers –

the Waterless Eagle

and the Waterless

Pelican.

The Pelican is a

three-wheel sweeper.

The patented dry

dust control feature includes a dust

skirting system, dust separator in the

hopper, and a dust control fan with a

maintenance-free filter, working togeth-

er to control fugitive dust without the

use of spray water. A powerful vacuum

fan on the sweeper creates an air stream

through the debris hopper, conveyor,

and skirted areas. The inward rushing

air carries the airborne dust into the de-

bris hopper where it’s allowed to settle

The DustBoss DB-60 is an oscillating, 25 horse-power fan

that can cover 21,000 square feet with a blanket of fine

mist. Photo courtesy of Dust Control Technology.

“The nation’s 1,400 coal-fired units consume more than 900 million tons of coal each year.”- EIA

1307PE_32 32 6/27/13 5:00 PM

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1307PE_33 33 6/27/13 5:00 PM

www.power-eng.com34

Manufacturers Association President

Randy Rawson. “For those users that

are fueled by oil, they’re looking to

go to natural gas if they can in their

localities. For those fueled by coal,

they’re probably looking to do the

same thing.”

The second driver for boiler up-

grades is environmental regulations,

Rawson said, especially for owners

of industrial boilers looking to com-

ply with the Industrial Boiler Maxi-

mum Achievable Control Technology

Standard.

“The Industrial Boiler MACT is

probably right now the largest driver

in that segment simply because it’s

the newest,” Rawson said. “There are

other local rules and standards in vari-

ous areas of the country that have pro-

vided challenges to boiler owners, but

clearly not to the degree the Industrial

Boiler MACT probably has.”

The new Industrial Boiler MACT

rules lean heavily on energy assess-

ments and boiler tune-ups. Rawson

said those are both good areas to look

not only for meeting the standards of

the rule, but also to ensure a boiler is

running efficiently or effectively. The

focus of the rules also means some

operators may not need to make many

changes in their boiler room.

“If you’re lucky enough to have an

up-to-date, state-of-the-art boiler

room, you’re not going to have to do

much upgrading,” he said. “If you

haven’t operated and maintained the

boiler room in accordance with OEM

(original equipment manufacturer)

recommendations, then you may have

to do some tweaking. And depending

on the boiler’s age, tweaking may be

easy or difficult.”

Some companies who find it diffi-

cult to tweak their boiler into compli-

ance with the rule may find it easier to

convert to a natural-gas fired boiler.

While an oil-fired burner may be able

to be converted to fire natural-gas, a

boiler that fires solid fuel, such as coal,

may need to be replaced completely.

“If you’re burning coal, and I think

the boiler MACT gets to the coal user

more than anyone else, you’re going to

The phrase “boiler up-

grade” might call to

mind images of increas-

ing a boiler’s efficiency

or output. While that

does make up a portion of the current

boiler upgrade work, the main drivers

for boiler upgrades currently are very

different.

“The primary influence would

probably be the cost of fuel, because

that’s always the long-term cost of a

boiler system,” said American Boiler

Boiler Upgrades and ConversionsBY JUSTIN MARTINO, ASSOCIATE EDITOR

Nationwide Boiler Inc. has been working with many

customers who are choosing to replace their boiler

systems with a natural gas-fired boiler system.

1307PE_34 34 6/27/13 5:02 PM

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1307PE_35 35 6/27/13 5:02 PM

36

abandoned in place after they’re made

safe, or they can be removed from ser-

vice entirely and either sold for scrap

or sold on the open market, depending

on the condition of the component,”

he said.

In addition, the windboxes and

burners would also need modification,

Baranski said, and may be removed

entirely and rebuilt. Depending on the

size and complexity of the burners,

as well as what is available from the

original equipment manufacturer, cer-

tain portions or components could be

rebuilt and replaced.

Flame scanners in the boiler would

need to be removed and replaced for

“The bulk unloading of coal would

be removed from the equation,” he

said. That includes the storage where

coal is held in inventory, the system

used to convey coal to the boiler and

bunkers that hold a supply of coal

above a pulverizer, if that is being used

in the boiler.

“All of these components need to be

have to take a good, hard look at what

you need to do to upgrade,” Rawson

said.

Joe Baranski, lead engineer at Day

& Zimmermann, said the company

is working with many customers that

have already made the decision to

switch from their current fuel to natu-

ral gas. Switching to a natural gas-fired

boiler can involve many changes in the

boiler and the facility itself, he said.

Plants that are running boilers using

solid fuels such as coal currently have

to offload the fuel in bulk, Baranski

said. The coal could be delivered by

truck, although large boilers might

have coal delivered by train.

Tennessee Valley Authority will be adding scrubbers and

selective catalytic reduction systems to its Gallatin coal-

fired power plant by the end of 2017 to reduce emissions.

“Depending on the boiler’s age, tweaking may be easy or difficult.”- Randy Rawson, ABMA

1307PE_36 36 6/27/13 5:02 PM

TO THE RESCUE

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1307PE_37 37 6/27/13 5:02 PM

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natural gas. When that is done, the

owner has the option to upgrade the

boiler to lower nitrogen oxide (NOx)

emissions.

“The OEMs and the burner subsup-

pliers have made great advances in low

NOx burner technology,” Baranski

said. “These can be accommodated in

the new windbox.”

On the downstream side of the

system, Baranski said there are a few

changes that can be made. The scrub-

ber, precipitator, fabric filter (or bag-

house) and carbon injection system

for mercury removal can be removed

from service or isolated. In addition,

the gas pass to the stack can possibly

Nationwide Boiler has worked with many clients seeking to re-

place their current boiler system with a natural gas-fired boiler,

including this boiler that was installed at Duke University.

1307PE_38 38 6/27/13 5:05 PM

www.power-eng.comFor info. http://powereng.hotims.com RS# 23

be readjusted to reduce pressure losses

in the gas side, which would result in a

cost savings.

It’s also possible that some of the

components within the heat transfer

surfaces of the boiler would have to

be changed, he added. The charac-

teristics of the combustion of natural

gas are different from coal, especially

with the pulverized coal often used by

the boilers Day & Zimmermann work

with. More of the heat release and heat

recovery with coal occurs inside the

furnace, where water walls will take up

a large portion of the radiant energy,

while in natural gas combustion, more

of the radiant energy occurs in the

back end of the boiler.

“There are a lot of elements to be

considered in making the transition,”

Baranski said.

Those elements can become more

complex when dealing with larger

boilers, such as those that might be

used by a utility power station. While

most small boilers may only use one

or two burners, large boilers may use

multiple burners.

“Once you get to multiple burners,

there are lots of permutations on how

you would fire those burners to meet a

given steam demand,” he said. “And if

you have multiple burners that need to

be fired, the fuel-air ratio control sys-

tem is also increased in complexity.”

The downtime to convert a boiler to

natural gas can vary depending on the

size of the boiler, though the general

rule of thumb is six months to a year.

Baranski said one client the company

worked with had excellent controls on

an integrated engineering and con-

struction schedule and was able to

trim time off that.

The key to reducing the amount of

time a boiler would need to be down is

doing as much work ahead of the shut-

down as possible, he added.

Another method to prevention dis-

ruption to the facility is to arrange for

a different source of power to avoid a

shutdown.

“Our clients who have smaller

installations or smaller developed

sites are able to use rental boilers to

complement their infrastructure so

the interruption for steam generation

is minimalized,” Baranski said. “In

that case, what I loosely refer to as

prework can be included prior to the

shutdown of the rental boiler. You

wouldn’t notice the difference because

the steam would keep coming.”

Despite the complexity and the

possible need for a shutdown, there are

many reasons companies may choose

to convert their current boiler system

“The choice is to clean up the coal or make the transition over to a natural gas fuel.”- Joe Baranski, Day &

Zimmermann

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many companies are waiting for

government agencies to finalize the

regulations, then researching the

available options and comparing the

effectiveness and costs relative to other

options.

Regardless of what a boiler owner

chooses to do to upgrade their boiler,

Rawson said it’s important companies

make decisions quickly in order to

help control cost and the time it would

take to do the necessary work.

“Regardless of what is motivating

you to retrofit, upgrade or replace, the

longer you wait, the more expensive

it’s going to be,” he said. “I don’t think

anybody can make that determination

easily, but they need to be very careful

because sooner or later when they

knock on our doors there are going to

be delays and the costs will have gone

up farther than they are today.”

to firing natural gas. The price of

natural gas is attractive to many of Day

& Zimmermann’s clients, Baranski

said. Other factors include the ease of

using gas compared to a fuel like coal

and environmental regulations that

put more of a burden on coal-fired

power generation than gas-fired power

generation.

“The choice is to clean up the coal or

make the transition over to a natural

gas fuel,” he said.

Tim McBride, sales engineer at

Nationwide Boiler Inc., said emission

controls are less of an issue for

companies with natural gas-fired

burners. Although some states such as

California may require more stringent

environmental controls, most new

natural gas-fired boilers are able to

meet environmental regulations

without major upgrades.

Like Baranski, McBride said he has

seen many companies choosing to

convert to a natural gas-fired boiler.

“A lot of people are running to gas

for a lot of reasons,” he said. “Coal is

going away.”

For some operators, however,

switching to natural gas may not be

the best option. Mark Minniti, NAES

Corp. director of business development

for the maintenance and construction

group, said there are a variety of factors

to consider before making a switch.

“I believe it is a mix based on

many factors, such as geographic

location, number of other plants in

the generator’s system, the generator’s

current fuel diversity, anticipated

capacity requirement, age and size

of the units, the cost to add control,

whether the generator is regulated or

unregulated and politics in the state,

region or locale,” he said.

A number of different controls can be

fitted onto a boiler system in order to

reduce the emissions of the unit. Flue-

gas desulfurization, selective catalytic

reduction, active carbon injection

and dry sorbent injection technology

can all be added to a plant’s emission

system. Other options include a new

fabric filter or adding or upgrading

electrostatic precipitators.

All of these options are used to

help control the amount of emissions

from a boiler, including sulfur

oxides, nitrogen oxides, carbon

dioxide, mercury and particulate

matter. Deciding which options are

needed may make the situation more

complicated, however. Minniti said

“A lot of people are running to gas for a lot of reasons. Coal is going away.”- Tim Martin,

Nationwide Boiler

1307PE_41 41 6/27/13 5:05 PM

www.power-eng.com42

uncles—it was pretty devastating,” he

says today, his irrepressible smile tinged

with a hint of solemnity around what was

clearly a serious event. “I was asked by my

parents to come back home to help out.”

Fortunately, he’d been a summer in-

tern at the Beaver Valley Power Station,

near Pittsburg, back when its Unit 2 re-

actor was still under construction. After

finishing school he was offered a job at

the plant, and so began a career in the

nuclear industry that has led to where

he is today: president and chief executive

officer of AREVA Inc., a leader in one of

the most dynamic and future-oriented

industries on earth.

Power Engineering: What is the

AREVA Solutions Complex and why is

it important?

Mike Rencheck: The AREVA Solu-

tions Complex is basically an innovation

center. It’s a collection of areas where we

produce technologies to make the nu-

clear fleet safer, more reliable and more

economical. For nuclear applications,

we have a 7-GHz, ten-thousand pound

shaker table. It’s one of the largest, if not

the largest, in this hemisphere. We have

ovens to commercially test equipment.

We have other environmental cham-

bers. We have metallurgical labs and a

full chemistry lab. We have one of two

electron microscopes in the world there,

where we can turn the electron beam on

a piece of either contaminated or non-

contaminated metal and it will tell you

the chemical composition of the metal;

then you can start to peel back the grain

boundaries. We have machine shops,

refurbishment areas, a motor area and a

fuel inspection area, plus classrooms. We

can even do electrical component reverse

engineering.

We set this complex up so that we could

continue to keep the existing fleet run-

ning, looking at plant life extensions to

eighty years–we have all the tools avail-

able to analyze an existing plant system

and make sure it is capable of running

for 80 years. We’re also developing repair

techniques and inspection techniques,

which we are deploying. It’s a unique fa-

cility in the industry and we think it will

help the existing fleet of nuclear plants

stay in business.

Power Engineering: Where do you

see AREVA’s future in North America?

Mike Rencheck: AREVA is vertically

integrated across the entire nuclear foot-

print, so we have mining, enrichment,

While Mike Ren-

check was fin-

ishing up a

degree in elec-

trical engineer-

ing at Ohio State University there was

trouble back home in Pittsburg, where

the closure of a steel mill sent his fam-

ily’s finances into a tailspin. “The entire

family lost their jobs in a matter of about

six months—brother-in-laws, cousins,

Opportunity in NuclearBY DENVER NICKS, ASSOCIATE EDITOR

A Conversation with Mike Rencheck, President & CEO, AREVA Inc.

Mike Rencheck, President

& CEO, AREVA Inc.

1307PE_42 42 6/27/13 5:18 PM

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www.power-eng.com44

decisions, sometimes very difficult ones.

Other times, you have to be the kind face,

the gentle face, to make sure that people

are inspired and motivated to do new

things. You have to be creative. You have

to be willing to take risks and understand

that those risks are manageable, and you

have to be able to help folks manage risks.

There are a lot of people, especially in the

engineering world, that are risk-adverse,

but true innovation won’t happen with-

out taking some risks. So, as a leader, you

have to make it okay for that to happen,

because you fail nine times before you

find the one true success that’s going to

help the industry.

So, when we look for leaders within

a region we’re looking for people with

people skills, with the ability to both

take a risk, be kind and gentle, and at

the same time be firm and make deci-

sions when needed. We’re looking for

these people as they come through the

ranks, to help shape the next generation

of leaders here within the industry and

within our company. When you look

at the top fifty innovative companies

in the world, AREVA is ranked number

thirty-eight, and we view that as a re-

sponsibility in the industry.

Nuclear is our business. Without

nuclear we have very little business, al-

though now we’re getting into renew-

ables and also medical isotopes. It’s a

tough business in that you have to have

high standards, be able to articulate those

standards, and have others adopt and fol-

low those high standards while keeping

everything in balance. This industry is

all about safety and for us, when we in-

novate, that has to be first and foremost.

We always say we start with excellence

in mind, and then we frame everything

around safety, quality, high performance,

and delivering results.

Power Engineering: Prospects for

nuclear fusion power?

Mike Rencheck: On a global basis,

we’re part of the ITER team. We’re work-

ing on the cooling systems and have a

high enough to send a signal to build

new generating plants. It’s also not high

enough to cover both the operating cost

and in some cases the capital investment

costs to keep some of the facilities operat-

ing, be they gas, coal, or nuclear.

How long will this last? If it lasts too

long we’ll see decisions made around

short-term profitability, especially for

investor-owned utilities in the market-

place. So we could be in for the ‘perfect

storm’ where we retire too much capac-

ity in the near-term because of market

pricing signals and some market distor-

tions due to weak demand. Then, when

the economy recovers and the electricity

markets pick up, we find ourselves in an

upside-down position, with real elec-

tricity shortages and the need to build

capacity fast. That could force us in a

direction of very volatile fuel sources,

typically fossil fuel sources.

Power Engineering: What about

the prospect for something like a

carbon tax?

Mike Rencheck: A carbon tax

would have a big impact on how nu-

clear is viewed within the industry. It

would send a signal for cleaner forms

of generation. However, with energy

demand down as a whole, unless the

tax is very high, it would not likely be

enough to stimulate new build.

So you’re looking at a merchant mar-

ket condition that is somewhat tenu-

ous. The Electric Reliability Council

of Texas (ERCOT) is a perfect example

of that right now. If you watch ERCOT

and how they’re going about dealing

with capacity shortages or potential

capacity shortages, you see a market-

place that is struggling to add new

sources of generation, time and time

again, without the proper price signals.

Power Engineering: What do you

look for in hiring people?

Mike Rencheck: There’s a lot to be

said about how one behaves as a leader.

One, you have to be willing to make

we make fuel assemblies, service exist-

ing plants and we build new reactors. We

have reactor designs that start with the

EPR™ at 1,600 MW. We also have a boil-

ing water reactor, KERENA, at 1,200 MW;

the ATMEA, which was just selected for

use in Turkey, is a 1,100 MW pressurized

water reactor, and we have small reactors.

Here in North America, our high-temper-

ature gas reactor design has been selected

by the Next Generation Nuclear Plant

Alliance, and we’re involved with several

companies developing small modular re-

actors. So we have a full product range of-

fered by reactors and services group.

We also specialize in keeping the exist-

ing fleet running and are one of the in-

novators in license renewal. We also have

a back-end division, which basically does

dry-cask storage, as well as technologies

for decommissioning and recycling. And

last but not least–our front-end division

has a fuel plant in Richland, Washington,

where we make both boiling water reac-

tor and pressurized water reactor fuel.

We’re capable of making many other

styles of fuel there as well. We’re also pur-

suing the Eagle Rock Enrichment Facility

in Idaho; we already have a license for

the facility from the Nuclear Regulatory

Commission, and we’re working to find

an investor for the early years and are still

in discussions with the Department of

Energy for a loan guarantee.

Power Engineering: What’s the cli-

mate for nuclear build or nuclear ac-

tivities in general in the U.S.?

Mike Rencheck: There are a few

things that electric utilities need to factor

in. One is fuel diversity. If we start focus-

ing on one source of fuel, such as natu-

ral gas, we’ll be setting ourselves up for

failure at some point in the future. Now

what’s causing that sentiment is prob-

ably a better question. When you look at

what’s happening in the economy right

now, it’s low energy demand that is driv-

ing pricing to a point where, whether it’s

a new gas plant, coal plant, nuclear plant,

solar plant, wind plant, that price isn’t

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www.power-eng.com46

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Improving Safety,

Service and

Standards

innovation and creativity, high standards

for safety, performance, and at the same

time it requires you to manage the fi-

nancial aspects, public interface points

. I think when you enter this industry at

a young age, you learn how to do these

things, including project management

skills.

I wasn’t in nuclear my entire career. I

left nuclear around 2001 went into tra-

ditional generation including environ-

mental controls on power plants, main-

tenance and related aspects. I found that

the skill set I had learned in nuclear or

around management of facilities di-

rectly applied in that space. We didn’t

need all the regulatory paperwork and

its burdens, but the techniques of the

management ideas all fit very well. We

saw great improvements in terms of fos-

sil plant outage durations, construction

times, the ability to build large facilities

in a very orderly manner. So as my son

considers joining the nuclear industry, I

think as a young engineer coming out of

college, he’ll have that same opportunity.

So should he, when he graduates, decide

to become a nuclear engineer or work nu-

clear power, I would be very happy with

that.

Power Engineering: Anything else?

Mike Rencheck: I think nuclear will

offer the opportunity for jobs, not only

in the near-term, but in the long-term.

When you look at what’s happening right

now within the industry, you’ll see the

national demographic shift where we

have roughly seventy million boomers

and thirty million gen-X’ers take place.

In nuclear, a very highly technical field,

you’ll see the number of job openings

swell. What you see happening now with

children as they’re moving through grade

school, the ninth grade has about four

million or so students, and when you get

very keen interest in what’s happening in

California at the Lawrence Livermore Na-

tional Lab (LLNL) where fusion is being

tested in the U.S. We’ve had a number of

people visit and really take a good hard

look at what they’re doing at LLNL, and

they seem to be making progress. Fusion

is probably still out there in the future,

but we have folks that are actively work-

ing on different projects for it.

Power Engineering: You men-

tioned there’s another Mike Ren-

check in the world who may go into

the nuclear field—your son. How do

you feel about prospects for his ca-

reer should he go into nuclear pow-

er?

Mike Rencheck: I think they’re very

good. One of the things the nuclear in-

dustry gives you is it really teaches you

how to lead people and how to manage

in times and circumstances that require

1307PE_46 46 6/27/13 5:18 PM

www.power-eng.com

For info. http://powereng.hotims.com RS# 29

to the point of graduating from college, you’re down to roughly

a 170,000 students that will graduate with a science, technol-

ogy, engineering or math (STEM) degree. So think about those

demographics, think about the job opportunities in that space.

I’ve read different articles that say by 2018 there’ll be a million

job openings for STEM positions.

Power Engineering: The Nuclear Energy Institute says

by 2016 maybe as much as thirty-nine percent of the

nuclear work force will enter retirement age.

Mike Rencheck: I’ve seen statistics for companies our size

where the number of employees over 60 equals 20 to 25 per-

cent of the company and that’s not unique. You talked about

my son specifically, but when you look at that from a popula-

tion perspective, if you want a job and you want a good pay-

ing job, nuclear offers that opportunity. Our starting salary

is pretty high and that’s for folks with and without a college

degree. So if you get into a technical field and go work in the

AREVA Solutions Complex, working on qualifying equip-

ment or components, that’s a pretty high-paying salary, espe-

cially in Lynchburg, where you don’t have the cost of living of

a place like Washington, D.C.

The industry is safe. There haven’t been any fatalities in the

industry as a result of a nuclear accident. They’re good jobs.

They’re not just short-term jobs. You can build a career in this

industry. You can go to work like myself at the age of twenty as

an intern, and thirty years later, you have a career to look back

on. And if you choose to leave it, the skill sets that you attain

are applicable elsewhere.

I think in the near-term, if you’re talking about opportu-

nity, with the Boomers retiring and the need for energy always

alive, you’re seeing vast employment opportunities in the en-

ergy field that often go overlooked.

Nuclear power has a safety accident rating from OSHA (Oc-

cupational Safety and Health Administration) of 0.06 report-

able events per 200,000 hours worked. The financial industry

has a higher accident rate. Think about that. Manufacturing as

a whole is 4.4. That stunned me, because when I look at that,

for our paradigm that would be completely unacceptable.

It’s just the opportunity, the genuine standards and skill

sets that you get taught and safety that you can apply in any

industry. If you look at Alcoa’s financial turn-around years

ago by Paul O’Neill, he focused on one thing: safety. He would

talk about safety in front of Wall Street analysts. They’d want

to talk about numbers and he’d want to talk about safety and

what happened to the performance of that company? It just

took off.

It’s those value systems, those leadership traits, those man-

agement traits, that set you in a good way whether you decide

to stay in the industry or not. I think that these leadership

traits are unique to this industry.

1307PE_47 47 6/27/13 5:18 PM

www.power-eng.com48

reduction (SCR), selective non-catalytic

reduction (SNCR) and sorbents (materi-

als used to absorb gases and liquids).

While this market addressed the needs

of power generators in the early 1990s,

it may be time to consider the needs of

2013 and beyond. As the Electric Power

Research Institute (EPRI) noted under its

Integrated Environmental Controls pro-

gram (Program 75), “fossil fuel-burning

power plants also need lower-cost and

better-performing sorbents and technol-

ogies than those currently available.”

One of key reasons to review emissions

control options is that NOx and SOx are

not the only pollutants that are regulated.

Gas and coal power generation plants

must address emissions to remain com-

petitive due to additional regulations by

the Environmental Protection Agency

(EPA). The introductions of the Mercury

and Air Toxics Standards (MATS) and up-

grades to the Maximum Achievable Con-

trol Technology (MACT) rules need to be

tied into NOx and SOx control strategies.

Traditional emission control

Since the passage of the Clean

Air Act, fossil-fired power

generators have fueled a ro-

bust market for technologies

to address nitrogen oxides

(NOx) and sulfur oxides (SOx) emis-

sions. The industry estimated in 2009

that it had spent $75 billion to comply

with the Clean Air Interstate Rule alone.

A number of different technologies have

succeeded in addressing one or both of

these pollutants, including flue gas de-

sulfurizers (FGDs), selective catalytic

NOx & SOx as Piecesof an Overall EmissionsControl Puzzle

BY KEVIN CRAPSEY, VICE PRESIDENT OF CORPORATE STRATEGY AND DEVELOPMENT, ECO POWER SOLUTIONS

1307PE_48 48 6/27/13 5:22 PM

www.power-eng.com 49

5MW to 1500MW. Approximately 85 per-

cent of FGDs units installed in the United

States are wet scrubbers, 12 percent are

spray dry systems (similar to dry injec-

tion systems) and 3 percent are dry injec-

tion systems. On average, web scrubbers

achieve the highest SOx removal rates –

above 90 percent - and dry injection sys-

tems achieve the lowest – below 80 per-

cent. The choice between the two is often

dependent on costs and the nature of the

power generation facility.

With selective catalytic reduction

(SCR) systems, flue gas is first treated with

a reactant, which oxidizes it, and then is

absorbed into a catalyst. These catalysts

are manufactured from various ceramic

materials, which are used as carriers, and

active catalytic components that are ei-

ther oxides of base metals, like vanadium

or tungsten, zeolites or precious metals.

Naturally, each catalyst component that

makes up an individual catalyst has its

advantages and disadvantages, so com-

ponent selection is often tailored to the

nature of each facility and mix of gases

that will be absorbed. Commercial SCR

systems generally reduce the level of NOx

by 70 to 95 percent and can be found on

large utility boilers, industrial boilers and

municipal solid waste boilers.

These systems have their limitations.

SCR systems have been documented as

sensitive to contamination and plugging

during normal, and abnormal, opera-

tions. The pores of the catalyst are easily

plugged by a variety of compounds pres-

ent in ordinary flue gas and certain pol-

lutants can render the system ineffective

at NOx reduction, or cause oxidation of

ammonia present (forming more NOx).

They require tuning to perform properly,

which can be time consuming and cost

restrictive and have a period during their

start-up cycles where exhaust tempera-

tures are too cool for NOx reduction to

occur. This can lead to unchecked emis-

sions and fines from government offices.

When speaking specifically about coal-

fired power plants, SCR systems have

technologies only capture one or two pol-

lutants at a time, meaning that addressing

the full complement of regulated emis-

sions requires capital expenses for mul-

tiple technologies and excess space to in-

stall. The lack of technological options to

comply with EPA regulations has resulted

in uncertainty among power plant opera-

tors about the ability to meet deadlines

and deliver cost-effective electricity.

The emission control industry, how-

ever, has introduced some advanced sys-

tems that may solve this problem. Multi-

pollutant emissions control systems have

been documented capturing NOx and

SOx – as well as many other regulated

emissions - with one system, less costs

and, generally, less space. Also, many of

these systems capture greater amounts of

NOx and SOx than traditional technolo-

gies, can be modified to accommodate

predicted future emissions restrictions

and can be installed in comparably short

amounts of time.

CURRENT NOx AND SOx

CONTROL OPTIONS

Traditional flue gas desulfurizer (FGD)

systems are built for the express purpose

of removing SOx from the exhaust flue

gases of fossil-fuel power plants and

sometimes from the emissions of other

SOx emitting industrial processes. These

systems generally employ five removal

methods:

• Wet scrubbing that uses alkaline

sorbent or seawater to scrub the flue

gas;

•  The spray-dry scrubbing that uses

similar sorbent slurries;

• Wet sulfuric acid process that recov-

ers sulfur in the form of sulfuric acid;

•  SNOX Flue gas desulfurization that

removes sulfur dioxide, nitrogen ox-

ides and particulates from flue gases;

•  And dry sorbent injection systems.

FGDs employ two stages: one to re-

move fly ash and the other to remove

SOx. In wet scrubbing systems, the flue

gas passes through a fly ash removal de-

vice, either an electrostatic precipitator or

a wet scrubber, and then into the SOx-

absorber. In dry injection or spray dry-

ing operations, the SOx reacted first with

the sorbent, and then the flue gas passes

through a particulate control device.

These devices have been applied to

combustion units firing coal and oil from

NOx & SOx as Pieces Emissions

Eco Power Solutions operates two of its systems – one

on gas-fired boiler and the other for coal-fired - at their

technology center in Louisville, Ky. Photo courtesy of Eco

Power Solutions.

1307PE_49 49 6/27/13 5:22 PM

www.power-eng.com50

particulate matter, into an oxidized, wa-

ter soluble compound. The flue gas then

passes through a series of high pressure

fogging arrays that inject a water mist into

the gas stream that creates a condensable

acidic mist. The water mist cools the flue

gas and the pollutants are condensed out

from the flue stream once the tempera-

ture drops below the acid dew point. The

waste stream is then treated, neutralized

and disposed of safely. The remaining

water can them be treated and recycled

back into the process to conserve water.

There are also several other technolo-

gies taking a multi-pollutant approach.

Lextran Ltd reduces SOx, NOx and

mercury. Like SCR systems, Lextran’s ab-

sorbs pollutants through a catalyst, in this

case an organic substance in an emulsion

form, in a wet scrubber environment pro-

cess. The Lextran catalyst contains an ac-

tive sulfur-oxygen functional group, hav-

ing properties that enhance the oxidation

reactions of SOx, and NOx into SO4 and

NO3 anions.

After initial oxidation the catalyst is re-

leased and recycled back into the process,

leaving the pollutants in a chemical form

amenable enough to become commer-

cially beneficial by-products. They first

must be neutralized by ammonia, KOH,

or other basic reagents to control the type

of by-products, which could include am-

monium nitrate, ammonium sulfate, po-

tassium sulfate and potassium nitrate.

Hamon Research Cottrell’s ReACT

system captures NOx, SOx and mercury

deadlines. Also, multi-pollutant technol-

ogies generally require a smaller footprint

since their processes are encapsulated in

one system.

Given the advantages of multi-pollut-

ant emissions control technologies, what

are the barriers to larger scale deploy-

ment in the power sector?

The primary barrier is that traditional

emissions control technologies seem like

a safe bet because they have been used

by the industry for years. The owners of

fossil-fired power plants know the capital

investment, and operations and mainte-

nance (O&M), costs of older technologies

and operators can more easily anticipate

problems that may arise.

However, the commercial readiness

of multi-pollutant emissions control sys-

tems has been overlooked.

Eco Power Solutions operates two of its

systems – one on gas-fired boiler and the

other for coal-fired – at their technology

center in Louisville, Kentucky. Visiting

engineers, investors and public officials

can see, in real time, the performance of

the systems in real world tests. As demon-

strated during at technical tour at Coal-

Gen 2012, the technology scrubbed the

flue gas from the coal-fired boiler and

removed 98.6 percent on NOx, 99.9 per-

cent of SOx and captured 75.5 percent of

CO2.

Its system injects ozone and hydro-

gen peroxide into the flue gas stream to

convert the criteria pollutants, which in-

clude NOx, SOx, mercury, acid gases and

operational difficulty with binding of

the catalyst by fly ash. Because of these

issues, SCR catalysts have a limited op-

erational lifetime of 16 to 40 thousand

hours in coal-fired power plants, depend-

ing on the flue gas composition, and up

to 80 thousand hours in cleaner gas-fired

power plants.

In selective non-catalytic reduction

(SNCR) systems, a reagent is injected into

the furnace to react with the heated flue

gas and convert the present NOx into ni-

trogen and water, which can then be cap-

tured and stored. Though in theory SNCR

systems can achieve roughly 90 percent

removal rates, practical constraints like

required minimum temperatures, time

and mixing often lead to results rang-

ing from 30 to 50 percent. Though SCR

systems have been documented as more

effective in NOx removal, SNCR systems

are often favored due to their lowers cost

since they do not use a catalyst.

A typical SNCR system consists of re-

agent storage, multi-level reagent-injec-

tion and control instrumentation equip-

ment. The SNCR reagent storage and

handling systems are similar to those for

SCR systems, but because of the higher

stoichiometric ratios, both ammonia and

urea SNCR processes require three or four

times as much reagent as SCR systems to

achieve competitive NOx reductions.

ADVANCED EMISSIONS

CONTROL TECHNOLOGY

With multi-pollutant emissions con-

trol technologies, a single system is able

to remove multiple pollutants from flue

gas before they are released into the at-

mosphere. Currently, the emissions tar-

geted include NOx, SOx, mercury and

other heavy metals, halogens and par-

ticulate matter. A considerable advan-

tage of a multi-pollutant strategy is lower

capital investment when compared with

investing in several different technolo-

gies to address each pollutant. Likewise,

the installation of a single unit is faster

and requires less downtime. This is espe-

cially relevant due quickly approaching

With multi-pollutant emissions control technologies, a single system is able to remove multiple pol-

lutants from flue gas before they are released into the atmosphere. Currently, the emissions targeted

include NOx, SOx, mercury and other heavy metals, halogens and particulate matter.

FGD SCR SNCRMulti-pollutant emissions control

NOx 0 70 - 95% 30 – 50 % 85-98%

SOx 50 – 98% 0 0 98-99%

Mercury 0 0 0 95-98%

Particulate matter 0 0 0 50-99%

CO2 N/A N/A N/A 30-75%

Advanced Emissions Control Technoloy

1307PE_50 50 6/27/13 5:22 PM

For info. http://powereng.hotims.com RS# 30

1307PE_51 51 6/27/13 5:22 PM

NOx & CO Compliance

Fuel Conversion

Combustion Components Associates, Inc.884 Main St. • Monroe, CT 06468 • USA

Tel: 203-268-3139

Fax: 203-261-7697

www.cca-inc.net

[email protected]

• Low-NOx Burners

(New & Retrofit)

• Low NOx Waste Fuel Burners

• Flue Gas Recirculation (FGR)

• Rich Reagent Injection (RRI)

• Overfire Air (OFA)

• Selective Non-Catalytic

Reduction (SNCR)

• Selective Catalytic Reduction (SCR)

• TRIM-NOX®

Urea to Ammonia SCR

• CFD Modeling

• Feasibility Studies

• Boiler MACT Compliance

• Coal/Oil to Gas Conversions

• #6 to #2 Oil Conversion

CCA is a global

provider of fuel

conversion,

in-furnace and SCR

technologies for

reducing NOx, PM,

unburned carbon

and CO emissions

For info. http://powereng.hotims.com RS# 31

Regenerated activated coke is

screened to remove fines and returned

to the absorber while the sulfur rich

gas is processed using conventional

technology to produce salable sulfu-

ric acid. This process is best suited for

utilities burning low sulfur coals, such

as PRB coals, and for sites where water

use, water treatment or discharge are

issues.

TWO OPTIONS FOR

THE INDUSTRY MOVING

FORWARD

Power generators should understand

that NOx and SOx are parts of a ho-

listic emissions control strategy. MATS

and MACT are only hints of what is

to come. Most industry experts are

expecting some form of carbon regu-

lation and even stronger restrictions

on the emission of heavy metals, acid

gases and particulate matter.

The industry faces two options:

continued reliance on the technolo-

gies that are meeting the needs of

yesterday’s regulations or investing in

advanced emissions control technolo-

gies that meet the needs of today and

tomorrow. Eco Power Solutions, Lex-

tran Ltd and Hamon Research Cot-

trell’s technologies have already been

short-listed by the EPA as systems that

“offer(s) the potential of reduced com-

pliance costs and improved overall en-

vironmental performance.”

These technologies represent the

forefront of innovation in the fossil-

power generation industry and pro-

vide a cost-effective option to continue

operating aging plants that still have

significant service time available. Like-

wise, it is an option for co-ops and mu-

nicipal utilities that lack the resources

to invest in a series of traditional tech-

nologies yet do not have the option of

shutting down their power generation

facilities if they cannot comply.

while reducing particulates. With this

system, a moving bed absorber pro-

vides contact between flue gas and ac-

tivated coke pellets, where SO2, SO3,

NOx and mercury are absorbed onto

the carbon surfaces. Ammonia is then

injected upstream in order to promote

the SO2 and NOx reactions as the mov-

ing bed acts as a particulate collection

step. The impingement of the flue gas

on the activated coke pellets provides

“polishing” control of particulate.

Cleaned flue gas moves to the smoke

stack for discharge with little or no

plume compared to SDA, CDS, or

WFGD processes. Activated coke from

the absorber is then processed in a re-

generator vessel that completes the re-

duction of NOx to N2, and drives off

SOx in a concentrated sulfur rich gas

stream. Absorbed mercury is retained

in the activated coke in a region of the

regenerator where temperature condi-

tions allow the mercury to accumulate.

1307PE_52 52 6/27/13 5:22 PM

norit-americas.com/extra

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For info. http://powereng.hotims.com RS# 32

1307PE_53 53 6/27/13 5:22 PM

www.power-eng.com54

specific plant using specific auxiliary

systems.

Retaining the institutional knowl-

edge of retiring engineers eventually

nets out in the cost of time – search-

ing for the right candidates, training

time and on-the-job experience can

take years and thousands of dollars.

The classic alternative is to use con-

sultants to fill that void. However,

there can also be a significant amount

of time associated with training the

consultant and getting the solution

implemented and tested as well as the

additional use of consultants required

whenever there needs to be a change in

the system. Neither training new engi-

neers nor utilizing consultants seems

appropriate in today’s world of increas-

ing efficiency.

The potential loss of institutional

knowledge can be overcome in part

by the use of pre-engineered control

strategies. The intent is to allow power

Today in the power in-

dustry, there are many

companies that are

dealing with an increas-

ing number of plant

engineers that are approaching retire-

ment. The loss of that institutional

knowledge is a challenge since boiler

controls require experience to install,

replace and operate. Years of experi-

ence are often needed to understand

the art associated with controls at a

Pre-engineered Strategies Maximize Knowledge Base to Ensure Efficiency & Reduce DowntimeBY ALAN HINCHMAN, GE GLOBAL MARKETING DIRECTOR-INFRASTRUCTURE & HEAD OF ENERGY, OIL & GAS, WATER AND COMMERCIAL BUILDINGS OFFERINGS

With GE’s Steam Cycle solution, users can

significantly cut solution implementation time and

avoid development delays—increasing uptime and

profitability. Photo courtesy of General Electric.

1307PE_54 54 6/27/13 5:24 PM

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� ������������������������������������

For info. http://powereng.hotims.com RS# 33

1307PE_55 55 6/27/13 5:24 PM

www.power-eng.com56

For info. http://powereng.hotims.com RS# 34

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UPTIME IN PRACTICETIER 4 FINAL READY

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DE-TIER CAPABILITY

plants to obtain sophisticated control

strategies without having to reinvent

the wheel when it comes to control-

ling all of the elements required to de-

liver consistent steam to the turbine.

Leveraging proven strategies ensures

not only that the boiler will operate

efficiently, but that it will also operate

safely. Pre-engineered strategies can

cut the implementation time of a new

Distributed Control System (DCS),

thereby allowing installation during a

short maintenance outage. This allows

the time savings to be realized months

before a traditional DCS could be in-

stalled.

This strategy also allows current

operators to increase the operating ef-

ficiency of the plant while optimizing

the labor resources required to per-

form specific tasks such as startup of

heat recovery steam generators. Users

can implement sophisticated strategies

used at larger power plants in mid-

sized and smaller plants with more

confidence and more quickly than in-

stalling a traditional DCS with custom

or less sophisticated strategies. Addi-

tionally, the ease of installation is also

accompanied by ease in changing the

parameters to allow the knowledge of

existing employees to be captured in

the control system.

ADVANTAGES OF USING

ADVANCED CONTROLS

Significant improvements can be

made to boiler operations through

advanced controls to help the plant

to operate closer to the maximum

nameplate ratings. Specifically, the

benefits to be gained are focused on

delivering consistent steam to the tur-

bine. However, these improvements

in operations also focus on improv-

ing safety, decreasing emissions and

decreasing consumption of excess fuel

and water.

Other benefits of advanced controls

include reduction in capital costs for

inconsistent Btu values in fuels. Sen-

sors for determining the Btu content

of the fuel (such as municipal solid

waste) are expensive, and the benefits

provided rarely cover the expense.

Compensation from the software can

provide a significant advantage to op-

erations and limit the capital outlay.

A DCS with sophisticated control

strategies can increase the perfor-

mance of mid- and small-size plants

because they make sophisticated

strategies, usually only found at large

plants, available to all plants. The re-

sult is a plant that has higher efficiency

and safety while providing consistent

1307PE_56 56 6/27/13 5:24 PM

www.power-eng.com 57

Oxygen analyzer delays can cause effciency loss

MudDrum

ID Fan

ID FanAT

LIC_Drum

Economizer

Steam

Drum

Boiler 8

boilers provides consistent steam de-

livery from the boilers. Consistent

steam decreases fatigue on turbines,

thus decreasing maintenance costs on

turbines. Additionally, balancing the

boilers provides safe operations of the

boilers by not having one boiler pro-

viding for the load variation and in-

creasing the temperatures in the boiler

beyond the desired set point.

ANALYZER DELAY

COMPENSATION

OF O2 TRIM

Problem: During load swings, the

O2 set point is adjusted based on a

load index. There is, however, a delay

from the O2 analyzer. If this delay is

not taken into account, the control will

incorrectly adjust the O2 either higher

or lower than optimal, leading to ef-

ficiency loss through excess hot air es-

caping up the stack or a high level of

combustibles exiting the stack with the

flue gas. Losses of 1 percent or more of

efficiency can occur during transients

or ramping.

Solution: The control strategies

should provide O2 trim control with a

minimum O2 set point (which is oper-

ator adjustable). The control strategies

should account for analyzer response

delays and incorporate these delays to

improve response and thus efficiency.

Value: Fuel usage is optimized dur-

ing load swings which saves on fuel

costs and reduces unintended emis-

sions such as CO.

STEAM FLOW

COMBUSTION CONTROL

IN STOKER BOILERS

Problem: Solid fuels fired on grates

such as coal, biomass and municipal

solid waste have varying Btu per mea-

sured weight, and constant heat can-

not be assured as when using natural

gas or oil. The available Btu must be

inferred in order to control relative

air flow to maintain suitable combus-

tion. Unfortunately, O2 trim cannot

steam to the turbine. Additionally,

utilizing an advanced DCS can reduce

the time required to implement a new

DCS. The reduction in implementation

time can save on custom engineering

hours and allow for faster achievement

of the efficiencies of sophisticated con-

trol strategies.

Power plants are often faced with

problems that challenge their opera-

tional efficiencies. Listed below are

some of the common problems plants

face, and how sophisticated control

strategies can address these problems.

Often these are not implemented due

to either a lack of knowledge about a

control strategy solution, or the per-

ception that the engineered solution is

beyond the financial scope of a proj-

ect. But what if that solution was pre-

engineered, and the knowledge of how

to solve that problem was part of a pro-

ductized solution?

PLANT MASTER

AND FUEL MASTER

Problem: Plants with multiple

boilers are faced with balancing their

output such that the steam delivery

matches the load demand from the

turbine or turbines. When a boiler that

supplies steam into a common steam

header for multiple boilers is taken out

of service, the other boilers will have

to compensate to ensure smooth and

consistent steam to the turbine. The

varying load swings on the boilers may

lead to unbalanced conditions which

could cause varying steam delivery or

in the worst case scenario, water car-

ryover to the turbine.

Solution: Proper system design

should accommodate both a plant and

fuel master. The plant master function-

ality should allow for selecting which

controller is the overall plant master

to allow maintenance on one of the

boilers or its controls. The fuel mas-

ter controls the feeders or pulverizers.

Input to the fuel master is from the

plant master. The fuel master should

provide a balancing and auto loop re-

sponse correction to account for the

number of burners in automatic mode

versus manual mode or out-of-service

for maintenance. Manual operation of

a burner should not be required even

during ramp-up or while using fuel

with varying Btu content.

Value: Correct balancing of the

1307PE_57 57 6/27/13 5:24 PM

www.power-eng.com

DONíT WASTE TIME AND MONEY

COLLECTING DUST. CLEAN YOUR AIR.

When OPPD was ready to

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mitigation, they turned to Martin.

Martin conducted a safety and

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to rebuilding coal transfer points to

contain dust and reduce spillage

and installing MartinÆ Air Cleaners

on load zones to further reduce

the escape of fugitive materials.

ìMartin has been very responsive...

throughout our on-going relationship,

giving us competitive pricing, standing

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Supervisor at OPPD. OPPD was

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approach with the steam flow correct-

ed for heat storage is utilized. This en-

sures that the combustion process is ef-

ficient and safe. The use of the adjusted

steam flow/air flow system over a basic

parallel system can increase efficiency

by five percent or more. A minimum

air set point and smother protection

override also provides increased safety

and boiler availability.

Value: Both safety and maintenance

concerns are alleviated by properly

controlling the combustion cycle. By

allowing a minimum air set point, the

combustibles in the stack are limited

below hazardous levels. Maintenance

concerns are minimized by providing

more consistent steam flow, thereby

decreasing fatigue on the turbine.

COMPENSATION FOR

MULTIPLE FANS, FEEDERS

AND STOKER RESPONSE

Problem: When multiple devices

like feeders, FD and ID fans, etc., are

controlled from a single PID loop, it

is desirable to compensate the loop

for the number of devices in manual

mode for activities such as manual

loading in order to maximize loop

response. Upsets due to poor response

can lead to decreases in efficiency and

mechanical stress.

Solution: Control strategies should

automatically adjust the control loop

response based on the status of the

individual driven devices. For example,

where multiple feeders are driven from

a single master fuel controller, the

loop automatically compensates the

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www.power-eng.com60

BY JUSTIN MARTINO, ASSOCIATE EDITOR

Entergy may have started

with burning sawdust to

generate power, but since

then the company has

grown to build a diverse

foundation of power-generating projects.

Entergy began in 1913 when Harvey

Couch, president of Arkansas Power

Co., made a handshake agreement with

H.H. Foster, president of the Arkansas

Land and Lumber Company, to gener-

ate power from sawdust from Foster’s

lumber company. Arkansas Power Co.,

which provided power for two Arkan-

sas towns, started with two 550 kW

generators and 22 miles of transmis-

sion lines.

One hundred years later, the company

has 30,000 MW of generating capacity,

revenues of more than $10 billion and is

one of the leading nuclear generators in

the U.S.

BUILDING A DIVERSE

POWER GENERATION

PORTFOLIO

Entergy, which is based out of New Or-

leans, provides power for around 2.8 mil-

lion customers in four states and operates

more than 40 power plants in the U.S.

The company’s power generators run

off of a variety of fuel and include coal-

fired, natural gas-fired, hydroelectric and

nuclear generators.

Having that level of fuel diversity helps

Entergy keep its prices as low as possible

Entergy Blends A Dedication To Energy With A Dedication To Customers

for its utility customers, said Jeff Richard-

son, Entergy’s Director of Major Projects

– Nuclear.

“When you have spikes in natural gas

prices or coal or oil or uranium prices, we

have enough fuel diversity to shield our

customers from those kinds of volatile ac-

tions in the commodities markets,” Rich-

ardson said.

In addition, having a diverse fuel mix

allows Entergy to help control its emis-

sions. Entergy’s nuclear reactors can help

offset emissions from other power gen-

erating sources, such as coal-fired power

plants.

Richardson noted that nuclear power

is not only a cost-effective and less-vola-

tile source of energy, but it also provides

a near-zero emissions source of power

generation.

“From that perspective, we think

nuclear has very strategic advantages in

the long term in a world that’s more and

more concerned with the multi-pollutant

requirements and concerns about cli-

mate change and CO2 and those kinds of

things,” he said.

On the fossil fuel side of power genera-

tion for Entergy, Entergy Vice President

– Fossil Generation Etienne Senac said

the company is currently working more

with natural gas than coal, although the

company still has three coal-fired power

plants with five total units. Senac said

that while coal is still being used globally,

uncertainty about regulations in the U.S.

as well as costs have pushed the U.S. to-

ward using more natural-gas fired power

plants.

“We’re kind of all being funneled in

the gas technologies at the present time

because people just don’t see where the

future of coal is going to be in the United

States,” he said.

NINEMILE STATION

Entergy’s most current large project fol-

lows the trend of using natural gas rather

than coal for power generation. The com-

pany is building a combined cycle gas tur-

bine unit, Ninemile 6, located at its cur-

rent Ninemile Point plant in Westwego,

La. that will provide 550 MW of power

capacity.

The unit, which will cost $721 million

to construct, will be one of the most ef-

ficient gas-fired units in Entergy’s fleet as

well as in the state, according to the com-

pany. It will replace Ninemile units 1 and

2, which first came online in the early

1950s and have been deactivated.

The company said the unit will have

significantly lower emissions than the

units that were deactivated and will be

one of the cleanest gas-fired generating

units in the U.S.

The unit will use GE 7FA.04 combus-

tion turbine generators and a Toshiba

TCDF 33.5” steam turbine generator. The

heat recovery steam generator is a model

manufactured by Vogt.

Entergy is using subsidiaries of CB&I as

1307PE_60 60 6/27/13 5:25 PM

www.power-eng.com 61

Entergy’s Hot Spring power plant is one of its

natural-gas fired power generation plants.

1307PE_61 61 6/27/13 5:25 PM

www.power-eng.com62

sense to the company, including pro-

viding license renewal services to other

utilities and contracting for operations

at nuclear power plants owned by other

companies.

DEALING WITH

UNCERTAINTY IN

EXPANSION

As Entergy continues with its long-

term plans and goals, looking at regula-

tion and potential changes in the market

will be important to making decisions

that will help the company continue its

success, Senac said. Although natural gas

may appear to be the best fuel to be using

right now, changes in the market could

raise prices and make another fuel more

desirable.

“You always have to keep your options

open and think about diversification,

where it makes sense, because certainly,

as we’ve seen historically, you’ve got po-

tential for a lot of volatility in the price of

fuels,” he said.

Senac noted that as more coal units

are being shut down, and some compa-

nies consider closing down nuclear units,

more power plants in the U.S. will likely

switch to using natural gas for power

engineering, procurement and

construction contractors.

“We’re pretty happy that we’re

back to building some genera-

tion,” Senac said.

Building Ninemile 6 is part

of Entergy’s plan to continue

to change its sources of power

generation in order to continue

to provide efficient, reliable

and lower-cost electricity to its

customers. Besides building the

unit, the company is also plan-

ning to acquire combined cycle

gas turbine units for sale when

the purchase is economical and

would meet reliability needs. The com-

pany also intends to enter into long-term

agreements with suppliers of efficient,

lower-cost power.

Entergy has also recently completed

several major projects for its nuclear

power generation, including a steam gen-

erator replacement at its Waterford 3 unit

in Killona, La., and a power uprate at its

Grand Gulf Nuclear Station in Port Gib-

son, Miss.

Although no projects on the scale of the

Grand Gulf uprate or Waterford’s steam

generator replacement are planned at any

of its stations currently, Richardson said

Entergy spends millions of dollars each

year at each of its nuclear sites for capital

upgrades. Those upgrades may involve

adding automation, upgrading computer

and mechanical systems or adding facili-

ties for employees at the stations.

Entergy works with multiple compa-

nies for its capital upgrades at nuclear

sites, including Westinghouse Electric;

GE Hitachi, a consortium between the

two companies that focuses on nuclear

operations; Areva; and Siemens.

Richardson also said the company

continues to look for ways to expand En-

tergy’s business in areas where it makes

generation, increasing the demand. In

addition, the U.S. Environmental Protec-

tion Agency is researching potential envi-

ronmental damage caused by hydraulic

fracturing, a method used to obtain natu-

ral gas, which could lead to more regula-

tions in the future.

“The whole natural gas industry could

be impacted by that, and you could see a

price rise in natural gas due to demand

and environmental regulation,” he said.

Environmental regulation plays a large

role in the future of the company’s coal-

fired power generation as well. Federal

regulations regarding emissions are forc-

ing many U.S. coal-fired power plants to

either shut down or make major invest-

ments in emissions control technology.

Senac said there are no regulatory

mandates that would require any of the

company’s five coal-fired units to install

scrubbers at this time, but the company

continues to monitor all regulations that

come out. Based on final rules being

made by the EPA, the company will make

decisions on capital improvements to its

current energy fleet.

Four of the company’s coal-fired units

are in Arkansas, which is currently put-

ting together a state implementation plan

The Hot Spring plant is located in Arkansas, which

is one of four states that Entergy serves.

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www.power-eng.com64

worked on ways to reduce emissions to

help reduce the impact of global climate

change. The company was the first U.S.

utility to voluntarily commit to stabi-

lize its greenhouse gas emissions, and J.

Wayne Leonard, who retired as chairman

and chief executive officer of Entergy on

Jan. 31, has advocated for a per-ton fee on

carbon emissions.

“You start to find yourself posing the

question of ‘After I die, what?’, and then it

really starts to dawn on you that the real

question is, ‘Before I die, what?’” Leonard

said in a speech to members of the Na-

tional Wildlife Federation while accept-

ing an award for Entergy’s environmental

programs last November.

“I can think of no time in history when

the planet is in as much peril as it is to-

day,” he said. “We were not supposed to

be facing the possibility of mass extinc-

tions in anybody’s lifetime ... but here we

are.”

Senac said one of Leonard’s issues, and

an issue likely to continue to be looked

at by current chairman and CEO Leo De-

nault, is how to encourage investments

in technology that can reduce emissions

and be used globally. Senac said it will be

key for manufacturers to produce viable

technology that can be used on a com-

mercial scale and also makes enough

economic sense that other countries will

for EPA regulations.

“A lot depends on how that turns out,”

Senac said.

If the company will be required to

install scrubbers on its coal-fired units,

Senac said it will look at the economics

of the regulations, along with the cost of

fuel, and make a decision on how to pro-

ceed based on those factors.

“We think probably in the next two or

three years we’ll get a little bit of clarity

and more certainty on some of the regu-

lations,” he said.

“I think it’s difficult for the industry

because there is a lot of uncertainty sur-

rounding the regulations and the stan-

dards. A lot of these things we see, we an-

ticipate that regulations are going to come

out and next thing you know, things get

held up in the court system, they get over-

turned and vacated. When you’re looking

at billions of dollars worth of capital in-

vestment and infrastructure, the uncer-

tainty really is a big, big detriment to that.

You just don’t have many people today

that want to step out and build sizable

coal units in the United States because

there’s just so much uncertainty.”

A COMMITMENT TO

THE ENVIRONMENT

Despite the uncertainty around regula-

tions for energy companies, Entergy has

choose to invest in it as well.

He warned, however, that it is also im-

portant to not get too far ahead of what is

required because of potential cost recov-

ery issues with regulatory commissions

but added the company is taking steps to

reduce emissions on current units as well

as retiring older, less efficient units to cut

down on emissions. Entergy’s nuclear

fleet also helps in reducing emissions cre-

ated from power generation.

Entergy was named in the 2012/2013

Dow Jones Sustainability North America

and World Indices and the 2012 Carbon

Disclosure Leadership Index. It was one

of only two U.S. companies in the electric

utility industry selected to the Dow Jones

Sustainability World Index. Being named

to the indices marked the 11th consecutive

year the Dow Jones Sustainability Index

has included Entergy on either the world

or North America index. In addition,

Entergy has been named to the Carbon

Disclosure Leadership Index eight of the

past nine years.

“I think as a company we have done a

very good job trying to reduce our total

emissions,” Senac said.

GIVING

Entergy’s dedication to helping im-

prove quality of life isn’t limited to just its

emissions, however. The company works

to help its customers and is active in giv-

ing to charities, including endowing a

$5 million charitable fund in Leonard’s

name when he retired from the com-

pany. The charitable fund was endowed

through shareholder-funded donations

to the Entergy Charitable Foundation.

During Leonard’s tenure as CEO,

which began in 1999, Entergy has do-

nated more than $50 million to chari-

table initiatives and advocacy efforts that

successfully helped move low-income

residents toward self-sufficiency, includ-

ing $16.5 million in grants in 2011 to

improve the quality of life in the areas

where it operates. Among them were

campaigns to improve early childhood

Entergy’s current project, a new combined

cycle natural gas-fired unit, will be located at

its current Ninemile Point plant.

1307PE_64 64 6/27/13 5:25 PM

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other similar factors.

Another part of providing the best pos-

sible services to Entergy’s customers is an

ability to respond quickly to major storm

events, which can include everything

from hurricanes to ice storms in Entergy’s

service area. Senac said the company has

education programs and financial sup-

port of a matched-savings program that

has helped 19,000 people and created an

economic impact of $69 million over the

last 10 years.

“I think that we are a very caring com-

pany that is truly concerned about our

customer base,” Senac said.

He added the company’s service ter-

ritory includes areas with some of the

highest poverty rates in the U.S., and the

company is very passionate about do-

ing everything it can to provide reliable

service and the lowest possible rates for

its customers. Having low rates not only

helps its residential customers, but it also

helps keep costs down for the company’s

industrial base, which helps spur eco-

nomic growth in the area.

Senac said it is also important to

provide reliable service for Entergy’s

customers.

“I think we have excellent reliability

performance, especially in the area we

serve where we have some of the greatest

fluctuations of power on a daily basis,”

he said, noting that the southern U.S. can

have large energy peaks in the summer

because of the air conditioning loads and

Ninemile Unit 6 will cost around $721 mn to build and will provide 550 MW of energy.

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ago, growth and change is not a new

concept. Senac said there has been

rapid technological change in the past

25 years, and he expects Entergy to

take advantage of that change to better

serve its customers.

“If you just think about

a long history of handling storms and is

recognized across the industry for its abil-

ity to do so.

“It really is what I would consider

one of our core competencies,” he said.

“Where we live, we’re kind of under the

constant threat all across the summer of

having storms.”

STILL GROWING

As Entergy continues to work best to

serve its customers, the company will

continue to go through improvements

and upgrades.

“I do believe that our entire industry

is at a critical juncture,” Senac said, add-

ing that a lot of utilities are hitting the

same century mark as Entergy and that

there is a lot of infrastructure in the util-

ity industry that requires upgrading.

Entergy has worked to make upgrades

in its infrastructure and changes to

benefit its customers, and recently has

proposed some changes with its trans-

mission business. It has received all

necessary approvals from regulators in

Arkansas, Louisiana, New Orleans, Mis-

sissippi and Texas to join the Midconti-

nent Independent Transmission System

Operator, which is planned for Decem-

ber 2013. Customer savings are project-

ed to reach approximately $1.4 billion in

the first decade of MISO membership,

according to Entergy.

In addition, Entergy and ITC Holdings

Corp. filed a joint application with the

Federal Energy Regulatory Commission

for approval to spin off and merge Enter-

gy’s transmission assets into a subsidiary

of ITC. The move, announced in Decem-

ber 2011, would allow for “greater capac-

ity for investment, singular focus and

excellence in operations,” according to

Theo Bunting, Entergy’s group president

of utility operations. The companies

hope to receive all regulatory approvals

and complete the transaction in 2013.

For a company that began with a

handshake agreement and two sawdust-

operated power generators 100 years

advancements in technology, commu-

nications, the medical arena, just the

growth and demand for energy across

the globe … I think it’s going to be con-

tinuous,” he said. “I think you’ll see

phenomenal change in the next quar-

ter of a century.”

1307PE_67 67 6/27/13 5:25 PM

www.power-eng.com68

concern over FAC seems to be fading

away in the minds of plant management

at many facilities. A contributing factor

undoubtedly is the many retirements in

the power industry, where new person-

nel simply do not understand the impor-

tance of FAC control. Yet, FAC continues

to generate international conferences, the

most recent of which was held in March

in Washington, D.C. In a presentation

to the PPEC meeting attendees, Kevin

Shields, one of Dr. Dooley’s colleagues,

provided the following bullet items in an

introductory slide. [2]

•  FAC occurs in >70% of fossil plants,

and represents >40% of all tube fail-

ures in HRSGs despite R&D since the

1960s, and

• Many 100s of plant assessments

worldwide, and

• Numerous fatalities and serious fail-

ures, and

• Much application and development

This article focuses upon FAC and

methods to prevent it, and will hopefully

serve as a warning document for plant

management at the many hundreds of

facilities that continue to be constructed

and brought on-line not only in the U.S.

but worldwide.

When I began my utility career in

1981, conventional wisdom said that

any dissolved oxygen which entered the

condensate/feedwater system of utility

boilers was harmful. At that time, more

than 50 percent of the power produced

in the U.S. came from coal. Coal-fired

units typically have complex conden-

sate/feedwater networks with numerous

feedwater heaters. The prevalent think-

ing was that any trace of dissolved oxy-

gen (D.O.) would cause corrosion, and

indeed oxygen corrosion can be very

problematic in uncontrolled situations.

Therefore, virtually all feedwater systems

for high-pressure steam generators were

equipped with a deaerator for dissolved

gas removal. A properly operating deaer-

ator can lower D.O. concentrations to 7

parts-per-billion (ppb).

However, any residual D.O. concen-

tration was still considered harmful,

so chemical deaeration was a standard

process at most plants. The workhorse

for many years was hydrazine (N2H

4), a

reducing agent which reacts with oxygen

as follows:

N2H

4 + O

2 → 2H

2O + N

2↑ Eq. 1

Also, a primary, and arguably the pri-

mary, benefit of hydrazine is that it will

passivate oxidized areas of piping and

tube materials as follows:

A main topic at the spring

2013 meeting of the

ASME Research Commit-

tee on Power Plant & En-

vironmental Chemistry

was once again flow-accelerated corro-

sion (FAC) and its prevention. The issue

has not lost any importance since four

workers were killed by an FAC-induced

failure in 1986, [1] with a number of fa-

talities since. In fact, FAC is the top corro-

sion mechanism in heat recovery steam

generators (HRSG), so the issue has, if

anything, become more important.

However, as was pointed out by several

of the meeting attendees (and most no-

tably Dr. Barry Dooley of Structural In-

tegrity Associates and formerly of EPRI),

Plant Management: Don’t Lose Focus on FAC IssuesBY BRAD BUECKER, CONTRIBUTING EDITOR

Author

Brad Buecker is a contributing editor for

Power Engineering and also serves as a

process specialist with Kiewit Power En-

gineers in Lenexa, Kan.

Single-phase FAC. Note the orange

peel texture. Photo courtesy of Dave

Johnson, ChemTreat.

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www.power-eng.com70

100

80

60

40

20

00 50 100 150 200 250 300 350

0 122 212 302 392 482 572 662

Temperature (˚F)

Temperature (˚C)

NH3 pH0.1 ppm 8.75

0.2 ppm 8.90

0.3 ppm 9.05

0.5 ppm 9.20

1.0 ppm 9.40

2.0 ppm 9.60

ppb

Fe

Carbon Steel Matrix Dissolutionas a

Function of pH and Temperature

dissolution is greatly influenced by not

only reducing conditions but also by so-

lution pH and temperature.

As Figure 1 illustrates, corrosion reach-

es a maximum at 300° F. Thus, feedwater

systems and HRSG low-pressure evapora-

tors are particularly susceptible locations.

Also note the influence of pH, as reflect-

ed by ammonia concentration, on the

corrosion characteristics. As we shall see,

this factor is quite important with regard

to control of FAC.

The quest to maintain a non-detectable

oxygen residual in feedwater systems led

to FAC at many coal-fired power plants. I

observed this first hand at one of two util-

ities in which I was employed in the past.

At this plant, a feedwater heater drain line

failed due to FAC, shutting down an 800

MW supercritical unit. Infinitely more

serious was FAC-induced failure of an at-

temperator line in 2007 at another of the

This program became

known as all-volatile treat-

ment reducing [AVT(R)].

Due to the suspected car-

cinogenic nature of hydra-

zine, alternative chemicals

such as carbohydrazide,

methyl ethyl ketoxime,

and others gained popu-

larity. Regardless, all still

had the same purpose, to

establish a reducing envi-

ronment in the feedwater

circuit, thus inhibiting oxi-

dation of metal. The tech-

nique became a standard

in the industry.

“This changed in 1986.

On December 9 of that

year, an elbow in the con-

densate system ruptured

at the Surry Nuclear Power

Station [near Rushmere,

Va.] The failure caused four

fatalities and tens of mil-

lions of dollars in repair

costs and lost revenues.” [1]

Researchers learned from

this accident and others

that the reducing environment produced

by oxygen scavenger feed results in single-

phase flow-accelerated corrosion (FAC).

The attack occurs at flow disturbances

such as elbows in feedwater piping and

economizers, feedwater heater drains,

locations downstream of valves and re-

ducing fittings, attemperator piping, and,

most notably for the combined-cycle in-

dustry, in low-pressure evaporators. The

effect of single-phase FAC is outlined in

the next illustration.

Metal loss occurs gradually until the

remaining material at the affected loca-

tion can no longer withstand the process

pressure, whereupon catastrophic failure

occurs. The thinning is due to the com-

bination of a reducing environment and

localized fluid flow disturbances, which

cause dissolution of ferrous ions (Fe+2)

from the metal and metal oxide matrix.

Results from EPRI showed that iron

N2H

4 + 6Fe

2O

3 → 4Fe

3O

4 + N

2 ↑ + 2H

2O

Eq. 2

N2H

4 + 4CuO → 2Cu

2O + N

2↑ + 2H

2O

Eq. 3

Fe3O

4, magnetite, is the protective lay-

er that forms on carbon steel when it is

placed into service. Cu2O forms on cop-

per alloys, although we will not discuss

this chemistry in great depth, as the use

of copper alloys in condensate/feedwater

systems has greatly diminished in large

part due to the potential for copper car-

ryover to steam in high-pressure utility

boilers.

Hydrazine residuals were typically

maintained at relatively low levels of per-

haps 20 to 100 parts-per-billion (ppb).

Oxygen scavenger treatment was coupled

with feed of ammonia or an amine to

maintain feedwater pH within a mildly

alkaline range, now 9.1 to 9.3 for mixed-

metallurgy feedwater systems and a bit

higher for all-ferrous systems.

NH3 + H

2O ⇔ NH

4+ + OH– Eq. 4

Photo of tube-wall thinning caused

by single-phase FAC. Photo courtesy

of Dave Johnson, ChemTreat.

1307PE_70 70 6/27/13 5:25 PM

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short-radius elbows. Thus, the HRSG

contains numerous spots susceptible to

single-phase FAC. A primary method to

mitigate this attack is selection of proper

feedwater treatment, which we will now

examine.

More than 40 years ago, researchers in

Germany and then Russia began using a

program known as oxygenated treatment

(OT) to minimize carbon steel corro-

sion and iron dissolution in supercritical

steam generators. The key component of

the program was, and still is, deliberate

injection of pure oxygen into the con-

densate/feedwater network to establish

oxygen residuals of up to 300 ppb. What

chemists discovered is that in very pure

feedwater (cation conductivity, ≤ 0.15 µS/

cm), the magnetite becomes overlayed

with a tenacious and very insoluble film

of ferric oxide hydrate (FeOOH). Results

quickly showed that OT can lower feed-

water iron concentrations to 1 ppb or

less, and greatly minimize single-phase

FAC. Now, OT is the preferred feedwater

treatment for once-through utility steam

generators around the world. Common

in the United States is an oxygen residual

range of 30 to 150 ppb, with a recom-

mended pH range of 8.0 to 8.5. OT has

been applied to a few drum units, where

EPRI guidelines call for a feedwater pH

range of 9.0 to 9.4 with a dissolved oxy-

gen concentration of 30 to 50 ppb.

Although OT has been successfully ap-

plied to drum boilers, another program

has evolved that is very popular for con-

densate/feedwater in these steam gener-

ators. To this point in time with AVT(O),

oxygen has not been deliberately in-

jected into the condensate, but rather

the amount that enters from condenser

air in-leakage (per “normal” conditions,

where we will examine “normal” short-

ly) is allowed to remain without any

oxygen scavenger/metal passivator treat-

ment. It should be noted at this point

that OT or AVT(O) are not permissible

for feedwater systems containing copper

alloys, as the oxygen would simply be

too corrosive to the metal. The following

HRSG chemistry control. It is obvious

that this mindset clearly has not been

expunged at many locations.

SOLUTIONS TO SINGLE-

PHASE FAC AND CHANGING

THE REDUCING-AGENT

MINDSET

HRSGs by their very nature typi-

cally have many waterwall tubes with

utility’s stations, which killed two work-

ers and seriously injured a third.

In large measure, coal plant personnel

have recognized the problem of single-

phase FAC, and have adopted alter-

native feedwater treatment methods

to mitigate the issue. However, I regu-

larly review combined-cycle propos-

als in which the developer specifies

an oxygen scavenger feed system for

1307PE_72 72 6/27/13 5:25 PM

www.power-eng.com

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for feedwater pH now recommend a

range of 9.2 to 9.6. With EPRI’s phos-

phate continuum program or with caus-

tic treatment alone, the drum pH can

be controlled within a range of 9 to 10

quite readily. However, a complication

sometimes arises due to HRSG design.

Most HRSGs are of the multi-pressure,

drum, vertical tube style. In some cases,

text therefore focuses upon AVT(O) for

all-ferrous systems.

When researchers developed AVT(O),

they took into account the pH effect on

carbon steel dissolution, as previously il-

lustrated in Figure 3. AVT(O) guidelines

evolved to the following parameters.

•  Recommended pH range, 9.2-9.6

•  Feedwater D.O. concentration, 1-10

ppb

As with OT, the condensate in an

AVT(O) programs must be quite pure

to allow oxygen to generate the FeOOH

protective layer rather than cause pitting.

However, the cation conductivity upper

limit with AVT(O) is a bit more relaxed at

≤ 0.2 µS/cm.

AVT(O) chemistry is evolving. Chem-

ists have discovered that even 10 ppb

D.O. in the feedwater may not be suf-

ficient to generate a complete FeOOH

passivation layer. It is possible that delib-

erate injection of oxygen, similar to OT

programs, may in the future be recom-

mended where needed.

The amount of air in-leakage that es-

tablishes the “normal” condition of 10

ppb or less dissolved oxygen in the con-

densate is not a hard and fast value. The

old rule of thumb for proper condenser

conditions is a limit of 1 scfm (standard

cubic feet per minute) of air in-leakage

per 100 MW of capacity. However, I have

worked with units in which the air in-

leakage ratio was significantly higher, but

where the condenser vacuum pumps had

sufficient capacity to remove the gases.

Quite often, a failure at the condenser

shell or within auxiliary equipment may

cause a sudden spike in dissolved oxygen

concentration. As contrasted to pure oxy-

gen feed such as with OT, air in-leakage

also allows carbon dioxide to be drawn

into the condensate, which raises the con-

ductivity. In such cases, plant personnel

need to search for the leak or leaks and

repair them promptly. Much more prob-

lematic is a condenser tube leak, which

not only raises the condensate dissolved

solids concentration, but introduces

impurities to the steam generator. These

effects can be quite dramatic.

ADDITIONAL

CHEMICAL AND MATERIAL

SELECTION TECHNIQUES

TO MINIMIZE FAC

Elevated pH also has a beneficial effect

in mitigating FAC. Thus, the guidelines

1307PE_73 73 6/27/13 5:25 PM

www.power-eng.com74

two-phase fluid flow. As fluid flashes

upon entering a deaerator, oxygen de-

parts with the steam. Thus, the water

that impinges upon metal surfaces

does not maintain an oxidizing envi-

ronment.

Also, the pH of entrained water

droplets within the steam is usually

lower than the bulk water pH. The

combination of these factors often ini-

tiates FAC.

As has been noted, elevated pH will

help to mitigate FAC, but the HRSG

configuration dictates how the maxi-

mum treatment allowed.

If the LP system is utilized for heat-

ing of feedwater to the IP and HP

circuits, solid alkali treatment (tri-

sodium phosphate or caustic) of the

LP circuit is not permissible. Control

of pH can only be accomplished by

ammonia, but it should be noted that

ammonia hydrolysis, as previously

outlined in Equation 4, decreases with

increasing temperature.

As with single-phase FAC, a method

to combat two-phase FAC is fabrica-

tion of susceptible locations with

chromium-containing steel. Again,

this adds cost to the project.

CONCLUSION

FAC is an issue to be taken very seri-

ously.

I continue to see a large number of

power plant proposals that still call for

an oxygen scavenger feed system, and

this is quite frustrating.

In addition to the references I have

included in this article, I also encour-

age readers to access the web site of

the International Association for the

Properties of Water and Steam (www.

IAPWS.org).

This group, in which Dr. Dooley is

one of the directors, offers free down-

loadable and cutting-edge technical

information regarding power plant

water/steam chemistry.

References

Guidelines for Controlling Flow-Accelerat-

ed Corrosion in Fossil and Combined Cycle

Plants, EPRI, Palo Alto, CA: 2005. 1008082.

K. Shields, [A report on the] “International

Conference on Flow-accelerated Corrosion

in Fossil, Combined-Cycle/HRSG and Renew-

able Energy Plants” at the 2013 spring meet-

ing of the ASME Research Committee on

Power Plant & Environmental Chemistry, April

15-17, Houston, Texas.

the feedwater circuit is designed such

that feedwater separately enters each

pressure circuit separately. In many oth-

ers, however, the entire feedwater stream

is routed to the low-pressure (LP) evapo-

rator for heating before being distributed

to the intermediate-pressure (IP) and

high-pressure (HP) steam generators.

For this configuration, phosphate or

caustic feed to the LP circuit is not per-

missible due to the downstream effects

on attemperator chemistry, and IP and

HP economizers. In these situations, LP

pH control is dependent upon the am-

monia injected into the feedwater. If the

condenser is tubed with ferrous materi-

als, the pH may be taken higher than

the 9.2 to 9.6 range listed above without

ill effects. However, copper-alloy tubes

would suffer corrosion at higher ammo-

nia concentrations.

For new HRSGs, single-phase FAC

control can also be addressed by mate-

rials selection. The addition of a small

amount of chromium in the material

at FAC-susceptible locations virtually

eliminates the corrosion. A primary

example is LP waterwall elbows. Fab-

rication of the elbows from 1¼ or 2¼

chrome alloy can provide great benefit.

While this alloy addition adds some cost

to the project, the materials are quite re-

sistant to FAC.

TWO-PHASE FAC

Many steam generators, regardless

of type, are susceptible to two-phase

FAC. As the name implies, this corro-

sion mechanism occurs where water

flashes to steam, resulting in a mixed-

phase fluid.

For conventional units, feedwater

heater shells and heater drains are

common locations for two-phase FAC,

but this equipment is not common for

HRSGs.

However, deaerators also experience

Two-phase FAC in a deaerator. Photo courtesy of Tom Gilchrist, Tri-State G&T (ret.)

1307PE_74 74 6/27/13 5:25 PM

For info. http://powereng.hotims.com RS# 45

1307PE_75 75 6/27/13 5:25 PM

www.power-eng.com76

PRODUCTS

with the option of fve types of end connectors

that are available on all cable lengths and types.

The cables are available for online purchase

directly from the Mueller website at www.muel-

lerelectric.com or through the company’s global

distribution network.

Mueller Electric Co. Inc.

Hydrogen fuel-cell

powered generator

Multiquip’s H2G EarthSmart hydrogen fuel

cell-powered generator is the industry’s

frst mobile hydrogen fuel cell-powered genera-

tor. The H2G is non-polluting, with no particulate

emissions. Because the machine does not use

fossil fuel sources, no combustion occurs in the

process, making it safer for use in any environ-

ment, indoors or out. The generator operates

cleanly with zero emissions and can be operated

inside and for tunnel/underground applications.

Multiquip

Inverter and charger

OutBack Power Technologies Inc. announced

its grid-interactive Radian Series GS7048E

Inverter/Charger. The charger offers 230 V of

adjustable power for residential, industrial, com-

mercial and other applications.

Grid-tied renewable energy systems save

money by offsetting utility costs, while off-grid

systems provide energy independence when grid

power is unavailable.

OutBack Power Technologies Inc.

Info http://powereng.hotims.com RS#: 402

Rubber pocket bumpers

Rubber pocket bumpers from Heyco are

designed to use as mounting feet to prevent

equipment from sliding or moving. Designed

for through hole installation, the rubber pocket

bumpers offer a 60-70 durometer range and

are available in 29 sizes from .500’’ (12.7

mm) to 2.500’’ (63.5mm) to accommodate

various mounting holes and panel thicknesses,

and to provide vibration dampening. They are

constructed out of Styrene Butadiene and have

an operating temperature range of -40°F (-40°C)

to 221°F (105°C).

Heyco Products Inc.

Info http://powereng.hotims.com RS#: 403

Alarm management system

AMETEK Power Instruments added the

IEC61850 protocol t its SER Alarm

Management System. The system is designed to

interconnect all intelligent electronic devices via

a station bus.

The Web browser-based alarm manage-

ment system records alarms with 1 millisecond

precision for determining root cause and cor-

rective actions. The system can also simulta-

neously receive digital alarm contacts that are

time stamped and archived in the database for

one common Web browser-based display and

analysis. The protocol also reduces installation

time by eliminating the need for discrete wiring

and providing a standardized approach to system

confguration using the open protocol.

AMETEK Power Instruments

Info: http://powereng.hotims.com RS#: 400

BACnet controller

Wago Corp.’s 750-830 BACnet Controller

features software with extended func-

tionality and simplifed system-wide integration/

confguration.

The new model fea-

tures text messaging

support, control algo-

rithms, alarm queries,

object types and cre-

ation of a Trend Log and Calendar dynamic objects

during runtime.

Part of the Wago I/O system can pair with a

750-493 3-Phase Power Measurement Module for

energy monitoring and data collection.

Wago Corp.

Info http://powereng.hotims.com RS#: 401

Thermal Insulation

Ceramic Blankets

Cotronics 370R REACH compliant ceramic blan-

kets are made from alkaline earth silicate wool

and were specifcally designed for use in applica-

tions that require

highly effcient

thermal insulation

and compliance

with strict safety

requirements and regulations. 370R blankets are

thermally stable to 2730ºF, fexible, and resilient

with non-wetting characteristics, low heat storage

and low shrinkage.

Cotronics ceramic blankets are designed

to replace noncompliant, RCF blankets.

Applications include: furnace and boiler linings;

chemical reactors, ovens, door seals, reusable

steam and gas turbine insulation; mold wraps

and investment castings, expansion joint

packing, high temperature flters, fre protection,

sound absorption, non-contaminating brazing

and sintering separators, melting furnace back

up insulation, aluminum ladle and trough covers

and more. Not recommended for use with HF,

H3PO4, NaOH and KOH.

Cotronics

Turbine ignition transformers

Foster Transformer’s high voltage ignition

transformers for stationary gas turbines are

designed to operate in ambient temperatures of

up to 275 degrees F and are proven for turbines

manufactured by GE, Pratt & Whitney, Allison,

Westinghouse and more.

Standard input volt-

age 115/230 V, 50 –

400 Hz, custom input

voltages and frequen-

cies available. Output

voltage is 15,000 V, with power rating 0.450 kVA,

and 8-32 screw terminal line voltage connection.

Each ignition transformer is encapsulated in

MIL-PRF-23586F UL940V Silicone Elastomer for

protection against shock and vibration, thermal

cycling stress, dielectric failure and corrosion.

Foster Transformer

Info http://powereng.hotims.com RS#: 402

Static discharge grounding cables

Mueller Electric Co. Inc. is offering static and

electrostatic discharge grounding cables

that are designed to protect workers and asso-

ciated equip-

ment from the

potential harm-

ful efforts of

static electric-

ity and electrostatic discharge. The cables are

available in multiple lengths and in insulated and

non-insulated versions with copper or stainless

steel wire construction. The cables also come

1307PE_76 76 6/27/13 5:26 PM

www.power-eng.com

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shock accelerometer

family. These trans-

ducers are designed

for measuring long

duration transients

and short duration shock impacts of structures or

systems.

Models within the series meet both SAE J211

Inverter series

Power-One Inc. is offering the ULTRA-

700/1100/1500-TL inverter series available

in 780 kW, 1.17 MW and 1.56 MW models.

The AURORA ULTRA extends

the power range of their inverters

to 1.56 MW. They are made with

a 98.6 percent effciency and up

to four independent maximum

power point tracking (MPPT) al-

gorithms along with a 690 V AC output voltage.

Power-One Inc.

Info http://powereng.hotims.com RS#: 404

Pressure regulator

Marsh Bellofram Corp.’s BelGAS division in-

troduced the Type P143 spring loaded pres-

sure regulator designed to provide high accuracy

natural gas and air pressure regulation within

commercial, residential and light industrial burn-

ers and unit heaters.

The regulators are

available in ¾-inch,

1-inch or 1-1/4-inch

pipe sizes and incor-

porates a corrosion-

resistant stainless steel body with a lightweight alu-

minum bonnet. The units also offer internal relief

to reduce internal pipe stresses with an available

low-pressure cutoff version.

Marsh Bellofram Corp.

Info http://powereng.hotims.com RS#: 405

Remote Measurement Display

The Remote Measurement Display, from Setra

Systems, Inc., facilitates clear and remote view-

ing capabilities of real-time “at a glance” HVAC/R

conditions, ensuring effective climate control man-

agement within a variety of critical environments.

The CE-compliant

display accepts 0-10

and 0-5 VDC analog

signals from virtually

any sensing technol-

ogy, including temperature, humidity, CO2, pres-

sure, and others. The 1-inch, 3.5 digit LCD display

may be clearly viewed from across a room with re-

duced glare and readings may be easily calibrated

by the user. It is also wipedown capable, with no

special maintenance requirements. These fush

mount style units are compatible with standard

4-11/16 electrical box confgurations.

Setra Systems, Inc.

Info http://powereng.hotims.com RS#: 406

Shock accelerometer series

Meggitt Sensing Systems introduced its

Endevco Model 7264 Series piezoresistive

1307PE_77 77 6/27/13 5:26 PM

www.power-eng.com78

etc., can be printed in minutes from a standard

laser or thermal transfer printer while the adhesive

permanently bonds to all surfaces, including pow-

er-coated and cast metal surfaces, oily smooth

plastic.

CILS International

Info http://powereng.hotims.com RS#: 411

Telecontrol modules

WAGO Corp.’s TO-PASS Compact Telecontrol

Modules provide I/O monitoring, error-re-

porting and supple-

mentary I/O control

via bidirectional SMS

text messaging. TO-

PASS is designed to

eliminate wiring and

radio repeaters and

bring SCADA-style capabilities to existing applica-

tions and create new ones.

The eight digital inputs send eight different error

messages via email or fax to four user-designated

receivers. Users can customize command text

through dedicated confguration software.

WAGO Corp.

Info http://powereng.hotims.com RS#: 412

Tigerhood Futura

XXL Welding Helmet

The Fibre-Metal brand Tigerhood Futura XXL

welding helmet, from Honeywell Safety

Products, delivers a large wide-view, distortion-

free auto darkening flter lens with the highest-

quality optics available in the U.S. and Canada.

With a total viewing area mea-

suring 10.2 square inches,

the XXL model provides a 40

percent larger viewing area

than standard auto darkening

flters. ADC technology delivers

uniform shading and distortion-free vision across

the entire viewing area, even peripherally. As a re-

sult, welders can see clearly and work at awkward

angles more easily. Engineered to perform across

the spectrum of electro-arc welding processes,

the Tigerhood Futura XXL is ideally suited for those

working in the shipbuilding, heavy fabrication,

mining, oil and gas, and petrochemical industries.

Honeywell Safety Products

Info http://powereng.hotims.com RS#: 413

impact testing and SAE J2570 anthropomorphic

device testing standards as well as Euro NCAP

standards. They also include a “B” variation, the

Endevco model 7264B series, and the “C” varia-

tion, the model 7274C series.

Meggitt Sensing Systems

Info http://powereng.hotims.com RS#: 407

Gas detectors

Sierra Monitor has introduced the new IT

Series network-enabled gas detectors, fea-

turing user-friendly digital display, 4-20 mA out-

put, RS-485 Modbus

output, HART, integral

relays, SentryBus output

and extensive self-diag-

nostics for reliable, ac-

curate monitoring. The

IT Series meets the user

needs in integrated gas monitoring with plant-

wide safety monitoring.

Sierra Monitor

Quality control software

Kistler North America has announced the intro-

duction of the STASA Quality Control plastics

injection molding process optimization software,

designed to optimize machinery parameters. The

software is based on a repeated systematic design

of experiments method for determining best ma-

chinery setting operating points as well as online

process. The methodology allows for machinery

behavior simulation and visualization, preventing

unnecessary experiments.

The software offers lower overall production

costs with shorter cycle times, fewer defective

parts and greater ability to accurately forecast

parts processes. Additional benefts include re-

duced cycle time and rejection rate; setup phase

systemization; and enhanced setup process docu-

mentation and knowledge.

Kistler North America

Industrial generators

Subaru’s Industrial Generators feature four mod-

els all featuring power and reliability.

The models are the R1100, which features a

2.4 horsepower EH09-2 Subaru engine and deliv-

ers a maximum output of 1,100 watts. The next

three models, the RGX2900, the RGX3600 and the

RGX4800, all feature Subaru’s EX series overhead

cam engines and are equipped with a 4.4 gallon

fuel tank and a gauge, as well as a full tubular steel

frame.

Subaru

Info http://powereng.hotims.com RS#: 408

Industrial generators

Subaru’s Industrial Generators feature four mod-

els all featuring power and reliability.

The models are the R1100, which features a

2.4 horsepower EH09-2 Subaru engine and deliv-

ers a maximum

output of 1,100

watts. The next

three models,

the RGX2900,

the RGX3600

and the RGX4800, all feature Subaru’s EX series

overhead cam engines and are equipped with a

4.4 gallon fuel tank and a gauge, as well as a full

tubular steel frame.

Subaru

Info http://powereng.hotims.com RS#: 409

Sump cleaners

The Eriez Hydrofow line of heavy-duty indus-

trial wet/dry vacuum sump cleaner units are

designed to clean virtually any machine tool sump,

tank or pit.

Eriez offers

six models of

sump clean-

ers: The Top

Sump Cleaner,

the Reversible Liquid Vacuum, the Sump Cleaner,

the Single Compartment Sump Cleaner, the Push

Sump Cleaner and the Truck Sump Cleaner.

Eriez Hydrofow

Info http://powereng.hotims.com RS#: 410

Tamper evident labels

CILS International introduces its CILS-8800B

label series designed to provide label strength

needed for long-term product identifcation, yet

will destruct on at-

tempted removal.

Variable data,

such as barcodes,

serial numbers,

1307PE_78 78 6/27/13 5:26 PM

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Weld tracking

and positioning systems

Lincoln Electric says its Arc Products’ weld

tracking and positioning systems are made to

position arc and track joints for wind tower sec-

tion fabrication.

Products in-

clude Seam Tracker

Systems for auto-

mated weld joint

tracking, Motorized

Slide control systems

for manual joint po-

sitioning and Cross

Slide Assemblies to mount submerged arc or

GMAW single or tandem welding arc equipment.

All of the products are designed for wind tower

section fabrication as well as tanks, pipe, pres-

sure vessels, beams and stiffeners and rims/

wheels.

Arc Products

Info http://powereng.hotims.com RS#: 415

Radio transmitter

Ritron introduces the Quick Talk RQT, an

industrial-grade radio transmitter with sen-

sor inputs and voice recording storage that au-

tomatically alerts

radio -equipped

personnel when

plant conditions

change.

The RQT ra-

dio can operate

stand-alone on 6 AA batteries or it can be pow-

ered by an optional 110V AC adaptor. The poly-

carbonate enclosure is gasketed and sealed and

offers built-in mounting fanges.

Ritron

Info http://powereng.hotims.com RS#: 414

Wire-Tap Branch Connectors

WAGO Corporation¹s 730 Series Wire-Tap

Branch Connectors expedite terminations

for facility managers and engineers overseeing

vertical transportation applications. Available in

3- and 6-pole variants, 730 Series female sock-

ets utilize IDC to tap individual conductors at

any place with-

out stripping.

Male plugs

employ vibra-

t ion - res is tant

CAGE CLAMP

Spring Pressure

C o n n e c t i o n

Technology to ensure reliability within elevator

shafts. 730 Series is rated 300V/10A; female

sockets accommodate fne-stranded conductors

AWG 18¬16, male plugs accommodate solid,

stranded and fne-stranded conductors AWG

28¬14. Created for switching functions, e.g., door

switches or interlocks, 730 Series bright orange

3-pole Wire-Tap Branch Connector features an

Isolation Blade that automatically cuts and iso-

lates Live conductors in one step.

WAGO Corporation

1307PE_80 80 6/27/13 5:26 PM

www.power-eng.com 81

GENERATING BUZZ

Wisconsin-based Helical Robotics offers fve different-sized

robots: the HR-MP5 (shown), the HR-MP20, the HR-MP100,

the HR-JP10 Javelin and the HR-JP10M Javelin. The robots

are remote controlled and can scale the wind tower while

carrying cameras, tools and other equipment needed

to inspect the towers, blades or other parts that may be

dangerous or diffcult for workers to access. Deployment

takes less than a minute and the robot can be used on a

wide range of towers, the company’s website says. Most of

the robots are magnetic, which helps them to cling on to the

side of a wind turbine.

Helical Robotics

1307PE_81 81 6/27/13 5:26 PM

Be sure to mark your

calendar to return to North

Americaís most in ̌uential all-renewable

event November 12-14 in the Orange County Convention

Center ñ Orlando, FL. Once again, weíll be co-locating with

POWER-GEN International ñ bringing renewable energy to

the forefront of the mainstream energy industry.

Learn more & register @ RenewableEnergyWorld-Events.com

ProgressiveChangesfor the future

Owned & Produced By: Co-located With: Presented By: Supported By: Media Sponsor:

Nov. 12-14, 2013Orange County

Convention CenterOrlando, FL

For info. http://powereng.hotims.com RS# 52

1307PE_82 82 6/27/13 5:26 PM

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www.power-eng.com 83

SOLVAir trona effectively cleans flue gas by reacting with acid gases, such as SO

2, SO

3, Hg and HCl. This applica-

tion guide shows how to calculate the quantities of trona needed to achieve desired results when used in DSI systems.

www.solvair.us

Contact: Rosemary [email protected]

713.521.7450

Air Pollution Control

Why Should You

Filter Your Water?

$%&$'�'��'�������'���'� �'�������'��'�����'���

�����'$$%����$''�����'����$�$�'''���'�����'����%�&�

����������� !''''��" #������� !

The Best Engineered Water Filteration Solution Always Costs Less

���� � ���� �� �������� ���� ����

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� ��� ��

Automatic Filters

(800) 615-9296 ■ [email protected]

a brand of TerraSource Global

www.TerraSource.comTerraSource™ Global is a wholly-owned subsidiary of Hillenbrand, Inc.

(NYSE: HI) ©2013, TerraSource™ Global. All rights reserved.

Handling a World of Materials

BOILER FEED SYSTEMS

Your source for custom-designed,

ruggedly-built mechanical and pneumatic

systems for feeding of biomass and alternative

fuels directly into boilers and kilns.

High-pressure, low-pressure and vacuum

conveying components available.

Boiler Feed Systems

Bechtel is among the most respected engineering, project management, and construction

companies in the world.

Bechtel operates through five global business units that

specialize in civil infrastructure; power generation; communica-tions and transmission; mining

and metals; oil, gas and chemicals; and government

services.

Since its founding in 1898, Bechtel has worked on more than 22,000 projects in 140

countries on all seven continents. Today, our 53,000

employees team with customers, partners and

suppliers on diverse projects in nearly 50 countries.

www.bechtel.com

EPC Firm

POWER PLANT

Decommissioning

Environmental Remediation

Retrofitting

(800) 932-2869 | www.brandenburg.com

Brandenburg®

Brandenburg is the premier demolition and

environmental remediation contractor for

power plant decommissioning and retrofi t-

ting. Brandenburg services utility companies

throughout the U.S. by performing demo-

lition and repurposing projects ranging from

selective removal of obsolete equipment

to complete closure of power plant facilities.

Demolition/Decommissioning

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�����������������������

� �������������������������

������������������� ���������������������������� ���������������������������������� �������� �� ��� ����� ������� ���� ������������������������������ �������������������������������������� ��� ����������

PE113

Concrete Buildings

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http://powereng.hotims.com/RS#304http://powereng.hotims.com/RS#303

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http://powereng.hotims.com/RS#305

1307PE_83 83 6/27/13 5:26 PM

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Lubricant contamination caused by ferrous metals negatively impacts the operation of your critical rotating equipment. Philadelphia Gear’s CORE®Filtration System virtually eliminates ferrous metal particles, even as small as one micron, making this problem a thing of the past. For more information visit: www.philagear.com.

Filtration System

in E

xis

ting a

nd E

volv

ing E

nerg

y N

eeds

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Gas Turbine

Mobil SHC™ Gear

Lubricants

Mobil SHC Gear lubricants are expertly formulated, fully synthetic products that provide power plant operators with outstanding protection against conventional wear modes, such as scuffing, enhanced resistance to micropitting fatigue, and long oil life.

© 2013 Exxon Mobil Corporation. All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries.

Approved by Siemens for use in Flender gearboxes.

Gear Lubricants

Crown Electric

Iso Phase Bus

FabricationInstallation

Upgrades & UpratesGSU Change Outs

175 Edison Dr.

Middletown, OH 45044

www.crown-electric.com

[email protected]

ext.

201513 539-7394

Iso Phase Bus

EVERY ASPECT OF OUR

ENGINEERED SYSTEM IS

THE BEST IN THE INDUSTRY

INCLUDING THE SINGLE

CONTACT WHO WILL MANAGE IT

©2013 Cleaver-Brooks, Inc.

Single source, single responsibility for

every aspect of your industrial steam

system projects, from burner to stack,

custom built for you. Our boilers,

burners, HRSGs have long been the

industry benchmark with the best

effi ciency and lowest emissions possible.

www.cleaverbrooks.com/engineered

402-434-2000

Heat Recovery

http://powereng.hotims.com/RS#306 http://powereng.hotims.com/RS#308http://powereng.hotims.com/RS#307

http://powereng.hotims.com/RS#309 http://powereng.hotims.com/RS#310

Arching, plugging, uncontrolled flow, and no flow are common problems with many bulk materials such as coal, limestone, frac sand, oil sands, ash, cement, asphalt, and fine ores.

Testing with Jenike & Johanson and field applications have shown CRODON Wear Plate to often be a superior solution in select applications with abrasive materials that are also sticky/difficult to flow.�

Use CRODON Wear Plate to transport your difficult materials efficiently with less down time and better productivity.

For more information

contact us at:

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or call us at (888) 346-4747

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Donít Get Buried

Material Handling Solution

http://powereng.hotims.com/RS#311

1307PE_84 84 6/27/13 5:26 PM

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85 www.power-eng.com

Media Blasting Services

www.molemaster.com

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From Dry Ice to

Walnut Shells,

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Abrasive Blasting

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Media Blasting Services

Learn More

1-800-992-0209

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Pollution Control

®

Introducing the Arrangement 9Pressure Blower

Arrangement 9 motor orientationoffers a reduced fan footprint. Used as part of a system for conveying coal dust or incinerating off a gas in a gas-handling system.

THE NEW YORK BLOWER COMPANY

800.208.7918 | www.nyb.com

©2012 The New York Blower Company

Pressure Blower

http://powereng.hotims.com/RS#312 http://powereng.hotims.com/RS#314http://powereng.hotims.com/RS#313

Service

Ideal for Injection & Selective

Catalytic Reduction

Small Drops, Big Results.

BETE’s XA Series Air Atomizing

Nozzles

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REMARKABLYSIMPLE

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WWW.VOLVOPENTA.COM

1.757.436.2800

Volvo Engines

http://powereng.hotims.com/RS#315 http://powereng.hotims.com/RS#317http://powereng.hotims.com/RS#316

1307PE_85 85 6/27/13 5:27 PM

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LASSIF

IED

S

1319 Macklind Ave., St. Louis, MO 63110 Ph: (314) 781-6100 / Fax: (314) 781-9209

www.ampulverizer.com / E-Mail: [email protected]

Quality and Service Since 1908

Ring Granulators, Reversible Hammermills,

Double Roll Crushers, Frozen Coal Crackers

for crushing coal, limstone and slag.

For info. http://powereng.hotims.com RS# 458

For info. http://powereng.hotims.com RS# 453

For info. http://powereng.hotims.com RS# 450

ELIMINATE

Valve Cavitation

x� Eliminate valve cavitation by placing one or more diffusers downstream of the valve.

x� Noise and pipe vibration will also be eliminated or reduced.

x� Valve’s first costs and mainte-nance burden will also be reduced.

For sale or rent

The world’s verybest portable end

prep tools and abrasive saws

800-343-6926www.escotool.com

Tur bine ControlsWoodward, GE, MHC

Parts and ServiceObsolete Parts Inventory

Control System, ModernizationTraining, Troubleshooting

(610) [email protected]

TurboGen Consultants, Inc.

For info. http://powereng.hotims.com RS# 456

WE ARE BUYING!!!

ARE YOU SELLING?

VALVES

INSTRUMENTATION

ELECTRICAL CONTROLS

PROCESS EQUIPMENT

PROCESS CONTROLS

PLANT MACHINERY

PSA SNUBBERS, ETC.

VISITwww.FerncroftManagement.com

email:[email protected]

T. 978-815.6185 Fax. 603-814.1031

FerncroftManagement,LLC

LIMITORQUE OPERATORS WANTED

NOISE?���������������������������������

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Houston: 713-789-9400

Calgary: 403-259-6600

www.HFPacoustical.com

[email protected]

For info. http://powereng.hotims.com RS# 451

For info. http://powereng.hotims.com RS# 459For info. http://powereng.hotims.com RS# 452

For info. http://powereng.hotims.com RS# 457

For info. http://powereng.hotims.com RS# 455

POWER PROFESSIONALS

Opportunities in Operations and Maintenance,

Project Engineering and Project Management.

Business and Project Development.

First-line Supervision to Executive Level Positions.

Employer pays fee. Send resumes to:

P.O. BOX 87875,

VANCOUVER, WA 98687-7875

email: [email protected]

(360) 260-0979 • (360) 253-5292

www.powerindustrycareers.com

For info. http://powereng.hotims.com RS# 454

EMPLOYMENT

1307PE_86 86 6/27/13 5:27 PM

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For info. http://powereng.hotims.com RS# 466

For info. http://powereng.hotims.com RS# 464

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24 / 7 EMERGENCY SERVICE

BOILERS20,000 - 400,000 #/Hr.

DIESEL & TURBINE GENERATORS50 - 25,000 KW

GEARS & TURBINES25 - 4000 HP

LARGEST INVENTORIES OF:

Air Pre-Heaters • Economizers • DeaeratorsPumps • Motors • Fuel Oil Heating & Pump Sets

Valves • Tubes • Controls • CompressorsPulverizers • Rental Boilers & Generators

847-541-5600 FAX: 847-541-1279 visit www.wabashpower.com

FOR SALE/RENT

POWER

EQUIPMENT CO.

444 Carpenter Avenue, Wheeling, IL 60090

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For info. http://powereng.hotims.com RS# 460

For info. http://powereng.hotims.com RS# 462

CONDENSER OR GENERATOR AIR COOLER TUBE PLUGS

THE CONKLIN SHERMAN COMPANY, INC.

Easy to install, saves time and money.ADJUSTABLE PLUGS - all rubber with brass insert.

Expand it, install it, reverse action for tight fit.

PUSH PULL PLUGS - are all rubber, simply push it in.

Sizes 0.530 O.D. to 2.035 O.D.

Tel: (203) 881-0190 Fax: (203) 881-0178

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For info. http://powereng.hotims.com RS# 465

GEORGE H. BODMAN, INC.Chemical cleaning advisory services for

boilers and balance of plant systems

George H. BodmanPres / Technical Advisor

P.O. Box 5758 Office (281) 359-4006Kingwood, TX 77325-5758 1-800-286-6069email: [email protected] Fax (281) 359-4225

For info. http://powereng.hotims.com RS# 463

For info. http://powereng.hotims.com RS# 467rental

equipment

the steam & power special forces®

1-800-990-0374

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Rental Boilers • Deaerator Systems •

Economizers • Water Softener Systems •

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FIND CONDENSER LEAKS FAST WITH FOAM METHOD LEAK DETECTION, TUBE PLUGS IN STOCK

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Get a thorough mix with:

Pugmill Systems, Inc.P.O. Box 60

Columbia, TN 38402 USA

Ph: 931-388-0626 Fax: 931-380-0319

www.pugmillsystems.com

For info. http://powereng.hotims.com RS# 461

1307PE_87 87 6/27/13 5:27 PM

www.power-eng.com88

INDEX

RS# COMPANY PG# SALES OFFICERS# COMPANY PG#

1421 S. Sheridan Rd., Tulsa, OK 74112 Phone: 918-835-3161, Fax: 918-831-9834 e-mail: [email protected]

Sr. Vice President North American Power Group Richard Baker

Reprints Foster Printing Servive 4295 Ohio Street Michigan City, IN 46360 Phone: 866-879-9144 e-mail: [email protected]

National Brand Manager Rick Huntzicker Palladian Professional Park 3225 Shallowford Rd., Suite 800 Marietta, GA 30062 Phone: 770-578-2688, Fax: 770-578-2690 e-mail: [email protected] AL, AR, DC, FL, GA, KS, KY, LA, MD, MO, MS, NC, SC, TN, TX, VA, WV

Brand Sales Manager Dan Idoine 806 Park Village Drive Louisville, OH 44641 Phone: 330-875-6581, Fax: 330-875-4462 e-mail: [email protected] CT, DE, IL, IN, MA, ME, MI, NH, NJ, NY, OH, PA, RI, VT, Quebec, New Brunswick, Nova Scotia, Newfoundland, Ontario

Brand Sales Manager Tina Shibley 1421 S. Sheridan Road Tulsa, OK 74112 Phone: 918-831-9552; Fax: 918-831-9834 e-mail: [email protected] AK, AZ, CA, CO, HI, IA, ID, MN, MT, ND, NE, NM, NV, OK, OR, SD UT, WA, WI, WY, Alberta, British Columbia, Saskatchewan, Northwest Territory, Yukon Territory, Manitoba

International Sales Mgr Anthony Orfeo The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 609, Fax: +44 1992 656 700 e-mail: [email protected] Africa, Asia, Central America, Europe, Middle East, South America

European Sales Asif Yusuf The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 631, Fax: +44 1992 656 700 e-mail: [email protected] Europe and Middle East

Classifieds/Literature Showcase Account Executive Jenna Hall 1421 S. Sheridan Rd. Tulsa, OK 74112 Phone: 918-832-9249, Fax: 918-831-9834 email: [email protected]

21 Michigan Seamless Tube 37 www.mstube.com

3 Mobil Industrial Lubricants 7 mobilindustrial.com

7 N B Harty General Contactor Inc 15

9 NEM BV 19 www.nem-group.com

36 New York Blower Company 59 nyb.com

32 Norit Americas Inc 53 norit-americas.com/extra

8 PCC Energy Group 17 pccenergygroup.com

48 PennWell GEN-HUB 80 generationhub.com/trial

26 Phillips 66 Lubricants 43 phillips66lubricants.com

47 POWER-GEN WEEK 79 powergernerationweek.com

50 ProEnergy Services LLC C4 proenergyservices.com

18 Railserve, Inc. 31 www.RailserveLEAF.biz

45 Reliable Turbine Services 75 www.reliableturbineservices.com

52 Renewable Energy World 82 powergernerationweek.com

33 Rotork Controls Inc 55 www.rotork.com

20 Roxul Inc 35 www.roxul.com

10 Santee Cooper 21 www.santeecooper.com/wpsale

30 SEI Group 51 www.southernenvironmental.com

2 Siemens Ag 5 siemens.com/energy/controls

5 SMA America LLC 11 www.SMA-America.com

17 Stanley Consultants Inc 30 www.stanleyconsultants.com

44 The Society for Protective Coatings 73 sspc.org

34 Volvo Penta of the Americas 56 www.volvopenta.com

27 Weg Electric Motors 45 www.weg.net/us

1 Westinghouse Electric Co C2 www.westinghousenuclear.com

Advertisers and advertising agencies assume lia-bility for all contents (including text representation and illustrations) of advertisements printed, and also assume responsibility for any claims arising therefrom made against the publisher. It is the advertiser’s or agency’s responsibility to obtain appropriate releases on any items or individuals pictured in the advertisement.

14 Ail Sound Walls 26 alisoundwalls.com

38 Ametek Process Analytical 65 www.ametekpi.com

4 Areva 9 us.areva.com/atrium

6 Ashross 14 ashross.com

22 Babcock Power Inc. 38 babcockpower.com

Bechtel 3

49 Bete Fog Nozzle Inc C3 www.bete.com

11 Brand Energy and 23 Infrastructure Services

www.beis.com

39 Buckman 66 buckman.com

12 Carver Pump Company 24 www.carverpump.com

25 Clearspan Fabric Structures 41 wwwClearSpan.com/ADPWRE

24 COAL-GEN 40 coal-gen.com

31 Combustion Components 52 Associates

www.cca-inc.net

13 Corrpro 25 www.corrpro.com

16 Elster 29 www.elster-instromet.com

46 Enercon Services Inc 77 enercon.com

23 Fibrwrap 39 www.fibrwrap.cpm

19 Fluor Corp 33 www.fluor.com

41 GE 69 www.ge-energy.com/energysavings

42 Haldor Topsoe AS 71 www.topsoe.com

43 Harco 72 harcolabs.com

28 Hydratight 46 hydratight.com/nuclear

40 Hydrolox 67 hydrolox.com

15 Kiewit Power Inc 27 kiewit.com

35 Martin Engineering 58 martin-eng.com

37 Matrix PDM Engineering 63

29 Membrana 47 liqui-cel.com

1307PE_88 88 6/27/13 5:27 PM

BETE. Your strategic partner for engineered spraying solutions.

Meeting the demands for cleaner, more efficient operations

For over 50 years, BETE has been recognized as the leader in spray nozzle design and innovation for the power industry. BETE’s technological advancements have revolutionized nozzles used for atomizing, evaporation, cooling, misting, and fogging. Achieve higher spray nozzle efficiency and reliability using BETE nozzles.

Performance Through Engineering

BETE’s Application Engineers are known for their ability to find creative solutions to difficult spraying challenges. As specialists in fluid flow, BETE’s engineers design everything from individual spray nozzles to lance assemblies that can be integrated into existing processes. From engineering concept to delivery, we are dedicated to producing the highest quality nozzles.

BETE... highly efficient

and reliable nozzles

for all your power generation

challenges.

TFXP Nozzles

for fire protection and evaporative cooling with the largest free passage which are full cone and are clog resistant

MaxiPass™ Nozzles

provide maximum free passage to deliver atomized slurry into the absorber tower with a finely atomizing full cone spray

TH Nozzles

patented geometry designed to give the most uniform liquid distributionaround the periphery of the spray

Made in the USA

BETE Fog Nozzle, Inc.

T(413)772-0846

F(413)772-6729

www.bete.com

TH Nozzles

Large free passage with the most uniform liquid distribution

SpiralAir Nozzlesare finely

atomized full cone sprays

available in a range of spray

angles

TF Nozzlesprovide an exceptional

clog-resistant spray for cooling gases

For info. http://powereng.hotims.com RS# 49

1307PE_C3 3 6/27/13 4:50 PM

For info. http://powereng.hotims.com RS# 50

1307PE_C4 4 6/27/13 4:50 PM