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“Enhanced Plant Performance via Effective SO 3 Control” Sterling Gray, URS Corporation

“Enhanced Plant Performance via Effective SO 3 Control” Sterling Gray, URS Corporation Mick Harpenau, Duke Energy EUEC Conference Phoenix, AZ February 3, 2010. SO 3 Adversely Impacts …. Equipment Corrosion. Air Heater Reliability. Mercury Capture. NOx Removal. Heat Rate.

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“Enhanced Plant Performance via Effective SO 3 Control” Sterling Gray, URS Corporation

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  1. “Enhanced Plant Performance via Effective SO3 Control” Sterling Gray, URS Corporation Mick Harpenau, Duke Energy EUEC Conference Phoenix, AZ February 3, 2010

  2. SO3 Adversely Impacts … Equipment Corrosion Air Heater Reliability Mercury Capture NOx Removal Heat Rate CO2 Emissions

  3. Impact on Corrosion Potential

  4. Air Heater Fouling Ash Sulfuric Acid Ammonium Bisulfate Source: Alstom Airpreheater Company

  5. Impact on Heat Rate

  6. Impact on CO2 Emissions

  7. Impact on NOx Control • Increase SCR NOx Removal • limit ABS formation via SO3 reduction • permit operation at elevated NH3 slip • Extend Useful Life of Catalyst • elevated slip permits lower reactor potential • Extend Low-Load Operation of SCR • reduce SO3 level at SCR inlet • lower Min Op Temp (min load) • Strategy can be Applied to SNCR

  8. Impact on NOx Removal

  9. Impact of SO3 on ACI Performance Source: EPRI

  10. Impact on Hg Capture in Ash

  11. Impact on Hg Removal with ACI Source: EPRI, Mercury Research Center, March 2007

  12. Comparison of SO3 Controls

  13. Features Patented Technology Simple Solution Injection Sodium-Based Reagent Dual-Fluid Atomization Selective Reactions High SO3 Removal Low Injection Rate Product Collected with Ash Benefits Opacity Elimination Corrosion Reduction ESP Enhancement HCl and Se Removal Potential Heat Recovery SCR/SNCR Flexibility Hg Capture Enhancement CO2 Reduction SBS Injection™ Technology Maximum Benefits with “Upstream” Injection

  14. INJECTION AIR: PLANT AIR OR COMPRESSOR SBS DILUTION WATER FILTER (SOFTENED) DUPLEX STRAINER SOLIDS WETTING PUMP DILUTION WATER TANK DILUTION WATER PUMP FLUE GAS INJECTION LANCES DE FE FE HOPPER TRUCK INJECTION FEED PUMP REAGENT SOLUTION STORAGE TANK Simplified SBS Flow Diagram

  15. SBS Injection Locations SCR Inlet SCR Outlet Air Heater Outlet

  16. SBS Injection Installations 12,500 MW Installed on 20 Boilers

  17. Gibson “Pre-SCR” Injection Ammonia Injection Grid SCR First Catalyst Layer TurboMixers Economizer Outlet SBS Injection Lances (Par Mixers removed)

  18. Baseline SBS Injection Gibson SO3 Test Results

  19. SCR Min Op Temp vs SO3 Baseline – 615°F Composite Range of MOT Information Provided by Catalyst Suppliers Δ MOT ~ 80°F With SBS – 635°F

  20. Summary • SO3 Adversely Impacts Plant Performance • Corrosion • AH Fouling • Heat Rate • CO2 Emissions • NOx Removal • Mercury Capture • SO3 Removal can Generate Millions $ in Benefits • Avoided Forced Outages • Fuel Savings • Lower Environmental Compliance Costs • SBS Injection Offers Cost-Effective SO3 Control • Treats upstream of SCR / AH • Very high SO3 removal (~98%) • Proven - 20 units - 12,500 MW – 7 yrs SO3 Removal: It’s not just for “Blue Plume” anymore

  21. Questions?

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