zeeco power hour · 2020. 9. 28. · • ammonia (nh 3) injection grid (aig) • scr catalyst •...
TRANSCRIPT
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Bob Langstine
Regional Sales Manager, Eastern US & Canada
Zeeco, Inc.
Zeeco Power Hour
Overview of Emissions Reduction Challenges & Techniques
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First, a Safety Moment Equation
Be sure to shift your weight to match the activities, even in your personal activities.
+ =
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Emissions Toolbox (Agenda)
Burner solutions
Flue Gas Recirculation (FGR)
Inert injection
Overfire Air/Staging (OFA)
Managing Combustion Air temperature vs unit efficiency
Selective Non-Catalytic Reduction (SNCR)
Selective Catalytic Reduction (SCR) (also CO Catalyst)
Electrostatic Precipitator (ESP)
Fabric Filters (Baghouse)
Scrubbers
Summary
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Emission Limitations
NOx▪ O2, Excess Air
▪ Combustion Temperature
▪ Reaction with Nitrogen
▪ Lowering CO
CO▪ O2, Excess Air
▪ Combustion Efficiency
▪ Low NOx and FGR
▪ Combustion Temperature
▪ Air in-leakage
VOC▪ Combustion Efficiency
▪ Combustion Temperature
What factors determine achievable emissions?
▪ SOx▪ Fuel Dependent (Sulfur Content)
▪ Particulates▪ Fuel
▪ Combustion efficiency
▪ Fuel availability
▪ Technology Choices
▪ Cost
▪ Politics
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Emissions – NOx
Fuel NOx Fuel Bound Nitrogen (FBN)
• Highly dependent on the concentration of fuel bound nitrogen
• Virtually all becomes NOx
Prompt NOx• Formed in the very early portion of the flame zone where air and fuel
first mix or react. The reaction occurs in a part of the flame where little, if any, Thermal NOx is formed.
Nothing can be done to prevent either of these, except changing fuel.
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Emissions – NOx
Thermal NOx• For most gaseous fuels, the major concern is Thermal NOx.
• Thermal NOx formation rates are highly sensitive to peak flame temperatures.
• Thermal NOx begins to form at 2800°F (1538°C)
• Above 3200°F (1760°C), the NOx formation rate doubles for every 190°F (88°C) increase in flame temperature.
Thermal NOx is the prime target of Low NOx burners
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• Burners
• Flares
• Incinerators
• Combustion Systems
TO CONVERT To:
Multiply by
From NOx SOx CO lb/MMBtu g/GJ
mg/Nm3
ppm ppm ppm COALa OILb GASc COALa OILb GASc
mg/Nm3
1 0.487 0.350 0.800 6.65E-04 6.25E-04 5.92E-04 0.286 0.269 0.255
NOx ppm 2.053 1 1.36E-03 1.28E-03 1.21E-03 0.587 0.552 0.523
SOx ppm 2.858 1 1.90E-03 1.78E-03 1.69E-03 0.818 0.768 0.728
CO ppm 1.250 1 8.30E-04 7.80E-04 7.39E-04 0.358 0.336 0.318
COALa 1503 734 527 1205 1 429.95
lb/MMBtu OILb 1600 781 561 1283 1 429.95
GASc 1689 824 592 1353 1 429.95
COALa 3.495 1.702 1.223 2.797 2.33E-03 1
g/GJ OILb 3.721 1.813 1.302 2.978 2.33E-03 1
GASc 3.928 1.913 1.374 3.143 2.33E-03 1
Notes:
a: COAL: Flue Gas dry 3% excess O2; Assumes 263 dsm3/GJ - 9780 dscf/MMBtu - Reference EPA 40CFR pt. 60, App. A, Meth. 19
b: OIL: Flue Gas dry 3% excess O2; Assumes 247 dsm3/GJ - 9190 dscf/MMBtu - Reference EPA 40CFR pt. 60, App. A, Meth. 19
c: GAS: Flue Gas dry 3% excess O2; Assumes 234 dsm3/GJ - 8710 dscf/MMBtu - Reference EPA 40CFR pt. 60, App. A, Meth. 19
STANDARD CONDITIONS (IMPERIAL); 68oF, 1 atm.
NORMAL CONDITIONS (SI); 32oF, 1 atm.
COMMON EMISSION
CONVERSION CHART
Emission Conversion Chart
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Burner Zone Heat Release - BZHR
What do we mean by Burner Zone
Heat Release (BZHR)?
Available heating surface area
compared to the heat input.
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NOx Correlation – The ‘Battle’ of Parameters
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Proper Combustion Air Flow
95% OF MASS FLOW IN THE COMBUSTION PROCESS IS AIR, NOT FUEL
THREE FUNDEMENTAL ASSUMPTIONS OF BURNER DESIGN
1. Balanced airflow to all burners +/-2%
2. Even peripheral distribution around each
burner entrance +/-15%
3. No swirl entering the burner, other than
what’s imparted by the burner itself
Getting this right pays dividends for the life of the system.
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Airflow Imbalance = Flame Imbalance = Emissions
BURNER #1 - PERIPHERAL VELOCITY DISTRIBUTION
0
1000
2000
3000
4000
5000
6000
7000
8000
12:00
1:30
3:00
4:30
6:00
7:30
9:00
10:30
Before Correction
After Correction
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Physical Flow and CFD Modeling
▪ Burner-to-burner balance for multi-burner
installations
▪ Lowers excess air requirements
▪ Used on all burners* / OFA / FGR systems
▪ Required for all fuels and unit types
▪ Lowers CO2 footprint
▪ Minimizes startup and commissioning times
▪ Can Eliminate Combustion Vibration
* Except burners with E-style Windboxes
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Dual Register Burner
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• A portion of the exhaust gas is directed back to dilute the air/fuel stream of the burner in order to:• Absorb some of the heat of combustion
• Reduce adiabatic flame temperature, and thereby reducing Thermal NOx
• FGR is most often expressed as a percent and refers to the mass percent of the flue gas exiting the stack that is being directed back to the burner
Flue Gas Recirculation
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Flue Gas Recirculation (FGR) - Lower Thermal NOx
Applied to Field-erected and Package boilers alike
Forced FGR Fan and Duct requirements▪ Higher capital and maintenance▪ Added controls▪ Less efficient system
External FGR will impact balance of heat transfer ▪ Lower radiant furnace heat transfer and higher convective heat transfer▪ Lower FEGT out of furnace ▪ More mass flow through convective bank▪ When adding more than 10% FGR, a boiler impact study should be
performed
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Flue Gas Recirculation Rates
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Flue Gas Recirculation Systems
• Induced Flue Gas Recirculation – IFGR• Uses the FD Fan Inlet to draw flue gas from the boiler outlet • Fan sizing could be influenced• System design and flow control can be difficult• Great mixing of inert flue gas with combustion air
• Forced Flue Gas Recirculation – FGR• Includes a dedicated FGR Fan to push flue gas into the burner• FGR Fan increases capital cost• There’s a Lifetime O&M Cost too
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Induced FGR System
Flue Gas Recirculating to FD Fan
FD Fan with FGR Mixing Box
FGR-CombustionAir Mixture
15%-85% Typical
FGR Manual Damper
Flue Gas Outlet
Comb Air Inlet
Boiler Gas Out
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Forced FGR System
Flue Gas Recirculating Fan
FD Fan
FGR Sparger Pipes (4)
Windbox
Boiler Outlet
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Low NOx Burner
Low NOx Design:
▪ 50-80ppm w/no FGR
▪ 30ppm with 15% FGR
▪ 100ppm CO
Staged Gas within throat for NOx Reduction
Steam Injection for NOx ‘polishing’
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Axial Flow Register
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Dual Register Burner
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Burner Stabilization
• Swirling air produces a vortex at the burner outlet which induces hot furnace gases to flow back towards the burner
• This is referred to as the Internal Recirculation Zone (IRZ)
• The IRZ creates burner stability
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Airflow Dynamics
• Burner Swirl Number (Sn) represents the ratio of tangential momentum to axial momentum
• Sn = Tangential Momentum• Axial Momentum
• A ratio of 0.6 is required to form an IRZ
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GB Low NOx Burner Technology
Capacity: 15 – 430+ MMBtu/hr (single burner)
Emissions:
▪ NOx:
▪ CO: 100 ppm
Excess Air: 10%
RDL: 5-12 in. w.c.
Turndown:
▪ 10:1 gas; 8:1 oil (operation)
▪ 4:1 (emissions)
No FGR 15% FGR
Nat. Gas 50 25
#2 Oil 80 50
#6 Oil 250 125
PPM
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Firing example – ~100% load
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Fuel Oil firing
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• Avoid unnecessary airflow disruptions
Airflow Dynamics
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Defining Ultra-low NOxFrom a combustion point of view
ULTRA-LOW NOx = CONTROLLED INSTABILITY
A very important point to be aware of and take into consideration. The significance of significant digits
▪ EPA MACT Requirement is 0.01 lb./MMBtu
▪ 0.01 does not necessary equal 0.010
▪ 9 ppm equals 0.011 (9 ppm NOx = 23.22 mg/Nm3)
▪ 0.010 equals 8 ppm
▪ 0.01 technically equals anything up to 0.0149 (12 ppm) (12 ppm or 24mg/Nm3)
▪DON’T PAINT YOURSELF INTO A BOX WHEN APPLYING FOR PERMITS!
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Ultra-low NOx Burner
• Center Fired Gas (CFG) for Stability
• Staged outer gas for NOx Reduction
• Stages fuel and air, and local combustion
gases to dilute fuel
• Fuel gas is mixed with inert products of
combustion before combustion occurs, thus
“reconditioning the fuel gas”
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Ultra-low NOx Burner Technology
Applicable to virtually any boiler type, industrial and power applications
Lowest NOx / 10-15% Excess Air
▪ 9 ppm NOx with 12-18% external FGR
▪ 30 ppm NOx with no external FGR
▪ 50 to 100 ppm CO
▪ Up to 360 MMBtu/hr in a single burner
Can use Internal and External FGR
Multi-fuel Capability
Turndown: 4 to1 on emissions, 10 to 1 on operation
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Ultra-Low NOx Burner Technology
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FREE-JET Ultra-Low NOx Burner Technology
Capacity: 15 – 440+ MMBtu/hr (single burner)
Emissions:▪ NOx:
▪ CO: 100 ppm
Excess air: 18%
RDL: 5-12 in. w.c.
Turndown:▪ 20:1 gas; 8:1 oil (operation)
▪ 4:1 (emissions)
No FGR 15% FGR
Nat. Gas 30 9
#2 Oil 80 50
#6 Oil 250 125
PPM
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Different NOx Reduction Methods – OFA
Applied to Field Erected Boilers w/ “headroom”
Not applicable to package style / horizontal gas path boilers
Generally want 1-2 burner pitch (~6-16’) from top row of burners to
OFA ports
Minimum of 2 burner pitch (12-16’) from OFA port to nose
BOOS (Burners Out Of Service)
Typically designed for 15-30% of total Combustion Air
Can achieve 10-50% NOx reduction – depending on boiler
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Tubular Type Air Preheater
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Regenerative Type Air Heater
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Combustion Air Heaters
• Replace Air Preheater with Economizer• Recommended when converting from coal to all gas• Improves unit efficiency; reduces combustion air temp• Allows use of existing fans, even when adding FGR• Reduces Register Draft Loss (RDL)
• Eliminate Steam / Hot water coil heaters• Unless needed for cold ambient conditions
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• Heat Exchanger
• Increases boiler efficiency• 1% for every 10⁰ increase in feedwater
temperature
Economizer
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Different NOx Reduction Methods
FUEL/ TECHNOLOGYGASEOUS LIQUID/ SOLID
STEAM INJECTIONEXCELLENT
MODERATE (LFO)/
POOR (OTHERS)
COMBUSTION AIR
TEMP REDUCTION EXCELLENT POOR-NONE
OFA
FGR
MODERATE EXCELLENT
EXCELLENT
MODERATE (LFO)/
POOR (OTHERS)
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Burner & Boiler Room Capabilities
Low/ultra-low NOx burners
Duct burners
Ignition & pilot systems
Physical airflow modeling and CFD
Flame scanners
Fuel train systems
Ancillary burner and combustion equipment
Aftermarket & service
Products ApplicationsIndustrial water tube boilers
Field erected & utility boilers
HRSG’s & OTSG’s
Fluidized bed & circulating fluidized bed boilers
CO boilers
Oil/coal to gas burner retrofits
Start-up burners & ignitors for solid fuel boilers
Recovery boilers
Marine boilers
Stoker boilers (bark, hog fuel, garbage, bagasse)
Turn-key installed projects
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What We Don’t Do
Burners for firetube boilers
Residential/commercial package burners
Solid fuel and coal burners
▪ But we can do Ignitors & Scanners
Burners for gas turbines
▪ But we do the HRSG Duct Burners
SNCR / SCR
▪ But we collaborate for best results
Baghouses / ESP
Scrubbers
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46
Beyond Burners and NOx
NOT a nuclear Power Plant.Hyperbolic Cooling Tower.
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47
Beyond Burners and NOx
≠
Yes, this was bad.
This is not bad. It’s steam.
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NOx Reduction Strategies – SNCR
48
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SNCR Components
Photo courtesy of FuelTech
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Main Components:
• Urea Distribution System• Urea Delivery/Storage
• Urea Mix station and tank
• Urea Control Flow Unit
• Urea Injectors
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SNCR Components
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SNCR Components
Optimum reaction between 1517°F – 1922°F
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Selective Catalytic Reduction - SCR
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Applications
• Boiler
• Incinerator
• GT
• HRSG
• Heater
Courtesy of Nationwide/Catastack
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NOX
NOX
NOX
NOX
NOX
NOX
SCR
CATALYST
N2 + H2O
+ NH3
+ NH3
+ NH3
SCR Technology - Principles
Ammonia
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• Ammonia (NH3) Injection Grid (AIG)
• SCR catalyst
• Injected ammonia acts as a chemical reagent
– SCR chemical reaction (exothermic: 1oC for each 100 ppm reduced)
– H2O and N2 are released to the atmosphere
Courtesy of Nationwide/Catastack
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Reagent:
• Ammonia– Historically used reagent
– Aqueous – safer than anhydrous but more costly
– Anhydrous – simple system. If small enough, bottle system is very convenient
• Urea– Safest reagent
– Requires higher temperature or longer residence time for direct injection
– Multi step conversion to NH3
– Easily transportable and simple to store
– Readily available
– Cost of use is similar to aqueous ammonia
Courtesy of Nationwide/Catastack
SCR Technology - Principles
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• Exhaust Gas Flow Profile – Velocity distribution
– Temperature distribution
– NOx distribution
– Allowable pressure drop
• Fuel– Natural Gas – lower sulfur, no
particulate, good NO/NO2 ratio
– Other fuels may have poisons,
particulate, temp limits due to SO3
• Physical Constraints– Vertical / Horizontal – Horizontal
configuration adds a complexity to the
sealing design
– Retrofit / New Build – How to add the tail end
system within an existing process
• Reagent– Ammonia – Anhydrous
– Ammonia - Aqueous
– Urea – Diesel Exhaust Fluid (DEF)
SCR Design Considerations
Courtesy of Nationwide/Catastack
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SCR Design Considerations
Distribution of reagent is critical to performance and Reduction efficiency
Courtesy of Nationwide/Catastack
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Main Components:
• Ammonia Distribution System
• Ammonia Control Flow Unit
• AIG (Ammonia Injection Grid)
• Reactor Housing
• De-NOx Catalyst
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SCR Components
Courtesy of Nationwide/Catastack
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SCR Catalyst
Catalyst is generally Corrugated plate, Bent Plate or Honeycomb construction, depending on SCR Supplier and application
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Electrostatic Precipitators
Electrically charged particles attach to the plate and get mechanically knocked off by a rapper at the top and collect I the bottom hoppers
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Electrostatic Precipitators
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Electrostatic Precipitators
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Fabric Filters / Baghouses
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Fabric Filters / Baghouses
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Fabric Bags with Support Cages
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Dry Scrubber
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Scrubbers - Wet
Zeeco Power Hour – June 11, 2020
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Comprehensive Emissions Control
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Clean Skies!
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Thank you!
Bob Langstine
Regional Sales Manager, Eastern US & Canada
Zeeco Inc. - Boiler Burner Division
Cell: 470-345-7032