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Session 3A_Dr. Enrique Bosch_INERCO Energy Technologies.pdf
- 1. Paper #42: Advanced DeNOx Technologies for the Technologies for the Minimization of Capital and Operating Costs in Combustion Facilities Speaker: Dr. Enrique Bosch Co-Authors: Dr. Francisco Rodriguez, Enrique Tova, Miguel Delgado, Miguel Morales Power-Gen India & Central Asia 2017
- 2. • Indian Environmental Regulation • Combustion Optimization System • Flexible Combustion • Flexible Combustion • Advanced SNCR • Economic Assessment
- 3. • Indian Environmental Regulation • Combustion Optimization System • Flexible Combustion • Flexible Combustion • Advanced SNCR • Economic Assessment
- 4. Pollutant TPP before Dec 31, 2003 TPP after Jan 1, 2004 before Dec 31, 2016 TPP after Jan 1, 2017 Particulate Indian Environment Protection Amendment • New emission standards: PM, SO2, NOX and Hg based on year of commissioning Particulate matter (PM) 100 mg/Nm3 50 mg/Nm3 30 mg/Nm3 SO2 600 mg/Nm3 units < 500 MW, 200 mg/Nm3 units ≥ 500 MW 100 mg/Nm3 NOX 600 mg/Nm3 300 mg/Nm3 100 mg/Nm3 Mercury 0.03 mg/Nm3 units ≥ 500 MW 0.03 mg/Nm3 0.03 mg/Nm3
- 5. Indian Environment Protection Amendment • New emission standards: PM, SO2, NOX and Hg based on year of commissioning Pollutant TPP before Dec 31, 2003 TPP after Jan 1, 2004 before Dec 31, 2016 TPP after Jan 1, 2017 Technologies available • Primary measures: Low NOX burners, OFAs, combustion optimization systems • Secondary measures: Selective Non-Catalytic Reduction (SNCR), Selective Catalytic Reduction (SCR) NOX 600 mg/Nm3 300 mg/Nm3 100 mg/Nm3
- 6. • Indian Environmental Regulation • Combustion Optimization System • Flexible Combustion • Flexible Combustion • Advanced SNCR • Economic Assessment
- 7. • Location: Alberta, Canada • 405 MW gross load (385 MWn) • Sub-bituminous coal • ABACO Combustion Optimization System Case Study • Twin furnace design • 5 mills. MCR achieved with 4 mills • 8 corners – 5 burner elevations + CCOFA • Baseload unit (until 2015) • NOX baseline: 550 to 850 mg/Nm3 CCOFA Level A Level B Level C Level D Level E
- 8. improvement BAT for NOx reduction and efficiency improvement Monitoring System Combustion Optimization System Remote supervision
- 9. • Characterization of local combustion conditions next to boiler walls, in the flame envelope of each burner or selected areas • Direct measurement of actual in-furnace gas concentrations (O2, CO, NOX, CO2) • No averaged values. No interpolation software • Not affected by fuel type, dirtiness or optical-path alignment ABACO Combustion Optimization System Fixed non-cooled probes Retractable water-cooled probes
- 10. Minimum modifications in the combustion system Operating variables for ABACO setup Item Operating variable Range I Mills in service Mills A to E II Auxiliary Air AA, EE and OFA 0 - 100% III Auxiliary Air AB, BC, CD, DE ± 20% IV Fuel air ± 20% ABACO Combustion Optimization System IV Fuel air ± 20% V Excess O2 ±1,0% (absolute scale) VI Fuel nozzle tilts ±30º
- 11. ABACO Combustion Optimization System • INERCO supervises the performance of the ABACO to guarantee the achievement of the NOX reduction and efficiency objectives in all the operating scenarios • Daily and monthly reports with critical information about the unit are provided to our clients 20%-30% NOX reduction – all scenarios – all scenarios Efficiency improvement 0.6% 15,000 tons/yr CO2 avoided
- 12. • Indian Environmental Regulation • Combustion Optimization System • Flexible Combustion • Flexible Combustion • Advanced SNCR • Economic Assessment
- 13. Retrofit of coal pipe layout to: • Reduce NOX emissions • Improve boiler efficiency, flexibility and maintenance Conventional situation Temperatures Residence time Flexible Combustion BOOS MOOS NOX LOI Efficiency
- 14. Residence Retrofit of coal pipe layout to: • Reduce NOX emissions • Improve boiler efficiency, flexibility and maintenance Flexible Combustion NOX LOI Efficiency Residence Time MOOS
- 15. OFA Capability Retrofit of coal pipe layout to: • Reduce NOX emissions • Improve boiler efficiency, flexibility and maintenance Flexible Combustion NOX LOI Efficiency Residence Time OFA Capability BOOS
- 16. Case Study: 580 MWe / T-fired 5 6 41% NOx reduction 35%-45% NOX reduction 400 mg/Nm3 Efficiency improvement 0.6% Flexible Combustion 10% 15% 20% 25% 30% 1 2 3 4 Coalflow rate per boiler level (%) Boiler level Baseline FLEXICOM
- 17. • Indian Environmental Regulation • Combustion Optimization System • Flexible Combustion • Flexible Combustion • Advanced SNCR • Economic Assessment
- 18. Individual injection in each point based on: • Temperature profile • Flue gas composition (CO, O2, NOX) through in-furnace monitoring Injection profile LEVEL 5 ½ T~1,600 ºF Efficiency Ammonia slip 0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 0,24 0,26 0,28 0,30 0,32 0,34 0,36 0,38 0,40 0,42 0,44 Reagent flow (l/min) Local NO x (lb/MMBTU) Distribution profiles along the boiler Local NOx profile Reagent supply profile LEVEL 5 ½ T~1,600 ºF LEVEL 5 T~1,750 ºF
- 19. Case study – 350 MW opposed wall fired – 5 mills
- 20. 400 500 600 700 800 (mg/Nm 3 ) NOX reduction 57% 0 100 200 300 NO X (mg/Nm 57% NOX reduction 72% Ammonia slip ~ 5 ppmv Baseline
- 21. • Indian Environmental Regulation • Combustion Optimization System • Flexible Combustion • Flexible Combustion • Advanced SNCR • Economic Assessment
- 22. Scenario Technologies Relative Capital Cost (LNB =1) NOX reduction I. Limit 600 mg/Nm3 Combustion optimization system and/or minor furnace modifications .25 25% Low NOX burners (LNB) 1 40% Economic Assessment II. Limit 300 mg/Nm3 Combustion optimization systems and Low NOX burners 1-1.5 60% Low NOX burners and SNCR 2-3 70% SCR 7-10 70% III. Limit 100 mg/Nm3 SCR 10 85% Baseline Indian plants 700-900 mg/Nm3 Operating costs of SCR can be reduced +50% with the proper approach
- 23. Thanks! Dr. Enrique Bosch ebosch@inerco.com +1 716 548 8151 Power-Gen India Central Asia 2017