NOx: Troubleshooting and Optimization of Combined Cycle SCR Systems

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1 NOx: Troubleshooting and Optimization of Combined Cycle SCR Systems L. J. Muzio Fossil Energy Research Corp. Laguna Hills, CA CEMTek Environmental 216 Emissions Monitoring Seminar and Training September 28, 216 Santa Ana, CA

2 Optimizing Gas Turbine SCR Performance Topics Troubleshooting - How to Distinguish NH 3 Maldistribution from Bypass AIG Tuning - Catalyst Inlet NH 3 /NO x Distribution Identifying Flue Gas Bypass Catalyst Management/Measuring Catalyst Activity 2

3 Simple Cycle Gas Turbine SCR Ammonia Injection Grid (AIG) SCR Catalyst Perforated Plate Diffuser Vanes CO Catalyst SCR Performance Parameters: - NO x Reduction - Ammonia Slip Uniform NH 3 /NO x Profile at Catalyst Inlet is Critical! Tempering Air Flue gas 75- F NH 3 NH 3 Dilution Air 3

4 Combined Cycle Gas Turbine SCR No Diffuser Vanes No Perforated Plates No Tempering Air Ammonia Injection Grid (AIG) CO Catalyst SCR Catalyst SCR Performance Parameters: - NO x Reduction - Ammonia Slip Uniform NH 3 /NO x Profile at Catalyst Inlet is Critical! Steam Tube Banks Flue gas ~55-65 F NH 3 NH 3 Dilution Air 4

5 Direct Injection/Dual Function Catalyst Direct Injection of Ammonium Hydroxide 5

6 Troubleshooting Measurement Limit 8 NH 3 slip is too high Why? NH3 Slip, ppm NOx, ppm 6

7 Why? Catalyst Activity (K)? Poor NH3/NOx Distribution? How active the material is in reducing NOx f(material, geometry) 8 Measurement Limit Want NH 3 /NO x uniform across the catalyst Local NH 3 /NO x >1=NH 3 slip NH3 Slip, ppm NOx, ppm Reactor Potential? Ability of the catalyst bed to reduce NO x RP= K*A sp *V cat /Q fg Minimum Reactor Potential NH3 slip=2.5ppm NH3 slip=5 ppm NOx out=5 ppm Flue Gas Bypass? Any bypass by the catalyst increases stack NO x & NH Inlet NOx, ppm 7

8 A simple stack test can distinguish (NH 3 Maldistribution/Flue Gas Bypass) NH 3 /NO x RMS Effects Bypass Effects RMS=% RMS=2% RMS=3% ByPass=% ByPass=2.5% ByPass=5% ByPass=7.5% 4 4 NH3 Slip, ppm@15%o2 dry NH3 Slip, ppm@15%o2 dry NOx, ppm@15%o2 dry NOx, ppm@15%o2 dry 8

9 How to best generate this data? Wet Chemical NH 3 measurements? Continuous NH 3 measurements? 9

10 TDL Instrumentation Testing facilitated using a continuous TDL NH 3 analyzer Data set can be generated in less than a day Data available in real time Unisearch NH 3 TDL Dual Path Two Channel Fiber Optic Coupled

11 NH 3 -TDL Lines of Site NH3 TDL Optical Paths Gas Flow 11

12 TDL NH 3 Measurements on a Large Combined Cycle NH 3 /NO x RMS Effects Bypass Effects NH3 Slip, ppm@15%o2 dry RMS=% RMS=2% RMS=3% Test Data 5 15 NOx, ppm@15%o2 dry NH3 Slip, ppm@15%o2 dry Test Data ByPass=% ByPass=2.5% ByPass=5% ByPass=7.5% RMS=% 5 15 NOx, ppm@15%o2 dry 12

13 AIG Tuning What is it? Making sure that NO x and NH 3 are matched up at every location on the catalyst How is it Done? By making NO x measurements at the exit of the catalyst It is not necessary to measure both NO x and NH 3 13

14 Gas Turbine SCR AIG Tuning Tuning is Facilitated by Installing a Permanent Sample Grid at the Catalyst Exit: Not feasible to manually traverse a large combined cycle system for AIG tuning Typically need 36 to 6 probes depending on AIG design With Permanent Probes Tuning can Typically be done in One Day The NO x Profiles at the Exit of the Catalyst can also Help Identify Bypass 14

15 NH 3 /NO x Distribution and AIG Tuning RMS=5% RMS=% RMS=15% RMS=25% 8 New Catalyst NH3 Slip, ppm Catalyst Near End-of-Life NH3 Slip, ppm NOx Reduction, % 15

16 How Well is Your AIG Tuned? (As Found RMS Values) Most of the GT AIGs we encounter are not tuned very well! RMS (%)

17 How Important is the NH 3 /NO x Distribution? SCAQMD is pushing NO x from 5 to 2 ppm in So. Cal. Assumption is that just adding more catalyst will be the solution RMS=2% Add Catalyst Tune AIG To RMS=% K=8/RMS=2% RMS=2%, 5% More Cat K=8/RMS=% K=8/RMS=2% NH3 slip, dry NOx, ppm@15% O2 dry NH3 slip, dry NOx, ppm@15% O2 dry Just tuning the AIG allows 2 ppm NO x to be achieved Adding 5% more catalyst helps, but not as much as tuning 17

18 Outside View of a Permanent Sample Grid on a Large Combined Cycle Sample probe exit ports Sample probe lines brought down to grade 18

19 Sample Probes Attached to Catalyst Modules 19

20 FERCo s Multipoint Instrumentation Samples 48 points in minutes (4 groups of 12) NO x and O 2 2

21 AIG Design Affects Tuning No Adjustments: Some systems have no adjustment valves- Bad Idea!!! 1-D: Commonly used design Multi Zone: Better Two Horizontal Zones Horizontal and Vertical Lances Three Horizontal Zones 21

22 AIG With No Adjustability 22

23 AIG: No Adjustability Permanent Probe Grid for Tuning. Difficult to Tune Without! 23

24 Normalized NH 3 /NO x Profiles As Found Orig. AIG RMS = 35% NH 3 Header NH 3 Header North Wall (ft) Bottom of the Duct

25 Normalized NH 3 /NO x Profiles Before & After Orig. AIG RMS = 35% All Holes Resized RMS = 16% NH 3 Header North Wall (ft) NH 3 Header North Wall (ft) Bottom of the Duct 25 5 Bottom of the Duct

26 Duct Burners Impact AIG Tuning Duct Burners Off (Inlet NO x ppm) Duct Burners On (Inlet NO x ppm) AIG Difficult to Tune 2 15 NH

27 AIG Tuning, 1-D AIG Design; NH 3 /NO x As Found, RMS = 22% Tuned, RMS = 13% y Catalyst Inlet North Wall (ft) North Wall (ft) Adjustments across the width not possible

28 AIG Tuning, 1-D AIG Design; Outlet NO x As Found Tuned West Wall (ft) Reagent consumption reduced 5% NH 3 West Wall (ft)

29 AIG Tuning, 2-D AIG Design; Outlet NO x AIG Design:2-Zones Horizontally 29

30 AIG Tuning, Multi Zone AIG Design; NH 3 /NO x As Found, RMS = 19% Tuned, RMS = 5% 3

31 Direct Injection of Aqueous Turbine exhaust As Found, RMS = 14% Tuned, RMS = 3% 31

32 Benefits of AIG Tuning Reduce NH 3 slip at required outlet NO x Reduced Reagent Consumption GT Load As Found Tuned Reagent Reduction MW lb/hr lb/hr % Reduced Required GT Water Injection GT Water Inj Inlet NO x NH 3 Slip GPM ppm ppm

33 Coal SCR: AIG Design Influences Tuning Cross Grids Multi-Zones Flow Flow Into Page Mixer with 1-D Adj. Mixer with Multi Zone Grid Delta Wings mixer mixer mixer mixer Flow Flow Flow

34 Coal:AIG Design Effects 8 RMS NH3/NOx, % Delta Wing Static Mixer A Static Mixer B Multi Zone Cross Grids AIG Design

35 Bypass 35

36 NO x Profiles Can Also Help Detect Bypass 7 Base Year Possible Bypass 7 Two Years later

37 NO x Profiles Can Also Help Detect Bypass Possible Bypass

38 Catalyst Management 38

39 Catalyst Management Tracking catalyst activity and NH 3 /NO x distribution Ensure continued environmental compliance Plan for catalyst replacements 39

40 Measuring Catalyst Activity There are Laboratory Protocols for testing SCR catalyst Coal Natural Gas (Gas Turbine Systems) 4

41 Measuring Catalyst Activity: Coal VGB Guidelines EPRI Protocol 41

42 Measuring Catalyst Activity: GT SCR/CO Until recently there were no standard testing guidelines for GT SCR or CO catalyst. This led to variations among laboratories. Last year EPRI issued a guideline for testing GT SCR & CO Catalyst Available at the EPRI Website (Report 32642) 42

43 Catalyst Management Tracking catalyst activity and NH 3 /NO x distribution Insure continued environmental compliance Plan for catalyst replacements NH3 slip NH3 slip Limit End of Life Amonia Slip RMS=25% K/K Activity History NH3 Slip, ppm RMS=25% 123,864 RMS=% 134, K/Ko , 4, 6, 8,, 12, 14, 16, Operating Hours 43

44 Measure RP Insitu While sending samples to a lab for activity measurements historically has been a key step in catalyst management, it is no longer necessary. Today an owner operator can take control of catalyst management with the CatalysTraK, a system that measures catalyst activity and RP in-situ. Insitu tests are performed at actual full scale operating conditions Tests can be conducted at any time, no outage required Performed during an annual compliance test At any time there may be an issue with catalyst performance Applicable to both NO x and CO catalyst 44

45 In Situ Catalyst Activity Measurement* Traditional Lab Measuremett Typically one per year K Lab = -A Vdesign ln(1- NO x ) FERCo s CatalysTrak * in situ measurement No outage required K In-situ = -A Vactual ln(1- NO x ) full locally * Patented Process 45

46 In Situ CatalysTrak TM Measurements: Individual Layers CatalysTraK was originally developed for coal-fired SCR s. These systems are characterized by multiple catalyst layers. Relative Reactor Potential (RP/RPo) Layer 1 Layer 2 Layer First 4-years of operation beginning in 25 7 MW unit E. bituminous coal SCR on-line May 22 Seasonal operation Two reactors configuration Initial load: 3 layers honeycomb catalyst Layer 1 replaced with plate catalyst prior to 26 ozone season Operating Hours 46

47 Volume of Data: Laboratory vs. In Situ Annual Laboratory Analysis On-Demand CatalysTrak TM Measurements Laboratory Relative Activity (K/Ko) Layer 2 Layer 3 Relative Reactor Potential (RP/RPo) Layer 2 Layer Operating Hours Operating Hours 47

48 CatalysTraK Supplemental Injection Grid Supplemental injection grids located upstream of both CO and NO x Catalysts. 48

49 CatalysTraK Reactor Potential Results CatalysTraK tests run over two years show the RP is well above the minimum level required Average Reactor Potential Year 1 Year 2 49

50 CO Catalyst Testing As with SCR catalyst, CO catalyst performance also degrades over time. Laboratory CO tests involves just measuring the amount of CO oxidation that occurs across the sample, while simulating full-scale temperature and space velocity. Why not just measure the oxidation across the actual CO catalyst bed while it is operating? 5

51 CatalysTraK CO Catalyst Test Results The tests run over two years show CO oxidation rates of between 96% and 98%. 9 Average % CO Oxidation Year 1 Year 2 51

52 Summary Simple stack measurements (NH 3 vs NO x ) can distinguish Gas Bypass from NH 3 /NO x maldistribution Facilitated by using a continuous TDL analyzer to make the NH 3 measurements AIG tuning facilitated using a permanent probe grid at the catalyst exit With a probe grid and multipoint sampling, AIG tuning completed in one day AIG Design affects how well a unit can be tuned NO x profiles at the SCR outlet can also help diagnose areas of Gas Bypass 52

53 Summary (Continued) Historically, lab tests have been used to monitor the performance of both SCR and CO catalysts over time. EPRI recently released GT SCR/CO testing guidelines (Report 32642) Recent tests showed both SCR and CO catalysts can easily be characterized in-situ. The in-situ technique is simple. It can be done easily during the annual compliance test, does not require an outage, and provides an opportunity to obtain a more comprehensive data set. 53

54 Questions? 54

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