VP of Eneractive's Power Plant Solutions Division, Bill Gretta, delivered a presentation on CO and SCR System Evaluation Tools to key stakeholders at the NAES Plant Managers' Conference in Bellevue, WA.

1. POWER PLANT
SOLUTIONS
CO and SCR System
Evaluation Tools
For
2014 Plant Managers’ Conference
September 23, 2014
Bellevue, WA
Uncovering Value, Instilling Confidence

2. OUTLINE
Uncovering Value, Instilling Confidence
 SCR System Basics
 Catalyst
 Flow Modeling
 AIG Tuning
 SCR Inspections

3. 4NO + 4NH3 + O2 4N2 + 6H2O
Catalyst
2NO + NO2 + 2NH3 3N2 + 6H2O
SCR SYSTEM BASICS
 Selective Catalytic Reduction
(SCR) is the process of
removing NOx (NO and NO2)
out of the flue gas stream by
injecting ammonia (NH3) into
the flue gas as a reagent.
 The flue gas passes over a
fixed bed of catalyst installed
in a reactor.
 Ammonia reacts with nitrous
oxides on the catalyst surface
to form safe and clean
nitrogen and water.

4. SIMPLE CYCLE SCR DESIGN - TYPICAL
Tempering
Air

5. CO CATALYST – COMBINED & SIMPLE CYCLE
 Designed to reduce CO from
engine
 Simple reaction (no reagent
required):
O2 + 2CO 2CO2
 Made from stainless steel
substrate with precious metals
added (platinum)
 >90% Reduction typical
 Deactivation over time can
dramatically reduce performance

6. CO CATALYST SAMPLING
 Should be tested when
performance problems
develop
 Annual testing can identify
problems before problems
develop

7. CO CATALYST DEACTIVATION
 The effect of
catalyst aging
results in
degradation of
performance
 There are fewer
active site and,
typically, lightoff
temperatures will
increase, with a
slower ramp-up.
 Maximum
conversions will
also be lower.
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
CO Oxidation vs. Temperature (Lightoff Curves)
0 100 200 300 400 500 600 700 800 900
% CO Oxidation
Temperature, °F
NEW AGED

8. SCR CATALYST – COMBINED & SIMPLE CYCLE
 Designed to reduce NOx from
engine
 >90% Reduction typical
 Ammonia Required
 Deactivation over time can
dramatically reduce
performance

9. SCR CATALYST SAMPLING
 Should be tested when performance problems
develop
 Annual testing will assure that goals are being met
or when replacement is required
1.4
1.2
1
0.8
0.6
0.4
0 10000 20000 30000 40000 50000
Operating Time (h)
K/Ko (-)
Unit-1 Unit-2 Initial Required Design

10. SCR CATALYST MANAGEMENT
 “Cost effective planning for end of catalyst life”
 Testing is a significant aid to optimal catalyst
management
 Sample testing
 Performance testing
 Operations
 Options:
1. Replace catalyst with new
2. Rejuvinate used catalyst
3. Regenerate used catalyst

11. FLUID FLOW DESIGN CONSIDERATIONS
 Poor flow distribution can have huge
effect on system performance
 Physical or CFD modeling is an effective
economical means to identify AND fix flow
problems
 Poor flow, ammonia and temperature
distribution can affect:
1. CO performance
2. SCR performance
1. NOx reduction
2. Ammonia Slip
3. Ammonia Usage

12. AIG TUNING
 AIG should be designed with ability to
tune as much as possible
 Systems designed with no tuning
capability have very limited flexibility
 Adjustments to AIG can have significant
benefit to performance

13. AIG DESIGN – THE NEED FOR GOOD AMMONIA DISTRIBUTION
 Poor NH3/NOx distribution can significantly impact NH3 slip
 As shown, the better (lower %RMS) the NH3/NOx distribution, the lower the overall
High Aspect Ratio
More Vertical Zones
ammonia slip (and ammonia usage)

14. AIG TUNING
 Tuning performed by measuring NOx and O2 at the inlet and outlet
of SCR catalyst
 Can be done by manual traverse, but a permanent grid will provide
much easier long-term testing and tuning

15. SCR INSPECTIONS – COMBINED & SIMPLE CYCLE
Inspections are a great method for identifying problems before
performance issues develop
 Take catalyst samples (CO and SCR)
 Check for Leaks - Gas Bypass is major contributor to performance problems
 Seals between modules and along perimeter of reactor should be checked
Configuration Ammonia Slip,
ppmvd @ 15% O2
Original Sealing System 6.8
With ENERActive Modified
Sealing/Reinforcement System
2.0

16. SCR INSPECTIONS – COMBINED & SIMPLE CYCLE
 Insulation Buildup can result in significant drop in performance
 Pressure Drop
 NOx and CO Reduction
 Ammonia Slip
 Source should be determined and corrected

17. ENERACTIVE OVERVIEW
 Northeast Base with National Reach
 Asbury Park, New Jersey
 Clinton, New Jersey
 New York, New York
 Beltsville, Maryland (Washington DC)
 Team Comprised of Field Engineers,
Performance Engineers, Energy
Engineers, Project/Construction
Managers, and SMEs
 Independent Technical Advisor for
Component, System, and Plant
Solutions
 Projects Ranging From Simple
Analyses to Multi-Million Dollar
Implementation Efforts
 #24 on Forbes List of Most Promising
Companies

18. POWER PLANT SOLUTIONS
 Services Include:
 Complete Turnkey
Projects
 System Inspections
 Performance Testing
 Flow Modeling
 Performance Engineering
 AIG Tuning
 Catalyst Testing (CO and
SCR)
 Coal-Fired SCR
Optimization
 Combined Cycle/Simple
Cycle SCR System
Optimization
 CO Catalyst Systems for
RICE
 System Commissioning
 Control System Upgrades
 Specification
Development
 Feasibility Studies
 SCR Maintenance &
Catalyst Cleaning
 Catalyst Management

19. Energy Solutions…
Efficient
Results