jeremy harris simultaneous reduction of pm, nox, hc & co from large stationary diesel engines...
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Jeremy Harris
Simultaneous Reduction of
PM, NOx, HC & CO
From Large Stationary Diesel Engines
March 21, 2006
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OUTLINE
• Overview/Introduction
• Particulate, HC and CO Reduction - CRT® Particulate Filter System
• NOx Reduction
• SCR Catalyst System
• Urea Injection System
• Operating Data
• Conclusions
• Acknowledgements
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SNOW SUMMIT MOUNTAIN RESORT
Courtesy of Snow Summit Mountain Resort
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INTRODUCTION
• Snow Summit Mountain Resort is an isolated site• Two Cummins 2700DQLA generators powered by Cummins
QSK78-G6 diesel engines• South Coast Air Quality Management District (SCAQMD)
requires BACT for these engines• Johnson Matthey elected to use a combination of SCR and
patented CRT® (Continuously Regenerating Technology) particulate filter system
• This combined system is marketed by Johnson Matthey as an SCRT® system
• Systems commissioned late 2003
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ENGINE BASELINE & SCAQMD EMISSION LIMITS
Emission Baseline Levels Regulation Levels
% Reduction Required
Nitrogen Oxides (NOx) 8.75 g/bhp-hr 0.60 g/bhp-hr 93.2%
Carbon Monoxide (CO) 0.72 g/bhp-hr 0.60 g/bhp-hr 16.7%
Hydrocarbon (HC) 0.20 g/bhp-hr 0.15 g/bhp-hr 25%
Particulate Matter (PM) 0.30 g/bhp-hr 0.045 g/bhp-hr 85%
The maximum ammonia slip is 10 ppmvd @ 15% O2
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SCHEMATIC OF EMISSION CONTROL SYSTEM
CRT® Filter System
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OUTLINE
• Overview/Introduction
• Particulate, HC and CO Reduction - CRT®
Particulate Filter System• NOx Reduction
• SCR Catalyst System
• Urea Injection System
• Operating Data
• Conclusions
• Acknowledgements
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GENERAL DESCRIPTION OF CRT®
• Johnson Matthey’s CRT® system is a passive regenerating filter technology
• Upstream platinum based oxidation catalyst oxidizes CO and HC, as well as NO to NO2
• Downstream particulate filter (either cordierite or silicon carbide) traps particulate which is oxidized to CO2 by NO2
• CO + ½ O2 CO2
• HC + O2 CO2 + H2O
• NO + ½ O2 NO2
• C + 2NO2 CO2 + 2NO
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CRT® BASICS
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Particulate Filters Operation Requirements
• Ultra-low Sulfur Diesel <15PPM Sulfur
• NOx to PM Ratio > 15-20
• Low Ash Engine Lubricating Oils
• Minimum Regenerating Temperature > 465 F.
• Data Logger to Monitor Temperature/Backpressure Conditions
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CRTdm Diagnostic Module and Remote Display Module
• Extended data logging capability
• Stores up to 24 hours of data
• Continuously logs exhaust temperature & backpressure
• High speed RS-232 communications
• Maintenance alerts
• Programmable alarm settings
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ENGINES AND PARTICULATE FILTER UNITS
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OUTLINE
• Overview/Introduction
• Particulate, HC and CO Reduction - CRT® Particulate Filter System
• NOx Reduction
• SCR Catalyst System
• Urea Injection System
• Operating Data
• Conclusions
• Acknowledgements
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SCR CHEMISTRY
• Urea Decomposition: • (NH2)2CO + H2O 2NH3 + CO2
• Catalytic Reduction of NOx:
• NH3+ NOx + O2 N2+ H2O
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SNOW SUMMIT SCR UNIT
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OUTLINE
• Overview/Introduction
• Particulate, HC and CO Reduction - CRT® Particulate Filter System
• NOx Reduction• SCR Catalyst System
• Urea Injection System
• Operating Data
• Conclusions
• Acknowledgements
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INJECTION SYSTEM PRINCIPLES
• Two fluid injection of air & urea solution ensures excellent
atomization & distribution
• Single control unit module contains all necessary hardware &
electronics for stand alone hands free automatic operation
• Built in redundancy for critical components
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INJECTION SYSTEM CONTROL MODULE
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INJECTION SYSTEM CONTROL MODULE
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INJECTION SYSTEM CONTROL MODULE INTERNALS
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INJECTION SYSTEM CONTROL MODULE ELECTRONICS
• PC based ladder logic controllers
• Multiple touch screens are very user friendly and enable all
operational parameters to be readily input by user.
• No need for external laptop for setup etc., all self contained
• Screens give visual reference to all parameters
• Modbus communications for remote monitoring
• CRTdm data logger fitted to monitor back pressure and
temperature
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EXAMPLE OF INJECTION SYSTEM TOUCH SCREENS
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INJECTION LANCE
• Two fluid pipe in pipe arrangement - urea in center pipe
• Air utilized for cooling and atomization
• Urea and air mix in the injection nozzle
• Small urea droplet size facilitates the SCR reaction
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OUTLINE
• Overview/Introduction
• Particulate, HC and CO Reduction - CRT® Particulate Filter System
• NOx Reduction
• SCR Catalyst System
• Urea Injection System
• Operating Data• Conclusions
• Acknowledgements
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SOURCE TEST DATA ENGINE #1
Pollutant SCAQMD
Emissions limit @15% O2
Actual Emissions
Target Reduction
Achieved Reduction
PM10 0.045 g/bhp-hr <0.005 g/bhp-hr 85% >90%
NOx 50 ppm 35 ppm 93.2% >94%
CO 89 ppm 24 ppm 17% >90%
VOC 0.15 g/bhp-hr 0.05 g/bhp-hr 25% >75%
NH3 10 ppm 0.01 ppm Surpassed
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SOURCE TEST DATA ENGINE #2
Pollutant SCAQMD
Emissions limit @15% O2
Actual Emissions
Target Reduction
Achieved Reduction
PM10 0.045 g/bhp-hr <0.005 g/bhp-hr 85% >90%
NOx 50 ppm 44 ppm 93.2% >94%
CO 89 ppm 4 ppm 17% >90%
VOC 0.15 g/bhp-hr 0.02 g/bhp-hr 25% >75%
NH3 10 ppm 0.00 ppm Surpassed
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OUTLINE
• Overview/Introduction
• Particulate, HC and CO Reduction - CRT® Particulate Filter System
• NOx Reduction
• SCR Catalyst System
• Urea Injection System
• Operating Data
• Conclusions• Acknowledgements
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CONCLUSIONS
• First site to require multiple CRT® catalyst and filters housed in a single unit
• First site where PM control is used in conjunction with SCR on a stationary diesel engine application
• After almost 2 years of successful operation, the SCRT® System demonstrates that it is readily possible to simultaneously remove HC, CO, NOx and PM with minimal ammonia slip from a large stationary diesel engine exhaust
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ACKNOWLEDGEMENTS
The authors would like to thank the following for permission topublish this work:
• Snow Summit Mountain Resort
• Cummins Cal Pacific
• Johnson Matthey, Stationary Source Emission Control
For More Information Contact:Jeremy Harris 610-971-3110 [email protected]