A&WMA, CA SCAQMD, Diamond Bar, CA. Challenges for Meeting New Lower Air Emissions
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1 A&WMA, CA SCAQMD, Diamond Bar, CA. Challenges for Meeting New Lower Air Emissions September 21, 2017 Wayne Jones, Business Development Manager
2 AGENDA New Products Dual functions SCR/CO/VOC catalyst Low Temperature SCR catalyst Challenges to meet lower NOx and ammonia slip limits Ammonia to NOx uniformity (KEY) Flue Gas Bypass Stack measurement (CEMS) Future compliance during initial engine/unit start-up 2
3 New Products CATALYST Proven: o Dual Function SCR Catalyst o Over 60 references o Purchased in 2016 by major OEM for new construction HRSG o Over 22,000 hours of operations on (2) MHI 501G HRSG s o Supports liquid reagent injection (ammonia or urea solutions) In Development: o Improved Low Temperature SCR Catalyst o 2+ times higher activity between 300F & 450F o Primary application is small boilers and heaters 3
4 Performance Advantages of Dual Function Catalyst in a HRSG Optimized Dual Function Arrangement Dual Function Catalyst Lowest specific system pressure drop Lowest SO2 oxidation Lowest NO oxidation Easiest installation Air Gas GTC-802 Lower NH3 slip Compressor Turbine Can utilize frameless module design SCR & CO catalyst C Liquid ammonia injection 4
5 Reference List Dual Function Catalyst: USA Total 63 Dual Function References (NOx, CO, VOC) No. of Units Location User Type Year Installed Catalyst Type Status 1 USA Diesel Engine 2011 DNX-929 / DNO-1929 Running 4 ECUADOR HRSG (Siemens STG - 100) 2012 DNX-929/ DNO-1929 Running 1 USA Ethanol 2012 DNX-929/ DNO-1929 Running 1 USA HRSG (GE LM ) 2014 GT-201 /GTC-802 Running 2 USA HRSG (Taurus 70) 2014 GT-301 / GTC-803 Running 7 USA Large NG Engine 2015 DNX-929/ DNO-1929 Running 3 USA Large NG Engine 2015 DNX-929/ DNO-1929 Running 2 USA Large NG Engine 2015 DNX-929/ DNO-1929 Running 3 USA Large NG Engine 2015 DNX-929/ DNO-1929 Running 2 USA HRSG (MHPS M501G) 2015 GTC-802 Running 1 USA Boiler 2016 DNX-929 / DNO Running 2 USA Auxiliary Boilers 2016 DNX-929 / DNO Running 1 USA Refinery FCC Unit (High Dust) 2016 DNX-FCC / DNO-1664 Running 1 USA Cement Plant (After Baghouse) 2016 DNX-939 / DNO 1939 Running 1 USA Carbon Black - Thermal Oxidizer 2016 DNX-929 / DNO Running 1 USA Auxiliary Boiler 2016 DNO-1929 Running 2 USA HRSG (MHPS M501GAC) 2018 (Expected) GT-201 / GTC-802 On Order 1 USA Auxiliary Boiler 2018 (Expected) DNX-929 / DNO On Order 2 USA Refinery Heater 2018 (Expected) DNX-939 / DNO 1639 On Order 3 USA Large NG Engine 2017 DNX-929/ DNO-1929 Running 1 USA Chemical Plant Boiler 2018 (Expected) DNX-929/ DNO-1929 On Order 1 USA Steam Methane Reformer 2018 (Expected) DNX-929/ DNO-1929 On Order 5
6 Operating Performance SOR until May 2017 DeNOx 662F / 350C & 0 ppm CO Testing Performed on Bench Scale Reactor Exelon, Wolf Hollow Units 1&2 Sample Tested Hours Sample Length Gas velocity Nm/s NH3/NOx ratio K NOx Nm/hr SOR, Oct mm April , mm March , mm May , mm
7 Operating Performance SOR until May 2017 CO Oxidation Performance, with 70 ppm ammonia injection Testing Performed on Bench Scale Reactor Exelon, Wolf Hollow Units 1&2 Sample Tested Hours Sample Length Gas Temperature F / C Gas velocity Nm/s NH3/NOx ratio CO Oxidation % SOR, Oct mm 700 / April , mm 700 / March , mm 700 / May , mm 700 /
8 Response Comparison GT vs GTC Catalyst 250 mm catalyst length, NH 3 /NO x = 1.0 8
9 Challenges to meet lower NOx and slip limits Ammonia to NOx uniformity üaig design & tunability (1, 2 or 3 zones; mult. zone) üsupplemental firing / duct burners may require (2) AIG s üpermanent sample / test grid üliquid reagent injection (ammonia or urea) Compliance through start-up Flue gas bypass * Stack measurement mult. point (CEMS) * 9
10 Relationship of NH3 to NOx Uniformity and NH3 Slip Minimum NH 3 injection temp ~350 F/ 177 C Ammonia / NOx Mal-distribution Reagent Grade needed 16 Ammonia slip given for end of guarantee period 14 Ammonia slip will typically gradually increase over time due to loss of catalytic activity (except in high temp applications) NH3-slip, ppm % RMS 5% RMS 7% RMS 9% RMS 11% RMS 15% RMS Ammonia to NOx maldistribution is critical in high reduction low slip systems DeNOx, % 10
11 Achieving 2.0 ppm NOx and 2.0 ppm NH3 slip 7 RMS=5% RMS=7.5% RMS=10% RMS=15% 6 5 NH3 Slip, ppmc NOx, ppmc 11
12 Impact of Catalyst Volume on NH3 Slip Based on 90% DeNOx design (20ppm-2ppm) & 5 ppm slip 10 RMS=5% RMS=10% RMS=15% RMS=20% NH3 Slip@ 2ppm NOx Relative Catalyst Volume 12
13 AIG Design and Tunability AIG Must Have Adjustment Valves Single Zone - Common Double - Zone Multiple Zone 3 Zone Vert. Adjustment 13
14 Permanent Sample/Test Grid Sample lines run to ground level and labeled 14
15 Liquid Reagent Injection - HRSG Direct Injection of Aqueous Ammonia or a Urea Solution 15
16 Liquid Ammonia Injection - HRSG GE Frame 9FA Engine 16
17 Start-up Compliance Not only NOx reduction but also control of ammonia slip. Difficult due to system dynamics during startup. Guaranteed compliance in 10 minute window with unlimited start ups and shutdown over 5 year period 0-2 min. (Ambient to 629 F / 332 C) 10 min. (Max temp 787 F / 420 C) Includes: NOx spikes which require 96.77% NOx reduction (Full load 92%) CO spikes which require 98.53% oxidation (Full load 96.7%) NH3 Slip of < 5 O 2 17
18 Response Comparison GT vs GTC Catalyst 250 mm catalyst length, NH 3 /NO x =
19 THANKS QUESTIONS? 19
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