SCR and HAPs Converters for Stationary Engines
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1 SCR and HAPs Converters for Stationary Engines MARAMA / ICAC Webinar November 9, 2012 Wilson Chu Johnson Matthey
2 Presentation Outline Catalysts for NOx, HC, CO and HAPs Catalytic Converter Designs HAPGuard Exhaust Monitor SCR Systems for NOx Orange County Sanitation District Digester Gas SCR and Oxidation System Case Study
3 Catalysts and Catalytic Converters
4 Catalysts 3-Way NSCR, 2-Way Oxidation, SCR Metallic or Ceramic Coated or Extruded Round, Rectangular or Square
5 Converter Designs Modulex C Modulex B D u a l O x
6 Catalytic Converter Features and Benefits Features Modular Design Benefits Low cost option Catalyst Hatch Easy access for element cleaning or replacement Construction Carbon Steel or Stainless Steel Silencing Low Back Pressure Design Critical Grade (25-30 dba) Hospital Grade (30-35 dba) 4 to 5 w.c. un-silenced 14 w.c. with silencer
7 DualOx Converters
8 DualOx Converter Silencer
9 HAPGuard Exhaust Monitor RICE NESHAP compliance Monitors the system and alerts the operator if the pressure drop across the catalyst is not within ± 2 w.c. at 100% load Monitors the temperature and alerts the operator if : Rich Burn: 750 F < T (catalyst inlet) < 1250 F Lean Burn: 450 F < T (catalyst inlet) < 1350 F Engine tested Battery backup LCD display Removable memory, 5 years data storage Suggested list price - $2,500
10 SCR Systems
11 SCR Selective Catalytic Reduction Controlled urea injection Capable of >90% NOx reduction Concerns: Urea decomposition and distribution Operating temperature
12 SCR System
13 SCR System Components Oxidation Catalyst or DPF, if required Mixing Duct Injection Lance/Nozzle Urea Injection System Temperature Probe SCR Housing SCR Catalyst Options - Burner(s), NOx Analyzer, Insulation, Differential Pressure Measurement, Pressure Blowers)
14 SCR Housing and Catalyst (Cutaway View)
15 Mixing Duct Urea Connection Compressed Air Connection Internal Static Mixer
16 Injection Lance and Static Mixer
17 Urea Injection Control System PLC-Based Control Touch Screen HMI Precise Injection Dosing Pump Urea or Aqueous Ammonia Remote Monitoring Data logging Options AC Option Heater Option Enclosure Options
18 SCR Applications
19 Natural Gas Drilling Rigs in WY Challenge: Freezing temperatures Dynamic load changes Portability
20 Hotel & Casino in CA Challenge: Reliability (off grid)
21 Staten Island Ferry (John Noble) Challenge: Small space 2 ppm max. NH 3 slip
22 University of Central Florida Challenge: Small space 3 ppm max. NOx Sound Attenuation
23 Orange County Sanitation District Digester Gas SCR and Oxidation System SCAQMD Rule Technology Demonstration (slides courtesy of OCSD, Lisa Rothbart)
24 Demonstration Engine 3471 Hp lean burn Cooper Bessemer V12 (1992) 2500 kw generator HRSG NOx and CO CEMS
25 Digester Gas Composition Min. Max. Avg. (%) (%) (%) CO CH N O
26 Sulfides in the Digester Gas Compound Carbon Bed Inlet Min. Max. Avg. (ppmv) (ppmv) (ppmv) Hydrogen Sulfide Carbonyl Sulfide Methyl Mercaptan Ethyl Mercaptan Dimethyl Sulfide Carbon Disulfide n-propyl Thiol iso-propyl Thiol Dimethyl Disulfide ND ND ND Isopropyl Mercaptan n-propyl Mercaptan
27 Siloxanes in Digester Gas Compound Carbon Bed Inlet Min. Max. Avg. (ppmv) (ppmv) (ppmv) Hexamethyldisiloxane (L2) <MDL <MDL <MDL Hexamethylcyclotrisiloxane (D3) Octamethyltrisiloxane (L3) Octamethylcyclotetrasiloxane (D4) Decamethyltetrasiloxane (L4) Decamethylcyclopentasiloxane (D5) Total Siloxanes
28 Pre-Engine Digester Gas Cleaning Single fixed bed of activated carbon by Applied Filter Technology 9900 lbs capacity
29 Catalytic Oxidizer/SCR System Urea Injection SCR Catalyst Catalytic Oxidizer
30 SCR Urea Injection Control Panel and Urea Tank
31 Emission Levels Achieved, ppmv Pollutant Engine Exhaust Stack Outlet Average NOx (best was 0.8) Average % Conversion 77% (best was 97%) Rule limit 11 CO % 250 VOC % 30
32 Contact Information Wilson Chu Cell
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