Pre and Post Combustion Aqc Emissions Reduction

AIR QUALITY CONTROL SECTIONB&V ENERGYPRATIK MEHTA

PRE AND POST COMBUSTION AQC EMISSIONS REDUCTION TECHNOLOGY OVERVIEW

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AGENDAAbout Black & Veatch

NOx Control Methods

SO2 Control Methods

Particulate Control Methods

CO & VOC Control Methods

HAPs Control Methods

AQC Implementation Challenges

Questions & Open Discussions

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ABOUT BLACK & VEATCH

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Ranked 1st in Power by Engineering News Record (ENR)

Founded in 1915

Global workforce of more than 9,000

More than 100 offices worldwide

Projects in more than 100 countries on 6 continents

$2.6 billion in annual revenues in 2011

Ranked on Forbes Americas Largest Private Companies listing

One of the largest majority employee-owned company in the U.S.

Reputation of integrity, competence and highest safest standards

BLACK & VEATCH CORPORATION IS A LEADING GLOBAL ENGINEERING, CONSULTING AND CONSTRUCTION COMPANY

19 April 2012POWER-GEN India

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BVCPL Global Talent and knowhow brought locally

Business in India from 1977; office established in 2004

Business Areas Energy and Telecom

Workforce More than 150 professionals

Energy Departments Engineering (Mechanical, Electrical & Controls, Civil & Structural), Project Control, Proposals, Procurement, Quality, Human Resources, and Administrative

Office with project execution capabilities

Equipped with commercial and B&V proprietary engineering tools

BLACK & VEATCH CONSULTING PVT LTD (PUNE)


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CAPABILITIES BY ENERGY SCOPE

PE

E CM

P

PE C

p

EXPANDED SCOPEPROJECT SERVICESENGINEERING SERVICES

Techno Economic Feasibility Reports

Detail Project Reports

Owners Engineering Services

Lenders Engineering Services

Independent Engineer Services

Detail Engineering Services

Project Management

Procurement

Construction Management

Startup Services

Operator Training

Outage Management


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PROJECT APPROACH

Phase IProject Development

Phase IIDetail Design Engineering

Phase IIIConstruction, Startup, and

Commissioning

Conceptual Engineering

Detailed Cost Estimate

Develop Design and Instruction Manuals

Procurement Execution Plan

Permitting

Detailed, Multi-Discipline Engineering for Balance of Plant

Interface with Existing Plant Systems

Procurement

Level 2/3 Schedule Development

Project Controls

Construction Management

Quality Assurance Management

Project Controls

Startup and Commissioning

Performance Testing


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NOx CONTROL METHODS

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LOW NOx BURNERS AND OVER-FIRE AIR

Source: Babcock & Wilcox Source: Siemens


9Delayed combustion and air stagging

SELECTIVE CATALYTIC REDUCTION (SCR)

BypassDamper System (optional)

Gas Flow DistributionDevices

Sonic Horns

VaporizedAmmonia

Flue Gas toAir Heater

Catalyst

Temperature Measurement Grid

Tuning / Monitoring Grid

Flue GasFrom

Economizer

Space For Future Catalystand Sonic Horn Addition


10Most widely used post-combustion technology in the world

SELECTIVE NON CATALYTIC REDUCTION (SNCR)

Combustion Air

InjectionLevel 2

InjectionLevel 3

Burners

Steam GeneratorAir Heater

Injection Level 1

Flue Gas

Ammonia or Urea Storage Tank


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IN-DUCT HYBRID SCR

Source: Clean Environmental Protection Engineering


12Optimized ammonia usage

NOx CONTROL METHODS COMPARISON

19 April 2012

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POWER-GEN India

NOx Control Methods LNB OFA SCR SNCRIn-Duct

Hybrid SCR

Controlled NOx emissions, mg/Nm3

310 - 350 280 - 3001 60 - 752 210 - 2502 135 - 1602

Capital cost Low Low Highest Medium High

O & M cost Low Low Highest Medium High

Auxiliary power Low Low Highest Medium High

Pressure drop Low Low Highest Medium High

BOP impactsReduced

boiler efficiency

Reduced boiler

efficiency

Air heater fouling

Air heater fouling

Air heater fouling

Fly ash sales impact None None Yes Yes Yes

Safety and hazard risks None None Yes Yes Yes

Additional pollutant or byproduct formation

High CO emissions

High LOIAmmonium

bisulfateAmmonium

bisulfateAmmonium

bisulfate

Additional AQC equipment required

None None

Particulate control

equipment upstream

None

Particulate control

equipment upstream

Notes:1.When used in conjunction with LNB.2.When used in conjunction with LNB and OFA.

NOx Removal Experience from early 1980s

LNB / OFA

25 + Engineering

7,900 MW +

SCR/SNCR

25 + Engineering

18,300 MW +

B&V NOx CONTROL METHODS EXPERIENCEVaporized

Ammonia

Catalyst

Flue Gas


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SO2 CONTROL METHODS

1515

DUCT SORBENT INJECTION

Source: Solvay


16Alkaline reagents - sodium or lime based sorbents

WET FLUE GAS DESULFURIZATION


17Most widely used technology in the world

SEMI- DRY FLUE GAS DESULFURIZATIONAtomizers

Fabric Filter

Stack

Flue GasInducedDraft Fan

Semi Dry FGDReactor

Fly ash forDisposal OrRecycle


18Integral particulate control equipment

DRY FLUE GAS DESULFURIZATION


19Second generation dry scrubber systems

SEAWATER FLUE GAS DESULFURIZATION


20Natural alkalinity of sea water

SO2 Control MethodsFurnace or Duct

Sorbent Injection Wet FGD Semi-Dry FGD Dry FGD Seawater FGD

Controlled SO2 emissions, mg/Nm3

120 - 160 50 - 75 80 - 100 80 - 100 100 - 120

Capital cost Low High High High Medium

Reagent cost High Low High High None

O & M cost Low High Medium Medium Low

Auxiliary power Low High Medium Medium Medium

Pressure drop Low High Medium High Medium

SO3 removal High Medium High High Medium

HCl removal Low High High High High

HF removal Low High High High High

Particulate removal High Medium High High Medium

Oxidized mercury removal Low High High High High

Material of construction Carbon Steel

High corrosion resistant alloy or non-metallic liner

or FRP

Carbon Steel Carbon Steel

High corrosion resistant alloy or

non-metallic liner or FRP

Liquid waste NoneYes - may require

waste water treatment plant

None NoneYes - discharge

to sea

Byproduct sales impact Not saleable Saleable Not saleable Not saleable None


Particulate control equipment

downstream

Gas to Gas Reheater


downstream


downstream

Gas to Gas Reheater

SO2 CONTROL METHODS COMPARISON

19 April 2012

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POWER-GEN India

SO2 Removal Experience from early 1960s

SO2 Removal Experience from 4 MW to 900 MW

FGD

90+ Engineering

42,600 MW+

OEM experience

Third party scrubber experience

B&V FGD EXPERIENCE


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PARTICULATE CONTROL METHODS

2323

DRY ELECTROSTATIC PRECIPITATOR (DESP)


24Most widely used technology in the world

Source: Babcock & Wilcox

FABRIC FILTER (FF)

Pulse Air Header

Filter Bag with internal cage

Outlet poppet damper

Inlet manifold

Tube sheet

Outlet manifold

Inlet louver damper

Pulse air pipe


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Second generation particulate control equipment

WET ELECTROSTATIC PRECIPITATOR (WESP)


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Fine particulate control equipment

Particulate Control Methods DESP FF WESP

Controlled particulate emissions, mg/Nm3

50 - 75 15 - 20 Co-benefit

Capital cost Low High Low

O & M cost Low High Low

Auxiliary power Medium Medium High

Pressure drop Low High Low

SO3 removal Low Low High

Fine particulate removal Low Medium High

Mercury removal Low Medium High

Fuel and operating flexibility Low High Medium

Temperature limitations None Yes None

Reagent injection for multi-pollutant capabilities

Limited Good None

Material of construction Carbon Steel Carbon SteelHigh corrosion resistant alloy or non-metallic liner or FRP

Liquid waste None None Yes


None None Wet FGD system upstream

PARTICULATE CONTROL METHODS COMPARISON


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Particulate Removal Experience from 4 MW to 825 MW

ESP 100+ Engineering

24,500 MW+

FF 50+ Engineering

13,000 MW+

ESP Dry & Wet

FF PJFF and RGFF

B&V ESP AND PJFF EXPERIENCE


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CO & VOC CONTROL METHODS

2929

OXIDATION CATALYST

FromCT

SCR CatalystAmmonia Injection Grid

COVOC

CO2 + H2O

Oxidation Catalyst


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HAPS CONTROL METHODS

3131

POWDERED ACTIVATED CARBON (PAC) INJECTION

Source: Nol-Tec Systems


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AQC IMPLEMENTATIONCHALLENGES

3333

Retrofit Space constraints

Programming methodology Initial study to execution

Compliance strategy Future emission limits

Customized solutions Not one technology fits all

Outage planning

Strong partners and team

AQC IMPLEMENTATION CHALLENGES


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Our team and our processes are focused on achieving success for the Owner

Mitigating and managing risk

Controlling cost and schedule through project planning and management of change

Keeping the labor force engaged and safe

Achieving performance and quality goals

ELEMENTS OF EXECUTION SUCCESS


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Preliminary Design

PlanningCost EstimatingManpower EstimateSchedule Development Outage PlanningConstruction PlanningRisk Identification

Project Monitoring

and Forecasting

Project Execution

Adjustments and

Mitigation(as needed)

Successful Project

Completion

The payoff of planning

B&V can accurately assess

the performance of the

project and make EARLY

corrections, when needed

PROJECT PLANNING AND CONTROL

Plan the work, Work the plan


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QUESTIONS & OPEN DISCUSSIONS

CONTACT US: BOOTH 1139 - HALL 11

3737

www.bv.com

Pre and Post Combustion Aqc Emissions Reduction

Documents

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